Training Report

BTPS

Chinmay Chaudhari
Polytechnic KCE, Jalgaon
INDUSTRIAL
TRAINING
REPORT
BHUSAWAL
(DEEPNAGAR)
THERMAL POWER
STATION
MAHAGENCO (BTPS).
KCE College of Engineering, Jalgaon.
Academic Year:- 2023-2024.
Programme:- Polytechnic In Electrical Engineering.

Semester:- V

REPORT ON INDUSTRIAL TRAINING

Bhusawal Thermal Power Station.
Starting Date:- 12/06/2023 - End Date:- 22/07/2023.

Submitted By:-

Name:- Mr. Chinmay Tukaram Chaudhari

Roll Number:- 2116990002
 Acknowledgement

I Would like to thanks to course co-ordinator Shri. Ali Sir of

Training centre department under Bhusawal (Deepnagar) Thermal power
plant (B.T.P.S) for allowing us to work on such an interesting and
informative Unit.

I am are highly indebted to all our training faculty & various distinguished
faculty for their guidance and words of wisdom. They always showed as the right direction
during the course of this project work.I am duly thankful to them for touring us to site like
CHP, boiler, AHP, etc and providing all the technical expertise and knowledge needed in order
to run a thermal power plant efficiently.

Success in such comprehensive report cannot be

achieved single handed. It is the team effort that sail the ship to the
coast. Last but not the least, we would also like to thanks all our
teacher & friends for their constructive criticism given in right spirit and
thanks god for providing us with as opportunity to excel in our life.
 Contents

Sr. No Name Of Topic

1. Introduction

2. Overview
3. Water Treatment Plant

4. Coal Handling Plant

5. Boiler
6. Turbine

7. Condenser
8. Generator
9. Electrostatic Precipitator (ESP)

10. Ash Handling Plant

11. Effluent Treatment Plant

12. Transformer
13. Cooling Tower
14. Super Critical Technology

15. Advantages and Disadvantages

16. Solar Power Generation Plant

17. Purpose of Visit

18. Conclusion
Schematic Diagram Of Coal Based Thermal Power Plant
 Introduction To MAHAGENCO:

 It was established by Government of Maharashtra under the central electricity act- 2003 with
theprincipal objective of engaging in the business of generation of electricity & Mahagenco
producescheapest power for consumers in state.
o Mahagenco is committed to expanding the generation capacity to meet the
ever growing power supply need of Maharashtra.

 Mahagenco has the highest overall generation capacity and the highest thermal
installed capacityamongst all the state power generation utilities in india.
 In terms of installed capacity, it is the second highest generation company after NTPC.
 Mahagenco having generation capacity of 13602 MW comprising of
o 1210 MW Thermal,
o Was established by government of Maharashtra.

 Mahagenco believes in quality management. All major thermal, hydro and gas
o turbine powerstations have adopted the ISO 9001:2000 certification.
 Mahagenco is an eco-friendly power generating company and has received
certification under ISO:14001 and ISO:18001 for its major power stations at
Chandrapur, Koradi, Khaperkheda, Nasik, Paras, Parli and at Koyna and Uran power
stations also.
 The company is implementing a huge capacity addition programme. Mahagenco
generates powerfor more than 1, 50, 00,000 end consumers in Maharashtra at
economical and affordable rates.
 Mahagenco has a gross fixed asset base of Rs. 28346 crores (March 2014) with an
annualturnover of about Rs. 16538 crores (March 2014).
 Mahagenco is powered by a dedicated and committed highly skilled work force of
more than15000.
Sr. No. POWER UNIT CAPACITY INSTALLED CAPACITY
STATION ..(MW) …..(MW)

 THERMAL POWER STATION:-

1. Koradi 2 x 210 + 3 x 660 2400

2. Nasik 3 x 210 630
3. Bhusawal 1 x 210 + 2 x 500 1210
4. Paras 2 x 250 500
5. Parli 2 x 210 + 3 x 250 1170
6. KhaparKheda 4 x 210 + 1 x 500 1340
7. Chandrapur 2 x 210 + 5 x 500 2920
Total 10,170

 GAS TURBINE POWER STATION:-

1. Uran G.T. 4x108 432

2. W. H. R 2x120 240
Total 672

 HYDRO POWER STATION:-

1 Koyna Hydro 4x70 + 4x80, 4x80, 4x250 & 2x18 1956

2 Small Hydro 374

3 Ghatghar Pump Storage 2x125 250

Total 2580
  SOLAR POWER STATION:-

1. Chandrapur 3 MWp (Thin Film) +2 MWp 5

(Crystalline)
2. Shivajinagar, Sakari 50 MWp (Thin Film) +75 125
MWp(Crystalline)

3. Shirsuphal, Baramati 50 MWp (Crystalline) 50

Total 180

TOTAL 13602
(A+B+C+D)
 Introduction To BHUSAWAL (DEEPNAGAR) THERMAL POWER STATION

 Bhusawal (Deepnagar) Thermal Power Station power plant is one of the coal based power
plants of MAHAGENCO.
 The coal for the power plant is sourced from Coal India limited.
 The plant was officially inaugurated on 1968.
 The total capacity of 1210MW, the plant is the 4 th largest power plant in the Maharashtra.
 The plant gets water supply from Hatnur Dam & Tapi River in normal condition.

Stage Unit Number Installed Date of Commissioning Status

Capacity..(MW)

Stage I 1 62.5 1968 July Closed

Stage II 2 210 1979 August Retired
Stage II 3 210 1982 September Running

Stage III 4 500 2012 November Running

Stage III 5 500 2014 January Running

Stage V 6 660 Planned

 Overview
 A Thermal power station is a power plant in which the prime mover is steam driven. Coal is used
as a fuel to heat water in a coal based thermal power plant. Water when heated turns into steam
which drives a steam turbine. After passing through the turbine, the steam is condensed in a
condenser and recycled to where it washeated [Rankine Cycle].

 Energy Conversion:-

Stage 1. Conversion of chemical energy of a coal to heat energy in boiler.

Stage 2. Conversion of heat energy to mechanical energy of steam in Turbine.
Stage 3. Conversion of mechanical energy to rotational energy of turbine which drives generator.
Stage 4. Rotational energy to electrical energy based on Faraday’s law of electromagnetic induction.

Chemical Energy of Coal

Heat Energy of water due combustion of Coal

Kinetic Energy of steam in Nozzle

Mechanical energy due to rotation of Turbine

Electrical Energy developed in Generator armature due to Rotation

 Water Treatment Plant (W. T. P)
 Water treatment has prime importance. Water contains different types of impurities, when
these impurities enter inside the boiler it will produce slice formation inside boiler tube
due to which heat will not transfer properly hence tubes will melt. This impurities deposits
inside the water tubes & block the water tubes. Presence of oxygen & carbon dioxide
leads to corrosion of water tubes. So, in thermal power plant, we use following three types
of water.

1. Demineralized water (DM water) for producing steam.

2. Soft water for Cooling purpose.
3. Raw Water for Ash slurry.

 F ollowing impurities are present in raw water-

1. Turbidity- It is due to mud, minerals.

2. Organic Matter- Organic present is due to the decomposition of dead animals, trees, leaves.
3. Colour & odour- Colour & odour comes to water due to its organic matter contains.
4. Dissolved gases- Gases like carbon monoxide, oxygen are dissolves in water.
5. Living micro-organism

 Water goes through following processes during treatment:-

A. Pre-treatment.
B. Post-treatment.

o Pretreatment of water- Pretreatment is used to kill disease-causing organisms and help control taste
and odor causing substances. A pretreatment chemical could be any number of oxidants or
disinfectant.
o During pretreatment for D.M. water, following process is carried out.

o Screening - In this process material like logs, branches, fish, etc are being removed. This
is donemechanized trash removal system.
o Coagulation - In this process we add chemicals such as alum which produces the positive charges to
neutralize the negative charges of a particle. This process involves the addition of chemical such as
alumand lime. It is uniformly distributed with the help of rotating machine.
o Flocculation - Now the particles having a neutral charge which can stick together. Now the water
flow into the tank with paddles it is slowly mixing .it brings the small particles together to form large
particlesand create flocs.
o Sedimentation - Water flow into the tank called sedimentation basin gravity causes the flocs to
settle to the bottom. large particles settle down very rapidly than small particles. So, the clarified
water with mostof the particle removed moves on a filtration step.
o Filtration - Filtration apparatus is a concrete box which contains sand, gravel, under drain. After
the filteris operated, sand becomes clogged with particles and must be backwashed. Flow through
the filter is reversed and the sand and particles get suspended. The particles are lighter than sand
so they rise up and flushed from the system.
o Disinfection - In this process bacteria and viruses get destroyed by addition of disinfectant
like bleachingpowder.
o Softening - Area where water comes in contact with lime stones there may be high level of
calcium andmagnesium present in it, these chemicals make the water hard. This hardness is
removed by a processcalled softening. Chemical like lime, CaO, Soda ash, Na2CO3 is used.

 In BTPS water treatment plant, following process sequence is used:

Water from Dam

One day reserve tank

Flash mixer

Flocculator

Rapid Gravity filter

Water sump

Post treatment plant

a. One day Reserve tank - One day reserve tank is used to store sufficient water storage,
which will last long nearly one day. Sometimes water supply from dam is interrupted due to
certain interrupts. Therefore, to continue plant operation without any interrupts. Water from
one day reserve is taken out. Water is stored in this tank, due these suspended particles,
heavy impurities, silica particles settled down here. Besides this, one day reserve tank is used
as a water source during any emergency.

b. Flash Mixture - Alum and lime is added in water. Effect of adding alum and line is as follows:
Alum not only settles certain hazardous chemicals and suspended solids but also bacterial
colonies. Alum has a negative charge and tends to disperse in water very fast and very well. This
causes it to join up with all of the offending particles and neutralize them. Now that the particles
don't have any repelling charges, they tend to clump together into 'flocs'.

c. Addition of lime - Softening can be achieved by adding lime in the form of limewater,
Ca(OH)2, which, in a carbonatation reaction with CO2, forms calcium carbonate precipitate,
reacts next with multivalent cat ions to remove carbonate hardness, then reacts with anions to
replace the non-carbonate hardness due to multivalent cations with non-carbonate hardness
due to calcium. The process requires re-carbonation through the addition of carbon dioxide to
lower the pH which is raised during the initial softening process.
As lime is added to raw water, the pH is raised and the equilibrium of carbonate species in the
water is shifted. Dissolved carbon dioxide (CO2) is changed into bicarbonate (HCO3-) and
then carbonate (CO32-). This action causes calcium carbonate toprecipitate due to exceeding
the solubility product. Additionally, magnesium can be precipitated as magnesium hydroxide
ina double displacement reaction.
The byproduct from the reaction of water with lime produces large volumes of calcium
carbonate and magnesium hydroxide sludge. This residual stream can substantially increase
costs associatedwith the process. The sludge can be used as an agricultural soil amendment (it
is an alkalinity supplement) and can also be used as a filler material in certain cementitious
materials such as low strength concrete.

d. Clariflocculator - is a device in which flocculation & clarification reaction takes place

simultaneously. Clariflocculator contains two concentric water tanks. The inner tank serves as
a flocculation chamber. And the outer tank serves as a clarifier chamber.
During flocculation reaction flocs hydroxide is formed & then settled down. This floc is
removed as a sludge by blow down process.
Mechanism of clariflocculator is as follows -
a. These provide gentle agitation by slow moving paddles.
b. This action serves to break up the mass rotation of liquid and promote mixing.
c. The specially designed flocculation paddles enhance flocculation of the feed solids
d. Agglomeration of the destabilized colloids is achieved as a result of particulate
transportin the flocculation compartment.
 e.Increased particle contact will promote floc growth and aids faster settling.

e. Rapid sand filter - Rapid sand filters contains relatively coarse sand and other granular media like
bolder to remove particles and impurities that have been trapped in a floc through the use of
flocculationchemicals—typically salts of aluminum or iron. Water and flocs flows through the
filter medium under gravity or under pumped pressure and the flocculated material is trapped
in the sand matrix.
Mixing, flocculation and sedimentation processes are typical treatment stages that
precede filtration. Chemical additives, such as coagulants, are often used in conjunction
with the filtrationsystem. Rapid sand filters must be cleaned frequently, often several
times a day, by backwashing, which involves reversing the direction of the water and
adding compressed air. During backwashing, the bed is fluidized and care must be taken
not to wash away the media.

f. Water Sump: Water sump is a water storage tank in which pretreated water is stored. From thank
water is sent for post treatment.

Post treatment is different for both -

g. Demineralized water (D.M. water)
h. Soften water

i. Demineralized water - DM water is demineralized water. Dissolved impurities and dissolved

gases in water. Sometimes wateris hard, temporary hardness or permanent hardness and which is
badly affects the boiler which helpsformation of scales in sides the boiler.

In D.M. water plant , water is passed through activated carbon filter for absorbing dissolved carbon
dioxide. For removing temporary hardness and permanent hardness ion exchanging process used. By Ion-
exchange process from which the minerals have been removed and get Demineralized water.
Demineralized water has following qualities -
 Neutral P.H (6.5-7.5).
 Conductivity of water (<10µs/cm).

During demineralization process water is passed through following ion beds-

 Pressure Sand Filter (P. S. F) - Pressure sand filter consist of a pressure vessel. it
contain gradedsandwhich supported by graded pebbles & silex. Distributor nozzle
installed at top distributes water throughout the cross-section of filter.To collect water
under drain system is provided.
  Working Principle-
In pressure sand filter raw water flows down wards through the filter bed and as the suspended
Matter - which has usually been treated by addition of acoagulant like alum- is retained on the
sand surface and between the sand grains immediately below the surface. There is steady rise in
the loss of head as the filtration process continues and the flow reduces once the pressure drop
across the filter is excessive.

The filter is now taken out of service and cleaning of the filter is effected by flow reversal. To
assist In cleaning the bed, the backwash operation is often preceded by air agitation through the
under drain system. The process of air scouring agitates the sand with a scrubbing action, which
loosens the intercepted particles. The filter is now ready to be put back into service.

a. Activated charcoal filter (A. C. F) - Activated charcoal means activated carbon. It is a

form of carbon processed to be riddled with small, low-volume pores that increase the surface
area available for chemical reactions. Activated charcoal have good carbon trapping quality
due to this property chemical & organic impurities can be removed.

b. Strong acid cation -

Porus type synthetic resin is filled in strong acid cation exchanger.SAC resins can neutralize strong
bases and convert neutral salts into their corresponding acids. SAC resins derive their functionality
from sulfonic acid groups (HSO3¯). When used in demineralization, SAC resins remove nearly all raw
water cations, replacing them with hydrogen ions, as shown below-

The exchange reaction is reversible. When its capacity is exhausted, the resin can be regenerated with
an excess of mineral acid. Strong acid cation exchangers function well at all pH ranges. These
resins have found a wide range ofapplications.
 a. Weak Base Anion (W. B. A) -
Weak base anion bed absorb acid from the water. & convert it in to neutral salts. When this bedabsorb
acid after it is exhausted. it is need to regenerate it. Regeneration needs only to neutralize the absorbed
acid: it need not provide hydroxide ions. Lessexpensive weakly basic reagents such as ammonia (NH3)
or sodium carbonate can be employed.
b. Degasser -
Degasser is a device in which dissolved gases from water is removed.It also removes small bubbles trapped
in water layer. In Degasser tank water from the degasser is stored. this water sends to strong base
anion bed.

c. Strong base anion (S.B.A)-

In this bed anionic contamination is removed from water.

d. Mixed Bed (M. B) -

The strong acid cation and strong based anion bed are intermixed. The cation & anion is taking
place over & over within resin bed.Both anion & cation escaped from prior bed is trapped in
mix bed. By using mix bed high quality of D.M.water can be obtained.

e. Demineralized water tank -

Water passed from above process is stored in this tank. this water is send as make up water in
boiler. Anion& cation vessels are exhausted during the treatment. This ion bed is regenerative.
In following ways this beds are regenerated-

Water
Vessel Impurities Regenerativ capacit
eelement y(M3)
Gelatinous Backwash by 8500
P.S.F. material filtered water

A.C.F. turbidity - - - 8500

S.A.C. (Ca^+2), (Mg^+2), HCl acid 8500
(Na^+2)
W.B.A. (Cl^-), (SO4^-2) NaOH solution 8500
S.B.A. silicates NaOH 8000
M.B. Any particles HCL +NaOH 13200
other than above
Before feeding D.M. water to boiler chemical conditioning is done.
 D.M. water is corrosive by nature. Hence, ammonia (NH3) is added.
 Hydrazine (N2H4) which is colorless is added, to remove dissolved oxygen from
D.M.water. This reaction gives water & nitrogen gas.
 Phosphate (PO4) is dose directly in boiler drum. It form phosphate of dissolved
impurities. After particular period blow down is given to the boiler. This
phosphateform is removed during this process.

f. Soft water plant -

Water softening is the removal of calcium, magnesium, and certain other metal cations in hard water.
The resulting soft water is more compatible with soap and extends the lifetime of plumbing.
Water softening is usually achieved using lime softening or ion-exchanger resins.
Soften water is used for cooling purpose, drinking purpose. In CSTPS, there are 11 no. of stream
and each stream contains3 softening containers. In 210MW plant 15000(M^3) soften water is
required as a makeup per hour flow of each softener is 250(M3/Hr.)
 COAL HANDLING PLANT IN THERMAL POWER GENERATING STATION

 Introduction to Coal Handling Plant:-

In a coal based thermal power plant, the initial process in the power generation is “Coal
Handling”. So in this article i will discuss the overall processes carried out at a Coal Handling
plantin a coal based thermal power generating station. The huge amount of coal is usually
supplied through railways. A railway siding line is taken into the power station and the coal is
delivered inthe storage yard. The coal is unloaded from the point of delivery by means of wagon
tippler. It israck and pinion type. The coal is taken from the unloading site to dead storage by
belt conveyors.The belt deliver the coal to 0m level to the pent house and further moves to
transfer point 8. Thetransfer points are used to transfer coal to the next belt. The belt elevates
the coal to breaker house. It consists of a rotary machine, which rotates the coal and separates
the light dust from itthrough the action of gravity and transfer this dust to reject bin house
through belt. The belt further elevates the coal to the transfer point 7 and it reaches the crusher
through belt. In the crusher a high-speed 3-phase induction motor is used to crush the coal to a
size of 50mm so as to be suitable for milling system. Coal rises from crusher house and reaches
the dead storage by passing through transfer point 8.

 Equipment used in a Coal Handling Plant:-

1. Pull chord switch:- A series of such switches are arranged in series at a 1m distance on
the sideof conveyor belt. The power supply to rotor of the conveyor belt is established only if
all switchesin series are connected.

2. Vibrating feeder:- The coal stored in a huge hub is collected on the belt through
vibrations created by the vibrating feeder.

3. Flap gates:-These are used to channelize the route of coal through another belt in case
the former is broken or unhealthy. The flap gates open let the coal pass and if closed stop its
movement.

4. Magnetic separator:-These are used to separate the ferrous impurities from the coal.

5. Metal detector:-The transmitter consists of a high frequency oscillator, which produces a

oscillations of 1500 Hz at 15V. The receiver receives this frequency signal. If there is any
presence of metal in the coal. Then this frequency is disturbed and a tripping signal is send to
relay to stop the conveyor belt.

6. Belt weightier:-It is used to keep an account of the tension on the belt carrying coal and
is moves accordingly to release tension on the belt.

7. Reclaim hopper:-Reclaimation is a process of taking coal from the dead storage for
preparation or further feeding to reclaim hoppers. This is accomplished by belt conveyors
  Stages in Coal Handling Plant:

1. Tipplers:-Coal from the coal wagons is unloaded in the coal handling plant. This unloading
is done by the “Tipplers”. This coal is transported up to the raw coal bunkers with the help of
conveyor belts.

2. Crush house:-After hand picking foreign material, coal is transported to the Crush house by
conveyor belts where it is crushed to small pieces of about 20 mm diameter. The crushed
coal is then transported to the store yard. Coal is transported to bowl mills by coal feeders.

3. Bowl Mill:-The coal is pulverized in the bowl mill, where it is grounded to a powder form.
The mill consists of a round metallic table on which coal particles fall. This table is rotated
with the help of a motor. There are three large steel rollers, which are spaced 120” apart. When
there is no coal, these rollers do not rotate but when the coal is fed to the table it packs up
between rollers and the table and this forces the rollers to rotate.
Coal is crushed by the crushing actions between the rollers and rotating tables.
4. Furnaces :-This crushed coal is taken away to the furnace through coal pipes with the help of
hotand cold air mixture from P.A Fan. P.A Fan takes atmospheric air, a part of which is sent to Air
pre heaters for heating while a part goes directly to the mill for temperature control. Atmospheric air
from F.D Fan is heated in the air heaters and sent to the furnace as combustionair.

 Following are the different coal handling methods are used:

1. Transportation by river - The coal can be transported from the mines to the power stations
by means of ships or large boats through the ocean or river. The unloaded coal from the ship can
be either sent to the storage yard or directly to the conveyor system which directly to the
combustion chamber hopper.

2. Transportation by Rail - In this case, the railway is used to transport the coal from the mines
directly to the power stations, most of the thermal power stations will receive the coal from rail
transport. The coal from the railway wagon is taken to the power station and is either delivered
to the storage yard or close to the point of consumption.

3. Transportation by Roadways - It is the most efficient method of transporting coal from the
mineto the power station. It is particularly used when the distance between the power station and
mine is less than 10 km. The major advantage of such a system is, it supplies the coal
continuously and free from worker’s strike which is common with rain transport.

4. Transportation by Road - The coal can be transported from mines to the power plant by
meansof trucks, tippers, tractors etc., through road, but it is used only for small capacity
power stations. The major advantage of this type is that the coal can be carried directly into
the powerhouse up to the point of consumption
 BOILER
It is an enclosed pressure vessel in which water is converted into steam by gaining heat from any source
(coal, oil, gas etc).
According to Indian boiler (Amendment) act 2007, boiler means a pressure vessel in which steam is
generated for use external to itself by application of heat which is wholly or partly under pressure when
steam is shut off but does not include a pressure vessel,
(i) With capacity less than 25 litres (such capacity being measured from the feed check valve to
the main steam stop valve);
(ii) With less than one kilogram per centimetre square design gauge pressure and working gauge
pressure; or
(iii) In which water is heated below one hundred degrees centigrade:

Boiler in thermal power plant accumulates the steam and build up a pressure to expend it in turbine
and convert thermal energy to mechanical energy. The generator which is connected to turbine
converts the mechanical energy into electric energy.
 TYPES OF BOILER:-
1. Based on tube content:-
➢ Fire tube: Hot flue gases flow inside the tube and the water outside the tubes.

➢ Water tube: Water flow inside the tube and flue gases outside the tube.

2. Based on Operating:-
➢ Supercritical boiler: 22.1MPa < Pressure ≤ 27.0MPa.

➢ Subcritical boiler: 16.7MPa ≤ Pressure ≤ 22.1 MPa.

➢ Ultra-high pressure boiler: 13.7MPa ≤ Pressure
≤16.7MPa.
➢ High pressure boiler: 9.8MPa < Pressure ≤ 13.7MPa.
➢ Sub-high pressure boiler: 5.4MPa < Pressure
≤9.8MPa.

➢ Medium pressure boiler: 3.8MPa ≤ Pressures

5.4MPa.
3. Based on Fuel Used:-

➢ Solid Fuel Fired

➢ Stoker Fired Boilers
➢ Pulverized Fuel Boilers
➢ Fluidized Bed Combustion (FBC) Boilers

➢ Oil Fired
➢ Gas Fired Boilers

4. Based on Draught System:-

❖ Natural Draught
➢ Mechanical Draught
➢ Forced Draught System
➢ Induced Draught System
➢ Balanced Draught System

❖ BOILER AUXILLARIES:-
1. BOILER DRUM
2. ECONOMIZER
3. PRIMARY HEATER
4. SUPERHEATER
5. REHEATER
6. PA FAN
7. FD FAN
8. ID FAN
 1. Boiler Drum:-
It works as a storage device of steam and water mixture for continuous supply of them toboiler and
turbine.Main function is to separate steam and the water.Also chemical dosing (phosphate) to
maintain pH of boiler water and blow down giventhrough steam drum.

1. ECONOMIZER:-
A feed water economizer reduces steam boiler fuel
requirement by transferring heat from the flue gasto
incoming feedwater. Boiler flue gases are often
rejected to the stack at temperature higher than the
temperature of the generated steam.

PRIMARY AIR HEATER:-

Air preheater is used to heat the air which is required for
combustion inside boiler, before it enter in boiler. It helps in
improving rate of combustion of coal in boiler.
2. SUPERHEATER:-
The superheater is a collection of boiler pipes located in the flow of hot gas from combustion. The
heatfrom this gas is transferred to Saturated Steam in the superheater pipe, so it turns into
superheated steam

3. REHEATER:-
Reheater is a part of the boiler which reheat steam which comes out from HP Turbine. Reheated
steamwill again absorb the heat energy from the boiler to be used in the next level steam turbine.
Reheater isone way to improve the thermal efficiency of the Ranking Cycle. It increases or
manage to maintain temperature of steam at 540deg, so that it can pass through I.P. Turbine with
dry saturated steam.

4. PRIMARY AIR FAN (PA Fan):-

PA fan is used to carry the pulverized coal to boiler from coal mills and also to remove moisture from
thecoal.

5. FORCED DRAUGHT FAN (FD Fan):-

An FD fan draws air from the atmosphere and forces it into the furnace through a preheater. These
fansare located at the inlet of the boiler to push high pressure fresh air into combustion chamber,
where it mixes with the fuel to produce positive pressure.

6. INDUCED DRAUGHT FAN (ID Fan):-

Induced draft fan is normally located at the outlet between dust collector and chimney. The fan
takeshot flue gases from the boiler through dust collector and delivers it to the chimney into the
open atmosphere. ID fan creates negative pressure or suction to discharge the gases out after
combustion from the furnace.
 Turbine
Turbine is a device which converts the kinetic energy of the steam in the mechanical rotational
energy of rotor. Steam from the boiler is passed over the blade of the turbine, which tends to rotate
the shaft of the turbine. Turbine shaft is mechanically coupled with generator shaft .when turbine
shaft rotate generator shaft also rotate.

Basically turbine is of following type-

 Impulse turbine.
 Reaction turbine.

On 5 different basis turbine is classified, those are as follows-

 Type of compounding.
 Type of blading.
 Division of flow.
 Type of steam flow.
 Type of exhausting condition.

Turbine set consist of 3 turbine defined on the basis of the pressure inside it. These turbines with
their type are as follows-
 High pressure turbine - Impulse turbine.
 Intermediate pressure turbine – Reaction turbine.
 Low pressure turbine – Reaction turbine.

The Turbine contained one row of stationary blade & one row of rotating blades alternatively. The
fixed blades are carefully shaped to direct the flow of steam against the moving blades at an angle
and a velocity that will maximize the conversion of the steam's heat energy into the kinetic energy of
rotary motion. Because the steam's temperature, pressure and volume change continuously as it
progresses through the turbine, each row of blades has a slightly different length, and in certain parts
of the turbine the twist of the blade is usually varied along the length of the blade, from root to tip.
One set of stationary & rotating blade is called as stage. These nos. of stages can be varied as per
requirement.
 In BTPS, no of stages for a given turbine is given in following table-
Type of turbine No of stages
H.P. turbine 12
I.P. turbine 11
L.P. turbine 4+4=8

The steam from the boiler is initially provided to high pressure turbine (H.P. turbine). Steam is expanded inside
H.P. turbine .H.P. gives the starting torque & operating speed to the turbine rotor. The expanded
steam from the H.P. turbine again brought into the boiler for heating. After rising the temperature of
steam, it is fed to the intermediate pressure turbine (I.P.).then this steam is supplied to the low
pressure turbine (L.P.). The function of I.P. turbine & L.P. turbine is to provide torque to the rotor.

As steam transferred from I.P. turbine to L.P. turbine, steam pressure goes on the decreasing, and hence
steam goes on expanding. In L.P turbine steam is expand in huge amount hence it requirement of space.
To overcome this limitation steam is bifurcated in L.P. turbine. Turbine is design so that steam enter at
the middle part of the turbine & exit from the both end. The blades in each half face opposite ways, so
that the axial forces negate each other but the tangential forces act together. This design of rotor is
called two- flow, double-axial-flow or double-exhaust. This arrangement is common in low- pressure
casings of a compound turbine.

This arrangement has following advantages-

➢ Required space is less.

➢ Vibration cause is less.
➢ Steam can be expands up to require amount.
➢ Maintain the correct rotor position and balancing, thisforce must
be counteracted by an opposing force.
❖ Following are the turbine peripheries

Emergency stop Valve:-

 Hydraulically operated.
 Operate live steam
Live steam is steam under pressure, obtained by heating water in a boiler.
 1. Control Valve:-
Control valves used to control the flow of steam in boiler. During light load period, by
controlling flow of steam we can generate limited electricity. Control valves are mounted on
casing of H.P. turbine at themiddle bearing side, it is common for H.P. & I.P turbine.

There are total 4 no. of C.V in one turbine.Turbine

rotorconnection Rotor of I.P. & L.P. turbine is connected by semi

flexible rod.3 rotors are supplied with 5 bearings.

i. H.P. & L.P. turbine is combined on radial bearing.

2. Barring gear-
barring gear is structure to support the rotor during sagging & hogging due to differential
temperature between the top of the rotor shaft and the bottom. Once the rotor is cooled to
ambient temperature, unless there is a supplementary support structure for the rotor, it should
be barred periodically to avoid sagging of the rotor under its own weight.

❖ Cycle of Turbine:-

 Cooling water cycle.-

 Two circulating water pump (C.W. pump) are circulating water, taken from sump.
 Water from the condenser water tube is cooled in cooling tower.
 27000ton water per hour is cooled in one cooling tower.
 14 C.T fans are employed in 210MW plant cooling tower.
 Temperature in cooling tower should be 28-30degree cel.

Following dia. shows the cooling water cycle-

 Condenser
The condenser condenses the steam from the exhaust of theturbine 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 function of condenser is

1. To provide lowest economic heat rejection temperature for steam.

2. To convert exhaust steam to water for reserve thus saving on feedwater

requirements.

3. To introduce make up water. The heat absorbed by the circulating cooling water in the
condenser tubes must also be removed to maintain the ability of the water to cool as it
circulates. This is done by pumping the warm water from the condenser through either
natural draft, forced draft or induced draft cooling towers (as seen in the image to the
right) that reduce the temperature of the water by evaporation, by about 11 to 17 °C (20
to 30 °F)—expelling waste heat to the atmosphere. The circulation flow rate of the
cooling water in a 500 MW unit is about 14.2 m³/s (500 ft³/s or 225,000 US gal/min) at
full load.

 Regenerative Feed Water cycle:-

Regenerative water is obtained from the condensate from the condenser. When steam in condenseris
passed over the cool water tube, it condensate & collected in hot well. Hence regenerative feed water
starts from hot well & end at boiler drum. 2 condensate extraction pumps are running & 1 pump is
stand by.
It is as follows-
 Condenser

C.E.P - C.E.P - C.E.P -

De
aerator

 Feed Water Cycle:-

In feed water cycle 2 boiler feed pumps (B.F.P.) are running & 1is stand by at a time.
Feed water cycle is as follows-
 Feed water cycle (F.S.T)

B.F.P.-1 B.F.P.-2 B.F.P.-3

Economizer
 GENERATOR

❖ Electric generator:-
This article is about electromagnetic power generation. For electrostatic generators like the Van de Graaff
machine, see Electrostatic generator. In electricity generation, a generator is a device that converts
mechanical energy to electrical energy for use in an external circuit. Sources of mechanical energy include
steam turbines, gas turbines, water turbines, internal combustion engines and even hand cranks. The first
electromagnetic generator, the Faraday disk, was built in 1831 by British scientist Michael Faraday.
Generators provide nearly all of the power for electric power grids. The reverse conversion of electrical
energy into mechanical energy is done by an electric motor, and motors and generators have many
similarities. Many motors can be mechanically driven to generate electricity and frequently make
acceptable manual generators.

❖ Terminology
Early Ganz Generator in Zwevegem, West Flanders, Belgium. Electromagnetic generators fall into one of
two broad categories, dynamos and alternators. Dynamos generate pulsing direct current through the use of
a commutator Alternators generate alternating current Mechanically a generator consists of a rotating part
and a stationary part.

Rotor:- The rotating part of an electrical machine

Stator:-The stationary part of an electrical machine, which surrounds the rotor One of these parts
generates a magnetic field, the other has a wire winding in which the changing field induces an electric
current
Field winding or field magnet:-The magnetic field producing component of an electrical machine. The
magnetic field of the dynamo or alternator can be provided by either wire windings called field coils or
permanent magnets. A generator using permanent magnets is sometimes called a magneto.
Armature:- power-producing component of an electrical machine. In a generator, alternator, or dynamo
the armature windings generate the electric current, which provides power to an external circuit. The
armature can be on either the rotor or the stator, depending on the design, with the field coil or magnet on
the other part.
Generator cooling:-
While small generators may be cooled by air drawn through filters at the inlet, larger units generally
require special cooling arrangements. Hydrogen gas cooling, in an oil-sealed casing, is used because it has
the highest known heat transfer coefficient of any gas and for its low viscosity which reduces windage
losses. This system requires special handling during start-up, with air in the generator enclosure first
displaced by carbon dioxide before filling with hydrogen. This ensures that the highly flammable
hydrogen does not mix with oxygen in the air.
The hydrogen pressure inside the casing is maintained slightly higher than atmospheric pressure to avoid
outside air ingress. The hydrogen must be sealed against outward leakage where the shaft emerges from
the casing. Mechanical seals around the shaft are installed with a very small annular gap to avoid rubbing
between the shaft and the seals. Seal oil is used to prevent the hydrogen gas leakage to atmosphere.
The generator also uses water cooling. Since the generator coils are at a potential of about 22 kV, an
insulating barrier such as Teflon is used to interconnect the water line and the generator high-voltage
windings. Demineralized water of low conductivity is used.

❖ Generator high-voltage system:-

The generator voltage for modern utility-connected generators ranges from 11 kV in smaller units to 30
kV in larger units. The generator high-voltage leads are normally large aluminum channels because of
their high current as compared to the cables used in smaller machines. They are enclosed in well-grounded
aluminum bus ducts and are supported on suitable insulators. The generator high-voltage leads are
connected to step-up transformers for connecting to a high-voltage electrical substation (usually in the
range of 115 kV to 765 kV) for further transmission by the local power grid.

The necessary protection and metering devices are included for the high-voltage leads. Thus, the steam
turbine generator and the transformer form one unit. Smaller units may share a common generator step-up
transformer with individual circuit breakers to connect the generators to a common bus.
 Electrostatic Precipitator

An electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate collection

device that removes particles from a flowing gas using the force of an induced electrostatic
charge.
Electrostaticprecipitators are highly efficient filtration devices that minimally impede the flow of
gases through the device, and can easily remove fine particulate matter such as dust and smoke
from the airstream.

Stack- stack is vertical pipe through which the flue gases are exhausted to atmosphere from boiler.
 Ash handling Plant

The ash handling system handles the ash by bottom ash handling system, coarse ash
handling system, fly ash handling system, ash disposal system up to the ash disposal area and
water recovery system from ash pond and Bottom ash overflow. Description is as follows:

❖ Bottom ash Handling System:-

Bottom ash resulting from the combustion of coal in the boiler shall
fall into the over ground, refractory lined, water impounded, maintained level, double V-Section
type/ W type steel- fabricated bottom ash hopper having a hold up volume to store bottom ash
and economizer ash of maximum allowable condition with the rate specified. The slurry formed
shall be transported to slurry sump through pipes.

❖ Coarse Ash Handling System:-

Ash generated in Economizer hoppers shall be evacuated
continuously through flushing boxes. Continuous generated Economizer slurry shall be fed
by gravity into respective bottom ash hopper pipes with necessary slope.
❖ Air Preheater Ash Handling system:-
Ash generated from APH hoppers shall be evacuated once in a shift by vacuum conveying
systemconnected with the ESP hopper vacuum conveying system.

❖ Fly Ash Handling System:

Fly ash is considered to be collected in ESP Hoppers. Fly ash from ESP hoppers extracted by
Vacuum Pumps up to Intermediate Surge Hopper cum Bag Filter for further Dry Conveying to
fly ashsilo. Under reach surge hopper ash vessels shall be connected with Oil free screw
compressor for conveying the fly ash from Intermediate Surge Hopper to silo. Total fly ash
generated from each unit will be conveyed through streams operating simultaneously and in
parallel.

❖ Ash Slurry Disposal:

Bottom Ash slurry, Fly ash slurry and the Coarse Ash slurry shall be pumped from the
common ash slurry sump up to the dyke area which is located at a distance from Slurry pump
house.
 Effluent Treatment Plant

➢ Main function of E.T.P. is to clean gas clean plant (G.C.P.) effluent & recycle it for further use. Sewage
water is treated as per is pollution control norms in E.T.P.

➢ This water is used for ash handling.

 Transformers
Generating Transformer:-

Transformer is a static device which step up or step down electrical energy. Function of transformer in
power plant is to step up the voltage level to the transmission voltage level. Following table shows the
transformer component and its function.

Component Function

Core Provide path for magnetic lines of flux.

Primary winding Receive electrical energy from energysource &

creates magnetic field.

Secondary winding Receive electrical energy from primarywinding &

deliver to the load

Enclosure Protect the above component from

environmental attack
Core is made up of CRGO steel which have high magnetic properties due to which losses are
reduced, & permeability is increase

Transformer bushing-

Transformer bushing is used to take out the terminal of the secondary winding
to connect it to the transmission lines. Electrical power is the product of voltage and current, the
insulation in a bushing must be capable of withstanding the voltage at which it is applied, and its
current carrying conductor must be capable of carrying rated current without overheating the
adjacent insulation. The bushing must also be able to withstand the various mechanical forces
applied to it.

 Transformer Insulation:

In power transformer, insulation is provided on two places in stator winding-

 Insulation between two winding turn in same layer. It is called as basic insulation.
 Insulation between two layers of winding.
 Basic insulation need not by excessive because the voltage difference between a winding
turn and its neighboring turn is small in value and its the voltage across one winding turn. To insulate layer
of winding from the other layer of winding paper insulation is used.

Some of the salient features of our insulating materials are listed below:-

o Excellent flexibility.

o Heat resistant.

o Moisture resistant.

o Brilliant electrical properties.

o Resistant to smoke or odour.

In power transformer, when transformer is loaded with load. Current is flows through
the transformer winding which causes I2R losses in transformer. Due to I2R losses heat is
produced in transformer. hence as load goes on increasing amount of heat developed also
increases. Excess amount of heat is developed is main reason behind transformer winding
insulationbreakdown. It also adversely affects the life of the transformer. Hence cooling system
isemployed in transformer.

 Transformer Cooling System:-

In generating transformer, heat developed is extremely high. Natural air cooling is not sufficient tomaintain
transformer temperature. Hence oil cooling system is employed in power transformer. Oil is used in transformer to
insulate & cool the winding. Transformer core & both winding are immersed in oil filled up in oil tank. This
transformer oil shouldhave following properties-

 Breather:-
Whenever electrical power transformer is loaded, the temperature of the insulating oil increases,
consequently the volume of the oil is increased. As the volume of the oil is increased, the air, above
the oil level in conservator, will come out. Again at low oil temperature the volume of the oil is
decreased, which cause, the volume of the oil to be decreased which again causes air to enter into
conservator tank. The natural air always consists of more or less moisture in it and this moisture can
be mixed up with oil if it is allowed to be entered into the transformer. The air moisture should be
resisted during entering the air into the transformer, because moisture is very harmful for transformer
insulation. A silica gel breather is most commonly used as a means of filtering air from moisture. Silica
gel breather for transformer is connected with conservator tank by means of breathing pipe.
 Conservator:-
It is the important periphery of transformer. Conservator is a tank which conserves oil. When
transformer is loaded, oil inside it is heated. Due to heating oil expand. To provide extra volume
conservator is employed. When oil gets cooled it returns to transformer oil tank. Conservator tank is
partially filled with oil.

So, the vacuum space is filled up by the atmospheric air. A filtering device, called breather is
attachedwith the conservator to ensure that only dry and clean air can enter into the transformer. So, a
conservator ensures the safety operation of a transformer. High temperature of oil also leads to generate
sludge, which occurs in the presence of air. If somehow the transformer is subjected to a major fault,
then the temperature rise becomes quite high and this causes vaporization of a part of the oil. This oil
vapour forms an explosive mixture with air and can ignite and cause huge damage.So, to prevent the
contact of oil and moisture- enriched air, conservator and breather assembly is used.

Buchholz Relay:

Principle of operation of buchholz relay is very simple. It is a mechanical phenomenon

Whenever there will be a minor internal fault in the transformer such as an insulation faults between
turns, break down of core of transformer, core heating, the transformer insulating oil will be
decomposed in different hydrocarbon gases, CO2 and CO. The gases produced due to
decomposition of transformer insulating oil will accumulate in the upper part the Buchholz
Container which causes fall of oil level in it
 Fall of oil level means lowering the position of float and thereby tilting the mercury switch. The
contacts of this mercury switch are closed and an alarm circuit energized.Sometime due to oil
leakage on the main tank air bubbles may be accumulated in theupper part the Buchholz Container
which may also cause fall of oil level in it and alarm circuit will be energized. By collecting the
accumulated gases from the gas release pockets on the top of the relay and by analyzing them one
can predict the type of fault in the transformer.

 Pressure Released Valve:-

It is a oil pressure relief valve. When oil is heated in transformer tank, it expands & it exerts pressure.
If this pressure crosses certain limit then this P.R.V. is operated. Pressure relief is very simple
construction. It contains an aluminum foil of required thickness is fitted on the opening of valve.
Whenever surge developed in oil. The aluminum foil is busted.

 Circuit Breaker:-
Circuit breaker is nothing but the switch. Circuit breaker is enclosed in a close vessel. It is operated by
external media. When is produced in it. To extinguish relay senses faults. Then relay sends signal and
then circuit breaker breaks the circuit, Due to high voltage arc
Its following methods are used-

 Bulk oil
 Minimum oil
 Air blast
 Vacuum
 SF6 ( sulfur hexafluoride)
  Station Transformer:-
Station transformer is also called as start-up transformer. This station transformer providesinitial
power to the plant auxiliaries, when no power is available. Following are the function of station
transformer- Provide electricity to auxiliaries of power plant, during start-up.
During normal operation, power to the C.H.P. auxiliaries. it is because of working of all unitis
depends upon coal supply from C.H.P.

following auxiliaries are installed in C.H.P.-

 Motors of conveyor belts.
 Motors of crusher.

Lightening system provide power to the boiler feed pump (B.F.P.). it is very important auxiliaryof thermal
power plant. If boiler drum level is not maintain, then many complications (like boiler over heating
which damage boiler tubes & many other components) are arises. Hence power supply to B.F.P. must be
maintained. To maintain this supply power supply is taken from station transformer.

Station transformer is connected to the grid transmission lines, hence power supply reliability is maintained, even
though generating units are tripped up.
 Cooling Tower
A cooling tower is a heat rejection device which rejects waste heat to the
atmosphere through the cooling of a water stream to a lower temperature.
Cooling towers may either use the evaporation of water to remove
process heat and cool the working fluid to near the wet-bulb air
temperature or, in the case of close circuit dry cooling towers, rely solely
on air tocool the working fluid to near the dry-bulb air temperature.

Common applications include cooling the circulating water used in oil

refineries, petrochemical and other chemical plants, thermal power
stations and HVAC systems for cooling buildings. The classification is
based on the type of air induction into the tower: the main types of
cooling towers are natural draft and induced draft cooling towers.

Cooling towers vary in size from small roof-top units to very large hyperboloid
structures (as in the adjacent image) that can be up to 200 metres (660 ft) tall
and 100 metres (330 ft) in diameter, or rectangular structures that can be
over 40 metres (130 ft) tall and 80 metres (260 ft) long. The hyperboloid
cooling towers areoften associated with nuclear power plants although they
are also used to some extent in some large chemical and other industrial
plants. Although these large towers are very prominent, the vast majority of
cooling towers are much smaller, including many units installed on or near
buildings to discharge heat from air conditioning.
 S uper Critical Technology-

 Why super Critical Technology:-

To reduce emission for each KWh of

energy.

 Most economical way to enhance efficiency.

 To achieve fuel cost saving. Operating Flexibility.
 Reduces boiler size per MW.

 To reduce start up time.

Understanding sub critical Technology:-

1. Water when headed to sub critical pressure, temperatureincreases tillit

starts boiling.
2. This temperature is kept constant till all the water isconverted
to steam.
3. When all liquid is converted to steam then again
temperature rises.

4. Sub Critical boiler typically has Boiler Drum to separatesteam and

water

5. The mass of the boiler drum limits the rate at which thesub critical
boiler responds to load changes.

6. Too great a firing rate will result in thermal stresses in theboiler

drum.

 Understanding Super critical Technology:-

1. When water is heated at constant pressure above

thecritical pressure, its temperature will never be constant.
2. No distinction between the liquid and gas, the
massdensity remains the same.
3. No stage where water exists as two phases and
requiresseparation. Hence, no boiler drum.
4. The actual location of transition from liquid to steam in aonce through
super critical boiler is free to move with different
conditions: Sliding Pressure Operation

5. For changing boiler load and pressure, the process is able to optimize
the amount of liquid and gas regions for effective heat transfer.
 Advantages and Disadvantages of Thermal Power Plant

 Advantages:-

1. Economical for low initial cost other than any generating plant.
2. Land required less than hydro power plant.
3. Since coal is main fuel and its cost is quite cheap than petrol
or diesel so generation cost is economical.
4. These are having easier maintenance.
5. Thermal power plant can be installed in any location
where transportation and bulk of water are available.

 Disadvantages:-

1. running cost for a thermal power station is comparatively high due tofuel
maintenance etc.
2. Large amount of smoke causes air pollution. The thermal powerstation
is responsible for global warming.

3. Overall efficiency of thermal power plant is low like 30%.

 Purpose Of Industrial training

The main reason Industrial training at the

power plant was to understand andget complete knowledge
about practical overview of energy generation plant.

Since we are studying the theoretical

working and details about various thermal plants in
our syllabus, this visit helped us to correlate between
the various equipments and parameters used in
actual power generation technique with the one given
in books.

C onclusion

After completing Industrial

training at this power station we came to know about
the practical generation process of electrical energy. We
understood the function of various components in
thermal power station, their importance, their
arrangements and the precaution to be taken for safety
inthe power plants. In engineering we studied about the
various components in theory, thus by visiting CSTPS
we came to know about this components and their
working practically. This visit to BTPS Deepnagar was
an exciting experience, since the hard work of
Mahagenco and mutual cooperation of their staff and
workers is really appreciable. I would like to thank our
staff members for arranging this quality Industrial
training.