Punj Lloyd

Thermal
Thermal Power
Power Plant
Plant

By,
Sadhana...
Engineer

Punj Lloyd

Power Generation in 2008-09 & Requirement

in 2010

At present, Indias total installed power capacity stands at 1,47,402.81MW. Of this, the
contribution of each sources are
Thermal

Hydro

93,392MW
36,647.76MW

Nuclear sources

4,120 MW

Renewable energy

13,242.41 MW.

Indias power generation capacity 68% below target in 2009.

There is a huge demand for power in FY10.It is expected to grow by 4.6% with a
capacity of 7,730 MW are likely in FY10.

Punj Lloyd

Types of Power Plants

Mechanical Energy

Electrical Energy

1.

Thermal Station: The turbine is rotated by steam which is produced by the heat
generated by burning
fuel in a Boiler.

2.

Hydel Power Plant: The mechanical energy is produced by inducing high pressure water
through a
nozzle onto the turbine.

3.

Nuclear Power Plant: Nuclear power is power (generally electrical) produced from
controlled (i.e., nonexplosive) nuclear Reactions i.e. fission or Fusion.

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Operation Mechanism

The coal is brought and crushed to powder. This is feed to Boiler for producing heat

In Boiler the water is converted to steam.

In Super heater the moisture content is removed from the steam and that steam is
called super heated steam

The superheated steam rotates the shaft of the High pressure turbine

The Exhausted steam is sent to preheater and the steam then rotates the Intermediate
pressure(IP) Turbine

The steam from the IP turbine is then feed to low pressure turbine.

The turbine shaft is connected to the Generator, which produces Electric Power.

The power generated is then Transmitted.

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Thermal Power Plant

Power plant order is placed on EPC contract, which is divided into 2 parts

EPC

BOP
Balance of
plant 40% of
total contract
value

BTG
60% of total
contract value

Boiler, Turbine
& Generator

MBOP
Mechanical
Contributes
60%

CBOP
Civil
contributes
25%

EBOP
Electrical
contrbutes
15%

BOP includes supply , erection and commissioning of complete plant excluding Boiler,
Turbine & Generator.

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BTG & BOP

Boiler, Turbine & Generator includes supply, erection & commissioning of

Boiler

Turbine

Generator

BTG constitutes Approximately 60% of total contract value

Balance of Plant is given as a separate contract which include supply, erection &
commissioning of

Coal Handling Plant

Water Handling Plant( water treatment)

Ash Handling Plant

Switch Yard

Switch Gear

This constitutes Approximately 40% of total contract value

Punj Lloyd

Boiler

The boiler is fed with HFO and LDO initially to ignite the coal in the Boiler.
Types of boilers:
1. Water tube Boiler: A boiler in which water circulates in tubes heated externally by the
fire.
2. Fire tube Boiler: Water is present in the drum inside the boiler and Hot air is
circulated around to
maintain the temperature.
Fuel
Air
HFO,LDO & Coal

Boiler

Fuel
HFO,LDO & Coal

Air
Dryer

The fuel and air are feed from 2

directions to increase the
efficiency

Air compressor
FD Fan

Atmospheric Air

Punj Lloyd

Turbine

In a Thermal Power Plant generally 3 turbines are used to increase the efficiency.

High Pressure Turbine(HPT): The superheated steam is directly fed to this turbine to rotate it.

Intermediate Pressure Turbine(IPT): The out put from the HPT is reheated in a reheater(RH) and
used to
rotate IPT .

Low Pressure Turbine(LPT): The Exhausted steam from the IPT is directly fed to rotate the shaft of
LPT.

*All the turbines are connected to a single shaft which is connected to the Generator.
Super
Heater

Steam
Shaft

HPT
RH

IPT

LPT
Steam

Condenser

Generator

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Generator

The Synchronous Generator is used to Generate power by connecting the shaft of the Turbine
to the shaft of the generator which cuts the magnetic flux producing Emf.

The Generated Voltage will generally 11KV to 20 KV max.

The Generated Voltage is stepped up by connecting Step up transformer and is

transmitted and is also used for Auxiliary purposes.
UAT
20Kv to 6.KV

Bus Duct
SYNCHRONOUS
GENERATOR

Generator
Transformer
20KV to 400KV
Unit Auxiliary Transformer: This transformer is used to step down the produced
voltage and use
for Auxiliary purpose.

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Coal Handling Plant

Raw Coal Wagon- Coal is brought to the site

through a
Wagon as per requirement.

Wagon tippler-The coal is unloaded from the

Wagon
and is transported to
crushers and for
storage place through
conveyor.

Junction tower- JTs are used where the

conveyor has
any angular deviation.

Primary Crusher-The Raw coal is crushed into fine

pieces to 45mm grit). Primary crusher is also
called Rotary Breaker since the coal is
crushed by a rotating plate.

Secondary Crusher-The fine pieces of coal is

crushed to
powder (to 25mm grit)

Rejected- The
stones and
unwanted
coal is
rejected

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Two way conveyor

Stacker & Reclaimer- It is

used to store the powdered
coal for emergency purpose

Junction Tower

Mill Bunker-The 25mm grit coal is crushed into very fine

powder for feeding the boiler. We will have a spare
Bunker for each Boiler.

BOILER

Atmospheric air
(Through FD fan)

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Water Handling Plant(WHP)

Water in a Power Plant is used for

1.

Production of Steam- for rotating turbine.

2.

Cooling Purpose- For cooling of various equipment .

Water is recycled and used for various purpose:

Raw
Water

Conde
nser

Steam

Purified
DM
water

For
cooling
purpos
e

3% of water is wasted during this process.

Appx 4 cubic mt water is lost /day/MW

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Reservoir

Water
Water Cycle
Cycle
Water Clarification

Chlorification
&
Filtration

DM Plant
(Demineralized Plant)
Auxiliary cooling
Water (ACW)

DMCW
Demineralized
cooling Water

Various Equipment

Various Equipment

Boiler
Steam

DMCWP

Condenser

PHE
25D
35D

CT

Cooling Water

25D
20D

water

CWP
CWP

Steam to
Water
Cool water
from CWP

PHE-Pre heat Exchange

CWP
Cool water

D-Degrees
CWP-cooling water Pump

Hot water

Dearator

Hot Well

Cooling
Tower
CT

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Ash Handling Plant

Flue Gases

The Ash from the boiler is collected in two forms:

1.

Bottom Ash(Slurry):Its a waste which is dumped into a Ash Pond

2.

Fly ash: Fly ash is separated from Flue Gases in ESP(Electro

static Precipitator).

Economizer : Reduces the temperature

Boiler

Bottom
ash(wet
ash)

Fly Ash
& Flue
Gases

Chimney
Economizer

Flue Gases

ESP

Fly ash

Ash Pond

Cylo

Cemen
t

DCS-Distributed Control System

DCS- It merges all communication capabilities of IEDs across a network to perform
protection,control,metering and Automation scheme.
Substation Automation-The systems used to monitor & control power systems It typically
include Station

SW, HMI, Bay Control / Automation .

Protection units, Protection devices,

Telecommunication systems and interfaces,

Data gateways, plus comprehensive

engineering, Project management,

maintenance and training.