National Thermal Power Corporation

27th MAY 6th JULY
2013
SUBMITTED BY:
MANPREET SINGH CHADHA B.TECH(HONS.) MECHANICAL ENGINEERING ROLL NO. 11001082 LPU PUNJAB
Summer Internship Report Lovely Professional University
National Thermal Power Corporation

BADARPUR THERMAL POWER STATION BADARPUR, NEW DELHI
TRAINING REPORT 27-05-13 to 06-07-13
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWAR OF THE DEGREE OF BACHELOR OF TECHNOLOGY (Mechanical Engineering) SUBMITTED TO
LOVELY PROFESSIONAL UNIVERSITY, JALANDHAR

SUBMITTED BY Name of Student Registration ID Manpreet Singh Chadha 11001082
Lovely Professional University, Jalandhar PUNJAB
National Thermal Power Corporation

BADARPUR THERMAL POWER STATION BADARPUR, NEW DELHI
TRAINING REPORT 27-05-13 to 06-07-13
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF THE DEGREE OF BACHELOR OF TECHNOLOGY (Mechanical Engineering) SUBMITTED TO
LOVELY PROFESSIONAL UNIVERSITY, JALANDHAR

SUBMITTED BY Name of Student Registration ID Manpreet Singh Chadha 11001082
Lovely Professional University, Jalandhar PUNJAB
TRAINING AT BTPS I was appointed to have 6 week training at this esteemed organization from 27 th May to 6th July, 2013. I was assigned to visit various section of this thermal plant, which are as follows: Boiler Maintenance Department (BMD I/II/III) Plant Auxiliary Maintenance (PAM) Turbine Maintenance Department (TAM)
This 6 weeks training was a very educational for me. It was really exciting to see the plant by myself and learn how electricity is produced.
This report has been made by my experience at BTPS. The material in this report has been gathered from my textbook, senior student reports and trainers manuals and power journals provided by training department. The specification and principles are as learned by me from the employees of each division of BTPS.
MANPREET SINGH CHADHA
ACKNOWLEDGEMENT
I would like to place on record my deep sense of gratitude to Mr. Manmohan Singh, Deputy General Manager, Student Training Cell, BTPS, New Delhi for giving me opportunity to complete my 4
internship in such a prestigious organization. I also thank him for his generous guidance, help and useful suggestions. I express my sincere gratitude to Er. P.K. Prabhakar, Er. Gaurav Goyal, Er.S.K. Garg Assistant General Manager Assistant Manager Deputy General Manager Boiler Maintenance department, Plant Auxiliary Maintenance Turbine Maintenance Department
of Badarpur Thermal Power Station, New Delhi, for sharing their knowledge and experience with me . I also thank them for their stimulating guidance, and continuous encouragement.
I am extremely grateful to all the technical staff of BTPS / NTPC for their co-operation and guidance that has helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted of them for this value addition in me.
I am extremely thankful to Prof. Harminder Singh Saggu, HOD, Lovely Professional University Jalandhar, for valuable suggestions and encouragement . I am also thankful to Mr. Sushil Kumar Jand, Training and placement officer, LPU, Jalandhar for providing the opportunity to gain this level of knowledge.
I would also like to thank all the faculty members of Mechanical Engineering Department for their effort of constant co- operation, which have been a significant factor in the accomplishment of my industrial training.
Manpreet Singh 11001082
ABOUT NTPC
NTPC Limited is the largest thermal power generating company of India, It is a Public Sector Company of INDIA. It was incorporated in the year 1975 to accelerate power development in the country as a wholly owned company by the Government of India. At present, Government of India holds 89.5% of the total equity shares of the company and the balance 10.5% is held by FIIs, Domestic Banks, Public and others. Within a span of 31 years, NTPC has emerged as a truly national power company, with power generating facilities in all the major regions of the country.
NTPC's core business is engineering, construction and operation of power generating plants and providing consultancy to power utilities in India and abroad.
Presently, NTPC generates power from Coal and Gas. With an installed capacity of 41,184 MW, NTPC is the largest power generating major in the country. It has also diversified into hydro power, coal mining, power equipment manufacturing, oil & gas exploration, power trading & distribution. With an increasing presence in the power value chain, NTPC is well on its way to becoming an Integrated Power Major. By 2017, the power generation portfolio is expected to have a diversified fuel mix with coal based capacity of around 53000 MW, 10000 MW through gas, 9000 MW through Hydro generation, about 2000 MW from nuclear sources and around 1000 MW from Renewable Energy Sources (RES). NTPC has adopted a multi-pronged growth strategy which includes capacity addition through green field projects, expansion of existing stations, joint ventures, subsidiaries and takeover of stations.
Figure A.1 NTPC Across INDIA
NTPC Vision
7
To be the worlds largest and best power producer, powering Indias growth.
Mission
Develop and provide reliable power, related products and services at competitive prices, integrating multiple energy sources with innovative and eco-friendly technologies and contribute to society.
Core Values BE COMMITTED

B Business Ethics E Environmentally & Economically Sustainable C Customer Focus O Organizational & Professional Pride M Mutual Respect & Trust M Motivating Self & others I Innovation & Speed T Total Quality for Excellence T Transparent & Respected Organization E Enterprising D Devoted
Figure A.2 Yearly growth of NTPC
NTPC has been operating its plants at high efficiency levels. Although the company has 18.79% of the total national capacity it contributes 28.60% of total power generation due to its focus on high efficiency. NTPCs share at 31 Mar 2001 of the total installed capacity of the country was 24.51% and it generated 29.68% of the power of the country in 2008-09. Every fourth home in India is lit by NTPC. 170.88BU of electricity was produced by its stations in the financial year 2005-2006. The Net Profit after Tax on March 31, 2006 was INR 58,202 million. Net Profit after Tax for the quarter ended June 30, 2006 was INR 15528 million, which is 18.65% more than for the same quarter in the previous financial year. 2005). NTPC has set new benchmarks for the power industry both in the area of power plant construction and operations. Its providing power at the cheapest average tariff in the country. NTPC is committed to the environment, generating power at minimal environmental cost and preserving the ecology in the vicinity of the plants. NTPC has undertaken massive a forestation in the vicinity of its plants. In 1991, it set up Ash Utilization Division
Corporate Social Responsibility As a responsible corporate citizen NTPC has taken up number of CSR initiatives. NTPC Foundation formed to address Social issues at national level NTPC has framed Corporate Social Responsibility Guidelines committing up to 0.5% of net profit annually for Community Welfare. The welfare of project affected persons and the local population around NTPC projects are taken care of through well drawn Rehabilitation and Resettlement policies. 9
The company has also taken up distributed generation for remote rural areas.
Partnering government in various initiatives Consultant role to modernize and improvise several plants across the country. Disseminate technologies to other players in the sector. Consultant role Partnership in Excellence Programme for improvement of PLF of 15 Power Stations of SEBs. Rural Electrification work under Rajiv Gandhi Garmin Vidyutikaran.
Environment Management All stations of NTPC are ISO 14001 certified. Various groups to care of environmental issues. The Environment Management Group. Ash Utilization Division. Afforestation Group. Centre for Power Efficiency & Environment Protection. Group on Clean Development Mechanism. NTPC is the second largest owner of trees in the country after the Forest department.
Table A.1 JOURNEY OF NTPC
1975
1997 2004 2005
NTPC was set up in 1975 with 100% ownership by the Government of India. In the last 30 years, NTPC has grown into the largest power utility in India. In 1997, Government of India granted NTPC status of Navratna being one of the nine jewels of India, enhancing the powers to the Board of Directors. NTPC became a listed company with majority Government ownership of 89.5%. NTPC becomes third largest by Market Capitalization of listed companies The company rechristened as NTPC Limited in line with its changing business portfolio and transforms itself from a thermal power utility to an integrated power utility. 10
2008 2009 2012 2017
National Thermal Power Corporation is the largest power generation company in India. Forbes Global 2000 for 2008 ranked it 411th in the world. National Thermal Power Corporation is the largest power generation company in India. Forbes Global 2000 for 2008 ranked it 317th in the world. NTPC has also set up a plan to achieve a target of 50,000 MW generation capacity. NTPC has embarked on plans to become a 75,000 MW company by 2017.
ABOUT BTPS
Badarpur thermal power station started working in 1973 with a single 95 mw unit. There were 2 more units (95 MW each) installed in next 2 consecutive years. Now it has total five units with total capacity of 720 MW. Ownership of BTPS was transferred to NTPC with effect from 01.06.2006 through GOIs Gazette Notification .Given below are the details of unit with the year they are installed. Table A.2 Details about BTPS Address: Telephone: Fax: Installed Capacity Derated Capacity Location Coal Source Water Source Beneficiary States Unit Sizes Badarpur, New Delhi 110 044 (STD-011) 26949523 26949532 720 MW 705 MW New Delhi Jharia Coal Fields Agra Canal Delhi 3X95 MW 2X210 MW Units Commissioned Unit I- 95 MW - July 1973 Unit II- 95 MW August 1974
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Unit III- 95 MW March 1975 Unit IV - 210 MW December 1978 Unit V - 210 MW - December 1981 Transfer of BTPS to NTPC Ownership of BTPS was transferred to NTPC with effect from 01.06.2006 through GOIs Gazette Notification
TABLE OF CONTENTS
Title Acknowledgement i About NTPC and BTPS List of Tables List of Figures List of Abbreviation List of Nomenclature Chapter 1: INTRODUCTION 1.1 BASIC STEPS OF ELECTRICITY GENERATION 1.1.1 Coal to Steam 1.1.2 Steam to Mechanical Power 1.1.3 Mechanical Power to Electrical Power 1.2 BASIC POWER PLANT CYCLE 1.3 FACTORS AFFECTING THERMAL CYCLE EFFICIENCY Chapter 2: BOILER MAINTENANCE DEPARTMENT 2.1 2.2 BOILER AND ITS DESCRIPTION SPECIFICATIONS OF THE BOILER 6 8 ii xi xii xiii xiii Page No.
1 1 3 3 4 5
2.3
AUXILIARIES OF THE BOILER 2.3.1 2.3.2 2.3.3 Furnace Boiler Drum Water Walls
9 9 9 10
12
2.3.4 2.3.5 2.3.6 2.3.7 2.3.8
Reheater Superheater Economizer Air Preheater Pulverizer 2.3.8.1 2.3.8.2 Types of Pulverizer Advantages of Pulverized Coal
11 11 12 13 13 14 15
Chapter 3: PLANT AUXILIARY MAINTENANCE 3.1 WATER CIRCULATION SYSTEM 3.1.1 3.1.2 Theory of Circulation Types of Boiler Circulating System 3.1.2.1 Natural Circulation System 16 17 17 16 16 16
3.1.2.2 Controlled Circulation System 3.2 ASH HANDLING PLANT
3.2.1 3.2.2 3.2.3

3.3
Hydraulic Ash Handling System Fly Ash Collection Bottom Ash Collection and Disposal
18 18 18
19 20 20 21 21 22 22 22 23 23
WATER TREATMENT PLANT 3.3.1 3.3.2 Pretreatment Section Demineralization
3.4
DRAUGHT SYSTEM 3.4.1 3.4.2 3.4.3 3.4.4 Natural Draught System Induced Draft System Forced Draught System Balanced Draught System
3.4.5 Primary Air Fan 3.5 COMPRESSOR HOUSE
Chapter 4: TURBINE MAINTENANCE DEPARTMENT 4.1 TURBINE CLASSIFICATION 4.1.1 Impulse turbine: 4.1.2 Reaction turbine: 13 25 25 25
4.2
COMPOUNDING 4.2.1 Velocity Compounded Turbine
25 25 26 26 26 27 27 28 29 30 31 31 31 32 33 34 34 34 37 39
4.2.2 Pressure Compounded Turbine 4.2.3 Pressure Velocity Compounded Turbine 4.3 SPECIFICATIONS OF THE TURBINE 4.4 STEAM TURBINE 4.5 MAIN TURBINE 4.6 TURBINE COMPONENTS 4.6.1 Turbine Casing 4.6.2 Rotors 4.6.3 Blades 4.7 VACUUM SYSTEM 4.7.1 Condenser 4.7.2 Ejectors 4.8 CONDENSATE SYSTEM 4.8.1 Condensate Pumps 4.8.2 L.P. Heaters 4.8.3 Deaerator Chapter 5: CONCLUSION REFFERENCE Appendix 1
List of Tables
Table
Title
Page
14
A.1 A.2 4.1
JOURNEY OF NTPC Details about BTPS CONDENSATE CYCLE
vii viii 33
15
LIST OF FIGURES
Figure
A.1 A.2 1.1 1.2
Title
NTPC across INDIA Yearly growth of NTPC Block Diagram representing path of conversion of coal to Electricity Block Diagram Showing functioning of POWER PLANT at various sections 1 2
Page
iii v
1.3 1.4 2.1 2.2 2.3 2.4 2.5 2.6 3.1 3.2 3.3 3.4 3.5 3.6 4.1 4.2 4.3 4.4
A simplified diagram of a thermal power plant Thermodynamic Representation of Steam Cycle in a POWER PLANT Boiler Site of the Badarpur Thermal Power Station, New Delhi Schematic diagram of a coal-fired power plant steam generator View of Tubes of reheater A view of economizer tube plates Operation Cycle of Air Preheater Section view of Coal Pulverizer Ash Volume and properties at different section of the power plant Water treatment plant at BTPS, New Delhi Site ;Demineralization tank BTPS, New Delhi Operational cycle: induced draught system Primary air fan at BTPS, New Delhi Compressor house at BTPS, New Delhi The 95 MW Generator at BTPS, New Delhi Main Turbine A typical water cooled condenser Labled Deaerator
4 4 6 7 11 12 13 14 17 19 20 22 23 24 25 28 32 35
NOMENCLATURE
16
Psi MPa Cr MO V
Pounds per Square inches Mega Pascal Chromium Molybdenum Vanadium
ABBREVIATIONS
PA FD ID HP IP LP APH
Primary Air Forced Draught Induced Draught High Pressure Intermediate Pressure Low Pressure Air Preheater
17
Chapter 1
INTRODUCTION
1.1 BASIC STEPS OF ELECTRICITY GENERATION
The basic steps in the generation of electricity from coal involves following steps: Coal to steam Steam to mechanical power Mechanical power to electrical power
COAL TO ELECTRICITY: BASICS The basic steps in the generation of coal to electricity are shown below:
Figure 1.1 Block Diagram representing path of conversion of coal to Electricity
1.1.1
Coal to Steam
Coal from the coal wagons is unloaded in the coal handling plant. This Coal is transported up to the raw coal bunkers with the help of belt conveyors. Coal is transported to Bowl mills by Coal Feeders. The coal is pulverized in the Bowl Mill, where it is ground to powder form. The mill consists of a round metallic table on which coal particles fall. This table is rotated with the help of a motor. There are three large steel rollers, which are spaced 120 apart. When there is no coal, these rollers do not rotate but when the coal is fed to the table it packs up between roller and the table, this forces the rollers to rotate. Coal is crushed by the crushing action between the rollers and the rotating table. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold air mixture from P.A. Fan.
18
P.A. Fan takes atmospheric air, a part of which is sent to Air-Preheaters for heating while a part goes directly to the mill for temperature control. Atmospheric air from F.D. Fan is heated in the air heaters and sent to the furnace as combustion air. Water from the boiler feed pump passes through economizer and reaches the boiler drum. Water from the drum passes through down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat and density difference, the water rises up in the water wall tubes. Water is partly converted to steam as it rises up in the furnace. This steam and water mixture is again taken to the boiler drum where the steam is separated from water.
Figure 1.2 Block Diagram Showing functioning of POWER PLANT at various sections Water follows the same path while the steam is sent to superheaters for superheating. The superheaters are located inside the furnace and the steam is superheated (540C) and finally it goes to the turbine. Flue gases from the furnace are extracted by induced draft fan, which maintains balance draft in the furnace (-5 to 10 mm of wcl) with forced draft fan. These flue gases emit their heat energy to various super heaters in the pent house and finally pass through air-preheaters and goes to electrostatic precipitators where the ash particles are extracted. Electrostatic Precipitator consists of metal plates, which are electrically charged. Ash particles are attracted on to these plates, so that they do not pass through the chimney to pollute the atmosphere. Regular mechanical hammer blows cause the accumulation of ash to fall to the bottom of the precipitator where they are collected in a hopper for disposal.
19
1.1.2
Steam to Mechanical Power
From the boiler, a steam pipe conveys steam to the turbine through a stop valve (which can be used to shut-off the steam in case of emergency) and through control valves that automatically regulate the supply of steam to the turbine. Stop valve and control valves are located in a steam chest and a governor, driven from the main turbine shaft, operates the control valves to regulate the amount of steam used. (This depends upon the speed of the turbine and the amount of electricity required from the generator). Steam from the control valves enters the high pressure cylinder of the turbine, where it passes through a ring of stationary blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on a disc secured to the turbine shaft. The second ring turns the shafts as a result of the force of steam. The stationary and moving blades together constitute a stage of turbine and in practice many stages are necessary, so that the cylinder contains a number of rings of stationary blades with rings of moving blades arranged between them. The steam passes through each stage in turn until it reaches the end of the high-pressure cylinder and in its passage some of its heat energy is changed into mechanical energy. The steam leaving the high pressure cylinder goes back to the boiler for reheating and returns by a further pipe to the intermediate pressure cylinder. Here it passes through another series of stationary and moving blades. Finally, the steam is taken to the low-pressure cylinders, each of which enters at the centre flowing outwards in opposite directions through the rows of turbine blades through an arrangement called the double flow- to the extremities of the cylinder. As the steam gives up its heat energy to drive the turbine, its temperature and pressure fall and it expands. Because of this expansion the blades are much larger and longer towards the low pressure ends of the turbine.
1.1.3
Mechanical Power to Electrical Power
As the blades of turbine rotate, the shaft of the generator, which is coupled to that of the turbine, also rotates. It results in rotation of the coil of the generator, which causes induced electricity to be produced.
20
1.2
BASIC POWER PLANT CYCLE
Figure 1.3 A simplified diagram of a thermal power plant The thermal (steam) power plant uses a dual (vapour+ liquid) phase cycle. It is a close cycle to enable the working fluid (water) to be used again and again. The cycle used is Rankine Cycle modified to include superheating of steam, regenerative feed water heating and reheating of steam.
Figure 1.4 Thermodynamic Representation of Steam Cycle in a POWER PLANT On large turbines, it becomes economical to increase the cycle efficiency by using reheat, which is a way of partially overcoming temperature limitations. By returning partially expanded steam, to a reheat, the average temperature at which the heat is added, is increased and, by expanding this reheated steam to the remaining stages of the turbine, the exhaust wetness is considerably less than it would otherwise be conversely, if the maximum tolerable wetness is allowed, the initial pressure of the steam can be appreciably increased.
21
Bleed Steam Extraction: For regenerative system, nos. of non-regulated extractions is taken from HP, IP turbine. Regenerative heating of the boiler feed water is widely used in modern power plants; the effect being to increase the average temperature at which heat is added to the cycle, thus improving the cycle efficiency.
1.3
FACTORS AFFECTING THERMAL CYCLE EFFICIENCY
Thermal cycle efficiency is affected by following: Initial Steam Pressure. Initial Steam Temperature. Whether reheat is used or not, and if used reheat pressure and temperature. Condenser pressure. Regenerative feed water heating.
22
Chapter 2
BOILER MAINTENANCE DEPARTMENT

2.1 BOILER AND ITS DESCRIPTION
The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60 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 centre. 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 and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700 F (370 C) and 3,200 psi (22.1MPa). It is separated from the water inside a drum at the top of the furnace.
Figure 2.1 Boiler Site of the Badarpur Thermal Power Station, New Delhi
23
The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion cylinder. Here the steam is superheated to 1,000 F (540 C) to prepare it for the turbine. The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. The generator includes the economizer, the steam drum, the chemical dosing equipment, and the furnace with its steam generating tubes and the superheater coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include: forced draft (FD) fan, air preheater (APH), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or baghouse) and the flue gas stack. For units over about 210 MW capacity, redundancy of key components is provided by installing duplicates of the FD fan, APH, fly ash collectors and ID fan with isolating dampers. On some units of about 60 MW, two boilers per unit may instead be provided.
Figure 2.2 Schematic diagram of a coal-fired power plant steam generator
24
2.2
SPECIFICATIONS OF THE BOILER 1. Main Boiler (AT 100% LOAD): i. ii. iii. Evaporation Feed water temperature Feed water leaving economizer 700 tons/hr 247C 276C 341C 540C 332C 540C 158. 20 kg/cm2 149.70 kg/cm2 137.00 kg/cm2 26.35 kg/cm2 24.50 kg/cm2
2. Steam Temperature: i. ii. iii. iv. Drum Super heater outlet Reheat inlet Reheat outlet
3. Steam Pressure: i. ii. iii. iv. v. Drum design Drum operating Super heater outlet Reheat inlet Reheat outlet
4. Fuel Specifications A) Coal i. ii. iii. iv. v. vi. vii. B) Oil i. ii. iii. iv. v. vi. Low Heat value Sulphur Moisture Flash point Viscosity 1500 redwood at Sp. Weight 10000 kcal/kg 4.5% w/w 1% w/w
0
Fixed Carbon Volatile Matter Moisture Ash Grindability High Heat Coal size to Mill
38% 26% 8.0% 28% 55HGI 4860 Kcal/Kg 20 mm
66 C.
0
37.8 C.
0
0.98 at 38 C.
25
5. Heat Balance i. ii. iii. iv. v. vi. vii. Dry gas loss Carbon loss Radiation loss Unaccounted loss H in air and H O in fuel
2 2
4.63% 2% 0.26% 1.5% 4.9% 13.3% 86.7%
Total loss Efficiency
2.4 AUXILIARIES OF THE BOILER 2.3.1 Furnace Furnace is primary part of boiler where the chemical energy of the fuel is converted to thermal energy by combustion. Furnace is designed for efficient and complete combustion. Major factors that assist for efficient combustion are amount of fuel inside the furnace and turbulence, which causes rapid mixing between fuel and air. In modern boilers, water furnaces are used.
2.3.2
Boiler Drum Drum is of fusion-welded design with welded hemispherical dished ends. It is provided with stubs for welding all the connecting tubes, i.e. downcomers, risers, pipes, saturated steam outlet. The function of steam drum internals is to separate the water from the steam generated in the furnace walls and to reduce the dissolved solid contents of the steam below the prescribed limit of 1 ppm and also take care of the sudden change of steam demand for boiler.
The secondary stage of two opposite banks of closely spaced thin corrugated sheets, which direct the steam and force the remaining entertained water against the corrugated plates. Since the velocity is relatively low this water does not get picked up again but runs down the plates and off the second stage of the two steam outlets.
From the secondary separators the steam flows upwards to the series of screen dryers, extending in layers across the length of the drum. These screens perform the final stage of the separation.
26
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 the down comers 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/vapour in the water walls, the steam/vapour once again enters the steam drum.
The steam/vapour is passed through a series of steam and water separators and then dryers inside the steam drum. The steam separators and dryers remove the 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 tripout are avoided by flushing out such gases from the combustion zone before igniting the coal.
The steam drum (as well as the superheater coils and headers) have air vents and drains needed for initial start-up. The steam drum has an internal device that removes moisture from the wet steam entering the drum from the steam generating tubes. The dry steam then flows into the superheater coils. Geothermal plants need no boiler since they use naturally occurring steam sources.
Heat exchangers may be used where the geothermal steam is very corrosive or contains excessive suspended solids. Nuclear plants also boil water to raise steam, either directly passing the working steam through the reactor or else using an intermediate heat exchanger.
2.3.3
Water Walls Water flows to the water walls from the boiler drum by natural circulation. The front and the two side water walls constitute the main evaporation surface, absorbing the bulk of radiant heat of the fuel burnt in the chamber. The front and rear walls are bent at the lower ends to form a water-cooled slag hopper. The upper part of the chamber is
27
narrowed to achieve perfect mixing of combustion gases. The water wall tubes are connected to headers at the top and bottom. The rear water wall tubes at the top are grounded in four rows at a wider pitch forming g the grid tubes.
2.3.4
Reheater Reheater is used to raise the temperature of steam from which a part of energy has been extracted in highpressure turbine. This is another method of increasing the cycle efficiency. Reheating requires additional equipment i.e. heating surface connecting boiler and turbine pipe safety equipment like safety valve, non return valves, isolating valves, high pressure feed pump, etc: Reheater is composed of two sections namely the front and the rear pendant section, which is located above the furnace arc between water-cooled, screen wall tubes and rear wall tubes.
Figure 2.3 View of Tubes of reheater 2.3.5 Superheater Whatever type of boiler is used, steam will leave the water at its surface and pass into the steam space. Steam formed above the water surface in a shell boiler is always saturated and become superheated in the boiler shell, as it is constantly. If superheated steam is required, the saturated steam must pass through a superheater. This is simply a heat exchanger where additional heat is added to the steam. In water-tube boilers, the superheater may be an additional pendant suspended in the furnace area where the hot gases will provide the degree of superheat required. In other cases, for example in CHP schemes where the gas turbine exhaust gases are relatively cool, a separately fired superheater may be needed to provide the additional heat.
28
2.3.6
Economizer The function of an economizer in a steam-generating unit is to absorb heat from the flue gases and add as a sensible heat to the feed water before the water enters the evaporation circuit of the boiler.
Earlier economizer were introduced mainly to recover the heat available in the flue gases that leaves the boiler and provision of this addition heating surface increases the efficiency of steam generators. In the modern boilers used for power generation feed water heaters were used to increase the efficiency of turbine unit and feed water temperature.
Figure 2.4 A view of economizer tube plates Use of economizer or air heater or both is decided by the total economy that will result in flexibility in operation, maintenance and selection of firing system and other related equipment. Modern medium and high capacity boilers are used both as economizers and air heaters. In low capacity, air heaters may alone be selected. Stop valves and non-return valves may be incorporated to keep circulation in economizer into steam drum when there is fire in the furnace but not feed flow. Tube elements composing the unit are built up into banks and these are connected to inlet and outlet headers.
29
2.3.7 Air Preheater
Combustion Air TO BOILER
Flue Gas FROM BOILER
Air Inlet To STACK
Figure 2.5 Operation Cycle of Air Preheater
Air preheater absorbs waste heat from the flue gases and transfers this heat to incoming cold air, by means of continuously rotating heat transfer element of specially formed metal plates. Thousands of these high efficiency elements are spaced and compactly arranged within 12 sections. Sloped compartments of a radially divided cylindrical shell called the rotor. The housing surrounding the rotor is provided with duct connecting both the ends and is adequately scaled by radial and circumferential scaling.
Special sealing arrangements are provided in the provided in the air preheater to prevent the leakage between the air and gas sides. Adjustable plates are also used to help the sealing arrangements and prevent the leakage as expansion occurs. The air preheater heating surface elements are provided with two types of cleaning devices, soot blowers to clean normal devices and washing devices to clean the element when soot blowing alone cannot keep the element clean.
2.3.8
Pulverizer A pulverizer is a mechanical device for the grinding of many types of materials. For example, they are used to pulverize coal for combustion in the steam-generating furnaces of the fossil fuel power plants.
30
2.3.8.1 Types of Pulverizer
i.
Ball and Tube mills A ball mill is a pulverizer that consists of a horizontal cylinder, up to three diameters in length, containing a charge of tumbling or cascading steel balls, pebbles or steel rods. A tube mill is a revolving cylinder of up to five diameters in length used for finer pulverization of ore, rock and other such materials; the materials mixed with water is fed into the chamber from one end, and passes out the other end as slime.
ii.
Bowl mill It uses tires to crush coal. It is of two types; a deep bowl mill and the shallow bowl mill.
Figure 2.6 Section view of Coal Pulverizer
31
2.3.8.2 Advantages of Pulverized Coal Pulverized coal is used for large capacity plants. It is easier to adapt to fluctuating load as there are no limitations on the combustion capacity. Coal with higher ash percentage cannot be used without pulverizing because of the problem of large amount ash deposition after combustion. Increased thermal efficiency is obtained through pulverization. The use of secondary air in the combustion chamber along with the powered coal helps in creating turbulence and therefore uniform mixing of the coal and the air during combustion. Greater surface area of coal per unit mass of coal allows faster combustion as more coal is exposed to heat and combustion. The combustion process is almost free from clinker and slag formation. The boiler can be easily started from cold condition in case of emergency. Practically no ash handling problem. The furnace volume required is less as the turbulence caused aids in complete combustion of the coal with minimum travel of the particles.
32
Chapter 3
PLANT AUXILIARY MAINTENANCE
3.1 3.1.1
WATER CIRCULATION SYSTEM Theory of Circulation
Water must flow through the heat absorption surface of the boiler in order that it be 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 down corners 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. 3.1.2 i. ii. iii. Types of Boiler Circulating System Natural circulation system Controlled circulation system Combined circulation system
3.1.2.1 Natural Circulation System Water delivered to steam generator from feed water is at a temperature well below the saturation value corresponding to that pressure. Entering first the economizer, it is heated to about 30-40C below saturation temperature. From economizer the water enters the drum and thus joins the circulation system. Water entering the drum flows through the down corner 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 superheating and then sent to the high-pressure turbine. Remaining water mixes with the incoming water from the economizer and the cycle is repeated.
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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. Therefore natural circulation is limited to the boiler with drum operating pressure around 175 kg/ cm2. 3.1.2.2 Controlled Circulation System Beyond 80 kg/ cm2 of pressure, circulation is to be assisted with mechanical pumps to overcome the frictional losses. To regulate the flow through various tubes, orifices plates are used. This system is applicable in the high sub-critical regions (200 kg/ cm2). 3.2 ASH HANDLING PLANT
The widely used ash handling systems are: i. ii. iii. iv. Mechanical Handling System Hydraulic System Pneumatic System Steam Jet System
Figure 3.1 Ash Volume and properties at different section of the power plant
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The Hydraulic Ash handling system is used at the Badarpur Thermal Power Station. 3.2.1 Hydraulic Ash Handling System
The hydraulic system carried the ash with the flow of water with high velocity through a channel and finally dumps into a sump. The hydraulic system is divided into a low velocity and high velocity system. In the low velocity system the ash from the boilers falls into a stream of water flowing into the sump. The ash is carried along with the water and they are separated at the sump. In the high velocity system a jet of water is sprayed to quench the hot ash. Two other jets force the ash into a trough in which they are washed away by the water into the sump, where they are separated. The molten slag formed in the pulverized fuel system can also be quenched and washed by using the high velocity system. The advantages of this system are that its clean, large ash handling capacity, considerable distance can be traversed, absence of working parts in contact with ash. 3.2.2 Fly Ash Collection
Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag filters (or sometimes both) located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators or bag filters. Generally, the fly ash is pneumatically transported to storage silos for subsequent transport by trucks or railroad cars. 3.2.3 Bottom Ash Collection and Disposal
At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from the bottom of the furnace. 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.
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3.3
WATER TREATMENT PLANT
As the types of boiler are not alike their working pressure and operating conditions vary and so do the types and methods of water treatment. Water treatment plants used in thermal power plants used in thermal power plants are designed to process the raw water to water with a very low content of dissolved solids known as demineralized 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.
Figure 3.2 Water treatment plant at BTPS, New Delhi The type of demineralization process chosen for a power station depends on three main factors: i. ii. iii. The quality of the raw water. The degree of de-ionization i.e. treated water quality. Selectivity of resins.
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Water treatment process is generally made up of two sections: 3.3.1 Pretreatment section. Demineralization section Pretreatment Section
Pretreatment plant removes the suspended solids such as clay, silt, organic and inorganic matter, plants and other microscopic organism. The turbidity may be taken as two types of suspended solid 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 settle able. Long term ability to remain suspended in water is basically a function of both size and specific gravity. 3.3.2 Demineralization
This filter water is now used for demineralizing purpose and is fed to cation exchanger bed, but enroute being first dechlorinated, which is either done by passing through activated carbon filter or injecting along the flow of water, an equivalent amount of sodium sulphite through some stroke pumps. The residual chlorine, which is maintained in clarification plant to remove organic matter from raw water, is now detrimental to action resin and must be eliminated before its entry to this bed.
Figure 3.3 Site ;Demineralization tank BTPS, New Delhi
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A DM plant generally consists of cation, anion and mixed bed exchangers. The final water from this process consists essentially of hydrogen ions and hydroxide ions which is the chemical composition of pure water. The DM water, being very pure, becomes highly corrosive once it absorbs oxygen from the atmosphere because of its very high affinity for oxygen absorption. The capacity of the DM plant is dictated by the type and quantity of salts in the raw water input. However, some storage is essential as the DM plant may be down for maintenance. For this purpose, a storage tank is installed from which DM water is continuously withdrawn for boiler make-up. The storage tank for DM water is made from materials not affected by corrosive water, such as PVC. The piping and valves are generally of stainless steel. Sometimes, a steam blanketing arrangement or stainless steel doughnut float is provided on top of the water in the tank to avoid contact with atmospheric air. DM water make-up is generally added at the steam space of the surface condenser (i.e., the vacuum side). This arrangement not only sprays the water but also DM water gets deaerated, with the dissolved gases being removed by the ejector of the condenser itself.
3.4
DRAUGHT SYSTEM
There are four types of draught system: i. ii. iii. iv. 3.4.1 Natural Draught Induced Draught Forced Draught Balanced Draught Natural Draught System
In natural draft units the pressure differentials are obtained have constructing tail chimneys so that vacuum is created in the furnace. Due to small pressure difference, air is admitted into the furnace.
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3.4.2
Induced Draft System
In this system, the air is admitted to natural pressure difference and the flue gases are taken out by means of Induced Draught (I.D.) fans and the furnace is maintained under vacuum.
Figure 3.4 Operational cycle: induced draught system
3.4.3
Forced Draught System
A set of forced draught (F.D.) fans is made use of for supplying air to the furnace and so the furnace is pressurized. The flue gases are taken out due to the pressure difference between the furnace and the atmosphere. 3.4.4 Balanced Draught System
Here a set of Induced and Forced Draft Fans are utilized in maintaining a vacuum in the furnace. Normally all the power stations utilize this draft system.
3.4.5 Primary Air Fan PA Fan if flange-mounted design, single stage suction, NDFV type, backward curved bladed radial fan operating on the principle of energy transformation due to centrifugal forces. Some
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amount of the velocity energy is converted to pressure energy in the spiral casing. The fan is driven at a constant speed and varying the angle of the inlet vane control controls the flow. The special feature of the fan is that is provided with inlet guide vane control with a positive and precise link mechanism. It is robust in construction for higher peripheral speed so as to have unit sizes. Fan can develop high pressures at low and medium volumes and can handle hot-air laden with dust particles.
Figure 3.5 Primary air fan at BTPS, New Delhi 3.5 COMPRESSOR HOUSE
Instrument air is required for operating various dampers, burner tilting, devices, diaphragm valves, etc: in the 210 MW units. Station air meets the general requirement of the power station such as light oil atomizing air, for cleaning filters and for various maintenance works. The control air compressors and station air compressors have been housed separately with separate receivers and supply headers and their tapping.
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Figure 3.6 Compressor house at BTPS, New Delhi
Air-Drying Unit Air contains moisture which tends to condense, and causes trouble in operation of various devices by compressed air. Therefore drying of air is accepted widely in case of instrument air. Air drying unit consists of dual absorption towers with embedded heaters for reactivation. The absorption towers are adequately filled with specially selected silica gel and activated alumina while one tower is drying the air.
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Chapter 4
TURBINE MAINTENANCE DEPARTMENT
4.1 4.1.1
TURBINE CLASSIFICATION Impulse turbine:
In impulse turbine steam expands in fixed nozzles. The high velocity steam from nozzles does work on moving blades, which causes the shaft to rotate. The essential features of impulse turbine are that all pressure drops occur at nozzles and not on blades. 4.1.2 Reaction turbine: In this type of turbine pressure is reduced at both fixed and moving blades. Both fixed and moving blades act like nozzles. Work done by the impulse effect of steam due to reverse the direction of high velocity steam. The expansion of steam takes place on moving blades.
Figure 4.1 The 95 MW Generator at BTPS, New Delhi 4.2 COMPOUNDING
Several problems occur if energy of steam is converted in single step and so compounding is done. Following are the type of compounded turbine 4.2.1 Velocity Compounded Turbine:
Like simple turbine it has only one set of nozzles and entire steam pressure drop takes place there. The kinetic energy of steam fully on the nozzles is utilized in moving blades.
#To learn more about Compounding see Appendix 1
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4.2.2
Pressure Compounded Turbine:
This is basically a number of single impulse turbines in series or on the same shaft. The exhaust of first turbine enters the nozzles of next turbine. The total pressure drop of steam does not take on first nozzle ring but divided equally on all of them.
4.2.3
Pressure Velocity Compounded Turbine:
It is just the combination of the two compounding and has the advantages of allowing bigger pressure drops in each stage and so fewer stages are necessary. Here for given pressure drop the turbine will be shorter length but diameter will be increased.
4.3
SPECIFICATIONS OF THE TURBINE Type: type. Rated power: Number of stages: cylinder. Rated steam pressure: valve. Rated steam temperature: Steam flow: H.P. turbine exhaust pressure: Condenser back pressure: Type of governing: Number of bearing; Lubrication Oil: Gland steam pressure: Critical speed: Ejector steam parameter: 535C after reheating at inlet. 670T / hr. 27 kg /sq. cm., 327C 0.09 kg /sq. cm. nozzle governing. 5 excluding generator and exciter. turbine oil 14 of IOC. 1.03 to 1.05 kg /sq. cm (Abs) 1585, 1881, 2017. 4.5 kg /sq. cm. 130 kg /sq. cm before entering the stop 210 MW. 12 in H.P., 11 in I.P. and 4*2 in L.P. Tandem compound 3 cylinder reheated
Condenser cooling water pressure: 1.0 to 1.1 kg /sq. cm. Condenser cooling water temperature: 27000 cu. M /hr. Number of extraction lines for regenerative heating of feed water: seven.
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4.4
STEAM TURBINE
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam and converts it into useful mechanical work. From a mechanical point of view, the turbine is ideal, because the propelling force is applied directly to the rotating element of the machine and has not as in the reciprocating engine to be transmitted through a system of connecting links, which are necessary to transform a reciprocating motion into rotary motion. Hence since the steam turbine possesses for its moving parts rotating elements only if the manufacture is good and the machine is correctly designed, it ought to be free from out of balance forces. If the load on a turbine is kept constant the torque developed at the coupling is also constant. A generator at a steady load offers a constant torque. Therefore, a turbine is suitable for driving a generator, particularly as they are both high-speed machines. A further advantage of the turbine is the absence of internal lubrication. This means that the exhaust steam is not contaminated with oil vapour and can be condensed and fed back to the boilers without passing through the filters. It also means that turbine is considerable saving in lubricating oil when compared with a reciprocating steam engine of equal power. A final advantage of the steam turbine and a very important one is the fact that a turbine can develop many time the power compared to a reciprocating engine whether steam or oil.
4.5
MAIN TURBINE
The 210MW turbine is a cylinder tandem compounded type machine comprising of H.P. and I.P and L.P cylinders. The H.P. turbine comprises of 12 stages the I.P turbine has 11 stages and the L.P has four stages of double flow. The H.P and I.P. turbine rotor are rigidly compounded and the I.P. and L.P rotor by lens type semi flexible coupling. All the 3 rotors are aligned on five bearings of which the bearing number is combined with thrust bearing. The main superheated steam branches off into two streams from the boiler and passes through the emergency stop valve and control valve before entering the governing wheel chamber of the H.P. Turbine. After expanding in the 12 stages in the H.P. turbine then steam is returned in the boiler for reheating.
# For principal of Turbine see Appendix 1
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The reheated steam from boiler enters I.P. turbine via the interceptor valves and control valves and after expanding enters the L.P stage via 2 numbers of cross over pipes. In the L.P. stage the steam expands in axially opposed direction to counteract the thrust and enters the condenser placed directly below the L.P. turbine. The cooling water flowing through the condenser tubes condenses the steam and the condensate the collected in the hot well of the condenser. The condensate collected the pumped by means of 3x50% duty condensate pumps through L.P heaters to deaerator from where the boiler feed pump delivers the water to the boiler through H.P. heaters thus forming a closed cycle.
Figure 4.2 Main Turbine
4.6
TURBINE COMPONENTS Casing. Rotor. Blades.
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4.6.1
Turbine Casing
4.6.1.1 HP Turbine Casings: Outer casing: a barrel-type without axial or radial flange. Barrel-type casing suitable for quick startup and loading. The inner casing- cylindrically, axially split. The inner casing is attached in the horizontal and vertical planes in the barrel casing so that it can freely expand radially in all the directions and axially from a fixed point (HP- inlet side).
4.6.1.2 IP Turbine Casing: The casing of the IP turbine is split horizontally and is of double-shell construction. Both are axially split and a double flow inner casing is supported in the outer casing and carries the guide blades. Provides opposed double flow in the two blade sections and compensates axial thrust. Steam after reheating enters the inner casing from Top & Bottom.
4.6.1.3 LP Turbine Casing: The LP turbine casing consists of a double flow unit and has a triple shell welded casing. The shells are axially split and of rigid welded construction. The inner shell taking the first rows of guide blades is attached kinematically in the middle shell. Independent of the outer shell, the middle shell, is supported at four points on longitudinal beams. Steam admitted to the LP turbine from the IP turbine flows into the inner casing from both sides.
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4.6.2
Rotors
4.6.2.1 HP Rotor: The HP rotor is machined from a single Cr-Mo-V steel forging with integral discs. In all the moving wheels, balancing holes are machined to reduce the pressure difference across them, which results in reduction of axial thrust. First stage has integral shrouds while other rows have shroudings, riveted to the blades are periphery.
4.6.2.2 IP Rotor: The IP rotor has seven discs integrally forged with rotor while last four discs are shrunk fit. The shaft is made of high creep resisting Cr-Mo-V steel forging while the shrunk fit discs are machined from high strength nickel steel forgings. Except the last two wheels, all other wheels have shrouding riveted at the tip of the blades. To adjust the frequency of thee moving blades, lashing wires have been provided in some stages.
4.6.2.3 LP Rotor: The LP rotor consists of shrunk fit discs in a shaft. The shaft is a forging of Cr-Mo-V steel while the discs are of high strength nickel steel forgings. Blades are secured to the respective discs by riveted fork root fastening. In all the stages lashing wires are provided to adjust the frequency of blades. In the last two rows, satellite strips are provided at the leading edges of the blades to protect them against wet-steam erosion.
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4.6.3
Blades Most costly element of the turbine. Blades fixed in stationary part are called guide blades/ nozzles and those fitted in moving part are called rotating/working blades. Blades have three main parts: Aerofoil: working part. Root. Shrouds. Shroud are used to prevent steam leakage and guide steam to next set of moving blades.
4.7
VACUUM SYSTEM This comprises of: Condenser: 2 for 200 MW unit at the exhaust of LP turbine. Ejectors: One starting and two main ejectors connected to the condenser locared near the turbine.
4.7.1 Condenser There are two condensers entered to the two exhausters of the L.P. turbine. These are surface-type condensers with two pass arrangement. Cooling water pumped into each condenser by a vertical C.W. pump through the inlet pipe. Water enters the inlet chamber of the front water box, passes horizontally through brass tubes to the water tubes to the water box at the other end, takes a turn, passes through the upper cluster of tubes and reaches the outlet chamber in the front water box. From these, cooling water leaves the condenser through the outlet pipe and discharge into the discharge duct. Steam exhausted from the LP turbine washes the outside of the condenser tubes, losing its latent heat to the cooling water and is connected with water in the steam side of the condenser. This condensate collects in the hot well, welded to the bottom of the condensers.
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Figure 4.3 A typical water cooled condensor 4.7.2 Ejectors There are two 100% capacity ejectors of the steam eject type. The purpose of the ejector is to evacuate air and other non-condensating gases from the condensers and thus maintain the vacuum in the condensers. The ejector has three compartments. Steam is supplied generally at a pressure of 4.5 to 5 kg /cm2 to the three nozzles in the three compartments. Steam expands in the nozzle thus giving a high-velocity eject which creates a low-pressure zone in the throat of the eject. Since the nozzle box of the ejector is connected to the air pipe from the condenser, the air and pressure zone. The working steam which has expanded in volume comes into contact with the cluster of tube bundles through which condensate is flowing and gets condensed thus after aiding the formation of vacuum. The noncondensing gases of air are further sucked with the next stage of the ejector by the second nozzle. The process repeats itself in the third stage also and finally the steam-air mixture is exhausted into the atmosphere through the outlet.
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4.8
CONDENSATE SYSTEM
This contains the following
Condensate Pumps: 3 per unit of 50% capacity each located near
condenser hot well. LP Heater: Normally 4 in number with no.1 located at the upper part of Deaerator; one per unit located around 181 M level in CD bay.
the condenser and nos. 2,3 & 4 around 4m level.
Table 4.1 CONDENSATE CYCLE

HOT WELL
CONDENSATE PUMPS
MAIN EJECTOR
GLAND STEAM COOLER WITH EJECTOR
LP HEATER 2
LP HEATER 3
LP HEATER 4
DEAERATOR
BOILER FEED PUMP
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4.8.1
Condensate Pumps
The function of these pumps is to pump out the condensate to the desecrator through ejectors, gland steam cooler and LP heaters. These pumps have four stages and since the suction is at a negative pressure, special arrangements have been made for providing sealing. The pump is generally rated for 160 m3/ hr at a pressure of 13.2 kg/ cm2 .
4.8.2
L.P. Heaters
Turbine has been provided with non-controlled extractions, which are utilized for heating the condensate, from turbine bleed steam. There are 410 W pressure heaters in which the last four extractions are used. L.P. Heater-1 has two parts LPH-1A and LPH1B located in the upper parts of the condenser A and condenser B, respectively. These are of horizontal type with shell and tube construction. L.P.H. 2,3 and 4 are of similar construction and they are mounted in a row of 5m level. They are of vertical construction with brass tubes the ends of which are expanded into tube plate. The condensate flows in the U tubes in four passes and extraction steam washes the outside of the tubes. Condensate passes through these four L.P. heaters in succession. These heaters are equipped with necessary safety valves in the steam space level indicator for visual level indication of heating steam condensate pressure vacuum gauges for measurement of steam pressure, etc:
4.8.3
Deaerator
The presence of certain gases, principally oxygen, carbon dioxide and ammonia, dissolved in water is generally considered harmful because of their corrosive attack on metals, particularly at elevated temperatures. One of the most important factors in the prevention of internal corrosion in modern boilers and associated plant therefore, is that the boiler feed water should be free as far as possible from all dissolved gases especially oxygen. This is achieved by embodying into the boiler feed system a deaerating unit, whose function is to remove the dissolved gases from the feed water by mechanical means. Particularly the unit must reduce the oxygen content of the feed water to a lower value as far as possible, depending upon the individual circumstances. Residual oxygen content in condensate at the outlet of deaerating plant usually specified are 0.005/ litre or less.
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Figure 4.4 Labled Deaerator
4.8.3.1 PRINCIPAL OF DEAERATION It is based on following two laws. Henrys Law Solubility
The Deaerator comprises of two chambers: Deaerating column Feed storage tank
Deaerating column is a spray cum tray type cylindrical vessel of horizontal construction with dished ends welded to it. The tray stack is designed to ensure maximum contact time as well as optimum scrubbing of condensate to achieve efficient deaeration. The deaeration column is mounted on the feed storage tank, which in turn is supported on rollers at the two ends and a fixed support at the centre. The feed storage tank is fabricated from boiler quality steel plates. Manholes are provided on deaerating column as well as on feed storage tank for inspection and maintenance. The condensate is admitted at the top of the deaerating column flows downwards through the spray valves and trays. The trays are designed to expose to the maximum water surfaces for efficient scrubbing to affect the liberation of the associated gases
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steam enters from the underneath of the trays and flows in counter direction of condensate. While flowing upwards through the trays, scrubbing and heating is done. Thus the liberated gases move upwards alongwith the steam. Steam gets condensed above the trays and in turn heats the condensate. Liberated gases escapes to atmosphere from the orifice opening meant for it. This opening is provided with a number of deflectors to minimize the loss of steam.
4.8.3.2 Booster Pump Each boiler feed pump is provided with a booster pump in its suction line which is driven by the main motor of the boiler feed pump. One of the major damages which may occur to a boiler feed pump is from cavitation or vapor bounding at the pump suction due to suction failure. Cavitation will occur when the suction pressure of the pump at the pump section is equal or very near to the vapor pressure of the liquid to be pumped at a particular feed water temperature. By the use of booster pump in the main pump suction line, always there will be positive suction pressure which will remove the possibility of cavitation. Therefore all the feed pumps are provided with a main shaft driven booster pump in its suction line for obtaining a definite positive suction pressure.
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CONCLUSION & RESULT
I visited various divisions of Badarpur Thermal Power Plant, New Delhi and tried my best to gain as much as possible. I spent a lot of experience sharing time with various engineers at NTPC which helped to increase my knowledge and make me aware about actual working conditions. I learnt how to deal things going in a line process. The environment of such a big, prestigious and highly engineering corporation helped me to gain the feel me true engineer and think like an engineer.
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REFERENCES
1 Textbook of power plant engineering 4 edition, r. K. Rajput ,laxmi publications, 2008, 1083 pages 2 Power plant engineering, gupta, manoj kumar, 348 pages 3 Thomas C. Elliott, kao chen, robert swanekamp (coauthors) (1997). Standard handbook of powerplant engineering (2nd edition ed.). Mcgraw-hill professional.isbn 0-07019435-1.
4 Wiser, Wendell H. (2000). Energy resources: occurrence, production, conversion, use. Birkhuser. P. 190. Isbn 978-0-387-98744-6 5 Various data books at gyan sarita library btps, new delhi
6 J.C. Hensley (editor) (2006). Cooling tower fundamentals (2nd ed. Ed.). Spx cooling technologies
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Appendix 1
P.1 Turbine OPERATING PRINCIPLES
A steam turbines two main parts are the cylinder and the rotor. The cylinder (stator) is a steel or cast iron housing usually divided at the horizontal centerline. Its halves are bolted together for easy access. The cylinder contains fixed blades, vanes and nozzles that direct steam into the moving blades carried by the rotor. Each fixed blade set is mounted in diaphragms located in front of each disc on the rotor, or directly in the casing. A disc and diaphragm pair a turbine stage. Steam turbines can have many stages. A rotor is a rotating shaft that carries the moving blades on the outer edges of either discs or drums. The blades rotate as the rotor revolves. The rotor of a large steam turbine consists of large, intermediate and low-pressure sections. In a multiple-stage turbine, steam at a high pressure and high temperature enters the first row of fixed blades or nozzles through an inlet valve/valves. As the steam passes through the fixed blades or nozzles, it expands and its velocity increases. The high velocity jet of stream strikes the first set of moving blades. The kinetic energy of the steam changes into mechanical energy, causing the shaft to rotate. The steam that enters the next set of fixed blades strikes the next row of moving blades.
As the steam flows through the turbine, its pressure and temperature 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 turbine stage, the steam exhausts into the condenser or process steam system. The kinetic energy of the steam changes into mechanical energy through the impact (impulse) or reaction of the steam against the blades. An impulse turbine uses the impact force of the steam jet on the blades to turn the shaft. Steam expands as it passes through thee nozzles, where its pressure drops and its velocity increases. As the steam flows through the moving blades, its pressure remains the same, but its velocity decreases. The steam does not expand as it flows through the moving blades.
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P.2
Compounding OF Steam Turbine
Velocity Compounding
Pressure Compounding
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Velocity- Pressure Compounding
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