summer training report on Anpara thermal power station MMD-1 anpara sonbhadra.

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SUMMER TRAINING REPORT ON
MMD-I
3X210MW,ANPARA ‘A’ THERMAL POWER STATION
ANPARA,SONBHADRA(U.P) OF U.P. RAJYA VIDYUT UTPADAN
NIGAM LIMITED (UPRVUNL)
DURATION- 4Weeks(14th
June – 11th
July)
Submitted By:-
Maneeshkumar shukla
B.Tech, 4th
year
Mechanical(Production) Er. Sunil Kr. Pandey
Ambalika Institute Of Executive Engineer(MMD-I)
Management& TechnologyLucknow 3x210 MW, ATPS Anpara

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ACKNOWLEDGEMENT
I wish to extend my deepest gratitude to all the respected persons who helped me in
successefully completing the four week summer training at Anpara ‘A’ Thermal power
station , Anpara Sonbhadra (UPRVUNL)
I thank heartily and pay my regards to the management of Anpara ‘A’ Thermal
power station Anpara, Sonbhadra (UPRVUNL), particularly Mr. Sunil Kr. Pandey
(Executive Engineer MMD-I ,A.T.P.S)Who allowed me to have my training in UPRVUNL
, Anpara, Sonbhadra. And I would also like to thank Mr Algu Ram & Mr. Arun Kumar
(Junior Engineer MMD-I ,A.T.P.S)fortheir humble and able guidance and interest shown
by them in an amiable and helpful manner throughout my training period .
And last but not least , I thank all the technicians and workers throughout the plant
who helped me have a better understanding of working of machines and process.
Submitted By:-
Maneesh kumar Shukla
B.Tech 4th year ,Mechanical Engg.
A.I.M.T Lucknow

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CERTIFICATE
This is to certify that MANEESH KUMAR SHUKLA student of Mechanical Engineering
from Ambalika Institute of Engineering & Technology, Lucknow has carried out his
summer training work during “14th jun – 11th july” presented in this report entitled
“(ANPARA THERMAL POWER PROJECT ANPARA)” under The supervision of
Er.Sunil Kr. Pandey (EXECUTIVE ENGINEER M.M.D-I ATPS)and his entire team.
Submitted By:-
Maneesh kumar Shukla

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ABSTRACT
A thermal power station is a power plant in which the prime mover 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 greatest variation in the design
of thermal power stations is due to the different fuel sources. Some prefer to use the term
energy center because such facilities convert forms of heat energy into electricity. Some
thermal power plant also deliver heat energy for industrial purposes, for district heating, or
for desalination of water as well as delivering electrical power. A large part of human CO2
emissions comes from fossil fueled thermal power plants; efforts to reduce these outputs are
various and widespread.
At present 54.09% or 93918.38 MW (Data Source CEA, as on 31/03/2011) of total
electricity production in India is from Coal Based Thermal Power Station. A coal based
thermal power plant converts the chemical energy of the coal into electrical energy. This is
achieved by raising the steam in the boilers, expanding it through the turbine and coupling
the turbines to the generators which converts mechanical energy into electrical energy.

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INTRODUCTION
The site of Anpara Thermal Power Station is situated at the border of Madhya Pradesh
and Uttar Pradesh at Southern most tip of district Sonbhadra in Uttar Pradesh and on the
left bank of Rihand reservoir along the national highway No. 51 near village Anpara & 3
K.M. from the existing Renusagar Thermal Power Station.
Given below are some of the salient feature of Anpara Power Project, (2630 M.W.)
1. Station Units- ATPP, BTPP & DTPP.
2. Capacity a) Transiently installed 2630 M.W
(Including Units) (3x210M.W.ATPP,2x500M.W.-
BTPP,2x500 M.W.- DTPP)
b) Effective 2630 M.W.
3. Land details a) Plant area acres-1035.65
b) Ash dump area acres-1534.928
c) Employee township acres-453.432
d) Labour colony acres-160.000
4. Cooling water a)Source of cooling water Rihand reservoir
b)Method of cooling Open Cycle
c) Cooling water Requirement -100000(ATPS),14000(BTPS)m3/hr
5. Fuel(Coal) a)Consumption 25000 metric ton/day
b)source Khadiya Mines and kakadi Mines

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THERMAL POWER STATION
In a power plant , the heat released by the combustion of coal produces steam in a
boiler at high pressure & temperature which when passes through steam turbine, gives
internal energy as mechanical energy. The steam turbine acts as a prime mover & drives
the electric generator (alternator).
Electricity is indispensable for the development of a vast developing country like
India. Anpara Thermal Power Project in this respect plays always a crucial role in power
generation.
In India, as of now about 65% electrical power is used is generated in Thermal
Plants. The remaining 35% comes from hydro stations. Coal is the fuel for most of the
steam plants the rest depends on Oil/ Natural gases & Nuclear fuels.
The generation capacity of A.T.P.S is 2630MW (3x210, 2x500 & 2x500). The whole
power station is divided into three subparts:-
1. ATPP (3x210)MW
2. BTPP (2x500)MW
3. DTPP (2x500)MW
The electrical equipments used in ATPP & DTPP is almost of BHEL while BTPP is
established by help of Japan .
The power is transmitted to the distant areas form 400KV bus bars for economic
considerations & for supplying power to the station & to connect the station from other
power stations operating in the region, a 132KV bus bars systemis also in the switchyard &
maintenance division of ATPP is equipped with advanced technical equipments & expert
manpower in technical fields so as to handle any emergency situation arising in the plant &
keep the supply reliably & safely.

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COAL HANDLING AND COMBUSTION
We take coal from northern coal field (NCL)through our MGR system (Railway) to
track hopper and transport it through conveyor belt to crusher house and crush it up to 25
mm in size.
Again transport it through conveyor belt to bowl mills. Excess coal is stacked in the
coal stockyard through conveyor belt pulverized coal is transported through pipes to boilers
burner to burn it in close area. Ash dust from boiler is collected in Electrostatic precipitator
(ESP) up to 98% to 99% to minimize the air pollution is & collected ash is transported to
ash dyke in the form of ash slurry through pipes.
We take de-mineralized water from D.M water plant to the boiler tubes to make it
super heated steam at 535degree C and 135atm. Pressure to run the system turbines which
function as prime movers from turbo generators. Electricity is exported to different part of
our country through 400KV transmission line.
There is no intermediate productand byproductin the process exceptwaste
product(burntcoal ash) which is not so harmful . even though we try to arrest ash dustby
different method ESP, dust extraction system and tallest chimney e tc.

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PRODUCTION OF SYSTEM
Coal from the coal wagons is unloaded in the coal handling plants track hopper. This
coal is transported up to the raw bunkers with the help of belt conveyor. Coal is transported
to the bowl mills by coal feeders. The coal is pulverized in the bowl mill, where it is
grinded to powder form. The mill consist of a round metallic table on which coal particles
falls . This table is rotated with the help of electric motor there are three large grinding
rollers which are spaced 1200 apart when there is no coal these forces to roller to rotate.
When the coal is fed to the table it packs up between rollers and tables and these forces to
rollers to rotate.
Coal is crushed by the crushing action between the rollers and the rotating table .
This crushed coal is taken away to the furnace through coal pipes with the help of hot and
cold air mixture from PA fan takes atmosphere air, apart of which is send to the air
preheaters for heating , while a part goes directly to the mills for temperature control.
Atmospheric air from FD fan is heated in the air heater and sent to the furnaces secondary
air for coal combustion in the boiler.
Water from the boiler feed pump passes through HP heaters, feed regulatory station,
economizer etc water through the drum passes through down corners and goes to the bottom
ring header. Water from the bottom ring header is divided to all the four sides of the
furnaces due to heat and density difference , the rises up on the water wall tubes . water is
partly converted to steam and water mixture is again taken to the boiler drum where steam
is separated from water . Water follows the same path while steam is sent to super heaters
for super heating. The super heaters are located inside the furnace and the steam is super
heated to 540 degree C and finally goes to turbine through CVS and cover control and
emergency stop valves.
Flue gases from the furnace are extracted by induced draft fan, which maintain
balance draft in the furnace with forced draft fan. Theses flue gases emit their heat energy to
various super heaters, LTSH, Economizer tubes, etc finally passes through air preheaters
and goes to ESP where ash particles are extracted. ESP consists of, metal plates, which are
electrically charged. Ash particles attract on these electrodes and coils so that they do not
pass through the chimney to pollute the atmosphere. Regular mechanical hammers blow
cause the falling of the accumulated ash to the bottom of the precipitator where they are
collected in a hopper for disposal. This ash mixed with water to form slurry and is pumped
to ash pond.

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POWER OF STEAM
In the boiler the steam pipe conveys steam to the turbine through stop valves and
through control valves that automatically regulate the supply of steam to the turbine. Stop
valves and control valves are located in the steam chest and governor driven from the main
turbine shaft operate the control valve to regulate the amount of steam used. This depends
upon speed of the turbine and the amount of the electricity required from the generator.
Steam from the control valves enters the high pressure cylinder of the turbine where
it passes through a ring of stationary blades fixed to the cylinder walls . This actc as nozzles
and direct steam into a second ring of moving blades mounted on disk secured to the
turbines shaft. This second ring turns the shaft as a result of the force of steam . The steam
passes through each stages until it reaches the end of the high pressure cylinder and in its
passage some of its heat energy is change into the mechanical energy.
The steam leaving the high pressure cylinder goes back to the boiler for reheating and
return by a further pipe to the IP 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 outward in opposite direction through the row of blade and arrangement
is known as double flow of the 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 such large towards the low pressure end of
the turbines. The turbine shaft usually rotates at 3000rpm . This speed is determined by
frequency of the electrical system used in the country and is the aped at which 2-pole
generator must be driven to generate as alternating current at a frequency of 50 cycle per
second. When as much energy as possible has been extracted from the steam it is exhausted
directly to the condenser. The condenser consist of a large containing some 20000tubes,
each about 25mm in diameter. Cold water is circulated then steam , a vacuum created in
condenser. This allows the steam to reduce down the 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 by boiler feed pumps. It is passed through further
fed heaters to the economizer and to the recon version into the steam. A power station
generating 1630KW electricity requires about 28000cibic meter of water an hour in open
loop.

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GENERATOR SYSTEM
As the turbine moves the generator also moves and the magnetic lines of force is
cutted by coil and hence electricity is produced in the coil. We have to supply exciter
magnetic field for the magnetic field previously . Generally in small generators they have
their own exciter and any other exciter will not be attached but in large generator an exciter
unit is compulsory.
Small generators are cooled by air, but bigger are cooled by hydrazine . In big
generators the stator coil is also cooled by water . When turbine moves in its rated speed the
generators rotor also moves that speed so there is a flux generated in the stator which is
produces the electricity in K.W.
TRANSFORMER SYSTEM
To increase or decrease voltage we use step up or step down transformer . There are
two types of transformer used in the thermal project.
1. Main Transformer
2. Auxiliary Transformer
The main transformer takes the generator voltage from 16KV a generator. After then
it convert to 220 or 440 volts are required.
The auxiliary transformer takes sourcepart of the generated electricity to work out
the pumps fan , mills and motors. Some part of this is directly consumed by other auxiliary .
There are many other small systems related to these systems, which are responsible
for managing and controlling these systems and also to increase the efficiency of the
thermal project. We have to do many other extra function. Such as by pass of steam
reaching to the turbine this makes to increase efficiency.

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MMD-1
MMD is the short form of Mechanical Maintenance Department . The main function of this
department are to provide the circulating water (CW water) for the purposeof open system
cooling and to provide clean and pressurized air for the control system operating in the plant
and cleaning purpose. Forthe CW water , CW Pumps are used and for the compressed air ,
instrument air and plant compressors are used.
COMPRESSOR:- The pressurized air sent into the plant is of two types, plant air amd
instrument air . Instrument air is used to run the various pneumatic measuring instrument
and control system . Due to the high need of precession and small size of the instrument ,
the instrument air should be at high pressure and should be very clean . For this purpose ,
Instrument air compressors are employed.
The compressor is of reciprocating type and is run by a motor. It contains two
cylinder, L.P. cylinder i.e. the low pressure cylinder and H.P. cylinder I.e. the high pressure
cylinder. The air is taken from atmosphere and taken in the L.P cylinder through suction
valve. Here its pressure rises to 2kg/cmsq. Through discharge valve , it is sent in the cooler
tank. From the cooler tank, its passes through a copper tube heat exchanger which cools it
since the temperature of air increases. Now the air moves to the H.P. cylinder where its
pressure is further increased to 8kg/cmsq. The air is again passed through a intercooler
which cools it down again. The air is sent to receiver which is sort of a storage. From the
receiver , it is sent to the drier and filter. First it is passed through the air filter and then to
the air drier. This air contains Encona valve which is a chemical which absorbs all the
moisture in it. From here , the air is sent to aftercooler and then to another receiver. From
this receiver , it is sent to the plant. The plant air compressor Is similar to the instrument air
compressor. Only the air is not filtered in it.

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WATER MANAGEMENT AND DISTRIBUTION
(C.W. Pump and Auxiliary Pump)
The main function of the C.W pump is to draw water from the reservoir and to
provided it to the plant for the steam of turbine in the condenser. The water supply is taken
from the Rihand Dam. Water reaches the pump through a channel approximately 3.5km
long and 100m wide. At the intake, water is first filtered for microscopic impurities. The
water channel converges to 50 meters at the intake. At the intake, there are four travelling
water screens. These screens have chain sieves of grate size 10mm. The chain sieves are
arranged in a vertical loop of which the lower part remains submerged in the water. The
water going into each Sieve is bifurcated using a separation valve. Thus, the water enters
the sieve through both side of the loop. The sieves rotate in clockwise manner. There are
brackets provided in the sieves which collect the impurities and bring them above the water
level. Now a jet of water is applied to force the impurities out on the ground level.
At the CW pond, there are nine vertical centrifugal pumps which pick up water from
the pond and feed into a pressure duct. The three condensers of the ATPP takes water from
this duct. Which after cooling, is discharged again in the dam. From the pressure duct, water
is also sent to the Auxiliary pond. From this pond, the water is picked up using 10 pumps
and sent to various parts of the plant for various purposes. Thepumps and the purposes they
serve are listed below:-
1. CRW:- Clarified Raw water pump. These are 3 in number. These are used to send
clarifies raw water. From these pumps, the CW water is sent to Pre-treatment
plant. From there, the water is sent through 5 clarifies pumps to the plant where it
is used for bearing cooling.
2. PRW:- Potable Raw water pump. These pumps are three in number and send
water to filtration plant where it is filtered for drinking purposes.
3. SRW:- Service Raw water. These pumps are two in number. These send water to
the plant for cleaning and sanitation purposes.
4. PTRW:- Pretreatment plant-II. These send the CW water to pre-treatment plant-Ii
from where the clarified water is sent to the DM plant. The water is demineralised
in the DM plant.

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THE SPECIFICATIONS OF THE EQUIPMENTS IS GIVEN BELOW.
1) Travelling Water Screen:
1. Type Dual flow , 4 post
2. No. of units. 4
3. Basket width 4meters
4. Wt. of screen inclusive of guideways - 40tons
5. Rated capacity 70000cubic meter/hour
6. Shaft capacity 23774.4meter
7. Wall depth 24meter
8. Wire mesh 12swg. 10mm sq. opening
9. No. of nozzles 27
10.Haulage chain pitch 609.6mm
11.No of baskets 88
12.Drive motor details 5/7.5 HP Dual speed spiral
cage/induction motors.
13.Velocity of screen 1.5 to 3.0 mm/min
14.Control Electrical control system
15.Speed reducer Elecon make worm type.
2) Circulating water pumps:
1. O/A No. and date 06/2/107/-8177.ANP,DT 28.3.81
2. Delivery size flange BHQ-95M, single stage external clear
water lubricated pump
3. Drn. Of rotation clockwise viewed from top
4. Net weight A. Pump unit-41000kg,
B. Motor Unit-20800kg
5. Application Condenser circulating water pump.
6.Speed 493 Rpm
7.Working head Shut off head 12.5 meter, 54 meter

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8.Bowl head 24.694meter
9.MIinimum submerged required 4.0 meter
10.Impeller Inclosed mixed flow 1245mm OD.
11.Motor HP and make 2115.5 HP(1825KW)
209.5 AMP BHEL

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AUXILIARY PUMPS:-
Sr.
No
Pump
Specification
CRW PRW SRW PTRW
1. Stage 1 2 5 2
2. Capacity,mcu/hr 4000 1400 400 400
3. Total Bowl Head 28.52 55.5 80.73 32.37
4. Speed 985 1489 1485 1480
5. Shaft Size 43/16’’ 31/16’’ 3/2’’ 19/16’’
6. Column size 30 20 10 10
7. Driver VSS motor
430kw,6.6kv
VSS
motor,300kw,
6.6kv
VSSmotor
130kw,0.4kv
VSSmotor
55kw/0.4kv
GENERAL DESCRIPTION OF THE SALIENT COMPONENTS OF A
POWER PLANT
1.BOILER:- In boiler , steam is saturated at high temperature& pressure by transfer of heat
to water, produced due to combustion of fuel i.e. coal takes place in the boiler a no. of water
pipes links are present. Water from the drum goes to those pipes which are surrounding the
furnace, hence water takes heat from the wall of furnace & the steam rise upward in the
pipe ultimately goes to the upper portion of the drum. Here from 500MW steam should
have temperature 540 ˚C. By passing through the super heaters.
THE SALIENT FEATURES :-
Made By Mitsubishi Heavy Industries
Type Radiant Reheat& controlled circulation boiler
Design Pressure 205kg/cm²
MCR 1720T/hr
Super Heater 170 kg/cm²
Re-Heater 51 kg/cm²
Steam Temperature 543˚C (At Super Heater Outlet)

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Feed Water Temperature 257˚C
Relative Humidity 70%
Firing System 100% Coal firing & 20% fuel oil firing for warm up
establishing & ignition for bed startup & establishing in low load ,
fuel oil is utilized.
2. TURBINE:- Turbine is a mechanical device which converts heat energy into rotational
energy. This rotational energy is then used to rotate the prime mover of generator/alternator,
which in turn produces electrical energy. The description of turbine used in Anpara is given
.
Description ATPS
Types Tandem Compound
No. of units 3 cylinder
Make 3x210 MW
No. of storage/cylinder
HP
IP
LP
Single flow with 25 reaction stages
Double flow with 20 reaction stages
Double flow with 8 reaction stages
Exhaust pressure 0.1187kg/cmsq
Exhaust pump 49 C
Type of governing HP Throttle
Details of governing fluid Servo prime 4.6(IOC)
No. of Heater Ejectors provided
HP
LP
02
02
Turbine Efficiency 40%

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3. GENERATOR:-A Generator is a device which converts mechanical energy into
electrical energy by the means of relative motion between insulated coils and electrical
fields. The general description of the generators used in Anpara Power Project Is given
below.
Description ATPS
No of unit 3
Make BHEL
Type THW- 210-2
Rated capacity
 KW
 KVA
210MW
210000
214700
Power Factor 0.85lag
Frequency 50HZ
Stator
 Voltage
 Amp.
15.75
9051
Rotor
 Max. voltage
 Current
 Sc ratio
310
2600
0.49
Excitation system Static
Cooling Hydrogen

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