A Report on RGTPP

Khedar
(Division of HPGCL)

Submitted To

Submitted By xyz
University Roll NO. : 1234567890
Training Period : 13 June 2011 – 8 July 2011 (4 weeks)

Guru Jambheshwar University Of Science and Technology

Hisar
 ACKNOWLEDGEMENT

Firstly I would like to thank my University & equally to chairperson of our Mechanical
Engineering department, Dr abc , who has given me a chance to learn something new
practically by means of adding practical training as one of our subject.

Then I would hereby like to express my profound sense of gratitude to Chief Engineer,
Haryana Power Generation Corporation Ltd. for giving me the opportunity to carry out my
industrial training at Rajiv Gandhi Thermal Power Plant Hisar ( RGTPP ) under their
experienced and highly qualified staff. Equally I am thankful to Mr. axzpqr ( AE BMD-I ) for his
invaluable guidance during the training period from 13th June to 8th July , who despite of their
busy schedule and workload , were able to find some time for us and impart us the knowledge
that paved a way for better understanding of the fundamentals and their applications alike.

I duly acknowledge the help, direct or indirect of whole department and staff members of the
organization for providing all the facilities for the training. The knowledge gained herein and
the practical experience learnt will be invaluable in the long run.

Contents

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Plant Profile………………………………………………………………………4
Salient Features of the RGTPP Hisar…………………………………………..5
Training Schedule………………………………………………………………...6
Different Sections of Plant………………………………………………………..7
General Equipments Used In Thermal Stations…………………………………..8
Thermal Power Station……………………………………………………………9
Coal Handling Plant……………………………………………………………...10
Feed Water Heating and Deaeration……………………………………..………11
Air circulation………………………………………………………………..…..12
Boiler………………………………………………………………………….....13
Bottom Ash Collection and Disposal……………………………………………16
HP Heaters……………………………………………………………………….16
Economiser………………………………………………………………………16
Superheater………………………………………………………………………16
Air Preheater……………………………………………………………………..17
Electrostatic Precipitator (ESP)………………………………………………….17
Turbine Stages…………………………………………………………………...18
Condenser………………………………………………………….…………….19
Cooling Towers………………………………………………………………….20
Chimney…………………………………………………………………………20

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Rajiv Gandhi Thermal Power Plant, Hisar

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 Plant Profile

Rajiv Gandhi Thermal Power Plant Khedar Hisar

A division of Haryana Power Generation Corporation Ltd. ( HPGCL )

ISO: 9001, ISO: 14001 and OHSAS: 18001

Haryana Power Generation Corporation Limited (HPGCL) is the electricity generating

company of the Government of Haryana in India. It has been entrusted with the responsibility of
setting up of new generating stations in state of Haryana.

RGTPP

Name and Address Units Capacity

Rajiv Gandhi Thermal Power Project Unit-I 600 MW

(RGTPP), Khedar, 20 K.M mile
stone from Hisar city NH 65

Hisar
Unit-II 600 MW
Phone: 01693-

Fax: 01693-243555

The work for turnkey implementation of 1200 MW Hisar Thermal Power Project was awarded
during January, 07. The total estimated cost of the project is Rs.4512 crores. The cost of Rs. 3.19
crore per MW for this project is the lowest in the Country and is being talked about as a new
benchmark .The Power Project was awarded to M/s Reliance Energy Ltd.

Salient Features of the RGTPP Hisar

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  This is the first project in the Northern Region to be awarded Mega Project status with
attached benefits under the Mega Project policy of Govt. of India
 Very low per MW EPC cost - Rs. 3.19 Crore per MW.

Haryana State is able to provide additional 288 lac units per day to its consumers from this
Project, while operating at rated capacity.

Brief Information of the Project

Installed Capacity 2 X 600 MW

Available Land 989 acres

Location Khedar, Hisar

EPC Contractor M/s Reliance Energy Ltd,

EPC Cost Rs 3775.428 crore (total estimated cost Rs.4512 crore)

Administrative approval 31.12.2005

Project Consultancy M/s Desein was appointed Project Consultant and CEA
were engaged as Review Consultants

Coal Sources M/s Mahanadi Coalfields Ltd., Orissa

Equity contribution State Govt. is contributing 20% equity for the project
vide letter dated 10.10.2002. Balance 80% has been
arranged through PFC.

Issue of LOI Issued to M/s REL vide letter dated 29.01.2007

Training Schedule

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Training Period 13 June 2011 – 8 July 2011 ( 4 Weeks )

Department Assigned Boiler Maintenance Department – I (BMD- I)

Supervisor Mr. Ashok Kumar (AE BMD –I)

Sites Visited During Training

Coal Handling Plant ( CHP )

Coal Mills

Boiler Furnace

Boiler Drum

Turbine Section

Boiler Feed Pump

Economiser & Air Preheater Section

Fans( ID & FD)

Chimney

Different Sections of Plant

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 Demineralised Water Plant ( DM Water Plant)

 Coal Handling Plant

 Boiler Maintenance Department – I (BMD – I )

 Boiler Maintenance Department – II (BMD – II )

 Turbine Generation I (TG – I )

 Turbine Generation II (TG – II )

 Electrical maintenance Department – I (EMD – I )

 Electrical maintenance Department – II (EMD – II )

 Switching Room

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 General Equipments Used In Thermal Stations

Typical diagram of a coal-fired thermal power station

1. Cooling tower 10. Steam Control valve 19.Superheater

2. Cooling water pump 11. High pressure steam turbine 20.F.D. Fan

3. Transmission line (3-phase) 12. Deaerator 21.Reheater

4. Step-up transformer (3-phase) 13. Feed water heater 22.Air Intake

5. Electrical generator (3-phase) 14. Coal conveyor 23.Economiser

6. Low pressure steam turbine 15. Coal hopper 24.APH

7. Condensate pump 16. Coal pulverizer 25.Precipitator

8. Surface condenser 17. Boiler steam drum 26.I.D.Fan

9. Intermediate pressure steam turbine 18. Bottom ash hopper 27.Flue gas stk.

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Thermal Power Station

A thermal power station is a power plant in which the prime mover is steam driven. Water is
heated, turns into steam and spins a steam turbine which drives an electrical generator. After it
passes through the turbine, the steam is condensed in a condenser and recycled to where it was
heated; this is known as a Rankine cycle.

Rankine Cycle flow with reheat

Rankine Cycle

1. Heat is added in a water boiler, where the water becomes steam.

2. Steam is fed to a steam turbine, which generates mechanical energy.

3. After turbine the steam becomes water again in a condenser.

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Coal Handling Plant
Here Coal used is of F grade imported from M/s Mahanadi Coalfields Ltd., Orissa by the
railway Plant have special provision for the rail to directly come inside the plant to coal handling
plant. Where coal is automatically taken off from train by magnetic trimpler which is mechanical
system work with electricity.

After removing coal it is taken to the Coal storage house with the help of conveyor belt system.
From storage house coal when need is taken to crusher which crushes the coal in pieces of 2-3
cm. From crusher coal is taken to bunkers which work as temporary storage for unit. In plant
eight ( 8 ) bunkers are installed for a single unit .

View of transmission of coal through conveyor belts

Here the coal used is peat, which is a poor quality of coal. To make it good, we blend it with
Indonesian coal of highly superior quality.

This coal is then passed into 8 mills of boilers which crushes the coal in fine particle of about 70-
80 µ known as pulvarisation of coal. The temperature of pulvarised coal is maintained by proper
supply of hot and cold air. Primary seal air is regularly passed on the periphery of mills so that
the coal does not cause blockages in bearing and valves of the mills.

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Feed Water Heating and Deaeration

The feed water used in the steam boiler is a means of transferring heat energy from the burning
fuel to the mechanical energy of the spinning steam turbine. The total feed water consists of
recirculated condensate water and purified makeup water. Because the metallic materials it
contacts are subject to corrosion at high temperatures and pressures, the makeup water is highly
purified before use. A system of water softeners and ion exchange demineralizers produces water
so pure that it coincidentally becomes an electrical insulator, with conductivity in the range of
0.3–1.0 microsiemens per centimeter. The makeup water in a 500 MWe plant amounts to
perhaps 20 US gallons per minute (1.25 L/s) to offset the small losses from steam leaks in the
system.

The feed water cycle begins with condensate water being pumped out of the condenser after
traveling through the steam turbines. The condensate flow rate at full load in a 500 MW plant is
about 6,000 US gallons per minute (400 L/s).

The water flows through a series of six or seven intermediate feed water heaters, heated up at
each point with steam extracted from an appropriate duct on the turbines and gaining temperature
at each stage. Typically, the condensate plus the makeup water then flows through a deaerator
that removes dissolved air from the water, further purifying and reducing its corrosiveness. The
water may be dosed following this point with hydrazine, a chemical that removes the remaining
oxygen in the water to below 5 parts per billion (ppb) It is also dosed with pH control agents
such as ammonia or morpholine to keep the residual acidity low and thus non-corrosive.

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 Air circulation
FAN Used

 Primary Air Fan

 FD Fan
 ID Fan

Primary AIR circulation

Primary Air

APH To Mills ( As seal air )

FD Fan

FD Fan APH Furnace

ID Fan Circulation

Furnace Exhaust To Economiser APH ID Fan

To Chimney

Boiler Specification
Type : Water Tube ( Critical)

Boiler Rating : 64712 Mt. Sq.

Working Pressure : 19.79 MPa

Boiler Feed Pump Rating : 9 MW

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Boiler

The coal enters from the 4 corners of boilers through 8 pipes arranged at each elevation. At first
the LDO & HFO are used to ignite the coal but once the burning starts the air is sufficient to
continue it. The water from the boiler drum goes along the boiler in 6 pipes and circulate it in
through motors as the natural siphon is not sufficient. These are then passed to super heater
tubes.

Pulverised coal feeding in furnace at all corner by a single mill

The boiler is a rectangular furnace about 50 feet (15 m) on a side and 130 feet (40 m) tall. Its
walls are made of a web of high pressure steel tubes about 2.3 inches (58 mm) in diameter.

Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly
burns, forming a large fireball at the center. The thermal radiation of the fireball heats the water
that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the
boiler is three to four times the throughput and is typically driven by pumps. As the water in the
boiler circulates it absorbs heat and changes into steam at 700 °F (371 °C) and 197 bar .It is

13
separated from the water inside a drum at the top of the furnace. The saturated steam is
introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as
they exit the furnace. Here the steam is superheated to 1,000 °F (500 °C) to prepare it for the
turbine.

Inside view of furnace showing Fire Ball

Once water inside the boiler or steam generator, the process of adding the latent heat of
vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical
reaction of burning some type of fuel.

The water enters the boiler through a section in the convection pass called the economizer. From
the economizer it passes to the steam drum. Once the water enters the steam drum it goes down
to the lower inlet water wall headers. From the inlet headers the water rises through the water
walls and is eventually turned into steam due to the heat being generated by the burners located
on the front and rear water walls (typically). As the water is turned into steam/vapor in the water
walls, the steam/vapor once again enters the steam drum. The steam/vapor is passed through a
series of steam and water separators and then dryers inside the steam drum. The steam separators

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 View of Boiler Shape

and dryers remove water droplets from the steam and the cycle through the water walls is
repeated. This process is known as natural circulation.

The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot blowers,
water lancing and observation ports (in the furnace walls) for observation of the furnace interior.
Furnace explosions due to any accumulation of combustible gases after a trip-out are avoided by
flushing out such gases from the combustion zone before igniting the coal.

The steam drum (as well as the super heater coils and headers) have air vents and drains needed
for initial start up. The steam drum has internal devices that removes moisture from the wet
steam entering the drum from the steam generating tubes. The dry steam then flows into the
super heater coils.

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Bottom Ash Collection and Disposal
At the bottom of the furnace, there is a hopper for collection of bottom ash. This hopper is
always filled with water to quench the ash and clinkers falling down from the furnace. Some
arrangement is included to crush the clinkers and for conveying the crushed clinkers and bottom
ash to a storage site.

HP Heaters
Water is then passed into HP heaters before they are delivered to economizers so that proper heating of
feed water should be possible.

Economiser
Economizers (US), or economisers (UK/international), are mechanical devices intended to
reduce energy consumption, or to perform another useful function like preheating a fluid. In
simple terms, an economizer is a heat exchanger. Economiser is an auxiliary for the boiler as it
increases the efficiency by utilizing flue gases for increasing the temperature of feed water.

Superheater
A superheater is a device used to convert saturated steam or wet steam into dry steam used for
power generation or processes. There are three types of superheaters namely: radiant,
convection, and separately fired. A superheater can vary in size from a few tens of feet to several
hundred feet (a few metres or some hundred metres).A convection superheater is located in the
path of the hot gases.

Simple Super Heater view

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Air Preheater
An air preheater (APH) is a auxiliary designed to heat air before, combustion in a boiler)with the
primary objective of increasing the thermal efficiency of the process. They may be used alone or
to replace a recuperative heat system or to replace a steam coil.

The purpose of the air preheater is to recover the heat from the boiler flue gas which increases
the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas. As a
consequence, the flue gases are also sent to the flue gas stack (or chimney) at a lower
temperature, allowing simplified design of the ducting and the flue gas stack. It also allows
control over the temperature of gases leaving the stack
In the plant rotary type of Air Preheater is used.

Electrostatic Precipitator(ESP)
An electrostatic precipitator (ESP), or electrostatic air cleaner is a particulate collection device that
removes particles from a flowing gas (such as air) using the force of an induced electrostatic charge.
Electrostatic precipitators are highly efficient filtration devices that minimally impede the flow of gases
through the device, and can easily remove fine particulate matter such as dust and smoke from the air
stream.In contrast to wet scrubbers which apply energy directly to the flowing fluid medium, an ESP
applies energy only to the particulate matter being collected and therefore is very efficient in its
consumption of energy (in the form of electricity).

ESPs continue to be excellent devices for control of many industrial particulate emissions, including
smoke from electricity-generating utilities (coal and oil fired), salt cake collection from black liquor
boilers in pulp mills, and catalyst collection from fluidized bed catalytic cracker units in oil refineries to
name a few. These devices treat gas volumes from several hundred thousand ACFM to 2.5 million ACFM
(1,180 m³/s) in the largest coal-fired boiler applications. For a coal-fired boiler the collection is usually
performed downstream of the air preheater at about 160 °C (320 deg.F) which provides optimal resistivity
of the coal-ash particles. For plant applications with low-sulfur fuel hot-end units have been built
operating above 371 °C (700 deg.F).

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Turbine Stages
The turbine generator consists of a series of steam turbines interconnected to each other and a
generator on a common shaft. There is a high pressure turbine at one end, followed by an
intermediate pressure turbine, two low pressure turbines, and the generator. Steam fed at pressure
of about 150 -175 bar and temperature about 560 C. As steam moves through the system and
loses pressure and thermal energy it expands in volume, requiring increasing diameter and longer
blades at each succeeding stage to extract the remaining energy. The entire rotating mass may be
over 200 metric tons and 100 feet (30 m) long. It is so heavy that it must be kept turning slowly
even when shut down (at 3 rpm) so that the shaft will not bow even slightly and become
unbalanced. This is so important that it is one of only five functions of blackout emergency
power batteries on site. Other functions are emergency lighting, communication, station alarms
and turbogenerator lube oil.

View of multi stage Turbine

Superheated steam from the boiler is delivered through 14–16-inch (360–410 mm) diameter
piping to the high pressure turbine where it falls in pressure to (4.1 MPa) and to 600 °F (320 °C)
in temperature through the stage. It exits via 24–26-inch (610–660 mm) diameter cold reheat
lines and passes back into the boiler where the steam is reheated in special reheat pendant tubes
back to 1,000 °F (500 °C). The hot reheat steam is conducted to the intermediate pressure
turbine where it falls in both temperature and pressure and exits directly to the long-bladed low
pressure turbines and finally exits to the condenser.

The generator, 30 feet (9 m) long and 12 feet (3.7 m) in diameter, contains a stationary stator
and a spinning rotor, each containing miles of heavy copper conductor—no permanent magnets
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here. In operation it generates up to 21,000 amperes at 24,000 volts AC (600 MW) as it spins at
3,000 rpm, synchronized to northen the power grid. The rotor spins in a sealed chamber cooled
with hydrogen gas, selected because it has the highest known heat transfer coefficient of any gas
and for its low viscosity which reduces windage losses. This system requires special handling
during startup, with air in the chamber first displaced by carbon dioxide before filling with
hydrogen. This ensures that the highly explosive hydrogen–oxygen environment is not created.

The power grid frequency is50 Hz across India.

The electricity flows to a distribution yard where transformers step the voltage up to 200 KV AC
as needed for transmission to its destination.

The steam turbine-driven generators have auxiliary systems enabling them to work satisfactorily
and safely. The steam turbine generator being rotating equipment generally has a heavy, large
diameter shaft. The shaft therefore requires not only supports but also has to be kept in position
while running. To minimize the frictional resistance to the rotation, the shaft has a number of
bearings. The bearing shells, in which the shaft rotates, are lined with a low friction material like
Babbitt metal. Oil lubrication is provided to further reduce the friction between shaft and bearing
surface and to limit the heat generated.

Condenser
Surface condenser is the commonly used term for a water-cooled shell and tube heat exchanger
installed on the exhaust steam from a steam turbine in thermal power stations. These condensers
are heat exchangers which convert steam from its gaseous to its liquid state at a pressure below
atmospheric pressure. Where cooling water is in short supply, an air-cooled condenser is often
used. An air-cooled condenser is however significantly more expensive and cannot achieve as
low a steam turbine exhaust pressure as a water cooled surface condenser.

Surface condensers are also used in applications and industries other than the condensing of
steam turbine exhaust in power plants.In thermal power plants, the primary purpose of a surface
condenser is to condense the exhaust steam from a steam turbine to obtain maximum efficiency
and also to convert the turbine exhaust steam into pure water (referred to as steam condensate) so
that it may be reused in the steam generator or boiler as boiler feed water.

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Cooling Towers
Natural draught cooling tower is used which is hyperbolic in nature. The water from condensers is
circulated through it so that it may be cooled. The height of each cooling tower is 175 m.

Chimney
Draft Type: Induced

Height: 275 m

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