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Acknowledgment
The result of all engineering efforts whatever from they take a direct outcome of not
just an individuals thinking but represents the organization. The same view holds
good this seminar report.
I extended my sincere gratitude towards Er. SAMIR BHATNAGAR SIR
(EXECUTIVE ENGINEERING B.M.D.I, BTPS) for giving us invaluable
knowledge & Technical guidance.
I would like to thanks Er. SAMIR BHATNAGAR SIR (EXECUTIVE ENGINEER
B.M.D.I, BTPS) for giving me their kind co-operation & inspiration to do my seminar
work.
I also thanks all the staff members and my friends for their endless Help and support.
Abstract
A thermal power station is a power plant in which the prime mover is steam
driven. Water is heated, turns into steam and spins a steam turbine which
drives an electrical generator. After
it passes through the turbine, the steam is condensed in a condenser and recycled
to where it was heated; this is known as a Rankine cycle. The greatest variation in
the design of thermal
power stations is due to the different fuel sources. Some prefer to use the term
energy center because such facilities convert forms of heat energy into electricity.
Some thermal power plants also deliver heat energy for industrial purposes, for
district heating, or for desalination of water as well as delivering electrical power.
A large part of human CO2 emissions comes from fossil fueled thermal power
plants; efforts to reduce these outputs are various and widespread.
At present 54.09% or 93918.38 MW (Data Source CEA, as on 31/03/2011) of total
electricity production in India is from Coal Based Thermal Power Station. A coal
based thermal power plant converts the chemical energy of the coal into electrical
energy. This is achieved by raising the steam in the boilers, expanding it through
the turbine and coupling the turbines to the generators which converts mechanical
energy into electrical energy.
Contents
1. BRIEF HISTORY/INTRODUCTION OFORGANIZATION...5
2. PRODUCTS AND SPECIFICATION6
3. PRODUCT FLOW CHART7
4. PRODUCTION PROCESS..9
5. PRINCIPAL......................................................................................................................11
6. COMPONENTS OF COAL FIELD THERMAL POWER STATION.12
7. TURBINE18
8. 210 MW TURBINES IN PARICCHA24
9. SUGGESTIONS..30
10. CONCLUSION....31
Brief history
This is a project run under Uttar Pradesh Rajya Vidhyut Utpadan Nigam Ltd.UPRVUNL is
wholly owned state thermal power utility with present generating capacity of 4082MW,
operating 5
Thermal Power Stations within Uttar Pradesh. Poised to contribute in the growth of state, we're
in the process of adding further 2000 MW capacity to our existing fleet by year 2012.
The name of this power project is paricha thermal power project its foundation war laid in 1979
and it started producing electricity in 1983. It is a state owned semi government project. It has
four units which are generating electricity. Two no of 250MW which are likely to be completed
tip to year 2011.
Total installed capacity of the plant at present is 640 mw. The total installed capacity of the
plant will be 1140 mw in the year 2011 presently it is thermal power project of UPRVUNL.
This project is thermal based power project in which combustion of coal is used to convert
water into steam and then steam is used to rotate the turbine the rotation of turbine drives an a.c.
generator, thereby producing a.c. power. The entire thermal power project needs continuous
supply of water and thus they are built near Betwa River. A dam has been constructed for this
purpose of collection of water, by the name of parichadam. Coal is also required for this project
and it is supplied from mines of BCCL, ECL. At present, four units of Parichha are generating
640 mw of electricity. Uttar Pradesh Rajya Vidyut Utpadan Nigam Ltd. was constituted on 25
August 1980 under the companys act 1956 for construction of new thermal power projects in
the state sector. On 14th Jan 2000, in accordance to up state electricity reforms acts 1999, UP
state electricity board, till then responsible for generation, transmission and distribution of
power within the state of Uttar Pradesh, was unbundled and operations of the state sector
thermal power stations was handed over to UPRVUNL.
Production process
In a coal based power plant coal is transported from coal mines to the power plant by
railway in wagons or in a merry-go-round system. Coal is unloaded from the wagons to a
moving underground conveyor belt. This coal from the mines is of no uniform size. So it is taken
to the Crusher house and crushed to a size of 25mm. From the crusher house the coal is either
stored in dead storage ( generally 20 days coal supply) which serves as coal supply in case of
coal supply bottleneck or to the live storage(8 hours coal supply) in the raw coal bunker in the
boiler house. Raw coal from the raw coal bunker is supplied to the Coal Mills by a Raw Coal
Feeder. The Coal Mills or pulverizer pulverizes the coal to 200 mesh size. The powdered coal
from the coal mills is carried to the boiler in coal pipes by high pressure hot air. The pulverized
coal air mixture is burnt in the boiler in the combustion zone. Generally in modern boilers
tangential firing system is used i.e. the coal nozzles/ guns formatngent to a circle. The
temperature in fire ball is of the order of 1300 deg.C. The boiler is a water tube boiler hanging
from the top. Water is converted to steam in the boiler and steam is separated from water in the
boiler Drum. The saturated steam from the boiler drum is taken to the Low Temperature
Superheater, Platen Superheater and Final Superheater respectively for superheating.
The superheated steam from the final superheater is taken to the High Pressure Steam
Turbine. (HPT). In the HPT the steam pressure is utilized to rotate the turbine and the resultant is
rotational energy. From the HPT the out coming steam is taken to the Reheater in the boiler to
increase its temperature as the steam becomes wet at the HPT outlet. After reheating this steam is
taken to the Intermediate Pressure Turbine (IPT) and then to the Low Pressure Turbine (LPT).
The outlet of the LPT is sent to the condenser for condensing back to water by a cooling
water system. This condensed water is collected in the hot well and is again sent to the boiler in
a closed cycle. The rotational energy imparted to the turbine by high pressure steam is
converted to electrical energy in the Generator.
Principal
Coal based thermal power plant works on the principal of Modified Rankine Cycle.
Air path
External fans are provided to give sufficient air for combustion. The forced draft fan takes
air from the atmosphere and, first warming it in the air preheater for better combustion, injects it via the
air nozzles on the furnace wall. The induced draft fan assists the FD fan by drawing out combustible
gases from the furnace, maintaining a slightly negative pressure in the furnace to avoid backfiring
through any opening.
superheater coils.
Superheater
Coal based power plants can have a superheater and/or reheater section in the steam generating
furnace. Nuclear-powered steam plants do not have such sections but produce steam at
essentially saturated conditions. In a coal based plant, after the steam is conditioned by the
drying equipment inside the steam drum, it is piped from the upper drum area into
tubes inside an area of the furnace known as the superheater, which has an elaborate set up of
tubing where the steam vapor picks up more energy from hot flue gases outside the tubing and
its temperature is now superheated above the saturation temperature. The superheated steam is
then piped through the main steam lines to the valves before the high pressure turbine.
Reheater
Power plant furnaces may have a reheater section containing tubes heated by hot flue gases
outside the tubes. Exhaust steam from the high pressure turbine is rerouted to go inside the
reheater tubes to pickup more energy to go drive intermediate or lower pressure turbines. This is
what is called as thermal power.
The steam turbine-driven generators have auxiliary systems enabling them to work satisfactorily and
safely. The steam turbine generator being rotating equipment generally has a heavy, large diameter
shaft. The shaft therefore requires not only supports but also has to be kept in position while running.
To minimize the frictional resistance to the rotation, the shaft has a number of bearings. The bearing
shells, in which the shaft rotates, are lined with a low friction material like Babbitt metal. Oil
lubrication is provided to further reduce the friction between shaft and bearing surface and to limit the
heat generated.
Barring gear
Barring gear (or turning gear) is the mechanism provided to rotate the turbine generator shaft at
a very low speed after unit stoppages. Once the unit is tripped (i.e., the steam inlet valve is
closed), the turbine coasts down towards standstill. When it stops completely, there is a tendency
for the turbine shaft to deflect or bend if allowed to remain in one position too long. This is
because the heat inside the turbine casing tends to concentrate in the top half of the casing,
making the top half portion of the shaft hotter than the bottom half. The shaft therefore could
warp or bend by millionths of inches. This small shaft deflection, only detectable by eccentricity
meters, would be enough to cause damaging vibrations to the entire steam turbine generator unit
when it is restarted. The shaft is therefore automatically turned at low speed (about one percent
rated speed) by the barring gear until it has cooled sufficiently to permit a complete stop.
Condense
The surface condenser is a shell and tube heat exchanger in which cooling water is circulated
through the tubes. The exhaust steam from the low pressure turbine enters the shell where it is
cooled and converted to condensate (water) by flowing over the tubes as shown in the adjacent
diagram. Such condensers use steam ejectors or rotary motor-driven exhausters for continuous
removal of air and gases from the steam side to maintain vacuum. For best efficiency, the
temperature in the condenser must be kept as low as practical in order to achieve the lowest
possible pressure in the condensing steam. Since the condenser temperature can almost always be
kept significantly below 100 C where the vapor pressure of water is much less than atmospheric
pressure, the condenser generally works under vacuum. Thus leaks of non- condensible air into
the closed loop must be prevented. Plants operating in hot climates may have to reduce output if
their source of condenser cooling water becomes warmer; unfortunately this usually coincides
with periods of high electrical demand for air conditioning. The condenser generally uses either
circulating cooling water from a cooling tower to reject waste heat to the atmosphere, or oncethrough water from a river, lake or ocean.
Deaerator
A steam generating boiler requires that the boiler feed water should be devoid of air and other
dissolved gases, particularly corrosive ones, in order to avoid corrosion of the metal. Generally,
power stations use a deaerator to provide for the removal of air and other dissolved gases from
the boiler feedwater. A deaerator typically includes a vertical, domed aeration section mounted
on top of a horizontal cylindrical vessel which serves as the deaerated
boiler feedwater storage tank.
Cooling tower
A cooling tower is a heat rejection device, which extracts waste heat to the atmosphere though
the cooling of a water stream to a lower temperature. The type of heat rejection in a cooling
tower is termed evaporative in that it allows a small portion of the water being cooled to
evaporate into a moving air stream to provide significant cooling to the rest of that water stream.
The heat from the water stream transferred to the air stream raises the airs temperature and its
relative humidity to 100%, and this air is discharged to the atmosphere. Evaporative heat
rejection devices such as cooling towers are commonly used to provide significantly lower water
temperatures than achievable with air cooled or dry heat rejection devices, like the radiator
in a car, thereby achieving more cost-effective and energy efficient operation of systems in need
of cooling.
The cooling towers are of two types: 1. Natural Draft Cooling Tower
2. Mechanized Draft Cooling Tower
i. Forced Draft cooling tower
ii. Induced Draft cooling tower
iii. Balanced Draft cooling tower
TURBINES
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and
converts it into rotary motion. Its modern manifestation was invented by sir Charles Parsons in
1884.
It has almost completely replaced the reciprocating piston steam engine primarily because of it
greater thermal efficiency and higher power-to-weight ratio. Because the turbine generates
rotary motion, it is particularly suited to be used to drive an electrical generator-about 80% of all
electricity generation in the world is by use of steam turbines.
TYPES
Steam turbines are made in a variety o f sizes ranging from small <1 hp (<0.75 kw) units (rare)
used as mechanical drives for pumps, compressors and other shaft driven equipments , to
2,000,000 hp (1,500,000 kW) turbines used to generate electricity. There are several
classifications for modern steam turbines.
Turbine efficiency
Schematic diagram outlining the difference between an impulse and a reaction turbine
To maximize turbine efficiency the steam is expanded, doing work, in a number of stages .These
stages are characterized by how the energy is extracted from them and are known as either
impulse or reaction turbines. Most steam turbines use a mixture of the reaction and impulse
steam turbines use a mixture of the reaction and impulse design; each stage behaves as either one
or other, but the overall turbine uses both. Typically, higher pressure sections are impulse type
and lower pressure stages are reaction type.
Impulse turbines
An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These
jets contain significant kinetic energy, which the rotor blades, shaped like buckets, convert
into shaft rotation as the steam jet changes direction. A pressure drop occurs across only the
stationary blades, with a net increase in steam velocity across the stage. As the steam flows
through the nozzle its pressure falls from inlet pressure to the exit pressure (atmospheric
pressure, or more usually, the condenser vacuum). Due to this higher ratio of expansion of
steam in the nozzle the steam leaves the nozzle with a very high velocity. The steam leaving the
moving blades has a large portion of the maximum velocity of the steam when leaving the
nozzle. The loss of energy due to this higher exit velocity is commonly called the "carry over
velocity" or "leaving loss".
REACTION TURBINES
In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles. This
type of turbine makes use of the reaction force produced as the steam accelerates through the
nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator. It
leaves the stator as a jet that fills the entire circumference of the rotor. The steam
then changes direction and increases its speed relative to the speed of the blades. A pressure
drop occurs across both the stator and the rotor, with steam accelerating through the stator and
decelerating through the rotor, with no net change in steam velocity across the stage but
With a decrease in both pressure and temperature, reflecting the work performed in the driving
of the rotor.
Speed regulation
The control of a turbine with a governor is essential, as turbines need to be run up slowly, to
prevent damage while some applications (such as the generation of alternating current
electricity) require precise speed control. Uncontrolled acceleration of the turbine rotor can lead
to an over speed trip, which causes the nozzle valves that control the flow of steam to the
turbine to close. If this fails then the turbine may continue accelerating until it breaks apart,
often spectacularly. Turbines are expensive to make, requiring precision manufacture and
special quality materials. During normal operation in synchronization with the electricity
network, power plants are governed with a five percent droop speed control. This means the full
load speed is 100% and the no-load speed is 105%. This is required for the stable operation of
the network without hunting and drop-outs of power plants. Normally the changes in speed are
minor.
Adjustments in power output are made by slowly raising the droop curve by increasing the
spring pressure on a centrifugal governor. Generally this is a basic system requirement for
all power plants because the older and newer plants have to be compatible in response to the
instantaneous changes in frequency without depending on outside communication.
Since I got specially assigned to the turbine department, I had the privilege of understanding
turbines more closely. Apart from the kind of turbine employed, its specifications, I came across
various concepts regarding the steam turbines like axial shift, casing expansion and learnt about
the same.
The turbine used for electricity generation is a three cylinder- reheat- condensing turbine. This
name means that the turbine assembly is made of three turbines, namely:1) HP turbine (high pressure turbine)
2) IP turbine (intermediate pressure turbine)
3) LP turbine (low pressure turbine)
The term reheat is used to imply that the steam, after passing the hp turbine and before
entering the ip turbine, is reheated by passing it through the boiler again.
Since the previous introduction we are well aware of the importance of a turbine and its
working in a power plant. There are various other aspects like axial shift, casing expansion,
bearings, turbine lubrication etc. Turbine requires perfect conditions to work efficiently. The
manufacturer of turbine is BHEL which is abbreviation of BHARAT HEAVY ELECTRICALS
LTD. The turbine is based on KWU design, Which stands for KRAFT WORKS UNION.
The given manufacturer as specified certain condition for turbine working and certain
specification of the same, which are as follows.
Construction
The turbine is a tandem compound machine which separates the hp, ip and lp sections. The hp
section is single flow while ip & lp are dual flow. The turbine rotor and generator rotor are
connected by rigid couplings. The hp turbine is throttle controlled, the steam is entered ahead of
blades via combination of two stop and control valves. A swing check valve is installed between
the exhaust and the reheater, to prevent the flow of hot steam back into the hp turbine. The
steam coming from reheater is passed to ip turbine via combination of two reheat stop and
control valves. Cross around pipes connects the ip and lp cylinders. Connections are provided at
several point of turbine for feed water extraction.
HP TURBINE
The outer casing of turbine is of barrel type, which has neither axial nor a radial flange.
This prevents mass concentration which would cause high thermal stresses. The inner turbine is
axially split, which is accommodate thermal expansion.
IP TURBINE
The ip turbine is a dual flow turbine, with horizontally split casings. This is to facilitate thermal
movement of inner casing within outer casing.
LP TURBINE
The lp turbine is dual flow. It has a three shell design which are horizontally split and are of rigid
welded construction. The innermost shell, which carries first row of stationary blades, is
supported, so as to allow the thermal expansion of inner shell within intermediate shell.
BLADING
The entire turbine provided with reaction blading. The moving blades of hp and ip turbine and
the blades of front rows of lp turbine are designed with integrally milled T-roots and shrouds.
The last stages of lp turbine are fitted with a twisted drop-forged moving blades with firtree
roots engaging in corresponding grooves in rotor.
Highly stressed guide blades of hp and ip parts have inverted T roots and shrouding are
machined from one piece like the moving blades. The other guide blades have inverted L root
sand riveted shrouding. The last three stages of lp turbine have fabricated guide blades.
BEARINGS
The HP rotor is supported on two bearings, a journal bearing on its front end and a
combined journal and thrust bearing immediately next to the coupling of the ip rotor. The ip and
lp rotors have journal bearings at each of their rear ends. The combined journal and thrust
bearings incorporates a journal bearing and a thrust bearing which takes up residual thrust from
both direction. The bearing metal temperatures are measured by thermocouples directly under
the babbit lining. The temperature of the bearing is measured in the two opposite
thrust pads on each side.
VALVES
The hp turbine is fitted with two main stop and control valves. One main stop valve and control
valve with stems arranged at right angles to each other, are combined in the common body. The
main stop valves are single seat spring action valves. The control valves are also single seat
valves but use diffuser a reduce the pressure losses.
The ip turbine has two reheat stop valves and control valves. The reheat stop valves are single
seat spring action valve, while the control valves are single seat valves loaded with diffusers.
The control valves operate in parallel and are completely open in the upper load range.
The main, reheat and control valves are supported free to move in thermal expansion. All the
valves are operated by individual hydraulic servomotors.
AXIAL SHIFT
The axial shift is the measure of axial displacement of the shaft within the thrust bearing. Axial
shift is set at zero when thrust is at the center of the axial clearance at the thrust pads. Axial
shift towards generator is positive and towards generator is negative. Alarm and tripping is
provided when the axial shift reading exceeds the set value.
SUGGESTIONS
The plant is working fine with not many hindrances, but the main concern is the
cleanliness of plant. The plant, especially 110X2 units building of the plant is not
clean enough. What I believe is that cleaner environment might help in
improving of productivity and decrease the rate of break downs. This might
improve the efficiency of the unit as lesser number of foreign elements will be
present which prevent the proper functioning of the unit. If the efficiency
increases, the coal consumption will be reduced for the same load and that would
provide a better profit to the organization.
CONCLUSION
From all the study it can be concluded that the Pariccha thermal power project of
210X2 units is a fairly organized unit with the latest machinery available.
The turbine is a very sophisticated assembly of machinery which requires specific
conditions of steam temperature and pressure to work efficiently. Any alteration of
the specific requirementsmay proves hazardous to the turbine.
Another interesting yet worrying fact is the quantity of coal consumed which
approximately10800 tone per day. The level of pollution is always controlled
according the established norms, but still I consider it to be quite enough. Well,
efforts are always underway in reducing the pollution and improving the efficiency
of the plant.
All in all, a thermal power project is very large establishment with many
components and it awesme to see how all the components work in a
synchronized manner.