Professional Documents
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INTRODUCTION
Talwandi Sabo Power Limited (TSPL) was incorporated as an SPV by Punjab State
Electricity Board (PSEB) with the purpose of constructing a 1980 (3x660) MW thermal
power plant at Village Banawala, Mansa-Talwandi Sabo Road, District Mansa, Punjab,
India. Sterlite Energy Limited (a Vedanta group company) was selected as the developer
of the project based on the Tariff Based Competitive Bidding Process (Case-2) on BOO
basis for supply of 100% power to Punjab State Electricity Board (PSEB) for 25 years as
per the guidelines of Government of India. Power Purchase Agreement and other related
agreements were signed between TSPL and PSEB on September 1, 2008, and the
ownership of Talwandi Sabo Power Limited was transferred to Sterlite Energy Limited
(Now Vedanta Limited) on that date. Vedanta Resources plc (“Vedanta”) is a London
Stock Exchange listed FTSE 100 diversified metals and mining major with revenues in
excess of USD 12.9 billion. The group produces Aluminium, Copper, Zinc, Lead, Iron
ore and commercial energy. Vedanta has operations in India, Zambia and Australia and a
strong organic growth pipeline of projects. With an empowered talent pool of over
87,000 people, comprising over 25,000 direct employees and 59,500 contractors globally,
Vedanta places strong emphasis on partnering with all its stakeholders based on core
values of entrepreneurship, excellence, trust, inclusiveness and growth.
TSPL is one of the first few Supercritical plants being constructed in the country. The
Supercritical technologies are environment friendly and energy efficient technologies
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TALWANDI SABO POWER LIMITED, is a company incorporated under the
Companies Act 1956 and having its registered office at Village Banwala, Distt. Mansa,
Punjab (hereinafter referred to as the “Owner” which expression shall unless repugnant
to the subject or the context thereof mean and include its successors and permitted
assigns), owning a 1980 MW (3 x 660 MW) power station known as Talwandi Sabo
Power Limited at Village Banwala, Distt. Mansa, Punjab (“Plant”, as further defined
herein), and Talwandi Sabo Power Limited (TSPL) a subsidiary of Vedanta Resources
Limited, was incorporated as an SPV by Punjab State Electricity Board (PSEB) with the
purpose of constructing a 1980 MW (3x660) Super critical thermal power plant at Village
Banawala, Mansa-Talwandi Sabo Road, District Mansa, Punjab, India. The project is
based on the Tariff Based Competitive Bidding Process (Case-2) on BOO basis for
supply of 100% power to Punjab State Electricity Board (PSEB) for 25 years as per the
guidelines of Government of India. Power Purchase Agreement is signed with PSEB and
Linkage Coal is available. The station is fully commissioned and operational since
Sep’2017. The EPC contractor was M/s. SEPCO-I, China. Total engineering, supply,
erection, testing and commissioning of the power plant were in the scope of the EPC
contractor. Plant is connected through Railways. Facilities such as Railway Package, Ash
handling (Wet Ash beyond bottom Ash), Raw-water reservoir, Zero Discharge system,
Ash Dyke was constructed by owner. TSPL had employed M/s DCPL as technical
consultant for the whole power plant.
The O&M Operator is required to provide services, commencing from the takeover of
Plant for a period of at least 5 years (can be extended on mutual agreement for further
two years). It is required that the successful Bidder depute its staff and technicians in
each of the disciplines (Mechanical, Electrical, C&I and BOP and Main plant Operation,
CHP, Railways, Environment management facilities etc including local operation etc.,)
along with the Plant Manager is deputed at site from the date of takeover for fulfilling the
requirements of TSPL Plant operation requirements as per PPA
The salient features of the 3x660 MW super Critical Power Plant are as below:
1 Primary Fuel Non-coking Coal
2 Source of Coal Domestic Coal
2
(MCL/CIL), Imported
(as & when required)
3 Start-up Fuel LDO / HFO/HSD
4 Water Source From Punjab Canal
Network through Jagga
Canal which is almost 5
KM from plant
5 Pulverizing System Ball and tube mill
6 Boiler Super Critical,
Pulverised fuel, Natural
circulation with
superheater and
Reheater
7 Steam Turbine Three cylinder, with
Reheat and regenerative
cycle & Nozzle and
throttle governed
turbine
The power from the TSPL is to be supplied 100% to PSPCL as per PPA already existing.
As mentioned in this document Contractors are required to adhere to the instructions and
guidelines. Any queries on the document should be received within one (1) week of
receipt of the document. Bidders may visit the site at their convenience, if not done
already. This document is issued to only those Bidders who fulfill the following criteria: -
* Relevant experience of complete O&M of Coal fired Thermal Power Station of similar
capacity.
* Agency must have capability to operate plants in India.
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* The financial capability of the agency :- Minimum Annual Turnover>100 Cr (last three
FY)
* Bidders having long term interest in carrying out such type of work in India.
* Bidders should have capability & experience of Plant & performance engineering
experience of large size units
TSPL reserves the right to accept or reject any or all of the proposals without assigning
any reason whatsoever. Issue of the document doesn’t qualify the bidder for
consideration of bid by the Owner.
All the three units & power 25th Aug 2016
station is already
commissioned. Station COD
had already been performed
and accepted by PSPCL on
8th September 2016.
Unit 1 COD Date
Unit 2 COD Date 05th July 2014
Unit 3 COD Date 25th Nov 2015
Station COD Date 08th Sept 2016
Any item of PPE imposes a barrier between the wearer/user and the working
environment. This can create additional strains on the wearer; impair their ability to carry
out their work and create significant levels of discomfort. Any of these can discourage
wearers from using PPE correctly, therefore placing them at risk of injury, ill-health or,
under extreme circumstances, death. Good ergonomic design can help to minimise these
barriers and can therefore help to ensure safe and healthy working conditions through the
correct use of PPE.
Practices of occupational safety and health can use hazard controls and interventions to
mitigate workplace hazards, which pose a threat to the safety and quality of life of
workers. The hierarchy of hazard controls provides a policy framework which ranks the
types of hazard controls in terms of absolute risk reduction. At the top of the hierarchy
are elimination and substitution, which remove the hazard entirely or replace the hazard
with a safer alternative. If elimination or substitution measures cannot apply, engineering
controls and administrative controls, which seek to design safer mechanisms and coach
safer human behavior, are implemented. Personal protective equipment ranks last on the
hierarchy of controls, as the workers are regularly exposed to the hazard, with a barrier of
protection. The hierarchy of controls is important in acknowledging that, while personal
protective equipment has tremendous utility, it is not the desired mechanism of control in
terms of worker safety.
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thermal agents, from sources such as welding torches and UV light, also contribute to
occupational eye injury.
While the required eye protection varies by occupation, the safety provided can be
generalized. Safety glasses provide protection from external debris, and should provide
side protection via a wrap-around design or side shields.
Goggles provide better protection than safety glasses, and are effective in preventing
eye injury from chemical splashes, impact, dusty environments and welding. Goggles
with high air flow should be used to prevent fogging.
Face shields provide additional protection and are worn over the standard eyewear;
they also provide protection from impact, chemical, and blood-borne hazards.
Full-facepiece respirators are considered the best form of eye protection when
respiratory protection is needed as well, but may be less effective against potential
impact hazards to the eye.
Eye protection for welding is shaded to different degrees, depending on the specific
operation.
PPE for hearing protection consists of earplugs and earmuffs. Workers who are regularly
exposed to noise levels above the NIOSH recommendation should be furnished hearing
protection by the employers, as they are a low-cost intervention.
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1.4 Plant
(a) the electric power generating facility that is being constructed in TSPL, Mansa,
Punjab India consisting of, among other things, three Units, each to be constructed with a
Rated Capacity (as defined in the EPC Contract) of 660 MW and in accordance with (i)
the plant specifications described in Schedule and (b) without reducing or derogating
from clause (a) or (c), all associated equipment, land, the Site, buildings, engineering and
design documents, other energy producing equipment and all auxiliary equipment,
Railway, Coal handling, fuel handling and storage infrastructures, water supply and
treatment facilities, ash disposal facilities and all other equipment installed or to be
installed within the Plant boundary & Associated facilities like water intake system &
Railway terminal points as mentioned in battery limits pursuant to obligations contained
in the Plant Agreements, and (c) without reducing or derogating from (a) or (b), means,
with respect to the delivery of Services by the Operator and the scope of the
responsibilities and obligations of the Operator hereunder, the items described in (a) and
(b), including without limitation the Units, the Switchyard (as defined in and to the extent
a responsibility of the Owner), are not constructed under and pursuant to the EPC
Contracts.
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It means the period of time commencing on the takeover of the Plant by the O&M
Contractor and continuing until the end of the fifth (5th) Contract Year thereafter or until
the Contract is terminated / extended as per the provisions of the Contract.
a. the loading, unloading, handling and storage of Coal or Secondary Fuel and
b. the private electric power generation industry with respect to the design, engineering,
construction, testing, metering, repair, operation and maintenance of electric generating,
transmission and distribution facilities, including in the procurement of spare parts, spare
equipment and spare components in relation thereto; which in any such case should have
been expected to accomplish the desired result at the lowest reasonable cost, consistent
with licensing and regulatory considerations, environmental considerations, reliability,
safety and expedition. Prudent Utility Practices is not intended to be limited to the
optimum practice, method or act, to the exclusion of all others, but rather to be a
spectrum of possible practices, methods or acts employed by owners and operators of
facilities similar in size and operational characteristics to the Plant.
“Rated Capacity”
It means the generating capacity of the Plant which shall be 1980 MW or 660 MW for
one Unit and subject to adjustment in accordance with the EPC Performance Test results.
Representative
It means, for each Party, a Person designated by notice in writing to the other Party.
Scheduled Maintenance
It means such scheduled and pre-agreed maintenance as may be authorised in the relevant
Annual Operating Plan.
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Preventive, predictive and break down maintenance of Unloading station/wagon tripler,
stacker declaimer, coal feeders/ conveyors/chutes/dust extraction, dust suppression
system/fans fasteners/ducting/bag dust collectors/gear boxes/coal crushers/automatic coal
sampling equipment / coal lab equipment etc., taking trial run of the above system to the
satisfaction. Belt vulcanizing etc. will be in the scope of contractor.
1.8Esp
Periodical inspection of ESP internals whenever required and necessary ,repairs of
collecting electrodes, discharge electrodes, its rapping mechanism,
gearboxes/hoppers/chutes/scrapper conveyor rotary air lock valves and bottom hopper
fluidizing system and root blowers etc., and taking trial of the above machinery and plant
to the satisfaction.
Preventive and break down maintenance of Bag filter, solenoid valve, bag replacement,
cleaning of bags, Control system, PLC logic setting and maintenance, Electrical system
and mechanical system.
1.9 DM Plant
Overhauling of pumps, valves/ lubrication/ replacement of leader/ nozzles/valves
/gaskets/ pipes/ arresting leakage of water, providing assistance to transfer the
resins/sand/activated carbon for replacement or for internal inspection, repairs of
acid/alkali storage tanks/pipe lines/valves/pumps/supports and chemical dosing system to
boiler and providing assistance for acid / alkali unloading etc., and circulating water
treatment.
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/fasteners/arresting leakage in the piping replacement of valves and piping etc. During
operation of turbo-generator any deviations of parameter like vibration, HP/LP
differential expansion, axial shift, top/bottom casing temp etc. needs correction has to be
taken up by O&M operator which may need alignment, balancing, lifting of HP/LP
casing, reworking of insulation, and generator rotor thread in, thread out etc.
The contractor shall arrange for specialized services as & when required for turbine
balancing, Experts visit during turbine overhauling and On-line leak sealing /valve
internal machining
Online Sealing
On-line leak sealing Steam and water etc., (Identification of exact leakage by removing
insulation, scaffolding & preparatory jobs to carry out the work.)
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Gland steam condenser is a heat exchanger which is used to condense the shaft end steam
leak-off and valve steam (air) leak-off for the recovery of working medium and heat. One
of the cooling medium of the gland steam condenser is feed water, therefore during the
unit normal operation; feed water will go through gland steam condenser.
HP/LP bypass systems are in series & having maximum capacity 60% of BMCR. HP
bypass system is connected in between main steam pipe line to CRH line. HP de-
superheating water comes from BFP discharge. LP bypass system connects HRH line to
condenser. LP de-superheating water comes from CEP discharge. This system is suitable
for constant pressure operation & slip pressure operation of the unit. It is used for
development the steam parameters during cold startup & avoid re-heater starvation.
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main oil tank (75m3), main oil pump, and oil injector. AC lubricating oil pump, DC
emergency oil pump, overflow valve, oil cooler, switching valve, exhausting unit,
ultrasonic oil level Detector and other instruments for measurement and control system.
Condensate system
* There are two condensate extraction pumps (CEP) whose suction is taken from
Hotwell. After the condensate pumps, the condensate delivered to the Deaerator storage
tank through a gland steam condenser (GSC) and four LP Heaters. During this process
the condensate will be heated by turbine extraction steam in low pressure heaters &
deaerator.
* The system incorporates two nos. (2x100%) constant speed electric motor driven
vertical centrifugal type condensate extraction pumps (1 operation + 1 standby).
* The system combined with four surface LP heaters and one integrative deaerator, Each
LP heater will be furnished with its own bypass. In case of tube leakage, the relevant
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heater will be switched off.- No.7 and No.8 LP heater is furnished with the common
bypass.
* A set of control valves adopted on main condensate piping to adjust Deaerator water
level. Steam is drawn to deaerator from No 4 extraction in normal condition & from
auxiliary steam in start-up condition.
* The pumps furnished with a minimum recirculation line installed from the downstream
of the gland steam condenser and returning to the main condenser.
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* Open Cycle Cooling Water system (OCCW)
CCCW system uses demineralized water as working medium. Because of this corrosion
of the cooling equipments decreases & heat exchange efficiency increases. It avoids the
jamming of flow path thereby increasing reliability & reducing the maintenance time.
Two (2x100%) CCCW pumps & two (2x100%) water-water heat exchangers are
installed in CCCW system.
OCCW system takes water from CW pump outlet pipe, which is filtered by electrical
strainer followed by an increase in pressure by pressure pumps. After cooling the
equipments the return line is connected to the CW return pipe system.
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Air compressor:
There are total 02 compressor house, 01 is for ash handling system and 01 is for Main
plant instruments & service air requirement -
Instrument air Compressor
No of Compressors: 5 numbers screw compressors
Capacity of Compressors: 30nm3/min, P=0.80mpa
Drier Type: Regenerative type
Capacity and number of driers: 50nm3/min and 4 numbers
Ash Compressors
No of Compressors: 17numbers screw compressors
Capacity of Compressors: 60nm3/min, P=0.80mpa
Drier Type: Regenerative type and refrigerant type
Capacity and number of driers: 4Regenerative type of 50nm3/min and 11 nos refrigerant
type of 90nm3/min
The function of compressed air system is to supply all kind of compressed air for
different purpose:
* The control & instrumentation air,
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* Enclosed galleries are provided for proper ventilation & illumination. The Galleries
provided with windows and translucent sheet for lighting.
* Underground tunnels equipped with proper ventilating equipment.
* The coal conveyors and coal transfer plant have a complete interlock system to ensure
smooth operation.
house. Two(2) Roller screens and two(2)Ring hammer crushers are installed under
C3A. Others are installed under C3B. One(1)electric driven splitter is installed under
C3 A. The coal can be separate uniform double streams and drop into two (2) Roller
* The design capacity of Ring hammer crusher is 1250t/h. The size of coal inputted will
* On line temperature and vibrating monitor and ZSS are installed for crushers and it
could be hooked up to centralized vibration analysis system.
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* Two(2) Hang-type magnetic separators for belt width 1600mm will be installed in
* Two(2) Metal detectors for belt width 1600mm will be installed in the middle of C3
Belt Scales
* Two(2)belt scales will be installed at the middle of C3 and C12 separately, total four
(4).
* Motional circle chains will be installed as calibration device for belt scale, total four
(4).
* Belt scale range:20% to 120% of design capacity requirement with 100% overload
protection.
Auxiliary Equipment
* Auxiliary system such as ventilation, dust removal, firefighting, lighting and
communication are provided.
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* The hoisting equipments in the system such as Crane, Electric Hoist are installed
suitably at: 1. Transfer Tower 2. Crusher House 3 Bunker bay and 4. Bulldozer garage
F2491C-D-01。
* Supervision and control of unit will be composed of DCS and other thermodynamic
control systems, DCS is the main part. In CCR operator stations with LCD and keyboard
/ mouse will be the main control and monitoring interface. The system will be governed
by the operating system running in a real time mode. It will be Microsoft Windows 2000/
Window XP based system.
* When serious failure of DCS is happened (for example loss of power, communication
interrupt, all operator stations fault, important controller fault etc.), the unit can be auto
shut down. And can shut down safely under the rule of “fail-safety” through the several
hardwired emergent pushbuttons that mounted on the operator console in order to protect
person and equipment. These pushbuttons must be hardwired and independent from the
DCS.
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VIEW OF TALWANDI SABO POWER PLANT
19
CHAPTER-2
COAL HANDLING PLANT
It can be called the heart of thermal power plant because it providedthe fuel for
combustion in boiler. The coal is brought to the TSPL through rails there arefour tracks
in all for transportation of coal through rails. Everyday 7 to 8 trains of coal are unloaded
at TSPL. Each train consists of 58 wagonsand each wagons consists of 60 tones of coal.
The approximate per day consumption atTSPL is about 35000 tones. The coal is firstly
unloaded from wagon by wagontriplers then crushed by crushers and magnetic pulley and
pulverized to be transformed to the boiler. The whole transportation of coal is through
conveyor belt operated by 3 Inductionmotor.
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1) Wagon Unloading System.
2) Crushing System.
3) Conveying System.
Wagon Tripler:-
It unloads the coal from wagon to hopper. The hopper, which ismade of Iron , is in the
form of net so that coal pieces of only equal to and less than 200mm. size pass through it.
The bigger ones are broken by the workers with the help ofhammers. From the hopper
coal pieces fall on the vibrator. It is a mechanical systemhaving two rollers each at its
ends.The rollers roll with the help of a rope moving on pulley operated by a slip ring
induction motor with specification:
Wagon tripler
Fig 2.2
Wagon Tripler
Rated Output. : 71 KW.
Rated Voltage. : 415 V.
Rated Current. : 14.22 Amp.
Rated Speed. : 975 rpm.
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No. of phases. : 3
Frequency. : 50 Hz.
The four rollers place themselves respectively behind the first and the last pair of wheels
of the wagon. When the motor operates the rollers roll in forward direction moving the
wagon towards the “Wagon Table”. On the Wagon table a limit is specified in which
wagon to be has kept otherwise the triple would not be achieved.
Primary Crushers:
Primary crushers are provided in only CHP stage 3 system, which breaking of coal in
CHO Stage 1 & Stage 2 system is done at wagon tripler hopper jail up to the size (-) 250
mm.
Secondary Crusher:-
Basically there are four ways to reduce material size : impact attrition , Shearing and
Compression. Most of the crushers employ a combination of three crushing
methods.Ring granulators crush by compressing accompanied by impact and
shearing.The unique feature of this granulator is the minimum power required for
tone for this type of material to be crushed compared to that of other type of
crushers.
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hung on a pair of suspension shaft mounted on rotor discs. Crushers of this type employ
the centrifugal force of swingingrings stroking the coal to produce the crushing action.
The coal is admitted at the top and the rings stroke the coal downward. The coal
discharges through grating at the bottom.
Stacker-reclaimer
A stacker usually operates on a rail-like structure with movable wheels, but the main
operation is performed on a fixed place. Stackers are used to stack into different patterns,
such as cone stacking and chevron stacking. Stacking in a single cone tends to cause size
segregation, with coarser material moving out towards the base. Raw cone ply stacking
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is when additional cones are added next to the first cone. Chevron stacking is when the
stacker Stacker-reclaimer travels along the length of the stockpile adding layer upon
layer of material.
Luffing:
This is vertical movement (that is, up & down)by hydraulic cylinders .
Travelling: The stacker moves on a rail track. All the controls are in the controller's cabin
which is above the boom conveyor. The new stackers can be controlled remotely.
Slewing
This is the movement of the stacker around its central axis (that is, rotary movement).
This allows aligning or placing the stockpile in the required area as per requirement. This
works mostly by swel penion which rotates around a swel base. This type of gear
assembly is called the sun and planet.
Stacker-Reclaimer
Fig 2.3
Operation of Conveyors
Various conveyors are provided for transporting the coal from Track hopper to Bunkers.
The following precautions are to be taken before taking any conveyor into service:
a) There is no oil leakage at gearboxes / fluid couplings and the oil levels are correct.
b) The Discharge and Receiving chutes are free from jamming and choking.
c) The Flap Gates are in correct positions.
d) All inspection doors are in the closed position.
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e) All pull-cords are reset and the EPB is released and ensure that all protections are
healthy.
f) The Alarm Siren is in working order.
g) Communication facility is available.
h) The lighting is adequate.
i) No Permit To Work (Isolation) is pending against that conveyor.
2.5 Metal Detector System
Metal Detectors are used to detect tramp metal pieces from the raw materials coming on
the conveyor belt metal detector are used to prevent damage to the processing machinery
like crushers, cutting machines,cutters, mills, rollers,etc.
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running over a pair of end drums or pulleys and supported by series of rollers (known as
idlers) provided at regular intervals. The return idlers which support the empty belt are
plain rollers and are space wide apart.The initial cost of this coal carrying system is not
high and power consumption is also low. The belt conveyors are successfully used on
inclination up to 20o to the horizontal. The load carrying capacity of the belt conveyors
may vary from 50 to 100 tonnes/hr and it can be easily transferred through 400 meters
Transfer of coal in thermal power plant including carrying of coal from unloading point
to the storage site. It may require one equipment or several depending on the site of the
thermal power plant.
Conveyor belts
Fig 2.5
2.6 Conveyor Protection System
Conveyor as discussed is a very important thing in thermal power plant .So we have to
protect it also from various factors like overspeed, misalignment of belt, overloading of
coal,fire etc so in order to save belt various equipments are being put in the conveyor
belt.
1) Pull Chord
2) Belt sway
3) ZSS(zero speed switch)
4) IR
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Pull chord-
Pull Cord Switch is an emergency switch to stop the belt conveyor instantly when an
accident happens. Since the Pull Cord Switch is so designed that it should be installed at
the side of belt conveyor and the pull cord should be mounted along conveyor, the switch
can be actuated at any position. According to the Industrial Safety & Health Regulations,
it has been assigned to install the Pull Cord Switch to belt conveyor in Japan.
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Belt sway
Fig 2.7
ZSS(zero speed switch )-
Electronic Speed Monitor is used to monitor speed of conveyors, crushers, rolling mills,
agitators, mixers, stirrers, screw conveyors, and other industrial machinery. This device
actuates relay contacts at preset speed. Using these contacts desired control action such as
zero speed protection / under speed protection/ over speed protection can be achieved.
Advantages
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IR-
The UV/IR Detector and Linear Heat Detection Cable each represent a fire zone in a
particular fire protection zone on the conveyor belt, hence Zone 1 is the UV/IR detector
and Zone 2 is the Linear Heat Detection Cable. Both of these devices are connected to the
fire control panel of which a 2 zone panel will be suitable. The devices are all joined with
the fire panel through steal wired armored cable which has a fire resistance of 30 minutes.
We then also install a Combination Strobe/Sounder near the panel that is installed at the
specific zone, this device serves as a warning to personnel in the area should a fire break
out. Each fire control panel has a potential free contact which activates on the detection
of fire on Zone 1 or Zone 2. This is the contact that we use to trigger the water
suppression system by converting the potential free contact into a 24VDC switch.
If smouldering coal or glowing embers are loaded onto a conveyor it is probable that
these will be transferred to a crusher, silo or bunker. At such places hot coal may ignite
combustible dust accumulations that then leads to a full scale fire incident. This results in
loss of critical equipment, loss of production, loss of property and human lives. With the
additional adverse effect this would have on the environment.
IR
Fig 2.8
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CHAPTER-3
TG AREA
The turbine generator consists of a series of steam turbines interconnected to each other
and a generator on a common shaft. There is usually a high-pressure turbine at one end,
followed by an intermediate-pressure turbine, and finally one, two, or three low-pressure
turbines, and the generator. As steam moves through the system and loses pressure and
thermal energy, it expands in volume, requiring increasing diameter and longer blades at
each succeeding stage to extract the remaining energy. The entire rotating mass may be
over 200 metric tons and 100 feet (30 m) long. It is so heavy that it must be kept turning
slowly even when shut down (at 3rpm) so that the shaft will not bow even slightly and
become unbalanced. This is so important that it is one of only six functions of blackout
emergency power batteries on site. (The other five being emergency
lighting, communication, station alarms, generator hydrogen seal system, and turbo
generator lube oil.)
For a typical late 20th-century power plant, superheated steam from the boiler is
delivered through 14–16-inch (360–410 mm) diameter piping at 2,400 psi (17 MPa;
160 atm) and 1,000 °F (540 °C) to the high-pressure turbine, where it falls in pressure to
600 psi (4.1 MPa; 41 atm) and to 600 °F (320 °C) in temperature through the stage. It
exits via 24–26-inch (610–660 mm) diameter cold reheat lines and passes back into the
boiler, where the steam is reheated in special reheat pendant tubes back to 1,000 °F
(540 °C). The hot reheat steam is conducted to the intermediate pressure turbine, where it
falls in both temperature and pressure and exits directly to the long-bladed low-pressure
turbines and finally exits to the condenser.
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during startup, with air in the chamber first displaced by carbon dioxide before filling
with hydrogen. This ensures that a highly explosive hydrogen–oxygen environment is not
created.
TG FLOW
Fig 3.1
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OVERVIEW PROCESS DIAGRAM OF TG AREA
Fig 3.2
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3.3 Steam turbine
A steam turbine is a device that extracts thermal energy from pressurized steam and uses
it to do mechanical work on a rotating output shaft. Its modern manifestation was
invented by Sir Charles Parsons in 1884.
Because the turbine generates rotary motion, it is particularly suited to be used to drive
an electrical generator – about 90% of all electricity generation in the United States
(1996) is by use of steam turbines.The steam turbine is a form of heat engine that derives
much of its improvement in thermodynamic efficiency from the use of multiple stages in
the expansion of the steam, which results in a closer approach to the ideal reversible
expansion process.
STEAM TURBINE
Fig 3.3
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CHAPTER-4
WATER TREATMENT PLANT
The principle problem in high pressure boiler is to control corrosion and steam quality.
Internal corrosion costs power station crores of rupees in repair without strict control
impurities in steam also form deposit over turbine blades and nozzles. The impurities
present in water are as follows :-
1) Un-dissolved and suspended solid materials.
2) Dissolved slats and minerals.
3) Dissolved gases
4) Other minerals ( oil, acid etc.).
5). a) Turbidity & Sediment.
b) Silica.
c) Micro Biological.
d) Sodium & Potassium Salt.
e) Dissolved Sales Minerals.
6). a) O2gas.
b) CO2 gas.
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then enters de-gasified unit where free CO2 is scrubbed out of water by upward counter
flow of low pr. air flow through degasified lower and degassed water is pumped to strong
base exchanger ( anion exchanger). Arrangement for dosing ammonia solution into de-
mineralized water after mixed bed unit has been provided p+1 correction before water is
taken in de-condensate transfer pump the DM water to unit condensor as make up.
Raw water for the plant will be taken from Jagga Canal. Raw water from the Jagga Canal
is delivered to raw water Reservoir through Water conveyance system. Raw water from
the reservoir is taken to inclined plate filter for the pretreatment through the raw water
pump house.
Raw water treatment system consists of inclined plate filter basin, and gravity filter
,service and portable water basin .The total water requirement for the plant is 5337
cum/hr. Four numbers of Raw water pumps (3W+1S) each with capacity 1779 Cum/hr.
And also provided with four numbers of Service water pumps (3W+1S) each with
capacity 753 Cum/hr. Five numbers of inclined plate filters each with capacity 1340
cum/hr. Three numbers of clarified water basins each with capacity of 4300 cum/hr is
provided which will satisfy the 8 hrs of requirement. Chemicals dosing system consists of
powder plunge equipment, solution preparing tank and dosing pump. Solution
preparation tank can meet the Eight hours requirement. Water for CT make up is going
from CW make-up basin15100m3 capacity. 2000m3 storage basin water will be supplied
to CW make up basin by two CW transfer pump of capacity of 1372-2744 m3/hr, head
19-11 m, motor power 160 KW (one operating and one standby). From 15100m3 CW
make up basin, CW make up supply water to cooling tower basin through three CW make
up pumps of capacity 972-1440 m3/hr, head 19.3-12.3 m, motor power 75 KW (two
operating one standby). The clarified water is fed to 2 nos. gravity filters, each having
capacity Q=50m3/hr. This filtered water is stored in the potable water basin of capacity
100m3, a part of the 4300m3 service water storage tank. The portable water is pumped to
all users after dosing of chlorine for disinfecting purposes. The capacity of each potable
water pump is 50 m3/hr. Service water (SW) for the entire plant is going from service
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water basin through 4 SW pumps (three operating and one standby), each having capacity
of 753 Cum/hr
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Chapter-5
Fig 5.1
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5.1 Fuel and ash plant:-
Coal is used as combustion material in TSPL, In order to get an efficient utilization of
coal mills. The Pulverization also increases the overall efficiency and flexibility of
boilers. However for light up and with stand static load , oil burners are also used. Ash
produced as the result of combustion of coal is connected and removed by ash handling
plant. Ash Handling Plant at TSPL consists of specially designed bottom ash and fly ash
in electro static precipitator economizer and air pre-heaters hoppers.
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5.4 Utilization:-
Utilisation of coal-ash is always practise than its disposal. There are various methods of
utilisation of coal-ash along with established engineering technologies some of them are
mentioned below:
1. Manufacturing of building materials.
2. Making of concrete.
3. Manufacturing of pozzuolana cement.
4. Road construction etc.
In all the above cases financial constraint discourages the entrepreneurs to take up the
work. In view of the environmental impact of disposal, Government may give attractive
subsidy and create marketing facility so that entrepreneurs may come forward to use as
their raw material.
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