VOCATIONAL TRAINING

On
500MW

THERMAL POWER PLANT AT

NTPC LIMITED

RIHAND SUPER THERMAL POWER PROJECT,

RIHAND NAGAR SONEBHADRA (U.P.) BY DINESH SINGH RINGWAL OF

PUNJAB POLYTECHNIC COLLEGE, LALRU, DISTT. MOHALI (PB.)

UNDER THE EXPERT GUIDANCE OF Mr. P.Kashya , D.G.M.(BMD) Mr. V!"as "#$ar, Sr.E%&r.

ACKNO'LEDGEMENT With feelings of joy and thanks, I placed in your CERTIFICATE hand my Project report. It is my pleasant privileges to thank all those who have help me in molding and shaping my project. Without their guidance, cooperation and best wishes it would have been impossible for me to complete my dissertation report. A big thanks to all those who helped me by sparing time amidst their busy schedule and for being kind enough to help me whenever I needed them. NATIONAL THERMAL POWER CORPORATION LTD. As(A man is a social animal. !e re"uires the GOVERNMENT OF INDIA ENTERPRISE) encouragement and THERMAL affection PO'ER of hisPROJECT parents and RIHAND SUPER P.O.(R!ha%) Na&ar, D!s**. S+%,-ha)ra (U.P.) friends to accomplish his goal and I have been #ucky to get it and make this DATE(./0120.113 project report a success. CERTI4ICATE $inally, I am thankful to all the respected E5,6#*!7, ,$ 8+y,,s !" N.T.P.C RIHAND,RIHANDNAGAR, for TO 'HOMSOEVER IT MAY CONCERN providing me the necessary information, cooperation in #OCATINAL TRAINING. I thank god almighty for his abundant blessing because without it this project was only a dream.
%I&'(! (I&)! *I&)WA# III +ear ,echanical 'ngg.

CERTI4ICATE
-his is to certify that this summer training report has been prepared by fulfillment of re"uirement of vocational training at &-P1 *ihand. -he matter was analy3ed by candidate under my guidance and this report embodies the work done by him. We wish him a bright future. DINESH SINGH

RINGWAL (./ (h. -rilok (ingh, a student of %IP#/,A. 0,'1!. '&))2 in the partial

Approving Authority4

)uide4

A.5.-IWA*I %), 07,%2

P.5. 1!/6%!A*+ '&)I&''* 07,%2

A7/6- &.-.P.1.

-he &-P1 was formed in 89:; to meet the power re"uirement challenge faced by the nation during the period. &.-.P.1. 0&ational -hermal Power 1orporation2 is an Indian )ovt. undertaking. It has the installed capacity of <=,:>;,W including joint venture, contributing <?.:@ of the nationAs power generation with only 89.8@ of IndiaAs total installed capacity. 7ased on 899B data, carried out by %ata monitor 65, &-P1 is the ?th largest in terms of thermal power generation and the second most efficient in terms of capacity utili3ation amongst the thermal utilities in the world.

&-P1Cs core business is engineering, construction and operation of power generating plants and also providing consultancy to power utilities in India and abroad. As on date the installed capacity of &-P1 is <=,:>9 ,W through its 8= coal based 089,>BD ,W2, : gas based 0=,9;; ,W2 and = Eoint Fenture Projects 0=8> ,W2. &-P1 ac"uired ;D@ e"uity of the (AI# Power (upply 1orporation #td. 0(P(1#2. -his EF company operates the captive power plants of %urgapur 08<D ,W2, *ourkela 08<D ,W2 and 7hilai 0:> ,W2. &-P1 is also managing 7adarpur thermal power station 0:D; ,W2 of )overnment of India. *ecognising its eGcellent performance and vast potential, )overnment of the India has identified &-P1 as one of the jewels of Public (ector H&avratnasAI a potential global giant. Inspired by its glorious past and vibrant present, &-P1 is well on its way to realise itAs vision of being one of the worldAs largest and best power utilities, powering IndiaAs growth .

R!ha%) S# ,r Th,r$a8 P+9,r Pr+:,6* (;5<11 M')

INTRODUCTION
..= SALIENT 4EATURE L+6a*!+%4 7ijpur village, %istt. (onebhadra. 06.P2.

T+*a8 r+ +s,) 6a a6!*y4=DDD ,W, in = stages each of <J;DD,W Pr,s,%* 6a a6!*y> <DDD ,W 0(-A)'I8 K (-A)'I<2 0(-A)'I= is planned for future2 6P ,P -otal >?BD 8:;< ?>=< L.I;DD5v !F%1 7ipolar line to %adri 0%elhi2, >DDkF single circuit A1 line to (haktinagar and 5anpur. 6P, !aryana, Punjab, *ajasthan, EammuK5ashmir, !imachal Pradesh, 1handigarh and %elhi. 'Gport 1redit of pound sterling =>>million, aid from )ovt. of 6.5.pound sterling 8:: million.)ovt.of India afforded the rest cost of the project.

T+*a8 8a%) (!% a6r,s)> P+9,r E7a6#a*!+%> B,%,?!6!ary S*a*,s> 4!%a%6!%&> Ma:+r R,s+#r6,s>

COALI 0a2 (ource IAmlori mines. 0b2 ,aGimum consumptionI >=,=DD,-.%ay for =DDD ,W 0'I)rade 1oal2. 0c2 ,ode of -ransportationI ,)* *ail -ransportation (ystem. 'ATERI 0a2 (ourceI *ihand *eservoir. 0b2 ,aGimum 1onsumption M =DD cusecs. 0c2,aGimum cooling water re"uirementI 8;DDcusecs for 8DDD,W. Ch!$%,y> <<>.;mts0*11 structure with steel flue2. Ash )!s +sa8> Ash slurry pumped to Ash dyke. C+$$,%6,$,%* +? 9+r"> D9.D<.89B=. U%!*(= sy%6hr+%!@,)> =8.D=.89BB. U%!*(. sy%6hr+%!@,)> D;.D:.89B9. U%!*(/ sy%6hr+%!@,)> =8.D8.<DD; U%!*(; sy%6hr+%!@,)> =8.D:.<DD; U%!*(= 6+$$,r6!a8!@,) D8.D8.899D

U%!*(. 6+$$,r6!a8!@,)>

D8.8D.8998.

*ihand super thermal power project 0*h(-PP2 has the current generation capacity of <DDD,W. -here are four 6nits where each 6nit has the capacity of ;DD,W. 6nits 8 K < were commissioned in 89B9 and 6nit = K 6nit > were commissioned recently in August <DD;. -he power plant has two switchyards of >DD5F K 8=<5F which are interconnected to each other. -hese switchyards feed the northern power grid form where the transmission of power is done. /ne >DD5F bus is used for !.F.%.1. transmission which delivers power from *ihand to %adri near %elhi. -he thermal plant intakes water from the near by water reservoir the )ovind Fallabh Pant *eservoir based on *ihand river. -he reservoir rests on the dam named *ihand dam, which also powers the !ydro power station of <;D,W. -he re"uirement of coal is fulfilled from Amlori coal mines which are situated in ,adhya Pradesh. -he *h.(.-.P.P. powers various (tates such as 6ttar Pradesh, %elhi, Punjab, !imachal Pradesh, *ajasthan etc. N,9 *,6h%+8+&y (uper critical technology at &-P1 (ipat project 0=J?DD,W2 to increase the efficiency of the cycle and to decrease the green house gas emission. 1losed cycle seawater cooling at (imhadri project for first time in India. Introduction of I)11 0Integrated gasified combined cycle2 for clean and efficient utili3ation of coal. E%7!r+%$,%* $a%a&,$,%* #i"uid water treatment plants at $arakka and 5ahalgaon. Ash water recycling system at 5ahalgaon and 5orba to reduce water ash disposal at these station re"uirement for

ABSTRACT

Any thermal power plant is converting the chemical energy of fossil fuel 0coal2 into electrical energy. -he process involved for this conversion is based upon the ,odified *ankine 1ycle. -he major components that are used to accomplish the ,odified *ankine 1ycle are i2 7oiler feed pump, ii2 -he steam generator water walls 0evaporator2, iii2 (team generator super heaters, iv2 (team turbine, v2 *eheater,

vi2 1ondenser, vii2 *egenerative feed heaters etc.

All components of a power generating cycle are vital and critical in operation. In ,odified *ankine 1ycle the two most important aspect that is added are reheating K regenerative heating 7y reheating steam, coming from eGhaust of the turbines, is used to send back to the reheater of the boiler so that its enthalpy increases and more work can be done by this steam the other purpose is to make steam dry so that no harm will be done to the blades of the turbine.

In *!(-PP there are four turbines in -andem coupling namely one !.P -urbine, one #.P -urbine K two #.P -urbine coupled with the generator to which is synchronised with the grid to produce electricity at ;D!3.

. In all my modesty, I wish to record here that a sincere attempt has been made for the presentation of this project report. I also trust that this study will not only prove to be of academic interest but also will be able to provide an insight into the area of technical management.

MODI4IED RANKINE CYCLE A thermal power station operates using a closed steam power cycle, which is a dual 0vapourLli"uid2 phase cycle. In this cycle, the working fluid i.e. water undergoes various thermodynamic processes and is used repeatedly. Previously, rankine cycle was used in most of the thermal power plants. !owever, in modern power plants the rankine cycle is modified to include superheating of steam, regenerative feed water heating and reheating of steam. = < 8 ( -he modified cycle is represented on -I( diagram. Farious processes are4 8I< M Ideal pressure increase at constant entropy in boiler feed pump. <I= M !eat addition in the boiler at constant pressure. =I> M Isentropic eGpansion in !P turbine. >I; M *eheating at constant pressure. ;I? M Isentropic eGpansion in IP and #P turbines. ?I8 M 'Gtraction of latent heat in condenser. $actors affecting thermal efficiency of ,odified *ankine 1ycle are listed as under4 Initial (team Pressure. Initial (team -emperature. *eheat Pressure and -emperature. 1ondenser Pressure. *egenerative $eed Water !eating. ? > ;

MAIN BOILER
A . BOILER 4UNDAMENTALS
Pr!%6! 8,s +? 6+$-#s*!+%> 8. -he primary function of oil and coal burning systems in the process of steam generation is to provide controlled efficient conversation of chemical energy of fuel into heat energy, which is then transferred to the heat absorbing surfaces of the steam generator. When combustion is properly completed the eGhaust gases will contain, 1/<, water vapour, sulphur dioGide and a large volume of nitrogen, combining carbon and hydrogen with the oGygen in air brings about combustion. When carbon burns incompletely it forms carbon monoGide. .. C+$ +s!*!+% +? a!r> a2 :9@ nitrogen and <8@ oGygen by volume. b2 ::@ nitrogen and <=@ oGygen by weight. /. E56,ss a!r> In practice the theoretical "uantity is not sufficient to ensure complete combustion and eGtra air has to be supplied. -his eGcess air is known as eGcess air. >. I&%!*!+%4 $uel must be ignited before it can burn. *aising the to its ignition temperature brings about combustion. temperature of the fuel

;. -he following factors in efficient combustion are usually referred to as -he three -A( . a2 TIME4 It will take a definite time to heat the fuel to its ignition temperature and having ignited, it will also take time to burn. b2 TEMPERATURE4 A fuel will not burn until it has reached its ignition temperature. Preheating the combustion air increases the speed at which this temperature will be reached. 12 TURBULENCE> -urbulence is introduced to achieve a rapid relative motion between the air and the fuel particles. -his produces a "uick propagation of the flame and its rapid spread throughout the fuel.air miGture in the combustion chamber.

?2 1ombustion efficiency4 ,aGimum combustion efficiency depends on c2 %esign of the boiler d2 $uel used e2 (kill in obtaining combustion with the minimum amount of eGcess air. :2 -hermal efficiency of a boiler is measured by the amount of the heat water in the boiler by each 5g of the fuel used. transferred to the

ARRANGEMENT O4 THE MAIN BOILER> =). B+!8,r S*r#6*#ra8s4 -he boiler structurals are divided into two parts. a2 (upporting (tructures4 boilerIsupporting structure consists of a systematic arrangement of columns stiffened with hori3ontal beams and vertical diagonal bracings and comprise of low carbon steel material. -he main columns support the main boiler components vi3. drum, economi3ers air preheaters, burners and galleries at various levels. b2 )alleries and (tairways4 )alleries and stairways around the combustion and the heat recovery areas are provided for approach to the boiler. .) 4#r%a6,> A 7oiler furnace is that space under or adjacent to a boiler in which a fuel is burned and from which the combustion products pass into the boiler proper. It provides a chamber in which the combustion reaction can be isolated and confined so that the reaction remains under controlled force. In addition, it provides a support or enclosure for the firing e"uipment. -he wall construction of the furnace is waterI cooled walls i.e. the wall is of tube in which water is flowing continuously

/) B+!8,r )r#$> -he boiler drum forms a part of the circulation system of the boiler. -he drum serves two functions, the first and primary one being that of separating steam from the miGture of water and steam discharged into it. (econdary,the drum houses all e"uipments used for purification of steam after being separated from water. -he purification e"uipment is commonly reffered to as the drum intervals. -he "uantity of water contained in the boiler below the water level is relatively small compared to the total steam output. Primarily, the drum si3e is determine by the space re"uired to accommodate the steam separating and purifying e"uipments. -he steam space provided should be sufficient to prevent priming and foaming. ,aterial4 -he boiler drum is made of carbon steam plates. -he materials used should comply with the Indian 7oiler *egulations. 1omparing carbon steel and alloy steel as material for drum, the carbon steel costs less per ton of material but the overall weight of drum will be higher because that of thickness. DRUM INTERVALS> %rum intervals are used to separate water from steam and to direct the flow of water and steam in a manner so as to obtain the optimum distribution of drum matal temperature in boiler operation. -he arrangement of drum normally consists of two or more integrated device, each of which may be "uite different in design and operate on totally different principles. 'ach stage must have a higher separation efficiency. -he greater the number of stages of separation,the lower the re"uired efficiency of each stage .-hus, two stages at 99@ efficiency,three stages at 9D@ efficiency and siG stages at :D@ efficiency will give similar results. Water level gauge is mounted on each end of the steam drum. If water level goes outside of the prescribed operating limit then the boiler is tripped.-hus,with increase in pressure,the separation of water from steam by simple devices become more difficult.It become necessary to use more efficient apparatus if primary separation is to be achieved in a confined area.

;) E6+%+$!s,r> -he purpose of the economi3er is to preheat the boiler feed water before it is introduced into steam drum by recovering heat from the flue gases leaving the boiler. 'ntering first, the economi3er water is heated to about =D to >D deg 1 below saturation temperature. $rom economiser the water enters the drum and thus joins the circulation system. Water entering the drum flows down through the down comer and and enters ring header at the bottom. It is located in the boiler second pass below the superheater. -he economi3er is continuous loop type and water flows in upward direction and gas in the downward direction. All tube circuits originates from the inlet header and terminate at outlet header which are connected with the economi3er outlet headers through three rows of hanger tubes. <)D+9%6+$,rs> %own comers provide a passage for water from the boiler drum to bottom ring header. $rom bottom ring header the water goes to water walls for heat absorption and conversion into steam heating .-o achieve the circulation of water into water wall 7oiler circulation pumps are provided in down comers. 3)'a*,r9a88s> Water walls are the necessary elements of the boiler. -hey serve as the means of heating and evaporating the feed water supplied to the boiler from the economi3ers via boiler drum and down comers. In large boilers, water walls completely cover the interior surfaces of the furnace providing practically complete elimination of eGposed refractory surface. -hey usually consist of vertical tubes membrane and are connected at the top and at the bottom to headers. -hese tubes receive water from the boiler drum by means of down comers connected between drum and water walls lower header. Water walls absorb ;D percent of the heat released by the combustion of fuel in the furnace, which is utili3ed for evaporation of feed water. -he miGture of water and steam is discharged from the top of the water walls into the upper wall header and then passes through riser tubes to the steam drum. -he design and construction of the water walls depends upon the combustion and steam conditions and the si3e of the boiler. /rifices installed in the inlet of each water circuit maintain an appropriate flow of water through the circuit.

2)R!s,r *#-,s> A riser is a tube through which the miGture of water and steam pass from an upper water wall header to the steam drum.

A) S# ,r H,a*,r> -here are three stages of super heaterN the first stage consists of hori3ontal superheater of convection miGed flow type with upper and lower banks located above economi3er assembly in the second pass. -he upper bank terminates into hanger tubes, which are connected into the outlet header of the first stage super heater. -he second stage superheater consists of a pendant platen, which is a radiant parallel flow type. -he third stage superheater pendant spaced is of convection parallel flow type. In radiant super heaters heat is absorbed by direct radiation from the furnace and are generally located at the top of the furnace. (ince the furnace temperature, and therefore the amount of available heat from radiation, does not rise as rapidly as the rate of the steam flow, thus the steam temperature drops as the steam flow rises. 1onvection superheaters absorb mainly by the impingement of flow of hot gases around the tubes. A purely convection superheater has a rising steam temperature characteristic i.e. the amount of available heat from convection, rise as rapidly as the rate of steam flow. B)R,h,a*,r> -he function of the reheater is to reheat the steam coming out from the high pressure turbine to a temperature of ;>DO1. -he reheater is composed of two sectionsIone is front pedant section and rear pedant section. -he rear pedant section is located above the furnace arc and the rear water wall and the front pedant section is located between the rear water hanger tubes and the superheater platen section. -he cold reheat is the line from turbine to the boiler and is at a lower than the reheat line from boiler to the turbine called hot reheat steam. %ue to resistance of flow through the reheat section, the hot reheat steam is at a lower pressure compared to the cold reheat steam.

=1)B#r%,rs> -here are forty total pulveri3ed coal burners arranged on the corners at a height of 8B to <; meters and twelve oil burners provided each in between corner two pulveri3ed twoIfuel burner. -he pulveri3ed coal burners are arranged in such a way that ten mills supply the coal to burners at > corners, of the furnace. All the no33les of the burners are interlinked and can be tilted as a single unit from L=D to M=D. -he oil burners are fed with the heavy fuel oil till boiler load reaches to about <;@. ==)D,s# ,rh,a*,rs> A. S# ,rh,a*,r D,s# ,rh,a*,r> -he superheater desuperheater is fitted between stages > and ;0on transfer pipe2 to control the superheated steam at the specified terminal temperature of ;>D o1. -he maGimum design temperature reduction at the superheater desuperheater is from >>? o1 to =BB o1. -he desuperheater comprises a spray no33le shell and associated spray assembly projecting into a section of the superheater steam line. -his section of the steam line forms the desuperheater shell. (team assisted spray no33le assembly provides a fine spray of water which attemperates the steam passing through the desuperheater. (pray water for desuperheater is taken from the boiler feed water pump discharge. In addition, spray water regulating stations are provided further downstream in each line. B. R,h,a*,r D,s# ,rh,a*,r> -he reheater desuperheater is only brought into use when the reheater outlet temperature rises above the normal temperature. -he reheater desuperheater comprises of a spray no33le shell and associated spray no33le assembly projecting into a section of the steam line between the !P turbine outlet and the reheater inlet headers. -his section of the steam line forms the desuperheater shell. Water is fed into the shell from the discharge side of the boiler feed pumps via a reheater desuperheater spray water regulating station.

When the reheater desuperheater is called into service water is fed via the water tube and passes through the spray no33le thereby forming a spray which attemprates the steam passing through the desuperheater and thus decreasing e -he "uantity of water in the boiler drum is relatively small compared to the total steam output. (o, the drum si3e is determined by the space re"uired to accommodate the steam separating and purifying e"uipments. =.) B+!8,r 'a*,r C!r6#8a*!+%s P#$ s> 'ach boiler water circulation pump consists of a single stage centrifugal pump on a wet stator induction motor mounted with in a common pressure vessel. -he vessel consists of three main parts a pump casing, motor housing and motor covers. -he motor is suspended beneath the pump casing and is filled with boiler water at full system pressure. &o seal eGists between the pump and motor, but a provision is made to thermally isolate the pump from the motor. =/) I&%!*,rs> !igh 'nergy Arc type electrical igniters are provided which can directly ignite the heavy fuel oil. An eGciter unit stores up the electrical energy and releases the energy at a high voltage and short duration. A spark rod tip, which is designed such a way that converts the electrical energy into an intensive spark. A pneumatically operated retracts mechanism, which is used to position the spark rod in the firing position and retract to the non firing position. 'ach discrete spark provides a large burst of ignition energy as the current reaches a peak value of the order of <DDD amps. -hese sparks are effective in lighting of a wellI atomi3ed oil spray and also capable of blasting off any coke particle or oil muck on the surface of the spark rod. B. 'ATER CIRCULATION SYSTEM>

Water must flow through the heat absorption surface of the boiler in order that it is evaporated into the steam. In drum type units the water is circulated from the drum through the generating circuits and back to the drum where steam is separated and directed to the superheater. -he water leaves the drum through the downcomers at a temperature slightly below the saturation. -he flow through the furnace wall is at

saturation. !eat absorbed is the latent heat of vapori3ation creating the miGture of steam and water. At very a high pressure the density difference between steam and water becomes progressively less and a point is reached where natural circulation is too slow.&atural circulation is limited to boiler with drum operating pressure around 8:; kg.cmI<. -o overcome this forced circulation is employed which uses pumps to speed up the circulation of the water.

TECHNICAL DATA Ma!% -+!8,r Ty , Ma%#?a6*#r,r 4#r%a6, *y , Dr#$ a. /verall length b. %esigned pressure c. %esigned temperature S# ,rh,a*,r a.&umber of stages R,h,a*,r a. &umber of stages S*,a$ ?8+9 a* MCR a. (team at final superheater outlet b. (team at reheater outlet 'a*,r ?8+9 a* MCR a. $eed water entering economi3er C+a8 ?8+9 a* MCR S*,a$ r,ss#r, a* MCR ("s6) A* ?!%a8 s# ,rh,a*,r +#*8,* A* r,h,a*,r +#*8,* A* r,h,a*,r !%8,* 8:B >=.>? >;.B; 8:<;-P! =8?.> -P! 8:<; -P! 8;=D -P! = stages ? stages <<D:D mm <D>.9 5sc. =?? o1. ;DD,W 7alanced %raft ,%ry bottom,(ingle drum,*adiant $urnace, 1ontrolled 1irculation,-angentially $ired,-iltable &o33le. ,.( 7!'#01' %'(I)&2 1ontrolled 1irculation.

4r+$ )r#$ E6+%+$!@,r !%8,*

89=.; 89?.?

BOILER AUCILIARIES
MILLING SYSTEM> ( COAL BUNKER4 I -hese are inIprocess storage silos used for storing crushed coal coming from the coal handling plant through conveyor belts. -here are ten coal bunkers supplying coal to each mills and are located at top of the mills to aid in gravity feeding of the coal. 'ach bunker can store coal, which can be used for 8<hrs. COAL 4EEDER> ( -he purpose of coal feeder is to transfer coal at a preI determined rate, from coalbunker to the mill. -he coal feeder comprises two continuous chains with # sections flight bars mounted between the chains at every fifth link .-he chains runs on sprockets mounted at each end of the feeder to given an upper strand movement towards the driven ends and a lower strand movement in the opposite direction. -he drive shaft is supported on two self aligning bearing mounted in the Plummer block on support out side the feeder casing, shaft sealing is achieved by the lip seals in the sealing housing and mounted in board of the bearing to abut the feeder casing. -he tail sprocket shaft is mounted in adjustable bearing blocks adjacent to the feeder casing with positioned which allow the feeder chain to be tensioned. 7oth upper and lower strands run over full width carrying plates with the lower strands located by angle section guides mounted on the feeder wall. -he upper and lower carrying plates and the inside wall are protected from wear by replace by replaceable stainless steel panels, chains are kept clean by rubber wiper. $eeder input is achieved by roller chain drive to the conveyor via a fiGed speed electric motor driving a variable speed gear boG, tor"ue limiter and fiGed out put gear boG -he electric motor is flanged mounted to variable speed gear boG, coupled to the fiGed output gear boG by a fleGible coupling and tor"ue limiter. -he principle of operation of coal feeder is that coal flows from the bunker into the chain feeder via feed hopper and is conveyed to the mill feed inlet chute, when the feeder is in the operation, the conveyor chain drag a fiGed head of coal towards the driven ends of the feeder. At the end of the carrying plates the coal falls

through the conveyor onto the bottom plate, where it is picked up by the returning flight bars and dragged back along the feeder to fall into the mill feed chute. MILL CHUTE> ( ,ill chute trans port coal directly from the coal feeder to its associated mill, in addition an emergency chute is incorporated to allow coal to be removed from the coal bunker via coal feeder in the event that outage time is more than one month, or if there is a danger from fire in the mill chute area, coal feeder, or coal bunker. 'ach mill is provided which transport raw coal from the bunker to the inlet of mill at the desired rate. -he rate of feeding is controlled by variable speed gear boG . !ere chain type feeder is present in which continuous chain is moving round sprockets in which a sprocket is driven by a variable speed %.1 motor and the other sprocket is a return .(procket on this chain ,at different ,( plates are connected which are called as scrapers .-his type chain feeder are called scraper feeder. -he coal from the bunker falls on a platform which is below the scrapper feeder. When the scraper moves it will scrap the coal and at the end of platform the coal falls into the pulveri3er. PULVERISER MILL>( -here are ten mills for every ;DD ,W unit located adjacent to the furnace at D m level. -hese mills pulveri3e coal to desired fineness to be fed to the furnace for combustion . -he main structure of the pulverisering mill is fabricated from mild steel in three cylindrical sections, the bottom section 0the mill housing support 2which support the entire unit and encloses the mill drive gear unit, a center section 0the mill housing2that contains the rotary grinding element and upper section 0the classifier housing 2comprising an accommodate the gas loading cylinders of the mill loading gear .A platform around the upper section provide an access to an inspection door and to the top of the mill routine maintenance and is served by detachable ladder . . PULVERIDERS> -he pulveri3ser eGclusive of its feeder, consists essentially of a grinding chamber with a classifier mounted above it. -he pulveri3ing take place in a rotating bowl in which centrifugal force is utili3ed to move the coal, delivery by the feeder, outwards against the grinding ring 0buil ring2. *olls revolving on journals that are attached to the mill housing pulveri3e the coal

sufficiently to enable the air stream through the pulveri3er to pick it up. !eavy spring action through the journal saddles, provide the necessary pressure between the grinding surfaces and the coal. -he rolls do not touch the grinding rings , even when pulveri3er is empty. -ramp iron and other foreign material is discharged through a suitable spout. -he air and coal miGture passes upward the classifier with its deflector blades where the direction of the flow is changed abruptly, causing the coarse particles to be returned to the bowl for further grinding. -he fine particles, remaining in suspension, leave the classifier and pass on through the coal piping to the windboG no33les. LO' SPEED MILL> -hese are commonly known as tube ball mills and operate at approGimately 8: to <D rev.sec.(uch slow speed is essential with these types of mills as otherwise the balls will held along the rorating surface due due to centrifugal force and no milling takes place. Advantages of low speed mills4 082. Wearable part which needs replacement between annual overhaulsis only the ball and this can be done when mill is in operation. 0<2. &o maintenance for long period. 0=2. this mill has no relects and does not give tramp iron problem. 0>2. -here is reverse of fuel within the mill which makes the mill output more stable. %isadvantages of low speed mills4 082. power consumed per ton of coal pulverised is nearly to that of economic mills. 0<2. -his mill consumes more power.ton coal ground especially when not loaded fully as bulk of power is consumed in rotating mass of heavy ball charge. 7/W# ,I##4 -he ball mill is one of the most advanced design of coal pulveriser.-he advantages of this mills are 4 082. lower power consupton. 0<2. *eliability. 0=2. ,inimum maintenance. 0>2. Wide capacity08.: t.hr. to8DD t.hr.2.

MILL TECHNICAL DATA>( ,anufactureIIIIIIIIIIIIIIIIIIIIIIIIII,.( 7!'# -ype of pulveriser &o. of ,ill . boiler 7ase capacity of ,ill (peed of pulveriser &ormal capacitywith design coal ><rpm ;<.; -.!r 8DD=G *P 8D ?B-onnes.!r.

4ANS A fan is a device by which the air is made to flow at re"uired velocity and pressure in a defined path imparting 5.' of its impellers to air.flue gases . -his pressure boost is used to create a draught in the air and flue gas system. $ans mainly performs two functions4 i. ii. -hey supply air re"uired for combustion in the furnace with re"uired pressure K flow. -hey evacuate the product of combustion i.e. flue gases into the atmosphere via chimney.

P.A 4a% >( -he primary air fan supplies heated air to the coal mills to give dry and pulveri3ed coal to the furnace for efficient combustion.-he P.A fan also supply fresh air to prevent coal mills by overheating. -here are two P.A fans per boiler, each fan having pneumatically operated radial guide vanes at the fan inlet to control the fan output. -he fan impeller is a double inlet, centrifugal wheel with backward curved plate blades. Ambient air is drawn into the P.A duct by two ;D@ duty, motor driven centrifugal fans. -he air from each fan discharges into a hot air crossover duct via a steam air heater. -his duct eGtends around to each side of the boiler to supply the hot air to mills duct, both of which are branched to supply hot air to four coal mills.

4.D 4a%> -he forced draught fan system is provided to supply air re"uired for pulveri3ed coal combustion in the furnace, air for fuel oil combustion and over fire air to minimi3e &oG production. -he $.% fan system comprises of two single stage aGial flow, constant speed, and auto variable pitch fans per boiler. -hese fans provide pressuri3ed atmospheric air to the boiler for combustion. Ambient air is drawn into the secondary air system by two ;D@ duty, motor driven, aGial flow forced draught fans with variable pitch control. -he air from each fan discharges into a hot air crossover duct via a main air heater. -his duct eGtends around to each side of the boiler furnace to form two secondary air to burners ducts. At the sides of the furnace, each duct split to supply air to two corners, then split again to supply air to each of the nineteen burner.air no33le elevations in the burner boG. I.D 4a% sys*,$> -he induced draught system comprises of three centrifugal double inlet fans per boiler, two operating and one standby. 'ach fan unit consists of a backward curved plate bladed impeller, which is driven by an electric motor through a variable speed hydraulic coupling. -he I.% fan serves the purpose of evacuating the products of combustion or the flue gases in the atmosphere via chimney. -he flue gases after being cleaned in the precipitators is directed towards the atmosphere through the chimney. S6a%%,r a!r ?a% > (canner fans are installed in the boiler for supplying continuously cooling air to the flame scanner provided for the flame supervision. &ormally one fan remains in service while the other one remains available as standby. (canner air fan is centrifugal type. It takes suction from $.% fan outlet and boosts the pressure further to provide cooling air to the scanners. S,a8 a!r ?a%> (eal air fan supplies sealing air, at a pressure higher than that inside the mill, to a brush sealing around the stem of the coal mill yoke casting to prevent coal dust escaping to atmosphere. -here are eight seal air fans one per mill to provide sealing air. 'ach fan is a close coupled, electrically operated, centrifugal fan unit operated as part of the mill operating se"uence, which incorporates an autoIstart facility.

P#r&, +r 6++8!%& a!r ?a% -he function of the purge.cooling air system is to provide a continuous supply of clean air to cool all soot blowers in the retracted position, and to purge each retractable soot blower lance whenever it is in the retracted position. -here are two fans 0one operational, and one standby2 to provide purging.cooling air to each of the soot blowers, and also to prevent furnace gas blowIback into the sealing areas. 'ach fan comprises a close coupled, electrically driven centrifugal fan unit, which initially, is manually operated but which contains an automatic standby. <.E8,6*r+s*a*!6 r,6! !*a*+rs -he ash content in the Indian coal is of the order of =D@ to >D@. When coal is fired in the boiler, ashes are liberated and about BD@ of ash is carried along with the flue gases. If this ash is allowed to atmosphere, it is ha3ardous to health. (o, it became necessary to incorporate an electrostatic precipitator in the path of the flue gases going in the atmosphere. -he electrostatic precipitators are preferred to mechanical precipitators because they are capable of precipitating particles from sub micron to large si3es of particles. -he efficiency of the modern '(PAs is of the order of 99.9@. In &-P1 *ihand, the gas cleaning plant consists of two '(PAs that operate on the eGhaust gases from each of the ;DD ,W steam generators. -he electrostatic precipitator consists of a large chamber, which comprises of parallel rows of sheet type collecting electrodes suspended from the precipitator casing with wire type discharge electrodes arranged midIway between them. At the inlet of the chamber, gas distributor screens for uniform distribution of the gases in the chamber, are provided. -he collectors are connected to earth at positive polarity while the discharge electrodes are connected to a high voltage dc supply at negative polarity. When dustI laden gas flows between the electrodes, the corona discharge causes the dust particles to become charged, the particles then being attracted towards and, eventually, deposited on the collector electrodes. -his dust falls as the collecting electrodes are continuously rapped through a rapping system and is collected into the pyramid type hoppers, located beneath each collecting electrodes, from where it is removed by the ash handling system.

3.A!r h,a*,rs Air heater is a heat transferring device in which air temperature is raised by transferring heat from flue gases. Air heaters are capable of reclaiming heat from the flue gases at low temperature levels and thus reducing the amount of heat rejected to chimney. -his results in increasing the boiler efficiency. $or every <D D1 drop in flue gas eGit temperature, the boiler efficiency increases by about 8@. In &-P1 *ihand, recuperative type of air heaters is mainly used. In recuperative air heaters, the heating medium i.e. flue gases flows through a closely packed matriG structure and then air is passed through the matriG to pickup the heat. -here are two recuperative type of main air heaters for heating up the air from fans, two recuperative type air heaters for mill air heating.

S*,a$ a!r h,a*,rs -his type of air heaters does not utili3e the heat from the boiler flue gases and so does not affect the boiler efficiency. -hese are generally used during starting when the flue gases entering the regular air heater is low and hence further heat eGtraction is not possible and low temperature corrosion prevails. -here are two main steam air heaters and two mill air heaters. (team air heaters comprises of round tubes carrying steam to be condensed. -hese heaters are provided with air eGtraction system so that air entering with steam will not lock and prevent the operation of air heater. In addition, the outlet temperature of air can be controlled easily. 2. 4!r!%& sys*,$ &-P1 *ihand has direct firing system. In this system, a controlled "uantity of crushed coal is fed to each bowl mill 0pulveriser2 by its respective feeders and primary air is supplied from the primary air fans which dries the coal as it is being pulveri3ed and transports the pulveri3ed coal through the coal piping system to the coal burners. In this system, burners are set at each corners of the furnace and are directed to strike the outside of an I,A)I&A*+ 1I*1#' at the centre of the furnace. 7ecause the streams of fuel strike each other, eGtremily good miGing is obtained. (ince the body of the flame produced is given a rotary motion is leads to a longer flame travel and gases spread out and fill the combustion.

-here are ten pulveri3es out of which eight are used and two remains in standby. -he raw coal feeders supply :> -P! of coal to each mill. -he pulveri3ed coal and air discharged from the coal burners is directed towards the center of the furnace to form firing circle. -here are =< tilting, tangentially fired coal burners fitted at the four corners of the boiler at eight elevations. -he secondary air heating system supplies secondary air for combustion in the furnace around the pulveri3ed coal burners and through auGiliary air compartments directly adjacent to the coal burner compartments. -here are 8? airIatomi3ing ignitrons per boiler, which initially ignite the coal and air miGture. Above a predictable minimum loading condition, the ignition becomes selfI sustaining. 1ombustion is completed as the gases spiral up in the furnace.

SOOT BLO'ING SYSTEM

I%*r+)#6*!+% In *h(-PP, soot deposited in various regions of boiler is removed with the help of soot blowers, which utili3e steam as the main working medium. -his part is mainly concerned with the eGisting soot blowing system and the problems arising in the system during operation. -he removal of soot is very necessary for the efficient working of the plant. -his is because soot acts as an insulator for the heat transfer taking place between the flue gases and water.steam inside the tubes. /n the other side, it increases the metal temperature of superheater and reheater tubes located inside the boiler. -his temperature increase may cause damage of the tubes resulting leakages across the tubes. Which, in turn affect the working of the boiler. (o, regular soot blowing is very necessary in the boiler. (imilarly, soot is also deposited on the air preheater baskets, which causes plugging of the baskets. Also in case of oil firing during initial lightIup unburnt oil may deposit in baskets. -his deposited oil may cause fire ha3ard in air heater. -o avoid these problems soot blowing is done in air preheater also. S++* -8+9!%& r+6,ss> -he complete soot blowing process can be divided into following three major se"uential parts4 A. S$%& '!() *+!,-..I -his part of the process step checks the close status of all the valves. 7. W/+0 %* *+!,-..I In this step the valves according to the selected blower group open to provide hot steam to the selected blower group at certain pressure level. 1. B1!(2)3 *+!,-..I In this se"uence actual blowing of steam takes place. -he blower pairs under currently selected group when comes in to operation carries the steam inside the boiler and continues to blow till it returns to its park position.

S*,a$ -8+9!%& s6h,$,> When blowers go inside the boiler they carries steam, which is made available to the blowers through the section valves dedicated for the blower group. -hese section valves are all motori3ed and their positions are sensed by their end limit switches. Falves are classified in four categories according to their operational involvement. -hey are listed as follows4 a2 ,ain steam supply valves. b2 (team pressure control valves. c2 (ection valves. d2 %rain valves. -he main steam supply for soot blowing is obtained from two alternative sources each isolated by a separate motori3ed isolating valve. /nly one source can be selected at a time. &ow, this steam supply is distributed to four sections of the boiler and each section is isolated by a motori3ed section valve. %own stream of which a pressure switch monitors the steam pressure. -he air heaters can be cleaned using an auGiliary steam supply. -his supply is used eGclusively for the air heater soot blowers when the air heater is re"uired to be cleaned during start up of the boiler. -he auGiliary supply is connected downstream of the section valve, which remains closed when this source is being used. -he drainage pipe work is isolated by a number of motori3ed drain valves.

L+6a*!+% +? S++* B8+9,rs> -he blowers are divided into groups, numbered from 8 to 9. )roup 8 to > comprises of wall blowers and group ; to 9 comprises of long retractable soot blowers. -he soot blowers within each group are listed in pairs, with an odd numbered soot blower paired with an even numbered soot blower.

'a88 B8+9,r> Presently there are BB wall blowers, which are numbered from 8 to BB. All wall blowers are located at four levels, so grouped as groupI8, groupI<, groupI= K groupI>, of first pass of boiler each having << blowers. )roupI8 is below furnace 3one and other three are above furnace 3one.

L+%& R,*ra6*a-8, S++* B8+9,r> #*(7s are kept in #!( and *!( of the boiler. /dd numbered #*(7s are kept in *!( and even numbered #*(7s are kept in #!(. With an eGception of group ?, all soot blowers in a particular group are operated in synchronous pairs in an automatic se"uence i.e. an odd numbered soot blower with an even numbered soot blower #*(7s are mainly used to penetrate between the tube banks of the economi3er, superheater etc.It consists of a fabricated boG casing, steam lance tube, steam feed tube, steam isolating valve, traverse and rotary chains, etcP Whenever the signal to operate the soot blower is given from the control room, an electric motor drives the traverse reduction gearboG from its parked position, at a preset distance the steam isolating valve opens to allow steam to flow through the feed tube and out through the lance tube no33les. -he pattern of the steam jet from the no33les is helical with a different pitch on the inward stroke to that on the outward stroke. At about midIstroke a feed tube support rises to abut the feed tube preventing sagging. Whenever the eGtent of the stroke has been reached, a reverse limit switch is actuated causing the main gearboG.lance tube to reverse and return to its parked position engaging the stop limit ready for the neGt operation, having reIset the feed tube support mechanism and isolated the steam isolating valve. An air scavenge valve is fitted to the steam isolating valve which prevents the ingress of boiler gases into the valve chest and provides a positive air flow when the soot blower is in the parked position. Air is also provided for the wall boG to prevent gas leakage from the boiler.

SOOT BLO'ER ARRANGEMENT

PP8 PP< PP= PP> PP; PP? 8< 8 <= >; < <> >? = <; >: > <? >B ; <: >9 ? <B ;D => =; =? ;B =: ;9 =B ?D =9 ?8 8= 8> 8; 8? 8:

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STEAM TO MECHANICAL PO'ER INTRODUCTION A thermal power plant is based upon the principle of conversion of heat energy into mechanical energy. $or this conversion of energy a power plant re"uires a turbo machine. A turbo machine is a power producing thermodynamic machine. In order to function, a turbo machine re"uires a suitable working fluid, a source of highIgrade energy and a sink for lowIgrade energy. In a thermal power plant water is used as a working fluid and it is converted into steam. A steam turbine is a device that converts heat energy of the steam coming from the boiler into the mechanical energy of shaft rotation. &-P1 *ihand has four ;DD ,W units. 'ach unit has one steam turbine. $or large turbo machines, multicylinder designs are used. -he number of cylinder depends on the terminal conditions of steam and speed of rotation. -he turbine with a number of cylinders on a single shaft is described as a H-andem compound machineA. &-P1 *ihand is a fossilIfired power station using a typical turbine of ;DD ,W output in each unit. 'ach of the two turbines consists of a single flow !P, a double flow IP and two double flow #P turbines 0cylinders2 coupled to the generator shaft. 'ach section of steam turbine consists of a rotor from which project several rows of closely spaced blades. 7etween each row of moving blades there is a row of fiGed guide vanes 0blades2 that projects inward from circumferential housing. -he vanes are carefully shaped to direct the flow of steam against the moving blades at some angle and at a high velocity that will maGimi3e the energy conversion. -he crossIsectional diameter of a turbine section increases continuously and so the steam eGpands. In this process the temperature and pressure of the steam decreases and volume increases continuously. -he #P section has the largest crossIsectional diameter, whereas the !P has smallest crossIsectional diameter. (eparate stop valves and governing valves are provided to control the steam inlet and outlet from the turbines. -he main auGiliaries of a steam turbine are the rotor, blades, guide vanes, casing, bearings and couplings, bolting, steam chests, valves and critical piping.

INTRODUCTION TO <11 M' PO'ER PLANT

BOILER> -he boiler is a radient, controlled circulation drum, dry bottom type unit. -he boiler units are designed for the following terminal conditions 0mcr24 'vaporation a2(! outlet 4 8,:<; t.hr b2*! outlet4 8,;=D t.hr Working pressure after stop valve48:B kg.cmI< (team -emperature at (! outlet 4;>D deg 1 (team -emperature at *! Inlet (team -emperature at *! Inlet (team -emperature at *! Inlet 4=>>.8 deg 1 4>;.B; kg.cmI< 4>=.=? kg.cmI<

$eed Water -emperature at '1/ Inlet4<;? deg 1 $urnace %esign Pressure 4 L.I ??D mm wc0g2

-he boilers are of single furnace design,circulating pumps to provide assisted circulation. 'ach 7oiler corner is fitted with tilting tangential burner boGes comprising for high energy ignitors, four lightIup heavy oil fired burners and eight pulveri3ed coal burners. -he angle of tilt from the hori3ontal is about M=D deg to L=D deg. $eed water to the boiler passes through !P feed heaters into the economi3er and then to the steam drum from where it flows into the suction manifold and furnace wall circuits via the three boiler circulating pumps, returning to the steam drum as a water.steam miGture.-his miGture is separated into three stages and first two stages are incorporated into the turbo separators and the final stage takes place at the top of the drum just before the steam enters the connecting tubes comprising of first stage superheating . within the steam circuit there are a further four stages of superheating, making five in total. -here are also three stages of reheat. superheater temperature control is provided by spray attemperation situated in the connecting link between the superheater low temperature pendant outlet header and the superheater division panel inlet headers. Pulveri3ed coal system -he system for direct firing of pulveri3ed coal utili3es bowl mills to pulveri3e the coal and a tilting tangential firing system to admit the pulveri3ed coal together with the air re"uired for combustion0secondary air2 to the furnace.

As crushed coal is fed to each pulveriser by the feeder,primary air supplied from the primary air fans which dries the coal as it is being pulveri3ed the transports the pulveri3ed coal through the coal piping system to the coal no33les in the wind boG assemblies. -he pulveri3ed coal and air discharged from the coal no33les is directed towards the center of the furnace to form firing circle. Primary air system -he primary air draught plant supplies hot air to the coal mills to dry and convey pulveri3ed coal to the burners. -he P.A system comprises two P.A. fans,two steam coil air preheaters 0(1AP!2 and two regenerative air preheaters.'ach fans, which is of sufficient rating to support ?D@ ,1* load,discharges through a (1AP! into a common bus duct that has four outlets,two directing air into the primary air preheater for heating, two direct cold air straight to the pulveri3ed mills.

(econdary air system

-he secondary air draught plant supplies the balance of air re"uired for pulveri3ed coal combustion, air for fuel oil combustion, and overfire air to minimi3e the production of nitrous oGide0&/J2. -he secondary air system,comprises two forced draft 0$.%.2 fans, two steam coil air preheaters 0(1AP!2 and two regenerative type secondary air preheaters.

$lue gas handing system

-he flue gas handling plant draws the hot flue gases from the furnace and discharges, them to atmosphere through the chimney. %uring its passage to the chimney. %uring its passage to the chimney, flue gas is passed through a feed water economi3er and four regenerative air preheaters to improve boiler efficieny, and through four electrostatic precipitators to keep dust emission from chimney within prescribed limits.

soot blowing system

/n load,gas side cleaning of boiler tubes and regenerative air heaters is achieved using 8<? electronically controlled soot blowers which are disposed around the plant as follows4 BB => > I I I furnace wall blowers long retractable soot blowers Air heater soot blowers primary and secondary air heaters 4 steam 4 steam 4 steam

-6*7I&'
GENERAL DESCRIPTION -he turbine is a reaction, condensing type, tandem compound with throttle governing and regenerative system of feed water heating. It is coupled to directly to the generator. -he turbine is suitable for sliding pressure operation to avoid throttling losses at partial loads. -he turbine is a single shaft machine with separate !P, IP and #P turbines. !P turbine is a single flow cylinder where as IP and #P are double flow cylinders. (team flow to !P -urbine is controlled by four combined main stop and control valves by a simple throttle governing system. /n the two eGhaust lines of !P turbine, swing check valves are provided which prevent hot steam from the reheater flowing back into the !P turbine. -he hot reheat steam is admitted to the IP turbine through the four combined stop and control valves. IP eGhaust is connected to the #P turbine by cross over pipes without valve sat diametrically opposite points. HP TURBINE -he outer casing of the !P turbine is of the barrel type and has neither aGial nor a radial flange. -he guide blade carrier is aGially split and kinematic ally supported. -he space between the outer casing and the inner casing is fed from admission steam to !P turbine. -his steam is drained through !P casing drain during start up which promotes "uicker heating of inner casing which results in lesser problems of differential eGpansion. -he inner casing is attached in the hori3ontal and vertical planes in the barrel casing so that it can freely eGpand radially in all directions and aGially from a fiGed point. -he !P turbine is provided with a balance piston in the admission side to counter act the aGial thrust caused by steam forces. !P turbine is provided with 8B stages of reaction blades. IP TURBINE It is of double flow construction and consists of two casings. 7oth are aGially split and inner casing kinematically supported and carries the guide blades. -he inner casing is attached to the outer casing in such a manner as to be free to eGpand aGially from a fiGed point and radially in all directions. IP turbine is having 8> reaction stages per flow. 'Gtraction steam to high pressure heater no.; and deaerator are taken from IP turbine and the IPIeGhaust respectively.

LP TURBINE -he casing of the double flow #P cylinder is of threeIshell design. -he shells are aGially split and of rigid welded construction. -he inner shell taking the first rows of the guides blades, is attached kinematically in the middle shell. Independent of the outer shell, the middle shell, is supported at four points on longitudinal beams. -wo rings carrying the last guide blade rows are also attached to the middle shell. #P turbine is provided with ? reaction stages.flow. TURBINE SYSTEM HP STEAM SYSTEM -he high pressure and temperature steam is piped from the boiler stop valves to the steam inlet ends via two steam legs or steam pipes. -hese two steam pipes are further branched into four subIbranches. -hese branches endIup into four inlet valves of four hori3ontally arranged steam chests, two on each side of the !P cylinder. 'ach of the steam chest contains a !P emergency stop valve and a !P governing valve arranged coIaGially. -he !P stop valve is a crucial valve and is used only during emergency conditions. (team leaves the governor valves through branch pipes to the top and bottom inlet tee pieces on the !P cylinder. -he steam chest assemblies are mounted on the foundations close to the !P cylinder. 'ach stop and governor valve is opened by a hydraulic operating gear and closed by two coil springs. IP STEAM SYSTEM -he steam eGpands in the !P turbine and is fed into the reheater section of the boiler. $rom reheater section of the boiler the steam is piped into the steam inlet ends of the intermediate pressure turbine through four inlet pipes. -here eGists four steam chests two on each side of the IP cylinder. 'ach steam chests contains an IP intercept stop valve and an IP governing valve arranged coIaGially. (team leaves the governor valves through branch pipes to the top and bottom tee pieces on the IP cylinder. -he opening and closing mechanism of the valves of the IP turbine is similar to that of the !P stop valves and governing valves.

LP STEAM SYSTEM IP steam after eGpansion is eGhausted through four stub pipes, two at each end at the top half of the IP cylinder, and is ducted to the two #P cylinders by IP.#P crossover pipes. -he volume of steam at the IP outlet is enormous and to handle such an enormous volume of steam two #P turbines are provided. -he steam from each of the #P turbines after eGpansion is fed into the condensers mounted below the #P turbines. In the condensers the steam outlet from the #P turbines is condensed to give condensate, which further undergoes a cyclic process to give feed water for the boiler input. !ere, under slung condensers with BDD inclined tubes are used, using a connecting duct between the turbine outlet flange and condenser inlet flange. As the condenser tubes are normally much longer than the width of the turbine casing, so this duct is trape3oidal in shape. -he heat energy carried by the steam is converted into mechanical power, which results into the shaft rotation. -he turbine shaft is coupled with the generator shaft. -his rotary motion of the generator shaft is converted into electrical power by the generator. -he power output from the generator is at low voltage level of <D kFQ. -his low voltage is boosted to high voltage level of >DD kF to reduce the transmission losses . TURBINE AUCILIARIES T#r-!%, 6as!%& (team turbine casings are the massive steel casings that encase the internal stationary and rotating components of the turbine. -urbine casings have two critical functions4 a2 1ontaining the steam pressure and b2 ,aintaining support and alignment of the internal components. -here are generally two casings4 !) O#*,r 6as!%& -he outer casing is divided on the hori3ontal centerline into top and bottom half casings. 7oth the halves are bolted together with bolts and cap nuts at their hori3ontal joint flanges.

!!) I%%,r 6as!%& -he inner casing is subjected to the highest temperatures and pressures, is also divided at the hori3ontal centerline into top and bottom half casings, which are bolted together in a similar manner at their hori3ontal joint flanges. -he inner casing is supported within the outer casing in such a manner as to maintain proper alignment and allow thermal eGpansion. 1racking of the casing can lead to steam leaks and, in eGtreme situations, to bursting. 1racks in casings are typically located at the inlets of !P and IP turbine sections, where the local thermal stresses are higher. T#r-!%, B8a),s 7lades are the single most costly parts of the turbine. -he function of the turbine blades is to convert the available heat energy carried by the steam into mechanical energy. 7lades fitted in the stationary part are called Hguide bladesA or Hno33lesA and those fitted in the rotor are called Hmoving bladesA. S*,a$ 6h,s*s a%) 7a87,s 'ach of the !P, IP, #P cylinders of the turbine has four steam chests two on each side of the turbine. (team chests are the pressure vessels or steam carrying spaces, which performs the function of both carrying as well as transferring the steam at high pressure and high temperature via valves into the turbine cylinders. -hese steam chests comprises of a stop valve and a governing valve. -he steam from the superheaters outlets is admitted to the !P steam chests via four !P steam mains. -he steam from the steam chests is admitted to the !P turbine steam inlet pipe through the emergency stop valves and the associated governing valves which are housed in steam chests. After eGpansion in the !P turbine the steam is fed into the reheater and then to IP steam chests, through !P turbine steam outlet pipe. -he steam from IP steam chests is fed into the IP turbine via IP stop valve and IP governing valves and then to #P steam chests. S*+ 7a87,s -he stop valves are emergency valves placed in the steam chests and are provided in the main steam line. -he purpose of the emergency stop valves is to cut off the steam supply during periods of shutdown and to provide prompt interruption of steam flow through the turbine cylinders in an emergency trip.

&ormally, these valves are kept open fully but during emergencies these valves are fully closed 08DD@2. %uring such conditions, the plant is producing no power because no input is given to the turbine. G+7,r%!%& 7a87,s -he governing valves are also situated in the steam chests. -hese are the control valves i.e. they provide accurate control of the steam flow rate into the turbine, thus controlling the generator load when the machine is synchroni3ed to the grid. !P governing valves are the most important valves. -hey controls the amount of power produced by the plant or unit. $or a unit producing ;DD ,W power, the !P governing valve opening is kept as >DI>;@ of the total valve opening.

T#r-!%, O!8 Sys*,$> /I# (6PP#+ (+(-', -he oil supply system fulfills the following functions4 a2 #ubricating and cooling the bearings. b2 %riving the hydraulic turning gear during interruptions to operation, on start up and shut down R8S. c2 Eacking up the shaft at low speeds 0turning gear operation, start up and shut down2 R8,<S. OILSYSTEM 6nder normal operating conditions, the main oil pump 082 situated in the bearing pedestal and coupled directly to the turbine shaft draws oil from the main oil tank 0<?2 and conveys it to the pressure oil system. -he suction of the main oil pump is aided by two injectors 0<;2. -he injectors produce pressure at the suction connection to the main oil pump sufficient for all types of operation. -his guarantees that the main oil pump takes over the safe supply of oil and cavitations that could occur due to greater suction heads are avoided. -he amount of oil re"uired for driving is eGtracted from the pressure oil circuit and adjusted by means of the throttle 0=82. -he oil for the turning gear 0:2 is also eGtracted from the pressure oil system. /il is admitted to the no33les by opening the shut off valve 0==2. -he pressure oil is cooled in the oil coolers 0892 and

reduced to lubricating oil pressure in the throttle 08B2. -he throttle is adjusted on the initial startI up. -he amount of oil re"uired for each bearing is adjusted on start up by means of the oil throttles 08;2. 4ULL LOAD AUCILIARY OIL PUMPS %uring turning gear operation and start up and shut down operation, one of the two three phase a.c., full load auGiliary oil pumps 0<<,<>2 supplies the pressure oil system and takes over the function of the main oil pump when this is not in operation because the turbine is running too slowly. -he full load submersible auGiliary oil pumps are situated on the oil tank 0<?2 and draw in oil directly. EMERGENCY OIL PUMP When main and full load auGiliary oil pumps fail, the lubrication supplies oil directly to the lubricating oil line, by passing the oil cooler and thus preventing damage to the bearing shells.

OIL RETURN SYSTEM -he lubricating oil from the bearings is returned to the main oil tank via a header. ECTRACTION O4 OIL VAPOUR -he main oil tank is designed to the air tight. -he eGtractors 0<B2 produce a slight vacuum in the main oil tank and the bearing pedestals to draw off any oil vapour. 4ILTERS /il for the thrust bearing is passed through the dupleG oil filter which can be switched over and cleaned during operation. MAIN OIL TANK -he main oil tank contains the oil necessary for the lubricating and cooling of the oil bearings and for the lifting device. It not only serves as a storage tank but also for deaerating the oil. -he capacity of the tank is such that the full "uantity of oil circulated not more than B times per hour.

-his result in a retention time of approG. : to B minutes from entry into the tank to suction by pumps. -his time allows sedimentation and detainment of the oil. /il returning to the tank from the supply system first flow through a submerged inlet into riser section where the first stage deaeration takes place as the oil rises to the top of the oil tank. /il overflows from the riser section through the oil strainer into the adjacent section of the tank where it is then drawn off on the opposite side by the suction pipe of the oil pumps. ,ain oil tank has the following mountings4 8. <. =. >. ;. ?. :. A1 auGiliary oil pump %1 emergency oil pump (haft lift oil pumps /il injector /il vapour eGtractor /il level indicator (onar level M limit switch

-he main oil pump is situated in the front bearing pedestal and supplies the entire turbine with oil that is used for bearing lubrication, cooling the shaft journals and as primary and test oil. -he main oil pump is driven direct from the turbine shaft via the coupling. -hese pump also convey oil in the suction branches MAIN OIL PUMP 'ITH HYDRAULIC SPEED TRANSMITTER -he main oil pump is situated in the front bearing pedestal and supplies the entire turbine with oil that is used for bearing lubrication, cooling the shaft journals and as primary and test oil. -he main oil pump is driven direct from the turbine shaft via the coupling. -hese pumps also convey oil in the suction branches of the main oil pump for oil injectors that maintain a steady suction flow to main oil pump. !ydraulic speed transmitter operates on the same principle as centrifugal pump impeller. -he variation of the pressure in the primary oil circuit due to a speed variation serves as a control impulse for the hydraulic speed governor. -he hydraulic speed transmitter is supplied with control oil supplied from the control e"uipment rack. -he suction of the pump is always flooded and hence maintains an uniform suction pressure.

AUCILIARY OIL PUMP -he auGiliary oil pump is a vertical one stage rotary pump with a radial impeller and spiral casing. It is fiGed to the cover of the oil tank and submerges into the oil with the pump body. It is driven by an electric motor that is bolted to the cover plate of the main oil tank. -he pump shaft has a sleeve bearing in the pump casing and a grooved ball bearing in the bearing yoke. -he bearings are lubricated from the pressure chamber of the pumpN the sleeve bearing via a bore in the casingN the grooved ball bearing via lube line. DC BEARING OIL PUMP -his is a vertical, centrifugal submerged type and serves for lubrication and cooling of the bearing during emergency conditions when one of the other pump fails. -his is driven by a %.1. motor. SHA4T OIL PUMP -he lift oil pump is selfIpriming screw spindle pump with three spindles and internal bearings. -he pump supplies the oil to lift the turbine rotor at low speeds. OILVAPOUR ECHAUSTER -he function of oil vapour eGhauster is to produce a slight negative pressure in the main oil tank and in the bearing casing and thus draw off the oil vapour. OIL COOLER $unction of oil cooler is to cool the lubricating oil supplied to the bearing of the turbine. /il cooler consists of the tube nest, the inner, outer shell and water boGes. -he tube nest through which the cooling water flows is surrounded by the oil space formed by the outer shell. -he oil is to be cooled enters the oil cooler and flows to the inner shell. -his shell supports the large baffle plates, which are provided with an opening in the center. 7etween every two large plates there is a small intermediate plate is smaller in diameter than the inner shell and leaves an annular gap. -his arrangement serves to achieve a cross flow pattern forcing the oil flowing to the outlet branch to flow through the middle of the large plates, while passing round the edge of the short ones.

T#r-!%, &8a%) s,a8!%& sys*,$> !PI-urbine, IPI-urbine and #PI-urbine gland leak off are connected to seal steam header and vapour eGhauster system. Initially gland steam re"uirement for all the three cylinders is met by supplying auGiliary steam to the seal steam header and the header pressure is maintained by the seal steam control valve. When the unit load is raised above =D to =;@ !P K IPIglands start supplying gland leak off steam to the header to the re"uirement of #PIglands. 7eyond >D@ load, no auGiliary steam is re"uired. /nce the self sealing steam takes place, then seal steam header pressure is maintained by opening the leak of steam control valve to the condenser. )land steam header is provided with a motor driven drain valve which helps to raise the gland steam temperature during start up. -his drain valves normally remains open till the gland steam temperature to #P gland increases beyond 8;DT. CONDENSATE 'ATER SYSTEM> -!' P6*P/(' /$ -!I( (+(-', I( -/ (-/*' A& A%'U6A-' U6A&-I-+ /$ %',I&'*A#IV'% WA-'* -/ ,''- -!' ,A5' 6P *'U6I*','&-( $/* &/*,A# 1+1#' $#61-6A-I/&( A&% $/* A7&/*,A# /P'*A-I&) 1/&%I-I/&( W!'& (6PP#+ /$ %',I&'*A#IV'% WA-'* I( I&-'**6P-'%. -his system will transfer condensate to and from storage tanks as to satisfy main cycle re"uirements. -he main cycle flow and thermodynamic re"uirement is maintained by transporting the condensate collected in the condenser hotwell through various stages of feed water heating and other e"uipment to the deaerating feed water heater. -he condensate eGtraction pumps normally deliver the condensate through the three low pressure feedwater heaters, the deaerating feed water heater to the deaerating storage tank. -he low pressure feed water heaters receive eGtraction steam as it passes through feedwater heater. -he deaerating further preheats the condensate prior to its entry into the deaerating storage tank. -he deaeratig feed water heater is warmed by eGtraction steam during the normal operation and auGiliary steam K cold reheat steam are utili3ed as the heat source during start up and shut down condition.

-he normal make Mup to the condenser is supplied from deminerali3ing plant through the makeup pumps. &ormally, on low level in the condenser hotwell, condensate will flow from the condensate storage tank to hotwell by static head in the tank and differential pressure due to the condenser vacuum, however, this flow will be inade"uate, the condensate, transfer will supplement the flow. -his makeup is sprayed into the steam space above the tube bundles. -he condenser hotwell is condensate collection vessel, integral with the condenser shell, and located in a pit below the ground floor. 1ondensate collected in the hotwell is pumped by =W;D @ condensate eGtraction pumps to the feed storage tank through feedwater placed in series. -wo lines from hotwell, make a common header where from three lines are connected at the suction of three condensate eGtraction pumps. -he suction piping to the pumps is vented back to the condenser, to insure that the nonIoperating pumps stays completely flooded. -hese vent lines include manual valves on the vent for each pump. A minimum flow 0=;D -.hr2 recirculation line for each pump is provided, returning to the condenser via a flow control valve and a locked open shut off valve. -he shaft seals of these pumps are the waterIinjected type fed from a header to prevent the suction of air, particularly the pump that is not operating while the condenser is under vacuum. C+%),%sa*, E5*ra6*!+% P#$ > -he function of 1ondensate eGtraction pumps is to pump out the condensate to the deaerator through gland steam cooler, and #P heaters. -he steam from the #P cylinders eGhausts into the condenser shells where it is constrained to flow across the water tubes, through which cooling water is circulated. -he steam condensed on the tubes drain to the bottom of the shell .-he condensate is retained in the condenser shell bottom by means of the condenser level control valve. -he water in a condenser provides a head of water for the condensate eGtraction pump to suppress cavitations in its suction impellers. -here are two 8DD@ duty eGtraction pumps, one remains in duty and one remains stand by. With all the necessary instruments such as suction and discharge valve isolating and dump valves to insure efficient operation.

-he thrust bearings in the driving motors have temperatures sensor, which can trip the motors automatically. -he pump discharge the condensate via the gland steam condenser and the condensate polishing plant to the #P feed heating system.

A!r E5*ra6*!+% P#$ > -he function of the air eGtraction pump is to raise and maintain the vacuum conditions in the turbine main condensers, and to remove air and other nonIcondensable gases vented to the condenser from various parts of the turbine and feedwater heating system. G8a%) s*,a$ 6+%),%s,r An automatic turbine gland sealing system is used to prevent the escape of steam into the turbine hall, where it would condense on the walls and the plant. It also prevents the ingress of air at the rotor ends of all the turbine cylinders. -his is done by using the gland steam condenser. -he function of the gland steam condenser is to maintain a subIatmospheric pressure at the outermost leakIoff belt of the glands and thereby prevent the leakage of steam from the glands into the turbine hall.-he gland steam condenser condenses the steam from the steam. air miGture drawn from the outer pocket of the gland. -his heat given by the steam is absorbed by the feedwater. 1ondensate formed in the shell drains to the gland steam condenser drain tank. -his is again recirculated back to the condensers. Dra!% 48ash C+%),%s,r -he drain flash condenser receives heater drip or drain water from #P heaters. When the drain water enters the flash condenser through the disperses, steam is flashed off. -his steam is drawn into the tube nest where it condenses and cascade to the bottom of the shell. -he resulting drain water is delivered to the main condenser. -he water side of the %$1 is of the conventional to pass surface type in which the feed water flows through the tube and steam passes over them. -he vessel comprises a tube nest, a shell, an inlet and an outlet water boG. -he water boG has a dished end and incorporates

the feed water inlet and outlet connections. A flanged branch on the water boG is fitted with a davit type hinged cover to give access to the tube bores. A center plate and an end plate fitted with two stiffeners form a diversion plate, which separates the incoming, and outgoing flows .-he end plate carries a cover, which is located and bolted between the stiffening ribs. -he %$1 is mounted on steel work on four attachment points at the water boG bonded to upper and lower mild steel bearing plates.

B+!8,r 4,,) P#$ s> 7oiler feed pumps are an important part of any boiler operation. -hey control the amount of water fed to the boiler and the manner in which it is fed. C,%*r!?#&a8 I 1ontinuous T#r-!%, I Intermittent In order to properly select a boiler feed pump five key points must be considered4 '!88 *h, #$ s + ,ra*!+% -, 6+%*!%#+#s +r !%*,r$!**,%*E -his is an operational "uestion and is often answered by the type of level control found on the boiler that the pump will be servicing. As a general rule of thumb, boilers with a capacity of 8D,DDD lbs..hr. or less utili3e a float type switch that starts and stops the boiler feed pump to satisfy a predetermined water level within the boiler. -his is a classic intermittent operation. 7oilers with capacities eGceeding 8D,DDD lb..hr. typically employs a modulating feed water regulator and will continuously feed water to the boiler at various rates depending upon the water level in the boiler. 7y knowing which operation you are to satisfy, you can determine which pump design is best suited for your application. As a general rule of thumb a turbine pump is used in an onIoff situation and a centrifugal pump is used for continuous operation. 7ut remember, this is a general rule and is some cases a centrifugal could be used for an onIoff application and a turbine for continuous.

'ha* !s *h, *,$ ,ra*#r, +? *h, 9a*,r -,!%& #$ ,)E It is also important to know the temperature of water you intend to pump. ,ost pumps can usually handle <8;$ to <=D$, other pumps are available that can handle higher temperatures by using eGternal waterIcooling. 5eep in mind that a deaerator pump must be able to handle higher temperatures because they operate at a ; psi or <<:$. 'ha* !s *h, r,F#!r,) 6a a6!*yE !ow much water you intend to pump is dependent upon the evaporation rate of the boiler the pump will service. A safe figure for an onIoff application would be < times the evaporation rate of the boiler. With a modulating level control, a factor of 8.= times the evaporation rate plus recirculation is recommended. 'ha* !s *h, ),s!r,) )!s6har&, r,ss#r,E When you pump directly into the boiler you will need to overcome the pressure in the boiler as well as any piping losses. +ou can chose the right pump by looking at the pump curves to determine which will accomplish this task. (hould you have a modulating valve in the discharge line, the minimum you will need to add to the boiler operating pressure will be <D to <; lbs. ,ake sure that the pump can handle the pressure along with the flow rate needed. With an onIoff level control the pumps should be designed for the relief valve pressure.

'ha* !s *h, NPSH +r %,* +s!*!7, s#6*!+% h,a) r,F#!r,)E -his is the last piece of information that you will need. -his is the minimum absolute pressure at the suction no33le at which the pump can operate. -o avoid pump cavitation, the &P(!A of the system must be greater than the &P(!* of the pump. In other words, the available &P(! must be higher than the re"uired. We have always si3ed our deaerator stands to be two feet higher than the &P(! needed for the pump selection. *emember, the water level in the storage tank adds to the safety margin.

TDB4P -urbine driven 7$P uses turbine of 8> stages connected to condenser. -urbine is coupled with main pump having engage.disengage unit called Power pack unit using oil pressure. 7etween turbine and booster pump gear assembly is there. Farious system of -%7$P are discussed below4 82 #ube /il (ystem #ube oil system of both -%7$P( are provided with one ,ain /il -ank each in which oil level is separately maintained. It has two A1 A/Ps, one E/P A1 and one %1 A/P connected to tank. #ube oil pressure is maintained at =.DIkg.s". cm is called control oil which is used as governing oil. #ube oil after passing through coolers is led to various bearing of -%7$P system. %1 A/P discharge oil, which is, used on failure of A1 A/Ps bypass the coolers. %uring barring of -%7$P same lube oil at pr. >.DIkg. s". cm is used as power fluid in barring gear impellers. In the lube oil pressure by changing the recirculation flow. <2 (eal. Injection (ystem ,echanical seals are provided on 7P side for which continuous cooling is done by 1'P water. $or 7$P side constant seal injection pressure around 8BIkg.s". cm is maintained with the help of control valve. $ilters are also provided in this line. $rom this line small pipe provides water in the eGhaust steam as eGhaust load spray. (eals drain is collected as clean drain into drain tank and dirty drain flows into common drain header. =2 (team (ystem $or -%7$P there is three sources for steam namely 8. AuGiliary steam <. 1old reheat line =. IPI #P cross over steam. 'Gtraction steam parameters are maintained at >.D kg.s" cm. K =DD degree centigrade. %uring cold start when 1*! or IPI#P steam is not available, AuG. (teamis used for rolling of -%7$P for initial boiler filling. /nce steam is insufficient for increasing the speed beyond =;DD rpm, 1*! steam is automatically cut off.

>2 $eed Water (ystem Water from deaerator is taken through two suction into booster pump and then fed into 7$P suction. %rains K vents are provided in $W system for initial charging and venting of 7$P during rolling. ;2 )land (ealing of -urbine %ownstream steam from main turbine gland sealing is used for -%7$P sealing. 7efore opening of eGhaust valve gland sealing should be done as this is line is connected to condenser. ?2 )overning (ystem $or having the re"uired flow through 7$P, speed of turbine has to be adjusted and for what we need perfectly efficient governing system. )overning system is using the control oil at 9 kg.s" cm. which in turn depending on the position of starting device and speeder gear, will develop secondary oil and auGiliary secondary oil pressure for operating the >,1Fs and one A1F thereby adjusting the steam flow speed change is effected. )overning is achieved with the help of two governorsA namely hydraulic and 'lectrohydraulic governors having '!) control and !) follows it up. BOOSTER PUMP> 'ach boiler feed pump is provided with a booster pump in its suction line which is driven by the main motor of the boiler feed pump. /ne of the major damages which may occur to a boiler feed pump is from cavitation or vapour bounding at the pump suction due to suction failure. 1avitation will occur when the suction pressure at the pump suction is e"ual or very near to the vapour pressure of the li"uid to be pumped at a particular feed water temperature. -herefore all the three feed pumps are provided with a main shaft driven booster suction line for obtaining a definite positive suction pressure. -he boiler feed pump is coupled with its driving motor through hydraulic coupling. -he hydraulic coupling serves the purpose of controlling the speed of feed pump for maintaining a definite delivery head and delivered "uantity of the feed water as per the re"uirement of the boiler.

D,a,ra*+r> %eaerators are used to remove oGygen from boiler feedIwater. It performs the following functions4 It serves as a feedwater heater. $eedwater is deaerated by the removal of nonIcondensable gases present in the feedwater and reduce the oGygen content to a level of about D.DD: ppm. It acts as a HbufferA to the fluctuations of condensate feedwater flow that occur in service durations. -he tank height provides a hydrostatic head to satisfy the suction pressure re"uirements of the boiler feed pumps. -he presence of nonIcondensable gases in the feedwater causes the waterside corrosion or thinning of the boiler tube walls and this further leads to the rupture of walls by the internal fluid pressure. !ere steam injectionItype deaerator is used to deaerate the feedwater. $eedwater from #P heaters is admitted to the deaerator tank and steam is bled from two sources, one from the !P turbine 0which is known as cold reheat steam2, and the other from the IP turbine eGhaust. When this steam and feedwater come in direct contact with incoming water is heated and also gets deaerated. (team initially enters the deaerator through a special, stainless steel Eet (pray atomi3ing valve. -his valve is designed to fully atomi3e and provide complete deaeration under all load conditions. -his design insures that the purest steam comes in contact with the purest water. /nce this high velocity steam mechanically shakes out the last traces of nonIcondensable gases from the water, it flows upward into the preIheater area where it meets the incoming makeIup water and pumped returns. -his water continuously condenses the steam, which preheats and releases the nonIcondensable gases into the internal vent condenser where they are metered harmlessly to the atmosphere. -his action causes more steam to be drawn into ?the system to complete the cycle. $rom the bottom of the deaerator, feedwater is piped through three outlet pipes, each with a strainer, to the three boiler feed pumps and the used up steam is recirculated back to condenser. -he deaerator is mounted at a highIlevel with its centerline =>.?; m above the datum level.

-he deaerating heater utili3es steam by spraying the incoming water into an atmosphere of steam in the preheater section 0first stage2. It then miGes this water with fresh incoming steam in the deaerators section 0second stage2. In the first stage the water is heated to within < T 1 of steam saturation temperature and virtually all of the oGygen and free carbon dioGide are removed. -his is accomplished by spraying the water through self adjusting sprat valves which are designed to produce a uniform spray film under all conditions of load and conse"uently a constant temperature and uniform gas removal is obtained at this point. $rom the first stage the preheated water containing minute traces of dissolved gases flows into the second stage. -his section consists of either distributor or a several assemblies of trays. !ere the water is in intimate contact with an eGcess of fresh gas.free steam. -he steam passes into this stage and it is miGed with the preheated water. %eaeration is accomplished at all the rates of flow if conditions are maintained in accordance with design criteria. Fery little steam is condensed here as the incoming water has high temperature caused by the preheating. -he steam then rises to

the first stage and carries small traces of residual gases. In the first stage most of the steam is condensed and the remaining gases passes to the vent where the nonIcondensable gases flow to the atmosphere. -he water, which leaves the second stage, falls to the storage tank where it is stored for use. At this time the water is completely deaerated and is heated to the saturated steam temperature corresponding to the pressure within the vessel. -he condensate pressure just before the entry to deaerators shall be = psi more than the deaerator steam pressure. 4EED'ATER HEATERS A feed water heater is a special form of a shell and tube heat eGchanger designed for the application of recovering the heat from the turbine eGtraction steam by preheating the boiler feed water. Its principal parts are a channel and a tube sheet, tubes, and a shell. -he tubes may be either bent tubes or a straight tubes. $eed water heaters may be defined as highIpressure heaters when they are located in the feed water circuit upstream from the high pressure feed water pump. #owI pressure feed water heaters are located upstream from the condensate pump, whichAs takes its suction from the condenser hot well. -ypically low pressure feed water heaters are designed for feed water pressures between <: kg.cm s". and ;: kg.cm s"., high pressure feed water heaters range from 88< kg.cm s". to ==; kg.cm s". for super critical boilers. 'ach feed water heater bundle will contain from one to three separate heat transfer areas and 3ones. -hese are condensing, desuperheating, and subIcooling 3ones. 'conomics og design will determine what combination of the three is provided in each heater. A condensing 3one is present in all feed water heaters. #arge volumes of steam are condensed in this 3one and most of the heat is transferred here. -he desuperheating 3one is a separate heat eGchanger contained within the heater shell. -his 3oneAs purpose is to remove superheat present in the steam. 7ecause of the high steam velocities employed, condensation within the desuperheating 3one is undesirable. -he subIcooling 3one is another separate counter heat flow heat eGchanger whose purpose is to subIcooling incoming drains and steam condensate.

HEATER OPERATION4 Prior to opening the feed water valve, the channel start Mup vents are to be opened and remain open until all passages have been purged and feed water begins to discharge. -o remove air from the shell sides of a heater, which does not operate under vacuum, the shell start up vent valves should be opened prior to the admission of the steam to the feed water heater. -he eGtraction lines must be free of all the condensate to prevent the damage to the heater internals by slug flow.when the drains outlet valve is opened, the shell start up vent valves are to be closed and the operating air vent valves are to opened. 1ontinuous venting of air and other nonIcondensable is assured by keeping the shell operating vent valves open. /n initial plant start up of the hori3ontal feed water heaters, having integral drain coolers, the li"uid level is to be kept just below the highIlevel alarm point. /n initial plant startIup of hori3ontal feed water heaters, having integral drain coolers, the li"uid level is to be kept just below the highIlevel alarm point. -his will avoid the possibility of flashing at the subIcooler inlet and the possible tube damage that can result. Approach temperature in eGcess of B degree centigrade indicate the probability of flashing at the subIcooler unit. VENTING Proper venting is necessary on feedwater heaters. All operating air vent connections must be piped to permit continuous venting. -he venting system in a feedwater heater is designed to assure that all points where nonIcondensable gases could collected are vented. $ailure to utili3e all of the operating air vents can lead to corrosion damage and loss of performance due to air blanketing. Fent lines of heaters operating at a different shell pressure must not be piped to a common manifold. $ailure to run individual vent lines from each heater has resulted in inade"uate or no venting of heater operating at a lower shell side than other heaters, piped into a common manifold.

4EED'ATER BY(PASSING A feedwater heater may be severely damaged by erosion and vibration, if it is operated for any significant period or time with the neGt lower heaterAs feedwater flow by passed. When a heater is by passed, its normal feedwater is passed on to the neGt higher heater. -his neGt higher heater will come close to making up the duty of both the heaters. -his single heater will tend to draw a total amount of eGtraction of steam approG. e"ual to the flow of both the heaters. In case of heaters with desuperheating 3ones, the increased steam load due to by passing the previous heater can cause an eGcessive pressure drop in the desuperheating 3ones, which can cause an eGcessive pressure drop in the desuperheating 3one, which in turn can cause condensation. -he condensate flowing at high velocity can lead to severe tube erosion. 'Gcessive steam flow to a heater, resulting from by passing the feedwater side of the previous heater, can result in4 a2 #ocali3ed high velocity leading to vibration of the tubing. b2 $lows, which cannot be ade"uately handled by the drain, control valve. c2 1ondensation in the desuperheat 3one and high velocity impingement. LP 4,,) H,a*!%& Sys*,$ -he lowIpressure 0#P2 feedwater heating system is provided to improve the thermal efficiency of the heat cycle by heating condensate from the condenser with lowIpressure steam bled from the #P cylinder. #owIpressure 0#P2 feedwater heaters are basically simple straightforward Htube and shellA heat eGchangers, with the condensate passing through the tubes and the bled steam being admitted to the shell. -here are total three #P heaters used in the feed heating cycle. (ince, there is a significant volume of unused space between the eGhaust of a doubleIflow #P cylinder and on the top of under slung condenser, this space is utili3ed by inserting two #P heaters in a hori3ontal altitude. -his results in the lowIpressure drop and high temperature for the bled steam, which is used for heating the condensate, with conse"uential improvement in cycle efficiency. -he #P heater &o. = is located outside the periphery of the condensers. -he heaters are HstackedA so that the ultimate #P heater can drain its bledIsteam condensate into the condenser above the working level of condensate in its base.

HP 4,,) H,a*!%& Sys*,$ -he highIpressure 0!P2 feedwater heating system is provided to improve the thermal efficiency of the heat cycle by raising the temperature of the feedwater before it enters the boiler. #ike #P heaters !P feedwater heaters are also of traditional form, but are arranged in a hori3ontal altitude to ensure free gravity drainage of their bledIsteam lines and heaterItoIheater drainage. 7led steam to &o. ? !P heaters is fed from the !P turbine eGhaust system and to &o. ; !P heaters from IP turbine. -he system contains four !P heaters arranged hori3ontally in pairs with a drain flash vessel situated above and between each pair. -he pairs are identified as bank HAA and bank H7A and each contains a &o. ; !P heater, a &o. ? !P heater and the associated drain flash vessel. In the !P feed heating system, water is supplied from the boiler feed pumps via the boiler feed regulating station and is piped through three waysN one to each bank of heaters and one to the bypass pipe. When this feedwater is passed through the !P heaters, its temperature is increased. 'ach heater bank has its own feedwater inlet and outlet isolating valves, which, with the bypass pipe and its springIloaded valve, permits either bank to be taken out of service for minor maintenance or repairs while plant is on load. %rains from the !P heaters are taken either to the deaerator or to condenser A, depending on the levels of water and pressures eGisting in the heaters, which in turn depends on the generator load. -he drains are controlled by level controllers and at normal loads pass to the deaerator. At low loads, drains are diverted to the condenser. 4,,) R,&#8a*!%& S*a*!+% -o maintain the rate of feedIwater input to the boiler corresponding to the steam output from the boiler under all conditions of loading, feed regulating station is used. $or this purpose, feed regulating station has four regulating lines out of which one line remains standIby. Also to ensure security of steam supply it has been considered necessary to provide a multiple feedIwater regulating valve arrangement -he threeIelement feedIflow regulating system has been developed to meet the re"uirements of the boiler. -he essential factors that are mainly considered are the steam flow from the boiler, the feed water flow to the boiler and the water level in the boiler drum.

By( ass sys*,$s> -he byIpass system performs an important function. It permits the boiler to be operated independently of the turbineIgenerator system. -he byIpass system comprises two main unitsI !P 7yIpass system. #P 7yIpass system. HP By( ass sys*,$ -his system comprises of the operation of bypassing the !P steam without being passed through the !P turbine. -he !P steam is taken from each of the main steam lines after the !P steam stop valves. -he main steam passes into the cold reheat inlet pipes via four pressure control valves and their associated isolating valves. -he valve include the spray water supply and control e"uipment .-he !.P. valve will operate automatically to maintain upstream pressure on start .In addition upon rapid load rejection .-hese valves will operate to relieve ?D@ of ,1* rated steam flow to the reheat system .-he !XPXrelive valve mounted on the main steam pipe work will operate to relive eGcess steam to atmosphere LP By( ass sys*,$ -he #P byIpass system consists of four lines taken from the four hot reheat pipes 0upstream of the IP turbine control valves2. -hese four lines are then converged into two. -he steams in each line flows through an isolating valve, a pressure control valve and then into the condenser dump tube, bypassing the IP, #P turbines. G,%,ra*+r -he two ;8> ,W turbineIgenerator sets are set aGially in line in the turbine hall. -he generator is a <Ipole, =Iphase, hydrogen and waterIcooled machine, driven from the turbine. -he main eGciter is solidly coupled to the rear end of the generator shaft. A brush less main eGciter provides the eGcitation power for the generator. -he output from this eGciter is fed to the generator rotor. -he eGciter line is directly coupled to the turbine generator shaft and is driven at generator speed. 'ach generator has its own independent stator windings. !ydrogen is used to cool the generator rotor winding and stator core, the stator winding is directly waterIcooled.

G,%,ra*+r + ,ra*!+%a8 8!$!*s> *ated output *ated output &ominal stator voltage (peed Power factor $re"uency Ma!% ,56!*,r sys*,$ -he main eGciter system is a siGIpole, threeIphase, rotating armature generator. -he stator has %.1. $ield system and A.1. winding is mounted on the eGciter rotor. -he rotating rectifier is mounted on the eGciter unit shaft out board of the eGciter armature .-he rectifier modules, one Lve and other Mve are contained within the Lve and Ive rectifier hubs shrunk onto the eGciter unit shaft. -he main eGciter is solidly coupled to the rear end of the generator shaft. !ere a brush less main eGciter is used to provide the eGcitation power for the generator. -he output from this eGciter is fed to the generator rotor. -he eGciter line is directly coupled to the turbine generator shaft and is driven at generator speed -he main eGciter is supplied with power by a pilot eGciter whose output is rectified and controlled by the eGcitation control system 0'1(2. -his pilot eGciter is located to the front of the main eGciter and is a salient pole, permanent magnet, a.c. generator of the hetropolar type. -he pilot eGciter is airIcooled with an open, selfIventilated air system. E8,6*r!6a8 -arr!%& &,ar -he !P, IP and #P rotors must be turned continuously during startIup and shut down periods. -his provides even heating or warm up in the initial start up stage of the turbine and cooling during a shut down of the turbine. -o perform this operation an automatic engaging and disengaging electrical barring gear is used. -his electrical barring gear rotates the coupled turbine and generator rotors continuously at approGimately =; r.min. ;8> ,W ?D; ,FA <D kF =DDD r.min D.B; #ag ;D !3

'lectrical barring gear is a motor driven machine i.e. it receives power to operate from the motor, which is vertically mounted on a support plate outside the pedestal above the wormshaft. -his motor supplies =: kW power for the barring gear operation. -his power transmission between motor and barring gear takes place through worm and worm wheel arrangement. -he motor driven electrical barring gear is mounted on a pedestal at the eGtreme rear of the generator and eGciter and the drive to the turbine generator rotor is transmitted through a H(ynchronous (elf (hiftingA 0(((2 clutch, which automatically engages to drive the turbine generator rotor at a constant speed of approGimately =; r.min and automatically disengages when the rotor speed, under steam, rises above this value. If the electrical barring gear motor develops a fault or if the complete rotor re"uires turning for maintenance checks, it can be turned manually. -he individual rotors of each cylinder can be turned independently.

MAIN, COLD REHEAT AND HOT REHEAT STEAM LINE MAIN STEAM LINE MAIN STEAM STOP VALVE

S U P E R H E A T E R

HIGH PRESSURE TURBINE

MAIN STEAM LINE DESUPER HEATER

MAIN STEAM STOP VALVE HP BYPASS SYSTEM COLD REHEAT LINE HOT REHEAT LINE IV

R E H E A T I N

R E H E A T O U T

INTERMIDIATE PRESSURE TURBINE

IV TO LO' PRESSURE TURBINE

DESUPER HEATER .