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AT
(A joint venture of NTPC Ltd. &BSEB) MUZAFFARPUR THERMAL POWER STATION, KANTI, MUZAFFARPUR, BIHAR.
DURATION : 20.06.2011 to 31.07.2011
Mr. S. Chandra
Sr. Manager (EM)
Mr.N. D. Nayak
Engg.(EMD)
: 90010517123
ACKNOWLEDGMENT
This report pertains to take vocational training which was undertaken under KANTI BIJLEE UTPADAN NIGAM LIMITED, KANTI, MUZAFFARPUR, BIHAR ( A joint venture of NTPC & BSEB ) in partial fulfilment of the requirement for the BACHELOR IN ELECTRICAL N ELECTRONICS ENGINEERING from Adesh
Institute Of Engineering & Tech., Faridkot (Punjab) . The main purpose of the training
was to acquaint myself with practical experience of actual work condition in which we are required to work in future. I learnt a lot from the practical experience of the engineering & other personals under whom I was placed for training. This helped me to develop the habit of analysis critically various aspects of problem at the time of decision making.
Mr. D. Nayak,
for the power station .
Finally; I would like to express my thanks to all of the technical & non technical persons for the co- operation & valuable guidance during my training period
Bush Kumar
RECENT DEVELOPMENT
NTPC has opted for joint venture (jv) with BSEB. The main feature of this jv is as follows:
OBJECTIVE:
To take over Muzaffarpur Thermal Power station(2*110MW), a coal based power station at kanti , for carrying our restoration ,R&M and supplying power mainly to state of Bihar.
ABSTRACT
Any thermal power plant is converting the chemical energy of coal into electrical energy. The process involved for this conversion is based upon the modified Rankin cycle. The major components that are used to accomplish the modified Rankin cycle are:
Boiler feed pump, The steam generator water walls (evaporator), Steam generator super heaters, Steam turbine, Reheater, Condenser, Regenerative feed heaters etc.
All components of a power generating cycle are vital and critical in operation. In Modified Rankin cycle, the two most important aspects that is added are reheating & regenerative heating. By reheating we used to send the steam coming from exhaust of the turbine back to the reheater of the boiler so that its enthalpy increases and more work can be done by this steam the other purpose is to make steam dry so that no harm will be done to the blades of turbine. In MTPS Kanti, we have three turbines in Tandem coupling namely one H.P Turbine, one I.P Turbine & one L.P Turbine coupled with the generator to which is synchronized with the grid to produce electricity at 50Hz.
In all my modesty, i wish to record here that a sincere attempt has been made for the presentation of this project report. I also trust that this study will not only prove to be of academic interest but also will be able to insight into the area of technical management.
CONTENT
SI NO. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19
Description
An over view (NTPC) Plant introduction Schematic diagram of thermal power plant Working principle Process of generation of electricity Coal to steam Steam to mechanical Power Generation, Transmission & Distribution Single line diagram of grid Transmission Light up process Main boiler components Cooling water circuit Types of fan Types of pump Types of turbine Types of heater Unit control desk and panels References
An Overview
NTPC
NTPC was set up in 7th November 1975, the NAVRATNA power giant today generates more than one fourth of the total power in the country, ranked 5th largest power generating utility in the world, NTPC is the second most efficient in capacity utilization among the top ten thermal generating companies according to a survey conducted by Data monitor, United Kingdom. In a short span of two decades, NTPC has earn its prime status by setting up a total generating capacity of 22,249MW, with 19.14% of Indias operating capacity, the company generates 26.7% of country electricity through its 13 coal & 7 gas based power plants spread all over the country. Today, country needs a 10% sustained growth in power generation to ensure the momentum for a 7% overall growth in the economy. Recognizing this, NTPC has committed itself to achieving the status of a 30,000MW plus company by the year 2007 and 40,000MW plus company by the year 2012 and power generating capacity addition programme of 51,000MW (including nuclear energy and non-conventional sources of energy) for the tenth plan.
NEW TECHNOLOGY
Super critical technology at NTPC Sipat project (3*600MW) to increase the efficiency of the cycle and to decrease the green house gas emission, Closed cycle seawater cooling at Simhadri project for first time in India Introduction of IGCC (Integrated gasified combined cycle) for clean and efficient utilization of coal.
ENVIROMENT MANAGEMENT Liquid water treatment plants at Farakka and Kahalgaon. Ash water recycling system at Kahalgaon and korba to reduce water requirement for ash disposal at these stations.
PLANT INTRODUCTION
Salient Features Of Boiler Plant 1. General Single drum tangential firing & reheat type (water tube) Pulverized coal (Main fuel), Heavy oil & L.D.O (for light up & flame stabilization) 06 Pressurized type Bowl Mill Balanced draught 02 (each 60% capacity) 02 (each 60% capacity) 03 (each 60% capacity, one standby) 02 Trisector regenerative 01
Type of boiler Type of fuel used No. Of Mills Type of Mills Furnace P.A Fans F.D Fans I.D Fans Air heater Types of Air Heater Electrostatic Precipitator
2. M.C.R Parameter S.H. Outlet steam flow R.H. stem flow Pressure at S.H. Outlet Temp. at S.H. Outlet Pressure at R.H. Inlet Pressure at R.H Outlet Temp. at R.H. Inlet Temp. at R.H Outlet Pressure in drum Design pressure Flue gas temp. leaving Economiser Flue gas temp. leaving Air Heater Feed Water Temp. before Economizer 375 T/Hr 331 T/Hr 141.5 Ata 540c 37 Ata 32.9 Ata 369c 540c 148.69 Ata 158.0 kg/cm 350c 142c 235c
M.C.R. Value
WORKING PRINCIPLE
The working principle of thermal power plant is based on Rankin cycle. A central steam station basically works on the Rankin cycle. Steam is produced in the boiler , is expanded in the prime mover (Turbine) and is condensed in a condenser to be fed into the boiIer.
PROCESS ELECTRICITY
OF
GENERATION
OF
MTPS Kanti is a Thermal Power Plant. The functioning of every Thermal power plant is based on following process:1. 2. 3. Coal To Steam Steam To Mechanical power Power Generation, Transmission & Distribution.
Coal To Steam
Coal and water are the primary inputs to a thermal power plant.This process of conversion of water to steam by using heat energy produced by burning of coal by producing heat takes place in boiler and its auxiliaries. Coal burns in a furnace located at the bottom part of the boiler. Feed water is supplied to the boiler drum by boiler feed pumps, where water is heated and converted into saturated steam. This is further superheated in the super heaters.
Coal To Steam
We are taking coal from coal-yard as Wagon tippler load with the help of motor on which the conveyer belt is mounted. As Wagon tippler consist of rotor & pinion. The pinion use to rotate rotor. If in case Wagon tippler not working then mechanically coal is transfer into hopper to the belt. We supply coal in coal bunker watching the load on control room connected Ammeter & Voltmeter. Feeder is used to put coal on belt. Small motors are connected to belt for support. Coal being passed through metal detector after passing through metal detector it is passed through vibrating screen where coal of 5mm seperated from large coal ane fed to crusher then magnetic separator to remove iron particle from coal. Then fed to crusher to coal bunker.
From coal bunker coal is supplied, to pulverising mill. There are six coal bunkers supplying coal to each mill and are located at top of the mills to add in gravity feeding of coal. Each bunker store coal which can be used for 12 hrs. Coal is supplied to the mill by the four barriers. With the help of primary air fan we feed coal to pulveriser mill with high pressure of air. There are five pipes connected to mill from on we feed coal to mill and from other four pipes coal dust comes out from mill after pulverising. The coal is converted into powered form in the mill. The mill is ball mill of MTPS power station. With the help of primary air coal dust is feed into ignited boiler. The coal which we are using for thermal power plant is of class c. In boiler heat of coal is used to convert water into steam. Coal produces heat of 330c and that of super heated stem is 535 c.
Turbine
Types of turbine
1.
HP Turbine:-
HP turbine is a single flow design with eight stages of blading. Each stages compromises stationary and moving blades which are positioned into the rotor mounted on the diaphragms, directs steam into the rotor mounted on the moving blades. HP turbine is double shell construction comprising inner and outer casing. H.P steam enters the H.P turbine inner casing through inlet connection are mounted on the top and bottom outer casing. The steam exhausts through the two branches in the bottom half casing and returns to the boiler to be reheated to increase the temperature of the steam to 535c so that the efficiency increases.
2.
I.P Turbine: -
Intermediate pressure turbine is a double flow design with seven stages on blading on either side of central steam inlet. Each stage comprises stationary and moving blades which are positioned so that the stationary blades mounted on diaphragm, directs the steam into rotor mounted moving blades. The inner casing , diaphragm carrier ring and outer casing are made in halves bolted together in the horizontal centre.
3. L.P Turbine:L.P Turbine is a double flow design with six stages in each of its front and rear flow paths. Each stage consists of number of stationary blades incorporating in the diaphragm located in the casing and a set of rotating blades mounted on the rotor disc.
GENERATOR
A generator consists of rotor which consists of carbon brushes. The rotor rotates at 3000rpm in case of any fault if production of plants stops then we have bearing motor which rotates shaft of turbine continuously and rotor at 65rpm. This is because if shaft doesnt rotate then due to load it may bend. As generator produces 110MW or generates 11kv output. The output of generator is step up to 220kv by using step up transformer or generating transformer. Three phase is fed to station transformer. There are two station transformer1 and 2 which is step down transformer. Here 220kv is step down to 6.6kv for internal purpose. This 6.6kv is step down to 415v for low rating motors. At generating transformer we are using lighting arrestor which protects G.T from lighting. This 220kv is given to grid substation. In grid substation we are using some protective system before distribution we have Bus isolator, SF6 breaker, Line isolator, CT, lightning arrestor. Similarly we have two unit auxiliary transformers UAT-1 and UAT-2, which will step down voltage from 11kv to 6.6kv and it will supply to unit auxiliary board 1BA, 1BB. Similarly station transformer will supply to station board 9BA, 9BB. One unit is tie with other unit because during the failure of any one of the unit other unit will able to supply.
We are using web trap which changes the frequency 50Hz to 500Hz can be used for communicate in power plant. As three phase fed to station transformer (Auto transformer) by step up we fed to switchyard where circuit breaker is closed, when terminal voltage and frequency matched with the bus bar conductor.
Transmission
The KBUNL has capacity to generate 220MW of electricity but only one unit is working and the second unit is under R&M process. We are generating 90Mw out of 110MW and giving to the substation. The transmission is done through three phase, double circuit system. With the help of transformer, we are converting 11kv to 220kv and fed to substation. It is then step down to 132kv and feeded to BSEB and local areas.
Sub- Station
Control Room switchyard
Sub-Station:It is the place where power is changed, step down or step up and transmitted to other places. It consists of various protection equipments, switching circuits etc.
A substation consists of
a) b) c) d) e) f) g) Bus isolators circuit breaker Line isolator Current transformer CVT Lightning arrestor Wave trap
A.
Control Room:-
It is the brain of any sub-station. All the necessary steps about the transmission, protection, charging etc. are carried out in the control room. Measuring instruments of the control room:a) b) c) d) e) Relay circuit Fault locator Switch gears Voltmeters Ammeters
f) g) h)
a)
Components of electromagnetic relay:1. 2. 3. 4. Shaded pole Watt-hour meter Induction cup Single and double induction loop
b)
Fault locator:- A simple beam relay would measure the current seen by the
relay with the voltage at the relaying point. By comparing these two quantities the relay measure the line impedance (z=v/i) up to the point of fault.
c)
breaking the electric circuit in convenient way i.e just by the simple motion of a knob or a handle to connect together or disconnect two terminals to which cables are connected. There are two types of switch gears Air switch and Oil switch. d) Voltmeter:- It is an instrument, which measures the voltage along the phase. It actually measures the potential difference between the two points of the conductors. e) Ammeter:- It is an instrument, which measures the current across the conductor. It is mounted on the panel board. Where staff on duty can easily watch the readings. f) Power meter:- These instruments are used to measure the power in standard units i.e in MW. This instrument is also mounted on the panel board for easy watch for the operating staff. g) CRT screen:- It is a computer arrangement in which current information about the transmission line is seen. The circuit diagram of switchyard and control room is stored in hard disk. It also displays the current status of the transmission line. h) Battery room:- This room consists of several batteries and charges for emergency purpose. When power failure is there, then power is supplied by the battery to keep all the instrument or devices in on status.
B.
Switch yard:-
It is systematic arrangement of various components, where all the machines or equipments are connected with each other, looping, step down, step upof transmission line are done here only.
A switchyard consists of following equipments:a) b) c) d) e) Transformer Tower Conductor Insulator Circuit breaker
a)
of guard ring. it is located at the bottom of the tower so that any unauthorised person or animal cannot climb upto the tower. We have suspension type tower called as A type tower. The peak point angle is 0 to 2. In this type conductor is suspended with an insulator. B-type : angle lies between (2-15) C-type : angle lies between (15-30) D-type: angle lies between (30-60)
C) Conductor:- A conductor is very essential equipment which is used for transmission of power. It is generally made of aluminium. It is hanged on the tower with the help of insulators. Aluminium cost is cheap and has good conductivity. D) Insulator:- It is made up of porcelain material which is bad conductor of electricity. For transmission purpose generally PIN-TYPE insulators are used. The capacity of each disk is 20kv.
Connection with grid to synchronisation:1. The terminal voltage of alternator must be equal to the bus-bar voltage. 2. The running speed frequency must be equal to the bus-bar frequency. ( Ns=120f/P ) => ( f=PN/120 ) Where, f= frequency P= no. Of poles N= speed of alternator 3. The terminal voltage of two conductor must be equal to the two bus- bar terminal to place the external resistance to reduce the voltage drop.
Light up process
MTPS Kanti has direct firing system. In this system, a controlled quantity of crushed coal is fed to each bowl mill (pulveriser) by its respective feeders and primary air is supplied from the primary air fans which drives the coal as it is being pulverized and transports the pulverized coal through the coal piping system to the coal burners. There are six pulverisers out of which four are used and two remains in standby. The raw coal feeders supply 74TPH of coal to each mill. The pulverized coal and air discharge from the coal burners is directed towards the centre of furnace to form fire ball. There are 24 tilting, tangentially fired coal burners fitted at the four corners of the boiler at elevations.
The secondary air heating system supplies secondary air for combustion in the furnace around the pulverized coal burners and through auxiliary air compartments directly adjacent to the coal burner compartments. There are 12 air-atomizing ignitors per boiler, which initially ignite the coal and air mixture.
Above a predictable minimum loading condition, the ignition becomes self-sustaining. Combustion is completed as the gases spiral up in the furnace.
The major accessories of a steam-generating unit are listed as follows: Furnace Economiser Boiler drum Down comers Water walls Riser tubes Superheaters Reheaters De superheaters
Furnace:- A boiler furnace is the first pass of the boiler in which fuel is burned and
from which the combustion products pass to the super heater and second pass of boiler. The combustion process is a continuous process, which takes place in first pass of boiler and controlled by fuel input through coal feeders. It is a radiant type and watercooled furnace and enclosure is made up of water walls. The furnace is open at the bottom to allow ash/clinkers to fall freely into the furnace bottom ash hopper.
Down comers:- Down comer provide a passage for water from the boiler drum to
bottom ring header. From bottom ring header water goes to water walls for heat absorption and conversion into steam heating. To achive the circulation of water into water walls boiler circulation pumps are provided in down comers.
Riser tubes:- A riser is a tube through which the mixture of water and steam pass
from an upper water wall header to the steam drum.
Cooling tower
Types of fan :A fan is a device by which the air is made to flow at required velocity and pressure in a defined path imparting K.E of its impellers to air/flue gases. This pressure boost is used to create a draught in the air and flue gases system. Fans mainly perform two functions: 1. They supply air required for combustion in the furnace with required pressure and flow. 2. They evacuate the product of combustion i.e. flue gases into the atmosphere via chimney.
P.A fan:The primary air fan supplies heated air to the coal mills known as primary air, to give dry and pulverized coal to the furnace for efficient combustion. There are two P.A fans per boiler. The fan impeller is a double inlet, centrifugal wheel with backward curved plate blades.
F.D fan:The forced draught fan system is provided to supply secondary air required for pulverized coal combustion in the furnace, air for fuel oil combustion and over fire air to minimize NOX production. The F.D fan system comprises of two single stage axial flow, constant speed, and auto variable pitch fans per boiler. These fans provide pressurized atomospheric air to the boiler for combustion.
I.D fan:The induced draught fan system comprises of three centrifugal double inlet fans per boiler, two operating and one standby. Each fan unit consist of a backward curved plate bladed impeller, which is driven by an electric motor through a variable speed hydraulic coupling. The I.D fan serves the purpose of evacuating the products of combustion or the flue gases in the atmosphere via chimney.
Types of pump:1. Condensate Extraction pump (CEP):The function of condensate extraction pumps is to pump out the condensate to the deaerator through, L.P heaters. The steam from the L.P cylinders exhausts into the condenser shells where it is constrained to flow across the water tubes, through which cooling water is circulated.
2.Air extraction pump (AEP):The function of air extraction pump is to raise and maintain the vacuum conditions in the turbine main condensers, and to remove air and other non-condensable gases vented to the condensers from the various parts of the turbine and feedweater heating system.
3.Boiler feed pump (BFP):Boiler feed pump is the most critical component of a power plant. It is a rotary machine, which is coupled to a motor through variable speed coupling or turbo coupling. Under normal conditions two 50% boiler feed water pump sets are run in parallel to undertake the complete load of feeding the boiler, while the third 50% pump set is on standby duty.
Types of turbine
1. HP Turbine:HP turbine is a single flow design with eight stages of blading. Each stages compromises stationary and moving blades which are positioned into the rotor mounted on the diaphragms, directs steam into the rotor mounted on the moving blades. HP turbine is double shell construction comprising inner and outer casing. H.P steam enters the H.P turbine inner casing through inlet connection are mounted on the top and bottom outer casing. The steam exhausts through the two branches in the bottom half casing and returns to the boiler to be reheated to increase the temperature of the steam to 535c so that the efficiency increases.
I.P Turbine:Intermediate pressure turbine is a double flow design with seven stages on blading on either side of central steam inlet. Each stage comprises stationary and moving blades which are positioned so that the stationary blades mounted on diaphragm, directs the steam into rotor mounted moving blades. The inner casing , diaphragm carrier ring and outer casing are made in halves bolted together in the horizontal centre.
3. L.P Turbine:L.P Turbine is a double flow design with six stages in each of its front and rear flow paths. Each stage consists of number of stationary blades incorporating in the diaphragm located in the casing and a set of rotating blades mounted on the rotor disc.
Types of heater
1. High pressure heater (HPH):-In the water cycle temperature of feed
water from BFP is increased to approx, 130c by heating it in HP heater. As the heating of feed water in HP heater is done by the extra steam coming out of the High Pressure Turbine (HPT) hence, it is named as High Pressure Heater (HPH). 2. Low pressure heater(LPH):-In the water cycle, temperature of condensate from CEP is raised to approx. 80c by heating it in LP heater is done by the extra steam coming out of the low pressure turbine(LPT) hence, it is known as low pressure heater.
References:Modern power station practice: volume-b, volume-c. Power plant engg. By P.K NAG Control & instrumentation: volume 1 Operation and Maintenance manual (MTPS): volume 2