Chapter - 1

PROFILE OF VISAKHAPATNAM STEEL PLANT

1.1 INTRODUCTION
The economy of a nation depends on core sector industries like iron and steel. Steel is the basic input for construction, machines building and transport industries. Keeping in view the

importance of steel the Visakhapatnam Steel Plant with foreign collaborations was constructed in the public sector in the post independence era. The decision of the Government to set up an integrated steel plant was laid down by the then Prime Minister Smt. Indira Gandhi. The Prime Minister laid the foundation stone on 20th January, 1971. The consultant, M/s M N Dastur & Co (Pvt) Ltd. submitted a techno-economic feasibility report in February 1972, and detailed project report for the plant, with an annual capacity of 3.0 million ton of liquid steel. The Government of India and USSR signed an agreement on 12th June 1979 for the co-operation in setting up 3.0 million ton integrated Steel Plant. The project was estimated to cost to Rs. 3, 897.28 crores based on prices as on 4 th Quarter of 1981. However, on completion of the construction and commissioning of the whole Plant in 1992, the cost escalated to Rs. 8, 755 crores based on prices as on 2nd Quarter of 1994. Visakhapatnam Steel Plant is one of the most modern steel plants in the country. The plant was dedicated to the nation on 1st August 1992 by the then Prime Minister, Sri P.V.Narasimha Rao. New technology, large-scale computerization and automation etc, are incorporated in the Plant at the international levels and attain such labour productivity, the organizational manpower has been rationalized. The manpower in the VSP has been limited to 16,416 employees. The plant has the capacity of producing 3.0 million tons of liquid steel and 2.656 million tons of saleable steel. It has set up two major Blast Furnaces, the Godavari and the Krishna, which are the envy of any modern steel making complex.

1.2 CORPORATE PLAN

1.2.1 Vision To be a continuously growing world-class company.
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We shall:

Harness our growth potential and sustain profitable growth. Deliver high quality and cost competitive products and be the first choice of customers. Create an inspiring work environment to unleash the creative energy of people. Achieve excellence in enterprise management. Be a respected corporate citizen, ensure clean and green environment and develop vibrant communities around us.

1.2.2 Mission To attain 16 million tons liquid steel capacity through technological up gradation, operational efficiency and expansion, to produce steel at international standards of cost and quality, and to meet the aspirations of the stakeholders.

1.2.3 Objectives Objectives are measurable performance outcomes of the company and emanate from the Vision. The focus areas emerging from the analysis of SWOT Matrix are the basis for formulating the company objectives. They are Expand plant capacity to 6.3 MT by 2008-09, with the mission to expand further in subsequent phases as per the Corporate Plan. Sustain gross margin to turnover ratio > 25%. Be amongst top five lowest cost steel producers in the world by 2009-10. Achieve higher levels of customer satisfaction than competitors. Instill right attitude amongst employees and facilitates them to excel in their professional, personal and social life

1.2.4 Core Values Commitment Customer Satisfaction

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Continuous Improvement Concern of Environment Creativity and Innovation

VSP takes all necessary actions for the fulfilment of regulatory requirements. It has dedicated departments for this purpose. Energy conservation, environmental preservation, safety in work place, and occupational health gets highest priority in the company. Some of the policies in this regard are reproduced below. 1.3 COMPANYS CORPORATE SOCIAL RESPONSIBILITY RINLs concern for the society is reflected in its vision, mission, objectives and core values. The statement, We shall be a respected corporate citizen, ensure clean and green environment and develop vibrant communities around us forms a part of the vision of the company. Concern for environment is one the five core values. One of the companys objectives is to ensure zero effluents discharge by 2005-06 and contribute to improving quality of life (health, literacy and water) in at least one village every year. A comprehensive policy on Corporate Social Responsibility (CSR) has been formulated and processed for approval of the Board.

Major Sources of Raw Materials Iron Ore lumps & fines BF Lime Stone SMS Lime Stone BF Dolomite SMS Dolomite Manganese Ore Boiler Coal Coking Coal Water supply Power supply Bailadilla, Chhattisgarh Jaggayyapeta, A.P Jaisalmer, Rajasthan Dubai Madharam, A.P Chipuripalli, A.P Talcher, Orissa Australia Yeluru canal, Andhra Pradesh Captive power plant
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Main Productions of Visakhapatnam Steel Plant S No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Angles Billets Channels Beans Squares Flats Rounds Rebars Wire rods Steel Products Nut coke Coke dust Coal tar Anthracene oil H P Naphalene Benzene Toluene Zylene Wash oil Granulated slag Lime fines Ammonium Sulphate By Products

1.4 TECHNOLOGICAL HIGHLIGHTS

First shore based integrated steel plant. Selective crushing with pneumatic separation of coal blend. 7 Metre tall Coke Ovens. Dry Quenching of hot coke and production of steam and power from hot inert gases. 3200 M3 Blast Furnace having bell-less top equipment with conveyor charging. Granulation of 100% molten slag at the Cast House. B.F. top pressure recovery turbine for power generation. Desulphurisation facilities for pre-treatment of hot metal. Sub lance measurement of dynamic blowing control with computer. 100% continuous casting of liquid steel.
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High capacity, high speed, computer controlled multi-line mills. Use of on-line heat treatment Temp core processes for reinforcement bars. Use of No twist rolling and controlled cooling Stelmore of wire rods. First integrated steel plant to receive ISO 9002 certification for all its products.

1.5 POLLUTION CONTROL & ENVIRONMENTAL PROTECTION

Elaborate measures have been adopted to combat air and water pollution in Visakhapatnam Steel Plant. In order to be Eco friendly Visakhapatnam Steel Plant has planted more than 3 million trees in area of 35 square kilo meters and incorporated various technologies at a cost of Rs 460 crores and control measures. Production Performance (000 Tonnes)
Labor productivity (Tonnes /year) 211 226 260 262 265 282 285 287 297

Year 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09

Hot metal 3,165 3,485 3,941 4,055 3,920 4,153 4,046 3,913 3,546

Liquid steel 2,909 3,083 3,356 3,508 3,560 3,603 3,606 3,322 3,145

Saleable steel 2,507 2,757 3,056 3,169 3,173 3,237 3,290 3,074 2,01

Commercial Performance (Rs. Crores)

Year 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 Sales turnover 4,081 5,059 6,174 8,181 8,469 9,126 10,433 10,411 Domestic sales 3,710 4,433 5,406 7,933 8,026 8,702 9,283 10,333 Exports 371 626 768 248 443 424 950 781

Financial Performance (Rs. Crores)

Year 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 200-09 Gross Margin 15 252 504 690 1,049 2,073 3,271 2,383 2,633 3,498 2,300 Cash profit (-) 346 (-) 130 153 400 915 2,024 3,260 2,355 2,584 2.414 2,264 Net profit (-) 457 (-) 562 (-) 291 (-75) 521 1,547 2,008 1,252 1,363 1.942 1,958

1.6 WELFARE AMENITIES

Modern township with all amenities has been developed with 8032 quarters to house the plant employees and other agencies in 11 sectors. The township is having best facilities in terms of drinking water supply, drainage, roads, modern hospital, community centre, parks, schools, shopping complexes, recreational facilities etc. to cater to the needs of the employees.

1.7 ACHIEVEMENTS AND AWARDS

The efforts of VSP have been recognized at various forums. Some of the major awards received by VSP are in the area of energy conservation, environment protection, safety, quality, Circles, Rajbhasha, MOU, sports and a number of awards at the individual level. Some of the important awards received by VSP are:

ISO-9001-2000, ISO-14001 and OHSAS-18001 for all the Operational units of the plant.

SCOPE Award for- Best Turnaround : 2001. Best Enterprise Award from SCOPE, WIPS : 2001-02. Environment Excellence Award from Greentech Foundation for Energy conservation : 2002.

ISTD Award for "Best HR Practices" : 2002. Ispat Suraksha Puraskar (1st Prize) for longest Accident Free Period 1991-94. Indira Priyadarshini Vriksha Mitra Award : 1992-93. Nehru Memorial National Award for Pollution Control :1992-93 & 1993-94. EEPC Export Excellence Award : 1994-95.

CII (Southern Region) Energy Conservation Award : 1995-96. Golden Peacock (1st Prize) "National Quality Award-96" IIM in the National Quality Competition : 1996.

Steel Ministers' Trophy for "Best Safety Performance" :1996. Selected for 'World Quality Commitment Award-1997 of J*Ban, Spain. Gold Star Award for Excellent Performance in Productivity. Udyog Excellence Gold Medal Award for Excellence in Steel Industry. Excellence Award for outstanding performance in Productivity Management, Quality & Innovation.

Best Labour Management Award from the Govt. of AP. Prime Ministers Trophy for "Best Integrated Steel Plant-2002-03. Best Enterprise Award from SCOPE for surpassing MOU targets-2003-04. "Organizational Excellence Award" for 2003-04 by INSSAN. "World Quality Commitment International Star Award" in the Gold category conferred by Business Initiative Directions, Paris.

National Energy Conservation Award, 2004 and Special Prize from Ministry of Power, Govt. of India.

Mini Ratna status in PSE by Government of India on 26-05-2006. Won prestigious Prime Ministers Trophy for "Best Integrated Steel Plant 2005-06 second time.

The above awards are besides a number of awards at the local, regional & national level competitions in the area of Quality Circles, Suggestion Schemes etc. VSP has been bestowed with several national accolades significant among them being: National Energy Conservation Award for the 6th time in succession. National
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Award for Excellence in Water Management. ICWAI Award for excellence in Cost Management. Viswakharma Rashtriya Puraskar Awards (6 out of 32 at the national level). FAPCCI Best Industrial Productivity Award. INSAAN National Award for Organisational Excellence Best CEO Award

1.8 EXPANSION PLAN

Presently the Plant is operating at higher efficiency levels surpassing the rated capacities thus achieving 4.04 Mt of Hot Metal, 3.6 MT of Liquid Steel and 3.2 MT of Saleable Steel i.e. 122%, 120% & 122% of the respective rated capacities. The Organization has become net positive in 2005-06, having wiped out all accumulated losses and registered Rs. 1363 Crores net profit after taxes in 2006-07. In line with the vision in National Steel Policy envisaging 110 MT steel by 2019-20, Vizag Steel is also planning to expand its capacity. Considering the buoyancy in domestic steel market for long products, which is the product mix of VSP and the high acceptance of VSPs brand image in the market, an expansion plan has been proposed. The expansion plan of doubling the capacity of the plant has been cleared in a record time of 10 months and the entire Vizag Steel collective is totally geared up for completing the expansion in the stipulated 36 months. The consultant is in place and the funds are in hand. The expansion should give a strong footing for VSPs growth. The expansion programme is progressing well as per plans and the present focus is on creating an enabling infrastructure such as roads, water, power etc., for smooth execution. Also thrust is on finalization of the specifications and placement of orders. To leverage from our brand leadership in the long segment category, expansion has been cast to enhance volumes in the long product category.

CHAPTER 2 THERMAL POWER PLANT

2.1 The three main constituents of a thermal power plant

2.1.1 Boiler: Pulverized coal along with combustion air is fired in the Boiler where chemical energy of fuel is converted into heat energy to generate steam from DM (De-Mineralized) water. 2.1.2 Turbine: Steam at high pressure and temperature is then fed to the Turbine where heat energy of steam is converted into mechanical energy by rotating the turbine. The outlet steam from the turbine is condensed in the condenser. The condensed DM water is re-used in the boiler. Condenser is an indirect type heat exchanger where steam is condensed by sea water passing through the condenser tubes. 2.1.2 Generator: Turbine and generator are coupled together. As the turbine rotates, the generator too rotates. The generator generates power as electric excitation is applied.

Generated power at 21kv is stepped up to 400Kv and then fed to grid via the switch yard. Thermal power plant uses a dual cycle i.e. vapor and liquid cycle. It is a closed cycle where the working fluid can be used again and again. Here the c ycle used is RANKINE CYCLE which includes feed water heating, super heating of steam. It becomes economical by increasing the cycle efficiency. By super heating the steam before it is expanded, the Rankine cycle efficiency can be increased. The use of super heated steam also ensures longer life of turbine blade because of the absence of erosion from high velocity water particles that are suspended in water vapor. Other factors which effect thermal efficiency are:

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Initial steam pressure Initial steam temperature Condenser vacuum Feed water temperatures

Modern thermal power station involves three major systems namely generation of steam in boiler, conversion of heat energy to mechanical energy in turbine, power generation in generator and transmission of generated electric power.

2.2 GENERATION OF STEAM

Generation of steam involves the following systems Draft system

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Fuel system Water system Ash system

2.2.1 DRAFT SYSTEM This system consists of primary air and secondary air. There are three types of fans in balanced draft system viz. primary air fan (PA), forced draught air fan (FD) and induced draught fan (ID). PA fan takes atmospheric air, a part of which is sent to air-preheaters for heating while a part goes directly to the mill which is regulated for mill outlet temperature control. Atmospheric air from FD fan is heated in the air-preheaters and sent to the furnace as secondary air for combustion. ID fans suck out the combustion products in the system and release the same to the atmosphere through air preheaters and electro static precipitators (ESP). 2.2.2 FUEL SYSTEM Coal from the mines is transported and is unloaded in the coal handling plant. This coal is transported to the coal bunkers with the help of conveyers after crushing them to optimum sizes. Then it is carried to mills by coal feeders. This coal is pulverized in the mill, where it is ground to powder form. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold air mixture from primary air fan. Light diesel oil (LDO) is used initially and then heavy fuel oil (HFO) is taken over. After boiler becomes sufficiently hot and desired ignition temperature is reached coal is fired in the boiler. Once sufficient coal mills are taken into service LDO and HFO firing will be stopped. 2.2.3 WATER SYSTEM DM water from boiler feed pump passes through economizer and reaches the boiler water walls and due to the density difference between steam and water the water flows through water wall tubes to the drum. In case of bigger size boilers additional circulating water pumps are used to create sufficient flow of water. Water is partly converted into steam as it rises up in the furnace. This steam and water mixture passes to the boiler drum where steam is separated from water and sent to the super heaters where steam gets super heated before entering the turbine. Steam after performing work loses its heat and pressure energy and enters condenser where it is condensed to water. This condensate is recycled for steam generation. Water deficit due to vapor losses or
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leakages is made up with make up water. The steam leaving the turbine is passed through condenser in which steam is converted to condensate water. Cooling of steam is effected by supply of sea water through condenser tubes. Sea water after picking up heat from steam is further cooled in cooling towers and returned in closed cycle. 2.2.4 ASH SYSTEM Flue gases from the furnace is extracted by ID fan and passes through economizer, air preheaters and goes through electrostatic precipitator where ash particles are separated from the flue gas and the flue gases are thrown out of the chimney. The ash collected in ESP hoppers is mixed with water to form slurry and is dumped in an open area (ash pond) in case of wet system. In dry system fine ash collected is disposed through vacuum system into separate bunkers.

2.3 CONVERSION OF HEAT ENERGY TO MECHANICAL ENERGY Super heated steam from boiler passes through the turbine through control valves in three different stages i.e. high pressure cylinder and low pressure cylinder. The steam leaving the HP cylinder goes to LP cylinder. At this stage the steam loses its temperature and pressure. The decrease in the pressure and temperature occurs as the steam transmits energy to shaft and performs work thus rotating the turbine shaft

2.4 GENERATION AND LOADING DESPATCH OF ELECTRIC POWER When the turbine rotates generator also rotates. So when the rotor is rotated, the lines of magnetic flux cut through the stator windings. This induces an electromagnetic force in stator windings and electricity is generated.

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CHAPTER - 3 BOILER & ITS AUXILIARIES 3.1 INTRODUCTION The boiler is a radiant reheat, controlled circulation, single drum type unit. Boiler is fitted with tilting tangential pulverized coal and oil burners, high energy arc ignitors, light diesel and heavy fuel oil burners. Boiler includes many sub systems for conversion of chemical energy of fuels into heat energy in the form of steam. The steam generated is sent to the turbine for converting heat energy of steam into mechanical energy thereby rotating the turbo-generator.

3.2SAILENT FEATURES OF BOILER PRESSURE PARTS Feed water from feed control station to the boiler passes through the economizer and then to the drum from where it flows through boiler circulating water pumps (BCW) into furnace water wall circuits returning to the drum as steam/water mixture. The steam and water gets separated in the

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drum. The water follows the above path whereas steam separated passes through steam cooled water wall and super heater circuits. Super heater temperature control is provided by spray attemperation. The exhaust steam from the HPT goes to LPT. PULVERISED COAL SYSTEM The system for direct firing of pulverized coal utilizes bowl mills to pulverize the coal and a tilting tangential system to admit the pulverized coal together with air required for combustion to the furnace. The pulverized coal and air discharged is directed to the centre of the furnace to form a firing circle which is initially ignited by a suitable ignition source at the nozzle exit. Above a predictable loading condition the ignition becomes self sustaining. AIR / DRAFT SYSTEM PRIMARY AIR SYSTEM The primary air draught plant supplies hot air and cold air to the coal mills to dry and convey pulverized coal to the burners. The primary system consists of two primary air (P.A) fans, two steam coil air-preheaters (S.C.A.P.H) two regenerative type primary air pre heaters. Each fan, which is of sufficient rating to support the load, discharges through a SCAPH into a common bus duct that has four outlets, two directing air into primary air-preheater for heating and then to the mills, two direct cold air straight to the pulverizing mills. The SCAPHs are located in the PA fan discharge ducts to ensure that the primary air combined with coal temperature does not fall below the specified minimum to protect against cold end erosion. SECONDARY AIR SYSTEM The secondary air draught plant supplies the balance of air required for pulverized coal combustion, air for fuel oil combustion, and over fire air to minimize the production of nitrous oxide. The secondary air system consists of two forced draft (FD) fans, two steam coil air pre heaters and two regenerative type secondary air preheaters. Control of unit air flow is obtained by positioning the FD fans while the distribution of secondary air from wind box compartment to the furnace is controlled by secondary air dampers. The SCAPHs are located in the FD fan discharge ducts to ensure that the secondary air does not fall below the specified minimum to protect against cold end erosion.
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FUEL GAS SYSTEM The fuel gas draught plant draws hot flue gases from the furnace to the chimney by means of ID fan. Flue gas is passed through an economiser and regenerative air preheaters to improve the boiler efficiency, and through electrostatic precipitators to keep dust emission from the chimney within prescribed limits. SOOT BLOWING SYSTEM On-line gas side cleaning of boiler tubes and regenerative air-heaters is done using wall blowers and long retractable soot blowers.

3.3 PRESSURE PARTS 3.3.1ECONOMISER The heat from the flue gases is absorbed by the economizer which otherwise would leave the boiler as waste heat. This heat is added to the feed water before water enters the boiler. In modern boilers used for power generation, LP & HP feed water heaters are used to increase the efficiency of the turbine unit and feed water temp and hence relative size of the economiser is less. The economiser is continuous loop type and water flows in upward direction and gas in downward direction. 3.3.2 DRUM AND DRUM INTERNALS The function of boiler drum is to separate water and steam from the saturated steam & water mixture. The walls of the furnace absorb radiant heat from the furnace after the combustion and this mixture is then discharged into the drum. The drum is located on the upper surface of the boiler. The steam and water gets separated by means of turbo separators and primary and secondary screens. The boiler drum forms a part of the circulation of the boiler. Boiler water circulates from the steam drum into unheated down comer pipes, then from the pipes into heated furnace wall tubes back into the drum. The drum serves two functions, the first one being that of separating steam from the mixture of water and steam discharged into it. Secondly the drum houses all the equipments used for the
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purification of steam after being separated from water. This purification equipment is commonly referred to as the drum internals. The drum internals may consist of baffle arrangements, devices which change the direction of flow of steam and water mixture, separators employing spinning action for removing water from steam and screen dryers. These devices are used in conjunction with other to remove impurities from steam leaving the boiler drum. 3.3.3 FURNACE A boiler furnace is housed in the space within the boiler in which fuel is burnt and from which the combustion products are removed through a series of exhaust components before and finally getting discharged into the atmosphere. There is a separate chamber engulfed with water tube walls on all four sides in which the combustion process takes place isolated and confined so as to sustain controlled combustion. The firing system can be classified into direct firing system and indirect firing or intermediate bunker system. Direct firing system

Hot air whose temperature can be controlled with the help of cold primary air is permitted to flow through the mill which is fed with required coal. The air dries the coal and the fine coal is carried by the air through the coal burner to the combustion chamber. Indirect firing system

The combustion products pass through a series of super heater, re-heater tubes, economiser before escaping out from the boiler in the second pass. 3.3.4 WATER CIRCULATION SYSTEM IN BOILER Natural circulation system

The circulation in this type of system takes place by means of thermo-syphon principle due to different temperatures existing. The down comers contain relatively cold water, whereas the riser tube contain steam and water mixture whose density is comparatively less.

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Controlled circulation system

The circulation is to be assisted with mechanical pumps called controlled circulation (BCW) pumps beyond the pressure of 110kg/cm2. With the increase in the pressure the density difference between steam and water decreases. This is to overcome the frictional losses. Orifice plates are used to regulate the flow through various tubes. This system is applicable in high sub critical regions. 3.3.5 WATER WALLS Water walls serve as the only means of heating and evaporating the feed water supplied to the boiler from the economiser. Water walls consist of vertical tubes and are connected at the top and bottom to headers. These tubes receive water from boiler drum with the help of down comers. Boiler water walls absorb approximately 50% of heat released by combustion of fuel in the furnace 3.3.6 BURNER PANEL Burners help for the combustion process to take place. The pulverized coal is mixed with primary air flow which carries the coal air mixture to each of four corners of the furnace burner nozzles and into furnace. There are a total of 36 pulverized coal burners for corner fired boilers, nine burners per corner in the four corners and 20 oil burners provided each in between two pulverized fuel burners. All the nozzles of the burners are interlinked and are moved by burner tilt mechanism in unison. Burner tilt mechanism helps in positioning fire balls for temperature control. The boiler is fed up with light diesel oil and heavy fuel oil during initial start up of boiler. The high energy arc ignitors are used to ignite the oil. The ignition temperature varies for different fuels depending upon its properties. Raising the temperature of the fuel to its ignition temperature brings about combustion. Ignitors are used to ignite the fuel. 3.3.7 SUPER HEATER There are three stages of super heater besides the sidewalls & extended sidewalls. The first stage consists of low temperature super heater of connection flow type with upper and lower banks located above economiser assembly in rear pass. The second stage super heater consists of platen super heater. The third stage super heater consists of final super heater coil which is of radiant, convection and parallel flow type.
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3.4 PULVERISED COAL SYSTEM 3.4.1 COAL BUNKERS These are used for the storage of crushed coal coming from the coal handling system. Coal from mines comes in different sizes. These are crushed to a size less than 25mm size in crusher houses and sent to coal bunkers. These bunkers are located on the top of the mills so as to aid in gravity feeding of coal. 3.4.2 FEEDERS The purpose of the feeders is to transport coal from RC bunkers to the mills at the desired rate. The raw crushed coal is delivered from bunker to the individual feeder which in turn feed the coal at a controlled rate to the pulveriser. Feeder at TPP is gravimetric type and conveys coal through belt. Speed of feeder can be regulated and rate of coal fed to the mill is varied to meet the demand from the boiler. 3.4.3 MILLS Mills pulverize coal to desired fineness and fed to the furnace for combustion. Coal trapped in between bowl and rollers gets crushed and required crushing pressure is provided by springs in journal assembly. Pulverized fuel firing is a method where the coal is reduced to a required fineness such that 70 to 80% passes through a 200 mesh sieve. Crushed coal is carried by primary air through classifiers and fine coal is sent through pipes directly to burners and then to the boiler for combustion. When discharged into the combustion chamber, the mixture of air and coal ignites and burns in suspension. The different types of mills are. Medium speed mills such as bowl mills, ball mills are normally of vertical spindle type and operate between 30 to 100 rpm

The mills at TPP are of Bowl mill type. This is one of the most advanced design of coal pulverizer presently manufactured. The advantages of this mill are Lower power consumption Reliability Minimum maintenance
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Can be operated at various coal flows

Coal is fed from the feeders to the grinding zone of the mill where it is ground. Primary air enters at the bottom dries and transports coal from mill to boiler. Coarser coal gets separated in the classifier assembly and it falls back into the grinding zone. Fine coal along with air mixture flows to boiler for combustion. Foreign material falls into the scrapper chamber at bottom of mill which is removed and sent to reject bunker.

3.5 AIR AND DRAFT SYSTEM 3.5.1 FAN Fans are used to produce the air we need for the combustion in the furnace. They are also used to evacuate the flue gases produced after combustion. PA Fan

Air flow from PA fans is regulated by blade pitch mechanism depending upon the demand from the boiler. These are axial reaction two stage fans which supply primary air to the mills. Primary air gets preheated in air pre heater before entering mill. Primary air dries the moisture content in coal and also helps in transporting coal from mills to boiler for combustion. FD Fan

The FD fans are designed for handling secondary air for the boiler. Air from FD fan is called secondary air and is supplied to the boiler for combustion. Secondary air gets preheated in air pre heater before entering boiler. Air flow from FD fans is regulated by blade pitch mechanism depending upon the demand from the boiler. ID Fan

These fans draw the flue gases from furnace and sends to chimney and then to atmosphere. The flow is regulated by means of inlet guide vanes or variable frequency drive mechanism.

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Seal air Fan

These are used to supply seal air to the mills to prevent ingress of coal dust into gear box lubrication oil. Seal air fans take suction from primary air ducts.

DRAFT SYSTEM The term draft denotes the difference between the atmospheric pressure and the pressure in the furnace. Depending on the draft used, they are classified as Natural draft Natural draft Induced draft Forced draft Balancing draft system

In natural draft system units the pressure differentials are obtained by constructing tall chimneys so that vacuum is created in the furnace. Due to the pressure difference air is admitted into the furnace. Induced draft

In this system air is admitted due to natural pressure difference and the flue gases are taken out by means of induced draft fans. Forced draft

A set of forced draft fans are made use of for supplying air to the furnace and so the furnace is pressurized. The flue gases are taken out due to the pressure difference between the furnace and the atmosphere. Balance draft

Here a set of induced and forced draft fans are utilized in maintaining a vacuum in the furnace.

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3.6 Air pre-heater

Air pre-heaters transfer heat from flue gases to cold primary or secondary air by means of rotating heating surface elements. Flue gas from boiler enters on one half of APH dissipating heat to the heating elements. When these heating elements come in contact with the coal primary or secondary air, the air gets heated thus entering boiler at elevated temperature. This results in lesser heat energy requirement for combustion hence improving boiler efficiency.

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3.7 Electrostatic precipitator

ESP consists of large chamber in which collecting electrodes (which are plates) and discharged electrodes (thin wires) are suspended alternatively. The flue gas passing between the collecting and emitting electrodes gets charged and ionized due to corona effect. The suspended ash in the flue gas gets charged and gets collected in the collecting electrodes. ESP is used in the boiler to precipitate the dust in the flue gas which reduces the pollution which otherwise results in health hazards. The efficiency of modern ESPs is of the order of 99.9%.

3.8 Chimney These are tall RCC structures of height 180mts and form the final outlet of the flue gases which escape to the atmosphere at higher elevations.

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CHAPTER 4

TURBINE & ITS AUXILIARIES 4.1 INTRODUCTION The turbine is a three cylinder, reaction, condensing type with regenerative system of feed water heating. It is coupled directly to the generator. The turbine is a single shaft machine with separate High Pressure (HP), Low Pressure (LP) turbines. The HPT is a single cylinder having 24+1 stages and LPT are 25 stages respectively. The steam produced in the boiler is sent to the turbine where heat energy is converted into mechanical energy. 4.2 WORKING PRINCIPLE A steam turbine consists of two parts - cylinder and the rotor. The cylinder contains fixed blades, vanes and nozzles that direct steam into the moving blades carried by the rotor. Each fixed blade set is mounted in diaphragms located in front of each disc on the rotor. The rotor is a rotating shaft that carries the moving blades on the outer edges of either discs or drums. The blades rotate as the rotor revolves.

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In a multiple stage turbine, steam at high pressure and temperature enters the first row of fixed blades or nozzles through an inlet valve. As the steam passes through fixed blades or nozzles it expands and its velocity increases. The high velocity jet of steam strikes the first set of moving blades. The kinetic energy of steam changes into mechanical energy, causing the shaft to rotate. The steam then enters the next set of blades and strikes the next row of moving blades. As the steam flows through the turbine, its pressure and temperature decreases, while its volume increases. The decrease in the pressure and temperature occurs as the steam transmits energy to shaft and performs work. After passing through the last turbine stage, the steam exhaust into the condenser where it forms condensate which is recycled. 4.3 H.P TURBINE The outer casing is of barrel type and has neither axial nor a radial flange. An axially split guide blade carrier is arranged in the barrel type casing and is kinematically supported. The HP turbine is provided with a balance piston in the admission side to counteract the axial thrust forces exerted in the direction of flow of steam. The exhaust steam from HPT flows back to the boiler and passes through re-heater coils. The hot re-heat steam is then admitted into the LPT 4.4 LP TURBINE The casing of double flow LP cylinder is of three shell design. The shells are axially split and of rigid welded construction.

4.4 TURBINE COMPONENTS 4.5.1 ROTOR The rotor is machined from single (Cr-Mo-V) steel forging with integral discs. This specially designed by the BHEL for TPP. 4.5.2 BLADES Blades are the costliest elements of the turbine. Blades fitted in the stationary part are called guide blades or nozzles and those fitted in the rotor are called moving or working blades. The following are three main types of blades

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Cylindrical (of constant profile Twisted and varying profile blades.

4.5.3 COUPLINGS Couplings are required between any two rotors since it is made in small parts due to forging limitations and other technological and economic reasons. The coupling permits angular misalignment, transmit axial thrust and ensures axial location. 4.5.4 BEARINGS The HP rotor is supported by two bearings, a journal bearing at the front end of the turbine and a combined journal and thrust bearing directly adjacent to the coupling with the LP rotor. The combined journal and thrust bearing incorporates a journal and a thrust bearing which takes up residual thrust from both directions. The bearing temperatures are measured by thermocouples in the lower shell directly under the white metal lining.

4.6 TURBINE AUXILIARIES

The turbine cycle can be viewed in the form of different systems. They are: Lube oil system Control fluid system Condenser Vacuum Pumps Condensate extraction pump De-aerator

4.6.1 LUBE OIL SYSTEM This consists of main oil pump, auxiliary oil pump, emergency DC oil pump and jacking oil pump. When the machine is running, the main oil pump situated in the bearing pedestal draws oil from the main oil tank by injectors and conveys it to the system for lubrication purposes. When

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the main and auxiliary oil pumps fails, the lubrication oil is maintained by a DC driven emergency oil pump. This system fulfills the following functions: Lubricating and cooling the bearings Jacking up the shaft at low speeds. This enables the complete rotor assembly to be raised or floating in the bearing during turbine generator start up and shut down. This prevents damage to the bearing when shaft speeds are too low for hydro dynamic lubrication to take place. 4.6.2 CONTROL FLUID SYSTEM The turbine governing system is supplied with fire resistant control fluid and this system is independent of the lube oil system. The control fluid tank contains fire resistant control fluid pumps necessary for the governing system. Apart from its function, it also de-aerates the control fluid system. Control fluid pumps are situated on the control fluid tank and immerse with the pump bodies into the tank. They draw from the deepest point in order to supply control fluid that is as free of air as possible. The control fluid tank is provided with a local level indicator and level switches with which the maximum and minimum levels of the control fluid can be transmitted. A storage space is provided between the operating levels of the control fluid, which corresponds to the normal contents of the tank. This can accommodate the fluid in the entire control fluid system when the turbine is shut down. 4.6.3 CONDENSOR These are surface type condensers with two-pass arrangement. Cooling water is pumped into each condenser by a vertical cooling water pump through inlet pipe. To ensure healthy cleanliness of the condenser tubes on line tube cleaning is done where in balls are sent through the tubes which removes the scales. Steam looses its latent heat to the cooling water in the steam side of condenser. This condensate is collected in the hot-well welded to the bottom of the condenser and sent back to system by condensate extracting pumps. 4.6.4 VACCUM PUMPS The purpose of vacuum pump is to evacuate air and other non condensing gases from the condenser and thus maintain vacuum in the condenser. There are two pumps.

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4.6.5 CONDENSATE EXTRACTION PUMP The steam after condensing in the condenser, known as condensate, is extracted out of the hot well by condensate extraction pump and taken to the de-aerator through drain cooler, gland steam condenser and series of LP heaters. Steam from de-aerator or auxiliary steam header is supplied to the end seal of the turbine so as to prevent ingress of atmospheric air into the turbine through the end clearances. The gland steam cooler extracts this steam supplied to the end seals. 4.6.6 DE-AERATOR The presence of certain gases like oxygen, carbon dioxide and ammonia dissolved in water is generally considered harmful because of their corrosive attack on metals, particularly at elevated temperatures. The condensate admitted at the top of de-aerator column flows downwards through the spray walls and trays which are designed to expose to the maximum water surface for efficient scrubbing to affect the liberation of associated gases. Steam enters from the underneath of the trays and flows in counter direction of condensate. While flowing upwards through the trays, scrubbing and heating is done. Thus the liberated gases move upwards along with the steam. Steam gets condensed above the trays and in turn heats the condensate. Liberated gases escapes to the atmosphere from the orifice opening meant for it.

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CHAPTER 5 GENERATOR & ITS AUXILIARIES 5.1 INTRODUCTION

Generator is used to transform mechanical energy to electrical energy. Turbo generator for 500MW units are two pole water and hydrogen gas cooled generator. The two pole generator uses direct water cooling for stator winding, phase connections & bushings and direct hydrogen cooling for rotor winding. The generator frame is pressure resistant and gas tight equipped with one stator end shield on each side. The hydrogen coolers are arranged vertically inside the turbine end stator end shield.

5.2WORKING PRINCIPLE
The A.C generator is based upon the principle of electromagnetic induction and consists generally of a stationary part called stator and a rotating part called rotor. The stator houses the armature windings while the rotor houses the field windings. When the rotor is rotated, the lines of magnetic flux cut through the stator windings. This induces an emf in the stator windings.

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RESULT
On an average Thermal Power Plant at Visakhapatnam Steel Plant produces 250MW of power for the plant use and provide 6000 m3/hr cold blast to Blast Furnace Department and hot water to Rolling Mills.

FUTURE SCOPE
Thermal Power Plant at Visakhapatnam Steel Plant releases hot air into the atmosphere whose temperature is around 2000C. By reducing the 2000C temperature of the released gases into the atmosphere to atleast 1800C the company can get an annual profit of 20crores. (Case study done by Visakhapatnam Steel Plant employees)

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