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INTRODUTION
The TATA POWER Ltd. (Tata Power) is one of the oldest private
power sector utilities in our country. Till recently called Tata
Electric Companies (TEC) the Tata Power Group comprised three
companies.
TATA POWER
Set up in 1999
Andhra Valley
Set up in 1916
TATA Hydro
Set up in 1910
BASIC IDEA ON
THERMAL
POWER
GENERATION
As we know that CARNOT CYCLE is the mother of all basic
cycle. This Schematic diagram of the Carnot power cycle shows
that the water is heated in the boiler and is converted into
steam then this high pressure steam and high temperature
steam is used to rotate the turbine which is rigidly coupled the
generator. Then the low energy steam goes to the condenser
which is a heat exchanger and the steam is converted into
water. Then again with the help of compressor the water is
again pump to the boiler andBoiler
thus making the cycle to be a
closed cycle.
Compressor
(Pump)
Condenser
Turbine
ii)
iii)
Rankine Cycle
1-2: Water is pump from the Hot Well to the Deaerator through
CEP (CONDENSATE
EXTRACTION PUMP).
2-3-10: DEAREATOR removes air from the condensate water.
3-4: BOILER FEED PUMP delivers the feed water from the
deaerator to the boiler.
4-5-6: Feed Water enters the ECONOMISER and then to BOILER.
6-7: SUPERHEAT
RESOURCES
COAL
RESOURCE
S
OIL
WATER
COAL
The primary fuel is coal, 60% of which is procured. The balance
quantity is supplied by Mahanadi Coalfields Limited. The
specific Coal Consumption of the division is 0.76 Kg/kwh. The
two types of coal used are
Middlling Coal
WATER
The division gets its supply of water from Raw Water
pump House of TATA STEEL. The Specific water
consumption of the division is 2.49 l/kwh. Raw water is
treated in DM-Plant with pH limit of 5-7.5 , cond should be
between 1-0.5 and silica should be upto 20 ppm.
OVERVIEW OF JOJOBERA
POWER
PLANT
Unit#1
Unit#2
Unit#3
UNIT#4
UNIT#5
COMMISSIONED
1997
2000
2001
2005
2009
CAPACITY
67.5
120
120
120
120
Areas of operation
Fuel cycle
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The material used for power generation is coal, light diesel oil
and water. Two types of coal are used for power generation at
TATA power jojobera plant:
Middlig coal (from Bokaro ) having G.C.V of 4000
kcal.
IB valley coal (Mahanadi mines) having G.C.V of
25000 kcal.
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12
i) The
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FEEDER
The function of the feeder is to transfer the crushed coal from
the bunker to the mill. The speed of the feeder can be
monitored so that the amount of pulverized coal entering into
the furnace can be controlled to meet the power production
requirement at that particular time.
MILL
The mills are used to grid the crushed coal into fine pulverized
coal which is then conveyed to the boilers furnace by the
primary air. In Jojobera power plant ,XXP 783 Bowl Mills are
used
Where:
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SPECIFICATION
TYPE
MADE BY
CAPACITY
AIR FLOW
DRIVE
KW
RPM
VOLTAGE
BOWL XRP
783
BHEL
MAX36.5TP
H
MIN8TPH
MAX 50.5
TPH
INDUCTION
MOTOR
3000
966
6.6KV
Bowl mills are medium speed (40-70 rpm) vertical mill. It has
got three journal shaft assemblies and a Bull ring (bowl) which
is used to pulverized the coal. It is rotated by a Planetary
Gear Box,
WORKING
The mill receives the crushed coal from the feeder through the
centre pipe. Then in trhe mill the coal is grinded by the
combined effect of the bowl and the three journal shat
arrangement which are at an angle of 120. The clearance
between the journal shaft arrangements and the bowl should
be about 200 BS Mesh (75 micron). Coal is fed to rotating bowl
and thrown outward by centrifugal force to the rotating ring
where it is pulverized by rolling under spring loaded rollers. Air
sweeps by the bowl and removes the product to the classifier,
from which large particles are returned for further grinding.
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FURNANCE
The pulverized coal is then carried by the primary air from the
mill to the furnace. It is conveyed to the furnace through four
tables which fired the pulverized coal from each corners of the
furnace.
I.
II.
III.
IV.
CONDENSATE CYCLE
CONDENSATION SYSTEM
The water cycle thats starts from the condenser hot well to
the deaerator is known as condensate cycle. In the cycle the
steam that is condensed in the condenser is stored in the hot
well. It is then pumped by the CEP to SJAE, Gland Steam
Condenser, Drain cooler, LPH1 ,LPH 2 .LPH 3 and then finally to
the deaerator.
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HOT WELL
After the condensation of steam in the condenser, the
condensate water enters into the hot well. As the power plant is
closed cycle, but there are some water losses due to some
leakage or other factors, the level of hot well decreases. So in
order to maintain the level of water in the hot well, DM water is
being added as makeup of the system by water loss. This is
known as HOT WLL MAKE UP.
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Serial
No.
General
1.
2.
3.
4.
Manufacturer
Model No.
No. of pump
Type of Pump
5.
6.
Stages
Type of Suction
7.
Type of coupling
8.
9.
Type of seal
Type of thrust bearing
18
BHEL
EN7H32
2
Vertical, bowl type,
multi stage
7
Double suction at
first stage
Flexible, spacer
type
Mechanical
Tilting pad
type(between pump
and motor)
10.
Type of shaft
flexible
DRAIN COOLER
It also acts as a heat exchanger that is also used to increase
the condensate water temperature. The drip of the LPH3 flows
to LPH2 and from there it flows to LPH1. The drip is then flows
to the drain cooler then it flows to LP flash tank and then to
condenser. The temperature of the drip of the heaters in the
drain cooler is higher than the condensate water. So the drain
cooler acts as horizontal heaters for the condensate water.
LP HEATERS
Low pressure heaters are a heat exchanger. In Jojobera power
plant LPH are shell and tube type heaters. The function of LP
heater is to extract steam from the turbine end heat the feed
water to take a plant fuel efficient. Generally three LP heaters
are used to
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DEAERATOR
Economizer
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It is a feed water heater which derives heat from the flue gases.
The flue gas leaving the LTSH is at higher temperature and has
higher enthalpy. So, economizer is present in second pass to
increase the plant efficiency. It is an arrangement of tubes
through which fed water flows from BFP at high pressure and
flue gas passes over the tubes ,thus raising the temperature of
feed water. The use of economizer reduces per hour coal
consumption to a great extent.
STEAM CYCLE
Hp lp bypass system
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LP turbine glands.
The pressure at the last stage of LP turbine is less than the
atmospheric pressure. So the air can ingress from the
surrounding to the turbine casing which can damage the
turbine sacing due to the moisture content in the air and can
also reduce the efficiency of power plant. To minimize this
glands are provided, but they are not efficient enough to stop
the air form entering the turbine. So, excess steam that leaks
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out to the IPT & LPT is applied from inside of LPT to compensate
the effect of atmospheric air.
Working
This is a simple diagram of SJAE. Here the steam of 18 from the
APRDS enters into the inlet of the SJAE. SJAE has two
converging and diverging nozzle where a low pressure zone is
developed between the both sections.
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COOLING TOWER
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then the pump circulates the water back into the condenser.
Thus makes the cycle a closed one. All though it is a closed one
but there are some losses associated to it i.e evaporation loses
or some leakage.
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FEEDWATER HEATER
A feedwater heater is a heat exchanger designed to preheat
boiler feedwater by means of condensing steam extracted (or
bled) from a steam turbine. Preheating the feedwater reduces
the irreversibilities involved in steam generation and therefore
improves the thermodynamic efficiency of the system.
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ZONES
Zones are separate areas within the shell in a
feedwater heater.
Condensing Zone: All feedwaters have this zone. All
of the steam is condensed in this area, and any
remaining non condensable gases must be removed. A
large percentage of the energy added by the heater
occurs here.
Subcooling Zone: The condensed steam enters this
zone at the saturation temperature and is cooled by
convective heat transfer from the incoming feedwater.
Desuperheating Zone: The incoming steam enters
this zone, giving up most of its superheat to the
feedwater exiting from the heater.
In thermal power plant two type of regenerators are used.
1) Low Pressure Regenerator/Heater
2) High Pressure Regenerator/Heater.
Low pressure heaterIt is commonly known as LP heaters. These heaters are a kind
of Heat Exchanger which is used to transfer the heat energy
from one fluid to another. In LP heater extracted steam, which
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High pressure heaterIt is generally called LP heaters. H.P. heater is installed after
Boiler feed pump and it heats the feed water by exchanging
heat with the steam that is extracted from the H.P. Turbine from
different stages at different pressure.
HP Feed water heaters pressure ratings range from 100 to 300
kg/cm2.
Drip of LP3
Drip of LP2
LP2
Heat
er
To condenser
LP1
Heat
er
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Drip of HP6
Drip of HP5
Condensor
HP5
Heat
er
HP flash
tank
DEAREAT
OR
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CONCLUSION
TATA POWER Jojobera, Jamshedpur division was started
in 1997 by acquiring the 67.5 MW captive plants (CCP)
from TATA STEEL.
TATA POWER, Jamshedpur division is certified to ISO
9000:2001. An ISO 14000 certifications which are a
testimony to the excellent and the world class quality
management and environment standards respectively,
maintained by it. It is also certified by the organization
Health and Safety management standards certificate,
which is a standard for the safety and health on the
person there.
The primary fuel is coal of which 60% is obtained TATA
STEEL and remaining is Mahanadi Coalfields Limited
and West Bokaro. The verities of coal used in the TATA
POWER are IB- Valley and Middling. The GCV (Gross
Calorific Value) of valley is 27000-3300kcal/kg and ash
percent is 39%. The water comes from the river
Swarnarekha and is supplied by the JUSCO. The
secondary fuel used is Light Diesel Oil and is outsources
from the Indian Oil Corporation of JOCL or BPCL.
The TATA POWER is a signatory to the UN global
compact and its ten principles and countries to standby
these principles and activity implements them within
the scope of its business activities. It is committed to
be a good corporate citizen not only in compliance with
relevant laws and regulation but also by actively
assisting in the improvement of quality of the people in
communities in which it operates with the objective of
making self-reliant.
Such social responsibility would comprise to initiates
and support community initiatives in the field of
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