Malaviya National

Institute of
Technology
A Seminar presentation of
Summer Training on

Aravali Power
Company Private
Limited
Under the supervision of :
Dr. Rakesh Jain
Professor

Dr. Gopal
Agarwal
Professor

Aravali Power Company Private

Limited A brief Introduction :
In APCPL :
a) 50% share NTPC Ltd.
b) 25% share HPGCL, Haryana
c) 25% share IPGCL
) APCPL is a coal based power plant.
) Plant Capacity : 1500 MW (500*3)
) Key beneficiaries are Haryana, Delhi, Himachal, J&K, Uttar
)
)
)
)

Pradesh, Rajasthan, Telangana & Andhra Pradesh.

Coal Source Mahanadi Coadfield Ltd. & Eastern Coalfield
Ltd.
Water Source : Make up water from Jawahar Lal Nehru Feeder
Canal.
Land Area Covered : 2191 Acres.
Mega Power Project Status is given to APCPL

Aravali Power Company Private

Limited A brief Introduction :

Organisational Framework at NTPC Jharli :

GM

Departments :
1) Boiler Maintenance
2) Turbine Maintenance
3) Electrical Maintenance
4) Operations & Efficiency
5) Mechanical Erection
6) Electrical Erection
7) Maintenance Planning
8) Information Technology
9) Fuel Management

Coal Handling Plant

Handles the coal from its reciept to transferring it to bunkers.
The main objective is to supply the quanta of processed coal to its bunkers of

coal mills form boiler operation.

Coal has to be sized, processed and handled which should be done effectively
and efficiently.
80-90 % of requirement is fulfilled by railways.
Coal wagons are received in the form of racks.
55-60 wagons in each rack.
Coal Storage Capacity 12500 MT
Conveyor belt Specifications :
1. Capacity 2600 MT/hr
2. Width 1800 mm
3. Avg Speed 3.2 m/sec
4. Supplier Phonex
5. Coal Carrying Capacity 400 T/hr
6. Motor Capacity 250 HP
7. Speed of Transfer 250-300 m/min

Transportation of Coal :
Modes of Transportation :
1. Roadways :
Can carry 8-10 tons of Coal
Low Capacity
Low unloading rate
2. Railways :
Coal is brought by railway wagons.
80-90 % of coal transportation is done by railways.
Specifications :
Total No. of Wagons 303
No. of Locomotives - 7
Carrying Capacity of each wagon 60 MT
No of wagons in each rack 58
Total coal carrying capacity of rack 3500 MT
Coal Source Mahanadi Coalfield limited & Eastern Coalfield Ltd.

Crusher Specifications :
Supplier Thyson
Capacity 1500 MT
Frame Fabricated Steel plate.
No. of Suspension bar 8
Hammers 76,19 in each row.
Type of hydraulic coupling Voith
Oil used HLP 32
RPM 573
Cooling water flow 10 m3/hr

Track Hopper Specification :

Length of the track hopper 210 m
Capacity of hoppers 6200 MT

Layout Of CHP:
Wagon Tippler

Crusher House

Hoppe
r

Feeder

Surge
Hopper

Vibrating
Screens

Conv. Belts

Crushers
Tripper Trolley
Bunkers
12

11/4/15

Flow of Coal :
I.
II.
III.
IV.
V.
VI.

Coal is brought to power station by either

of modes.
Coal is then conveyed to primary crusher
with the help of conveyer belts.
In primary crusher, coal is first crushed to
100 mm size.
Coal is again conveyed to secondary
crusher via vibrating screens.
Coal of size 25 mm is obtained after
secondary crush.
This sized coal is then sent to bunkering
belt with the help of coal trippers.

Coal feeder

Coal Bunker

Coal mill

Operational Cycles in
CHP
Bunkering Cycle

1. Stacking : In case bunkers are full, then available coal is

stored in stack yard with the help of stacking cum

reclaimer. This cycle is called Stacking Cycle.
2. Reclaiming : In Emergency when coal is not available in
plant, then this stacked coal diverted to coal bunkers by
reclaiming conveyer belts.This cycle is called reclaiming
Cycle.
3. Bunkering : The normal flow of coal in a CHP is called
Bunkering Cycle.

Coal Cycle :

Boiler Maintenance
Department :
To produce steam

boiler converts
energy in the form
of coal to steam.
The boiler is lined
with steel tubing in
which pure boiler
feed water is
turned to steam by
the heat generated
from burning the
coal in the boiler.

Boiler :
Boiler has natural circulation of gases, steam & other things.
It contains vertical membrane water.
The pulverised fuel is being used in the furnace is fixed

tangentially.
The first pass of boiler has combustion chamber enclosed
with water walls of fusion welded construction on all four
sides.
Reheater sections are also there in combustion chamber.
The first pass is high heat zone as fuel is burnt in this pass.
The second pass is surrounded with steam cooled walls on
all four sides as well as roof of the boiler.
A superheater and an economiser are there in the second
pass.

Boiler Specifications :
Coal Consumption 700 Tonne/hour
Pressure 1370 Kg/cm2
Operating Temperature 540 C
Corner Fire Water Tube boiler

Boiler Components :
Boiler Drum
II. Furnace
III. Water walls
IV. Combustion chamber
V. Scraper conveyor
VI. Economiser
VII. Superheater
VIII. Air preheater
I.

Boiler Rotary Parts :

1) PA Fans :
) Primary Air fans are used to carry pulverised coal particles from mill

to boiler.
) Used to maintain the coal air temperature
Specifications :
) Flow Axial Flow
) Stage 2 (Double Stage)
) Reaction Type
) PA Fan Model No. AP2 20/12
) Uses 0.72% of the plant load for operation.
Components :
) Primary air path through cold air duct.
) Air Pre-Heater
) Hot air duct
) Mills

Primary air cycle :

2. FD Fans :
Forced draft fans are used to provide secondary air required
for combustion.
This fan forces the atmosperic air through the boiler furnace
& pushes out the hot gases from the furnace through
superheater, reheater, economiser & air heater to stacks.
Used to maintain the windbox diffrential pressure.
Specifications :
A. Model No. AP1 26/16
B. FD fan uses 0.36 % of plant laod for the 500 MW unit.
) Components of FD fan :
A. Secondary air path
B. Air Preheater
C.
D.

Hot Air duct

Wind box

Secondary Air Cycle :

3) ID Fans :
Provided at the outlet of the boiler, just before the
chimney.
The main purpose of an ID fan is to suck the flue gas
through these equipments :
a) Flue Gas through water walls
b) Super Heater
c) Re-heater
d) Platen Super heater
e) Low temperature super heater
f) Air preheater
g) Electrostatic precipitator
) An ID fan uses 1.41 % of plant load for each 500 MW
unit.

Super Heater :
Super heater is used to remove the moisture content from

the steam.
Types :
I. Seating super heater
II. Lower temperature super heater
III. Radiant superheater
IV. Final Super heater
) Function of super heater is to convert the wet steam into
dry steam.
) Superheater raises the temperature of steam over 540 C.
) Advantages of Superheater :
1) Increases the efficiency.
2) Reduces corroision of turbine blades.

AIR PREHEATER:
It is used to preheat

the air before entering

into the furnace.
It is a heat exchanger
from which further
heat is extracted from
flue gases and used to
heat the air coming
for combustion.

ECONOMISER :
Flue gases coming out of

boiler carries lot of heat.

Economiser extracts a
part of heat from flue
gases and uses for
heating the feed water.
Thus improves efficiency
of plant.
Temperature economiser
is about 315 C.

Water Treatment
Main Impurity In Water
Suspended impurities
Dissolved impurities of calcium and magnesium salts
Dissolved gases
Free minerals acids and oils.

Effect of impurities on Boiler Components: Sludge formation

Scale formation
Corrosion
Priming
Foaming
Caustic Embrittlement

Water treatment Plant :

The objective of the water treatment plant is to produce

de-mineralized water so that there shall be :

a) No scale formation causing resistance to passage of
heat & burning of tube.
b) No corroision
c) No priming or foaming problem.
) This will ensure that the steam generated shall be clean
and the boiler will provide uninterrpted serrvice.
) This plant is designed to process water from raw water
into demineralised water.
) Water treatment process is generally into two sections :
I. Pretreatment plant
II. Dimineralisation plant

Pre-Treatment Plant:
Pre-treatment plant removes the suspended solids such as clay,

silt,organic & inorganic matter, plants and other microscopic

organisms.
The coarse components such as sand, silt etc. can be removed
from the water by simple sedimentation.
Finer particles wont settle in reasonable time, hence must be
flocculated to produce large particles, which are separable.
Coagulation & Flocculation are used for pretreatment of water.
Coagulation Coagulation means to bring together the
suspended particles. The process describes the addition of
chemicals to colloidal dispersion resulting in particle
destabisation and brings them together.
Flocculation Flocculation is the formation of settable particles
from destablised colloidal sized particles is termed as
flocculation.

Demineralisation Plant :
The water from pretreatment plant is used for de-

mineralising purpose and is fed to cation exchanger bed.

Demineralisation is done using three bed systems with the
provision of removal of gaseous carbon dioxide from water
before feeding to anion exchanger.
First step is the dechlorination, which is done by passing
through activated carbon filter.
Strong acidic cation exchanger resin and strongly basic
anion exchanger resin is employed in DM Plant.
Resins have abiliity to exchange one ion for another, hold
it temporarily in chemical combination & give it to strong
electrolytic solution.
Chemically active group in a cationic resin is SOx-H(or R-H)
and in anionic resin the is R-OH.

Exchange
Reactions

De-Mineralisation PLANT

Reference
http://www.apcpl.co.in/about-us/about-igstpp.html
https://www.google.co.in/
http://www.ntpc.co.in/
www.wikipedia.com
P.K. Nag Engineering Thermodynamics; Tata McGraw

Hill publications
Material Provided In Power Plant

K
N
A
H
T
!
U
O
Y