Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Dt 14/05/14 03/06/14
I take this opportunity to express my profound gratitude and deep regards to Mr.
P.K. Dubey for his exemplary guidance, monitoring and constant encouragement
throughout the course of this thesis. The blessings ,help and guidance given by
him time to time shall carry me a long way in the journey of life on which I am
about to embark.
I also take this opportunity to express a deep gratitude to MEJIA THERMAL
POWER STATION, DVC, for their cordial support, valuable information and
guidance, which helped me in completing this task in various stages.
I am also thankful to Mr. N. C. Pal, the Dy. Chief engineer(mech), MTPS for his
guidance and constant support throughout the training period.
I am also thankful to the chief engineer and project head, MTPS and assistant
director, HR for providing me opportunity to carry out my vocational training in
MTPS.
I am obliged to staff members of MTPS, DVC for the valuable information and
time provided by them in their respective fields. I am grateful for their cooperation during the period of my assignment.
Damodar Valley Corporation was established on 7th July 1948.It is the most reputed
company in the eastern zone of India. DVC in established on the Damodar River. It also
consists of the Durgapur Thermal Power Plant in Durgapur. The MTPS under the DVC is
the second largest thermal plant in West Bengal. It has the capacity of 2340MW with 4
units of 210MW each, 2 units of 250MW each & 2 units of 500 MW each. With the
introduction of another two units of 500MW that is in construction it will be the largest in
West Bengal. Mejia Thermal Power Station also known as MTPS is located in the outskirts
of Raniganj in Bankura District. It is one of the 5 Thermal Power Stations of Damodar
Valley Corporation in the state of West Bengal. The total power plant campus area is
surrounded by boundary walls and is basically divided into two major parts, first the Power
Plant area itself and the second is the Colony area for the residence and other facilities for
MTPSs employees.
released during condensation. The water is then fed back to the boiler by the pump and the
cycle continues.
MECHANICAL OPERATION
COAL HANDLING PLANT
Generally most of the thermal power plants uses low grades bituminous coal. The conveyer belt
system transports the coal from the coal storage area to the coal mill. Now the FHP (Fuel
Handling Plant) department is responsible for converting the coal converting it into fine
granular dust by grinding process. The coal from the coal bunkers. Coal is the principal energy
source because of its large deposits and availability. Coal can be recovered from different
mining techniques like
shallow seams by removing the over burnt expose the coal seam
underground mining
The coal handling plant is used to store, transport and distribute coal which comes from the
mine. The coal is delivered either through a conveyor belt system or by rail or road transport.
The bulk storage of coal at the power station is important for the continues supply of fuel.
Usually the stockpiles are divided into three main categories.
live storage
emergency storage
long term compacted stockpile.
The figure below shows the schematic representation of the coal handling plant. Firstly the coal
gets deposited into the track hopper from the wagon and then via the paddle feeder it goes to
the conveyer belt#1A. Secondly via the transfer port the coal goes to another conveyer belt#2B
and then to the crusher house. The coal after being crushed goes to the stacker via the
conveyer belt#3 for being stacked or reclaimed and finally to the desired unit. ILMS is the inline
magnetic separator where all the magnetic particles associated with coal get separated.
COAL MILL- AB
anthracite and sand in layers. These filter beds are regenerated by backwashing and air blowing
through it.
Chlorination:
Neutral organic matter is very heterogeneous i.e. it contains many classes of high molecular
weight organic compounds. Humic substances constitute a major portion of the dissolved
organic carbon from surface waters. They are complex mixtures of organic compounds with
relatively unknown structures and chemical composition.
Boiler drum is located outside the furnace region or flue gas path. This stores certain amount of
water and separates steam from steam-water mixture. The minimum drum water level is
always maintained so as to prevent formation of vortex and to protect water wall tubes
(especially its corner tubes) from steam entrapment / starvation due to higher circulation ratio
of boiler. The secondary stage consists of two opposite bank of closely spaced thin corrugated
sheets which direct the steam through a tortuous path and force the remaining entrained water
against the corrugated plates. Since, the velocity is relatively low, this water does not get picked
up again but runs down the plates and off the second stage lips at the two steam outlets. From
the secondary separators, steam flows uniformly and with relatively low velocity upward to the
series of screen dryers (scrubbers), extending in layers across the length of the drum. These
screens perform the final stage of separation.
Super-heater:
Super-heaters (SH) are meant for elevating the steam temperature above the saturation
temperature in phases; so that maximum work can be extracted from high energy (enthalpy)
steam and after expansion in Turbine, the dryness fraction does not reach below 80%, for
avoiding Turbine blade erosion/damage and attaining maximum Turbine internal efficiency.
Steam from Boiler Drum passes through primary super-heater placed in the convective zone of
the furnace, then through platen super-heater placed in the radiant zone of furnace and
thereafter, through final super-heater placed in the convective zone. The superheated steam at
requisite pressure and temperature is taken out of boiler to rotate turbo-generator.
Re-heater:
In order to improve the cycle efficiency, HP turbine exhaust steam is taken back to boiler to
increase temperature by reheating process. The steam is passed through Re-heater, placed in
between final super-heater bank of tubes & platen SH and finally taken out of boiler to extract
work out of it in the IP and LP turbine.
De-super-heater (Attemperator):
Though super-heaters are designed to maintain requisite steam temperature, it is necessary to
use de-super-heater to control steam temperature. Feed water, generally taken before feed
water control station, is used for de-superheating steam to control its temperature at desired
level.
Drain & Vent:
Major drains and vents of boiler are (i) Boiler bottom ring header drains, (ii) Boiler drum drains
& vents, (iii) Super-heater & Re-heater headers drains & vents, (iv) De-super-heater header
drains & vents etc. Drains facilitate draining or hot blow down of boiler, as and when
required; while vents ensure blowing out of air from boiler during initial lighting up as well as
facilitate depressurizing of boiler.
The continuous blow down (CBD) valve facilitates reduction in contaminant concentration in
drum water and also complete draining of drum water. The intermittent blow down (IBD)
emergency blow down (EBD) valve helps to normalize the excess drum water level during
emergency situation.
Soot Blower:
Width
Depth
Volume
Fuel heat input per hour
Designed pressure
Super-heater outlet pressure
Low temp SH (horizontally spaced)
Platen SH(Pendant Platen)
Final SH(Vertically spaced)
FURNACE
13868 mm.
10592 mm.
5240 mm.
106 kcal
175.8 kg per sq. cm
155 kg per sq. cm
2849 sq. m total heating surface area
1097 sq. m total heating surface area
1543 sq. m total heating surface area
ATTEMPERATOR
Type
no. of stages
Spray medium
Spray
One
feed water from boiler feed pump
RE-HEATER
Vertical spaced
2819 sq. m.
Burner tilt and excess air
Type
Total H.S. area
Control
ECONOMISER
Type
Total H.S. area
Plain tube
6152 sq.m.
It is a water filled hopper placed below the furnace water wall ring headers to receive bottom
ash generated out of combustion of coal. BAH is generally of two types Dry Bottom and Wet
Bottom. In Dry Bottom type,the BAH is kept empty (i.e. not water filled) prior to receiving
Bottom Ash and quenched by separate spray arrangement from inside. In this system
continuous ash evacuation and disposal take place through ash handling devices like Scrapper
Conveyor (Ex. DTPS unit # 4) or Pneumatic Dry Ash conveying system. In the Wet Bottom type,
the BAH is filled with water for quenching, disintegrating and collecting the Bottom Ash in
water mixed condition. In this case ash evacuation & disposal is carried out periodically (ones in
a shift of 8 hrs., Ex. CTPS units, DTPS U#3).
There is a water seal, called Trough Seal placed in-between furnace bottom ring header and the
BAH. The water seal allows the Boiler to expand downwards. A level of water is maintained in
the Trough Seal for proper sealing of Boiler against air infiltration. The Bottom ash hopper is
generally filled with water, which reduces the temperature of deposited hot ash and clinkers.
Sudden quenching also helps in disintegration of clinkers. The deposited ash in the form of
granules & clinkers is taken out periodically with the help of either a moving chain grate
scrapper or by gravity to the clinker grinder chamber. The clinker grinder breaks huge lumps of
ash / clinkers into small sizes which are easily carried out with the help of hydro-ejector to a
slurry sump. The hydro-ejector is a water jet pump designed to provide the power to transport
slurry i.e. a mixture of small sized solid lump of ash / clinker and water to slurry sump through
pipeline. The hydro-ejector consists of convergent primary & secondary nozzles. High pressure
water is passed through the primary nozzle. The action of high pressure water creates high
suction at venturi throat of the secondary nozzle, which draws accumulated slurry at the outlet
chamber of the grinder. The total mixture then passes through the divergent part of the nozzle,
which converts the energy of motion (velocity head) back into pressure energy to facilitate
movement of the mixture to the slurry sump.
ELECTROSTATIC PRECIPITATOR
The principal components of an ESP are 2 sets of electrodes insulated from each
other. First set of rows are electrically grounded vertical plates called collecting
electrodes while the second set consists of wires called discharge electrodes.
The above figure shows the operation of an ESP. the negatively charged fly ash particles are
driven towards the collecting plate and the positive ions travel to the negatively charged wire
electrodes. Collected particulate matter is removed from the collecting plates by a mechanical
hammer scrapping system.
Induced draft fan (ID fan)
Induced draft represents the system where air or products of combustion are
driven out after combustion at boiler furnace by maintaining them at a progressively
increasing sub atmospheric pressure. This is achieved with the help of induced draft fan and
stack. Induced draft fan is forward curved centrifugal (radial) fan and sucks the fly-ash laden
gas of temperature around 125C out of the furnace to throw it into stack (chimney). The fan
is connected with driving motor through hydro-coupling or with variable frequency drive
No. of boiler
Type
Medium handled
Location
Orientation
Forced draft fan (FD fan) Forced draft represents flow of air or products of combustion at a pressure above atmosphere.
The air for combustion is carried under forced draft conditions and the fan used for this
purpose is called Forced Draft (FD) fan. It is axial type fan and is used to take air from
atmosphere at ambient temperature to supply air for combustion, which takes entry to boiler
through wind box. In all units except Durgapur TPS Unit #4, this fan also supplies hot /cold air to
the coal mills. The output of fan is controlled by inlet vane / blade pitch control system.
No. of boiler
Type
Medium handled
Location
Orientation
3
Radial
Clean air
Ground floor
45 degree horizontal, delivery bottom
horizontal
No. of boiler
Type
Medium handled
Location
Orientation
STEAM TURBINE
A steam turbine is a prime mover which continuously converts the energy
of high pressure, high temperature steam supplied by the boiler into shaft
work with low pressure, low temperature steam exhausted to a condenser.
journal and thrust bearing directly adjacent to the coupling with the IP rotor. The IP & LP rotors
have a journal bearing each at the end of the shaft.
500 MW (KWU) steam turbine (Mejia Ph II TPSs , unit 7 & 8):
HP turbine inlet steam: 170 kg/cm2 & 535 0C. Steam entry to HP turbine through two combined
stop and control valves and to IP turbine through four combined reheat stop and control valves.
Reheated steam pressure and temperature: 34 kg/cm2 & 535 0C. 500 MW KWU turbine is a
tandem compounded, three cylinders, single reheat condensing turbine provided entirely with
reaction blading.
Number of stages: HPT - 17 stages, IPT - double flow with 12 stages per flow and LPT - double
flow with 6 stages per flow. Six steam extractions for feed /condensate water heating have
been taken from HPT exhaust & 7th stages of IPT for high pressure heaters, from IPT exhaust
for de-aerator and from 2nd , 3rd & 5th stages of LPT for low pressure heaters. The turbine shaft
layout is similar to that of 210 MW KWU design.
TECHNICAL SPECIFICATION OF TURBINES
Maker
BHEL
Type
Reaction turbine
Type of governing
Throttling
No of cylinders
3
Speed
3000 rpm
Rated output
210 MW for 1,2,3,4 and 250 for 5,6
Steam pressure before emergency stop valve
150 kg per sq. cm
Steam temp before emergency stop valve
535C
Reheat temp
535C
Turbine oil system
The turbine oil system provides supply of oil to the journal bearings, maintains the temperature
of bearings at desired level and acts as operating medium for hydraulic governor and also as
sealing medium for hydrogen cooled generator. In units 500 MW and above, the practice is to
use fire resistant fluids in place of lubricating oil for governor system to eliminate the risk of fire
during oil leakage. Turbine oil system is operated by the following pumps:
Main Oil Pump (MOP):
This pump is mounted in the front bearing pedestal and connected with turbine rotor through
gear coupling. It supplies total system oil requirement during turbine in operation. Its discharge
pressure is 20 Kg/cm2 for LMW set and 8 Kg/cm2 for KWU set at normal turbine speed. The
lubrication oil is supplied through two injectors arranged in series.
Starting oil pump (SOP) or Auxiliary oil pump (AOP):
It is a multi stage centrifugal oil pump driven by A.C. electric motor. 1 x 100% duty Starting oil
pump for LMW set or 2 x 100% duty Auxiliary oil pump for KWU set are provided for meeting
the requirement of oil of the turbo set during start up or shut down i.e. when Main oil pump is
not in operation.
A.C. lub. oil pump (AC LOP):
This is a centrifugal pump driven by an A.C. electric motor and can meet requirement for
turbine lubrication system when the turbo-generator is on Turning Gear or under flushing of
standstill condition of the m/c. This pump automatically takes over under inter lock action
whenever the oil pressure in lubrication system falls to 0.6 kg/cm2 (gauge).
D.C. emergency oil pump (DC LOP or DC EOP):
This is a centrifugal pump driven by D.C. electric motor and automatically cuts in during A.C.
supply failure or when lubrication oil pressure falls to 0.5 kg/cm2 (gauge).
Jacking oil pump (JOP):
JOPs are positive displacement pumps that provide high oil pressure (around 120 bar) under
strategic journals of LMW turbine at Bokaro B and KWU turbines. The oil pressure lifts the
shaft slightly. This ensures no metal contact between journal and bearing. This greatly reduces
the static friction and bearings wear, also the starting torque of turning gear drive. JOP can be
stopped after the lubricating oil film is established in bearings at the time of putting TG in
turning gear, as in the case LMW set at Bokaro B.
Turbine oil purifier (Centrifuge):
The centrifuge purifies turbine oil by removing water and entrained solid matter. The centrifuge
consists of a bowl which rotates on a vertical axis in an outer casing. It draws oil from the
turbine oil tank or impure oil tank through an oil pump. After removing any water and
entrained solid matter, the clean oil is returned to the oil tank or pure oil tank. Sludge is
removed from the disc of centrifuge by periodic cleaning.
CONDENSER
Condenser:
Condenser is a huge heat exchanger and is located at the exhaust of LP turbine. The steam after
driving turbine is dumped into condenser for recycling. The dumped steam is cooled by
circulating water flowing through the tubes of condenser. The cooling takes place where the
steam comes into contact with condenser cold water tubes through which cooling water is
circulated with the help of Circulating Water (CW) pumps. The steam is thus condensed into
water and is taken into the system for reuse. The hot circulating water on absorption of heat in
condenser is either discharged into disposal canal (as in Durgapur TPS unit no. 3) or taken to the
top of cooling towers where it is allowed to fall under gravity for lowering its temperature for
recycling. Generally about 8-10 oC temperature difference is observed between CW inlet and
outlet of the condenser.
Turbine auxiliaries:
Condensate extraction pump (CEP):
It is generally multistage, vertical, centrifugal pump and takes suction from hotwell on few
inches of suction submergence i.e. on minimum net positive suction head (NPSH). Generally,
one pump is in service and one as standby. A vent line connected with hotwell equalizes vapour
pressure. It transports hotwell condensate to de-aerator through low pressure heaters. Its
discharge is also used for:
Sealing the gland of valves operating under vacuum.
Temperature control of LP bypass steam.
Filling siphons of main ejectors and siphon of drain expander.
Actuating the forced closing non-return valves of turbine extraction steam
lines.
Operation of group protection device for bypassing high pressure heaters. For cooling
steam dumped through steam throw off device.
For preparation of phosphate, hydrazine and ammonia solution.
Low pressure (LP) heater:
LP heaters take extraction steam from low pressure stages of turbine. Tube material is made of
admiralty brass. Drain from heaters is either cascaded by pressure difference or by drip pump
into the next LP heater.
De-aerator:
In De-aerator, condensate water is allowed to fall by gravity through steam scrubber to drive
out oxygen and other dissolved gases from condensate water. It also heats the incoming water
and acts as a reservoir to serve emergency. Pegging steam pressure, for maintaining required
NPSH at De-aerator water temperature, is also applied in the De-aerator.
Boiler feed pump:
Boiler feed pump (BFP) is a multistage pump provided for pumping de-aerator outlet water to
economizer through high pressure heaters. Generally, three pumps each of 50% of total
capacity are provided. Booster Pump, driven by the main BFP motor, is sometimes provided
before feed pp to maintain required NPSH even with lower de-aerator height. Operation of BFP
below NPSH may cause severe damage of the pump due to cavitation or vapour bounding.
High pressure (HP) heater:
Regenerative feed heaters improve the cycle efficiency substantially. The driving force for heat
transfer in feed heaters is the LMTD (Log mean temperature difference) and TTD (terminal
temperature difference) between heater outlet drip and feed water. Tube material is generally
of stainless steel. HP heaters may be in service either individually or in group.
H.P/ LP bypass system:
The HP/LP bypass system diverts the main steam (MS) before turbine stop valve (MSV) to the
cold reheat (CRH) line and LP bypass system diverts the hot reheat (HRH) before intercepting
valves (IV) to the condenser, after reducing and matching the pressure & temperature of the
steam in both the cases. Feed water is used as cooling water for HP bypass and condensate is
used as cooling water for LP bypass station. This system serves the following functions:
To establish flow through SH and RH for raising boiler parameters during start up.
To warm up the steam lines.
To match steam condition with turbine metal for quick or hot start up and
for reheater protection.
To shorten the start up time of the unit.
To minimize DM water consumption during start up.
To dump steam from boiler into condenser during huge turbine load throw
off.
To perform Turbine Trip to House Load (TTHL) operation.
COOLING TOWER
Cooling towers cool the warm water discharged from the condenser and feed the cooled water
back to the condenser. They thus reduce the cooling water demand in the power plants. Wet
cooling towers could be mechanically draught or natural draught. In M.T.P.S the cooling towers
are I.D. type for units 1-6 and natural draught for units 7&8.
chimneys of eight units are made of bricks. Chimneys are used to release the exhaust gases
(coming from the furnace of the boiler)high up in the atmosphere. So, the height of the
chimneys are made high.
synthetic resin having excellent electrical properties. Water cooled terminal bushings are
housed in the lower part of the stator on the slip ring side.
Rotor: Rotor is of cylindrical type shaft and body forged in one piece from chromium nickel
molybdenum and vanadium steel. Slots are machined on the outer surface to incorporate
windings. Winding consists of coil made from hand drawn silver copper with bonded insulation.
Generator casing is filled up with H2 gas with required pressure, purity of gas is always
maintained>97%. Propeller type fans are mounted on either side of the rotor shaft for
circulating the cooling gas inside the generators.
TURBOGENERATOR
TRANSFORMERS
The electricity thus produced by the generator then goes to the generating transformer where
the voltage is increased for transmission of electricity with minimized copper losses. In general
a transformer consists of primary and secondary windings which are insulated from each other
by varnish. In M.T.P.S. all are either oil cooled or air cooled. Some of the transformer
accessories are: 1. Conservator tank 2. Buccholz relay 3. Fans for cooling 4.
Lightning arrestors 5. Transformer bushings 6. Breather and silica gel.
AUXILIARY TRANSFORMRERS
Station Service Transformers
Normal source to the station auxiliaries and standby source to the unit auxiliaries during start
up and after tripping of the unit is station auxiliary transformer. Quantity of station service
transformers and their capacity depends upon the unit sizes and nos. Each station supply
transformer shall be one hundred percent standby of the other. Station service transformers
shall cater to the simultaneous load demand due to start up power requirements for the largest
unit, power requirement for the station auxiliaries required for running the station and power
requirement for the unit auxiliaries of a running unit in the event of outage of the unit source of
supply. The no. and approximate capacity of the SST depending upon the no. and MW rating of
the TG sets are indicated below.
CONCLUSION
The vocational training had been concluded in a very efficient way. We have acquired through
knowledge about generation, transmission and distribution of power. MTPS being one of the
largest power station in eastern India, had been acting as a pioneer in power generation over a
decade.
MTPS is a part of DVC which governs the power generation for industrial and commercial
requirement and attenuate the economic as well as social well-being of humankind.
We have carried out the training under well experienced and highly qualified engineers of
MTPS. The work culture of DVC is very noticeable and very energetic. Although this is an old
power plant, the machines and entire instruments are functioning very well due to proper
maintenance and skill in handling them. I was able to acquire practical knowledge of the
industry and about some theoretical engineering studies.
My heart is not permitting me to stop, but I have to stop due to time and space limitations.