2. ACKNOWLEDGEMENT –
It is often said that life is a mixture of achievements, failures,
experiences, exposures and efforts to make your dream come
true. There are people around you who help you realize your
dream.
I wish to express my sincere gratitude to my Company Guide, Mr.
Nishant Dixit and Mr. Santosh Dubey ,DGM (Mechanical
Department) for there guidance, help and motivation. Apart from
the subject of my study, I learnt a lot from them, which I am sure,
will be useful in different stages of my life.
I would like to thank Mr. Krishna Shukla, Senior Manager (HR)
and Mr. Raghavendra sir (HR) for providing me with this
wonderful opportunity to work at MB power plant.
Above from all, I would like to express my gratitude and sincere
thanks to Mr. Sajjan Kumar Sharma for providing me this lifetime
experience and help me at every step during training period.
Regards,
Prince Sharma
VIT University, Vellore
3. COMPANY OVERVIEW-
The Hindustan Thermalprojects is all set to change the scenario of power
deficit in India by installing high power thermal power plant. We focus on
generating power through coal- fired power stations in India.
Moving ahead through high investments and a definite raw coal
supply HPPPL is all set to install several high power producing
thermal power plant that will positively impact the grim situation of
development for the lack of electricity.
The arm is developing thermal Power projects with a combined
generation capacity of about 5000 MW in the states of Madhya
Pradesh & Chhattisgarh. Also the company’s thermal Power
project at Anuppur, Madhya Pradesh (2520 MW) is one of the
fastest developing projects and its first unit has been
commissioned in May 2015. The commissioning of second Unit
(600 MW) scheduled to be achieved in early part of 2016.
These thermal power plants are expected to help generate
developmental opportunities and address energy shortage in the
region.
4. Anuppur Thermal Powerproject –
The thermal arm is developing 2520 MW coal based Thermal
Powerproject in Anuppur district, Madhya Pradesh. The project
is planned to be executed in two phases as follows:
Phase - 1 : 1200 MW (2X600 MW)
Phase - 2 : 1320 MW (2X660 MW)
It is currently implementing the first phase of 1200 MW (2X600
MW) through its SPV (Special Purpose Vehicle) i.e. MB Power
Madhya Pradesh Limited (MBPMPL). Coal for the project will be
sourced from South Eastern Coalfields and water will be sourced
from River Son.
Thermal Power Plant at Anuppur, Madhya Pradesh (2520 MW) is
one of the fastest developing projects in India with commissioning
in 2014.
5. INTRODUCTION –
- India is one of the world’s largest consumer of energy
- Conventional sources: Thermal, Hydro and Nuclear.
- Non- conventional: Wind, solar, Geothermal, tidal.
- Installed capacity – 1,61,352MW
Thermal = 95151.74MW
Nuclear = 4,120MW
Hydro = 36877.76MW
Solar = 1324.41MW
A thermal power plant is a power plant in which the prime
mover is stream. Water is heated, turns into steam and
spins a turbine which drives an electrical generator. After it
passes through the turbine, the steam is condensed and
recycled to where it was heated,also called as Rankine
cycle.
6. Main parts of the plant are :
1. Coal handling Plant 2. DM Plant
3. Boiler 4. Super heater
5. Air preheater and Economizer 6. Deaerator
7. Turbine 8. Condenser
9. Cooling towers 10.ESP
11. Smoke stack(Chimney) 12. Generator
13.Control room & Switchyard
7. COAL HANDLING PLANT (CHP) –
Main objective of CHP are-
To supply the quanta of processed coal to bunkers of Coal
mills for Boiler operation.
To Stack the coal to coal yard.
Requirement of coal in MBPMPL is fulfilled from south eastern
coalfield and source of transportation is Indian railway. This one
is cheap and best facility at doorstep.They receive the coal
wagons in the form of rakes (55-60 wagons in each rake).Free
time is normally 7 hrs. from Receipt of coal.
Then chemical analysis of coal is carried out. Sample of coal is
randomly collected from each rake and detailed chemical
analysis, calculation of calorific value is carried out and is
confirmed whether it is as per agreement with the coal mines or
not.
8. Basic part of CHP –
1- Wagon Tippler-
These are used to unload the coal wagons into coal hoppers
in very less time (e.g. 20 wagons/hr. or more).
Weighing of coal is carried out at wagon tippler.
Normally 55-60 metric ton of coal come in each wagon.
2- Conveyor belt –
Used to transfer the coal.
Synthetic rubber.
4 ply means 4 nylon net in between 2 mm thick rubber
coating is used.Width varies from 500 mm -1400 mm.
3. Conveyor belt drive system-
9. 4. Idlers –
These are used to provide motion to conveyor belt. these are
connected to motor which control the rotating speed of
idlers.Angle between middle idler and the extreme idlers are fixed
in between of 20 – 30 degree which prevent coal to move
continuously.
5. Interlocking –
Interlocking is used for safety purpose.
If any belt fails all other belts stop working which are
interconnected.
6. Magnetic separator –
is used to remove metal particle from coal conveyed through
conveyor belt for improving boiler efficiency.
10. Crushing mechanism in CHP-
Three Stage Crushing System is used in Plant.
1.Double Roll Crusher
2.Rotary Breaker Crusher
3.Impact Crusher
COAL BUNKERS -
Power plant has total of 8 coal bunkers. Coal from impact crusher
is transferref to bunkers which is placed just above the coal mill.
The main function of coal bunker is to regulate the amount of coal
passing in coal mill.
COAL MILL-
Total of 8 coal mill are established which fulfill the coal
requirement of boiler. Main function of coal mills are to pulverize
the coal before it is passed to boiler. Cold primary air is used to
pulverize the coal and this air is supplied directly from PA fan.
11. From coal mill pulverized coal is transferred to boiler where
combustion take place.
12. BOILER SECTION–
Boiler is a closed vessel in which steam is generated by means of
heat energy. Main fuction of boiler is to convert chemical energy
of fuel into Heat Energy and then transfer heat energy to water for
evaporation & super heating.
Pulverized coal is air-blown into the furnace from fuel nozzles at
the four corners and it rapidly burns, forming a large fireball at the
center. The thermal radiation of the fireball heats the water that
circulates through the boiler tubes near the boiler perimeter. The
water circulation rate in the boiler is three to four times the
throughput and is typically driven by pumps. As the water in the
boiler circulates it absorbs heat and changes into steam at 540 c.
It is separated from the water inside a drum at the top of the
furnace.
13. Boiler is basically divide into 3 parts-
1 – First pass consist of
Bottom ring header
Drum
Platen super heater
2- Horizontal pass consist of
RH coils
Final Super heater
Roof Tubes
3- Second pass consist of
LTSH
Economiser
WATER WALL BOTTOM RING HEADER
DRUM
CRH IN
REAR ROOF
WATER INLET
SH STEAM OUTLET
EXTENDED
WW
FRONT ROOF
HRH OUT
LTSH
Economiser
14. Important parts of boiler-
1-Boiler drum-
To Ensure water storage to meet boiler load and to prevent
starvation of tubes. It is a reservoir for providing working fluid
circulation.
2-Economizer-
To Recover The Heat That Is Available In Flue Gas,The boiler
designers always keep the economizer water outlet temperature
to about 25 to 35 degrees below the drum saturation temperature.
This is done to mainly avoid steaming in the economizer.
Economizer alone gives 8% efficiency increase of Boiler.
3- Superheater-
Most of the modern boilers are having super heater and reheater
arrangement. Superheater is a component of a steam-generating
unit in which steam, after it has left the boiler drum, is heated
above its saturation temperature. The amount of superheat
added to the steam is influenced by the location, arrangement,
STEAM AND WATER TEMPERATURE - IN DEG. CENTIGRADE
Feed water ENTERING LEAVING
ECONOMISER 245 289
DRUM 345 350
LTSH 355 426
PLATEN SH 426 520
FINAL SH 520 540
REHEATER 344 540
15. and amount of super heater surface installed, as well as the rating
of the boiler. The super heater may consist of one or more stages
of tube banks arranged to effectively transfer heat from the
products of combustion.
4- Reheater-
Some of the heat of superheated steam is used to rotate the
turbine where it loses some of its energy. Reheater is also steam
boiler component in which heat is added to this intermediate-
pressure steam, which has given up some of its energy in
expansion through the high-pressure turbine. The steam after
reheating is used to rotate the second steam turbine where the
heat is converted to mechanical energy. This mechanical energy
is used to run the alternator, which is coupled to turbine , there by
generating electrical energy.
16. AIR PREHEATER-
The remaining heat of flue gases is utilized by air preheater. It is
a device used in steam boilers to transfer heat from the flue gases
to the combustion air before the air enters the furnace. Also
known as air heater; air-heating system. It is not shown in the lay
out. But it is kept at a place near by where the air enters in to the
boiler.
The purpose of the air preheater is to recover the heat from the
flue gas from the boiler to improve boiler efficiency by burning
warm air which increases combustion efficiency, and reducing
useful heat lost from the flue.
17. DEAERATOR-
A steam generating boiler requires that the boiler feed water
should be devoid of air and other dissolved gases, particularly
corrosive ones, in order to avoid corrosion of the metal.
Generally, power stations use a Deaerator to provide for the
removal of air and other dissolved gases from the boiler feed
water. A deaerator typically includes a vertical, domed deaeration
section mounted on top of a horizontal cylindrical vessel which
serves as the deaerated boiler feed water storage tank.
18. FORCED DRAUGHT FAN (FD FAN)-
This fan forces the atmospheric air through the boiler furnace and
pushes out the hot gases from the furnace through superheater,
reheater, economizer and air heater to stacks.
INDUCED DRAUGHT FAN (ID FAN)-
Here a fan called ID fan is provided at the outlet of ESP, that is,
just before the chimney.This fan sucks discharges gas into the
chimney.
PRIMARY AIR FAN(PA FAN)-
Primary air fans (PA) are high pressure fans used to supply the
air for the transportation of coal directly to the furnace.
19. ELECTROSTATIC PRECIPITATOR (ESP) -
It is a device which removes dust or other finely divided particles
from flue gases by charging the particles inductively with an
electric field, then attracting them to highly charged collector
plates. Also known as precipitator. The process depends on two
steps. In the first step the suspension passes through an electric
discharge (corona discharge) area where ionization of the gas
occurs. The ions produced collide with the suspended particles
and confer on them an electric charge. The charged particles drift
toward an electrode of opposite sign and are deposited on the
electrode where their electric charge is neutralized. The
phenomenon would be more correctly designated as electrode
position from the gas phase.
20. CHIMNEY-
A chimney is a system for venting hot flue gases or smoke from
a boiler, stove, furnace or fireplace to the outside atmosphere.
They are typically almost vertical to ensure that the hot gases flow
smoothly, drawing air into the combustion through the chimney
effect (also known as the stack effect). The space inside a
chimney is called a flue. Chimneys may be found in buildings,
steam locomotives and ships. In the US, the term smokestack is
also used when referring to locomotive chimneys. The
term funnel is generally used for ship chimneys and sometimes
used to refer to locomotive chimneys. Chimneys are tall to
increase their draw of air for combustion and to disperse
pollutants in the flue gases over a greater area so as to reduce
the pollutant concentrations in compliance with regulatory or other
limits.
21. Boiler Feed Pump -
• The boiler feed pump pumps water into the boiler,
overcoming the boiler pressure of 160 bar to achieve it
• The pump is driven by a steam turbine or an electric motor
• It runs at 7,000 revolutions per minute
Low Pressure Heaters (LPH) -
• Feed water from the condensate extraction pumps passes
through low pressure feed heaters. Steam is used to heat
the feed water
• After the last feed heater, the feed water is at around 160°C.
High Pressure Heaters (HPH) -
• With a similar purpose to the low pressure feed heaters, the
high pressure feed heaters are the last stage of feed water
heating before the feed water enters the boiler system at the
economizer
• Feed water leaving these heaters is at 250°C
22. TURBINE SECTION -
Turbine is very important part of a power plant whose rotatory
motion helps in rotating the generator and generation of
electricity. It extracts thermal energy from pressurized steam, and
converts it into rotary motion. The steam turbine is a form of heat
engine that derives much of its improvement in thermodynamics
efficiency through the use of multiple stages in the expansion of
the steam.
There are total of 4 turbines –
High pressure turbine- Superheated steam is used to drive the
HP turbine.
Intermediate pressure turbine- Reheat steam is used to drive
this.
Low pressure turbine- Remaining steam from IP turbine enters
the LP turbines and drives it. Total of 2 LP turbines are used in
series.
HP turbine is provided with one extraction that help in transfer of
some heat into HP heater which is further used there to preheat
the condensate.
LP turbine is provided with two extraction, one goes to LP
heater and other helps in rotating the BOILER FEED PUMP
TURBINE.
23.
24. CONDENSER-
Condenser is a device or unit used to condense a substance from
its gaseous to its liquid state, typically by cooling it.
The exiting steam from steam turbine, now a little above its boiling
point, is brought into thermal contact with cold water (pumped in
from the cooling tower) in the condenser. where it condenses
rapidly back into water, creating near vacuum-like conditions
inside the condenser chest.
25. COOLING TOWERS-
The condensate (water) formed in the condenser after
condensation is initially at high temperature. This hot water is
passed to cooling towers. It is a tower- or building-like device in
which atmospheric air (the heat receiver) circulates in direct or
indirect contact with warmer water (the heat source) and the
water is thereby cooled. We are using INDUCED DRAFT
COOLING TOWER in this plant.
26. SITE SELECTION
• Transportation network: Easy and enough access to
transportation network is required in both power plant
construction and operation periods.
• Geology and soil type: The power plant should be built in
an area with soil and rock layers that could stand the weight
and vibrations of the power plant.
• Topography: It is proved that high elevation has a negative
effect on production efficiency of gas turbines. In addition,
changing of a sloping area into a flat site for the construction
of the power plant needs extra budget. Therefore, the
parameters of elevation and slope should be considered.
• Water resources: For the construction and operating of
power plant different volumes of water are required. This
could be supplied from either rivers or underground water
resources. Therefore having enough water supplies in
defined vicinity can be a factor in the selection of the site.
27. IMPORTANCE OF A THERMAL POWER PLANT-
• Fuel used is cheaper
• Smaller space is required compared to hydro power plant
• Economical in initial cost compared to hydro plants and
running costs are less compared to gas plants or diesel
plants
• Thermal plants can be placed near load centers unlike hydro
and nuclear plants. Hence transmission of power losses can
be minimized
• Thermal plants are able to respond to the load demand more
effectively and supports the performance of the electrical
grid
28. “THANKS TO EACH AND EVERYONE WHO HELP ME
DURING MY TRAINING PERIOD AND TEACH ME SOME
IMPORTANT LESSONS.THIS WAS AN UNFORGIVABLE
EXPIRIENCE”
