TRAINING REPORT ON BADARPUR

THERMAL POWER STATION

Term Paper Report
A term paper report submitted in partial fulfillment of the requirement of
Bachelor of Engineering
in
Mechanical Engineering

Submitted By
Enrollment No.:
Submitted to
Mr. G.D. SHARMA

ACKNOWLEDGEMENT
I would like to thank NTPC BADARPUR for
providing me golden opportunity to work with them.
The support and the environment provided to me during
my training was more than what anyone would have
expected. I am very grateful to Mr. BRAHM
SHANKER (Dy. General Manager) who granted me the
opportunity of working as a trainee at Mechanical
Division of Power Engineering. I would also like to
thank Mr. MANMOHAN SINGH(Dy. Manager) and

G.D. SHARMA(training coordinator) and my

coordinators at B.M.D and P.A.M. department.
And at last I would like to thank all the people
involved in the training that helped me in
accomplishing it in such a wonderful way

PREFACE
NTPC is one of the most important industries for producing
electricity. There are various divisions in NTPC for various branches
like mechanical division, electrical division etc. The main objective of
preparing this report has been to present the operations of BMD and
PAM department of mechanical division in a logical and innovative
manner. The basic theory presented in this report has been evolved out
of simple and readily understood principles. A sincere effort has been
made to maintain physical concepts in various operations. An effort
has been made to give a balanced presentation of this report with the
help of figures, different types of data and related suitable theories as
well as concepts.

CONTENTS
TOPIC
1. CHAPTER 1 ABOUT N.T.P.C.
(NATIONAL THERMAL POWER CORPORATION)
1.1INTRODUCTION..
1.2POWER GENERATION...
1.3 INSTALLED CAPACITY..
1.4NTPC POWER STATIONS IN INDIA.......
2. ABOUT B.T.P.S
(BADARPUR THERMAL POWER STATION)
2.1 INTRODUCTION.
2.2 BASIC POWER PLANT..
3. ABOUT PAM..
(PLANT AUXILIARY MAINTENANCE DEPARTMENT)
3.1 THEORY OF CIRCULATION OF WATER.. .
3.2 ASH HANDLING PLANT.
3.3 CSP HOUSE..
3.4 WATER TREATMENT PLANT..
4. ABOUT TMD.
(TURBINE MAINTENANCE DEPARTMENT)
4.1 STEAM TURBINE THEORY........
4.2 STEAM CYCLE..
4.3 TURBINE CLASSIFICATION.
4.4 TURBINE CYCLE..
4.5 DESCRIPTION OF MAIN TURBINE.
4.6 TURBINE AUXILLIARIES AND THEIR ARRANGEMENT

CHAPTER 1: ABOUT OF NTPC

1.1 INTRODUCTION

The year 1975 witnessed the birth of an organization that went on

to achieve great feats in performance in a sector that was then,
characterized largely by lack of investment, severe supply shortages
and operational practices that mad the commercial viability of the
sector unsustainable.
NTPC symbolized hop of the country suffering from crippling
power black-outs, the Government of India, which was trying to pull
an ailing, economy back on the track and he World Bank, which was
supporting the country in many development initiatives. Thus, NTPC
was created not only to redraw the power map of India but also excel
in is performance and se benchmarks for others to follow. It
succeeded on both counts.
Today with an installed capacity of 39,174 MW, NTPC contributes
one fourth of the Nations Power generation, with only one fifth of
India total installed capacity. An ISO 9001:2000 Certified company, it
is world world`s 10th largest power generation in the world, 3rd largest
in the Asia. NTPC is #1 independent Power Producer (IPP) IN THE
WORLD. Also it is 384th largest company in be world (FORBES
2011).
It is one of the largest Indian companies in terms of market cap.
The corporation recorded a generation of 222.07 billion unit (BUS)
IN 2011-2012; through 16 coal based and 7 gas based power plant
spread all over the country and also has 07 plants in joint venture.
Rated as one of the best company to work for in India, it has
developed into a multi-location and multi-fuel company over the past
three decades.
Revenue

501.8852 billion (US$10.01 billion)(200910)

1.2 POWER GENERATION

Presently, NTPC generates power from Coal and Gas. With an
installed capacity of 39,174 MW, NTPC is the largest power
generating major in the country. It has also diversified into hydro
power, coal mining, power equipment manufacturing, oil and gas
exploration, power trading and distribution. With an increasing
presence in the power value chain, NTPC is well on its way to
becoming an Integrating Power Major.

1.3 INSTALLD CAPACITY

Be it the generating capacity or plant performance or operational
efficiency, NTPCs Installed Capacity and performance depicts the
companys outstanding performance across a number of parameters.
Table 1-1 installed capacity

NTPC OWNED
COAL
GAS/LIQUID FUEL
TOTAL
OWNED BY JVs
COAL AND GAS
TOTAL

NO. OF PLANTS
16
7
23
7
30

CAPACITY(MW)
30,855
3,955
34,810
4,364
39,174

1.3 POWER STATIONS IN INDIA

Table 1-2GAS BASED

SR. NO.
1.
2.

PROJECT
NTPC ANTA
NTPC AURAIYA

STATE
RAJASTAN
UP
6

INST. CAPACITY(MW)
413
652

3.
4.
5.
6.
7.
TOTAL

NTPC
NTPC
NTPC
NTPC
NTPC

KAWAS
DADRI
JHANOR
KAYAMKULAM
FARIDABAD

GUJARAT
UP
GUJARAT
KERALA
HARYANA

645
817
648
350
430
3955

Table 1-3 COAL BASED:

SR.
NO.
1.

PROJECT

STATE
THERMAL UTTARPRADES
H

2.,

SINGRAULI SUPER
POWER STATION
NTPC KORBA

3.

NTPC RAMAGUNDAM

4.

FARAKKA
SUPER
POWER STATION
NTPC VINDHYACHAL

ANDHRA
PRADESH
THERMAL WEST BENGAL

5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

CHHATTISGARH

MADHYA
PRADESH
RIHAND
THERMAL
POWER UTTAR
STATION
PRADESH
KAHALGAON SUPER THERMAL BIHAR
POWER STATION
NTPC DADRI
UTTAR
PRADESH
NTPC TALCHER KANIHA
ORISSA
FEROZE GANDHI UNCHAHAR UTTAR
THERMAL POWER PLANT
PRADESH
TALCHER THERMAL POWER ORISSA
STATION
SIMHADRI SUPER THERMAL ANDHRA
POWER PLANT
PRADESH
TANDA
THERMAL
POWER UTTAR
PLANT
PRADESH
BADARPUR THERMAL POWER DELHI
PLANT
SIPAT THERMAL POWER PLANT
CHHATTISGARH
NTPC
ASSAM
BONGAIGAON (COMMISSIONING
2013 ONWARDS )

INST.
CAPACITY
2000
2,600
2,600
2,100
3,760
2,500
2.340
1,820
3,000
1,050
460
1,500
440
705
2,980
750

17.

18.
19.

NTPC MOUDA (1 UNIT 500 MW

IS COMMISSIONED IN APRIL
2012 )
RIHAND
THERMAL
POWER
STATION (ERECTION PHASE)
NTPC BARH (COMMISSIONING
2013 ONWARDS )

TOTAL

MAHARASHTRA

1,000

UTTAR
PRADESH
BIHAR

500
3,300
31,995

CHAPTER 2: ABOUT BTPS

2.1

INTRODUCTION

The Badarpur Thermal Power Plant has an installed capacity of

705 MW. The main plant equipment was supplied by M/S. BHEL.
The
boiler
of
Stage-1
(395)MW
units
are
of
CZECHOSOLOVAKIAN design and that of 210 MW units are of
COMBUSTION ENGINEERING design. The Turbo-alternators,
supplied by M/S BHEL, are of RUSSIAN design and Control and
Instrumentation for Stage-1 (395) and Stage-2 units are mostly of
RUSSIAN design and for Stage-3 are of KENT design and supplies
by M/S Instrumentation Ltd., KOTA.
Table 2-4 BTP capacity

STAGE UNIT
NUMBER
First
1

INT.
CAPACITY(MW0
95

First

95

First

95

Secon
d
Secon

210

210

DATE
OF STATUS
COMMISSIONING
July, 1973
Runnin
g
August, 1974
Runnin
g
March, 1975
Runnin
g
December, 1978
Runnin
g
December, 1981
Runnin
8

Figure 2-1 BTP

2.2 BASIC THERMAL POWER PLANT

In thermal generating plants, fuel is converted into
thermal energy to heat water, making steam. The steam
turns an engine (turbine), creating mechanical energy to
run a generator. Magnets turn inside the generator,
producing electric energy.
Coal, oil and gas are used to make thermal electricity.
They all work basically the same way (with a few
exceptions: for example, in an oil- or gas-fired plant, fuel
is piped to the boiler).
1. Coal supply After haulers drop off the coal, a set
of crushers and conveyors prepare and deliver the
coal to the power plant. When the plant needs coal,
coal hoppers crush coal to a few inches in size and
conveyor belts bring the coal inside.

2. Coal pulveriser the belts dump coal into a huge

bin (pulveriser), which reduces the coal to a fine
powder. Hot air from nearby fans blows the powdered
coal into huge furnaces (boilers).
3. Boiler The boiler walls are lined with many
kilometres of pipe filled with water. As soon as the
coal enters the boiler, it instantly catches fire and
burns with high intensity (the temperatures inside
the furnace may climb to 1,300 C). This heat quickly
boils the water inside the pipes, changing it into
steam.
4. Precipitators and stack As the coal burns, it
produces emissions (carbon dioxide, sulphur dioxide
and nitrogen oxides) and ash. The gases, together
with the lighter ash (fly ash), are vented from the
boiler up the stack. Huge air filters called
electrostatic precipitators remove nearly all the fly
ash before it is released into the atmosphere. The
heavier ash (bottom ash) collects in the bottom of the
boilers and is removed.
5. Turbine and generator Meanwhile, steam moves
at high speed to the turbines, massive drums with
hundreds of blades turned at an angle, like the
blades of a fan. As jets of high-pressure steam emerge
from the pipes, they propel the blades, causing the
turbine to spin rapidly. A metal shaft connects the
turbine to a generator. As the turbine turns, it causes
an electro-magnet to turn inside coils of wire in the
generator. The spinning magnet puts electrons in
motion inside the wires, creating electricity.
10

6. Condensers and cooling water system Next, the

steam exits the turbines and passes over cool tubes
in the condenser. The condensers capture the used
steam and transform it back to water. The cooled
water is then pumped back to the boiler to repeat the
heating process. At the same time, water is piped
from a reservoir or river to keep the condensers
constantly cool. This cooling water, now warm from
the heat exchange in the condensers, is released from
the plant.
7. Water purification To reduce corrosion, plants
purify water for use in the boiler tubes. Wastewater is
also treated and pumped out to holding ponds.
8. Ash systems Ash is removed from the plant and
hauled to disposal sites or ash lagoons. Ash is also
sold for use in manufacturing cement.
9. Transformer
and
transmission
lines
transformers increase the voltage of the electricity
generated. Transmission lines then carry the
electricity at high voltages from the plant to
substations in cities and towns.

Figure 2-2 components of a coal fired thermal plant

Figure 2-3 boiler maintenance department

12

3
MAINTENANCE DEPARTMENT

CHAPTER
PLANT AUXILIARY

3.1 WATER CIRCULATION SYSTEM

THEORY OF CIRCULATION
Water must flow through the heat absorption surface of the boiler
in order that it is evaporated into steam. In drum type units (natural
and controlled circulation) the water is circulated from the drum
through the generating circuits and then back to the drum where the
steam is separated and directed to the super heater. The water leaves
the drum through the downcomers at a temperature slightly below the
saturation temperature. The flow through the furnace wall is at
saturation temperature. Heat absorbed in water wall is latent heat of
vaporization creating a mixture of steam and water. The ratio of the
weight of the water to the weight of the steam in the mixture leaving
the heat absorption surface is called circulation ratio.

Figure 4-4boiler circulating system

Types of boiler circulating system:

Natural circulation system
Controlled circulation system
14

Combines circulation system

NATURAL CIRCULATION SYSTEM

Water delivered to steam generator from feedheater is at a
temperature below the saturation value corresponding to that pressure.
Entering first the economizer it is heated to about 3040C below saturation temperature. From economizer the water enters
the drum and thus joins the circulation system. Water entering the
drum flows through the down comer and enters ring heater at the
bottom. In the water walls a part of the water is converted to steam
and the mixture flows back to the drum. In the drum, the steam is
separated, and sent to
superheater for super heating and then sent to the high pressure turbin
e.Remaining water mixes with the incoming water from theeconomize
r and the cycle is repeated. The circulation in this case takes place on
the thermo-siphon principle. The down comers contain relatively cold
water whereas the riser tubes contain a steam water mixture.
Circulation takes place at such a rate that the driving force and the
frictional resistance in water walls are balanced.
As the pressure increases, the difference in density between
water and steam reduces. Thus the hydrostatic head available will
not be able to overcome the frictional resistance for a flow
corresponding
to the minimum requirement of cooling of water wall tubes.There
fore

Figure 4-5NATURAL CIRCULATION SYSTEM

natural circulation is limited to the boiler with drum operating pressure around
175 kg/cm.

CONTROLLED CIRCULATION SYSTEM

Beyond 80 kg/cm of pressure, circulation is to be assisted with
mechanical pumps to overcome the frictional losses. To regulate
the flow through various tubes, orifice plates are used. This
system is applicable in the high sub-critical regions(200 kg/cm).

COMBINED CIRCULATION SYSTEM

Beyond the critical pressure, phase transformation is absent, and
hence once through system is adopted. However, it has been found
that even at super critical pressure, it is advantageous to recirculation
the water through the furnace tubes and simplifies the start up
procedure. A typical operating pressure for such a system is 260
kg/cm.

16

Figure 4-6COMBINED CIRCULATION SYSTEM

3.2 ASH HANDLING PLANT

The ash produced in the boiler is transportedto ash dump area by
means of sluicing type hydraulic ash handlingsystem, which
consists of Bottom ash system, Ash water systemand Ash slurry
system.

Bottom Ash System

In the bottom ash system the ash discharged from the furnace
bottom is collected in two water compounded scraper through
installed below bottom ash hoppers. The ash is continuously
transported by means of the scraper chain conveyor onto the
respective clinker grinders which reduce the lump sizes to the
required fineness. The crushed ash from the bottom ash hopper from
where the ash slurry is further transported to operation, the bottom ash
can be discharged directly into the sluice channel through the
bifurcating chute bypass the grinder. The position of the flap gate in
the bifurcating chute bypasses the grinder. The position of the flap
gate in the bifurcating chute is to be manually changed.

Fly ash system

The flushing apparatus are provided under E.P.

hoppers, economizer hoppers, air preheaters, and stack
hoppers. The fly ash gets mixed with flushing water and
the resulting slurry drops into the ash sluice channel.
Low pressure water is applied through the nozzle
directing tangentially to the section of pipe to create
turbulence and proper mixing of ash with water. For the
maintenance of flushing apparatus plate valve is provided
between apparatus and connecting tube.

Ash water system

High pressure water required for bottom ash hopper quenching
nozzles, bottom ash hopper spraying, clinker grinder sealing
scraper bars, cleaning nozzles, bottom ash hopper seal through
flushing, economizer hopper flushing nozzles and sluicing trench
jetting nozzles is tapped from the high pressure water ring mainly
provided in the plant area. Low pressure water required for bottom
ash hopper seal through make up, scraper conveyor make up,
flushing apparatus jetting nozzles for all fly ash hoppers excepting
economizer hoppers, is trapped from low pressure water rings
mainly provided in the plant area.

Ash slurry system

Bottom ash and fly ash slurry of the system is sluiced up to
ash pump along the channel with the acid of high pressure water
jets located at suitable intervals along the channel. Slurry pump
suction line consisting of reducing elbow with drain valve,
reducer and butterfly valve and portion of slurry pump delivery
line consisting of butterfly valve, pipe & fitting has also been
provided.
18

3.3
CSPH(CONTROL
PUMP HOUSE)

STRUCTURE

The control system has following pumps:Chlorine pump-2(for chlorination of water)

HP pump-6(for boiling of water)
LP pump-3(for EP pump house)
Fire pump-(incase of fire breakdown)
TWS pump-3(for screening of water)
CRW pump-3(supply water for water treatment)
This house is known as control house because amount of
water to be supplied for treatment is controlled from this
house with thehelp of these pumps. Generally 2 CRW
pumps out of 3pumpsremains opensimilarly, 1 F ,2 LP,4
HP,1 TWS pumps remainsopen. If more water is needed then
others pumps are opened.
3.4COMPRESSOR HOUSE

An air compressor is anything that increases the amount

of air that is contained within a particular space. By packing in
the air, the air pressure is increased. This creates a force that is
useful for a variety of purposes, such as industrial, manufacturing,
commercial and personal purposes. Stages
Another way to group air compressors is by the number of stages
they have. A two-stage air compressor usually is used for heavyduty use and offers a higher level of compression than smaller,
single-stage air compressors.
Two-stage air compressors
can
store air for future use and are more energy efficient because they
produce more air per unit of horsepower than single-stage
compressors. Also, less heat is generated in a twostage compressor, which means that wear on the unit is reduced.

Portable electric air compressors also are available for light-duty

applications.

Figure 4-7COMPRESSOR HOUSE

3.5WATER TREATMENT PLANT

As the types of boiler are not alike their working pressure and
operating conditions vary and so do the type sand methods
of water treatment. Water treatment plants used in
thermal power plants are designed to process the raw
water to water with very lowin dissolved solids known as
"dematerialized water". No doubt, this plant has to be engineered very
carefully keeping in view the type of raw water to the thermal plant,
its treatment costs and overall economics

Actually, the type of demineralization process chosen for a

power station depends on three main factors:
20

The quality of the raw water.

The degree of de-ionization i.e. treated water quality
Selectivity of resins.
Water treatment process which is generally made up
of two sections:
Pre-treatment section
Demineralization section

Pre-treatment section
Pre-treatment plant removes the suspended solids such as clay, silt,
organic and inorganic matter, plants and other microscopic organism.
The turbidity may be taken as of two types of suspended solids in
water. Firstly, the separable solids and secondly the non separable
solids (colloids). The coarse components, such as sand, silt etc., can
be removed from the water by simple sedimentation. Finer particles
however, will not settle in any reasonable time and must be
flocculated to produce the large particles which are settling able. Long
term ability to remain suspended in water is basically a function of
both size and specific gravity. The settling rate of the colloidal and
finely divided(approximately 001 to 1 micron) suspended matter is so
slow that removing them from water by plain sedimentation is tank
shaving ordinary dimensions is impossible. Settling velocity of finely
divided and collide particles under gravity also are so small that
ordinary sedimentation is not possible. It is necessary, therefore, to
use procedures which agglomerate the small particles into larger
aggregates, which have practical settling velocities. The term
"Coagulation" and "flocculation" have been used indiscriminately to
describe process of turbidity removal. "Coagulation" means to bring
together the suspended particles. The process describes the effect
produced by the addition of a chemical Al(SP)g to a colloidal
dispersion resulting in particle destabilization by a reduction of force
tending to keep particles apart. Rapid mixing is important at this stage
to obtain. Uniform dispersion of the chemical and to increase
opportunity for particles to particle contact. This operation is done by
flash mixer in thec1ariflocculator. Second stage of formation of settle
able particles from destabilized colloidal sized particles is termed as

"flocculation". Here coagulated particles grow in size by attaching to

each other. In contrast to coagulation where the primary force is
electrostatic or intrinsic, "flocculation" occurs by chemical bridging.
Flocculation is obtained by gentle and prolonged mixing which
converts the sub-microscopic coagulated particle into discrete, visible
& suspended particles. At this stage particles are large enough to settle
rapidly under the influence of gravity anomaly be removed
If pre-treatment of the water is not done efficiently then the
consequences are as follows:
Si02 may escape with water which will increase the anion loading.
Organic matter may escape which may cause organic foulingin the
anion exchanger beds. In the 'pre-treatment plant chlorine addition
provision is normally made to combat organic contamination.
Cation loading may unnecessary increase due to addition of Ca
(OH)2 in excess of calculated amount for raising the pH of the
water for maximum floe formation. If less than calculated amount
of Ca (OH)2 is added, proper pH flocculation will not be obtained
and silica escape to demineralization section will occur, thereby
increasing load on anion bed.

CHAPTER 4
TURBINE MAINTENANCE DEPARTMENT

22

4.1 STEAM TURBINE THEORY

Figure 5-8STEAM TURBINE

OPERATING PRINCIPLES
A steam turbines two main parts are the cylinder andthe rotor.As the steam passes through
the fixed blades or nozzles itexpands and its velocity increases. The high-velocity jet of
steamstrikes the first set of moving blades. The kinetic energy of thesteam changes into
mechanical energy, causing the shaft to rotate.The steam then enters the next set of fixed
blades and strikes thenext row of moving blades.As the steam flows through the turbine,
its pressure andtemperature decreases, while its volume increases. The decrease in pressure
and temperature occurs as the steam transmits .energy to the shaft and performs
work.
After
passing
through
the
last
turbinestage, the steam exhausts into the condenser or process steamsystem.
The kinetic energy of the steam changes into mechanical erringly through the
impact (impulse) or reaction of thesteam against the blades.

4.2 STEAM CYCLE

The thermal (steam) power plant uses a dual (vapour +liquid) phase cycle. It is a closed
cycle to enable the working fluid(water) to be used again and again. The cycle used is
"RankineCycle" modified to include super heating of steam, regenerativefeed water heating
and reheating of steam.
On
large
turbines,
it
becomes
economic
to
increase
thecycle efficiency by using reheat, which is a way of partiallyovercoming temperature limita
tions. By returning partiallyexpanded steam to a reheat, the average temperature at which
heatis added is increased and by expanding this reheated steam to
theremaining stages of the turbine, the exhaust wetness isconsiderably less than it would
24

otherwise be conversely, if themaximum tolerable wetness is allowed, the initial pressure of

thesteam can be appreciably increased.

Figure 5-9 steam cycle

MAIN TURBINE

Figure 5-10MAIN TURBINE

The 210MW turbine is a tandem compounded typemachine comprising of H.P. & I.P.
cylinders. The H.P. turbinecomprises of 12 stages the I.P. turbine has 11 stages & the L.P.
hasfour stages of double flow. The H.P. & I.P. turbine rotor are rigidlycompounded & the I.P.
& the I.P. rotor by lens type semi flexiblecoupling. All the three rotors are aligned on five
bearings of whichthe bearing no.2 is combined with thrust bearing.The main superheated
steam branches off into twostreams from the boiler and passes through the emergency
stopvalve and control valve before entering, the governing wheelchamber of the H.P. turbine.
After expanding in the 12 stages inthe H.P. turbine the steam returned in the boiler for
reheating.
The reheated steam from the boiler enter I.P. turbine viainterceptor valves and control
valves and after expanding enters the L.P. turbine stage via 2 numbers of cross
over pipes.In the L.P. stage the steam expands in axially oppositedirection to counteract the
trust
and
enters
the
condenser
placeddirectly below the L.P. turbine. The cooling water flowingthroughout the condenser tub
es condenses the steam and thecondensate
collected
in
the
hot
well
of the
condenser.Thecondensate collected is pumped by means of 3*50% duty condensate pumps
through
L.P.
heaters
todeaerator from where the boiler feed pump delivers the water to boiler through H.P. heaters
thus forming a closed cycle.

4.4 TURBINE CYCLE

Fresh steam from boiler is supplied to the turbinethrough the emergency stop valve. From
the stop valves steam issupplied to control valves situated on H.P. cylinders on the
front bearing end. After expansion through 12 stages at the H.P. cylinder steam flows back
to boiler for reheating and reheated steam from
the boiler cover to the intermediate pressure turbine trough twointerceptor valves and four
control valves mounted on the I.P.turbine.After flowing trough I.P. turbine steam enters the
middle part of the L.P. turbine through cross over pipes. In L.P. turbine theexhaust
steam condenses in the surface condensers welded directlyto the exhaust
part of L.P. turbine. The selection of extraction points and cold reheat
pressurehas been done with a view to achieve the highest efficiency.
Theseare two extractions from H.P. turbine, four from I.P. turbine
andone from L.P. turbine. Steam at 1.10 to 1.03 g/sq cm Abs issupplied for the gland
sealing. Steam for this purpose is obtainedfrom deaerator through a collection where pressure
of steam isregulated.From the condenser condensate is pumped with the helpof 3*50%
capacity condensate pumps to deaerator through the low pressure regenerative
equipments.

26

Figure 5-11TURBINE CYCLE

Feed water is pumped from deaerator to the boiler through the H.P. heaters by means of
3*50% capacity feed pumpsconnected before the H.P. heaters.

4.5 DESCRIPTION OF MAIN TURBINE

SPECIFICATION:
TURBINE MAIN DATA
Rated Power 210MW
Rated Speed 3000 rpmRated Steam(Pressure) before ESV 130 Kg`/cm2abs
Rated Steam Temp. Before ESV 5350C
Rated Steam pressure Before IV 27 Kg/cm2Abs
RatedSteam temp. Before IV 5350C
Rated Steam Flow 670 T/Hr
HPT Exhaust Pressure 27 Kg/cm2
HPT Exhaust Temperature 3270C
Rated circulating water quantity 27000 m3
through condenser
Condenser back pressure 0.09 Kg/cm2

Critical Speed 1585,1881,2017&2489

Rated condenser cooling water inlet 240C to 330C
Temperature
Rated condenser cooling water 1.0 to 1 Kg/cm2
PressureType of governing Hydro mechanicalNozzle
type
governingType of turbine condensing, tandem compoundThree
cylinder,
HorizontalNos. of bearing 5 Nos.( for turbine side only &HPC front bearingis combined
thrust & journal bearingBarring gear 3.4rpm, ac motor of 30kw, 730rpm, 50c/s,415v, 220:1
RatioLocation of anchor point of At the middle foundation frame of frontthe turbine exhaust
part of the L.P. Cylinder
CONSTRUCTIONAL DETAILS:
H.P. CYLINDER: 12 stages (1stis governing stage) each stageConsists of a diaphragm &a
set of movingBlades connected on a disc.
BODY: In two valves made of Creep Resistance(Cr-Mo-V) steel
STUDS & NUTS: High Creep Resistance (Cr-Mo-V) steelForgings
NOZZLE & STEAM CHEST:4 Nos (2 on Top & 2 on sides) madeof High Creep resisting
(Cr-Mo-V)Steel casting
I .P. CYLINDER: 11 stages
BODY:2 parts (a ) Pressure part made of Creep Resisting (Cr-Mo-V) steel
MAIN COMPONENTS OF TURBINE:
EMERGENCY STOP VALVE
Steam from the boiler is supplied to the turbine throughtwo emergency stop valves. The
emergency stop valve operated byhydraulic servomotor shuts off steam supply to the
turbine whenthe turbo set is tripped. The emergency stop valves connected
tothe four control valves through four flexible loop pipes of Chromium-MolybdenumVanadium steel.
H.P. CYLINDER
It is made of creep resisting Cr-Mo-V steel castingmade of two halves joined at the
horizontal plane.
The horizontal joint is secured with the help of studsand nuts made of high creep resisting
Cr-Mo-V
steel
forgings.
Toensure H.P. tightness the studs are tightened by heat to a predetermined temperature with
the help of electric heater.
H.P. ROTOR
The H.P. rotor has discs integrally forged with the shaftsand is mechanical forming single
Cr-Mo-V steel forging. A special process to prevent abnormal rotor deflection thermally
stabilizesthe rotor forging.

28

 L.P. ROTOR
It consists of shrunk fit discs on a shaft. The shaft is aforging of Cr-Mo-V
steelwhile the discs are of high strength Ni steel forging.The H.P. rotor is
connected by rigid couplings whole the I.P rotor and L.P. rotor are connected
by semi-flexible lens typecoupling. The rotors are dynamically balanced to a
very precisedegree.

Figure 5-12

L.P. ROTOR

 TURBINE BEARINGS
The three turbine rotors are supported on fine bearings.The second bearing from
pedestal side is a combined radial thrust bearing while all others are journal bearings.

Figure 5-13TURBINE BEARINGS

THRUST BEARINGS
It is Mitchell type with bearing surface distributed over a number of bearing surfaces.
They are pivoted in housing on the side of I.P. rotor thrust collar.During operation on oil
film is forced between padsand thrust collar and there is a no metal-to-metal contact. A
secondring of pads on opposite side of thrust collar takes the axial thrust as may
occur under abnormal conditions.

Figure 5-14THRUST BEARINGS

30

 L.P. HEATERS
Turbine
is
provided
with non-controlled
extractionswhichare utilized for heating the condensate from turbine bleedingsystem. There a
re four L.P. heaters. They are equipped withnecessary safety valves in steam space
level indicator for visual
Mauges are present for measurement of steam pressure.

Figure 5-15L.P. HEATERS

GLAND STEAM COOLER

Gland steam cooler has been provided to suck and coolt h e a i r s t e a m m i x t u r e f r o m
t h e g l a n d s e a t s . I t e m p l o y s a s m a l l ejector for which the working medium is steam
of low parameters,which can be taken either from the deaerator or auxiliary
source.The pressure and temperature of this steam should of this steam isretrieved to the
fullest possible extent as the gland steam cooler isalso interposed in the condensate heating
cycle thereby improvingoverall efficiency of the cycle.

CONDENSATE PUMPS
The function of these pumps is to pumps out thecondensate to the desecrator through
ejectors, gland steam cooler,and L.P. heaters. These pumps have four stages and since
thesuction
is
at
a
negative
pressure,
special
arrangements
havebeenmade for providing sealing. This pump is rated generally for 160m3 hr. at a pressure
13.2 Kg/cm2.

Feed Water System

The main equipments coming under this system are:
Boiler Feed Pump: Three per unit of 50% capacity eachlocated in the '0' meter

level in the TG bay.

High Pressure Heaters: Normally three in number and aresituated in the TG

bay.

Drip Pumps: Generally two in number of 100% capacity eachsituated beneath

the LP heaters.

Turbine Lubricating Oil System: This consists of Main OilPump (MOP) Starting

Oil Pump (SOP), AC standby oil pumpsand emergency DC' oil pump and Jacking
Oil Pump (JOP) (oneeach per unit).

BOILER FEED PUMPS

Boiler feed pump is used to feed water to steam generator boiler drum at desired pressure
and temperature. Boiler feed pump extract water from de-aerator and feed it to the boiler
drum via H.P heaters and economizer. It works with the steam extraction from Intermediate
Pressure (I.P.) turbine exhaust
This pump is horizontal and of barrel design driven byan Electric motor through a
hydraulic coupling. All the bearings of pump and motor are forced lubricated by a suitable oil
lubricatingsystem with adequate protection to trip the pump if the lubricationoil pressure falls
below
a
preset
value.The
high-pressure
boiler
feed
pump
is
very
expensivemachine which calls for a very careful operation and skilledmaintenance.
The safety in operation and efficiency of the feed pump depends largely on the
reliable operation and maintenance.Operating staff must be able to find out the
causes of defect at thevery beginning which can be easily removed without
endangeringtheoperator
of
the
power
plant
and
also
without
the
expensivedismantling of the high pressure feed pump.The feed pump consists of pump

barrel, into which ismounted the inside stator together with rotor. The hydraulic part
isenclosed by the high pressure cover along with the balancingdevice. The suction

side of the barrel and the space in the high pressure cover behind the balancing
device are enclosed by the low pressure covers along with the stuffing box casings.
The bracketsof the radial bearing of the suction side and radial and thrust bearing
of
the
discharge
side
are
fixed
to
the
low
pressure
covers.The entire pumps are mounted on a foundation frame. Thehydraulic
coupling and two claws coupling with coupling guardsare also delivered along with
the pump. Water cooling and oillubricating are provided with their accessories.

TURBINE DRIVEN BOILER FEED PUMP

32

The single cylinder turbine is of the axial flow type.The live steam flows through the
emergency stop valve and thenthrough the main Control Valves 5 nos. (Nozzle governing).
Thesevalves regulate the steam supply through the turbine in accordancewith load
requirements. The control valves are cylinder mounted on the turbine casing.The journal
bearings supporting the turbine shaft arearranged in the two bearing blocks. The front end
-bearing block also houses the thrust bearing, which locates the turbine shaft andtakes up
"the axial forces.There are 14 stages of reaction balding. The actuated by a lift bar which is
raised or lowered via a lever system by the relay balancing piston is provided at the. Steam
admission side to compensate theaxial thrust to the maximum extent. Since the axial thrust
varieswith the load, the residual thrust is taken up by the thrust bearing.The leak off from the
balancing piston is connected back to theturbine after 9th stage.The turbine is provided with
hydraulic andelectro-hydraulic governing system. A primary oil pump is used asa speed
sensor for hydraulic governing and shall Probes are used asa speed sensor for electro
hydraulic governing.Whenever steam is drawn from the cold reheat line
or auxiliary supply, steam flow is controlled by auxiliary controlvalve. During this period the
main control valves (4 nos.) willremain fully opened and the bypass valve across it will
remainclosed. (Bypass remains closed fora short period when change,over from IP steam to
CRH takes place).The steam exhaust for the BFP- Turbine is connected tothe main condenser
and the turbine glands are sealed by glandsteam.

HIGH PRESSURE HEATERS

These

are

regenerative

feed

water

heaters

operating
athigh pressure and located by the side of turbine. These aregenerally vertical type
and turbine bleed steam pipes are connectedto them.HP heaters are connected in

series on feed watersideand by such arrangement, the feed water, after feed pump
entersthe HP heaters. The steam is supplied to these heaters form the bleed point
of the turbine through motor operated valves.Theseheaters have a group bypass
protection on the feed waterside.In the event f tube rupture in any of the HPH and
the level of thecondensate rising to dangerous level, the group protection
devicediverts automatically the feed water directly to boiler, thus bypassing all the
3 H.P. heaters.

Following fittings are generally provided on the HP heaters

Gauge glass for indicating the drain level.
Pressure gauge with three way cock.
Air Vent cock.
Safety valve shell side.
Seal pot.
Isolating valves.
High level alarm switch.

SPEED GOVERNOR

It
is
directly
coupled
to
the
turbine
rotor
throughcoupling and has been designed to maintain automatically thespeed of the turbo set.
It is located with the front pedestals.
LOAD LIMITER
Turbine is equipped with the load limiter used in specialcases to limit the opening of
valves by speed governor.

PURPOSE:
To limit the load rising beyond the set point, can bevaried over the entire load
range.

TURBINE OIL LUBRICATING SYSTEM

This consists of main oil pump, starting oil pump emergencyD.C. oil pump and
each per unit.

5.1TYPES OF VALVES USED AND MAINTAINED IN TMD

Figure 5-16Gate Valve

34

Figure 5-17Regulating Valve

Figure 5-18Non-Return Valve

Figure 5-19Safety Valve

Valves are made of cast iron, cast steel, carbon steel,alloy steel.
Cast iron valves: 0-150 0 C temperature (used for water lines).
Carbon steel valves: 150-4250 C temperature (used for water/steam lines).
Alloy steel valves: 425-535 0 C (used for steam lines)