Shreya sankrityayan completed a summer training project at the Koderma Thermal Power Station. The report provides an overview of the thermal power generation process, describing the key components of a thermal power plant including the coal handling plant, water treatment plant, boiler system, ash handling plant, electrostatic precipitator, steam turbine, steam condensing system, generator, transformer, and switchyard. It also discusses control and instrumentation systems and concludes with lessons learned from the training experience.

1. 1
AN SUMMER TRAINING PROJECT REPORT
AT
KODERMA THERMAL POWER STATION
Submitted by
Shreya sankrityayan
JV-B/10/1687
in partial fulfillment of the requirement for the award of the degree of
BACHELORS IN ENGINEERING
IN
ELECTRONICS AND COMMUNICATION
Under
Professional Development Activity
Of
Directorate of Career Research and Relations
JAYOTI VIDYAPEETH WOMEN’S UNIVERSITY, JAIPUR

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ACKNOWLEDGEMENT
It was a great experience to perform the summer training at DVC KODERMA (KTPS). We
gathered knowledge and enhanced our understanding in the subject of Industrial Instrumentation
during this training.
We feel grateful to have the pleasure of conveying our heartiest thanks and gratitude to thank
to Mr. R.K. DUTTA [D.C.E (C&I)] & Mr. SHYAMSUNDAR CHAND [E.E.(C&I )] without
whom it would not have been possible to meet the goal. His enthusiasm and inspiration helped us to
make this summer training successful.
At this point of time, we would also like to thanks all the other staff members of DVC
KODERMA (KTPS) for their active cooperation throughout the course.
I also extend my sincere gratitude to Mr KAUSHIK CHAKRABORTY (HOD) who
provided her/his valuable suggestions and precious time in accomplishing the summer training
report.
Last but not the least our sincere thanks to Mr. Jitendra Jha, (TRANSLATOR-official language
department) for his reference and initial support for registration in training schedule.
And lastly we would also like to convey our thanks to our parents and friends for their sincere
support throughout the training.
Shreya sankrityayan
Jv-b/10/1687
Date -
Place-

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CERTIFICATE OF ORIGINALITY
This is to certify that Miss Shreya sankritayayan, Student of B.Tech 4rth year
(Electronics and Communication), JV-B/10/1687, JVWU Jaipur, attended the summer training
program at KODERMA THERMAL POWER STATION (DAMODAR VALLEY
CORPORATION an autonomous body under central goverment)- sponsored by JAYOTI
VIDYAPEETH WOMENS UNIVERSITY, JAIPUR from june 15th to july ……….. 2015. This
hands-on training program provided a detailed introduction of the content authoring for industrial
instrumentation course associated with thermal power production and distribution.
Date: / 07/2015.
Mr. R.K. Dutta Mr. SHYAMSUNDAR CHAND

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D.C.E (C&I) E.E. (C&I)
DECLARATION
I Shreya sankrityayan, student of B.Tech (ECE) 4rth year studying in 10th
trimester, hereby
declare that the Summer Training report submitted to Jayoti Vidyapeeth Women’s University,
Jaipur, in partial fulfillment of degree of BACHELORS IN ENGINEERING IN
ELECTRONICS AND COMMUNICATION the original work conducted by me, at
KODERMA THEMAL POWER STATION.
The information and data given in the report is authentic to the best of my knowledge.
This summer training report is not being submitted to any other place for award of any other
degree, diploma and fellowship.
Shreya sankrityayan
Date:
Place:

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TABLE OF CONTENT
INDEX
S.NO. NAME OF TOPICS PAGE NUMBER
1. Introduction 6
2. Overview of thermal power plant 9
3. Operation of power plant 11
4. Basic steps of electricity generation 14
5. Coal handling plant 17
6. Water treatment plant 21
7. Boiler system plant 23
8. Ash handling plant 27
9. Electrostatic precipitator 28
10. Boiler auxillaries 29
11. Steam turbine 31
12. Steam condensing system 33
13. Generator 38
14. Transformer 39
15. Switch yard 41
16. Control and instrumentation 42
17. Conclusion 45
18. Suggestion 46
19. Refrences 47

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1. INTRODUCTION
The electric power industry provides the production and delivery of electric energy, often known as
power, or electricity, in sufficient quantities to areas that need electricity through a grid connection. The
grid distributes electrical energy to customers. Electric power is generated by central power stations.
.
Although electricity had been known to be produced as a result of the chemical reactions that take place
in an electrolytic cell since Alessandro Volta developed the voltaic pile in 1800, its production by this
means was, and still is, expensive. In 1831, Faraday devised a machine that generated electricity from
rotary motion, but it took almost 50 years for the technology to reach a commercially viable stage. In
1878, in the US, Thomas Edison developed and sold a commercially viable replacement for gas lighting
and heating using locally generated and distributed direct current electricity.
Additionally, Robert Hammond, in December 1881, demonstrated the new electric light in the Sussex
town of Brighton in the UK for a trial period. In early 1882, Edison opened the world’s first steam-
powered electricity generating station at Holborn Viaduct in London, where he had entered into an
agreement with the City Corporation for a period of three months to provide street lighting. In time he
had supplied a number of local consumers with electric light. The method of supply was direct current
(DC).
It was later on in the year in September 1882 that Edison opened the Pearl Street Power Station in New
York City and again it was a DC supply. It was for this reason that the generation was close to or on the
consumer's premises as Edison had no means of voltage conversion. The voltage chosen for any
electrical system is a compromise. Increasing the voltage reduces the current and therefore reduces the
required wire thickness. Unfortunately it also increases the danger from direct contact and increases the
required insulation thickness. Furthermore some load types were difficult or impossible to make work
with higher voltages. The overall effect was that Edison's system required power stations to be within a
mile of the consumers. While this could work in city centres, it would be unable to economically supply
suburbs with power.
The mid to late 1880's saw the introduction of alternating current (AC) systems in Europe and the U.S.
AC power had an advantage in that transformers, installed at power stations, could be used to raise the
voltage from the generators, and transformers at local substations could reduce voltage to supply loads.
Increasing the voltage reduced the current in the transmission and distribution lines and hence the size of
conductors and distribution losses. This made it more economical to distribute power over very long
distances. Generators (such as hydroelectric sites) could be located far from the loads. AC and DC
competed for a while, during a period called the War of Currents.

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1.1 DAMODAR VALLEY CORPORATION
Damodar Valley Corporation (DVC) is public company which operates several power stations in
the Damodar River area of West Bengal, India. The company operates both thermal power
station and hydel power dams under the Indian Ministry of Power. DVC is headquartered in the city
of Kolkata, West Bengal, India.
The Damodar Valley Corporation, popularly known as DVC, is the first multipurpose river valley
project of independent India. The corporation came into being on July 7, 1948 by an Act of the
Constituent Assembly of India (Act No. XIV of 1948). It is modelled on the Tennessee Valley Authority
of the USA. Jawaharlal Nehru, prime minister of India, Dr. B.C.Roy, chief minister of West Bengal
and Sri Krishna Sinha, chief minister of Bihar, took personal interest to ensure early success of the
project.
The initial focus of the DVC were flood control, irrigation, generation, transmission and distribution of
electricity, eco-conservation and afforestation, as well as job creation for the socio-economic well being
of the people residing in and around areas affected by DVC projects. However, over the past few
decades, power generation has gained priority. Other objectives of the DVC, however, remain part of its
primary responsibility. The dams in the valley have a capacity to moderate peak floods of 650,000 to
250,000 ft³/s. DVC has created irrigation potential of 3640 square kilometres.
With the time DVC developed and expanded its infrastructure six thermal power stations,
three hydro-electric power stations with a capacity of 144 MW and one gas turbine station with a
capacity of 82.5 MW contribute to a total installed capacity of 6357.3 MW. Presently DVC has 35 sub-
stations and receiving stations more than 5500-circuit km of transmission and distribution lines. DVC
has also four dams, a barrage and a network of canals that play an effective role in water management.
The construction of check dams, development of forests and farms and upland and wasteland treatment
developed by DVC play a vital role in eco conservation and environment management.

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1.2 KODERMA THERMAL POWER STATION
KODERMA THERMAL POWER STATION (KTPS-Koderma) is located at Banjehdih, village in
Jaynagar block of Koderma district of Jharkhand state. The plant is 8 km from river Barakar and the
tailrace of TILAYA DAM. The nearest railway station are Hirodih and Koderma junction.
KTPS project started on 2007. This infrastrucure is of coal power plant type with a design
capacity of 1000MW (2x500). It has two units, the first unit started for commercial operation in
2013 It is operated by DVC (Damodar Valley Corporation)
CAPACITY
Unit No. Generation Capacity Commercial Operation Date Status
1 500 MW July, 2013 Running
2 500 MW June, 2014 Running

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2. OVERVIEW OF A THERMAL POWER PLANT
A thermal power plant continuously converts the energy stored in the fossil fuels(coal, oil, natural
gas) into shaft work and ultimately into electricity. The working fluid is water which is sometimes
in liquid phase and sometimes in vapour phase during its cycle of operation. Energy released by the
burning of fuel is transferred to water in the boiler to generate steam at high pressure and
temperature, which then expands in the turbine to a low pressure to produce shaft work. The steam
leaving the turbine is condensed into water in the condenser where cooling water from a river or sea
circulates carrying away the heat released during condensation. The water is then fed back to the
boiler by the pump and the cycle continues. The figure below illustrates the basic components of a
thermal power plant where mechanical power of the turbine is utilised by the electric generator to
produce electricity and ultimately transmitted via the transmission lines.
FIG: thermal power plant overview
1. Cooling tower.
2. Cooling water pump.
3. Transmission line (3-phase).
4. Unit transformer (3-phase).
5. Electric generator (3-phase).

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6. Low pressure turbine.
7. Condensate extraction pump.
8. Condenser.
9. Intermediate pressure turbine.
10. Steam governor valve.
11. High pressure turbine.
12. De-aerator.
13. Feed heater.
14. Coal conveyor.
15. Coal hopper.
16. Pulverised fuel mill.
17. Boiler drums.
18. Ash hopper.
19. Super heater.
20. Forced draught fan.
21. Re-heater.
22. Air intake.
23. Economiser.
24. Air pre heater.
25. Precipitator.
26. Induced draught fan.
27. Chimney Stack.

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3. OPERATION OF A POWER PLANT
Basic Principle
As per FARADAY s Law-“Whenever the amount of magnetic flux linked with a circuit changes, an‟
EMF is produced in the circuit. Generator works on the principle of producing electricity. To change the
flux in the generator turbine is moved in a great speed with steam.” To produce steam, water is heated in
the boilers by burning the coal.
3.1 STEAM POWER PLANT
3.1.1 POWER PLANT: -
A power station (also referred to as generating station, power plant, powerhouse, generating plant) is an
industrial facility for the generation of electric power.
Types of energy available for generation of electrical energy are follows.
1. Thermal Energy
2. Solar Energy
3. Atomic Energy
4. Hydro Power
5. Wind Power
6. Tidal Power
7. Geo-Thermal
8. Flue Gas

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3.1.2 PICTORIAL REPRESENTATION OF POWER STATION STATION
3.1.3 STEAM POWER PLANT: -
A steam-electric power station is a power station in which the electric generator is steam driven. Water
is heated, turns into steam and spins a steam turbine. After it passes through the turbine, the steam is
condensed in a condenser. The greatest variation in the design of steam-electric power plants is due to
the different fuel sources.
For a steam power plant, practical thermal cycle was suggested by Rankine called Ideal cycle or
Rankine cycle. A steam power plant continuously convert the energy stored in fossil fuels (Coal, Oil,
Natural Gas) or fissile fuels (Uranium, Thorium) into shaft power into shaft work and ultimately into
electricity. The working fluid is water, which is sometimes in liquid phase and sometimes in the vapour
phase during its cycle of operations. Figure below illustrate a fossil-fuelled power plant as a bulk energy
converter from fuel to electricity using water as working medium. Energy released by burning of fuel is

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transferred to water by boiler (B) to generate steam at a high pressure and temperature, which expands
in the turbine (T) to a low pressure to produced shaft work. The steam leaving the turbine condensed
into water in the condenser (C) where cooling water from river or sea circulates carrying away the heat
released during condensation. The water (condensate) is then fed back to the boiler by the pump (P), and
the cycle goes on repeating itself. But in practice the present thermal power plants obey “Modified
reheat regenerative Rankine cycle”.
3.2 THERMAL POWER STATION WORKS ON ‘RANKINE CYCLE’
Main Components of TPS:
1. Boiler
2. Turbine
3. Condenser
4. Boiler feed pump
5. Generator
Fig. Rankine or Steam Cycle

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4. BASIC STEPS OF ELECTRICITY GENERATION
The basic steps in the generation of electricity from coal involves following steps:
 Coal to steam
 Steam to mechanical power
 Mechanical power to electrical power
Fig: Energy conversion in TPS
Coal to Electricity: Basics

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16. 16

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Mechanical power to electrical power

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5. COAL HANDLING PLANT
5.1 INTRODUCTION: -
In thermal power plant coal is a principal fuel, hence design & layout of coal handling plant is important.
5.2 COAL: -
 Coal is a non-renewable solid fuel formed by a series of geochemical process from the plant
remains accumulated together with other sediments.
 For calculating usefulness of coal as a fuel it is analyzed by two types
i. Proximate Analysis: Determines moisture, ash, volatile matter and fixed carbon percentage
ii. Ultimate Analysis: Determines carbon, hydrogen, nitrogen, sulfur and oxygen within coal.
Main constituents of coal are
Fig: main constituents of coal

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5.3 TYPES OF COAL: -
According to quality (carbon content), the coal may be divided into following classes:
i. Anthracite: - It is the best quality coal and its carbon content is as much as 92% with a low
volatile matter and very little moisture. It is hard and heavy and burns with great heat.
ii. Bituminous: - It is also of good quality coal next to Anthracite. Its carbon content is up to 85%.
Coal mined in India, is mainly of bituminous type of Gondwana age.
iii. Sub-bituminous: -It is a type of coal whose properties range from those of lignite to those of
bituminous coal and are used primarily as fuel for steam-electric power generation. Sub-bituminous
coals may be dull, dark brown to black, soft. They contain 15-30% inherent moisture by weight and
are non-coking.
iv. Lignite: - It is inferior quality coal, full of moisture and volatile matter. Its carbon content is less
than 50%. It is also known as ‘brown coal’.
v. Peat: - It is the first stage in the formation of coal. It is light and woody and has poor heating
capacity.
5.4 COAL IN INDIA: -
The common coals used in Indian industry are bituminous and sub-bituminous coal. The calorific
value of Indian coal ranges from 4000-5000 Kcal/kg. Apart from low calorific value, Indian coal
suffers from high ash content (15-45%) which is about 30-40%.The good thing about Indian coal is
its low sulphur content.
5.5 Coal Mill: - A pulveriser or grinder is a mechanical device for the grinding of many different types of
materials. For example, a pulveriser mill (Coal Mill) is used to produce pulverize coal for combustion in
the steam generating furnaces of fossil fuel power plants.
5.5.1 Types of Coal Mills
i. Bowl Mill (Medium Speed)
ii. Ball & Race Mill (Medium Speed)
iii. Ball and Tube Mill (Low Speed)

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5.6 COAL HANDLING PLANT PROCEDURE
Generally most of the thermal power plants uses low grades bituminous coal. The conveyer belt
system transports the coal from the coal storage area to the coal mill. Now the FHP (Fuel Handling
Plant) department is responsible for converting the coal converting it into fine granular dust by
grinding process. The coal from the coal bunkers. Coal is the principal energy source because of its
large deposits and availability. Coal can be recovered from different mining techniques like
 shallow seams by removing the over burnt expose the coal seam
 underground mining.
The coal handling plant is used to store, transport and distribute coal which comes from the mine.
The coal is delivered either through a conveyor belt system or by rail or road transport. The bulk
storage of coal at the power station is important for the continuous supply of fuel. Usually the
stockpiles are divided into three main categories.
• Live storage

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• Emergency storage
• Long term compacted stockpile
5.6.1 GENRAL WORKING OF CHP
Fig: coal handling plant
The figure 5.6 shows the schematic representation of the coal handling plant. Firstly the coal gets
deposited into the track hopper from the wagon and then via the paddle feeder it goes to the conveyer
belt#1A. Secondly via the transfer port the coal goes to another conveyer belt#2B and then to the crusher
house. The coal after being crushed goes to the stacker via the conveyer belt#3 for being stacked or
reclaimed and finally to the desired unit. ILMS is the inline magnetic separator where all the magnetic
particles associated with coal get separated.

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6.WATER TREATMENT PLANT
Raw water supply:
Raw water received at the thermal power plant is passed through Water Treatment Plant to separate
suspended impurities and dissolved gases including organic substance and then through De-
mineralised Plant to separate soluble impurities.
Deaeration:
In this process, the raw water is sprayed over cascade aerator in which water flows downwards over
many steps in the form of thin waterfalls. Cascading increases surface area water to facilitate easy
separation of dissolved undesirable gases (like hydrogen sulphide, ammonia, volatile organic
compound etc.) or to help in oxygenation of mainly ferrous ions in presence of atmospheric oxygen
to ferric ions.
Coagulation:
Coagulation takes place in clariflocculator. Coagulant destabilises suspended solids and
agglomerates them into heavier floc, which is separated out through sedimentation. Prime
chemicals used for coagulation are alum, poly-aluminium chloride (PAC).
Filtration:
Filters remove coarse suspended matter and remaining floc or sludge after coagulation and also
reduce the chlorine demand of the water.
Chlorination:
Neutral organic matter is very heterogeneous i.e. it contains many classes of highmolecular weight
organic compounds. Humic substances constitute a major portion ofthe dissolved organic carbon
from surface waters. They are complex mixtures of organic compounds with relatively unknown
structures and chemical composition.

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DM (Demineralised Water) Plant
In De-mineralised Plant, the filter water of Water Treatment Plant is passed through the pressure
sand filter (PSF) to reduce turbidity and then through activated charcoal filter (ACF) to adsorb the
residual chlorine and iron in filter water.
Demineralized water also known as Deionized water, water that has had its mineral ions removed.
Mineral ions such as cations of sodium, calcium, iron, copper, etc and anions such as chloride,
sulphate, nitrate, etc are common ions present in water. Deionization is a physical process which
uses specially-manufactured ion exchange resins which provides ion exchange site for the
replacement of the mineral salts in water with water forming H+ and OH- ions. Because the
majority of water impurities are dissolved salts, deionization produces a high purity water that is
generally similar to distilled water, and this process is quick and without scale buildup.
De-mineralization technology is the proven process for treatment of water. A DM Water System
produces mineral free water by operating on the principles of ion exchange, Degasification, and
polishing. Demineralized Water System finds wide application in the field of steam, power,
process, and cooling.

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7. BOILER SYSTEM
Working principle of Boiler (Steam Generator): In Boiler, steam is generated from demineralized
water by the addition of heat. The heat added has two parts: sensible heat and latent heat. The
sensible heat raises the temperature and pressure of water as well as steam. The latent heat
converts water into steam (phase change). This conversion is also known as boiling of water,
which is dependent on pressure and corresponding temperature. Thermodynamically, boiling is a
process of heat addition to water at constant pressure & temperature. The quantity of latent heat
decreases with increase in pressure of water and it becomes zero at 221.06 bars. This pressure is
termed as critical pressure. The steam generators are designated as sub-critical or super critical
based on its working pressure as below critical or above critical pressure. The steam, thus formed
is dry & saturated. Further, addition of heat raises the temperature and pressure of steam, which is
known as superheated steam. The differential specific weight between steam and water provides
the driving force for natural circulation during the steam generation process. This driving force
considerably reduces at pressure around 175 Kg/cm2 and is not able to overcome the frictional
resistance of its flow path. For this, forced or assisted circulation is employed at higher sub-critical
pressure range due to the reason of economy. But, at supercritical pressures and above, circulation
is forced one (such boiler is called once through boiler).
7.1 Important parts of Boiler & their functions:
a. Economizer: Feed water enters into the boiler through economizer. Its function is to recover
residual heat of flue gas before leaving boiler to preheat feed water prior to its entry into
boiler drum. The drum water is passed through down-comers for Circulation through the
water wall for absorbing heat from furnace. The economizer circulation line connects down-
comer with the economizer inlet header through an isolating valve and a non-return valve to
protect economizer tubes from overheating caused by steam entrapment and starvation. This
is done to ensure circulation of water through the tubes during initial lighting up of boiler,
when there is no feed water flow through economizer.

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Fig: Economizer
b. Drum: Boiler drum is located outside the furnace region or flue gas path. This stores certain
amount of water and separates steam from steam-water mixture. The minimum drum water
level is always maintained so as to prevent formation of vortex and to protect water wall
tubes (especially its corner tubes) from steam entrapment / starvation due to higher
circulation ratio of boiler.
c. Super heater: Super heaters (SH) are meant for elevating the steam temperature above the
saturation temperature in phases; so that maximum work can be extracted from high energy
(enthalpy) steam and after expansion in Turbine, the dryness fraction does not reach below
80%, for avoiding Turbine blade erosion/damage and attaining maximum turbine internal
efficiency. Steam from Boiler Drum passes through primary super heater placed in the
convective zone of the furnace, then through platen super heater placed in the radiant zone of
furnace and thereafter, through final super heater placed in the convective zone. The
superheated steam at requisite pressure and temperature is taken out of boiler to rotate turbo-
generator.

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Fig: boiler structure

27. 27
d. Reheater: In order to improve the cycle efficiency, HP turbine exhaust steam is taken back
to boiler to increase temperature by reheating process. The steam is passed through reheater,
placed in between final superheater bank of tubes & platen SH and finally taken out of boiler
to extract work out of it in the IP and LP turbine.
e. De-superheater (Attemperator): Though superheaters are designed to maintain requisite
steam temperature, it is necessary to use de-superheater to control steam temperature. Feed
water, generally taken before feed water control station, is used for de-superheating steam to
control its temperature at desired level.
Fig: Dearator

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8.ASH HANDLING PLANT
A large quantity of ash is, produced in steam power plants using coal. Ash produced in about 40% of
the total coal burnt in the furnace. Handling of ash is a problem because ash coming out of the
furnace is too hot, it is dusty and irritating to handle and is accompanied by some poisonous gases. It
is desirable to quench the ash before handling due to following reasons:
1. Quenching reduces the temperature of ash.
2. It reduces the corrosive action of ash.
3. Ash forms clinkers by fusing in large lumps and by quenching clinkers will disintegrate.
4. Quenching reduces the dust accompanying the ash.
The total produced ash of a power plant unit is two typed:
a) Bottom Ash (20%)

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b) Fly ash (80%) is collected with an electrostatic precipitator(ESP)
9.ELECTROSTAIC PRECIPITATOR
The principal components of an ESP are 2 sets of electrodes insulated from each other. First set of
rows are electrically grounded vertical plates called collecting electrodes while the second set
consists of wires called discharge electrodes. The negatively charged fly ash particles are driven
towards the collecting plate and the positive ions travel to the negatively charged wire electrodes.
Collected particulate matter is removed from the collecting plates by a mechanical hammer
scrapping system.
Fig: Electrostatic precipitator

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Fig: electrostatic precipitator work
The above figure shows the operation of an ESP. the negatively charged fly ash particles are driven
towards the collecting plate and the positive ions travel to the negatively charged wire electrodes.
Collected particulate matter is removed from the collecting plates by a mechanical hammer
scrapping system.
10. BOILER AUXILIARIES
Induced draft fan (ID fan) or Exhauster fan:
Induced draft represents the system where air or products of combustion are driven out after
combustion at boiler furnace by maintaining them at a progressively increasing sub atmospheric
pressure. This is achieved with the help of induced draft fan and stack. Induced draft fan is forward
curved centrifugal (radial) fan and sucks the fly-ash laden gas of temperature around 125°C out of
the furnace to throw it into stack (chimney). The fan is connected with driving motor through hydro-
coupling or with variable frequency drive (VFD) motor to keep desired fan speed.
Forced draft fan (FD fan):
Forced draft represents flow of air or products of combustion at a pressure above atmosphere. The
air for combustion is carried under forced draft conditions and the fan used for this purpose is called
Forced Draft (FD) fan. It is axial type fan and is used to take air from atmosphere at ambient
temperature to supply air for combustion, which takes entry to boiler through wind box.

31. 31
Primary air fan (PA fan):
The function of primary air is to transport pulverized coal from coal mill to the furnace, to dry coal
in coal mill and also to attain requisite pulverized coal temperature for ready combustion at furnace.
10.1 Fuel oil system:
In a coal fired boiler, oil firing is adopted for the purpose of warming up of the boiler or assisting
initial ignition of coal during introduction of coal mill or imparting stability to the coal flame during
low boiler load condition. Efficient or complete combustion of the fuel oil is best achieved by
atomizing oil by compressed air for light oil (LDO) or by steam for heavy oil (HFO) in order to have
proper turbulent mixing of oil with combustion air. Use of HFO is beneficial with respect to LDO in
view of its lower cost and saving in foreign exchange. The oil burners and igniters are the basic
elements of oil system. Oil is supplied by light oil pump or by heavy oil pump through oil heater.
Steam heater reduces the viscosity of heavy oil and aids flow ability as well as better atomization.
The oil burners are located in the compartmented corner of wind boxes, in the different elevation of
auxiliary air compartments, sandwiched between the coal burner nozzles. Each oil burner is
associated with an igniter, arranged at the side.

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11. STEAM TURBINE
11.1 INRODUCTION: -
Turbine is an engine that converts energy of fluid into mechanical energy. The steam turbine is
steam driven rotary engine. Steam Turbine Converts the Heat Energy (Kinetic Energy) into
Mechanical Energy.
A steam turbine is a prime mover which continuously converts the energy of high pressure, high
temperature steam supplied by the boiler into shaft work with low pressure, low temperature steam
exhausted to a condenser.
11.2 WORKING PRINCIPLE OF STEAM TURBINE: -
i. A steam turbine works on the principle of conversion of High pressure & temperature steam into
high Kinetic energy, thereby giving torque to a moving rotor.
ii. For above energy conversion there is requirement of converging /Converging-Diverging
Sections.

33. 33
iii. Such above requirement is built up in the space between two consecutive blades of fixed and
moving blades rows.
Fig: Steam turbine and regenerative heat
11.3 TYPES OF STEAM TURBINE: -
According to the principle of action of the steam, turbine can be classified as:
i. Impulse Turbine: - In a stage of Impulse turbine the pressure/Enthalpy drop takes place only in
fixed blades and not in the moving blades.
ii. Reaction Turbine: - In a stage of Reaction Turbine the Pressure/enthalpy drop takes place in
both the fixed and moving blades.

34. 34
11.5 VALVES: -
It is a mechanical device to control the flow of fluid in pipe. Valves are said to be nerve centre of
power plant controlling high pressure steam & water.
 The HP turbine is fitted with two initial steam stop & control valves.
 A stop & control valve with stems arranged right angle to each other are combined in a common
body.
 The stop valves are spring operated single-seat valves, the control valves, are also of single seat
design, have diffusers to reduce pressure losses.
 The IP turbine has two combined reheat stop &control valves.
11.6 OIL SUPPLY SYSTEM: -

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 A single oil supply system lubricates & cools the bearing, governs the machine operates the
hydraulic actuators & safety and protective devices & drives the hydraulic turning gear.
 The main pump is driven by the turbine shaft draws oil from the main oil tank. Auxiliary oil
pumps maintain the oil supply on start up & shut down. During turbine gear operation & when
MOP is faulted.
 When the turning gear is stared, jacking oil pumps force high pressure oil under the shaft
journals to prevent boundary lubrication.
 The lubricating & cooling oil is passed through oil coolers before oil supply.
12.STEAM CONDENSING SYSTEM
12.1INTRODUCTION: -
Thermoelectric power plants boil water to create steam, which then spins turbines to generate
electricity. The heat used to boil water can come from burning of a fuel, from nuclear reactions, or
directly from the sun or geothermal heat sources underground. Once steam has passed through a
turbine, it must be cooled back into water before it can be reused to produce more electricity.
Colder water cools the steam more effectively and allows more efficient electricity generation.
Wet-recirculating or closed-loop systems reuse cooling water in a second cycle rather than
immediately discharging it back to the original water source. Most commonly, wet-recirculating
systems use cooling towers to expose water to ambient air. Some of the water evaporates; the rest is
then sent back to the condenser in the power plant. Because wet-recirculating systems only
withdraw water to replace any water that is lost through evaporation in the cooling tower, these
systems have much lower water withdrawals than once-through systems, but tend to have
appreciably higher water consumption.
12.2 STEAM CONDENSING SYSTEM COMPONENTS: -
i. Condenser
ii. Cooling tower
iii. Hot well

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iv. Condenser cooling water pump
v. Condensate air extraction pump
vi. Air extraction pump
vii. Boiler feed pump
viii. Make up water pump
ix. Deaerator
x. Air Ejector
xi. Drain Cooler
xii. Feed Water Heaters (HP/LP Heaters)
1.Condenser: -
The main purposes of the condenser are to condense the exhaust steam from the turbine for reuse in
the cycle and to maximize turbine efficiency by maintaining proper vacuum. As the operating
pressure of the condenser is lowered (vacuum is increased), the enthalpy drop of the expanding
steam in the turbine will also increase. This will increase the amount of available work from the
turbine (electrical output). By lowering the condenser operating pressure, the following will occur:
a. Increased turbine output
b. Increased Plant efficiency
c. Reduced steam flow

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Fig: Diagram of typical water cooled surface condensor
2.Hot Well: -
These are small storage tank of condensate water below condensers. They are maintained at
required level of condensate with the help of Hot Well Level Controller, provided just before drain
cooler. They are also equipped with make-up lines from DM Storage Tank and Surge Tank.
3.Suction Well: -
This is the storage well of condensate water and condensate pump is submerged in this well. It is
provided with continuous vent connection to condenser to maintain the flow of condensate water
from condenser by neglecting its vacuum.
4.Condensate Pump: -
There are two multistage centrifugal condensate pumps but both are capable of delivering full load
individually. It delivers condensate to SPE.
5.Cooling Tower: -
A cooling tower extracts heat from water by evaporation. In an evaporative cooling tower, a small
portion of the water being cooled is allowed to evaporate into a moving air stream to provide
significant cooling to the rest of that water stream.
Cooling Towers are commonly used to provide lower than ambient water temperatures and are
more cost effective and energy efficient than most other alternatives. The smallest cooling towers
are structured for only a few litres of water per minute while the largest cooling towers may handle
upwards of thousands of litres per minute. The pipes are obviously much larger to accommodate
this much water in the larger towers and can range up to 12 inches in diameter.
When water is reused in the process, it is pumped to the top of the cooling tower and will then flow
down through plastic or wood shells, much like a honeycomb found in a bee’s nest. The water will
emit heat as it is downward flowing which mixes with the above air flow, which in turn cools the
water. Part of this water will also evaporate, causing it to lose even more heat.
.7. Vacuum Pumps: -
The main functions of vacuum pumps are to create and maintain vacuum in condenser. This is done
by pulling out air and non-condensable gases from the condenser.

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8.Drain Cooler:-
When LP heaters are in service, condensate water heated up by extracted steam from LP turbine.
For this, the steams condensed and drip gather in bottom of LP heaters. This drips are sent to
condenser for reuse trough drain cooler. These drains of LP heaters cooled by condensate water in
Drain Cooler.
9.Flash Tank: -
The air from condensate water, which is exhausted to atmosphere through a vent condenser. The
bled steam directly condenses and gets mixed with condensate water from heater, and this is passed
to storage tank.
10. Deaerator: -
A deaerator is a device that is used for removal of oxygen and other dissolved gases from the feed
water to steam-generating boilers. In particular, dissolved oxygen in boiler feed water will cause
serious corrosion damage in steam boiler systems by attaching to the walls of metal piping and
other metallic equipment and forming oxides (rust). Dissolved carbon dioxide combines with water
to form acid that causes further corrosion.
11. Feed Water Heaters: -
This item is installed to improve power generator efficiency by heating supplied water and reducing
breakage due to heat stress from temperature differences in boiler tubes. Because a single heater
consists of cooling areas, condensing areas, and heating areas, this item requires thoughtful
engineering and production.
Feed water heaters are classified as low and high pressure heaters with one heater consisting of
overheating, condensing and overcooling areas, making it difficult to design and produce.
Use one or more low pressure feed water heaters to raise the temperature of condensate from
condensate pump discharge temperature to the de-aerator inlet temperature. Use one or more high
pressure feed water heaters to raise the temperature of feed water from de-aerator outlet
temperature to the required boiler economizer inlet temperature.

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ELECTRICAL OPERATION
INTRODUCTION: -
The electrical operation of a power plant comprises of generation, transmission and distribution of
electrical energy. In a power station both distribution and transmission operation can take place.
When power is sent from power station to all other power station in the grid, it is known as
distribution of power. When power plant is driving power from other power station it is known as
transmission of power/electrical energy.
13. GENERATOR
In electricity generation, a generator is a device that converts mechanical energy to electrical energy
for use in an external circuit. The source of mechanical energy may vary widely from a hand crank
to an internal combustion engine and turbine used in power plants. Generators provide nearly all of
the power for electric power grids.
13.2 PRINCIPLE OF GENERATION: - GENERATION OF AC POWER
The basic requirements for generation of AC power are as follows.
i. Conductor
ii. Magnetic field
iii. Relative speed
Faraday's laws of electromagnetic induction
 First Law: - Whenever there is change in magnetic flux associated with a coil, an emf is induced
in it.
 Second law: - The magnitude of induced emf is directly proportional to the rate of change of
flux through the coil.
Maximum electric speed to be achieved is 3000 RPM being 50 cycles per sec. is the quality of
electric supply in our India.

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Thus maximum speed shall be achieved by 2 poles machine. However multi pole generators are
used for Hydro Power Stations as speed depends upon depth of reservoirs i.e., water pressure, water
head available at first stage of runner of turbine.
14.TRANSFORMER
14.1 Introduction
A transformer is a static machine used for transforming power from one circuit to another without
changing frequency.
14.2 Uses of power transformer
Generation of electrical power in low voltage level is very much cost effective. Hence electrical
power is generated in low voltage level. Theoretically, this low voltage level power can be
transmitted to the receiving end. But if the voltage level of a power is increased, the current of the
power is reduced which causes reduction in ohmic or I2
R losses in the system, reduction in cross
sectional area of the conductor i.e. reduction in capital cost of the system and it also improves the
voltage regulation of the system. Because of these, low level power must be stepped up for efficient
electrical power transmission. This is done by step up transformer at the sending side of the power
system network. As this high voltage power may not be distributed to the consumers directly, this
must be stepped down to the desired level at the receiving end with the help of step down
transformer. These are the uses of electrical power transformer in the electrical power system.

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14.3 Types of Transformers:
Generator Transformer:
This is the main power transformer employed in the power plant. It step up the voltage from 21kV
to 230 or 400kV and delivers the power. Stepping up the voltage reduces the transmission losses
which occur during the power transmission to long distances. The rating of this transformer (MVA
rating) will be almost equal to the alternator or generator rating.
Unit Transformers (UT):
These transformers are connected to the Generator Transformer bus. These transformers steps down
the voltage from 21kV to 11kV and supply the power to the electrical auxiliaries present in the
plant (motors, drives, lighting and other plant loads).
Unit Auxiliary Transformers (UAT):
These transformers are connected to the secondary bus of UT. These transformers steps down the
voltage from 11kV to 3.3kV and supply the power to the 3.3 kV driven HT electrical equipments
like Motors for pumps.
Station Transformer or Startup Transformer:
This transformer provides electrical power to the plant during start up when no supply is available
to the plant (generator is not operating). It steps down the grid voltage 400 kV to 11 kV to supply
power the plant auxiliaries like unit transformers.
The output of Station Transformer and Unit Transformers are connected in standby mode. If unit
transformer fails, station transformer take the load immediately to supply power to the plant
auxiliaries.
14.4 AUXILIARY TRANSFORMRERS
Station Service Transformers
Normal source to the station auxiliaries and standby source to the unit auxiliaries during start up

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and after tripping of the unit is station auxiliary transformer. Quantity of station service
transformers and their capacity depends upon the unit sizes and nos. Each station supply
transformer shall be one hundred percent standby of the other. Station service transformers shall
cater to the simultaneous load demand due to start up power requirements for the largest unit,
power requirement for the station auxiliaries required for running the station and power.
15. SWITCH YARD
A switchyard is essentially a hub for electrical power sources. For instance, a switchyard will exist
at a generating station to coordinate the exchange of power between the generators and the
transmission lines in the area. A switchyard will also exist when high voltage lines need to be
converted to lower voltage for distribution to consumers. Here in MTPS there is a big switch yard
section for the units one to six, and also for seven & eight there also a switch yard. Some of the
operation of the components of the switch yard is sometimes done from the control rooms of
respective units. That is the switch yard under each unit is sometimes control from the control
rooms of each unit respectively.
Fig: 220Kv of KTPS
A switchyard may be considered as a junction point where electrical power is coming in from one
or more sources and is going out through one or more circuits. This junction point is in the form of
a high capacity conductor spread from one end to the other end of the yard. As the switchyard
handles large amount of power, it is necessary that it remains secure and serviceable to supply the
outgoing transmission feeder seven under conditions of major equipment or bus failure. There are
different schemes available for bus bar and associated equipment connection to facilitate switching
operation. The important points which dictate the choice of bus switching scheme are –

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a. Operational flexibility,
b. Ease of maintenance,
c. System security,
d. Ease of sectionalizing,
e. Simplicity of protection scheme,
f. Installation cost and land requirement.
g. Ease of extension in future.
1. Circuit breaker:
A circuit breaker is an equipment that breaks a circuit either manually or automatically
under all conditions at no load, full load or short circuit. Oil circuit breakers, vacuum circuit
breakers and SF6 circuit breakers are a few types of circuit breakers.
2. Isolator: Isolators are switches which isolate the circuit at times and thus serve the purpose
of protection during off load operation.
3. Current Transformer: These transformers used serve the purpose of protection and
metering. Generally the same transformer can be used as a current or potential transformer
depending on the type of connection with the main circuit that is series or parallel
respectively.
In electrical system it is necessary to
a) Read current and power factor
b) Meter power consumption.
c) Detect abnormalities and feed impulse to protective devices.

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16.CONTROL & INSTRUMENTATION
16.1 INTRODUCTION
This division basically calibrates various instruments and takes care of any faults occur in any
of the auxiliaries in the plant. “Instrumentation can be well defined as a technology of using
instruments to measure and control the physical and chemical properties of a material.”
“This department is the brain of the plant because from the relays to transmitters followed by the
electronic computation chipsets and recorders and lastly the controlling circuitry, all fall under this.
16.2 INSTRUMENTS
A. PRESSURE MONITORING
Pressure can be monitored by three types of basic mechanisms
1. Switches
2. Gauges
3. Transmitter type
For gauges we use Bourdon tubes. The Bourdon Tube is a non-liquid pressure measurement device. It is
widely used in applications where inexpensive static pressure measurements are needed. A typical
Bourdon tube contains a curved tube that is open to external pressure input on one end and is coupled
mechanically to an indicating needle on the other end, as shows schematically below.

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For Switches pressure switches are used and they can be used for digital means of monitoring as switch
being ON is referred as high and being OFF is as low. All the monitored data is converted to either
Current or Voltage parameter.
B. TEMPERATURE MONITORING
We can use Thermocouples or RTDs for temperature monitoring. Normally RTDs are used for low
temperatures.
Thermocouple selection depends upon two factors:
1. Temperature Range
2. Accuracy Required
Normally used Thermocouple is K Type Thermocouple:
In this we use Chromel (Nickel-Chromium Alloy) / Alumel (Nickel-Aluminium Alloy) as two metals.
This is the most commonly used general purpose thermocouple. It is inexpensive and, owing to its
popularity, available in a wide variety of probes. They are available in the−200°C to +1200°C range.
Sensitivity is approximately 41 μV/°C.
RTDs are used for measuring temperature of low range. We pass a constant current through the RTD. So
that if R changes then the Voltage also changes. Normally in power plants Pt-100 RTD is used.
C. FLOW MEASUREMENT
Flow measurement does not signify much and is measured just for metering purposes and for monitoring
the processes ROTAMETERS: A Rotameter is a device that measures the flow rate of liquid or gas in a
closed tube. It is occasionally misspelled as 'Rotometer'. It belongs to a class of meters called variable
area meters, which measure flow rate by allowing the cross sectional area the fluid travels through to
vary, causing some measurable effect. A rotameter consists of a tapered tube, typically made of glass,
with a float inside that is pushed up by flow and pulled down by gravity. At a higher flow rate more area
(between the float and the tube) is needed to accommodate the flow, so the float rises. Floats are made in
many different shapes, with spheres and spherical ellipses being the most common. The float is shaped so

47. 47
that it rotates axially as the fluid passes. This allows you to tell if the float is stuck since it will only rotate
if it is not.

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17. CONCLUSION
Here in this project we experienced the efficient working of a thermal power plant and generation
of electricity in it. It is a complex structure involving a number of stages working simultaneously
for the production of electricity. The most important and the necessary parts of the thermal plant are
boiler, turbine, condenser and generator. The efficiency of a thermal plant depends upon the
effective working of these parts.
In this we learnt about the whole process of power generation by the co-
ordination of various auxiliary systems. We saw that the major losses in are mainly due to steam
leaks in boiler tubes and condenser. The effective transfer of steam from boiler to condenser and
reuse it as feed water greatly improves the efficiency of a power plant Thus, I conclude that the
working of a thermal power plant does not entirely rely upon the boiler and generator but, the co-
ordination of various systems together get the efficient
generation.

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18.SUGGESTIONS
Power sector is an essential service and in the basis of industrialization and agriculture. It plays a vital
role in the socio-economic development. Therefore, improving efficiency of these thermal power stations
in addition to increasing their PLF (Plant Load Factor) has become the need of the hour to bring the cost
and maximize the generation levels. With this objective in view, several actions have already been
initiated by Ministry of Power (MOP) and other various agencies like CEA, NTPC, State Electricity
Boards, CBIP etc. to improve the operating efficiency and PLF of thermal power stations. Now I here
make it sort with my suggestions for improving efficiency of power plant and for various other factors on
the basis of what I have learned during my training are:
 With the deficit of electricity in our country, there is need of many projects and the exposure limit
should be increased to effectively assist the new projects.
 Proper maintenance of ESP must be done with regular maintenance of boilers and furnaces.
 Variable speed motors should be used.
 Auxiliaries power reduction.
 Use of automatic system for monitoring flue gases.
 Completely insulate the steam system.
 Turbine driven Boiler Feed Pumps should be used.

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19.REFERENCES
BOOKS:
1. THERMAL POWER ENGINEERING by R.K.RAJPUT.
2. A COURSE IN ELECRICAL POWER by J.B.GUPTA
3. Engineering Thermodynamics by P.K.Nag