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SONEBHADRA
Mahatma Gandhi Missions College of Engineering and Technology. Noida, U.P., India
CERTIFICATE
This is to certify that Mr. SANTOSH MAURYA of B. Tech. Mechanical Engineering, Class_BT ME, Roll No. 0809540040 has completed his Industrial Training during the academic year 2012 21-06-2011 to SONEBHADRA. 31-07-2011 at ATPS,ANPARA
CONTENT
Introduction1 Major requirement.1 Raw material used..2 Salient data and design specifications....3 Design parameter...3 Introductory overview...6 Coal fired thermal power station..8 Boiler and auxiliaries...9 Draught.11 Ash handling system12 Advantage & disadvantage..13 Induced draft fan..14 Milling system......16 Primary air preheater....17 Turbine-salient design..18 Constructional features.19 Role of turbine in power generation.20 Governing system.22.
INTRODUCTION TO ANPARA A
Name of the factory ANPARA THERMAL POWER STATION Address:A.T.P.P POST:-ANPARA Disst.:-Sonebhadra(u.p) Location- ATPP is situated at the north bank of Rihand reservoir about 220 kms south from Varanasi and about 35 kms west south from Renukoot by road. Total proposed capacity 4030MW in four stages (3*210MW+2*500MW+2*600MW+2*600MW) Present capacity 1630MW Anpara Project cost- Anpara ATPS-Rs.721Cr. Anpara BTPS-Rs-2060Cr.
Major Requirements COALA.Source-Kakri,Bina,Khadia coal mines. B.Maximum consumption-48,840 MT/ day for 3130 MW(F grade coal). C.Mode of transportation- MGR Rail Transportation System. Water Source-Rihand reservoir
Chimney height:- ATPS-220 meters, BTPS-275 meters. Ash disposal-ash slurry pumped to ash dyke. Commencement of Work-July 1980 Commissioning of Unit 1 of ATPS-28Mar 1986 Commissioning of Unit 2 of ATPS-28 Feb 1987 Commissioning of Unit 3 of ATPS-12 Mar 1988
Boundary Wall of the factory is about 1Km (in all direction from the main plant equipment).
Feed water:
Temp.at EOC inlet: Pressure at ECO inlet: Rated flow at ECO inlet: 242degreeC 180kg/cm^2 655T/hr
Fuel:
F/E grade bituminous coal of CV: Fixed carbon: Volatile matter: Moisture: Ash: Fusion temp: Pulverisers: Capacity: 3750Kcal/kg 28% to 24% 28% to 21% 11% to 15% 33% to 40% 1400degreeC 6 nos. 39.6T/hr.at55HGI
Steam turbine:
Reaction, condensing, reheating,horizontal tandem compound, three cylinder,regenerative,throttle governed.
Rated output: Speed: Pressure of steam at inlet: Temp. of steam at inlet: Condenser area: Circulating water flow: Condenser vacuum:
Generator:
247 MVA,PF0.85(lag),terminal voltage 15.75KV,rotor hydrogen cooled,stator water cooled.
Seal oil pressure: Hydrogen pressure: Stator water pressure: Static excitation system: Field breaker.
4.8 to 5.8kg/cm^2 3to3.5kg/cm^2 (hydrogen purity98.8%) 2.5 to 2.8kg/cm^2 Thirstier convertor power pack
At present 54.09% or 93918.38 MW (Data Source CEA, as on 31/03/2011) of total electricity production in India is from Coal Based Thermal Power Station. A coal based thermal power plant converts the chemical energy of the coal into electrical energy. This is achieved by raising the steam in the boilers, expanding it through the turbine and coupling the turbines to the generators which converts mechanical energy into electrical energy.
Introductory overviewIn a coal based power plant coal is transported from coal mines to the power plant by railway in wagons or in a merry-go-round system. Coal is unloaded from the wagons to a moving underground conveyor belt. This coal from the mines is of no uniform size. So it is taken to the Crusher house and crushed to a size of 20mm. From the crusher house the coal is either stored in dead storage( generally 40 days coal supply) which serves as coal supply in case of coal supply bottleneck or to the live storage(8 hours coal supply) in the raw coal bunker in the boiler house. Raw coal from the raw coal bunker is supplied to the Coal Mills by a Raw Coal Feeder. The Coal Mills or pulverizer pulverizes the coal to 200 mesh size. The powdered coal from the coal mills is carried to the boiler in coal pipes by high pressure hot air. The pulverized coal air mixture is burnt in boiler in the combustion zone. Generally in modern boilers tangential firing system is used i.e. the coal nozzles/ guns form tangent to a circle. The temperature in fire ball is of the order of 1300 deg.C. The boiler is a water tube boiler hanging from the top. Water is converted to steam in the boiler and steam is separated from water in the boiler Drum. The saturated steam from the boiler drum is taken to the Low Temperature Superheater, Platen Superheater and Final Superheater respectively for superheating. The superheated steam from the final superheater is taken to the High Pressure Steam Turbine (HPT). In the HPT the steam pressure is utilized to rotate the turbine and the resultant is rotational energy. From the HPT the out coming steam is taken to the Reheater in the boiler to increase its temperature as the steam becomes wet at the HPT outlet. After reheating this steam is taken to the Intermediate Pressure Turbine (IPT) and then to the Low Pressure
Turbine (LPT). The outlet of the LPT is sent to the condenser for condensing back to water by a cooling water system. This condensed water is collected in the Hotwell and is again sent to the boiler in a closed cycle. The rotational energy imparted to the turbine by high pressure steam is converted to electrical energy in the Generator.
PrincipalCoal based thermal power plant works on the principal of Modified Rankine Cycle.
Coal Preparation i)Fuel preparation system: In coal-fired power stations, the raw
feed coal from the coal storage area is first crushed into small pieces and then conveyed to the coal feed hoppers at the boilers. The coal is next pulverized into a very fine powder, so that coal will undergo complete combustion during combustion process. pulverizer is a mechanical device for the grinding of many different types of materials. For example, they are used to pulverize coal for combustion in the steam-generating furnaces of fossil fuel power plants. Types of Pulverisers: Ball and Tube mills; Ring and Ball mills; MPS; Ball mill; Demolition.
ii)Dryers
they are used in order to remove the excess moisture from coal mainly wetted during transport. As the presence of moisture will result in fall in efficiency due to incomplete combustion and also result in CO emission.
Dead storage stored for future use. Mainly it is for longer period of time, and it is
also mandatory to keep a backup of fuel for specified amount of days depending on the reputation of the company and its connectivity. There are many forms of storage some of which are 1. Stacking the coal in heaps over available open ground areas. 2. As in (I). But placed under cover or alternatively in bunkers. 3. Allocating special areas & surrounding these with high reinforced concerted retaking walls.
A Boiler or steam generator essentially is a container into which water can be fed and steam can be taken out at desired pressure, temperature and flow. This calls for application of heat on the container. For that the boiler should have a facility to burn a fuel and release the heat. The functions of a boiler thus can be stated as:1. To convert chemical energy of the fuel into heat energy 2. To transfer this heat energy to water for evaporation as well to steam for superheating. The basic components of Boiler are: 1. Furnace and Burners 2. Steam and Superheating a. Low temperature superheater b. Platen superheater c. Final superheater
Economiser:
It is located below the LPSH in the boiler and above pre heater. It is there to improve the efficiency of boiler by extracting heat from flue gases to heat water and send it to boiler drum. Advantages of Economiser include 1) Fuel economy: used to save fuel and increase overall efficiency of boiler plant. 2) Reducing size of boiler: as the feed water is preheated in the economiser and enter boiler tube at elevated temperature. The heat transfer area required for evaporation reduced considerably.
Air Preheater:
The heat carried out with the flue gases coming out of economiser are further utilized for preheating the air before supplying to the combustion chamber. It is a necessary equipment for supply of hot air for drying the coal in pulverized fuel systems to facilitate grinding and satisfactory combustion of fuel in the furnace
Reheater:
Power plant furnaces may have a reheater section containing tubes heated by hot flue gases outside the tubes. Exhaust steam from the high pressure turbine is rerouted to go inside the reheater tubes to pickup more energy to go drive intermediate or lower pressure turbines.
Steam turbines:
Steam turbines have been used predominantly as prime mover in all thermal power stations. The steam turbines are mainly divided into two groups: 1. Impulse turbine 2. Impulse-reaction turbine The turbine generator consists of a series of steam turbines interconnected to each other and a generator on a common shaft. There is a high pressure turbine at one end, followed by an intermediate pressure turbine, two low pressure turbines, and the generator. The steam at high temperature (536 c to 540 c) and pressure (140 to 170 kg/cm2) is expanded in the turbine.
Condenser:
The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be pumped. If the condenser can be made cooler, the pressure of the exhaust steam is reduced and efficiency of the cycle increases. The functions of a condenser are:1) To provide lowest economic heat rejection temperature for steam. 2) To convert exhaust steam to water for reserve thus saving on feed water requirement. 3) To introduce make up water.
We normally use surface condenser although there is one direct contact condenser as well. In direct contact type exhaust steam is mixed with directly with D.M cooling water.
Boiler feed pump is a multi stage pump provided for pumping feed water to economiser. BFP is the biggest auxiliary equipment after Boiler and Turbine. It consumes about 4 to 5 % of total electricity generation.
Cooling tower:
The cooling tower is a semi-enclosed device for evaporative cooling of water by contact with air. The hot water coming out from the condenser is fed to the tower on the top and allowed to tickle in form of thin sheets or drops. The air flows from bottom of the tower or perpendicular to the direction of water flow and then exhausts to the atmosphere after effective cooling. The cooling towers are of four types: 1. Natural Draft cooling tower 2. Forced Draft cooling tower 3. Induced Draft cooling tower 4. Balanced Draft cooling tower
In a boiler it is essential to supply a controlled amount of air to the furnace for effective combustion of fuel and to evacuate hot gases formed in the furnace through the various heat transfer area of the boiler. This can be done by using a chimney or mechanical device such as fans which acts as pump.
i) Natural draught:
When the required flow of air and flue gas through a boiler can be obtained by the stack (chimney) alone, the system is called natural draught. When the gas within the stack is hot, its specific weight will be less than the cool air outside; therefore the unit pressure at the base of stack resulting from weight of the column of hot gas within the stack will be less than the column of extreme cool air. The difference in the pressure will cause a flow of gas through opening in base of stack. Also the chimney is form of nozzle, so the pressure at top is very small and gases flow from high pressure to low pressure at the top.
2) Induced draught system 3) Balanced draught system Forced draught: In this system a fan called Forced draught fan is installed at the inlet of the boiler. This fan forces the atmospheric air through the boiler furnace and pushes out the hot gases from the furnace through superheater, reheater, economiser and air heater to stacks. Induced draught: Here a fan called ID fan is provided at the outlet of boiler, that is, just before the chimney. This fan sucks hot gases from the furnace through the superheaters, economiser, reheater and discharges gas into the chimney. This results in the furnace pressure lower than atmosphere and affects the flow of air from outside to the furnace. Balanced draught:-In this system both FD fan and ID fan are provided. The FD fan is utilized to draw control quantity of air from atmosphere and force the same into furnace. The ID fan sucks the product of combustion from furnace and discharges into chimney. The point where draught is zero is called balancing point.
The disposal of ash from a large capacity power station is of same importance as ash is produced in large quantities. Ash handling is a major problem. While barrows are used for this. The ash is collected directly through the ash outlet door from the boiler into the container from manually.
ii) Mechanical handling: Mechanical equipment is used for ash disposal, mainly bucket
elevator, belt conveyer. Ash generated is 20% in the form of bottom ash and next 80% through flue gases, so called Fly ash and collected in ESP. iii) Electrostatic precipitator: From air preheater this flue gases (mixed with ash) goes to ESP. The precipitator has plate banks (A-F) which are insulated from each other between which the flue gases are made to pass. The dust particles are ionized and attracted by charged electrodes. The electrodes are maintained at 60KV.Hammering is done to the plates so that fly ash comes down and collect at the bottom. The fly ash is dry form is used in cement manufacture.
Generator:
Generator or Alternator is the electrical end of a turbo-generator set. It is generally known as the piece of equipment that converts the mechanical energy of turbine into electricity. The generation of electricity is based on the principle of electromagnetic induction.
They can respond to rapidly changing loads without difficulty A portion of the steam generated can be used as a process steam in different industries Steam engines and turbines can work under 25 % of overload continuously Fuel used is cheaper Cheaper in production cost in comparison with that of diesel power stations
Maintenance and operating costs are high Long time required for erection and putting into action A large quantity of water is required Great difficulty experienced in coal handling Presence of troubles due to smoke and heat in the plant Unavailability of good quality coal Maximum of heat energy lost Problem of ash removing
Each fan consists of the following sub assemblies1. Suction chamber. 2. Impeller vane control. 3. Impeller supporting on two bearing. 4. Outlet guide vanes. 5. Diffuser. 6. Flexible coupling Pin type 7. Outlet damper. 8. Bearing - self oiling roller bearing type. Each fan driven by 6.6KV, 1520KW motor.
Specifications:
1. 2. 3. 4. 5. 6.
Fan type No. of fans per boiler Fan capacity Head developed Speed Motor rating lag, 95% 7. Power input to fan 8. Full load current
Axial impulse two 244m^3/sec 503mm WCL 990 rpm 6.6KV,1520KW,50Hz,3-phase 0.86 1432KW 162.6Amp.
45 Amp. F
Specification:1. Fan capacity 2. Head developed 3. Speed of fans& motor 4. motor rating 0.88 lag 94% 70 m^3/sec 1210 mm WCL, 720(MCR) 1480 rpm 6.6 KV, 1250 KW, 50 Hz 3-phase,
Milling system
There are six bowl mills in each unit of3*210 MWATPS fromwhich four millr are takeninti service for full load butdue to pour quality of coal five mills actually run.
AIR PREHEATER
The purpose of air preheater is to recover heat from the gases which isat considerable high temp. and transfer this heat to incoming cold air bymeans of continuously rotating heating surface element of specially formed metal plant as the rotor slowly revolves the mass of heating surface elements alternate through the gas air passes. Heat is absorbed by the heating surface elements passing through the hot streams, then as these same elements are carried through the air stream they realesed the stored up heat. This increases the temp of incoming cold air . tri sector air preheater has three sector for: I. II. III. Flue gases Primary air(use for drying and transportof coal through mill to burner) Secondry air (additional air for combustion around the burner)
Approximately heating surface Compressed air required for air motor Air line pressure Drive motor rating Wattage Speed Current
210MW KWUTURBINE-SALIENT DESIGN &CONSTRUCTIONAL FEATURESThe turbine is tendem compound design with separate design with separate hp,ip&lp cylinder. The hp turbine is of single flow type while ip & lpturbine are of double flow type. This is condencing type single reheat. It is basically engineered on reaction principle with throttle governing .the stage are arranged fully capacity turbo generator. The turbine is capable of accepting variation from the rated condition within the limit as recommended by IEC-45.
MODULAR CONCEPTThe turbine built on well proven design philosophy of modular principal in steam turbine engineering field the radially designed hp,ip, lp turbine modules are combined and sized to required output ,steam parameter and cycle configuration to give most economical turbine set .its main over ability is achieved without impairing the realibility of the modules which is governed by the shape and configuration or rotors ,cylinders and distance between the bearing.
I. Main steam pressure II. MAIN STEAM TEMP. III.Reheat temp IV. V. VI. VII. 535
150kg/cm2 535
FULL LOAD STEM FLOW 614T/hr Back pressuere range .03ATA to .12 ATA (ABS) NO. EXTRACTIONS 6 NO. OF stages in hpt 25 IPT 2*20 LPT 2*8
C. Weight,length&speedI. II. III. IV. V. VI. Weight of turbine Over all length Over all width Rated speed MAX. speed MIN. speed 475 tone 16.975 m 10.5m 3000rpm 3090rpm 2850rpm
CONSTRUCTIONAL FEATURESI.
HP TURBINEThe outer casing of the turbine is barrel type constructional without any massive horizontal flange. This unique constructional permits rapid start up from any thermal ,state and high rates of load change of the turbo sets . The steam and metal temp matching requirements are also less stringent . As there is not asymmetry of mass distribution in transverse or longitudinal planes.
II.
IP TURBINETHE IP TURBINE IS DOUBLE FLOW TURBINE with a horizontal spilit ,inner casing being pnumetically supported within the outer casing as well as lp inner casing is suspended from top halves so as to totally eliminate the effect on TG
center line with of flanges although the casing is off horizontal spilit design yet these do not impose any constraints on start thing and rapid fluctuations.
III.
LP TURBINELp turbine is also double flow type with area optimally selected for the expected vaccum conditions . the casing of lp turbine is connected with ip cylinder by two cross around pipes. One on either side of the machine level with the floor. The horizontally split fabricated ip casing is comprised of three shells the bearing pedestals are mounted on foundation.
After the steam exits the turbine it is fed to a cooling tower where the steam cools and reverts back to water. You can see this occurring when driving past a power plant and noticing the white plumes of smoke being emitted from large towers. This is not smoke, but rather a product of the hot pipes heating water vapor in the cooler air and generating steam. A similar turbine design is used to produce hydroelectric power at dams. When water is released from the lake side of the dam to the river side, it is fed across a series of turbines. The high rate of flowing water causes the turbines to turn rapidly where this energy captured and converted to electricity. Energy produced by hydro electric means has the added benefit of not using emission producing fossil fuels which will pollute the air. However, hydro-electric dams do affect the environment in other ways as they can disrupt vulnerable ecosystems that rely on the environment where the dam is built. There are also other forms of large scale electricity generation, like nuclear and geothermal; however they are still very similar in that they still use turbines to produce the electricity but the water is just heated by an alternative source. Some added risks are involved when using nuclear reactors to produce heat thus limiting their widespread use. Other smaller scale types of turbines exist to produce power in remote locations or to generate power in areas of the world where a power grid has yet to be established. The advantage of this type of turbine is its high efficiency rating. If the waste heat is recovered by heat exchanger and used to power another generator, in a combined cycle configuration, the efficiency can be as high as 60%. In a cogeneration configuration where the waste heat is recovered and used to for space and water heating, the efficiency can be as high as 90%. There are numerous other benefits to using a turbine to produce electrical power. Gas turbines produce a large amount of power in a small package. They can be turned on and off on demand and it costs a lot less money and takes a lot less time to build a turbine than it does to build a coal or natural gas burning power plant. They are also ideal for situations where high demand exists on a power grid for short periods of time, like hot days in the summer, and a turbine is in place to carry the extra load. Large electrical companies like Siemens and GE manufacture and custom build turbines from 10 MW to over 400MW depending on the customer's demands. There are also used dealers and distributors around the world that may have a new surplus or used turbine immediately available that fits your specifications. The simplistic design, versatility, and efficiency of turbines allow for its widespread use in electrical power generation. When deciding on your power supply, be sure to investigate the use of a turbine if the electrical demand is large enough.
GOVERNING SYSTEM
The turbine is equipped with electrohydraulic governing system to facilitate the operation of turbo set is an inter connected grid system . the electrical measuring of and processing of signal offer the advantage such as flexibility, dynamic stability , and simple representation of complicated functional relationship. The processed electrical signal is introduced at a suitable point in for control valve and the controls are continuous propotionaltype the offering following advantages the speed of turbine generator set can be control by these types Hydraulic speed control Electrohydraulic control. Change over from hydraulic to electro hydraulic control. Change over from electro hydraulic to hydraulic control.