details about the real thermal plant and its working.here is the knowledge that i gained through my internship in Aditya aluminium governed by Hindalco industries pvt.ltd.

1. SUBMITTED BY-DILIP KUMAR
SILICON INSTITUTE OF
TECHNOLOGY,SAMBALPUR
BRANCH – MECHANICAL ENGINEERING
GUIDED BY- MR. THABIRA SETH

3. Hindalco Industries Ltd., an aluminium and copper
manufacturing company, is a subsidiary of the Aditya Birla
Group.Its headquarters are at Mumbai, Maharashtra, India. It
is the Flagship company of the company in the metals
business.
The company has annual sales of US$ 15 billion and employs
around 20,000 people.It is listed in the Forbes Global 2000
at 895th rank.Its market capitalisation by the end of May
2013 was US$ 3.4 billion.Hindalco is one of the world's
largest aluminium rolling companies and one of the biggest
producers of primary aluminium in Asia.
Aditya Captive Power Plant. A 900 MW captive power plant located
at Lapanga, Sambalpur District Odisha. This plant supplies power to
Aditya smelter of Hindalco Industries

4. A thermal power plant is a power station in which heat energy is converted to
electric power. In most of the places in the world the turbine is steam-driven.
Water is heated, turns into steam and spins a steam turbine which drives an
electrical generator. After it passes through the turbine, the steam is condensed
in a condenser and recycled to where it was heated; this is known as a Rankine
cycle.
The Rankine cycle or Rankine Vapour Cycle is the process widely used by power
plants such as coal-fired power plants or nuclear reactors. In this mechanism, a
fuel is used to produce heat within a boiler, converting water into steam which
then expands through a turbine producing useful work.

7. CONDENSOR
HOTWELL
CEP
CONDENSATE EXTRACTIO PUMP
EJECTOR
GSC
GLAND STEAM
CONDENSOR
DRAIN
COOLER
LPH 1 LPH 2
DE-
AERATOR
BOOSTER
PUMP BFP HPH 5
HPH 6 FCS ECOMOMI
SER BOILER
SUPERHEAT
ER
HP TURBINE
IP
TURBINE
REHEATE
R
LP TURBINE CONDENSOR

8.  All the above equipment's are installed In order to increase the efficiency.
 If we directly supply water at normal temperature it will take more fuel to
convert into steam ,so we pass it through various heat exchanger to increase its
efficiency.
 Economizers play an important role to increase the temperature of water upto
250 degree Celsius by using the steam produced earlier.
 This power plant has 9 units and each units produces 150mw electricity. So
total capacity is 900mw
 Net demand for smelter and to run motors ,compressor , lightning and various
equipment is 750 mw
 One unit always remains in standby to handle the situation when other eunit
faces any problem.
 Turbine efficiency is 90%
 Boiler efficiency is 85%
 Turbine is rotated at rpm of 3000 to generate electricity of 50hz

11.  A pulverized coal-fired boiler is an industrial or utility boiler that
generates thermal energy by burning pulverized coal (also known
as powdered coal or coal dust since it is as fine as face powder in
cosmetic makeup) that is blown into the firebox.
 Here water tube boiler is used to generate steam.
 A water tube boiler is such kind of boiler where the water is
heated inside tubes and the hot gasses surround them. This is the
basic definition of water tube boiler. Actually this boiler is just
opposite of fire tube boiler where hot gasses are passed through
tubes which are surrounded by water

12.  It has shell tube arrangement. water passes inside the tube
and flue gas remains outside the tube to generate steam.
 Steam and water gets accumulated inside the drum and
steam from the drum is supplied to superheated to get dry
superheated steam than this steam is supplied to the
turbine
 Excess water in drum is supplied back to the bottom ring
header by down comer

13.  PA FAN-Primary Air Fans are used to lift the pulverized coal
from mill to boiler in a power plant.Further, the air from PA Fan
is preheated using air preheaters so that the fluidity of coal flow
can be maintained in coal pipes and also preheat the coal to a
certain temperature.They also provide suction for seal air fans
used
 FD FAN- forced draft, A fan is used to force air into the boiler to
provide more air for combustion. This is called FD fan.
 ID FAN -Induced Draft:- A fan is used to extract the air from
boiler post combustion via (Electrostatic Precipitator if present)
to exhaust through the chimney. This is called ID fan

14. BOILER
CORNER 1
CORNER2
CORNER3
CORNER 4
 A boiler has four corner
 Coal is supplied to the boiler at the four corner by the help of pa fan and oil is
also supplied by the oil gun which is necessary for combustion. When the
combustion starts the supply of oil is stopped
 We can tilt the burner position to vary the temperature according to our need
 Flame scanner is used to see the fire ball
 Scanner air fan is used to cool the scanner
 HFO ( heavy fuel station) and LDO ( low density oil station ) is made to supply
coal and oil respectively.
 Different valves are used to control the supply of oil and water like motorized
valve, glove valve, NRV valve, pneumatic valve

15.  APH-An air preheater (APH) is any device designed to heat air before
another process (for example, combustion in a boiler) with the
primary objective of increasing the thermal efficiency of the process.
They may be used alone or to replace a recuperative heat system or
to replace a steam coil.
 Economizers are mechanical devices intended to reduce energy
consumption, or to perform useful function such as preheating a
fluid. The term economizer is used for other purposes as well.
Boiler, power plant, heating, Refrigeration, ventilating, and air
conditioning (HVAC) uses are discussed in this article. In simple
terms, an economizer is a heat exchanger

16.  LRSB – long retractable soot blower is used to remove dust on
the coils of the boiler
 WB (wall blower)- wall blower is used to remove dust from the
walls
 Dust are removed by the help of high pressurized steam
 Soot blower pumping station is made in order to supply the
steam to remove the dust from the coils and walls of blower.
 ERV – ERV is a safety valve which opens automatically when the
safety valve fails to open
 MSSV –main stream stop valve is used to stop the supply of
water.

17.  Boiler produces 510 TPH superheated steam
 Main steam temperature is 540 degree celcius.
 Main steam pressure is 141bar
 Boiler efficiency is 85%
 0.76kg/kwh consumption
 0.132ltrs/kwh water consumption
 33 TPH coal is burnt in single unit.

18. DEFINATION-The initial process in coal based thermal power
plant is coal handling.The Function of coal Handling Plant in
thermal power plant is to receive , process, store, feed the coal
bunkers consistently over entire life of the power plant. Coal is
transported in thermal power station either by
railways,roadways or rope ways.

20.  First of all coal comes in coal yard by railways wagon
 Then coal is put into crusher to reduce its size upto 25 mm.
 Then its transported toward the bowl mill by help of conveyor belt.
 The coal is put into coal header
 Then is put into the bunker to store it.
 Then it is put into the feeder conveyor to measure the amount needed.
 Then it is put into the bowl mill.
 The bowl mill is the shape of bowl. It consist of four roller which is
made up of cast iron and it is covered with ceramic plates so that it
will protect the parent material and it can easily be replaced if wear
and tear happen.
 Mill is driven by gear box and gear box is driven by the motor.
 Primary air comes from the air preheater , passes through the guide
veins of the bowl mill to increase the velocity of air .
 Primary air carries the powdered coal to the upper compartment after
passing it by another guide vein due to which powdered coal forms a
cyclone and the fine particles is transported to the boiler by the four
pipes in the four corner of boiler, and the heavy particle settle down
due to centifugal action and it supplied back to the mill for further
grinding

21.  The bowl mill grinds the coal into size of 75 micron.
 The coal is transported to the boiler by help of primary air
after passing it by air preheater so to remove the moisture
content and to increase the temperature of coal for better
combustion.
Internal view of bowl mill.

22. BREAK DOWN PREVENTIVE PREDICTION
CLIT
(CLEAN,LUBRICATE,INSPECT
, TIGHT)
CONDITION BASED
MAINTAINANCE
PROACTIVE

23. Definition
Condition-based maintenance (CBM) is a maintenance strategy that
monitors the actual condition of an asset to decide what maintenance needs
to be done. CBM dictates that maintenance should only be performed when
certain indicators show signs of decreasing performance or upcoming
failure. Checking a machine for these indicators may include non-invasive
measurements, visual inspection, performance data and scheduled tests.
Condition data can then be gathered at certain intervals, or continuously (as
is done when a machine has internal sensors). Condition-based
maintenance can be applied to mission critical and non-mission critical
assets.
The goal of condition based maintenance is to monitor and spot
upcoming equipment failure so maintenance can be proactively
scheduled when it is needed – and not before. Asset conditions need to
trigger maintenance within a long enough time period before failure, so
work can be finished before the asset fails or performance falls below
the optimal level.

24.  The main role of CBM reduce the MTBF.
 Reduces the cost of asset failures
 Improves equipment reliability.
 Minimizes unscheduled downtime due to catastrophic failure
 Minimizes time spent on maintenance
 Minimizes overtime costs by scheduling the activities
 Minimizes requirement for emergency spare parts
 Optimizes maintenance intervals (more optimal than
manufacturer recommendations)
 Improves worker safety
 Reduces the chances of collateral damage to the system

25.  VIBRATION ANALYSIS
 OIL ANALYSIS
 ELECTRIC CURRENT SINGNATURE ANALYSIS
 SPECTRUM ANALYSIS
 ULTRASONIC
 OPERATIONAL PERFORMANCE
 PLANT EFFICIENCY TEST

26. In its simplest form, vibration can be considered to be the oscillation or
repetitive motion of an object around an equilibrium position. ... This type
of vibration is called "whole body motion", meaning that all parts of the
body are moving together in the same direction at any point in time.
There are three entity of vibration
 Velocity
 Acceleration
 Displacement
EFFECT OF VIBRATION ON MACHINES
Unchecked machine vibration can accelerate rates of wear (i.e. reduce
bearing life) and damage equipment. Vibrating machinery can create
noise, cause safety problems and lead to degradation in plant working
conditions.

27.  MIS-ALLIGNMENT
 LOOSENUTS
 SHORT FOOT
 BEARING FAULT
 ECCENTRICITY
 IMPELLAR ISSUE

28. Generally we used two equipment
1.VIB 15
2.EMERSON ASI -2140
 We follow ISO 10816 for vibration analysis
 This depend of motor rating and base ( flexible & rigid)
 The health of bearing is divided into three categories
1.normal 2.marginal 3.critical
 We take measurements in three direction of driving end and non
driving end
1. horizontal 2.vertical 3.axial
 We take the reading of
1. velocity in (mm/s)
2.acceleration in (g)
3.dispacement in (µ)
 After taking the measurement we analyze the cause of vibration and
we take necessary action.

30.  Similarly in spectrum analysis we take the reading in similar ways
 The data get stored in the device
 We analyze the data with the help of software
 Waves with different amplitude originates
 By analyzing these waves we get the problem and then we go for
resolving it

31. Oil analysis is a routine activity for analyzing oil health, oil contamination
and machine wear. The purpose of an oil analysis program is to verify that
a lubricated machine is operating according to expectations.
1.CONTAMINATION ANALYSIS – it is done to know the weight of metal
impurities. It’s unit is NAS . It follows NATIONAL AEROSPACE
STANDARD ( ISO 1638) AND INTERNATIONAL STANDARD
ORGANISATION (ISO 4406)
2.MOISTURE ANALYSIS- moisture analysis is very necessary to detect
the amount of water content in oil .its harmful for machinery because
it can oxidize the metal parts .it’s unit of measurement is (ppm).
3.Viscosity analysis – viscosity is very necessary for proper
lubrication.
It’s unit is (centi stoke (mm2/s))
4.WDA (wear debris analysis)- it is used to know about the quantity of
mettalic part or ferrous material in oil.

32.  To measure moisture HYDROGAUGE is used . It can measure moisture
up to 550(ppm)
 In this two reagent ,reagent A and reagent B is taken with 5 ml of oil in
a container and it is shaken . Due to the reaction pressure generate .a
sensor is calibrated to measure the pressure and it show the moisture
according to the pressure.
 Since reagents are costlier so we go fist with crackle test in this we
take small amount of oil 2 – 5 drops in a hot spoon like vessel ,if
crackling sound will occur then we can say that moisture is present
otherwise not.
 PAMAS particle counter is used to measure contamination in oil. It
can measure contamination of size between (2µm -100µm).
 Above 100µm patch test kit is used, here contamination is
measured by the help of filter paper of size 0.8µm(below liquid of
viscosity of 150 cs) and 5 µm above 150cs.

33.  Viscosity is measured by the help of viscosity gauge . It can measure
the viscosity up to 500 cs
 Viscosity gauge has two chamber both chamber have metallic ball
.in one chamber master fluid is filled and in other chamber we fill
the fluid whose viscosity is to be checked
 Now we tilt the gauge at an angle of 30 degree .both the ball wants
to come downward .we will mark the position of other ball when the
first ball reached the downward side .this will give the viscosity of
the fluid.

34. Ultrasonic non-destructive testing, also known as ultrasonic NDT or simply
UT, is a method of characterizing the thickness or internal structure of a
test piece through the use of high frequency sound waves.
It ranges above 20khz.
Ultra sound used for following purpose
 Bearing analysis (30khz)
 Valve leakage test (25khz)
 Electrical fault (40 kHz)
A bearing is a machine element that constrains relative motion to only
the desired motion, and reduces friction between moving parts.

35. Generally two types of sensor used in ultrasound
1.Contact burn 2. air burn
 Magnetic sensor and stethoscope sensor are contact bon sensor used
to check bearing condition.
 Trinsonic sensor and Long range module sensor (LRM) air bon sensor
used to check any leakage
 First of all we apply the sensor nearer to the bearing then we
hear the sound with the help of headphone.
 If discontinuous and noisy sound will come then there is
something wrong with the bearing .it may need lubrication or the
the bearing may be damaged.
 If smooth and continuous sound will come then the bearing is ok.

37. Ash handling refers to the method of collection, conveying, interim
storage and load out of various types of ash residue left over from solid
fuel combustion processes.
Ash should be disposed off properly ,so that it will not
affect our environment. Disposal of ash is a big challenge
for thermal power plants.
1.BOTTUM ASH HANDLING
2.FLY ASH HANDLING

38. he MAC® (Magaldi Ash Cooler) is a unique system for dry extraction, air
cooling and mechanical handling of bottom ash from pulverized coal-
fired boilers.

39. FURNACE
BOTTOM
DOOR
MAC
CONVEYOR +
CHAIN
PRE CRUSHERPRIMARY
CRUSHER
POST COOLER +
O CHAIN
HAMMER MILL/
INTERMEDIATE BOTTOM
SILO
2ND STAGE SILO
MAIN SILO
(3000M^3)

40.  First of all bottom ash goes in to the bottom door of furnace
 There are 12 bottom door, from the bottom door thev ash
goes into the MAC CONVEYER + CHAIN.
 with the help of conveyer it goes into the pre crusher ,here the
large sized lumps of ash is converted into small lumps.
 Primary crusher crushes the large sized lumps of ash which get
missed from pre crusher
 Then it is transported to post cooler and o chain to cool down
the temperature of ash.
 Then it goes in hammer mill which runs continuously to
convert the ash in very fine particle
 Then it goes in air lock tanks .it is shifted from air lock tanks
to second stage silo by the help of compressor pressure inside
the pipes ,same process happens in second stage silo and then
it goes into the main silo.
 From here ash is transported to various cement industries and
bricks industries by the help of trucks
 The excess ash is transported to the ash pond in the form of
slurry through the pipe.

41. 1.BELT CUTTING 2. GREASING OF ROLLER 3. ROLLER REPLACEMENT

42. Around 80% of ash generated in power plant is fly ash . It is in the very
fine particle .it is collected through ESP.
ESP ( ELECTROSTATIC PRECIPITATOR)
The electrostatic precipitator (ESP) is used in the thermal power plant for
removal of fly ash from the flue gas because of the environmental laws. ...
The electric charge on the electrode creates a corona field which imparts a
negative charge to the particulate.

44. ESP HOPPER
BUFFER HOPPER
SILO

45.  Ash gets collected in ESP hopper by the help of rapping and
hammering mechanism. There are 28 esp hopper in a unit.
 415 V AND 54.5A CURENT is supplied to ESP.
 870m3 /hr. fly ash gets collected in esp hopper..
 Ash get delivered into the the buffer hopper through vacuum
pump.
 The ash goes into the air lock tanks .
 From air lock tanks ,the ash goes to the fly ash silo by the help of
compressor pressure in the pipe.
 The running pressure of compressor is 0.8 bar and max pressure
is 2 bar.
 There are 3 fly ash silo of capacity 2550 m3

47. Specification of bottom ash compressor
6.6 KV ,400KW
Capacity -6400m3/hr.
Pressure 2 bar
Specification of fly ash compressor
6.5KV ,425 KW
Capacity 700m3/hr.
Pressure – 2bar
Specification of instrumentation compressor
415KV, 160KW
Capacity 1140m3/hr.
Pressure 8 bar
This compressor is used for instrumentation purpose , ex for opening
and closing of valves
Air receiver tank
Capacity 5m3 , pressure 2kg/cm2

48.  TURBINE – GIUDED BY MR. SATYAJEET JENA
 BOILER – GUIDED BY MR. TEJRAJ
 COAL HANDLING – GUIDED BY MR. BISWAJIT
 CBM – MR. SUDHANSU
 ASH HANDLING – GUIDED BY MR. SUSANTA AND MR. DINESH