INTRODUCTIO N 1

2 3

1.1 COMPANY PROFILE

NTPC Limited is a name to reckon with in the power sector due to its dedication and commitment. The corporation has not only excelled in power generation but also proven its expertise in all areas conceptualization, commissioning, managing state power stations and offering specialized services. It was established in 1975. It has capacity of 24249 MW. Today NTPC Ltd. stands sixth thermal generator and second most efficient in terms of capacity utilization in the World. It stands unsurpassed in the Indian power sector. With an impressive generating capacity of more than 24249 MW with coal, gas or naphtha based stations across the country; this corporation is racing towards achieving a generating capacity of 40,000 MW by 2012. NTPC Ltd. contributes one fourth of Indias power generation with only one-fifth of the countrys total power capacity. And now NTPC Ltd. lights up every fourth bulb in the country.

At present, Government of India holds 89.5% of the total equity shares of the company and FIIs, Domestic Banks, Public and others hold the balance 10.5%. With in 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. It is now taking up power projects using non- conventional energy sources also.

ORGANISATION AGENDA:
Vision
"To be one of the worlds largest and best power utilities, powering India's growth". NTPC's vision for the new millennium is inspired by a glorious past, vibrant present and a brilliant future. Mission
1.

Make available reliable and quality power in increasingly large quantities at appropriate and ensure timely realization of revenues. Speedily plan and implement power projects, with contemporary technologies.

tariffs,

2. 3. 4. 5.

Implement strategic diversifications in the areas of R&M, Hydro, LNG and non-conventional and eco-friendly fuels and explore new areas like transmission, information technology etc Promote consultancy and make prudent acquisitions. Continuously develop competent human resources to match world standards

Be a responsible corporate citizen with thrust on environment protection, rehabilitation and ash utilization Objectives In pursuance of the vision & mission, the following would be the Corporate Objectives of NTPC: 1. To add generating capacity within prescribed time and cost; 2. To expand consultancy operations and to participate in ventures abroad; 3. To diversify in Hydro and Non-Conventional Energy Sources Power Generation; 4. To diversify into power related businesses to ensure integrated development of energy sector in India. Performance Leadership To achieve continuous performance improvement in the areas of project implementation, plant operation and maintenance, generation efficiency etc. and to acquire and sustain internationally comparable standards in these areas with good business ethics and values Human Resources Development 1) To develop a learning Organization having knowledge-based competitive edge. 2) To create a culture of team building, empowerment and accountability to convert knowledge into productive action with speed, creativity and flexibility. Financial Soundness

1) To maintain and improve the financial soundness of NTPC by managing the financial resources in accordance with the best commercial utility practices. 2) To develop appropriate commercial polices which ensure remunerative tariffs and minimum receivables. Technology Leadership To acquire, assimilate and adopt reliable, efficient and cost-effective technologies and to disseminate knowledge to other constituents of the power sector in the country. CORE VALUES (Commitments)

Customer focus Organizational pride Mutual respect and trust Initiative and speed Total quality

POWER PLANT OPERATION

The operating performance of NTPC has been considerably above the national average. The availability factor for coal stations has increased from 78.21% in 1985-86 to 88.54% in 2000-01, which compares favorably with international standards. The PLF has increased from 70% in 1992-93 to 81.8% during the year 2000-01. However, for regions other than Eastern Region which has power evacuation constraints due to low system demand, a PLF of 88.6% was achieved during this year. Over eight years, employee productivity has increased almost threefold as measured by the ratio of turnover to number of employees.

It may be seen from the table below that while the installed capacity has increased by 49.36% in the last eight years, the employee strength went up by only 10.2%. This includes employees of Orissa State Electricity Board who had to be absorbed in NTPC consequent upon the take over of 460 MW Talcher Power Station from the Orissa Government on 3-6-1995 and 440 MW Tanda Thermal Power Project from U. P. Government on 15-01-2000.

For the year 2000-01, NTPC's Dadri Coal & Singrauli Station recorded a PLF of 93.6% which was the highest in the country. The table below shows the detailed operational performance of coal based stations over the years.

1.1.1 BADARPUR

THERMAL POWER STATION

BADARPUR THERMAL POWER STATION (BTPS) is situated at the south west corner of Delhi, on Mathura Road very near to the Delhi-Haryana boarder. BTPS is a government owned power plant, which is managed by NTPC. It has a capacity of 705 MW. M/s BHEL supplies the main plant equipments of these units. The boiler of stage -1(3 x 100 MW) units are of Czechoslovakian design and that of 210 MW units are of combustion engineering design. The turbo-alternators supplied by M/s BHEL are Russian design. It supplies power to New Delhi, U.P. & Haryana.. This plant has five units, out of which three units are of 95 MW and two units of 210 MW. This plant operates at 90% plant load factor. Its availability factor is 95%. It is the First Central Power Station in the country, was planned with the objective of providing a major backup for stabilizing power supply to the western part of the northern region. However, from April 1987 onwards, Delhi (National Capital Region) has been the sole beneficiary of the electricity generated from this station. Presently, more than 27 % of the over all electricity requirement of Delhi is being met by Badarpur Thermal Power Station.

SYNOPSIS OF NTPC BADARPUR:APPROVED CAPACITY INSTALLED CAPACITY LOCATION COAL SOURCE BENEFICIARY STATE WATER SOURCE UNITS COMMISSIONED:UNIT 1 UNIT 2 UNIT 3 UNIT 4 UNIT 5 95 MW 95 MW 95 MW 210 MW 210 MW 1973 75 1974 75 1974 75 1978 79 1981 - 82 : : : : : : 705 MW 705 MW NEW DELHI JHARIA & BOKARO FROM BIHAR DELHI & N.C.R. AGRA CANAL

BADARPUR THERMAL POWER STATION HIGHLIGHTS

Badarpur

Thermal Power Station has been supplying its entire electricity generation to the Capital City of Delhi since 1987 and currently meeting more than 27% of the city's consumption. 1 2 3 4
The

station has been accredited with ISO-14001 certification by the Bureau of Indian standards w.e.f. 27th May'2001 for having set a sound environment management system in place. The coal supply to the station has been improving as the station is maintaining positive advance with coal companies by making timely payments. The station has been granted 'Water Consent' up to 24th of April'2004 by Delhi Pollution Control Committee (DPCC) and the air consent up to 13th of May'2004. The station has achieved an ash utilization level of more than 100% during 2001-02 with an absolute utilization of 14.24 lakh tones & 6.53 LMT in 200-03.

1.2 Thermal Power Plant

Site Requirements

The basic requirements of the conventional power station are decided on the type, size and other essential specifications of the station to be constructed. It is necessary to know the capacity of the plant that will be required for the immediate development as well as for the period to follow thereafter. The capacity of the plant for immediate development (5 to 7 years ahead) gives the instruction for planning the initial development and the capacity anticipated during the period following (next 10 to 20 years) helps to select the site area sufficiently large for the ultimate development and services, railway sidings, water supply access and transmission connection to be developed in the most economic manner for the future requirement. The size of the site required depends on several factors like the fuel used and its mode of delivery to the site, the area to be provided for the fuel storage, cooling towers, switchyards, space needs for store yards, workshops, etc. Generally a 1000 MW fossil fuel fired station will be requiring a 90 to 200 acre site. The following factors are to be taken into consideration. 1. 2. 3. 4. 5. Station building Coal store and siding Cooling Towers Switch yard compound Surrounding area and approaches.

Geology The geology of the site should be reasonable as this affects the cost of the foundations. Modern power plants with their heavy structures impose a heavy load on the subsoil and hence are to be supported with suitable foundations.

Water for Power Stations

The water requirements for thermal stations come under two main groups, the first requirement is the water required for steam generation and the second requirement is for cooling purposes. As far as the water for steam generation is concerned, the problem is not of quantity but is of quality. The requirement of water in steam cycle is of the order of 3 to 4 Tons/hr/MW and make up quantity is 2 to 3% of the same. This requirement can be met from a small canal, city supply system or even through tube wells. The main problem is of quality. If the water is very hard the dematerializing cost will be very high and also it will require a large water treatment plant. The amount of water required for condensation is quite significant. In once through system of circulating water the amount required will be approx. 20,000 m3./hr/100 MW. This includes small portion of requirement for cooling of generator and other machines. Direct cooling will be possible only if perennial rivers, canals, or huge lakes are available. Where the availability of water is not perennial and formation of a reservoir as well cannot serve the purpose or flow through out the season is inadequate, the closed circuit cooling system involving cooling towers is utilized and in such a system only 3% (which consists of 1% as losses on account of evaporation and 2% for purging the salts) of make up water is required. As to which of the two systems of cooling be used will not only depend upon the availability of water but also on the cost consideration which are to be compared before final decision. It may be noted that water, from whatever source may be used has to be paid for either in the form of direct charges or pumping charges.

Coal for Power Station In India, the principal source of commercial energy is coal amounting to over 95% of the total primary energy resources of the country. The coal resources existing in our country are of the order of 1, 30,000 million tones or even more and new reserves are being located. The main areas where coal mines are located are eastern region i.e. Bihar, Bengal, Central region, Singrauli Coal fields, Tamil Nadu, Neyveli and small sources of coal are located in rest of the country as well. The economic and efficient utilization of high ash content coals for thermal power generation calls for special consideration. Firstly it is uneconomical to haul this coal over long distances because any transportation means paying freight and handling charges on the useless ash; thereby adversely effecting the cost of useful heat that can be recovered from these coals. The location of thermal Power station burning high ash coals is therefore of great importance since about 50 to 60% of the cost of generation of electric power is due to the delivered cost of coal at the generating stations. Hence, it is imperative that these plants should be located at near the pit head or the coal washeries. Consideration has to be given, in locating the pit head stations, for the cost of transmission system vis--vis the fuel transport costs and other connected problems. Transport In case of thermal power stations, the problem of transport is to be considered mainly from the view point of fuel viz. coal economics and for initial erection of the plant. Modes of transport are also to be considered but may not be over riding factor in decision regarding feasibility. At this stage the possibility of rail and road connections capable of taking heavy and over- dimensioned loads of the machines are to be considered. The bridges or tunnels of required size and load capacity are to be provided or existing once to be strengthened. On the basis of prevalent consumption pattern, the daily burden on transport system for a 500 MW station working at 80% load factor, due to various consumables excluding spar etc. will be as given below: 1. 2. 3. 4. Coal 4800 Tones Furnace Oil 60 KL. Hydrochloric Acid 1200 Kg. Sodium Hydroxide & other chemicals 600 Kg.

Disposal of Effluents The major effluents in case of thermal stations are in ash and the flu- gases. The disposal of chemically treated water generated in the water treatment plant is also an effluent, which requires attention for disposal. The disposal of the gases and ash concerns mainly the atmosphere and environment and that of water is concerned with the effect on marine life of the rivers and canals. The method of disposal of ash has been by converting it into slurry and pumping the same by means of ash disposal pumps or hydro aces to waste lands.

It is in this connection that the requirement of large area of waste lands for effluent disposal plays a decisive factor in location. One 100 MW unit will produce about 400 to 450 tonnes of fly ash per day on full load. Transmission A route must be available for the transmission lines from the site to the nearest grid system or major load point on the area board system, which can accept the station output. Increasing opposition from the public, amenity societies and planners to over head lines makes line routes increasingly difficult to obtain and sometimes the only solution is to lay underground sections of the line. The use of underground cabling however can have a major effect on the selection of sites when considered from economic merit because cable costs sixteen times more than over head lines of equivalent capacity. Climatic Conditions Climatic conditions of a place play a significant part in the economic; of capital investment. The tropical climate existing in most parts of our country, calls for special attention to the ventilation and cooling arrangements. The humid conditions with fluctuating temperature lead to dew point and hence the condensation which results in corrosion of insulation. It is a well-known fact that for tropical countries insulation of electrical machines has different standards and is costly. Further the modern stations use telemetering and control; the sensitive electronic equipment along with other equipment such as relays etc. are required to be located in air-conditioned rooms. This means addition to capital costs.

1.2.2 Coal to Electricity

Coal from the coal wagons is unloaded in the coal handling plant. This coal is up to the raw coalbunkers with the help of belt conveyers. Coal is transported to the bowl mills by coal feeders. The coal is pulverized in the bowl mill where it is ground to a 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. These are three large rollers, which are spaced 120 degree apart. When there is no coal, these rollers do not rotate but when coal is fed to the table it packs up between roller and the table and this force the roller to rotate. Coal is crushed by the crushing action between 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. This fan takes atmospheric air, a part of which is sent to air pre-heaters 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 boiler feed pump passes through economizer and reaches the boiler drum. Water from the drum pass through down comers and goes to 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 boilers drum where the steam is separated from the water. Water follows the same path while the steam is sent to super heaters for superheating. The super heaters are located inside the furnace and the steam is superheated (540 oC) finally it goes to turbine. A flue gas from the furnace is extracted from the induced draft fan, which maintains balance draft in the furnace with forced draft fans. These flue gases emits their heat energy to various super heaters in the pant house and finally passes through air pre-heaters and goes to electrostatic precipitator 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. A regular mechanical hammer causes the accumulation of ash to fall to the bottom of the precipitator where they are collected in a hopper for disposal. This ash is mixed with water to form slurry and is pumped to ash pond. The steam from the boiler is conveyed to the turbine through the steam pipes and through stop valve and control valve that automatically regulate the supply of steam to the turbine. Stop valves and control valves are located in a steam chest and governor driven from the main turbine shaft operates the control valves to regulate the amount used. Steam from the control valves enters the high-pressure cylinder of the turbine, where it passes through the ring of blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on the disc secured to the turbine shaft. The second ring turns the shaft as a result of the force of the steam. The stationary and moving blades together constitute a stage of a 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 though 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 in to 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 it enters at the center flowing outwards in the opposite directions through the rows of turbines blades an arrangement known as double flow-to extremities of the cylinder as the steam gives up its heat energy to drive the turbine its temperature and pressure falls and it expands, because of this expansion the blades are much larger and longer towards the low pressure ends of the turbine. The turbine shaft usually rotates at 3000rpm.this speed is determined by the frequency of the electrical system used in this country and is the speed at which a 2 pole generator must be driven to generate alternating current at a frequency of 50 cycles /sec.When as much as energy as possible has been extracted from the steam it is exhausted directly to the condenser. This runs the length of the low pressure part of the turbine and may be beneath on either side of it the condenser consist of a large vessel containing some 20000 tubes each about 25mm in diameter cold water from the river, estuary, sea or cooling tower is circulated through these tubes and as the steam from the turbine passes round them it is rapidly condensed into water condensate. Because water has a much smaller comparative volume than steam, a vacuum is created in the condenser. This allows the steam to reduce down to pressure below that of the normal atmosphere and more energy can be utilized. From the condenser, the condensate is pumped through low-pressure heaters by the extraction pumps after which its pressure is raised to boiler pressure by the boiler feed pump. It is passed through further feed heaters to the economizer and the boiler for the reconversion into steam.

A power station generating 2000000 KW of electricity requires about 227500 cubic meter of water an hour for cooling purpose. Here cooling towers are used, about 1/100 part of the cooling water evaporates and a certain amount is returned to its source to carry away any impurities that collects most of it is however recirculated.

Simple Coal to Electricity cycle

Basic Power Plant Cycle

RANKINE CYCLE: The thermodynamic cycle on which the steam (or thermal) power plant is operated is modified ranking cycle. A simple ranking cycle consists of four processes: reversible constant pressure heat addition; reversible adiabatic expansion; reversible constant pressure heat rejection; reversible adiabatic compression Water from the condenser at (a) is pumped to the boiler at (b). The steam from the boiler passes through point (c) and then through the turbine, at (d), where the generator, produces electricity. The used steam then passes through the condenser, where a closed cooling water circuit reduces the enthalpy and entropy of the water in the cycle. The diagonally oriented arrows indicated with the letters w" and "q" shows energy flow either into or out of the system T-S DIAGRAM: When following the line from (b) to (c), one first encounters a brief incline, then a flat portion, and then another incline. These distinct regions correspond to heating of liquid water, a phase change to gas, and then heating of the gaseous water. The severe drop in temperature from (c) to (d) results because of the tremendous pressure and volume changes realized as the gas expands through the turbine. This drop occurs at constant entropy. Then from d to a heat rejection takes place at constant pressure. Then from a to b pump work is done. RANKINE CYCLE WITH REHEAT: While regeneration achieves a higher efficiency of operation by returning the working fluid to the same turbine multiple times, the method known as reheat involves two or more turbines with intermittent heating of the fluid in the original boiler. The heavy black line in the top diagram of this figure shows that the steam route first passes through a high pressure turbine (THP), then through the boiler again between points (d) and (e), and finally enters a second turbine (TLP) at lower pressure. Heat (q) and work (w) inputs and outputs are also clearly shown. The temperature-entropy (TS) diagram in the lower left quadrant of the figure substantiates the thermodynamic principles involved in the ideal case. The various isobars, or lines of constant pressure, indicate the levels of supersaturation at which the steam exists at points of the cycle. In

a simple Ranking cycle, the vertical black line dropping from point (c) would normally extend all the way to the base pressure (pL) at point (m'). With the advantage of reheat, however, the enthalpy of the fluid is boosted back up to point (e) in the boiler, and then expansion through the second turbine drops the pressure to its lowest point as indicated by point (f'). Note that the second "spike" in the TS diagram provides more area under the curve than would be the case if it were excluded. Since this area under the curve represents energy, the reheat option evidently provides greater useful energy for power production been employed). The enthalpy-entropy (HS) diagram in the lower right quadrant of the figure shows diagonally oriented isobars, again indicated by the pressure (p) with corresponding subscripts. The intervals which illustrate drops in enthalpy at constant entropy, those from point (c) to point (d') and from point (e) to point (f'), mathematically equate to the work extracted from the fluid through the high and low pressure turbines, respectively. In both lower figures, the vertical dashed lines represent where the Ranking cycle would have terminated and reached the start again if reheat had not been considered.

REGENERATIVE CYCLE: The sample plant cycle illustrated with symbols, lines, and process units in this diagram is more complex than any previous examples. Note the two independent closed heaters at points (b) and (d). The other units in this cycle have their conventional roles in the generation of power from a working fluid. On the lower half of the diagram is the temperature-entropy (TS) diagram resulting from examination of the ideal process.

The stages of regeneration actually shift the water among different saturation lines, permitting an increase in temperature and therefore increases in both the maximum power output and thermal efficiency of the design without unduly altering entropy. Instead of boiling water at the low pressure pL or even at intermediate pressures pj or pi, the phase change occurs at the highest possible pressure, pH , available for the design. Since turbines operate most effectively and most efficiently when a large pressure drop is established, a plant employing regeneration of this type will be able to produce more power per unit of original energy resource and mass of water.

Regeneration basically means "generation again" or "repeat generation." As the heavy black line on the process flow diagram on the left shows, water is partially condensed between points (d) and (a), but then prior to arrival at the boiler for another heating stage, the working fluid enters the turbine again in order to extract all possible useful energy from the water and vapor .A thermal power plant works on a modified ranking cycle that is a combination of reheat and regenerative. So there is also a low and high pressure turbine for reheat purposes and heaters (L.P. and H.P.) for regenerative purposes.

Factors Affecting Cycle Efficiency

Thermal

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

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 (1) with the help of belt conveyors. Coal is transported to Bowl Mills (3) by Coal feeders (2) the coal is pulverized in the Bowl Mill, where it is ground to a 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 does not rotate but when the coal is fed to the table it packs up between roller and the table and this forces the rollers to rotate. Coal is crushed by the crushing action between the rollers and rotating table. This crushed coal is taken away to the furnace through coal pipes (4) with the help of hot and cold air mixture from P.A.Fan(5).P.A.Fan taken atmospheric air, a part of which is sent to Air preheaters (7) for heating while a part goes directly to the mill for temperature control. Atmospheric air from F.D. Fan (18) is heated in the air heaters (7) and sent to the furnace (6) as combustion air. Water from the boiler feed pump passes through economizer (8) and reaches the boiler drum (9). Water from the drum passes through down comers and goes to bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat andthe density difference the water rises up in the water wall tubes (12). "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 (9) where the steam is separated from water. Water follows the same path while the steam is sent to super heaters for superheating. The super heaters are located inside the furnace and the steam is superheated (540"C) and finally it goes to turbine. Flue gases from the furnace is extracted by induced draft fan (14) which maintains balance draft in the furnace (-5 to -10mm of wcl) with forced draft fan (18). These flue gases emits their heat energy to various super heaters in the pant house (15) and finally passes through air preheaters (7)and goes to electrostatic precipitator (16) 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 (17) to pollute the atmosphere. Regular mechanical hammers blows cause the accumulation of ash to fall to the bottom of the precipitator where they are collected in a hopper for disposal. This ash is mixed with water to form slurry and is pumped to ash pond.

Steam to Mechanical Power

As can be seen from figure below, from the boiler, a steam pipe conveys steam to the turbine through a stop valve (which can be used to. shut off steam in an emergency) and through control valves (2) that automatically regulate the supply of steam to the turbine. Stop valve and control valves are located in a steam chest and a governor (3), driven from the main turbine shaft (4), 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 (5) fixed to the cylinder wall (6). These act as nozzles and direct the steam into a second ring of moving blades (7) mounted on a disc secured to the turbine shaft. This second ring turns the shafts as a result of the force of the steam. The stationary and moving blades together constitute a 'stage' of the 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 (8) and returns by a further pipe (9) 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 it enters at the centre (10) flowing outwards in opposite directions through the rows of turbine blades - an arrangement known as 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. The turbine shaft usually rotates at 3,000 revolutions per minute. This speed is determined by the frequency of the electrical system used in this country and is the speed at which a 2- pole generator must be driven to generate alternating current at a frequency of 50 cycles per second. When as much energy as possible has been extracted from the steam it is exhausted directly to the condenser. This runs the length of the low-pressure part of the turbine and may be beneath or on either side of it. The condenser consists of a large vessel containing some 20,000 tubes, each about 25mm in diameter. Cold water from the river, estuary, sea or cooling tower is circulated through these tubes and as the steam from the turbine passes round them it is rapidly condensed into water condensate. Because water has a much smaller comparative volume than steam, a vacuum is created in the condenser. This allows the steam to reduce down to pressure below that of the normal atmosphere and more energy can be utilized.

BMD
(Boiler

Maintenance Division)

2.1 Principles of Combustion

The primary functions of oil and coal burning systems in the process of steam generation is to provide controlled efficient conversation of the chemical energy of the fuel into heat energy which is then transferred to the heat absorbing surfaces of the steam generator. The combustion element of a fuel consists of carbon, hydrogen and usually a small amount of sulphur. When combustion is properly completed the exhaust gases will contain, carbon dioxide, water vapour, sulphur dioxide and a large volume of Nitrogen, Combustion is brought about by combining carbon and hydrogen or hydrocarbons with the oxygen in air. When carbon burns completely, it results in the formation of a gas known as carbon dioxide. When carbon bums incompletely it forms carbon monoxide. Composition of air: the supply of oxygen for combustion is obtained from air. This is as important as the supply of fuel. The average composition of air is 79% nitrogen and 21% oxygen by volume77% nitrogen and 23% oxygen by weight. Nitrogen does not bum but passes through the combustion chamber to the chimney unchanged excepting its temperature. Ignition: Fuel must be ignited before it can burn. Combustion is brought about by raising the temperature of the fuel to its ignition temperature. This temperature varies with different fuels. Excess air: The amount of air required to burn any fuel can be calculated if the amount of the elements present in the fuel are known. This amount of air is known as the theoretical air. In practice this quantity is not sufficient to ensure complete combustion and extra air has to be supplied. This extra air is known as excess air. The loss of combustibles and unburnt gas reduces as excess air is added reaches maximum and any further additions of excess air beyond this stage, the boiler losses increase. Thus there is one and only one quantity of excess air, which will give the lowest combustion loss. The value of excess air needed depends upon the fuel used, the type of firing etc. The following factors in efficient combustion are usually referred to as "The three T's. Time: It will take a definite time to heat the fuel to its ignition temperature and having ignited, it will also take time to bum. Consequently sufficient time must be allowed for complete combustion of the fuel to take place in the chamber. Temperature: A fuel will not burn until it has reached its ignition temperature. The speed at which this Temperature will be reached is increased by preheating the combustion air. The temperature of the flame of the burning fuel may vary with the quantity of air used. Too much combustion air will lower the flame temperature and may cause unstable ignition. Turbulence: Turbulence is introduced to achieve a rapid relative motion between the air and the fuel particles. It is found that this produces a quick propagation of the flame and its rapid spread throughout the fuel/air mixture in the combustion chamber.

Combustion efficiency: It varies with individual different grades of fuel within each boiler. The idea to be aimed at is the correct quantity of air together with good mixing of fuel and air to obtain the maximum heat release. Maximum combustion efficiency depends on Design of the boiler Fuel used Skill in obtaining combustion with the minimum amount of excess air. Thermal efficiency of a boiler is measured by the amount of heat transferred to the water in the boiler by each Kg of fuel used and is expressed as a percentage of the total heat energy in one Kg. of fuel. Boilers, their classification and types Boiler is a device for generating steam for power, processing or heating purposes. Boiler is designed to transmit heat from an external combustion source (usually fuel combustion to a fluid) contained within the boiler itself. The heat generating unit includes a furnace in which the fuel is burned. With the advantage of water-cooled furnace walls, super heaters, air heaters and economizers, the term 'steam generator was evolved as a better description of the apparatus. Boilers may be classified on the basis of any of the following characteristics: Use Pressure Materials Size Tube Content Tube Shape and position Firing Heat Source Fuel Fluid Circulations Furnace position Furnace type General shape Trade name Special features.

Use: The characteristics of the boiler vary according to the nature of service performed. Customarily boiler is called either stationary or mobile. Large units used primarily for electric power generation are known as control station steam generator or utility plants. Pressure: To provide safety control over construction features, all boilers must be constructed in accordance with the Boiler codes, which differentiates boiler as per their characteristics. Materials: Selection of construction materials is controlled by boiler code material specifications. Power boilers are usually constructed of special steels. Size: Rating code for boiler

standardize the size and ratings of boilers based on heating surfaces. The same is verified by performance tests. Tube Contents: In addition to ordinary shell type of boiler, there are two general steel boiler classifications, the fire tube and water tube boilers. Fire tube boiler is boilers with straight tubes that are surrounded by water and through which the products of combustion pass. Water tube boilers are those in which the tubes themselves contain steam or water, the heat being applied to the outside surface. Firing: The boiler may be a fired or unfired pressure vessel. In fired boilers, the heat applied is a product of fuel combustion. A non-fired boiler has a heat source other than combustion. Heat Source: The heat may be derived from (1) the combustion of fuel (2) the hot gasses of other chemical reactions (3) the utilization of nuclear energy. Fuel: Boilers are often designated with respect to the fuel burned Fluid: The general concept of a boiler is that of a vessel to generate steam. A few utility plants have installed mercury boilers. Circulation: The majority of boilers operate with natural circulation. Some utilize positive circulation in which the operative fluid may be forced 'once through' or controlled with partial circulation. Furnace Position: The boiler is an external combustion device in which the combustion takes place outside the region of boiling water. The relative location of the furnace to the boiler is indicated by the description of the furnace as being internally or externally fired. The furnace is internally fired if the furnace region is completely surrounded by water-cooled surfaces. The furnace is externally fired if the furnace is auxiliary to the boiler. Furnace type: The boiler may be described in terms of the furnace type. General Shape: During the evaluation of the boiler as a heat producer, many new shapes and designs have appeared and these are widely recognized in the trade. Trade Name: Many manufacturers coin their own name for each boiler and these names come into common usage as being descriptive of the boiler. Special features: sometimes the type of boiler like differential firing and Tangential firing are described. Categorization of Boilers: Boilers are generally categorized as follows: Steel boilers Fire Tube type Water tube type Horizontal Straight tube Bent tube Natural Circulation Positive Circulation Shell type

 Cast Iron Boilers Special Design Boilers Nuclear Reactors Boiler classification according to end use, Boilers can be classified into two categories Viz. Utility Boilers Industrial Boilers The utility boners are large capacity steam generators used purely for the electrical power generation. The industrial boilers are mainly for use in the process industries and are characterized as follows: Non-reheat units Bi-drum boilers having partial steam generation in the boiler bank tubes. Though the physical arrangement and location of various heat transfer sections may differ considerably, the general design criteria from the performance aspect does not change much for the two classifications. Hence the further paragraphs of this section will be common for the utility and industrial boilers with special references, if required, for any, one application. Arrangement of Main Boiler (200/210 MW) Various accessories of a 200/210 MW Boiler includes: Economizer Boiler drum Down Comers Water walls Water wall platen (used for Low Pressure Boilers) Primary super heater Platen super heater Final super heater Reheater Burner Igniters Boiler structural: The boiler structural is divided into two parts. Supporting Structure Galleries and stair ways Supporting Structures: Consists of a systematic arrangement of columns stiffened with horizontal beams, vertical diagonal bracings and comprise of low carbon steel material.It is composed of 18 main columns and 12 auxiliary columns. The main columns support the main boiler components viz. drum, water wall membrane, panels, super heaters, Reheater, economizers, air preheaters, burners and galleries at various levels. The auxiliary columns, supports the boiler platforms and other ducts coming in that region. The total weight of supporting structures is about 970 M.T. Galleries and stairways: Galleries and stairways around the combustion and heat recovery areas are provided for proper approach to the boiler. Stairways on both the side of Boiler are

provided. All the floors are covered with floor gratings of required depth for walkway and are tig welded to the structure. The total weight of Galleries and stairway are 900 M.T. Furnace: A boiler furnace is that space under or adjacent to a boiler in which fuel is burned and from which the combustion products pass into the boiler proper. It provides a chamber in which the combustion reaction can be isolated and confined so that the reaction remains a controlled force. In addition it provides support or enclosure for the firing equipment. The furnace must provide the following Proper installation, operation and maintenance of fuel burning equipment. Sufficient volume for combustion requirements. Adequate refractories and insulation. Boiler Drum: The function of steam drum is to separate the water from the steam generated in the furnace walls and to reduce the dissolved solid contents of the steam to below the prescribed limit of 1 ppm. The drum is located on the upper front of boiler. Economizer: The purpose of economizer is to preheat the boiler feed water before it is introduced into the steam drum by recovering heat from the flue gases leaving the boiler. The economizer is located in the boiler rear gas pass below the rear horizontal superheated. The economizer is continuous unfinned loop type and water flows in upward direction and gas in the downward direction. Super Heater: There are three stages of superheated besides the side walls and extended sidewalls. The first stage consists of horizontal super heater of convection mixed flow type with upper and lower banks located above economizers assembly in the rear pass. The upper bank terminates into hanger tubes, which are connected to outlet header of the first stage superheated. The second stage super heater consists of pendant platen which is of radiant parallel flow type. The third stage superheated pendant spaced is of convection parallel flow type. The outlet temperature and pressure of the steam coming out from the super heater is 540C and 157 Kg/cm2 respectively for H.P.units Reheater: The function of reheater is to reheat the steam coming out from high pressure turbine to a temperature of 540C. The reheater is composed of two sections, the front pendant section and rear pendant section. The rear pendant section is located above the furnace arc and the rear water wall and front pendant section is located between the rear water hanger tubes and the superheater platen section. Burners: There are total twenty four pulverized coal burners for corner fired C.E. type boilers and twelve oil burners provided each in between two pulverized fuel burner. The pulverized coal burners are arranged in such a way that six mills supply the coal the burners at 4 corners, of the furnace. All the nozzles of the burners are interlinked and can be tilted as a single unit from +30 to -30. The oil burners are fed with heavy fuel oil till boiler load reaches to about 25%. Igniters: There are twelve side eddy plate oil/H.E.A igniters per boiler. The atomizing air for igniters is taken from plant air compressors at 7Kg/cm2 (gauge). The burners are located at three elevations. Each elevation has four oil burners and igniters. These elevations are normally known as AB elevation, CD elevation and EF elevation. Igniters are used for lighting the main oil gun. There are two igniter air fans supply air for combustion of igniter oil.

2.2 Boiler Auxiliaries

Coal Bunker: These are in process storage silos used for storing crushed coal from the coal handling system. Generally, these are made up of welded steel plates.' Normally, there are six such bunkers supplying coal of the corresponding mills. These are located on top of the mills so as to aid in gravity feeding of coal. Coal Feeders: Each mill is provided with a drag link chain/rotary/gravimetric feeder to transport raw coal from the bunker to the inlet chute, leading to mill at a desired rate. Mills: There are six mill (25% capacity each), for every 200 MW unit, located adjacent to the furnace at '0' M level. These mills pulverize coal to the desired fineness to be fed to the furnace for combustion. P.A. Fan: The primary air fans (2 per unit - 50% capacity each) are designed for handling atmospheric air upto a temperature of 50 OC. These fans are located at 0' M level near the boiler. Air Pre-heater: Air pre-heater transfers heat from flue gases to cold primary and secondary air by means of rotating heating surface elements. Beneath these regenerative type air pre-heaters, there exists a steam coil air pre-heater. These are located in the secondary pass of the furnace at a height of around '16' M level. Each 200 MW unit is provided with two such air pre-heaters. Burners: these are used for burning pulverized coal or oil. Every unit has a set of such burners located at different elevations of the furnace. F.D.Fan: The forced draft fans (2 per unit - 50% capacity each) are designed for handling secondary air for the boiler. These fans are located at '0' M level near the PA Fan. Wind Box: this act as distributing media for supplying secondary/excess air to the furnace for combustion. These are generally located on the left and right sides of the furnace while facing the chimney. Igniter Fan: These fans, again two per boiler, are used to supply air for cooling igniters and combustion of igniter air fuel mixture. Electrostatic precipitator: These are generally two plate type located between boiler and the chimney. The precipitator is arranged for horizontal gas flow and is constructed with welded steel casings. ID Fans: There are two induced Draft fans per boiler located between the Electrostatic precipitator and the chimney. These fans are used for sucking flue gas from furnace.

Chimney: These are tall RCC structures with single/multiple flues (one flue per 200 MW Unit). The height of these chimneys varies depending on the location considerations; anywhere between 150 m. to 220 m.

2.3 PULVERISING PLANT

MILLING CIRCUIT: Each boiler is provided with three identical closed milling circuits with suction type drum mills with partial recirculation of vapors in the circuit and with the pulverized coal bunkers. Regulated quantity of vapor is recirculated in the milling circuit and the remaining is burnt in the boiler through vapor burners. 1) Fuel Data: Guaranteed Coal: Type Net calorific value Moisture content in coal Ash content in the coal Volatile matter in combustibles Inlet size of coal grain to mill: max Grind ability index 2) Drying Medium: Medium Quantity of medium Temperature of flue gas 3) Cooling Water Requirement: Mill bearing oil cooler: Gear box oil cooler: Pressure of water Temperature 4) Mill output: Type of mill Output of mill Fineness of pulverized coal: Moisture in pulverized coal Temp. of medium after classifier Drum mill 300/579 25/50 t/hr 20 to 22%of remainder on sieve R90 2% 90 degree Celsius max. 2.5 cu.m./hr per mill 0.70 cu.m/hr per mill 2-3 kg/ sq.cm 40 degree Celsius max. Mixture of hot flue gas with recirculated vapour 15 chum. At 1000mm of water column Approximate 480 degree Celsius Bituminous Coal 4727 kcal/kg 7.5 % 32% 43% 20mm 50 hard grove 1.07 V T I

Milling System
DESCRIPTION OF INDIVIUAL EQUIPMENT: 1) LOWER PART OF RAW COAL BUNKER: It is provided with a flange for mixing needle type raw coal bunker closure. 2) RAW COAL BUNKER CLOSURE: The raw coal bunker closure is of needle type. Number of steel tubes (needles) is arranged in arrow and is guided in a frame. Each tube can be operated individually by hand. By operating a group of needles at a time, it is possible to avoid bridge formation in bunkers. 3) RAW COAL CHAIN FEEDER: The raw coal chain feeder transports coal from the raw coal bunker to the inlet chute leading to the pulverizer. Raw coal, which is pre-crushed in coal crusher to the required size, is conveyed to R.C. bunker by the coal handling equipment. A needle type hand operated bunker closure is interred posed between the bottom of R.C. bunker and top of the chain feeder. The assembly consists of: a) Hand operated bunker closure b) Feed hopper c) Tension head d) Driving head e) Spacers f) Double link chain g) Driving unit h) Supporting base frames The feeder casing is of welded construction duly stiffened and supported on steel frames and is lined with replaceable steel plates, which are screwed to the feeder casing. A welded double link chain fabricated from high tensile steel, moves on wheels, mounted on shafts in the tension and driving heads. The upper part of the casing is provided with removable covers at suitable places. The double link chain can be taken out through the rear side opening of the feeder, after removing the cover. Any slackness in the chain is compensated by volute springs in the tension head. The chain sweeps the raw coal falling on the top plate of the feeder, on to the bottom plate and scrapes it off to the raw coal chute. The height of the coal bed above the top plate can be adjusted manually by means of lever operated damper. The damper inside the chain feeder is bolted to a shaft, which protrudes out of the casing. A lever is keyed to the shaft outside end can be operated by hand and can be set in any desired position. The maximum and minimum heights of coal bed over the top plate are 200 mm and 120 mm respectively. Signaling equipment indicates the absence of the coal flow in the feeder. The signaling system consists of paddle mounted on a shaft inside the chain feeder. The shaft projects out of the casing and has levered screwed to it. The paddle normally rests over the top of the coal bed on the bottom plate. When there is nom coal flow, the paddle assumes a vertical position making the lever to contact a limit switch suitably located and this gives an indication of no coal flow in the control room. The main shaft in the driving head is connected to the driving unit, consisting of a variator, a gear box and a motor mounted as a single unit. The chain wheel on the driving head shaft is provided with a gear which will shear off and disconnect thee driving mechanism, if there is any over load in the feeder the speed of the chain feeder is automatically regulated by actuating the control spindle of the

variator by the servomotor. Rubber wires are provided both in tension and driving head to scrap off the coal dust from the moving chain. TECHNICAL DATA: Type of feeder Width of feeder Length Speed variation Depth of fuel bed inside the feeder Chain type R 600 600 mm 18,700 mm 0.0503-0.151 m/sec 120-200 rpm

Functions of chain feeder: The chain feeder serves for conveying the coal from R.C. bunker to the mill. The quantity of raw coal feed in to the mill can be controlled effectively by the speed control of the variator drive. The drive is a positive one and contains gear box, positively infinite variator and a motor as an integral unit. The needle type closure is provided at the outlet end of the raw coal bunker. By operating a group of needles at a time, at regular intervals the bridge formation in the bunker is avoided. The bunker closure needles are operated manually. The raw coal falls by gravity on top plate of the chain feeder and is carried on by the moving chain to the bottom part of the feeder from where it is dragged to the outlet chute of the chain feeder. Provision is made to take out raw coal samples from the feeder by means of spoon. The main shaft in the driving head is connected to the driving unit by means of a double row roller chain. DRUM MILL: Drum mill consists of: a) b) c) d) e) f) g) Single compartment mill drum antrification bearings Mill drive Fuel inlet and discharge elbows Foundations frame for drive and bearings Ball charge Lubricating equipment for mill bearings

MILL DRUM: Mill drum shell is fabricated from thick plates provided with fabricated ends and flange for bolting the gear rim. The entire inside surface of the mill is provided with armour plates, which is fastened to the drum shell by bolts with 10mm thick asbestos mill board interposed between armour plates and mill shell. The asbestos mill board is to be wet before inserting. The armour plates are cast from manganese steel and each armour plate can be removed and replaced individually whenever necessary. The hollow journals on both sides of the mill drum are provided with fabricated armour inserts with helix inside. This prevents the coal or balls being deposited inside the hallow journal. The journals are precisely machined from the steel casting.

ANTRIFICATION BEARINGS: The entire mill drum with mill journals is supported and rotates on two antrification bearings. Fixed bearing is on one side of the mill and free bearing is on the other side. The free is designed to take up the axial and is lubricated by forced lubrication. The oil from the lubricating equipment is forced on to the rollers of the bearings in the form of jet at two places from both sides producing effective cooling of the bearing. Drain holes at the bottom of the bearing housing. Suitable thermometer is provided to indicate the temperature of oil. The housing on the free bearing end is designed in such a way to allow for the expansion during operation. Labyrinth seals prevent the leakage of oil from the bearings. The pedestals of bearings are bolted to base frame. MILL DRIVE: Mill drive consists of a) HT motor: Squirrel cage, induction motor totally enclosed, air cooled circuit machine. The motor is bolted to base frame. b) Reduction gear box: it is of robust construction with single stage reduction. The gear box has a built in cooling coil for circulating water, which cools the oil in gear box. c) Counter shaft with pinion mounted on anti-friction bearing: the counter shaft is machined from high tensile carbon steel forging and is provided with key for pinion and half coupling. The counter shaft is supported on two antrification bearings. d) Gear rim: gear rim is machined from steel casting and is made up of two half pieces bolted together. The whole gear rim is bolted to the flange on the mill drum. e) Grid type flexible couplings: the advantage of this coupling is that the couplings can accommodate angular, parallel and axial misalignment between driving and driven machines and to absorb considerable torque over loads, thus achieving smoother running with consequent reduction of wear and tear on the machinery. The coupling consist of the grooved discs or hubs mounted one on the drive shaft and other on the drive shaft, interconnected by a grid spring. FUEL INLET AND DISCHAGE ELBOWS: elbows are fabricated from thick steel sheets and are provided with replaceable armour plate inside. These are bolted to the foundation frame. Packing is provided between the rotating part and stationary elbows to prevent leakage of air into the circuit. FOUDATION FRAME FOR DRIVE AND BEARINGS: The foundation frames are fabricated from thick steel sections. The frame under the drive consists of three parts with precisely machined mating surfaces bolted together. The whole foundation frame is leveled on the concrete, bolted to the foundation and grouted. Electric motor, gear box and counter shaft assembly BALL CHARGE: The ball charge of the mill consists of three different sizes of forged steel balls. The quantity of ball fitting will be around 24 to 26% of volume of the mill drum. The ball charge for each mill consists of: Dia. 40 mm: 22500kg Dia. 50 mm: 20000kg Dia. 60 mm: 10000kg Total: 52500kg

During operation only balls with diameter 60mm added and will be approximately 500 kg/week. Specification for Mill Balls: Ball dia in mm (Spherical) Theoretical weight per ball in kg Allowable tolerance on dia in mm 40 0.26 50 0.51 60 0.89

+3

+3

+3

Used for crushing coal in drum mills in power plants. The weight of balls should not differ by more than two percent from theoretical weight indicated in the table. Chemical Composition: O max 1.10 P max 0.06 S max 0.06 killed steel

Tensile Strength: 90 to110 kg/sq.mm Brinnel hardness: 270 to 330 f) Lubricating equipmentmill bearings g) Lubricating system consists of oil tank, gear pump, oil cooler, and a base frame mounts all the above said equipment . h) Lube oil pump: Lube oil tank is fabricated from steel sheet that is provided with oil filters, all level gauge, drain cock and glass to observe the inflow of oil from the bearings to the tank. i) Gear pump: -it is driven by electric motor through coupling mounted horizontally on a common base frame j) Oil cooler: - The oil from the bearing is cooled to the required temperature in this cooler by means of flowing water through the tubes k) Function of mill: - the mill drum with wall charge rotates onto antrification bearings the mill is driven by an electric motor through reduction gear box and a reduction gear. The inlet and discharge elbows are designed in such a way that it prevents the position of coal particles on its surface. The raw coal enters the mill through inlet elbow where it is crushed and powdered inside the rotating mills. The ball charge with the coal is carried to a certain height inside the mill and falls down. Due to the impact of the balls on the coal and attrition as a particle slide over each other, as well as over the armour liners, coal gets crushed. Large particles are broken by impact and the fine grinding is done by attrition. The drying and grinding operations take place simultaneously inside the mill.

CLASSIFIER: The classifier is fabricated from steel plates and consists of four main parts which are assembled together .the upper part is provided with outlet chutes, explosions diaphragms and regulating vanes. The central suction consists of two separate parts. The outer portion of the upper part of the central sector forms the inlet for pulverized coal and the coarse return through the inner portion of the central part. These are concentric and are separated by plates forming compartments. In the lower part of the central section there are an impact plate and a sheet metal cone with flaps resting on it. The lower part of classifier is formed of two compartments, which end with two branches. One forms inlet for the pulverized coal that comes from the mill and the other is a chute for the return of coarse grains back to the mill. Technical data: Type Size of classifier Height Weight Raymond type classifier 3300mm dia (max dia) 6320 mm 6700 kg

Function: It is equipment that separates fine pulverized coal particles from coarser particles. The pulverized coal along with the carrying medium strikes the impact plate through the lower part. Some of the coarse particles get separated due to the change in the direction of flow after lifting the impact plate. The medium then passes inside the outer shell of central and then passes through adjustable vanes, provided in the upper part of the classifier. The coarse particles are further separated in this region due to change in velocity and also due to inertial and centrifugal action. The stream then passes to the outlet branch of classifier through an adjustable telescopic tube. Due to change in direction of stream some more coarse particles are thus separated. Rough adjustment is thus affected by this telescopic arrangement. Finer adjustment is effected by the adjustment of the vanes. All the vanes are connected to a single operating screw by means of a ring in the upper part of classifier. A chain wheel is keyed on to the screw and is operated by chain.

CYCLONE SEPERATOR: The centrifugal type cyclone separator consists of two cyclones made up of welded sheets and provided with common tangential inlet and two separate outlet branches located centrally in each cyclone. Cyclones are mounted on the supporting steel structure. The conical discharge ends of the cyclones are connected to a common hopper. This common hopper is welded to the base of the supporting structure and is also provided with explosion pipe with diaphragm. The hand operated gate valve and rotary valve are bolted to the lower flange of the common hopper. Space between the floor hole and the cyclone is covered with sheets. Technical data: Type Size SEA 1600/2 (twin cyclone) 1600 mm dia

Function: The cyclone separator is equipment in the milling plant which serves for separating the pulverized coal from the vapor, i.e. carrying medium. Mixture of vapor and fine pulverized coal enters the cyclone separator tangentially in the upper part of the cyclone separator. Due to decrease in velocity and centrifugal action the pulverized coal is separated from vapor and falls down to the lower conical part. The vapor leaves the cyclone separator through the central cylindrical portion to the upper part of the separator. These vapors are drawn by vapor fans and are recirculated in the milling circuit and the balance is transported to the vapor burners. Explosions diaphragms are provided at top of the cyclone separator. PULVERISED COAL BUNKER (P.C. BUNKER): P.C. bunker is welded from thick steel plates and has a capacity of not less than four hours fuel consumption at maximum continuous output of the boiler from the guaranteed coal specified. The inside bunker construction will be free from protruding legs etc. and the inclination of the walls will be such as to avoid arching problems at the outlet. Suitable covers for the piping are provided on the roof of the pulverizing plant to prevent the rain water entering the plant. A platform is provided at 36.8 m level for easy accessibility to explosion diaphragms, provided above the cyclone separator. WORM CONVEYER: It is equipment used to distribute the pulverized coal uniformly either with in a bunker itself or from bunker of one circuit to bunker of another when the pulverized coal filling is not required in the first bunker. Operation: Due to action of gravity the raw coal is fed on to the chain feeder d from the raw coal bunker. From the chain feeder the coal is supplied to the ball mill. If theyre some amount of moisture in the coal it is removed by the passage of the hot combustion gases. As the coal reaches the ball mill, there it is crushed into small particles due to the impact of the balls and attrition of coal particles. Then the coal and the vapour mixture are sent to the classifier where the large and coarse particles are removed and again sent into the milling circuit for further crushing. After that the coal and vapour mixture reaches the cyclone separator. There the pulverized coal is separated out from vapour. So the vapour is sucked by forced-vapour fan, while the coal is stored in the pulverized coal bunker. Then the pulverized coal is sent to the furnace through the hoppers. And finally the pulverized coal reaches the furnace. This method is also called indirect

method of firing. This due to the fact that in this system we are using a cyclone separator and a P.C.bunker, so the mills are operated independent of boiler loading.

PAM
(Plant

Auxiliary Maintenance)

3.1 Ash Handling Plant

Bottom Ash System In the Bottom ash system the ash slag discharged from the furnace bottom is collected into water impounded scraper troughs installed below bottom ash hoppers. The ash is continuously, transported by means of the scraper chain conveyor, on to the respective clinker grinders which reduce the lump sizes to the required fineness. The crushed ash from the clinker grinders falls into the ash sluice trench provided below the bottom ash hopper from where the ash slurry is further transported to ash slurry sump aided by the ash sluice channel. If the clinker grinder is not in operation, bottom ash can be discharged directly into the sluice channel through the bifurcating chute bypass the grinder. The position of the flap gate in the bifurcating chute is to be manually changed. The main types of hoppers used in power stations are described below: Water Filter Hoppers This consists of a tank made of steel plate. The bottom ash from the boiler falls into water filled tank and is immediately quenched large pieces of ash break up due to thermal shock, thus the ash collected will be of fairly small size and during the disposal not much difficulty in terms of crushing aspects will be encountered. These hoppers may or may not be lined with refractory. The lined hoppers present difficulties with regard to the maintenance of refractory which goes off too frequently due to temperature variations. The unlined hoppers have problems on corrosion for which special coating are recommended. Quencher Cooled Ash Hopper This uses a series of quenchers located near the top of the hoppers which Quencher Cooled Ash Hopper

provide fine spray of water. This ensures that the ash is cooled sufficiently to prevent after combustion and simitering within the hopper. The spray water also keeps the refractory lining of the hopper cool. The quencher type hoppers are not very effective so far as the breaking up of ash due to thermal shocks is concerned. If there is a tendency of slag accumulation of large pieces clinker grinders are normally used.

Fly Ash System The flushing apparatus are provide under E.P.hoppers (40 nos), economizer hopper (4 Nos), air preheater hoppers (4 Nos) and stack hoppers (2 nos). The fly ash collected in these hoppers drop continuously to flushing apparatus where fly ash gets mixed with flushing water and the resulting slurry drops into the ash sluice channel. Low pressure water is applied through the nozzle directing tangentially to the section of pipe to create turbulence and proper mixing of ash with water. For the maintenance of flushing apparatus plate valve is provided between apparatus and connecting chute. Ash Water System High pressure water required for B.A. hopper quenching nozzles, B.A. hoppers window spraying, clinker grinder sealing scraper bars, cleaning nozzles, B.A. hopper seal through flushing, Economizer Hoppers flushing nozzles and sluicing trench jetting nozzles is tapped from the high pressure water ring main provided in the plant area. Low-pressure water required for bottom ash hopper seal through makeup, scraper conveyor makeup, flushing apparatus jetting nozzles for all F.A. hoppers excepting economiser hoppers, is tapped from Low pressure water ring mains provided in the plant area. Ash Slurry System Bottom ash and fly ash slurry of the system is sluiced upto ash slurry pump along the channel with the aid of high-pressure water jets located at suitable intervals along the channel. Slurry pump suction line consisting of reducing elbow with drain valve, reducer and butterfly valve and portion of slurry pump delivery line consisting of butterfly valve, pipe and fittings has also been provided.

3.2 Water Treatment Plant

Water Requirements of a Power Station
Bulk requirement of water is used in thermal plants for the purpose of cooling the steam in condensers. The requirement of water for this purpose is of the order of 1.5-to2.0 cusecs/MW of installation. The purpose of condensation is best served by running cold water if it is used one through without the necessity of recalculating the same water for cooling again and again. Second item of major consumptive use of water is the sluicing out ash that is produced by burning the coal. Of the total quantum of coal consumed in the boiler the percentage of ash may be of the order of 30 to 45%. Depending on the type of plant, a substantial quantum of water is required in the coal handling plant for the purpose of dust suppression. Since spraying is involved, it is necessary to ensure that the water is reasonably free from silt and other fibrous suspended material. Lastly, water is also required for various purposes like bearing/equipment cooling and various make-ups in the power station.

Sources of Water Supply

Main sources of water supply are river, reservoirs, natural lakes, canals, wells for small stations, and the ocean for coastal plants. After working out the total requirement of water for cooling and other purposes, Hydrological studies are carried out for the source to find the reliable discharge available. Dry and wet bulb temperature (Humidity), water temperature, hydrographs of rivers of various years is prepared and the maximum and minimum water level is found out to make techno-economic studies for adopting the type of circulating water system.

Direct Circulation Cooling System

From a River In this system, after studying the hydrological data of the river, if the river water is sufficient to meet the demands of the circulating water system, this method is adopted for cooling. The minimum flow in the main river should not be less than the ultimate requirement of water under all circumstances.

Intake Structure
Intake structure is located at such a point where the main channel of the river huge the intake structure bank. Intake structure should not endanger the foundations. The floor level of intake structure should be higher than maximum flood level of the river. Silting at the entrance should be avoided. Techno-economic studies are carried out to fix the capacity of the pump. Suitable trash racks are needed at the entrance of leaves, trees, logs, animals etc. Water drawn through such intake structures can be carried in an open channel or RCC ducts/pipes upto the powerhouse depending on techno-economic studies and site condition with respect to location of the condenser.

Sometimes two stages pumping may become necessary in case of excessive length and head in the condenser system. From the condenser, hot water is taken through a pipe to the RCC ducts and then to the open channel. The location of the discharge point should be so fixed that hot water does not cut short to find its way into the intake structure again. Inflow of hot water should not increase the temperature of raw water appreciably and endanger marine life.

Closed Circulating System

Closed circulating water system can be sub-divided into two types Where the water supply in scarce (by cooling tower spray pond) and Where the water supply is ample and hot water can be cooled by surface evaporation from a lake. In this system of cooling, the same water will be circulated again and again: water which gets hot is cooled by a cooling tower or by lake spread cooling system before being re-used. The quantity of soluble salts in circulating water will increase in case of cooling towers. Generally, arrangements are made to provide for taking the blow down discharge. Substantial quantum of water is lost by evaporation and drift in the process of cooling. This is required to be made up by fresh supply. Intake Structure The principle of design and construction of intake structure for make-up water is the same as that for once-through direct circulation intake, excepting for the fact that the volume handled in this case is smaller. This makeup water is led to the cooling tower basin. Water is drawn from the cooling tower basin by RCC duct. Proper arrangement of stop log and trash rack is made at the entrance of the water intake channel RCC ducts. Intake ducts are taken along the length of the main powerhouse and entry to the units is made in between the column. The capacity for RCC duct is fixed on 1.1 to 1.5 cusecs/MW. The velocity of water should not be less than 3 ft/sec, and not more than 8 ft/sec. Generally, 5 ft/sec, to 6 ft./sec. velocity is adopted for design of RCC duct. Suitable gates or stop logs should be provided in intake channels to isolate them from the units not under operation and for necessary maintenance and repairs.

Lake Cooling This system can suitably be adopted when a natural lake is available or an
artificial lake can conveniently be constructed by construction of a dam and when surface area of such lake even under draw down condition is adequate for the required quantum of cooling. Water is pumped or drawn from one end of the source to condensers and hot water is discharged at the other end into the source at a suitable location so that hot water is not drawn again. Hot water gets cooled in the reservoir by coming in contact with cooler water and air and evaporation. Extent of cooling of hot water depends on: Surface area of water Ambient temperature Reservoir water temperature Wind velocity Dry and wet bulb temperature i.e. humidity Inflow and outflow discharge from reservoir/lake. Location of intake structure and arrangement: Intake structure is located on the fringe of the reservoir so that the distance from main power house to intake structure is minimum. Elevation of condenser and elevation of minimum water level has a great bearing on the circulating water system. Power houses can be so located that the grade level of power house is about 8 to 10 ft. above high flood level of lake or reservoir. Water is drawn by open earthen channel or by RCC ducts and pumped to the condenser from where it should be able to discharge into the lake at maximum water level by gravity.

Water Treatment
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 are designed to process the raw water to a water with very low dissolved solids known as demineralised 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. Actually, the type of demineralisation process chosen for a power station depends on three main factors: The quality of the raw water The degree of deionisation i.e. treated water quality Selectivity of resins Following figures shows a schematic diagram of water treatment process which is generally made up of two sections: Pre-treatment section Demineralisation section

Pre-treatment section
Pre-treatment plant removes the suspended solids such as clay, silt, organic and inorganic matter, plants and other microscopic organism. The turbidity may be taken as of two types of suspended solids in water, the separable solids and 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 settleable. Long term ability to remain suspended in water is basically a function of both size and specific gravity. The settling rate of the colloidal and finely divided (approximately 001 to 1 micron) suspended matter is so slow that removing them from water by plain sedimentation is tanks having ordinary dimensions is impossible. Settling velocity of finely divided and collidal particles under gravity also are so small that ordinary sedimentation is not possible. It is necessary, therefore, to use procedure which agglomerates the small particles into larger aggregates, which have practical settling velocities. The term Coagulation" and "flocculation" have been used indiscriminately to describe process of turbidity removal. "Coagulation" means to bring together the suspended particles. The process describes the effect produced by the addition of a chemical Alg (SP^)g to a colloidal dispersion resulting in particle destabilization by a reduction of force tending to keep particles apart. Rapid mixing is important at this stage to obtain uniform dispersion of the chemical and to increase opportunity for particles to particle contact. This operation is done by flash mixer in the Clarifloculators. Second stage of formation of settleable particles from destabilised colloidal sized particles is termed a "flocculation". Here coagulated particles grow in size by attaching to each other. In contrast to coagulation where the primary force is electrostatic or interionic, "flocculation" occurs by chemical bridging. Flocculation is obtained by gentle and prolonged mixing which converts the sub microscopic coagulated particle into discrete, visible & suspended particles. At this stage particles are large enough to settle rapidly under the influence of gravity and may be removed. If pre-treatment of the water is not done efficiently then consequences are as follows: SiO4 may escape with water which will increase the anion loading. Organic matter may escape which may cause organic fouling in the anion exchanger beds. In the pre-treatment plant chlorine addition provision is normally made to combat organic contamination. Cation loading may unnecessary increase due to addition of Ca (OH) 4 in excess of calculated amount for raising the pH of the water for maximum floe formation and also AKOrD4 may precipitate out. If less than calculated amount of Ca(OH), is added, proper pH flocculation will not be obtained and silica escape to demineralisation section will occur, thereby increasing load on anion bed.

Demineralisation
This filter water is now used for demineralising 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 cation resin and must be eliminated before its entry to this bed. Normally, the typical scheme of demineralisation upto the mark against average surface water, is three bed systems with a provision of removing gaseous carbon dioxide from water before feeding to Anion Exchanger. Resins, which are built on synthetic matrix of a styrene divinely benzene copolymer, are manufactured in such a way that these have the ability to exchange one ion for another, hold it temporarily in chemical combination and give it to a strong electrolytic solution. Suitable treatment is a so given to them in such a way that a particular resin absorbs only a particular group of ions. Resins when absorbing and releasing cationic portion of dissolved salts, is called cation, exchanger resin and when removing anionic portion is called anion exchanger resin. We may see that the chemically active group in a cationic resin is SOxH (normally represented by RH) and in an anionic resin the active group is either tertiary amine or quaternary ammonium group (normally the resin is represented by ROH). The reaction of exchange may be further represented as below: Cation Resin RH + Na /k/ca/Mg > R (Na/k/ca/Mg) + (H2SO4/ HCl/ HNO3) 1 2 3 1 -----In the form of chloride sulphate nitrate or bicarbonate 2 -----Resin in H2CO3 exhausted or form 3 -----Removed by - aeration in, degassing tower Anion Resin ROH + (H2SO4/HCL/HNO3) > R (SO4/CL/NO3) + H2O 1 2 1------- (Mineral acids obtained from cation exchangers) 2------- (Resin in exhausted form) Recharging the exhausted form of resign i.e. regeneration employing 5% of acid/alkali as below: Cation Resin Na R (K/Ca/Mg) + Exhausted resin Anion Resin: R (SO4/CL/NO3) + Exhausted resin NaOH --------> fresh resin R OH + (Na2 SO4 NaCl NaNO3) removed by rinsing HCP > RH + fresh resin (NaCl/KCl2//CaCl2/MgCl2) removed by rinsing

As seen above the water from the ex-cation contains carbonic acid also sufficiently, which is very weak acid difficult to be removed by strongly basic anion resin and causing hindrance to remove silicate ions from the bed. It is therefore a usual practice to remove carbonic acid before it is led to anion exchanger bed. The ex-cation water is trickled in fine streams from top of a tall tower packed with rasching rings, and compressed air is passed from the bottom. Carbonic acid breaks into CO2 and water mechanically (Henry's Law) with the carbon dioxide escaping into the atmosphere. The water is accumulated in suitable storage tank below the tower, called degassed water dump, from where the same is led to anion exchanger bed, using acid resistant pump. The ex-anion water is fed to the mixed bed exchanger containing both cationic resin and anionic resin. This bed not only takes care of sodium slip from cation but also silica slip from anion exchanger very effectively. The final output from the mixed bed is exfira-ordinarily pure water having less than 0.2/Mho conductivity, H 7.0 and silica content less than 0.02 ppm. Any deviation from the above quality means that the resins in mixed bed are exhausted and need regeneration, regeneration of the mixed bed first calls for suitable back washing and settling, so that the two types of resins are separated from each other. Lighter anion resin rises to the top and the heavier cation resin settles to the bottom. Both the resins are then regenerated separately with alkali and acid, rinsed to the desired value and air mixed, to mix the resin again thoroughly. It is then put to final rinsing till the desired quality is obtained. It may be mentioned here that there are two types of strongly basic anion exchanger. Type II resins are slightly less basic than type I, but has a higher regeneration efficiency than type I. Again as type II resins are unable to remove silica effectively, type I resins also have to be used for the purpose. As such, the general condition so far prevailing in India, is to employ type II resin in anion exchangers bed and type I resin in mixed bed (for the anionic portion). It is also a general convention to regenerate the above two resins under through fare system i.e. the caustic soda entering into mixed bed for regeneration, of type I anion resin, is utilised to regenerate typeII resin in anion exchanger bed. The concept of utilising the above resin and mode of regeneration is now a days being switched over from the economy to a more higher cost so as to have more stringent quality control of the final D.M. Water.

Internal Treatment
This final D.M effluent is then either led to hot well of the condenser directly as make up to boilers, or being stored in D.M. Water storage tanks first and then pumped for makeup purpose to boiler feed. As the D.M.Water has a good affinity to absorb carbon dioxide and oxygen, and both are extremely harmful to metal surfaces for their destruction like corrosion, these have to be removed before it is fed to boiler. This is being done in deaerator. Still the residual oxygen which is remaining in the water is neutralised by a suitable doze of hydrazine, at the point after deaerator. To have further minimum corrosion, the pH of feed water is to be maintained at around 9.0 for which purpose ammonia in suitable doze is added to this make up water at a point along with hydrazine as stated above.

3.3 Compressed Air System

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 atomising 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.

Control Air System

Control air compressors have been installed for supplying moisture free dry air required for instrument used. The output from the compressors is fed to air receivers via. non return valves. From the receiver air is passed through the dryers to the main instrument air line which runs along with the boiler house and turbine house of 210 MW unit. Adequate number of tapings has been provided all over the area. There is one interconnection between service air and instrument air headers just at the inlet of air drying units. This connection has been provided as an emergency provision to meet the requirement of instrument air in case of non-availability of instrument Air Compressor. The line connecting the service air header with instrument air header is provided with two isolating valves, one oil separator, one activated carbon filter, one non return valve and one regulating valve. Oil and dust free air is supplied to the instrument air header which is then passed through air drier units. Instrument air compressors are of the double acting horizontal cross head type of two opposed cylinder. The compressors are driven by electric motor through V belts. Gear wheel type lubricating oil pump is provided to feed the main bearing. connecting rod bearing and cross heads of one side, i.e. to the opposite side of the crank shaft rotation piston. The cylinders are selflubricated as they are fitted with Teflon rings. Plate type valves are provided at suction and delivery. The compressor is equipped with water cooled inter cooler or header, pressure regulator to load and unload the compressor and safety valves for first and second stages. The suction air filter is at the middle of the cylinder so that air can enter at both ends of the piston. After compression the air passes through the delivery valves to the Inter-cooler where the air is considerably cooled and enters the H.P. cylinder. The entrapped air in HP side is compressed in a similar manner as in L.P.Cyinder to the required pressure and enters the header connected to the H.P. cylinders through the delivery valves and then finally to the air receiver. 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, the other tower is under recativation. Thus the unit maintains continuous supply of dry air for plant requirement. This system is completely automatic. Service-Air Compressor: The station air compressor is generally a slow speed horizontal double acting double stage type and is arranged for belt drive. The cylinder heads and barrel are enclosed in a jacket which extends around the valve also. The inter cooler is provided between the low and high pressure cylinder which cools the air between stage and collects the moisture that condenses. Air from L.P. Cylinder enters at one end of the inter cooler and goes to the opposite end wherefrom it is discharged to the high pressure cylinder, cooling water flows through the nest of tubes and cools the air. A safety valve is set at rated pressure. From the high pressure cylinder compressed air is led through water cooled " after cooler" which is provided

with inlet and outlet water connection and a drain. The "after cooler" cools the compressed air, condensing the water vapour. A moisture separator with a drain trap and a filter are provided to remove moisture and dust particles from the compressed air. The air is then led to the air receiver via a non-return valve. The receiver is located out side the compressor house. Receiver is provided with a pressure gauges safety valve and drain valve. Two selector switches one with positions Auto load/unload and Auto unload and another with positions Auto start-stop, non-stop have been provided on the control panel of the compressor. In auto-start-stop position the compressor will start when the receiver pressure drops down to 'Cut in' pressure and will stop when the receiver reaches the 'cut out' pressure. Hydrogen Plant Hydrogen is prepared by electrolysis of pure demineralised water. When D.C. current is passed through water it decomposes the water into two elements, one volume of oxygen and two volumes of Hydrogen. Pure distilled water is a bad conductor of electricity but if acid, alkali or salt is added it becomes a good conductor. To make economical use of the electrolysis of water, a solution termed as electrolyte has to be used which is prepared by adding NaOH or KOH with pure water. When current is passed through the electrolyte, hydrogen is given off at negative electrode, while oxygen is evolved at the positive electrode. Description of Arrangement A.C. Power at 400/440V, 3 phase, is changed to D.C.Power in a Transformer and rectifier. D.C. output of the plant is controlled by means of a regulator. D.C. from the terminals of the rectifier is supplied to the cells through busbars. Gas production is directly proportional to Direct Current passing through the solution of caustic potash and D.M. water. D.M water of high purity is collected in a storage tank from where it is fed by gravity to the cell bank for make up. An automatic float valve is mounted in gas washing tank to provide a continuous supply of water in proportion to usage. The gases, after leaving the cells, pass upwardly to the collection headers and then through a water seal to atmosphere or to the gas holder as the case may be. Cooling water is supplied to the water seal, which regulates the pressure head against which the cells operate and also prevents any backward flow from the gasholder when the plant is not in operation. Valve is provided in between the gas washing tank and gasholder for greeting the flow to atmosphere when desired. Hydrogen gas flows from the gas-washing tank to a low-pressure wet seal gasholder. From the gasholder it flows to a compressor, which compresses it to rated pressure. After the compressor it flows through carbon filter and through a silica gel dryer. The dry Hydrogen is then stored in storage cylinders from where it goes to the power station for generator use. Hydrogen gas is normally sent to H.P. compressors from the gas holder where it is compressed to a rated pressure. From the H.P. compressors, Hydrogen flows through a "After Cooler" Which has moisture separator columns and then to a point filling station where It is filled in portable cylinders. Oxygen produced in the process is let off to atmosphere. Gas Holders : The gas holder should be leak proof. It should float at a pressure of 4" water column, counter weights may be added if necessary. Valves are provided at the lowest points on the lines entering and leaving the gas holder so that any condensate may be drained. Initially the system is purged with CO2 for expelling air. If for any reason the pressure in the gas holder drops below atmospheric pressure repurging should be carried out in case air has entered. After CO2 purging H2 may be introduced into the gas holder from the cells to eliminate CO2

TMD
(Turbine

Maintenance Division)

4.1 Steam turbine

From a thermo-dynamic point of view, the main advantage of the steam turbine over, say a reciprocating steam engine is that in the turbine the steam can be expanded down to a lower back pressure, thereby making available a greater heat drop. If a reciprocating steam engine were to expand the steam down to a back pressure of the order of an inch or two of mercury, the low pressure cylinders would have to be a very large to deal with the large volume of steam resulting from these pressures. The construction of such large cylinders would be impracticable and uneconomic. In addition the internal efficiency of the turbine is high so it is able to convert a high proportion of this relatively large heat drop into 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 a 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 filters. It also means that it 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 times the power compared to a reciprocating engine whether steam or oil. General description The turbine is condensing, tandem compound, three cylinder, horizontal, disc and diaphragm type with nozzle governing and regenerative feed water heating. The double flow L.P. turbine incorporates a multi-exhaust in each flow. The complete turbine assembly is mounted on pedestals and sole plates, which are designed to ensure that the components are free to expand whilst correct alignment is maintained under all conditions. Live steam from the boiler enters two emergency stop valves of highpressure turbine. From ESV steam flows to four control valves (CV) mounted on the casing of high-pressure turbine (HPT) at the middle bearing side. Control valves unturned feed the steam to nozzle boxes located inside the HPT. The high pressure turbine comprises of 12 stages, the first stages being covering stage. The steam flow in HPT is designed for anti-clockwise rotation when viewed in the direction of steam flow. After passing through H.P. turbine, steam flows to boiler for reheating and reheated steam comes to the intermediate turbine (ITP) through two interceptor valves (IV) and four control valves (CV) mounted on the ITP itself.

The intermediate pressure turbine has 11 stages .HP & IP rotors are connected by rigid coupling and have a common bearing. After flowing through IPT, steam enters the middle part of low-pressure turbine (LPT) through the two crossover pipes. In L.P. turbine, steam flows in the opposite paths having four stages in each path. After leaving the L.P. turbine the exhaust steam condenses in the surface condensers welded directly to the exhaust part of the L.P. turbine. Rotors of the intermediate and low-pressure turbine are connected by a semi-flexible coupling. The direction of rotation of the rotors is clockwise when viewed from the front bearing end towards the generator. The common bearing of HP & LP rotors is a combined journal and radial thrust bearing. The anchor point of the turbine is located at the middle foundation frame of the front exhaust of low pressure cylinder .the turbine expands towards the front bearing by nearly 32mm and towards the generator by 3mm in steady state operation at full load with rated parameters. Turbine is equipped with a barring gear which rotates the rotor of the turbine at a speed of nearly 3.4. Rpm for providing uniform heating during starting and uniform cooling during shut down. In order to heat the feed water in the regenerative cycle of the turbine, condensate from the hot well of condenser pumps, and supplied to the deaerator through ejectors, gland cooler from deaerator the feed water is supplied to boiler by boiler feed pumps through the H.P. heaters. Extracted steam from the various points of the turbine is utilized to heat the condensate in these heat exchangers. SPECIFICATION Rated power Rated speed Rated steam (pressure) before ESV Rated steam temperature before ESV Rated steam pressure before IV Rated steam temperature before IV Rated steam flow 210 MW 3000 rpm 130 kg/cm^2 abs 535 degree Celsius 27 kg/cm^2 abs 535 degree Celsius 670 tons/hr 27 kg/cm2 327 degrees Celsius 27000m3 0.09 kg/cm2 1585, 1881, 2017 & 2489

HPT exhaust pressure HPT exhaust temperature Rated circulating water quantity through condenser Condenser back pressure Critical speed

Rated condenser cooling water inlet temperature Rated condenser cooling water pressure Type of governing

24 to 33 degree C kg/cm2 mechanical nozzle Type sing, tandem compounding Three cylinders, horizontal. 5 nos (for turbine side only) 3, 4 rpm Ac motor of 30KW, 730rpm, 50 c/s, 415 V, 220:1 ratio

Type of turbine No. of bearings

Barring gear

Locations of anchor points of the turbine

at the middle foundation Frame of front exhaust part Of the L.P. cylinder

4.2 MAIN COMPONENTS OF THE TURBINE

1.

TURBINE CASINGS: High pressure casing: the high pressure casing is made of creep resisting chromium molybdenum-vanadium (Cr-Mo-V) steel casing .the top and bottom halves of the casing are secured together at the flange joint by heat tightened studs to ensure an effective seal against steam leakage. There are four steam chests, two on the top and two on the sides are welded to the nozzle boxes, which in turn are welded to the casing at the middle bearing end. The steam chests accommodate the four control valves to regulate the flow of the steam according to the load requirement. Intermediate pressure casing: The intermediate pressure casing of the turbine is made in two parts. The front part is made of creep resisting Chromium-Molybdenum-Vanadium steel casings and the exhaust part is of steel fabricated structure. The two parts are connected by a vertical joint. each part consists of two halves having a horizontal joint. The control valves of I.P.turbine are mounted on the casing itself. In these turbines, the nozzle boxes are cast integral with the casing. The final stage nozzle segment of IPT is a welded construction like other diaphragms and mounted directly in the casing. Next two diaphragms are also housed in casing while other 8 diaphragms are housed in three liners, which in turn are mounted in casing. From IPT the steam is carried through cross over pipes to the double flow low-pressure turbine cylinder. Each cross over pipe is provided with a compensator for taking care of thermal expansion. And to ensure no heavy thrust or turning moments are thrown on the flanged connection at the intermediate pressure cylinder exhaust and the low pressure cylinder inlet. Low pressure casing: the L.P. casing consists of three parts i.e. one middle part and two exhaust parts. The three parts are fabricated from weldable mild steel. the exhaust casings are bolted to the middle casing by a vertical flange. The casings are divided in the horizontal plane through the turbine line. The lower half of the L.P. casing has integral bearing pedestals, which houses the following: Rear bearing of intermediate pressure rotor. Coupling between IP&LP rotors LP front and rear bearings. Generator coupling Generator bearing Barring gear

Steam enters the middle casing from top and then divides into two equal, axially opposed flows, to pass through four stages. The last but one stage on each side is Bauamnns stages. They expand a part of the steam down to the condenser pressure and allow rest of the steam to expand through the last stages. 2. ROTORS: High-pressure rotor: the H.P. rotor is machined from a single Cr-Mo-V steel forgings with internal discs. The rotor forging is thermally stabilized to prevent abnormal deflection. The blades are attached to their respective wheels by T root fastening. In all the moving wheels, balancing holes are machined to reduce the pressure difference across them, which result in reduction of axial thrust.

Intermediate pressure rotor: the I.P. rotor has seven disc integrally forged with rotor while last four discs are shrunk fit. The shaft is made of high creep resisting Cr-Mo-V

Steel forgings while the shrunk fit are machined from high strength nickel steel forgings. The blades on the integral disc are secured by T root fastenings while on shrunk fit disc by fork root fastening. Except the last two wheels, all other wheels have surroundings riveted at tip of the blades. To adjust the frequency of the moving blades, lashing wires have been provided in some stages. Low pressure blades: the L.P.rotor consists of shrunk fit discs on the shaft. The shaft is steel forging of Cr-Mo-V steel while the disc is of high strength a nickel steel forging. 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 the blades. In the last two rows satellite strips are provided at the leading edges of the blades to protect them against wet steam erosion. 3. BLADES: Blades are the single most costly element of turbine. Blades fitted in the stationary part are called guide plates or nozzles and those fitted in the Rotor is called moving or working blades. The following are the main types of blades: Cylindrical blades (or constant profile) Tapered cylindrical. (Tapered but similar profile) Twisted and varying profile blades have three main parts: Aerofoil: it is the working part of the blade and is one of the types described above. Root: it is portion of the blade, which is held with the disc, drum, casing. Shrouds

Three types of root arrangement are commonly used. They are: 1) T roots for small blades 2) Fir-Tree or Serrated roots for longer blades 3) Fork and Pin root for longer blades shrunk on disc type rotor. Shrouds can either riveted by tannon to main blade or it can be integrally machined with the blade. Now- a-days trend is towards integral shroud for shorter blades and free standing for larger blades. Sometimes lacing wires are also used to dampen the vibration and to match the frequency in longer blades. Since in the reaction type machine a pressure drop also occurs across the moving blades, it is necessary to provide effective sealing at the blade tips. This must be done to prevent leakage steam past the shrouding of the wheel and consequent loss efficiency particularly at the high pressure end of the machine. Now-a-days trend is for precision forged blades for long twisted blades as it saves valuable machining time, resulting in reduction of cost. Liners and Diaphragms: in reaction type turbines, guide blades are directly carried in the casing and hence liners and diaphragms are not generally used. In impulse turbine most of the pressure drop of a stage takes in guide blades resulting in higher deflection of guide blades. Additional bending strength to guide blades is provided by diaphragms. Welded diaphragms are used in higher temperature zones while cast diaphragms are used in low temperature zones. Two to four diaphragms are housed in a liner, which in turn is housed in the turbine casing, provided chamber for bleed steam and at the same save casing from higher speed steam erosion. With the use of the liners, machining of casing also becomes much simpler. 4. SEALING GLANDS: To eliminate the possibility of steam leakage to atmosphere from the inlet and exhaust ends of the cylinders, labyrinth glands of the radial clearance type are provided which provide a trouble free frictionless sealing.

Each gland sealing consist of a number of sealing rings divided into segments, each segment is backed by two flat springs. The sealing rings are housed in grooves machined in gland bodies, which are in turn housed in the turbine casing, or bolted to the casing at the end. Steam is supplied to the sealing chamber at 1.03 to 1.05 kg/sq.cm. abs and at a temperature 130 degree Celsius to 150 degree Celsius from the header, where the pressure is maintained constant with the help of electronic regulator .air steam mixture from the last sealing chamber is sucked out with the help of a special steam ejector to gland steam cooler. Provision has been made to supply the live steam at the front sealing of the H.P. &L.P. rotors to control the differential expansion, when rotor goes under contraction during a trip or sharp load reduction. EMERGENCY STOP VALVES AND CONTROL VALVES: Turbine is equipped with emergency stop valves to cut off steam supply and with control valves to regulate steam supply. Emergency stop valves are provided in the main steam line and the interceptor valves are provided in the hot reheat line. Emergency stop valves are actuated by servomotor controlled by the protection system. ESV remains either fully open or fully closed. Control valves are actuated by the governing system through servomotors to regulate steam supply as required by the load. Valves are either single seat type or double seat type. Single seat type is preferred though these require higher force for opening or closing. 1) COUPLINGS: Since the shaft (rotor) is made in small parts due to forgings limitations and other technological and economic reasons, the couplings are required for any two rotors this coupling permits angular misalignment, transmits axial thrust and ensures axial location. The couplings are either rigid or semi-flexible. The former neither permits angular nor lateral deflection while the later permits only angular deflection. Number of critical speeds depend upon the modes of vibrations are hence the type of coupling provided between the rotors. Generally in 200/210 MW turbines, coupling between HPT and IPT are of rigid type and between IPT and LPT is of semi-flexible lens type. 2) BEARINGS: Journal bearings are manufactured in two halves and usually consist of bearing body faced with anti- friction tin based babbiting to decrease the coefficient of friction. Bearing body match with adjustable seating assembly in the pedestal. Bearings are usually forced lubricated and have provision for admission of jacking oil. The thrust bearing is normally Mitchell type and is usually combined with a journal bearing, housed in spherically machined steel shell. The bearing between the HP and IP rotors is of this type; while the rest are journal bearings. Earlier each rotor used to have its own set of bearings. Now with the popularity of rigid couplings between rotors, it is possible to use only one between rotors. This arrangement will lead to more flexible rotors, for the same rotor design because span between bearings increases. With reduction in number of bearings, length of turbine gets reduced resulting in considerable saving in capital cost.

3) BARRING GEAR: The barring gear is mounted on the L.P. rear bearing cover to mesh with spur gear on L.P. rotor rear coupling. The primary function of the barring gear is to rotate the turbo-generator rotors slowly and continuously during start-up and shut down periods when changes in rotor temperature occur. When a turbine is shut down, cooling of its inner elements continues for many hours. If the rotor is allowed to remain standstill during this cooling period, distortion of rotor begins almost immediately. This distortion is caused by flow of hot vapours to the upper part of resulting in upper half of turbine being at a higher temperature than the lower half. Hence to eliminate the possibility of distortion during shut down, barring gear is provided to keep the rotor revolving until the temperature change has stopped and casings have become cool. This also results in maintenance of minimum inter stage sealing clearances with higher operating efficiency. The same phenomenon is also observed during the start-up of the turbine, when the steam is supplied to the sealings to create the vacuum. If the rotor were stationary there would be nonuniform heating of the rotor, which will result in distortions of the rotors. The barring gear during starting of the turbine, would slowly rotate the turbo-generator rotor and thereby resulting in the uniform heating of the rotor. Thus any distortion on the rotor would be avoided. During staring period operation of the barring gear eliminates the necessity of breaking away the turbine generator rotors from stand still and thereby provides for a more uniform, smooth and controlled starting. 4) TURBINE AUXILIARIES The turbine cycle can be viewed in the form of different systems as given below: 1) Vacuum System: This comprises of Condenser- 2 per 200MW unit at the exhaust of L.P. turbine.

Ejectors-one starting and two main ejectors connected to the condenser located near the turbine. 2) C.W. Pumps: normally two per unit of 50% capacity. Condensate system: This contains the following: Condensate Pumps 3 per unit of 50% capacity each located near the condenser hot well.

L.P. heaters Normally 4 in number with no.1 located at the upper part of the condenser and no. 2,3&4 around 4m levels. Deaerator- One per unit located around 18m levels in CD bay.

3) Feed water system: The main equipments coming under this system is: Boiler Feed Pump: Three per unit of 50% capacity each located in the 0m level in the TG bay. High Pressure Heaters: Normally three in number and are situated In TG bay. Drip pumps: Generally two in number of 100% capacity each situated beneath the L.P. heaters.

4) Turbine lubricating oil system: This consists of main oil pump (MOP), starting oil pump (SOP), AC standby oil pumps and emergency DC oil pump and jacking oil pump (JOP) (one each per unit). 5) Auxiliary Steam System: the main 16 at header runs parallel to BC bay at the level around 18m.

VACUUM SYSTEM
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 the brass tubes to the water 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, the cooling water leaves the condenser through the outlet pipe and discharges into the discharge duct. Steam exhausted from the L.P. turbine washing the outside of the condenser tubes losses its latent heat to the cooling water and is connected with the water in the steam side of the condenser. This condensate collects in the hot well, welded to the bottom of the condensers.

EJECTORS: There are two 100% capacity ejectors of the steam eject type. The purpose of the ejector is to evacuate air and other non condensing gases from the condensers. The ejector used in the plant, is a 3-stage ejector using steam from the deaerator with 11 at header as the working medium. The ejector has three has three compartments. Steam is supplied generally at a pressure of 4.5 to 5 kg/Esq. to the three nozzles in the three compartments. Steam expands in the nozzle thus giving a high velocity eject which creates a low pressure in the throat of the eject. Since the nozzle box of the ejector is connected to eh air pipe from the condenser, the air and pressure zone. The working steam which has expanded in volume comes in contact with the cluster of tube bundles through which condensate is flowing and gets condensed thus further aiding the formation of vacuum. The non condensing gases of air are further sucked with the next stage of the ejector by the action of 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. COOLING WATER PUMPS: The pumps, which supply the cooling water to the condensers, are called circulating water pumps. There are two such pumps for each unit with requisite capacity. These pumps are normally vertical, wet pit, mixed flow type, designed for continuously heavy duty; suitable for water drawn through an open gravity intake channel terminating in twin-closed ducts running parallel to the main building. The essential components of the pump are the fluid through the suction bowl/eye provided with streamlined guide vanes, whose function is to prevent pre-whirl and impart hydraulically correct flow to the liquid. The propeller, in turn imparts motion to the fluid. The purpose of the discharge bowl, provided with streamlined diffuser vanes, is to direct the flow of water into the discharge column.

GLAND STEAM & GLAND STEAM COOLER: Steam from deaerator or from auxiliary steam header is supplied to the end seals of the H.P, rotor and L.P. rotor generally at a pressure of 1.01 to 1.03 atm. Abs. So as to prevent ingress of atmospheric air in the turbine through the end clearances. This steam supplied to the end seals is extracted by the gland steam cooler by the action of single stage steam ejector. CONDENSATE SYSTEM: CONDENSATE PUMPS: The function of these pumps is to pump out the condensate to the deaerator through ejectors, gland steam cooler, and L.P. heaters. These pumps have four stages and since the suction is at a negative pressure, special arrangements have been made for providing sealing. These are rated generally for 160cu.m.hr. flow at a pressure 13.2 kg/sq.cm. L.P. HEATERS: Turbine has been provided with non-controlled extractions, which are utilized for heating the condensate, from turbine-bled steam. There are 4 low pressure heaters in which the last four extractions are used. L.P. Heater-1 has two parts LHP-1A and LHP-1B located in the upper parts of the condenser A and condenser B respectively. These are horizontal type shell and tube construction. L.H.P. 2, 3, 4 are of similar construction and they are mounted in a row at 5m level. They are of vertical construction with brass tubes the ends of which are expanded into the tube plate. These 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. 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 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 is the boiler feed water should be free as far 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 dissolved gases from the boiler feed water by mechanical means. Particularly the unit must reduce the oxygen content of the feed water to as low as a value possible or desirable, depending upon the individual circumstances, residual oxygen content in condensate at the outlet of desecrating plant usually specified is 0.005/liters or less .A constant pressure deaerator, pegged at 7 kg/sq.cm. abs is envisaged in turbine regenerative cycle to provide properly deaerate feed water for boiler, limiting gases to 0.005 cc/liters. It is a direct contact type heater combined with feed storage tank of adequate capacity. The heating steam is normally supplied from turbine extractions but during starting and low load operation the steam is supplied auxiliary source.

FEED WATER SYSTEM BOILER FEED PUMPS: This pump is horizontal and of barrel design driven by an electric motor through a hydraulic coupling. All the bearing of pump and motor are forced lubricated by a suitable oil lubricating system with adequate protection to rip the pump if the lubrication oil pressure falls below a pre-set value. The high-pressure boiler feed pump is very expensive machine, which calls for a careful operation and skilled maintenance. The safety in operation and the efficiency of the feed pump depends largely on the reliable operation and maintenance. Operating staff must be able to find out the causes of the defect at the very beginning which can be easily removed without endangering the operator of the power plant and also without the expensive dismantling of the high pressure feed pump. The feed pump consist of a barrel, into which is mounted the inside stator together with the rotor. The hydraulic part is enclosed by the high-pressure cover behind the balancing device. The suction side of the barrel and the space in the high-pressure cover behind the balancing device are enclosed by the low-pressure covers along with the stuffing box casings. The brackets of the radial bearing of the suction side and radial and thrust bearing of the discharge side are fixed to the low pressure covers. The entire pumps are mounted on a foundation frame. The hydraulic coupling and two claw couplings with coupling guards are also delivered along with the pump. Water cooling and oil lubricating connections are provided with their accessories. Mechanical seal: The use of mechanical seal reduces the losses of feed water in the stuffing box to a minimum and working ability of the feed pump increases. Cooling of stuffing box space should be perfect by the use of mechanical seal. Function: The water with the given operating temperature should flow continuously to the pump under a certain minimum pressure. It passes through the suction branch into the intake spiral and from there is directed to the first impeller. After leaving TURBINE DRIVEN BOILER FEED PUMP: The single cylinder turbine is of the axial flow type. The live steam flows through the emergency stop valves and then through the main control valves. These valves regulate the steam supply through the turbine in accordance with load requirements. The control valves are actuated by a lift bar, which is raised or lowered via a lever system by the relay cylinder mounted on the turbine casing. The journal bearings supporting the turbine shaft are arranged in the two bearing blocks. The front end-bearing block also houses the thrust bearing, which locates the turbine shaft and takes up the axial forces. There are 14 stages of reaction balding. The balancing piston is provided at the steam admission side to compensate the axial thrust to the maximum extent. Since the axial thrust varies with the load, the residual thrust is taken up by the thrust bearing. The leak off from the balancing piston is connected back to the turbine after 9th stage. The turbine is provided with hydraulic and electro-hydraulic governing system. A primary oil pump is used as a speed sensor for hydraulic governing and hall probes are used are used for electro hydraulic governing.

Whenever steam is drawn from the cold reheat line or auxiliary supply, steam flow is controlled by auxiliary control valve. During this period the main control valves will remain fully opened and the by pass valve across it will remain closed. (By pass remains closed for a short period when changeover from IP steam to CRH takes place). The steam exhaust from the BFP-Turbine is connected to the main condensers and the turbine glands are sealed by gland steam. HIGH PRESSURE HEATERS: These are regenerative feed water heaters operating at high pressure and located by the side of turbine. These are generally vertical type and turbine bled steam pipes are connected to them. HP heaters are connected in series on feed waterside and by such arrangement, the feed water, after feed pump enters the HP heaters. The steam is supplied to these heaters from the bled point of the turbine through motor operated valves. These heaters have a group bypass protection on the feed water side. In the event of tube rupture in any of the HPH and the level of the condensate rising to dangerous level, the group protection diverts automatically the feed water directly to boiler, thus bypassing all the `3` H.P. heaters. FEED REGULATING STATION: In order to ensure security of supply it has been considered necessary to provide a multiple feed-water regulating valve arrangement and on 210 MW There is a 100% regulating valve. In addition here are two smaller regulating valves for low load conditions, which can also be used for standby duty. TURBINE LUBRICATING OIL SYSTEM: The recommended working medium for governing and lubrication system of the turbine is the MOBIL DTE oil medium or turbine-14 of INDIAN OIL COMPANY. OIL SPECIFICATION: 1. 2. 3. 4. 5. 6. 7. Specific gravity at 50 deg Celsius Kinematic viscosity at 50 deg Celsius Neutralization number Flash Point Pour Point Ash Percentage by weight Mechanical Impurities 0.852 28 centistokes 0.2 201 deg. Celsius -6.6 deg Celsius 0.01% NIL

MAIN OIL PUMP: This pump is mounted in the front bearing pedestal .It is coupled with turbine rotor through a gear coupling. When the turbine is running at normal speed i.e. at 3000 rpm then the desired quantity of oil to the governing at 20 kg/cm^2 and to the lubrication system at 1kg/cm^2 is supplied by this oil pump. The oil to the lubrication at the level of turbine axis is supplied by two injectors arranged in series. First injector develops a suction pressure for the main oil pump and second injector develops a pressure of 3 kg/cm^2 before the coolers after the oil coolers, the pressure is 1 kg/cm^2 which goes to the lubrication system.

NCHP/CHP (New & Old Coal

Handling Plant)

5.1 Coal handling System

Coal Transportation System Each of the NTPC project requires transportation of large quantity of coals from the coal mines to the power station site of the order of 30,000 tons per day for a typical 2,000 MW station. This enormous coal requirement is being met from open cast mines. Each super Thermal Power project has been linked to a particular coal mine to meet its coal requirements for the span of its entire operational life. Techno-economic study conducted for coal transportation from mines to power station has revealed that captive merry-go-round (MGR) rail transportation system is most economic and is also reliable. This system calls for high-speed load- outstation at the mines, which have the following advantages: High loading enables loading of trains quickly thus achieving high turnover of wagons and reduction in rolling stock requirement. Top open railway wagons are loaded with maximum possible load consistently and accurately. Simple loading arrangement at a single point avoids the need for a big marshalling yard with cumbersome operational system. The high speed load outstation consists of one or two loading silos depending upon the coal requirement of the linked power station. The holding capacity of the loading silo is such that is adequate to fall at least one complete rake of wagon and in some cases two rakes. The capacity of the silos for the NTPC project varies between 2400 ton/4000 ton. Requirement of the power station linked to mine. 100% standby conveyor capacity is provided for complete reliability of feeding arrangement to the silo. For accurate weighing of coal, two inmotion weight bridges (one before the loading silo and another after the silo) are provided for registering the tare and gross weight of the wagons. Hydraulically operated horizontal snap gates are provided at the mouth of silos to control the feed of coal to wagons. The run of mine coal is sized to 300 mm by the primary crushing arrangement at the mine end. A sampling unit suitable for 20 mm size coal is provided at the feed point of the loading silo to collect samples for quality analysis. Since there is generally only one source of coal to the power plant, and independent closed circuit is provided for transporting coal. It is entirely independent of the conventional of the railway system. Dedicated unit trains are deployed to transport coal from mines to power stations. The loading operation of the coal rake takes place while it is moving under the silo at a present speed of 0.8 k.m. per hr. The loading time for each wagon is one minute. Wagons are provided with bottom discharge hoppers fitted with pneumatically operated automatic door actuating mechanism. For unloading of coal from wagons and under ground track hopper is provided at the power station end. Line side equipment is installed by the track hopper for initiating the opening of doors in groups of 10-14 wagons. The unloading operation of 60 tonne per load wagon takes about 20/30 seconds. The track hopper is designed to have an effective minimum holding capacity of the train load and is normally of 250-300m length. The complete operation of loading, unloading and running of trains is dovetailed is such a manner that there is no holdup in the operation of the MGR system. The capacity of reclaim conveyors installed below track hopper is such that the track hopper is evacuated before the arrival of the next train.

Coal handling System - Equipments The various equipments involved in the coal handling system have been described in this section and they are i) idlers, ii) pulleys, iii) Conveyor belt, iv) drive Unit, v) takeups, vi) Skirt board, vii) scrapper, viii) crushers, ix) vibrating screen, x) Stacker-cumreclaimer, xi) magnetic separators, xii) plough feeder, xiii) ring-granulator, xiv) Eliptex feeder, xv) motorised tripper. Idlers Idlers consist essentially of rolls made out of seamless steel tube enclosed fully at each end and fitted with stationary shaft, antifriction bearing and seals. The roll is sealed by seal assembly to keep the lubricant dust free. The following types of idlers are in general use : Troughing Idler Troughing trainer Return trainer Impact Idler Return Idler

In case of throughing idler rolls are mounted on brackets which are fixed to the idler base frame. The return idler brackets are directly mounted on the conveyor stringers and the pulley roll is supported in the brackets. The idlers support the belt and enable it to travel freely without much frictional losses and also keep the belt trained pr operly. The proper training is achieved on the principle that the belt will move towards the roll which touches the belt first in the direction of travel. Thus slight adjustment of the one side of idler base in the direction of belt travel will move the belt towards the opposite side since the pulley roll on opposite side will come in contact with the belt first due to swivelling of the idler caused by adjustment of the base. Troughing trainers and return trainers work on the same principle and keep the belt automatically trained after the initial training of the belt is done. Impact idlers These are provided with rubber discs for cushioning effect at the loading points and protect the belt from damage which may be caused otherwise due to heavy impact of material falling on belt. Return Idlers Rubber disc return idlers are suitable when materials are damp or sticky or tend to build up on conventional tube type return idler thus causing the off centre travel of the belt. These are also preferred where abrasive materials rapidly deteriorate metal rolls or when moisture tends to freeze on the belt surface. Pulleys Pulleys are made of mild steel. Rubber lagging is provided to increase the friction factor in between the belt and the pulley. Conveyor Belt The conveyor belt consists of layers or plies of fabric duck, impregnated with rubber and protected by a rubber cover on both sides and edges. The fabric duck supplies the strength to withstand the tension created in carrying the load while the cover protects the fabric carcass. Heat resistant belting is always recommended for handling materials at a temperature over 66 deg C.

Drive Unit This comprises of motor coupled to reduction gear box with the help of flexible couplings on the high speed shaft of the gear box. For inclined conveyors, bold backs are incorporated in the gear boxes to prevent running back of the conveyor under loaded condition. With the provision of the fluid coupling on the input side, the motor starts under no load conditions and the conveyor moves only when the motor reaches its full speed. This also eliminates the starting shock on the conveyor components. Take Ups All the conveyors are provided with take up which facilitate the effective functioning in the following ways: To maintain a slack side tension necessary for the drive to operate the belt. To keep sag of belt between idlers at a point where require horsepower will be at a minimum and load will move with least disturbance over idlers. Skirt Board Skirt boards are used in conjunction with chutes at the trail end. They guide the materials centrally on the belt while loading until it has settled down on the belt. It consists of a Fabricated Frame mounted along the conveyor length with the necessary supports. The skirt rubber is attached at the bottom keeping uniform pressure on the belting. Scrapper Conveyors are provided with scrapers at the discharge pulley in order to clean the carrying side of the belt and avoid the wear of return idlers due to the built up material on idler rolls. It is important that care should be taken to ensure that the scraper is held against the belt with the pressure sufficient to remove material without causing damage to <"be belt due to excessive force exerted by wiper. In case of counter weighted & spring loaded scrapers the pressure is altered by adjusting the weights on the arm or by adjusting the springs respectively. Wherever there is any danger of spilled material getting wedged between the tail pulley and the belt, a V plough scraper is mounted a little ahead of tail pulley on the return run of the belt. Following categories of scrapers are in common use : Steel blade scraper. Rubber or fabric blade scraper. Nylon brush scraper. Compressed air blast scraper. Crusher The role of crusher is to crush the coal from 200 mm to 20 mm size of coal received from the vibrating screen. This is accomplished by means ot granulators Refer Fig. 87 for a simplified cross-sectional view of a crusher. Inese granulators are of ring type and there are about 37 crushing elevations. In each elevation, there are four granulators; two of plain type and two of tooth type. These have been arranged in such a way that the two of the same type are not sideby-side. The granulators are of manganese steel because of their work hardening property. The coal enters the top of the crusher and is crushed between rotating granulators and fluid cage path. This crushed coal through a chute falls on belt feeder. Normally these crushers have a capacity of around 600 tons per hour.

Vibrating Screen The function of the vibrating screen is: To send the coal having size of less than 20mm to belt feeder through the bypass chute bypassing the crusher and To send the coal of more than 20mm size to the crusher. The screen is operated by four V-belt connected to motor. The purpose of the vibrating screen is such that when the unbalanced shaft is rotated with motor the coal particles travel along the screen. The vibration on the screen are damped by four springs mounted below the screen. The coal on the screen, while in running condition, comes into the crusher. Generally in each crusher there are four vibrating screens having a capacity of around 600 tons per hour. Digging Wheel The digging wheel is use for cutting and lifting the coal from the stock yard to the belt used for transferring coal from the yard. The above transfer takes place in case of reclaiming the coal only. During stocking operation, the coal from the crusher house is diverted towards tne stockyard conveyor at a transfer point. The above conveyor discharges coal to the boom conveyor through a discharge chute. The boom conveyor, running in the forward direction, creates coal stacks. During reclaiming, coal from the stock yard falls on the boom conveyor \ ' -h the help of the bucket wheel and the boom conveyor, during this period, rotates in backward direction. The coal from central chute falls on the conveyor belts used for transferring the coal from the stock yard. By this way, the coal moves on the underground conveyor belts connected to the main belts. A 6.6 KV motor is used for running the stacker-cum-reclaimer and has a cable reeling drum on which flexible cable is wrapped.

Magnetic Separators This is an electromagnet placed above the conveyor to attract magnetic materials. Over this magnet there is one conveyor to transfer these material to chute provided for dumping at ground level. Because of this, continuous removal is possible and also it is not necessary to stop the electric supply to the magnetic separators for removal of separated materials. Plough Feeder: The plough feeder is normally installed under slot bunkers or hoppers. It is imperative that the feeder is fed properly allowing even feed of material to the rotor blades. There must be adequate means of controlling the excessive feed from the slot bunker or hopper and this is normally achieved by adjustable lip plates fixed along the discharge lip of slot bunker or hopper. These feeders used in power station are generally rotary type. The rotary plough feeder consists of a main carriage frame, the top of which is connected the main body. The carriage, frame consists of a fabricated structure on four wheels, two of the wheels driven through chains from a counter shaft. The drive for traversing is by electric motor through a warm reducer. As saddle with eight sets of either impact or toughing idlers is connected from the carriage frame. Thus, a traveling loading point is automatically created as the plough feeder traverses on the rails. The main body consists of a fabricated frame on which is mounted the vertical double reduction worm gear. At the end of the output shaft a rotor is fitted which can rotate at the required speed. A bib by coupling is fitted on the output side of the dyno drive and connected to the input side of the main gear reducer. The rotor speed can be varied by means of dyno drive. Vibrating Feeder: It is used for throwing the coal on the underground conveyor belt from where coal goes to the bunker. Coal from the stockyard, with the help of bulldozer, is taken to the vibrating feeder via reclaimed hopper and under ground conveyor belt. In case the bunker requirement is more that the capacity of crusher or stacker reclaimed, then with the help of bulldozer the coal is sent to the bunker from the stock yard, through these feeders. Trippers: The tripper is provided in the conveyor to stack the material at desired location on either side or along the conveyor with the help of chute/chutes fitted with the tripper itself. The tripper is provided with wheels, which moves on rails, parallel to conveyor. These trippers have a rigid welded steel frame to resist shock and minimize distortion. There are mainly three type of trippers. They are a) Motorized tripper b) Belt propelled-manually operated tripper c) winch driven tripper. Motorized Tripper : Motorized tripper, propelled by independent motor, is used where continuous and uniform distribution .of material along the conveyor is required or where the tripper is to be moved or reversed frequently. It can be automatically reversed at end of its travel with the help of limit switches carried on the tripper.

MPD (Maintenance & Planning

Department)

MAINTENANCE PLANNING SYSTEM

CONCEPT An effective system known as Maintenance Management System has been developed in consultation with experts from BEI (UK) and adjusted to suit Indian Conditions. OBJECTIVE To maximize availability of generating units with minimum maintenance cost and down time. Most effective utilization of resources. To carry out maintenance jobs in accordance with the laid down procedures within stipulated time. To plan the major and annual overhaul statuary inspection and to obtain statuary certificate from the competent authority for the safe running of the equipment. To ensure safety during isolations, maintenance and re-commissioning. PRINCIPLE The maintenance management system has been conceived based on work control and feedback concept in which all maintenance activities are predetermined with its standard input like work instruction, manpower tools, spares and estimated completion time. The allocation and arrangement of resources, required for maintenance jobs are the prime objectives of the system. A central controlling office called work control office, permit to work control office and material control office are the main ingredients for implementation of the system. For the purpose of effective work control system equipment will form the basic maintenance unit and all its technical specifications/manufacturers details etc. will be recorded in plant inventory card. ORGANIZATION Maintenance Planning

Long Term Planning

Short Term Planning

Spare Parts Planning

Condition Monitoring

Contract System

LONG TERM PLANNING

Compilation of the station five year rolling plan. To prepare and ensure all necessary arrangements for the following years overhaul work program. Produce, distribute and monitor major overhaul and control programme. Operate section of permit to work system before, during and after major overhaul. To plan & coordinate other works resulting out of design modification. To plan for resources (Manpower, materials, contracts)

SHORT TERM PLANNING Development and efficient operation of station work control system. To Co-ordinate effective execution of works between various groups in maintenance To Co-ordinate with Operation & maintenance For effective implementation of work control system & permit to work system To maintain & improve coordination between plant operation & maintenance To schedule the plant insp. Programme & to monitor progress. To receive input documentation from LTP group & schedule accordingly. To draw committed work programme for all section of maintenance Dept. inclusive of PM schedule and planned outage. To ensure unit shutdown defects are correctly recorded on day to day basis. To maintain on-going lists of priority work and to ensure that short term plant overhaul programme are prepared and issued as required. To Review and improve methods of maintenance equip. and staff-skill and crew size to achieve safe and efficient maintenance. Revise work specification cards accordingly. To organize and provide a service to the daily planning meeting. To maintain history of all the equipment, plant inventory cards and spare list cards. CONTRACTS SYSTEM Preparation of Tender enquiry, specifications terms and conditions of contract. Preparation of standard maintenance work package with anticipated variations. Assessment of availability of expertise and resources with the contractors and their enlistment. Tender inquiries, review and final accord of contract, in consultation with concerned department / executives. SHORT TERM PLANNING WORK CONTROL CYCLE o Elements of Work Control Inventory Card Work Order Card Work Specification PM Schedule History Card Permit To Work (PTW) WORK SPECIFICATION The work specification is a step by step procedure of trouble shooting and undertaking a complete maintenance work within stipulated time. These work specification will prove as key to workman to undertake the work themselves accurately with a given time frame.

These work specifications have all the relevant information regarding type of craftsman required, estimated time for each activity, tools to be used, spares, engineering details, clearance, set values and other details along with safety to be followed. WORK ORDER CARD It is the main ingredient of Work control system which is a written requisition for maintenance service irrespective of its nature and source. 8 Preventive Maintenance 8Breakdown Defects Emergency Defects Other than emergency Operational defects Service defects Non operational defects The degree of urgency i.e. priority is also mentioned in the WOC. There are four types of priority 8 Emergency E Priority: This is for those type of defects which, if left unattended may cause substantial loss of generation of pose threat to plant/ equipment or manpower. This is to be attended within 24 hours even if resources have to be diverted from some other less important jobs. 8 A Priority: This is raised for those type of defects which can be taken up after planning suitably .This type of defects are to be attended within 72 hours. 8B Priority: This type of defect may be attended within 7 days. 8C Priority: This type of defects may be planned with the shutdown opportunities.

References

Power Plant Familiarization Power Management Institute , NOIDA Thermodynamics An Engineering approach , Yunus A. Cengel & Michael A. Boles Power Plant Technology , P K Nag Book on Thermodynamics , P K Nag Military handbook steam power plants www.wikipedia.org www.flir.com www.CSImeansreliability.com www.Sdtnorthamerica.com www.reliabilitydirect.com