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Dt 14/05/14 03/06/14
This project report has been prepared in fulfillment if industrial training to be
carried out in third year of our four year B.E course. For preparing the project
report, we visited MEJIA THERMAL POWER STATION under DAMADAR VALLEY
CORPORATION during the suggested duration for the period of 21 days, to avail
the necessary information. The blend of learning and knowledge acquired during
our practical studies at the company is presented in this project report.
The rationale behind visiting the power plant and preparing the project is to study
the mechanical operation in details, electrical overview, various cycles and
processes of power generation and details of control and instrumentation
required in thermal power plant.
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 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 co-
operation 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
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.
TECHNICAL SPECIFICATION OF MTPS
INSTALLED CAPACITY:
1. Total number of Units : - 4 X 210 MW(unit 1 to 4) with Brush Type
Generators, 2 X 250 MW(unit 5 and 6) with Brush less Type Generators,
2*500 MW(unit 7 and 8) Generators.
2. Total Energy Generation: - 2340 MW
3. Source of Water: - Damodar River
4. Sources of Coal: - B.C.C.L and E.C.L, also imported from Indonesia
In a Thermal Power generating unit, combustion of fossil fuel (coal, oil or natural gas) in
Boiler or fissile element (uranium, plutonium) in Nuclear Reactor generates heat energy.
This heat energy transforms water into steam at high pressure and temperature. This steam
is utilized to generate mechanical energy in a Turbine. This mechanical energy, in turn is
converted into electrical energy with the help of an Alternator coupled with the Turbine.
The production of electric energy utilizing heat energy is known as thermal power
generation.
The heat energy changes into mechanical energy following the principle of Rankin reheat-
regenerative cycle and this mechanical energy transforms into electrical energy based on
Faradays laws of electromagnetic induction. The generated output of Alternator is
electrical power of three-phase alternating current (A.C.). A.C. supply has several
advantages over direct current (D.C.) system and hence, it is preferred in modern days. The
voltage generated is of low magnitude (14 to 21 KV for different generator rating) and is
stepped up suitably with the help of transformer for efficient and economical transmission
of electric power from generating stations to different load centers at distant locations.
Soot Blower:
It is an on load arrangement of cleaning the accumulation of deposits on boiler heating surfaces
resulting from combustion of coal and to a relatively smaller extent from oil. Superheated
steam, taken out from main steam line and reduced to pressure around 30 kg/cm2, is passed
through different types of blowers placed at different location of boiler to clean the deposits for
effective heat transfer through the metal surface. The different types of blowers are (a) Long
retractable soot blower for cleaning the superheater, reheater zones, (b) Wall blower for
cleaning the furnace wall and (c) Air pre-heater soot blower for cleaning air preheater baskets
especially during oil firing to prevent damage of the basket materials from oil firing.
Air pre-heater:
The air pre-heater absorbs waste heat from flue gas and then transfers this heat to incoming
cold air by means of continuously rotating heat transfer elements of specially formed metal
plates known as Basket (rotary re-generative air pre-heater) or through stationery tubes
(recuperative or tubular air pre-heater). In re-generative type, thousands of high efficiency
elements are spaced and compactly arranged with sectors shaped compartments of a radially
divided cylindrical shell called the rotor. The housing surrounding the rotor is provided with
duct connections at both ends and is adequately sealed by radial and circumferential sealing
members forming an air passage through one or two sectors of the pre-heater and a gas
passage through the other sector. As the rotor slowly revolves the mass of elements through
the gas and air passages, heat is absorbed by the element surfaces passing through the hot gas
stream; then as these same surfaces are carried through the air stream they release the stored
up heat thus greatly increasing the temperature of the incoming air. In the recuperative type,
the flue gas is passed through the tubes and the air is passed over outer side of the tubes.
TECHNICAL DATA OF THE BOILER
Radiant, Reheat, Natural circulation, Single
Type Drum, Balanced drift, Dry bottom, Tilting
tangential, Coal and oil fired with DIPC (Direct
Ignition of Pulverized Coal) system.
FURNACE
Width 13868 mm.
Depth 10592 mm.
Volume 5240 mm.
Fuel heat input per hour 106 kcal
Designed pressure 175.8 kg per sq. cm
Super-heater outlet pressure 155 kg per sq. cm
Low temp SH (horizontally spaced) 2849 sq. m total heating surface area
Platen SH(Pendant Platen) 1097 sq. m total heating surface area
Final SH(Vertically spaced) 1543 sq. m total heating surface area
ATTEMPERATOR
Type Spray
no. of stages One
Spray medium feed water from boiler feed pump
RE-HEATER
Type Vertical spaced
Total H.S. area 2819 sq. m.
Control Burner tilt and excess air
ECONOMISER
Type Plain tube
Total H.S. area 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.
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.
CHIMNEY
A chimney may be considered as a cylindrical hollow tower made of bricks or steel. In MTPS the
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.
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.
Unit Auxiliary Transformer
The normal source of HV Power to unit auxiliaries is unit auxiliary transformer. The sizing of the
UAT is usually based on the total connected capacity of running unit auxiliaries i.e., excluding
the stand by drives. It is safe and desirable to provide about 20% excess capacity than
calculated. The no. and recommended MVA rating of unit auxiliary transformers are as shown
in the above table: The UATs shall have Ddo(ungrounded system) or Dy1 (for grounded system)
connection with on load tap changer to provide +10 % variation in steps of 1.25 %. Usual
cooling arrangement to unit auxiliary transformers are ONAN. Radiators are usually divided in
two equal halves.
EXCITATION SYSTEM
The purpose of excitation system is to continuously provide the appropriate amount of D.C.
field current to the generator field winding. The excitation system is required to function
reliably under the following conditions of the generator and the system to which it is
connected.
Functional components of an excitation system :
A good excitation system consists of properly co-ordinated functional components which are
a) Excitation Power source
b) Semiconductor Rectifier
c) Voltage controller
d) Protective, limiting and switching equipments
e) Monitoring, Metering and indicating equipments and
f) Cooling system
Types of Excitation System :
In earlier days DC excitation system was in use. Increase in generator capacity in turn raised the
demand of excitation power which was notachievable by the DC exciters. This led to the
accelerated development of AC excitation system in pace with generator capacity. With the
maturing of solid state semiconductor technology AC excitation system found to be superior
technically as well as economically. Excitation system can be categorized and subdividedinto
the following :
a) D.C. excitation system
i) Pilot Main Exciter excitation system
ii) Rotating Amplifier excitation system.
b) A.C. excitation system
i) Rotating High Frequency excitation system
ii) Static excitation system
iii) Brushless excitation system.
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.