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Sir,
Sub:- TS GENCO-RTS-B Station Mini Project Completion-Regarding
Ref:- SE/O&M/RTS/DE/AT&P/DM(HR)/JR.ASST/F.MINI Project work/
D.NO.687/17,Dt.01.05.2019.
CERTIFICATE
This is to certify that the following students of “MALLA REDDY
COLLEGE OF ENGINEERING AND TECHNOLOGY” have undergone project
work on “STUDY OF BOILER AND ITS PERFORMANCE” atRTS.B,
Ramagundam during the period 01-06-2019 to 30-06-2019 under the guidance of
Sri.P.RAJU ADE/BM. (I/C).
KAMSHETTY MADHU. 18N35A0316
1
CERTIFICATE
This is to certify that the project entitled
“STUDY OF BOILER AND ITS PERFORMANCE” is a bonafide work done by,
MEMBERS
A. SANDEEP 17N05A0304
A. RAMYA 17N05A0307
S. SHYAMALA 17N05A0337
Thimmapur, Karimnagar.
(Affiliated to JNTUH)
(2017-2020)
2
A partial fulfillment of the requirements for the award of B.Tech degree in
Mechanical Engineering
In
TS GENCO, RAMAGUNDAM
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
Submitted by
A. SANDEEP 17N05A0304
A. RAMYA 17N05A0307
S. SHYAMALA 17N05A0337
3
S.NO CONTENTS PAGE NO
1. ACKNOWLEDGEMENT 5
2. ABSTRACT 6
3. PROFILE 7
4. INTRODUCTION 8
4. BOILER 9-37
5. CONCLUSION 38
4
ACKNOWLEDGEMENT
We are also grateful to Sri. P.Raju ADE/BM (I/C), and M.Pravalika AE/BM
R.T.S ‘B’ under whose guidance we were able to complete the training.
We are very grateful to our principal Dr. G.Venkateshwarlu and our H.O.D,
Dr.Shashikanth, Mechanical Department, Sree Chaitanya college of Engineering
karimnagar, who give their kind co-operation & allowed us to do the Industrial
Training outside the college campus.
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ABSTRACT
The internship of RTS’B’ specifies about the overall plant view in detailed
manner. It consist of coal handling plant, Water treatment plant, Boiler and its
Auxiliaries, Turbine, and turbine auxiliaries, . It defines Generation and performance
of such equipment in this plant.
COAL PLANT: Coal is most important fuel in the thermal power station. The coal is
being received at the power station by road and rail from Godavarikhani of Singareni
collieries Co.Ltd. The entire coal requirement is received at plant by roadways by
means of trucks.
WATER TREATMENT PLANT: The raw water to the plant is drawn from the river
Godavari situated about 8km from the plant. The water from the river is pumped to a
reservoir on the top of hill near the plant. Water is supplied by gravity to DM plant
through clarifier and directly to CW to cooling tower basins as makeup.
BOILER: Boiler is a closed vessel in which water or other fluid is heated. The heated
are vaporized fluid exits the boiler for use in various processes or heating
applications.
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PROFILE
The coal is being received at the power station by road and rail from
Godavarikhani of Singareni Collieries Co.Ltd. At present coal is received by
roadways by means of trucks. And the raw water to the plant is drawn from the river
Godavari situated about 8km from plant. The water from river is pumped to a
reservoir on the top of hill near the plant. Water is supplied by gravity to DM plant
through clarifier and directly to CW cooling tower basins as make up.
It uses 9%-10%of its power for its auxiliary usage, which includes plant and
other peripherals uses it has installed with a single alternator supplied by G.E.
(General Electrical, USA), RTS works with a water tube, corner shoot type if boiler
from C.E., U.S.A. It shows a good performance in generating electricity.
TSGENCO has completed its first phase R&M during Jan-2007,in the field of
turbine and generator 2nd phase of Renovation and Modernization(R&M) works
carried out in 2014 controls to improve its performance.
1. INTRODUCTION
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Ramagundam B Super Thermal Power Plant is located
at Ramagundam in Telangana. The power plant is one of the coal based power plants
of TSGENCO.
The station has achieved the height plant load factor in all India level for four
times in the group of 62.5 MW to 63.5 MW units.
2. BOILER
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A boiler is a closed vessel in which water or other fluid is heated. The heated
or vaporized fluid exits the boiler for use in various processes." Like heating, power
generation etc.
Watertube boilers are designed to circulate hot combustion gases around the
outside of a large number of water filled tubes. Because the pressure is confined
inside the tubes, watertube boilers can be fabricated in larger sizes and used for
higher-pressure applications. Most modern water boiler tube designs are within the
capacity range 4,500 – 120,000 Kg/hour of steam, at very high pressures.
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Fire tube boilers consist of a series of straight tubes that are housed inside a
water-filled outer shell. The tubes are arranged so that hot combustion gases flow
through the tubes. As the hot gases flow through the tubes, they heat the water
surrounding the tubes. The water is confined by the outer shell of boiler. Fire tube
boilers are competitive for steam rates up to 12,000 Kg/hour and pressures up to 18
Kg/cm2.
In Corner Firing Boilers, the coal and other peripherals in a diagonal will face
each other.
In Middle Firing Boilers, the coal and other peripherals in the opposite sides
will face each other.
The air and fuel streams are vertically adjustable by means of movable air
deflectors and nozzle tips, which can be tilted upward or downward through a total
angle of 60 degrees.
These Boilers are similar to corner firing boilers, but the firing inlet angles are
little inclined to make a rotational path in the boiler.
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iii. Types boiler based on Construction:
b. Boiler Auxiliaries:
i. Super heaters:
Super heaters are meant to rise the steam temperature above the saturation
temperature by absorbing heat from the flue gas. Usually superheaters are classified,
according to the shape of the tube banks & the position of the header. General
classifications of superheaters are: Pendent Type Superheater, Horizontal Type Super
heater, Radiant Superheater, Convection Super heater and Combined Super heater. In
spite of classification, pendent type super heater and Radiant type Superheaters are
using in RTS. In this plant, the super heater is divided into primary and secondary of
14 coils and 50 coils respectively. The headers for both primary and secondary supers
are located in pent house, form there the super heaters are vertically erected in to the
boiler flue gas path.
ii. Economizers:
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Flue gases coming out of the boiler carry lot of heat. Function of economiser
is to recover some of the heat from the heat carried away in the flue gases up the
chimney and utilize for heating the feed water to the boiler. It is placed in the passage
of flue gases in between the exit from the boiler and the entry to the chimney. The use
of economiser results in saving in coal consumption, increase in steaming rate and
high boiler efficiency.
Water
outlet
Economizer
coils
Water inlet
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Details of Economizer in RTS ‘B’:
2. Length : 7150mm
6. Stainless Steel Shrouds In 2mm Stainless Steel Plate Suitable For 2 Inches
OD Economiser Tubelong Staight Shrouds For Staight Tube
8. Stainless steel shrouds 2mm stainless steel plate for 2” on economiser tube ,2”
inside curvature, 9” long straight,6” upward bend for bottom
Specifications Values
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No. of Tubes: Width Wise 60
Length Wise 19
Outside Diameter 51 mm
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2. Furnace access door bends
Radial : 628 m2
9. Arrey backed by a steel skin casing gas tight seal soot blower inserting
tubes
OD : 76.2 mm thickness
7.1 mm
Temperature : 4100 C
15
At soot blower area :
North : 74 East : 97
South : 74 West : 97
Air heaters are used in steam generating plants to heat the combustion air and
enhance the combustion process. Most of frequently, the flue gas is the source of
energy and the air heaters serves as a heat trap to collect and use waste heat from the
flue gas stream. This can increase the overall boiler efficiency by 5 to 10%. Air
heaters can also use extraction steam or other sources of energy depending up on the
particular application. These units are usually employed to control air and gas
temperatures by pre heating air entering the main gas-air heaters.
Super heaters, Economizers generally cannot fully extract the heat from flue
gases. Therefore Pre-heaters are employed which recover some of the heat from the
flue gases.
Air heaters are classified as recuperative and regenerative types based on their
operating principle.
In Recuperative type; Tubular Air Heaters, cast iron air heaters, plate air
heaters, steam air heaters, heat pipe are comes under this category.
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In Regenerative type air heaters Ljungstrom Air Pre-Heater and Rothemuhle
Air Pre-Heater are comes under this category.
In RTS, Ljungstrom Air Pre-Heater (LAPH) and Tubular Air Heaters (TAH)
are in use.
LAPH is a regenerative type air heater, which is using in RTS. The heating
medium flows through a closely packed matrix to raise its temperature and then air is
passed through the matrix to pick up the heat. Either the matrix or the hoods are
rotated to achieve this and hence leakage through sealing arrangements at the moving
surfaces is high.
The inlet of LAPH is 323.9°C of flue gas and 42.78°C at the rate of 317 T/hr
of air and the outlet is 154.4°C at the rate of 385 T/hr of flue gas and 246.11°C at the
rate of 290.45 T/hr of air.
LAPH 23VIR
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Hot End Basket ‘B’ type : 12 N0.s
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LAPH Double row radial spherical roller bearing : 2304CCKW33
SKF
TOP LAYER
Depth : 9/4 mm
BOTTOM LAYER
Depth : 350mm
Resisitance steel
Seals : Labryanth
MANUFACTURED BY:-
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The preheater company wellscille New York , US PATENTS
Order No : AP _2483
Heat No : 4614
Type : 23 VIR
M.O : 8-731169
Ratio : 87.5
O/p rpm : 20
one side and air is on the other side of tube or plate and heat transfer is by conduction
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through the material which separates the media. These are of static construction and
hence there is only nominal leakage through expansion joints, access doors, casings
etc.
TAH :-
Outer dia : 3”
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Air outlet temperature : 343.30 C
Horizontal spacing : 5”
Vertical spacing : 5”
Thickness : 2.52 mm
The function of Induced Draft fan is to suck the gases out of furnaces and
throw into the stack. Boiler is provided with a no. of Induced Draft Fans. Each ID fan
is provided with regulating damper control and scoop control for controlling the
loading on fans, Inlet/Outlet gates for isolation to facilitate startup/maintenance of
fan. Flue gas interconnection with damper is provided before ESP in order to maintain
balanced flow through both the APH when only one ID fan is running.
Usually, In RTS plant, the induced draft fan is a double inlet and single outlet
fan which was connected to the chimney from boiler path and it maintains the output
air from the furnace which is equal to the input, to furnace from FD fan. So, that the
fire from the burner compartment will not come out, by maintaining equal input and
output conditions. By controlling the blades of inlet, the outlet air can be controlled,
according to the requirement and passed to the chimney.
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Details of ID Fan in RTS ‘B’:
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Description unit Induced draft fan
Operating VFD
MCR DESIGN
Fan efficiency % 85 85
Casing IS 2062
Shaft 2C 35 &ST 37
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Impeller mixing Impeller is bolted to shaft flange which is
welded to shaft
In RTS, Single FD fan is used and has double inlet and single outlet. The air
flow can be controlled by controlling the inlet vanes and supplied the outlet air to the
furnace for combustion process.
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Boilers operating with both forced and induced draft use the forced draft fan to
push air through the combustion air supply system into furnace. The fan must have a
discharge pressure high enough to equal the total resistance of air ducts, air heater,
burners or fuel bed and any other resistance between the fan discharge and the
furnace. This makes the furnace the point of balanced draft or zero pressure. Volume
output of the forced draft fan must equal the total quantity of air required for
combustion plus air heater leakage.
Specifications Values
Unit 1
Specifications Values
Power 900 HP
Voltage 3.3 kV
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Impeller assembly : 1 set
Bearing : 2 sets
Gear coupling : 1 No
Temp : 51.70 C
HP : 900
Speed : 1000rpm
Volt : 3.3 KV
Type : Backward
vi. Boiler Feed Pumps (BFP): Boiler feed pump is usually a centrifugal pump. This
pump feeds the water to boiler through economizer.
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The water with given operating temperature should flow to the pump under
certain minimum pressure. Water passes through the suction branch into the intake
spiral and from there; it is directed to the first impeller. After leaving through the
impeller it passes through the distributing passages of the diffuser where it get certain
pressure rise and flows over to guide vanes to the inlet of the next impeller. This
process repeats from one stage to the other till it passes through the last impeller and
the end diffusers. Thus the feed water arriving into the discharge space develops the
necessary operating pressure; a small part of feed water i.e. about 10% is taken off
from the space behind the last impeller for the operation of automatic balancing
device to balance the hydraulic axial thrust of the pump rotor.
In RTS ‘B’, there are two Boiler Feed Pumps (BFP’s) which are BFP – 1A and
BFP – 1B with a pressure maintaining of 135 Kg/cm2 and temperature of 150°C to
160°C.
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Specifications Values
Temperature 325 °F
iv. Circulating Water Pump (CWP), Condensate Extraction Pump (CEP): The
next most usage of pumps are CWP and CEP, in thermal generation.
CWP: In RTS, It has two Circulating Water Pumps named CWP-A and CWP-B
which are used for circulating the water to the condenser for cooling the steam,
extracted in it.
Details of CWP:
Specifications Values
Quantity 2 No.s
Make Peerless
Single stage,
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Head 20.720 mtrs
CWBP:
Type : NP-3725
No. : 43310
Size : 10 x 10
Order No : BO/V/EPS97
Year : 1968
Monohead : 15-25
RPM : 960
BHP : 38.4
Motor HP : 50
SAFTEY VALVE :-
Size : 2 1/2 “
Temperature : 96000C
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Relieving capacity : 1,32,250
But weld inlets and 6”FLGD outlet3001/4 “R.FMFGS STD.Facing cadmium plate
springs
Disc : 1No.
Spindle : 1No.
Size 3 inches
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Body cast steel
Butt weld inlet and 6” flgd 300 1/16” rf.mfgs std facing cadmium plate springs
1. Disc 2No.
6. Spindle 2No.
Disc holder for saftey valve 1738 WA (for drum left and right)
-> Size 2 ½”
-> Size 2 ½”
Size :- 3”
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Parameters Day 1 Day 2 Day 3 Day 4
(oc)
(mpa)
In (kcal/kg)
33
Day 1:
= 0.239*2685.09
= 641.73 Kcal/kg
q * GCV
= 203 * 641.73
38.75 * 3960
=84.4%
Day 2:
= 0.239*2710.87
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= 712.96 Kcal/kg
q * GCV
= 161 * 712.96
39.51 * 3918
= 74.15%
Day 3:
= 0.239*2726.10
= 716.96 Kcal/kg
q * GCV
= 163 * 716.96
39.51 * 3918
= 80.34%
35
Day 4:
= 0.239*2671.43
= 702.58 Kcal/kg
q * GCV
= 170 * 702.58
37.5 * 3950
= 80.6%
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CONCLUSION
Comparing with the past, the demand of electricity has been doubled for last
two decades. RTS ‘B’ is running with a PLF of 87% from the date of commissioning.
RTS ‘B’ has adequate residual life and also for improving the performance by
implementing renovation and modernization works. Therefore TSGENCO has
completed its first phase R&M during Jan-2007, and the 2 nd phase of R&M completed
in 2014 the controls to improve its performance.
The unit has updated in using technology in every aspect including its
auxiliaries, instrumentation. Also the performance of boiler improved by regular
monitoring of parameters and with preventive maintenance. Recently in August 2018
new ID fan and ESP was commissioned to maintain the pollution within prescribed
norms of PCB.
In this period of project in learnt about design and working of air pre heaters
and economiser in power plant. By using air pre heaters and economists the efficiency
of plants can be increased. Gas flow distribution or heat transfer into economiser
section is improved through use of guide vanes at inlet of economiser duct. Analysis
of economiser module was carried out to predict the feed water outlet temperature.the
economiser size optimised by reducing no.of tubes of module by enhancing the heat
transfer across the module.by installing the air pre heater and economiser the total
husk consumption rate is reduced and the efficiency of plant is also increased.
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