TATA POWER- AN OVERVIEW

The TATA POWER Company Limited is one of the oldest power sector utilities in India. The Tata Power Group (TEC) comprises of 3 companies: ANDHRA VALLEY (set up in 1916) TATA HYDRO (set up in 1910) TATA POWER (set up in 1910) These companies merged in the year 2000 to form a single entity TATA POWER COMPANY LIMITED The TATA POWER manages around 3200 MW of generation, transmission and distribution business & has set goals to take this level 5000 MW by the year 2020.

TATA POWER began its operation in Jharkhand with the acquisition of 67.5 MW of coal based captive power unit of TATA STEEL in April 1996. TATA POWER has added 4 units of 120 MW each since then all at JAMSHEDPUR. The first unit began commercial operation in February 2001 followed by second unit in February 2002 while the third became operational by 2005. The fifth unit became operational by the end of 2010.

UNIT COMISSIONING:
UNIT # 1: 67.5 MW UNIT # 2: 120 MW UNIT # 3: 120 MW UNIT # 4: 120 MW UNIT # 5: 120 MW

NET GENERATION: 527.5 MW at JOJOBERA POWER PLANT, JAMSHEDPUR

FUEL

The materials used for power generation are Coal LDO (Light Diesel Oil) Water The Primary fuel is coal. The balance quantity is supplied by Mahanadi Coalfields Limited (MCL). The specific consumption of division is 0.76 kg/KWh. The secondary fuel used in the plant is Light Diesel Oil (LDO). It is sourced from Indian Oil Corporation or HPCL or BPCL. Specific LDO consumption of the division is 2.46 Liter/KWh. Water in water tubes, present inside the boiler is used to generate steam. Steam generation is one of the most important parameters of thermal power plant.

WASTE DISPOSAL
In the power generation process, coal ash is generated in two forms Fly Ash Bottom Ash Fly Ash is conveyed pneumatically to M/S Lafarge and through baulker to ACC and Grasim for cement making. Bottom Ash is disposed to Ash Pond by making slurry for setting and water is recovered, recycled and reused.

OVERALL PROCESS
Coal & Water are fed in the boiler. Steam is generated, is tangentially fired, pulverized coal generator (boiler). In the process, coal is fired in the boiler to convert water in superheated steam. Then the thermal energy stored in steam is utilized in the turbine-generator set to generate power after passing through the turbine, steam comes into condenser where it is condensed where it is condensed into water. The condensate water is reutilized in the steam generator for producing further steam and the system runs in a closed cycle. A small percentage of make-up water is required to compensate the losses in the process. To convert Turbine exhaust steam into condensate water in the condenser, circulating water system is provided. Coal is used as primary fuel & LDO firing system is provided for starting up/ Shut Down/ low-load operations. Coal is received in the coal yard & after primary & secondary crushing; coal is fed to coal bunkers through conveyors. From coal bunkers, it is fed into coal mills where pulverization takes place & coalprimary air mixture is pneumatically fed into boiler furnace through coal burners. The product of coal/LDO consumption i.e. flue gas comes out through boiler stack after passing air pre-heater & economize. Fly Ash thus generated is collected in bottom ash hopper beneath steam generator. To evacuate the Fly Ash & Bottom Ash, a mechanized ash evacuation system is provided. All 3 units are provided through Electrostatic Precipitator (ESP) to bring down the suspended particulate matter (SPM) level in conformity with the pollution control norms. Important parameters are monitored on continuous basis through DCS. VISTA & other systems all the important control loops run in Auto mode with self correcting characteristic. The power is generated at 11 KV level and then stepped up to 132 KV level by generator transformer. Electrical Power is supplied to Tata Steel at two voltage levels 132 KV and 32 KV. The Power at 132 KV level is directly fed to the main grid of Tata Steel at Golmuri Substation. The division feeds the 33 KV power to local industries

through a 33 KV substation directly as per guidelines given by Tata Steel. Power generation, in-house consumption & power supply to costumer is monitored on-line through Vista System.

DEMINERALIZING PLANT
The high pressure boiler at the Jojobera Thermal Power Station unit requires high purity water for their smooth & safety operation. This ensures that the boiler water will always have limited salinity and the problem of scaling and corrosion of boiler internals is prevented. Further in the event of high salinity in the boiler water there is always the danger of salts being carried over with the steam, to be ultimately deposited on lower pressure side of the turbine as it is emitted at a very high velocity. For producing this high quality water for the boiler feed purposes, DM plant is installed to remove all the salts to maximum extent from the available normal incoming raw water.

ELECTROSTATIC PRECIPITATORS (E.S.P)

Exhaust gases contain large quantity dust particles which are emitted into atmosphere. This poses threat to mankind as devastating health hazard. It has the following advantages: Ability to treat volume of gases at high temperature. Ability to cope up with corrosive atmosphere. Offer low resistance path to gas flow. E.S.P uses intense electric forces to separate suspended particles from the flue gases. Process involves: Collection of charged particles on collecting diodes. Electric charging of suspended particles. Removal of particles from collecting diodes. Electromagnetic control system is used. 5 fields to keep emission within limits. Ammonia dosing for better results.

COOLING TOWERS

Cooling tower is very large & is divided in smaller parts as the size of droplets. These water droplets drops fall from a height of 8 to 10 meters to the bottom of cooling tower. The splitting of water into small droplets, the draught provided by the tower & the large evaporating surface helps to cool water very quickly practically during the time when it is descending. Water from base of the cooling is pumped into the condenser and the cycle is repeated. Some water about 2% to 5% is lost due to evaporation 7 has to be added from the tank. Cooling tower are classified as atmospheric (or natural draught) and mechanical draught. Counter flow cooling tower with PVC fills. Chemical treatment, to avoid scaling & corrosion in condenser tubes.

D M PLANT
Environmental structures are to be strictly abided by governing authority of any industry with pollutants as effluent. So the Electrostatic Precipitator has been installed to extrude 99% of ash & prevent it from moving out in the air. As DM water is required in many of the power plant operation, a DM Plant is invariably required. It is basically a unit for producing clarified drinking, make-up water & mostly DM water. Apart from drinking, water is mostly used as a coolant in Heat Exchanger & Boiler. Some salt like Sulphate, Chloride, Silicate, not having retrograde solubility comes out of the solution for having excess solubility limit due to concentration. Ultimately the salt which comes out of solution, settle on the heat exchanger surface restricting heat transfer, thus reducing the heat transfer efficiency. The water supply source is river Subarnrekha which is treated with Na2Co3 to drive away Cl2, which would otherwise oxidize & damage resin permanently & then with iron-ammonium alum to precipitate suspended impurity materials.

DEGASSER

It removes the Carbonic Acid at the SAC outlet. At SAC inlet, soluble carbonates are there. They are converted in SAC to Carbonic Acid. An intimate contact b/w solution & air enables CO2 stripping. As the Bicarbonate content is nearly half to total anion load of the influent water to plant. Degasser induces the load on anion resin & regenerate significantly.

COAL HANDLING PLANT (C.H.P.)

Coal handling plant is the most essential part of any thermal power plant. The CHP is responsible for the procurement & supply of the coal to the coal mill bunkers so that the supply of pulverized coal required for filling of generation of power is maintained without interruption. Function of Coal Handling Plant are: Procurement of Coal. Unloading, sizing & storing of coal. Feeding of coal.

PROCESS FLOW CHAT

Railway rakes Wagon tippler Hopper Apron Feeder Primary Crusher Eccentric Disc Screen Secondary Crusher Conveyor Bunker.

ASH PLANT
Following functions are performed in the ash Plant: Dry collection of Ash Hoppers. Pneumatic conveying system to Silos. Provision of 4 types of Ash evacuation from Silos. Wet Ash disposal system. Ash conditioning for unloading into dumpers.

OPERATION OF THE PLANT

The steam cycle is working on a non heat regeneration cycle. Feed water is supplied to the drum through the Economizer outer limbs. Water in the boiler tubes absorbs heat from the furnaces. The mixture of water & the steam is discharged into the boiler drums. The separated saturated steam is led to the super heater where it is heated to about 810 K. Super heated steam from the boiler is fed to the turbine via the turbine top valve, emergency stop & governing valve. Steam first enters the HP turbine, gets expanded here & then it is directed to the inlet of the LP turbine for further expansion. In the process, the turbine starts rotating which in turn rotates the prime movers of the generator, thus producing electricity. Steam undergoing expansion in the turbine is allowed to flow through the condenser where steam is condensed by cooling water supplied by CW Pumps. The condensate collected in the hot wells & pumped by vertical condensate extraction pumps to the de-aerator through air ejector, gland steam condenser, drain cooler & LP heater. From the de-aerator, Feed water storage tank, feed water is pumped to the Economizer inlet header through 2-HP heater. During this process, the condensate steam collected in different system. Heat is recovered at various points & is fed to the main feed water system.

BOILER AND ITS AUXILLARIES

Steam generation is done in a radiant reheat, wet circulation, single drum, direct corner fired fitting burners & top supported type boiler. Super heater section Re-heater section Draught system Fuel firing system

TURBINE AND ITS AUXILLARIES

A turbine is a prime mover in which rotary motion is obtained by the gradual change of momentum of the steam. In a steam turbine, following are main parts: 1. The nozzle in which energy of high pressure is converted into kinetic energy, so that steam issue from nozzle at high velocity. 2. The blade which change the direction of motion & propel them. The turbine mainly consists of nozzle or set of nozzles & rotary blade wheel. The steam expanded from high pressure to low pressure either in nozzle or in the blades & kinetic energy thus obtained is supplied to the blades where it is transformed into mechanical work. The power is made available at a turbine shaft or with the help of reduction gear. Condensate extraction Pump. Hot-well make-up pump. Gland steam condenser. Surface Condenser. Extraction steam system. i. LP heater ii. HP heater iii. De-aerator

CONTROL AND INSTRUMENTATION