Declaration

I, hereby, declare that this piece of project work entitled Report on the power generation in 2x125 MW Captive Power Plant (CPP) at JSL Stainless Ltd., Jajpur Road is submitted by me for the vocational summer training for the partial fulfillment of the B. Tech degree of Biju Pattnaik University of Technology is an original work carried out under Er. Gautam Nayan, DGM, CPP, JSL, Jajpur Road. No part of this work has been submitted elsewhere for any degree or diploma in any other college.

Dibyasundar Nayak B. Tech, 4th Year Reg No. 0801106252 Mechanical Engineering College of Engineering and Technology, Bhubaneswar

Certificate
This is to certify that the project report entitled Report on the power generation in 2x125 MW Captive Power Plant (CPP) at JSL Stainless Ltd., Jajpur Road submitted for partial fulfillment of the B. Tech degree of Biju Patnaik University of Technology by Dibyasundar Nayak, a student of Mechanical Engineering department, College of Engineering and Technology, Bhubaneswar is a bona fide work carried out by him under my supervision and guidance.

Er. Gautam Nayan DGM, CPP JSL Stainless Ltd. Jajpur Road, Orissa

Acknowledgement
This project report pertains to take vocational summer training which was undertaken at the Captive Power Plant division of the Jindal Stainless Ltd., Jajpur Road for partial fulfillment of the requirement for the B Tech degree in Mechanical Engineering from the Biju Pattnaik University of Technology BPUT). The main purpose of the training program was to acquaint myself with practical experience of actual work condition in which we are required to work in future. I learnt a lot from the first hand experience which I acquired during the one month long training program. This helped me to develop the habit of critical analysis of various aspects of problem at the time of decision making. I would like to acknowledge the guidance and supervision provided by Er. Gautam Nayan, DGM, CPP, JSL who was my guide during the training program. He described the concepts and principles behind the working of the different parts of the power plant and cleared doubts that occurred from time to time. I would also like to thank Er Sraban Nayak, Er. A.K.Rout, Er. R.N.Panda and Er. A.Mohanty for taking me on visits to different parts of the plant to give a practical idea of the working of the different parts of the plant. I would also like to thank them for giving me clear details of how things work at the plant. I am also indebted to Mr. Tanzeem Alam and Mr. Kali Prasad Tripathy who facilitated my joining the JSL plant for the training program. Finally, I would like to express my thanks to all of the technical & non technical staff at the JSL for the co- operation & valuable guidance I received during my training period.

Dibyasundar Nayak B. Tech, 4th Year Reg No. 0801106252 Mechanical Engineering College of Engineering and Technology, Bhubaneswar

Content
Sl. No.
01 02 03 04 05 06

Subject
Introduction to Power Plant Types of Power Plant Principle behind Power Plant (Rankine Cycle) Company Overview (Jindal Stainless Ltd.) Basic introduction of 2x125 MW CPP Different parts and cycles of the power plant I) Coal Conveyor II) Coal Mill III) Boiler IV) Ash handling system V) Turbine, MSL, CRH, HRH VI) Condensate system VII) Cooling water circuit VIII) Power generation, transmission and distribution General description of Power Plant at Jindal Stainless Ltd, Jajpur Road Data Sheet Cold start up Conclusion Bibliography

07 08 09 10 11

INTRODUCTION

Power Plant
Introduction:
Otherwise known as power stations, power plant is the generating station of electric energy. It involves generator and a mechanism to rotate the shaft of the generator which converts the mechanical energy into electric energy.

Type of Power Plants:

Classification of the power plants can be done based on various criteria. 1) By Fuel: Fossil Fuelled Power Plant: These are the power plants that use fossil fuel for generating steam to rotate the turbine that is coupled with the generator shaft. This can be subdivided as per use of different types of fossil fuels like coal (in Thermal power plants) or natural gas. Nuclear Power Plant: This type of power plants use the heat generated by nuclear reactors to operate the generator. Geothermal Power Plant: This type of power plants use the steam extracted from underground rocks. Biomass Fuelled Power Plant: The heat required is obtained from bio waste products like sugar cane, solid waste etc. Solar Thermal Power Plant: This type of power plants uses solar energy to heat water and generate steam. 2) By Prime Mover: Steam Turbine Plant: Power plants using steam turbines are called as steam turbine plants. The steam turbine uses the dynamic pressure of the steam. Gas Turbine Plant: Power plants using gas turbines are known as gas turbine. This type of turbine uses the dynamic pressure of the flowing gases (air and combustion products). 3) By the use of power generated: Independent Power Plant (IPP): It generates power for commercial sale. Captive Power Plant (CPP): It generates for internal use of the company. Co-generation Power Plant (CGPP): Its main product is steam and by product is power. We will discuss the details of the thermal power plant.

Rankine Cycle:
Rankine Cycle is the governing principle behind the power generation in a thermal power plant. This cycle converts heat into work. The heat is supplied externally to a closed loop, which usually uses water. This cycle generates about 80% of all electric power used throughout the world.

Physical layout of the four main devices used in the Rankine cycle

T-S diagram of a typical Rankine cycle

The Rankine cycle is sometimes referred to as a practical Carnot cycle because, when an efficient turbine is used, the TS diagram of rankine cycle begins to resemble the Carnot cycle. The main difference is that heat addition (in the boiler) and rejection (in the condenser) are isobaric in the Rankine cycle and isothermal in the theoretical Carnot cycle. A pump is used to pressurize the working fluid received from the condenser as a liquid instead of as a gas. All of the energy in pumping the working fluid through the complete cycle is lost, as is most of the energy of vaporization of the working fluid in the boiler. This energy is lost to the cycle because the condensation that can take place in the turbine is limited to about 10% in order to minimize blade erosion; the vaporization energy is rejected from the cycle through the condenser. But pumping the working fluid through the cycle as a liquid requires a very small fraction of the energy needed to transport it as compared to compressing the working fluid as a gas in a compressor as in the Carnot cycle. The processes of the Rankine cycle are: Process 1-2: Working fluid is pumped from low to high pressure. In this process energy is input. Process 2-3: High pressure liquid enters the boiler. At this stage, it is heated at constant pressure Process 3-4: The dry saturated vapor expands through a turbine, generating power. This decreases the temperature and pressure of the vapor. Process 4-1: The wet vapor enters a condenser where it is condensed at a constant temperature to become saturated liquid.

Company Overview (JSL Stainless Ltd.)

Jindal Group
Jindal group was set up in 1970 by the Mr. O.P. Jindal. Now the organisation has grown from an indigenous single-unit steel plant in Hisar, Haryana to the present multi-billion, multi-national and multi-product steel conglomerate. The organization is still expanding and growing.

JSL Stainless Ltd.

JSL Stainless Ltd. is a subsidiary company of the Jindal Group. JSL Stainless Ltd. is an ISO: 9001 & ISO: 14001 company and is the flagship company of the Jindal Organization. The company today has come a long way from a single factory establishment, started in 1970.

JSL Greenfield Project in Orissa

JSL Stainless Ltd. is setting up a Greenfield integrated Stainless Steel project in the state of Orissa at jajpur Road which would involve mining of Iron, Manganese & chrome ore for production of ferroalloys and Stainless Steel in the melt shop and rolling mills. To meet the full requirement of power, JSL Stainless Ltd. will also set up a 500 MW captive power plant. This stainless steel plant will ultimately have a capacity of 1.6 million tons per annum. JSL has already started the 2x125 MW captive power plant. At JSL plant in Orissa, the operation in 2x125 MW Captive Power Plant (CPP) has started. The group is committed to sustainable development, of its people and the communities in which it operates, at the heart of its strategy and aspires to be a benchmark for players in the industry the world over.

Salient Features of JSL 2x125 Captive Power Plant

Type of boiler Type of fuel used No. Of Mills per boiler Type of Mills Furnace P.A Fans F.D Fans I.D Fans Air heater Types of Air Heater Electrostatic Precipitator Type of Turbine No. Of Cylinders No. Of LP Heater No. Of HP Heater Deaerator Single drum tangential firing & radiant reheat type (water tube) Pulverized coal (Main fuel), Heavy oil & L.D.O 05 Pressurized type Bowl Mill Balanced draught 02 02 02 02 Trisector regenerative 02

Reheat-Condensing
2 (HP-IP &LP) 03 02 01

Parts of a power plant

Parts of a power plant:

Main parts of a power plant are: 1. Coal conveyor 2. Pulverizer/coal mill 3. Boiler and auxiliaries 4. Turbine and auxiliaries 5. Cooling water pumps 6. Condenser 7. Electrostatic precipitator 8. Chimney 9. Cooling towers 10. Transformers 11. Generator 12. High-voltage power lines Power plant can be divided into 3 major components: 1. Boiler/Steam Generation Unit 2. Turbine-Generator 3. Balance of Plant (BOP) I. De-mineralizing plant (DM Plant) II. Ash handling plant (AHP) III. Central raw material handling system (CRMHS) IV. Fuel oil pump house (FOPH) V. Cooling Tower (CT) VI. Water treatment plant VII. Auxiliary pump house

Coal conveyor:
This is a belt type of arrangement. This arrangement is used to transport coal from coal storage place in power plant to the coal bunkers of respective boiler.

Coal Mill:
A coal mill/pulverizer is a device for grinding coal for combustion in a furnace in the power plant. The coal is then pulverized in coal mills/pulverizer. The coal is fed to coal mill through a coal feeder where coal is crushed into powder form. The coal is transported to the boiler after pulverization through primary air supplied by PA-Fans. Bowl type mill is used in JSL.

Boiler:
Definition: Steam Generator is a complex integration of furnace, superheater, reheater, boiler or evaporator, economizer and air pre-heater along with auxiliaries such as pulvarizers, burners, fans, dust collectors and precipitators, ash handling equipment, and chimney or stack. The boiler (or evaporator) is that part of steam generator where a phase change (or boiling) occurs from liquid (water) to vapor (steam), essentially at constant temperature and pressure. However the term boiler is traditionally used to mean the whole steam generator. Coal is burnt inside the combustion chamber of boiler. The combustion product gases which are at high temperature which vaporize the water inside the boiler to steam. Sometimes this steam is further heated in a superheater to ensure greater efficiency of the engine in converting the heat of steam into mechanical work. Although other fluids are sometimes used for these purposes, water is the most common because of its economy and suitable thermodynamic characteristics. Accessories of boiler: Accessories are used in boiler to increase the efficiency of the boiler. The important accessories are: I. II. Boiler Feed Pump (BFP): Feed pump is used to pump the water into the boiler. Economiser: It is used to pre heat the water before supply into the boiler. The function of an economiser in a steam generating plant is to absorb heat from flue gases and add this as sensible heat to the feed water before the feed water enters the evaporative circuit of boiler. This increases the efficiency of the boiler. The economiser is placed in the path of the flue gases leaving the boiler rear gas pass below the rear super heater. The economiser is continuous unfinned loop type and water flows in upward direction and gas flows in downward directions. Air Pre Heater: As the name suggests, it is used to pre heat the air. It is installed between the economiser and ESP to heat up primary air and secondary air required in boiler increasing the efficiency of the boiler. The heat used in it is extracted from the exhaust flue gas. Super Heater: The function of super heater is to convert wet steam to dry and super saturated steam. Superheaters are classified as convection, radiant or combination of these. Re-heater: Re-heater is provided for re-heating the HPT outlet in order to increase the cycle efficiency.

III.

IV.

V.

There are two types of boilers, fire tube and water tube. In JSL plant, water tube boiler is used. In water tube boiler, the water flows inside the water tubes which are surrounded by hot gas and flame. They consist of drums and tubes. Feed water enters the economizer and then to the drum. This water circulates through the water-wall tubes connected external to drum through down-comers and bottom ring header. Heat generated due to combustion of fuel in furnace which surround these tubes will convert the water in tubes in to steam-water mixture. This steam-water mixture is going back to boiler drum through riser tubes due to density difference. There after steam is separated from mixture through cyclonic separator in the boiler drum. They produce high pressure, easily accessible and can respond quickly to changes in steam demand. These are also classified as vertical, horizontal and inclined tube depending on the arrangement of the tubes. Large heating surfaces can be obtained by use of large number of tubes.

W ater Tube Boiler S yste m

Advantages of Water wall system: They form complete gas tube seal Due to heat transfer in furnace, flue gas temperature is reduced to acceptable levels in the super heater region Easy Maintenance

DIFFERENT PATHS AND FUNCTION OF BOILER:Mainly four paths of flows are there in boiler: i. Water path ii. Steam path iii. Air path iv. Flue gas path I. Water path:-

CEP

LPHs

DEARATOR FEED STORAGE TANK

BOOSTER PUMS

BOILER FEED PUMP (BFP)

HPHs

ECONOMISER

BOILER DRUM

II.

Steam path:-

BOILER DRUM

LTSH

PLSH

FINAL SUPER HEATER

HP TURBINE

REHEATER

IP TURBINE

LP TURBINE

CONDENSER

III.

Air Path:-

PA FAN:ATMOSPHERE PA FAN APH MILL FURNACE

FD FAN: ATOMOSPHERE FD FAN APH FURNACE

SA FAN:PA FAN SA FAN MILL FURNACE

SCANNER FAN:-

FD FAN

ATMOSPHERE

SA FAN

FURNACE

IV.

Flue Gas Path:-

FURNACE

LTSH

ECONOMISER

APH

ESP

ID FAN

CHIMNEY

PROCESS FLOW:ESP ID FAN

AHP (Ash Handing Plant)

Fuel+Air

Boiler (steam)

Turbine -----------Generator

HPH-5

HPH6

Economiser Condenser

Transformer

Grid Boiler feed pump Hot well

CEP Booster pump

Ejector (A) Dearator

Ejector (B)

LPH-3

LPH-2

LPH-1

Drain cooler

Gland Steam cooler

Major components of the boiler: Boiler Drum:

A boiler drum is a major part of a water tube boiler. It is a reservoir of water and steam at the top end of the furnace. The drum stores the steam generated in the water tubes and separate water by cyclone steam separator. The drum also houses all equipments used for purification of steam after being separated from the water. These equipments are known as drum internals. It reduces the dissolved solid contents of the steam to below the prescribed limit. Different pipes connected to the boiler drum are: I. Down comer pipe: This pipe is a passage between the drum and the bottom ring header. The water from the drum comes to the bottom ring header through the down comer pipe. From bottom ring header water goes to water walls for heat absorption and conversion into steam. To achieve the circulation of water into water walls boiler circulation pumps are provided with down comers. It is fitted in four corners of the furnace. II. Feed pipe: The water from the boiler feed pump enters the boiler through the feed pipe. It holds more pressure than that in the boiler drum. III. Outlet steam line: The outlet steam line is taken out from the final super heater. The steam is then injected to the turbine. IV. Riser tube: A riser is a tube through which the mixture of water and steam pass from an upper water wall header to the steam drum.The water passes from the bottom ring header to the water wall tube which is fitted inside the furnace through the riser tube. V. Cyclone separator: It is fitted inside the drum. It separates the steam and water.

Boiler Furnace:
Furnace is the evaporation zone of the boiler. It consists of the combustion chamber. Fuel is burned inside the furnace and the water flowing through the water tubes gets heated to the boiling point as a result of which converted into steam. The steam flows to the drum and dry steam from drum flows through different superheaters and converted into super saturated steam.

Boiler auxiliaries:
Soot cleaning system:
Long Retractable Soot Blower (LRSB): It is fitted on the side wall of furnace (mainly upper part of the furnace) to clean out soot deposited over different coils like economiser, superheater and reheater etc. by spraying steam. It helps in increasing the thermal conductivity of the tube. It also prevents heat and fuel loss. Soot Wall Blower: Fitted on the side walls of the lower part of the furnace, it washes the ash deposited over the furnace side wall tube. APH soot blowers: These are fitted in the APH internal for removal of soot deposits in APH.

Types of fans:
Different types of fans are used in the boilers that serve some very important purposes. The different types of fans and their functions are listed below. Primary Air (PA) Fan: In the primary air fan, air is suctioned from the atmosphere, pre heated in the air pre heater and then supplied to the coal mills to carry out coal powder to the furnace. There are two P.A fans per boiler. The fan impeller is a double inlet, centrifugal wheel with backward curved plate blades. Forced Draft (FD) Fan: Air is suctioned from the atmosphere by the FD Fan and then preheated in the air pre heater. The secondary air is supplied to the furnace for the combustion of the coal inside the furnace. It minimizes the NOx production. Induced Draft (ID) Fan: The induced draft fan system comprises of two centrifugal double inlet fans per boiler, two operating and one standby. Each fan unit consists of a backward curved plate bladed impeller, which is driven by an electric motor through a variable speed hydraulic coupling. The I.D fan serves the purpose of evacuating the products of combustion or the flue gases in the atmosphere via chimney. Scanner Fan: In order to check the perfect combustion of fuel inside the boiler flame, scanners are fitted in the boiler. Scanner air fan is used in the boiler to supply cooling air to the flame scanner to avoid burning due to high temperature.

Bottom Ash Hoppers:

It is situated at the bottom of the boiler and sealed with water to maintain furnace pressure. During burning of coal the big size ash particles fall down in bottom ash hopper. After grinding through clinker grinder the ash is disposed to ash pond.

Low Temperature Super Heater (LTSH):

The steam from drum before entering to final super heater passes thorough low temperature super heater by absorbing heat from flue gas.
BOILER DRUM FINAL SUPERHEATER

LTSH

PLSH

MSL

Economiser:
It is placed between low temperature super heater and air pre heater. Its function is to increase feed water temperature before it entering to drum. It also absorb heat from the flue gas.
FEED PUMP ECONOMISER FEED REGULATING SYSTEM BOILER DRUM

Economiser Hopper:
It is an ash collecting hopper placed below the economizer. The change in velocity of flue gas in LTSH and economizer cause drop down of ash particles in the hopper from where it is collected at ash pond through ash slurry system.

Air Pre Heater (APH):

It is a very useful and effective part of the power plant. The purpose of the air pre heater is to recover the heat from the flue gas and pre heating primary and secondary air thereby increasing the efficiency of the plant. In JSL Tri-sector regenerative type APH is in service. Inside the APH 3 stage heating elements is consist a. Hot end b. Intermediate end c. Cold end
FD AIR PA AIR Flue Gas Chimney

Secondary Air APH Primary Air

ESP ID Fan

Hopper

APH Hopper: When flue gas enters into APH ash particle in flue gas fall down in the hopper from where it is convened to ash silo by compressed air.
Ash Inlet

Vent Valve Discharge valve to silo

Level Sensor Vessel

Chimney

Ash Handling System: ESP (Electrostatic Precipitator)

ESP APH (HOPPER) (HOPPER) ID FAN

ESP is installed between the APH and the chimney. Electrostatic precipitators (ESP) are used to separate ash particles and other fine pollutants from the exhaust gases to control pollution. The ESP uses colleting electrode, emitting electrode and rapping mechanism for the operation. The spiral electrodes are used as emitting electrode and plate type are used as collecting electrode. The whole process happens in two steps. In the first step the suspension passes through an electric discharge (corona discharge) area where ionization of the gas occurs. The ions produced collide with the suspended particles and confer on them an electric charge. The charged particles drift toward an electrode of opposite sign and are deposited on the electrode where their electric charge is neutralized. In the ESP, the emitting electrodes are highly negatively charged and the particles became negatively charged hence attracted towards collecting electrode and deposited over it. Then by rapping and hammering system the deposited ash particles are collected in ash hopper. The ash free exhaust gas then escapes through chimney by ID fan.

ESP Hopper:
ESP hopper is placed at the bottom of the ESP. This hopper collects the ash from ESP and then the ash is transferred to silo by compressed air.

Chimney:

It placed after ESP. It is generally a high structure used to dispose exhaust gas to atmosphere. They are typically almost vertical to ensure that the hot gases flow smoothly, drawing air into the combustion through the chimney effect (also known as the stack effect). The height of chimney should be designed in such a way that the escaped gas should not affect pollution. Chimney is mainly used to safe guard the environment from pollution.

Turbine and MSL, HRH, CRH Turbine:

A steam turbine is a mechanical device that utilises thermal energy stored in a pressurized steam, and converts it into rotary motion. It is better as compared to the reciprocating piston steam engine primarily because of its greater thermal efficiency and higher power-to-weight ratio. Generally 3 types of turbines are used in a power plant. All the types of turbine with their functions in the power generation described below.

High Pressure (HP) Turbine:

HP turbine is a single flow design. There are several stages. Each stage compromises stationary and moving blades. Stationary blades are mounted on casing and moving blades mounted on rotor. HP turbine is double shell construction comprising inner and outer casing. H.P steam enters the H.P turbine inner casing through inlet connection that is mounted on the top of outer casing. After utilizing the energy in steam the energy that is remained is used again in IP turbine by reheating the steam in boiler.

Intermediate Pressure (IP) Turbine:

Intermediate pressure turbine is a single flow design. Each stage comprises stationary and moving blades which are positioned so that the stationary blades mounted on diaphragm, directs the steam into rotor mounted moving blades. The inner casing, diaphragm carrier ring and outer casing are made in halves bolted together in the horizontal centre. The reheated steam moves to the IP turbine.

Low Pressure (LP) Turbine:

L.P Turbine is a double flow design. The low pressure steam from the IP turbine passes to the LP turbine.

Superheater and MSL (MAIN STEAM LINE):

A Superheater is an important device of a thermal power plant. Its purpose is to increase the temperature of saturated steam without raising its pressure. It increases the efficiency. Generally super heater is of three typesI. Radiant super heater: placed directly in the combustion chamber II. Convection super heater: placed in the path of the hot gas III. Separately fired super heater: totally separated from the boiler
MSL

BOILER DRUM SUPERHEATER

HP TURBINE

The steam form super heater to HP turbine flows through Main Steam line (MSL).

Reheater and CRH (Cold Reheat):

After getting work done in HP turbine, the steam pressure and temperature gets down. Again the steam is supplied to re-heater through cold re-heat line (CRH) and temperature increases at constant pressure. After increasing temperature the steam is flows to IP turbine through hot-reheat (HRH) line.
CRH HRH

HP TURBINE EXHUST RE HEATER

IP TURBINE

Reheater and HRH (Hot Reheat):

HRH line comes from outlet of re heater. These lines enter in to IP Turbine. Then exhausts of IP turbine enter in to LP turbine.
HRH

REHEATER

IP TURBINE

LP TURBINE

Auxiliary PRDS (Pressure Reducing and De-Superheating):

PRDS line supplies steam to:I. De- aerator (for de-aerating of dissolved oxygen from water) II. Mill (Mill inert line for fire extinguishing purpose) III. Gland sealing of turbine (sealing of turbine in initial startup) IV. Ejector (for maintain vacuum inside the condenser) PRDS line is connected with both Main steam and CRH line. In initial light up it is charged from MS line and then in running condition it is charged from CRH line.

MSL

(SPRAY SYSTEM)

CRH

Aux. steam header

High Pressure by pass (HP by pass):

In initial light up, steam cannot be passed unless its temperature meets the required value. It is because wet steam can erode turbine blade. So we recirculate the steam to boiler through HP by pass. This system is put in Main Steam Line and cold-reheat line before HP turbine. The steam returned to re-heater through CRH line.

Low Pressure by pass (LP by pass):

It is the by-pass steam, which diverts the flow of steam from hot-reheat line to condenser instead of injecting into IP turbine. The main view is to avoid entering of wet steam to IP turbine.

Reheater Spray:
This is the spray required to control re-heated steam temperature. Due to some unavoidable operating condition and uneven fuel quality the temperature of steam coming out from re-heater increases. So in order to control the temperature water from BFP discharge is sprayed in CRH line.

Condensate System: Condenser:

In the JSL plant, Surface type condenser is used. The primary purpose of a surface condenser is to condense the exhaust steam from a steam turbine to obtain maximum efficiency and also to convert the turbine exhaust steam into pure water (referred to as steam condensate) so that it may be reused in the steam generator or boiler as boiler feed water. The steam turbine itself is a device to convert the heat in steam to mechanical power. The difference between the heat of steam per unit mass at the inlet to the turbine and the heat of steam per unit mass at the outlet to the turbine represents the heat which is converted to mechanical power. Therefore, the more the conversion of heat per pound or kilogram of steam to mechanical power in the turbine, the better is its efficiency. By condensing the exhaust steam of a turbine at a pressure below atmospheric pressure, the steam pressure drop between the inlet and exhaust of the turbine is increased, which increases the amount of heat available for conversion to mechanical power. Most of the heat liberated due to condensation of the exhaust steam is carried away by the cooling medium i,e water used by the condenser.

Hot Well:
It is placed below the condenser which stores the condensate coming out from condenser.

Condensate Extraction Pump (CEP):

It supplies water form hot well to Ejector, Gland stream cooler, drain cooler, LP heater and then to deaerator. The steam from the L.P cylinders exhausts into the condenser shells where it is constrained to flow across the water tubes around which cooling water is circulated.

Ejector:
It is placed after the CEP. It creates vacuum inside condenser by sucking the air and undissolved gases from condensate water.

LP Heater:

LP heater is placed between drain cooler and deaerator. The function of LP heater is to pre-heat the water before entering into deaerator. Here in JSL three no.s of LP heaters (LP heater 1, LP heater 2 and LP Heater 3) are in line. In the water cycle, temperature of condensate from CEP is raised to approx. 110c by heating it in LP heater. It is done by the extraction steam from low pressure turbine (LPT). Hence, it is known as low pressure heater.

Water CEP Steam From LP Turbine

Deaerator

Deaerator Tank:
Deaerator is device that is widely used for removal of oxygen and other dissolved gases from the feed water. Generally two types of de-aerators are use. I. Tray type. II. Spray type

Booster Pump:
Booster pump supplies feed water form deaerator to BFP (Boiler feed pump). It is used for supplying water to BFP at required suction pressure. It is coupled in one shaft with boiler feed pump.

Booster Pump

Motor

Hydro Coupling

BFP

Boiler Feed Pump (BFP):

Boiler feed pump is the most critical component of a power plant. It supplies the water to boiler drum through the HP heaters and economizer. It is a centrifugal machine, which is coupled to a motor through variable speed coupling or turbo coupling.

HP Heater:
The function of HP heater is to heat the feed water entering economizer from BFP by using extraction steam from HP & IP turbine. Here in JSL two nos of HP heaters (HP heater 5 and HP heater - 6) are in line.

HPH-5 WATER BFP STEAM From IP Turbine

HPH-6 WATER Economiser STEAM From CRH Line

Feed Control System:

It is the control station for controlling feed water supply to boiler as per requirement. The feed water from BFP flows through the control station. It consists of three lines. Out of these three two are full load lines and one is 30%load line. During initial light up water flows through 30% load line and in general running condition water flows through 100% line.

100% 100% BFP 30% Feed Control System Economiser

DMCCW Pumps (DM circulated cooling water):

It supplies the cooling water to the cooling system in plant for cooling. Generally during running of equipments the lubricant used for cooling of bearings in different equipments such as fans, coal mill, and boiler feed pump etc get heated up. So it is required to cool down the lubricant otherwise they performance get deteriorated and leads to damage of bearings. DM cooling water supplied by DMCW pumps are indirectly cooled by Aux. cooling water which is supplied by ACW pumps.

Cooling Water Circuit: Cooling Tower:

Cooling tower is a heat removal device used to transfer heat from hot water coming out from condenser by passing atmospheric air in counter flow direction. Here hot water mixed with air and gets cool down. Drift eliminators are used to reduce the carryover losses. It is one type of heat exchanger. Then the cooled water is supplied to condenser through CW (cooling water) pumps. The circulating water used in the condenser for condensation of steam. This hot circulating water is passed to cooling towers. It is a tower- or building-like device in which atmospheric air (the heat receiver) circulates in direct contact with warmer water (the heat source) and the water is thereby cooled. A cooling tower may serve as the heat sink in a conventional thermodynamic process, such as refrigeration or steam power generation, and when it is convenient or desirable to make final heat rejection to atmospheric air. Water, acting as the heat-transfer fluid, gives up heat to atmospheric air, and thus cooled, is recirculated through the system, affording economical operation of the process. Evaporative or wet cooling towers are used in JSL LTD. It transfers the heat from warmer water to cooler air mainly by an evaporation heat-transfer process and is known as the evaporative or wet cooling tower. Evaporative cooling towers are classified according to the means employed for producing air circulation through them: atmospheric, natural draft, and mechanical draft. Evaluation of cooling tower performance is based on cooling of a specified quantity of water through a given range and to a specified temperature approach to the wet-bulb or dry-bulb temperature for which the tower is designed. Because exact design conditions are rarely experienced in operation, estimated performance curves are frequently prepared for a specific installation, and provide a means for comparing the measured performance with design conditions.

Power Generation, Transmission & Distribution Generator:

An alternator or generator is an electromechanical device that converts mechanical energy to alternating current electrical energy. Most alternators use a rotating magnetic field.

Transformers:

It is a device that transfers electric energy from one alternatingcurrent circuit to one or more other circuits, either increasing (stepping up) or reducing (stepping down) the voltage. Transformers are used to raise the voltage from electric generators so that electric power can be transmitted over long distances with low power losses. Transformers act through electromagnetic mutual induction. The secondary voltage in transformer is calculated by multiplying the primary voltage by the ratio of the number of turns in the secondary coil to that in the primary.

GENERAL DESCRIPTION OF 2x125 MW CPP AT JSL, JAJPUR ROAD

GENERAL DESCRIPTION OF POWER PLANT AT JSL STAINLESS LTD, JAJPUR ROAD

Type: Natural circulation, Dry bottom, Tangentially fired, Balanced draft, Radiant reheat
type, Outdoor with direct fired pulverized coal system.

Pressure: Design:

158.0 kg/cm2 (Drum Pressure) SH Outlet: 138.0 kg/cm2

Designed Fuel:
Type: Indian E-grade coal Fixed Volatile Moisture Carbon Matter 23.7% 21.8% 12.0% Ash Grindability(HGI) Sulphur High Heating Value 3200 Kcal/kg Ash Fusion Temperature >14000 C

42.5%

50

0.6%

Furnace:
Type: Balanced Draft Construction: Fusion Welded Wall Width Depth Height 10.135 meter 8.382 meter 29.44 meter Volume 2501 cu. m. EPRS 1700 m2 Fuel Heat Input 302 Kcal/hr

Fuel Specifications:
A. Coal (proximate Analysis)
I. II. III. IV. V. VI. VII. Fixed Carbon Volatile Matter Moisture Ash Grindability High Heat Value (HHV) Coal Size to Mill 23.7% 21.8% 12.0% 42.5% 50 3200 Kcal/kg

B. Coal (Ultimate Analysis)

I. II. III. IV. V. VI. VII. Carbon Hydrogen Sulphur Nitrogen Oxygen Moisture Ash 32.99% 2.51% 0.6% 0.68% 8.72% 12.0% 42.5%

Pressure and Draft (Air & Gas):

Primary Air
Description Units 100% BMCR -8 854 833 780 661 277 HP Heaters In 125 MW -8 834 814 761 644 267 75 MW -4 790 778 755 643 272 -8 831 810 764 645 263 HP Heater Out

PA Fan Inlet PA Fan Outlet AH Inlet AH Outlet Mill Inlet Mill Outlet

mmwc mmwc mmwc mmwc mmwc mmwc

Secondary Air
Description Units 100% BMCR -16 230 207 139 100 HP Heaters In 125 MW -13 213 193 134 100 75 MW -5 141 134 112 100 -15 223 201 139 100 HP Heater Out

FD Fan Inlet FD Fan Outlet AH Inlet AH Outlet Windbox Pressure

mmwc mmwc mmwc mmwc mmwc

Flue Gas
Description Units 100% BMCR -5 -5 -6 -12 -24 -58 -71 -151 -174 -220 41 -10 HP Heaters In 125 MW 75 MW -5 -5 -6 -12 -22 -54 -67 -140 -162 -204 37 -10 -5 -5 -5 -7 -12 -33 -39 -72 -85 -104 17 -6 HP Heater Out

Furnace SH Plate Inlet RH Inlet LTSH Inlet Economiser Inlet Economiser Outlet AH Inlet AH Outlet EP Inlet ID Fan Inlet ID Fan Outlet Finish SH Inlet

mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc mmwc

-5 -5 -6 -12 -24 -58 -71 -143 -165 -210 40 -10

DATA SHEET
A) ID FAN
FAN:TypeMakeNosFlowPressureTempDriveSpeedMotorControlNDZV 26 SIDOR BHEL 02 128.6 m3/s 397 mmwc 150 0C Motor 740RPM 750 KW Hydraulic coupling + inlet damper MOTOR:DutyStator voltStator currentKw RpmInsulation classAmb.tempDegree of protectionDE BRGNDE LubricationHYDRAULIC COUPLING:MakeTypePaNeVoith turbo 1000 SVNL 613 kw 740 m-1 Coolant tempRelubricating intervalGrease quantityGrease750c/400C 2000 hrs 58 gms Servo gem-3 Continuous 6.6 KV 59 AMP 750 743 F 300C IP 55 NU 230m+c3 NU 226 m Servoprime 68

MOTOR

B) PA FAN
FAN:TypeMakeNosFlowPressTempDriveSpeedMotorVoltControlAP 217/12 BHEL 02 62m3/s 1305 mmwc 500C Motor 1480 RPM 1000KW 606KV Blade Pitch MOTOR:TypeStator voltStator AmpKWSpecificationDutySpeedInsulation classDegree of protection3 phase Induction Motor 6600 volt 106.5 (Y) 1000 IS-325 Continuous 1400 F 55

C) FD FAN
FAN:TypeMakeNosFlowPressureTempDriveSpeedMotorVoltControlAP1 15/11 BHEL 02 48.8 m3/s 390 mmwc 500C Motor 1480RPM 260 KW 6.6 KV Blade Pitch MOTOR:TypeRT TypeFrameDutyKW InsulationStator voltStator currentRPM3 phage induction motor Squirrel cage 1LA 75 66-6R Continuous 260 F 6600 volt 28.(Y) 1463

D) SCANNER AIR FAN FAN:MakeDoctaire

DC MOTOR:MakeCG

AC MOTOR:Type3 ph. Induction Motor 5.5 2880 415+10% 9.9 84%

TypeNosCapacityRPMSizeStatic pressBHP-

SWSI (centrifugal) 02 4000 m3/hr 2865 180SWS 200mmwg 4.49

TypeKW(HP)RPMArm. VoltsArm Amps Extn. Volts-

STAB.SHLWT 5.5 2860 220 31 220

KWRPMVoltAmpEfficiency-

Extn.Amps- 0.5 Grease 2 lithium Base-2

E) SEAL AIR FAN

FAN:Type MakeCapacityST. PressMotor SpeedMotor RatingCentrifugal(radial)back ward Precision Engg. Works 40.0m3/hr 500mmwc 1490 RPM 150/110KW MOTOR:MakeKWFrameVoltAmpRPMEigi Electric 110 315 S 415+-10% 183.9 1490

AIR HEATER
RE-GENERATIVE AIR PRE-HEATER Type No.Boiler Medium Tri Sector regenerative 27 vi72 (T) 2 i) Primary Air ii) Secondary Air iii) Flue gas 19000 per Air Heater

H.S IN M2

LRSB
LRSB: Model Head opening Travel Travel speed Rotor speed Lance material Nozzle size LPD-1E 350 5.2 mtr 1.63mpm 5.2 rpm AISI 602 18 TypeMake KW Amp Efficiency MOTOR 3 ph. Induction Remi 0.37 0.89` 87%

GEAR:Traverse power pack Gear ratio-155:1 Type-11

WALL DESLAGGER:Model NoWB-1E Lance RPM- 0.7 Travel Speed 6.1 mpm

ELECTOSTATIC PRECIPITATORS (ESP)

DESIGN CONDITIONS
I.) II.) III.) IV.) V.) VI.) VII.) VIII.) IX.) X.) XI.) XII.) XIII.) XIV.) XV.) Gas flow rate Temperature Dust concentration Inlet pressure Type Make No. of boilers No. of fields in series in each gas path No. of parallel pass per boiler Collection Efficiency Design pressure drop across precipitator Gas velocity at electrode zone Treatment time Gas wt. Pressure drop

UNIT # 1, 2
232.2m3/sec 1360C 94.22 gm/Nm3 mmwc 2X FAA-7x37.5-128150-2 BHEL 2 7 99.915% 15MMWC 0.53 m/sec. 49.8sec 673800 kg/hr 25 mmwc

RAPPERS FOR COLLECTING PLATES

No. & type One, Drop Hammer Rappers per row for 112.5 m2 collecting Surface area Rapper weight Frequency

RAPPERS FOR EMITTING ELECTRODES

No. & Type One, Spiral Hooks

4.9 Kg Rapper Weight 12 raps/hr - 0.5rap/hr frequency

Coal burners
I.) II.) III.) IV.) V.) VI.) VII.) Type Make No.per boiler Titling limit Control Capacity Disposition Titling tangential fired corner BHEL 20(4 each in 5 elevation) +/-30 deg. Cent. Air Damper 25.2X106 Kcal/hr Cornors

Igniters
I) II) III) IV) V) VI) VII) VIII) IX) X) XI) I) Type No.off Location Capacity Turn down ration Oio pr. At control cabinet Oil firing rate Atomizing air quality Atomizing air pir. Atomizing air consumption Combustion air quality Combustion air pr. At wind box 6 eddy plate oil side ignitors air atomized 12(4 per elevation) elevation AB,CD,EF 0.5 millions k.cal./hour Nil 12.5 to 14 kg/cm2 50kg/hr/ignitor water free service 5.5 to 7kg/cm2 14.5Nm3/hr/ignitor-when off 560 Nm3/hr/igniter 75 MMWC

COAL MILL
I) II) III) IV) V) VI) VII) VIII) Type No.Per boiler System Capacity Coal grindibility Max. moisture content Finness through 200 mesh Motor XRP 803 Bowl Mills 5 pressurized 36.MT/hr 50HGI 12% 70% 340 KW

LDO PUMPS
DESCRIPTION Make Type Capacity Discharge Pressure Speed KW UNLOADING PUMP Roto pumps Ltd multiple screw pump 20 m3/hr 2.5kg/cm2 1500 RPM 5.5 FUEL FIRING PUMP Tushako Pumps T3ST45/46 180/200Lit/min 25.kg.cm2 2920 RPM 12.5

DOSING SYSTEM
DESCRIPTION Soln. preparation tank Metering PHOSPHATE 1no. 600ltr 1 no. 600ltr HYDRAZINE 1 no. 500ltr 1 no. 500ltr

(A) PUMP
No of boiler Capacity Type Head 2 0-100ltr/hr Horizontal reciprocating 195 kg/cm2 2 0-30ltr/hr Horizontal reciprocating 110 mmwc

(B) ASH PUMP:

I) SLPA-1, 2, 3 (TWO SETS) IN ONE SET-3 PUMPS Make SAM turbo industry Ltd Special pumps Type AR 150/510 Head 46mtr Speed 930 RPM Size 200 x 150 Capacity 440 m3/hr Test Press. 27 kg/cm2 Input Capacity 110 KW BRG 6535/6580 MOTOR Make Volt Amp KW (HP) Speed BRG ABB (3 ph. Sq. cage induction) 415+/-10% 190 110(150) 1485 D NU319 N 6316 C3

II) HP PUMPS Make Type Size Capacity Head Speed Input Power

(02 Nos.) MOTOR SAM Turbo Industry Ltd ake M ZM11 530/01 Type 250 X 200 Volt 363 m3/hrs Current 82 mtrs Efficiency 1600 RPM KW (HP) 125 KW Speed BRG Relub hr (03Nos.) MOTOR SAM Turbo Industry Ltd ake M CPC 150/400 Type 200 X 150 Volt 33 mtr Current 344 m3/hr KW(HP) 1500 RPM Speed 45 KW Efficiency BRG

ABB (Sq.cage induction ) M2BA315SMB4(IEC-315m) 415+_10% 210 amp 95.5% 125 (170) 1485 6319 C3/ 6316 C3 3000 ABB (3 ph. Sq.cage ) HX +225 SMC 4 415+_10% 81 amps 45(60) 1470 93.3% D 6313 / C3 N6312/C3 650Grease IOC Servo Plex LC3

III) LP PUMPS Make Type Size Head Capacity Speed Input Power

(C) ASH ANALYSIS

I) Silica II) Alumina III) Iron oxide IV) Titanium oxide V) Lime VI) Magnesia VII) Sulfuric acid hydrous VIII) Phosphoric Anhydride IX) Alkalis 55.09-68.8% 19.8-29.8% 3.05-18.3% 10.0-2.05% 1.1-2.1% 0.26-1.2% 0.4-1.8% 0.19-0.28% 0.16-3.04

BOILER FEED PUMPS

MOTOR
Crompton greaves AC Induction Motor 30/40 415+_10%v 91.5% 296 rpm 21 amps

I) No 2 nos Make II) Make Kirloskar III) Type KPD 50/26 H Type IV) Discharge 30 M3/hr KW/HPV) Size 50 X 80 mm Voltage VI) Head 100 mtr Efficiency VII) Speed 2900 rpm Speed VIII) KW 19.18 Current IX) Impeller Dia.-CF8M/264 mm X) Recommended prime move rating -37 KW Connected to-boiler bottom drain header & deaerator

COMPRESSED AIR SYSTEM:

Compressed air is required in the system for service and controls as below: For service system For control system Total air required for the complete system 8.82 m3/min 10m3/min (8.82x2) + (10x2) = 37.64 m3/min

TURBINE AND AUX

SPECIFICATION TURBINE MAIN DATA Type of Turbine Turbine Model No of Cylinders Turbine installation Rated Power

Reheat-Condensing K30-16+N30-2 X 3.2 Two indoor NCR: 125 000 KW MCR: 125 000 KW 3000 RPM 135.9kg/cm2 540 0C 133 kg/cm2 537 OC 343.9 OC High Pressure (160 bar) Electro-Hydraulic 15%-108% 4-6% 0.06% condensing

Rated Speed Rated steam pressure at SH outlet Rated steam temp. at SH outlet Rated steam press. before strainer Rated steam temp. before strainer Rated CRH steam press. at RH Inlet Type of governing Governor Band Speed Regulation Speed regulator Dead Band Type of turbine condensing

STEAM EXTRACTIONS
No of extraction I (CRH) II(IPT) III (IPT) IV (LPT) VI (LPT) VII(LPT) Connected to HPH-6 HPH-5 D/A LPH3 LPH2 LPH1 Ext, steam press in ata 36.6 13.9 5.2 2.31 0.91 0.356 Ext,steam Temp. in 0C in 350 402 272 190 104 72.6 Steam flow T/hr 35.4 21.3 13.8 13.6 11.5 9

CONDENSATE SYSTEM
CONDENSER
Type-SURFACE CONDENSER DESIGN HEI STANDARD SHAPE OF RECTANGULA CONDENSER R WITH DIVIDED WATERBOX ARRANGEMENT TRANSVERSE TO TURBINE AXIS NO OF PASSES 2 ON TUBE SIDE STEAM FLOW T/Hr 260.93 PR DROP ON CW WATERBOX DESIGN PRESSURE WATER BOX TEST PRESSURE HOT WELL CAPACITY SPACE OF TUBE REMOVAL(NOTE .2) COND OVERALL DIMENSIONS MWC WATER BOXDESIGN PRESSURE Atg 8 3.5

AS PER CODE 2(Nl toLLL ~10500

min mm

Heat load

Kcal/hr

139.48 X 106

mm

L17000 X W 1100

CONDENSATE PUMP
General:Type of pump Model of Pump Manufacturer No. of Pump Pump operation Impeller type No.of stages : : : : : : : Condensate Extraction Pump EN 8H 32 BHEL, Hyderabad 2(1 working +1 standby)/ unit Vertical 1st stage double suction, other stages single suction 8

LP HEATERS & AIR EECTION SYSTEM

L.P. HEATERS
LPH-1: Location-inside upper part of condenser Design Data Design press (Kg/cm2) Hydro test press. (kg/cm2) Design Temp(OC) Hydrotest temp(OC) Corrosion Allowance (mm) Shell side 4.0 & full vacuum 5.2 150 Ambient 3.2 Tube side 27 35.1 150 Ambient 3.2

LPH-3: Design Data Design press (Kg/cm2) Hydro test press. (kg/cm2) Design Temp(OC) Hydrotest temp(OC) Corrosion Allowance (mm) Stress relieving Radiography No. of passes/zones Medium Shell side 4.0 & full vacuum 5.2 215 Ambient 3.2 No Spot Two zones Steam / drain Tube side 27 35.1 150 Ambient 3.2 No Full Two pass Condensate

GLAND STEAM COOLER FUNCTION

a. Eject steam and air mixture from turbine seals b. Eject spindle leak off from ESV, IV & control valves Gland sealing steam pressure Source of gland sealing steam Temperature of sealing steam Type of seals 350 to 450 mmwc 11 ATA header 2800C to 3200C Labyrinth glands of radial clearance type

DEAERATOR
Design press, ata Hydro test press, ata Storage tank design temp (max/min), OC Hydro test temp (max/min) OC Corrosions allowance, shells/heads RF pads/nozzles/flanges 02 content at outlet Storage tank capacity, m3 Operating press, ata Operating temp, OC No. of trays No. of spray nozzle 6.0 7.8 260/0 Ambient 3.2mm 1.6mm 0.005cc/lit 60 4.82 149.7 160 24

FEED WATER SYSTEM

BOILER FEED PUMP
A) PUMP General:Designation No. of pumps/unit Type of Operation Type of pump Pump model No. Type of drive B) Booster pump Type of pump Make No. of pump Pump model no. Discharge Head Speed Temp.

: Boiler feed Pump : 2 (1 working +1 standby)/unit : Continuous : Multistage, barrel : FK 6D 30 : Electric motor

: single stage, Volute type with horizontal split casing and double suction impeller : BHEL :2 : FAIB56 : 485 M3/HR : 102 mtrs : 1485 RPM : 105.8 OC

2 H.P.HEATERS (DESIGN SPECIFICATION)

Description Feed water inlet temp. in 0C Enthalpy of F.W. inlet in Kcal/kg F.W. outlet temp in 0C Enthalpy of F.W. at outlet in Kcal/kg F.W. flow (kg/hr) Ext.stem inlet pressure in kg/cm2 Ext.stem inlet temp. in 0C H.P.HEATER No.5 H.P.HEATER No6 166.76 170.70 184.92 189.51 643165 11.96 433 184.92 189.51 220.90 229.48 643165 26.20 314 60 to 70 Mw 89 kg/cm2 102 kg/cm2

Load at which H.p. Heater are taken into service Without H.P. Heaters ma. Curtis wheel pressure Full load Curtis wheel pressure with H.P. heaters

CW PUMPS
Make Kirloskar Pump type BHO70M-1STG Total Head 28.4 mtr Size 1200mm Discharge 9500m3/hr Speed 594RPM Pump input 803KW Material code A8/OA Impeller dia CF8M / 960mm `Recommended prime 950 KW Mover rating

MOTOR
Make Frame KW Stator volt Stator Amp RPM Duty Specification Connection Degree of protection RT type BRG DE/ NDE BHEL ILA7806-10 950 6600V 109.5 594 Continuous IS:325 Y IP55 Insulation class F Sq.Cage 6234C3/733 2B

Conclusion:
In the modern day advanced world, power is the most important need. Thermal power plants fulfil the major part of this power need. A complex mechanism works behind the power generation in the thermal power plant along with the implementation of numerous machine parts and mechanisms. The working of each part and mechanism is understood and described in this project report.

Bibliography
1. Power Plant Engineering By P.K NAG 2. Thermal power station From Wikipedia, the free encyclopedia 3. Rankine Cycle, From Wikipedia, the free encyclopedia