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Industrial Training
Report
On
Thermal Power plant
For
partial fulfillment of requirements for the degree
of
B.TECH, EIE, ( VIIth Sem)
At
Rajiv Gandhi Thermal Power Plant( hisar)
A Unit Of
Haryana Power Generation Corporation Ltd. (HPGCL)
Submitted by:
Shiksha
Roll No. 11080857
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Maharishi Markandeshwar University, Mullana
(Ambala)
ACKNOWLEDGEMENT
I am highly indebted to RGTPP Rajiv Gandhi Thermal Power Station Khedar, one of the
having new technology organizations of our nation, for letting me undertake six weeks
training course with them. It was really a very nice experience as we came to know how
actually Electricity generate.
I would like to express my gratitude towards Mr. Surender Parasher (General Manager)
who allowed us to join RGTPP as a trainee, & helped us in every possible way so that we
could complete our training successfully. I also thank Mr. Virender Singh who was there to
Provide training &support us whenever we needed help at every point of our training.
Last but not least I would like to thank all the staff members of RGTPP, especially member
of C&I Deptt, who made this training a rich experience & a success
Name:- Roll No. :-
Shiksha Goyat 11080857
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PREFACE
With the ongoing revolution in electronic where innovations are taking at the
blink of eye, it is impossible to keep the pace with the emerging trends.
Excellence is an attitude that that whole of human race is born with. It is the
environment that makes sure that whether the result of this attitude is visible
or otherwise. A Well planned, properly executed and evaluated industrial
training helps a lot in inculcating a professional attitude. It provides a
linkage between the student and industry to develop an awareness of
industrial approach to problem solving, based on a broad understanding of
process and mode of operation of organization.
During this period, the student gets the real experience for working in the actual Industry
environment. Most of the theoretical knowledge that has been gained during the course of
their studies is put to test here. Apart from this the student gets an opportunity to learn the
latest technology, which is immensely helps in them in building their career.
I had the opportunity to have a real experience on many ventures, which increased my
sphere of knowledge to great extent. I got a chance to learn new technology and was also
interfaced to many instruments.
And all this credit goes to organization Rajiv Gandhi Thermal Power Plant.
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Contents
Sr. No. Topic
1. Introduction 2. History
3. Deal with reliance
4. Constructional View of Thermal Power Station
5. Classification
6. Functional description
7. Components of Plant
8. Auxiliary systems
9. Electric generator
10. Advantages & Disadvantages of coal based thermal Power Plant
11. Thermocouple
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INTRODUCTION
In Rajiv Gandhi Thermal Power Plant .The work for 1200 MW Coal fire
power plant was awarded during 2007. The total estimated cost of the project
is around Rs 4297O crores. The cost of Rs 3.19 crore for MW for this project
is lowest among all the power plants. The first of two 600 MW was
commissioned
Almost all coal, nuclear, geothermal, solar thermal electric, and waste
incineration plants, as well as many natural gas power plants are thermal.
Natural gas is frequently combusted in gas turbines as well as b oilers. The
waste heat from a gas turbine can be used to raise steam, in a combined cycle
plant that improves overall efficiency. Power plants burning coal, oil, or
natural gas are often referred to collectively as fossil-fuel power plants.
Some biomass-fueled thermal power plants have appeared also. Non-nuclear
thermal power plants, particularly fossil-fueled plants, which do not use
cogeneration, are sometimes referred to as conventional power plants.
In thermal power stations, mechanical power is produced b y a heat engine
that transforms thermal energy, often from combustion of a fuel, into
rotational energy. Most thermal power stations produce steam, and these are
sometimes called steam power stations. Not all thermal energy can be
transformed into mechanical power, according to the second law of
thermodynamics. Therefore, there is always heat lost to the environment. If
this loss is employed as useful heat, for industrial processes or district
heating, the power plant is referred to as a cogeneration power plant or CHP
(combined heat-and-power) plant. In countries where district heating is
common, there are dedicated heat plants called heat-only boiler stations. An
important class of power stations in the Middle East uses by-product heat for
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the desalination of water.
Commercial electric utility power stations are most usually constructed on a
very large scale and designed for continuous operation. Electric power plants
typically use three-phase or individual-phase electrical generators to produce
alternating current (AC) electric power at a frequency of 50 Hz or 60 Hz
(hertz, which is an AC sine wave per second) depending on its location in the
world. Other large companies or institutions may have their own usually
smaller power plants to supply heating or electricity to their facilities,
especially if heat or steam is created anyway for other purposes. Shipboard
steam-driven power plants have been used in various large ships in the past,
but these days are used most often in large naval ships. Such shipboard power
plants are general lower power capacity than full-size electric company
plants, but otherwise have many similarities except that typically the main
steam turbines mechanically turn the propulsion propellers, either through
reduction gears or directly by the same shaft. The steam power plants in such
ships also provide steam to separate smaller turbines driving electric
generators to supply electricity in the ship. Shipboard steam power plants can
be either conventional or nuclear; the shipboard nu clear plants are mostly in
the navy. There have been perhaps about a dozen turbo-electric ships in
which a steam-driven turbine drives an electric generator which powers an
electric motor for propulsion.
Thermal power station is a power plant in which the prime mover is steam
driven. Water is heated, turns into steam and spins a steam turbine which
either drives an electrical generator or does some other work, like ship
propulsion. After it passes through the turbine, the steam is condensed in a
condenser and recycled to where it was heated; this is known as a Rankine
cycle. The greatest variation in the design of thermal power stations is due to
the different fuel sources. Some prefer to use the term energy center because
such facilities convert forms of heat energy into electrical energy.
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HISTORY
Reciprocating steam engines have been used for mechanical power sources
since the 18th Century, with notable improvements being made by J ames
Watt. The very first commercial central electrical generating stations in New
York and London, in 1882, also used reciprocating steam engines. As
generator sizes increased, eventually turbines took over theyencres the hose
power
Deal with reliance
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Reliance Infrastructure, part of the Anil Dhirubhai Ambani Group, Sunday said it has
commissioned a 600 MW unit at the Rajiv Gandhi Khedar Thermal Power Plant
(RGKTPP) at Hisar in Haryana.
The company said this was the countrys largest thermal power generating unit.
The Rs.3,800-crore project, with a total capacity of 1,200 MW, is being set up by the
state government-run Haryana Power Generation Corp and executed by Reliance
Infrastructure.
This project will not only benefit the state by adding 28.8 million units of energy per
day but will also create 15,000 job opportunities in the field of construction, operations
and maintenance, said S.C. Gupta, director-operations for Reliance Infrastructure.
The Reliance Anil Dhirubhai Ambani Group, a zero net debt company, has a market
capitalisation of around $30 billion, net worth in excess of $13.6 billion, operating cash
flow of $2.8 billion and net profit of around $1.8 billion.
Where RGTPP transmit energy?
It transmit electricity to two station one is KIRORY & FATEHABAD. These two are
grid. For transmission we have to use step down transformer to reduce danger. There istransmission from switch yard to grid.
Constructional View of Thermal Power Station
A thermal power station is a power plant in which the prime
mover is steam driven. Water is heated, turns into steam and spins a steam
turbine which drives an electrical generator. After it passes through the
turbine, the steam is condensed in a condenser and recycled to where it was
heated; this is known as a Rankine cycle. The greatest variation in the design
of thermal power stations is due to the different fuel sources. Some prefer to
use the term energy center because such facilities convert forms
of heat energy into electricity [1 ]. Some thermal power plants also deliver
heat energy for industrial purposes, for district heating, or for desalination of
http://en.wikipedia.org/wiki/Power_planthttp://en.wiktionary.org/wiki/prime_moverhttp://en.wiktionary.org/wiki/prime_moverhttp://en.wikipedia.org/wiki/Steamhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Electrical_generatorhttp://en.wikipedia.org/wiki/Condensationhttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Rankine_cyclehttp://en.wikipedia.org/wiki/Heathttp://en.wikipedia.org/wiki/Energyhttp://en.wikipedia.org/wiki/Thermal_power_station#cite_note-0http://en.wikipedia.org/wiki/Thermal_power_station#cite_note-0http://en.wikipedia.org/wiki/District_heatinghttp://en.wikipedia.org/wiki/Desalinationhttp://en.wikipedia.org/wiki/Desalinationhttp://en.wikipedia.org/wiki/District_heatinghttp://en.wikipedia.org/wiki/Thermal_power_station#cite_note-0http://en.wikipedia.org/wiki/Energyhttp://en.wikipedia.org/wiki/Heathttp://en.wikipedia.org/wiki/Rankine_cyclehttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Condensationhttp://en.wikipedia.org/wiki/Electrical_generatorhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steamhttp://en.wiktionary.org/wiki/prime_moverhttp://en.wiktionary.org/wiki/prime_moverhttp://en.wikipedia.org/wiki/Power_plant8/3/2019 Shiksha 1111
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water as well as delivering electrical power. A large part of human
CO 2 emissions comes from fossil fueled thermal power plants; efforts to
reduce these outputs are various and widespread.
Typical diagram of a coal-fired thermal power station
1. Cooling tower 10. Steam Control valve 19. Super heater
2. Cooling water pump11. High pressure steam
turbine
20. Forced draught
(draft) fan
3. transmission line (3-phase) 12. Deaerator 21. Reheater
4. Step-up transformer (3-phase) 13. Feedwater heater 22. Combustion air intake
5. Electrical generator (3-phase) 14. Coal conveyor 23. Economiser
6. Low pressure steam turbine 15. Coal hopper 24. Air preheater
7. Condensate pump 16. Coal pulverizer 25. Precipitator
8. Surface condenser 17. Boiler steam drum26. Induced draught
(draft) fan
9. Intermediate pressure steam
turbine18. Bottom ash hopper 27. Flue gas stack
CLASSIFICATION
http://en.wikipedia.org/wiki/Cooling_towerhttp://en.wikipedia.org/wiki/Control_valvehttp://en.wikipedia.org/wiki/Superheaterhttp://en.wikipedia.org/wiki/Cooling_tower_systemhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Electrical_power_transmissionhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Deaeratorhttp://en.wikipedia.org/wiki/Transformerhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Feedwater_heaterhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Electrical_generatorhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Conveyorhttp://en.wikipedia.org/wiki/Economiserhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Air_preheaterhttp://en.wikipedia.org/wiki/Condensate_pumphttp://en.wikipedia.org/wiki/Pulverizerhttp://en.wikipedia.org/wiki/Electrostatic_precipitatorhttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Steam_drumhttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Bottom_ashhttp://en.wikipedia.org/wiki/Flue_gas_stackhttp://en.wikipedia.org/wiki/File:PowerStation2.svghttp://en.wikipedia.org/wiki/Flue_gas_stackhttp://en.wikipedia.org/wiki/Bottom_ashhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Steam_drumhttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Electrostatic_precipitatorhttp://en.wikipedia.org/wiki/Pulverizerhttp://en.wikipedia.org/wiki/Condensate_pumphttp://en.wikipedia.org/wiki/Air_preheaterhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Economiserhttp://en.wikipedia.org/wiki/Conveyorhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Electrical_generatorhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Feedwater_heaterhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Transformerhttp://en.wikipedia.org/wiki/Deaeratorhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Electrical_power_transmissionhttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Cooling_tower_systemhttp://en.wikipedia.org/wiki/Superheaterhttp://en.wikipedia.org/wiki/Control_valvehttp://en.wikipedia.org/wiki/Cooling_tower8/3/2019 Shiksha 1111
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Thermal power plants are classified by the type of fuel and the type of prime mover
Installed.
By fuel
Nuclear power plants use a nuclear reactor's heat to operate a steam turbine
generator.
Fossil fuelled power plants may also use a steam turbine generator or in the
case of natural gas fired plants may use a combustion turbine. A coal-fired
power station produces electricity by burning coal to generate steam, and has
the side-effect of producing a large amount of carbon dioxide, which is
released from burning coal and contributes to global warming
Geothermal power plants use steam extracted from hot u nderground rocks.
Biomass Fuelled Power Plants may be fuelled by waste from sugar cane,
municipal solid waste, landfill methane, or other forms of biomass.
Solar thermal electric plants use sunlight to boil water, which turns the
generator.
By prime mover
Steam turbine plants use the dynamic pressure generated by expanding steam
to turn the blades of a turbineGas turbine plants use the dynamic pressure from flowing gases (air and
combustion products) to directly operate the turbine.
Combined cycle plants have both a gas turbine fired by natural gas, and a
steam boiler and steam turbine which use the hot exhaust gas from the gas
turbine to produce electricity
Reciprocating engines are used to provide power for isolated communities
and are frequently used for small cogeneration plants. Hospitals, office
buildings, industrial plants, and other critical facilities also use them to
provide backup power in case of a power outage
Microturbines, Stirling engine and internal combustion reciprocating engines
are low-cost solutions for using opportunity fuels, such as landfill gas,
digester gas from water treatment plants and waste gas from oil production
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Efficiency
Power is energy per unit time. The power output or capacity of an electric
plant can be expressed in units of megawatts electric (MWe). The electric
efficiency of a conventional thermal power station, considered as saleable
energy (in MWe) produced at the plant busbars as a percent of the heating
value of the fuel consumed, is typically 33% to 48% efficient. This efficiency
is limited as all heat engines are governed by the laws of thermodynamics
(See: Carnot cycle). The rest of the energy must leave the plant in the form of
heat. This waste heat can go through a condenser and be disposed of with
cooling water or in cooling towers. If the waste heat is instead utilized for
district heating, it is called cogeneration. An important class of thermal
power station is associated with desalination facilities; these are typically
found in desert countries with large supplies of natural gas and in these
plants, freshwater production and electricity are equally important co-
products.
Since the efficiency of the plant is fundamentally limited by the ratio of the
absolute temperatures of the steam at turbine input and output, efficiency
improvements require use of higher temperature, and therefore higher
pressure, steam. Historically, other working fluids such as mercury have been
experimentally used in a mercury vapor turbine power plant, since these can
attain higher temperatures than water at lower working pressures. However,
the obvious hazards of toxicity, and poor heat transfer properties, have ruled
out mercury as a working fluid.
BASIC DEFINITIONS
Steam is vaporized water and can be produced at 100C at standardatmosphere.
In common speech, steam most often refers to the visible white mist that
condenses above boiling water as the hot vapor mixes with the cooler air.
Turbine A turbine is a rotary engine that extracts energy from a fluid or air
flow and converts it into useful work.
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The simplest turbines have one moving part, a rotor assembly, which is a
shaft or drum, with blades attached. Moving fluid acts on the blades, or the
blades react to the flow, so that they move and impart rotational energy to the
rotor. Early turbine exare windmills and waterwheels.
Fig turbine:-
Electric generator An electric generator is a device that converts mechanical
energy to electrical energy. A generator forces electrons in the windings to
flow through the external electrical circuit. It is somewhat analogous to a
water pump, which creates a flow of water but does not create the water
inside.
Fig Generator:-
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A boiler or steam generator is a device used to create steam by applyingheat
energy to water. Although the definitions are somewhat flexible, it can be
said that older steam generators were commonly termed boilers and worked at
low to medium pressure
(1300 psi/0.06920.684 bar; 6.8952,068.427 kPa), but at pressures
above this it is more usual to speak of a steam generator.
A boiler or steam generator is used wherever a source of steam is requ ired.
The form and size depends on the application: mobile steam engines such as
steam locomotives, portable engines and steam -powered road vehicles
typically use a smaller boiler that forms an integral part of the vehicle;
Second law of thermodynamics The second law of thermodynamics is an
expression of the universal principle of entropy, stating that the entropy of
anisolated system which is not in equilibrium will tend to increase over time,
approaching a maximum value at equilibrium; and that the entropy change
dSof a system undergoing any infinitesimal reversible process is given by dq
/ T, where dq is the hea t suppli ed to the sys tem and T is the abs olute
temperature of the system.
Coal Handling Plant (CHP):- Extent of work: - In brief we can say that receipt of coal from coal
mines, weighing of coal, crushing it to required size and transferring
the quanta of coal to various coal mill bunkers. This is the
responsibility and duty of the CHP and its staff.
CHP is (C- Coal, H- Handling, P- Plant) a plant which handles the coal
from its receipt to transporting it to Boiler and store in Bunkers. It also
processes the raw coal to make it suitable for Boiler Opeartion.Receipt of Coal:-
Normally Thermal Power Station receives the coal by three modes of
transportation.
1. By Railway (80-90% of the requirement is fulfilled by this way)
2. By Road ( if required 5-10% of the requirement is fulfilled by this
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way)
3. By Arial ropeways
.. Arial ropeway is available only to the power stations which are near
the coal mines
Cost of coal transportation by road is much higher than that for rail
transport hence most of the coal requirement of the power stations is
fulfilled by railway transport.
Demurrage calculations on coal Rakes:-
We receive the coal wagons in the form of rakes (55-60 wagons in each
rake).
These coal rakes are to be unloaded in given free time normally 12-
14 hrs. from the time of receipt of coal rakes.
Free time is calculated from the receipt of written intimation of coal
rakes from the railway and written intimation of empty rake formation
from MSEB to railway.
Rate of demurrage is Rs.1/- per ton per hour.
If coal rake is not unloaded in given free time the demurrage shall be
charged on complete capacity (approx. 3300 metric ton) of coal rake at
the rate of Rs. 1/- per ton per hour
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FUNCTIONAL DESCRIPTION
Diagram of a typical coal-fired thermal power station
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
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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 Howells 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.
Components of Coal Fired Thermal Power Station:
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 hoppersat the boilers. The coal is next pulverized into a very fine powder, so that coal will
undergo complete combustion during combustion process.
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.
iii) Magnetic separators: coal which is brought may contain iron particles. These iron
particles may result in wear and tear. The iron particles may include bolts, nuts wire fish
plates etc. so these are unwanted and so are removed with the help magnetic separators.
The coal we finally get after these above process are transferred to the storage site.
Purpose of fuel storage is two
Fuel storage is insurance from failure of normal operating supplies to arrive. Storage permits some choice of the date of purchase, allowing the purchaser to take
advantage of seasonal market conditions. Storage of coal is primarily a matter of
protection against the coal strikes, failure of the transportation system & general
coal shortages.
There are two types of storage:
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1. Live Storage (boiler room storage): storage from which coal may be withdrawn tosupply combustion equipment with little or no remanding is live storage. This storage
consists of about 24 to 30 hrs. of coal requirements of the plant and is usually a
covered storage in the plant near the boiler furnace. The live storage can be provided
with bunkers & coal bins. Bunkers are enough capacity to store the requisite of coal.
From bunkers coal is transferred to the boiler grates.
2. Dead storagestored for future use. Mainly it is for longer period of time, and it isalso 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 Live Storage(boiler roomstorage): storage from which coal may be withdrawn to supply combustion equipment
with little or no remanding is live storage. This storage consists of about 24 to 30 hrs.
of coal requirements of the plant and is usually a covered storage in the plant near the
boiler furnace. The live storage can be provided with bunkers & coal bins. Bunkers
are enough capacity to store the requisite of coal. From bunkers coal is transferred to
the boiler grates.
Air path
External fans are provided to give sufficient air for combustion. The forced draft fan
takes air from the atmosphere and, first warming it in the air preheater for better
combustion, injects it via the air nozzles on the furnace wall.The induced draft fan assists
the FD fan by drawing out combustible gases from the furnace, maintaining a slightly
negative pressure in the furnace to avoid backfiring through any opening.
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Boiler furnace and steam drum
Once water inside the boiler or steam generator, the process of adding the latent heat of
vaporization or enthalpy is underway. The boiler transfers energy to the water by thechemical reaction of burning some type of fuel.The water enters the boiler through a
section in the convection pass called the economizer. From the economizer it passes to
the steam drum. Once the water enters the steam drum it goes down the down comers to
the lower inlet water wall headers. From the inlet headers the water rises through the
water walls and is eventually turned into steam due to the heat being generated by the
burners located on the front and rear water walls (typically). As the water is turned into
steam/vapor in the water walls, the steam/vapor once again enters the steam drum. The
steam/vapor is passed through a series of steam and water separators and then dryers
inside the steam drum. The steam separators and dryers remove water droplets from the
steam and the cycle through the water walls is repeated. This process is known as natural
circulation.
The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot
blowers, water lancing and observation ports (in the furnace walls) for observation of the
furnace interior. Furnace explosions due to any accumulation of combustible gases after a
trip-out are avoided by flushing out such gases from the combustion zone before igniting
the coal.
The steam drum (as well as the superheater coils and headers) have air vents and drains
needed for initial startup. The steam drum has internal devices that remove moisture from
the wet steam entering the drum from the steam generating tubes. The dry steam then
flows into the superheater coils.
Superheater
Coal based power plants can have a superheater and/or reheater section in the steam
generating furnace. Nuclear-powered steam plants do not have such sections but produce
steam at essentially saturated conditions. In a coal based plant, after the steam is
conditioned by the drying equipment inside the steam drum, it is piped from the upper
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drum area into tubes inside an area of the furnace known as the superheater, which has an
elaborate set up of tubing where the steam vapor picks up more energy from hot flue
gases outside the tubing and its temperature is now superheated above the saturation
temperature. The superheated steam is then piped through the main steam lines to the
valves before the high pressure turbine.
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. This is what is called as thermal power.
Deaerator
A steam generating boiler requires that the boiler feed water should be devoid of air and
other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the
metal.
Generally, power stations use a deaerator to provide for the removal of air and other
dissolved gases from the boiler feed water. A deaerator typically includes a vertical,
domed deaeration section mounted on top of a horizontal cylindrical vessel which serves
as the deaerated boiler feed water storage tank
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Fly ash collection
Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric
bag filters (or sometimes both) located at the outlet of the furnace and before the induceddraft fan. The fly ash is periodically removed from the collection hoppers below the
precipitators or bag filters. Generally, the fly ash is pneumatically transported to storage
silos for subsequent transport by trucks or railroad cars.
Bottom ash collection and disposal
At the bottom of the furnace, there is a hopper for collection of bottom ash. This hopper
is always filled with water to quench the ash and clinkers falling down from the furnace.
Some arrangement is included to crush the clinkers and for conveying the crushed
clinkers and bottom ash to a storage site.
Boiler make-up water treatment plant and storage
Since there is continuous withdrawal of steam and continuous return of condensate to the
boiler, losses due to blow down and leakages have to be made up to maintain a desired
water level in the boiler steam drum. For this, continuous make-up water is added to the
boiler water system. Impurities in the raw water input to the plant generally consist of
calcium and magnesium salts which impart hardness to the water. Hardness in the make-
up water to the boiler will form deposits on the tube water surfaces which will lead to
overheating and failure of the tubes. Thus, the salts have to be removed from the water,
and that is done by a waterdemineralising treatment plant (DM). A DM plant generally
consists of cation, anion, and mixed bed exchangers. Any ions in the final water from this
process consist essentially of hydrogen ions and hydroxide ions, which recombine to
form pure water. Very pure DM water becomes highly corrosive once it absorbs oxygen
from the atmosphere because of its very high affinity for oxygen.
The capacity of the DM plant is dictated by the type and quantity of salts in the raw water
input. However, some storage is essential as the DM plant may be down for maintenance.
For this purpose, a storage tank is installed from which DM water is continuously
withdrawn for boiler make-up. The storage tank for DM water is made from materials not
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affected by corrosive water, such as PVC. The piping and valves are generally of
stainless steel. Sometimes, a steam blanketing arrangement or stainless steel doughnut
float is provided on top of the water in the tank to avoid contact with air. DM water
make-up is generally added at the steam space of the surface condenser (i.e., the vacuum
side). This arrangement not only sprays the water but also DM water gets deaerated, with
the dissolved gases being removed by an air ejector attached to the condenser.
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 wind age 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 and water is conductive, 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 22 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
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supported on suitable insulators. The generator high voltage leads are connected to step-
up transformers for connecting to a high voltage electrical substation (of the order of 115
kV to 520 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.
Condenser
Diagram of a typical water-cooled surface condenser
The surface condenser is a shell and tube heat exchanger in which cooling water is
circulated through the tubes. The exhaust steam from the low pressure turbine enters the
shell where it is cooled and converted to condensate (water) by flowing over the tubes as
shown in the adjacent diagram. Such condensers use steam ejectors or rotary motor-
driven exhausters for continuous removal of air and gases from the steam side to maintain
vacuum.
For best efficiency, the temperature in the condenser must be kept as low as practical in
order to achieve the lowest possible pressure in the condensing steam. Since the
condenser temperature can almost always be kept significantly below 100 C where the
vapor pressure of water is much less than atmospheric pressure, the condenser generally
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works under vacuum. Thus leaks of non-condensable air into the closed loop must be
prevented. Plants operating in hot climates may have to reduce output if their source of
condenser cooling water becomes warmer; unfortunately this usually coincides with
periods of high electrical demand for air conditioning.
The condenser generally uses either circulating cooling water from a cooling tower to
reject waste heat to the atmosphere, or once-through water from a river, lake or ocean.
Feedwater heater
In the case of a conventional steam-electric power plant utilizing a drum boiler, the
surface condenser removes the latent heat of vaporization from the steam as it changes
states from vapour to liquid. The heat content (joules or Btu) in the steam is referred to as
enthalpy. The condensate pump then pumps the condensate water through a Air ejector
condenser and Gland steam exhauster condenser. From there the condensate goes to the
deareator where the condenstae system ends and the Feedwater system begins.
Preheating the feedwater reduces the irreversibilities involved in steam generation and
therefore improves the thermodynamic efficiency of the system. This reduces plant
operating costs and also helps to avoid thermal shock to the boiler metal when the
feedwater is introduced back into the steam cycle.
Conveyor system
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A conveyor system is a common piece of mechanical handling equipment that moves
materials from one location to another. Conveyors are especially useful in applications
involving the transportation of heavy or bulky materials. Conveyor systems allow quick
and efficient transportation for a wide variety of materials, which make them very
popular in the material handling and packaging industries. Many kinds of conveying
systems are available, and are used according to the various needs of different industries.
There are chain conveyors as well. Chain conveyors consist of enclosed tracks, I-Beam,
towline, power & free, and hand pushed trolleys.
Care and Maintenance of Conveyor Systems
Poor take-up adjustment
Lack of lubrication Product Handling: Bad Belt Tracking or Timing
Cooling tower
A cooling tower is a heat rejection device, which extracts waste heat to the atmosphere
though the cooling of a water stream to a lower temperature. The type of heat rejection in
a cooling tower is termed evaporative in that it allows a small portion ofthe water
being cooled to evaporate into a moving air stream to provide significant cooling to the
rest of that water stream. The heat from the water stream transferred to the air stream
raises the airs temperature and its relative humidity to 100%, and this air is discharged to
the atmosphere. Evaporative heat rejection devices such as cooling towers are commonly
used to provide significantly lower water temperatures than achievable with air cooled
or dry heat rejection devices, like the radiator in a car, thereby achieving more cost-
effective and energy efficient operation of systems in need of cooling. The cooling towers
are of two types: -
1. Natural Draft Cooling Tower2. Mechanized Draft Cooling Tower
i. Forced Draft cooling tower
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ii. Induced Draft cooling tower
iii. Balanced Draft cooling tower
Auxiliary systems
Oil systemAn auxiliary oil system pump is used to supply oil at the start-up of the steam turbine
generator. It supplies the hydraulic oil system required for steam turbines main inlet
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steam stop valve, the governing control valves, the bearing and seal oil systems, the
relevant hydraulic relays and other mechanisms.
At a preset speed of the turbine during start-ups, a pump driven by the turbine main shafttakes over the functions of the auxiliary system.
Monitoring and alarm systemMost of the power plant operational controls are automatic. However, at times, manual
intervention may be required. Thus, the plant is provided with monitors and alarm
systems that alert the plant operators when certain operating parameters are seriously
deviating from their normal range.
Battery supplied emergency lighting and communicationA central battery system consisting of lead acid cell units is provided to supply
emergency electric power, when needed, to essential items such as the power plants
control systems, communication systems, turbine lube oil pumps, and emergency
lighting. This is essential for a safe, damage-free shutdown of the units in an emergency
situation.
Electric generator
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In electricity generation, an electric generator is a device that converts mechanical
energy to electrical energy. A generator forces electrons in the windings to flow
through the external electrical circuit. It is somewhat analogous to a water pump,
which creates a flow of water but does not create the water inside. The source of
mechanical energy may be a reciprocating or turbine steam engine, water falling
through a turbine or waterwheel, an internal combustion engine, a wind turbine, a
hand crank, compressed air or any other source of mechanical energy.
The reverse conversion of electrical energy into mechanical energy is done by
an electric motor, and motors and generators have many similarities. In fact many
motors can be mechanically driven to generate electricity, and very frequently
make acceptable generators. a
Alternator
Without a commutator, a dynamo becomes an alternator, which is a synchronous
singly-fed generator. When used to feed an electric power grid, an alternator must
always operate at a constant speed that is precisely synchronized to the electrical
frequency of the power grid. A DC generator can operate at any speed within
mechanical limits, but always outputs direct current.
The primary advantage of the alternator is that the field windings can be swapped
from the exterior non-rotating shell to the interior rotating shaft, and the current
producing windings are on the exterior shell. This allows for extremely thick
current producing windings that stay in a fixed position with permament non-
moving wiring.
The rotating field coil by contrast can operate at high voltage and low current so
that only small, simple, and low-cost slip rings are needed. For example,
automotive alternators commonly only use a single carbon brush to supply power
to the field coil; the other end of the coil is attached to the vehicle ground by way
of the rotor bearings.
By using a rotary transformer to convey power to the rotating field coil, no
rubbing physical contacts are needed at all, and the alternator becomes an almost
maintenance-free power generation device
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Tachogenerator
Tachogenerators are frequently used to power tachometers to measure the speeds
of electric motors, engines, and the equipment they power. Generators generate
voltage roughly proportional to shaft speed. With precise construction and design,
generators can be built to produce very precise voltages for certain ranges of shaft
speeds
Sources of error:-
The common error sources of a PRT are:
Interchangeability: the closeness of agreement between the specific PRT's
Resistance vs. Temperature relationship and a predefined Resistance vs.
Temperature relationship, commonly defined by IEC 60751.
Insulation Resistance: Error caused by the inability to measure the actual resistance
of element. Current leaks into or out of the circuit through the sheath, between the
element leads, or the elements.
Stability: Ability to maintain R vs T over time as a result of thermal exposure.
Repeatability: Ability to maintain R vs T under the same conditions after
experiencing thermal cycling throughout a specified temperature range.
Hysteresis: Change in the characteristics of the materials from which the RTD is
built due to exposures to varying temperatures.
Stem Conduction: Error that results from the PRT sheath conducting heat into or
out of the process.
Calibration/Interpolation: Errors that occur due to calibration uncertainty at the cal
points, or between cal point due to propagation of uncertainty or curve fit errors.
Lead Wire: Errors that occur because a 4 wire or 3 wire measurement is not used,
this is greatly increased by higher gauge wire.
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2 wire connection adds lead resistance in series with PRT element.
3 wire connection relies on all 3 leads having equal resistance.
Self Heating: Error produced by the heating of the PRT element due to the power
applied.
Time Response: Errors are produced during temperature transients because the PRT
cannot respond to changes fast enough .Thermal EMF: Thermal EMF errors are
produced by the EMF adding to or subtracting from the applied sensing voltage,
primarily in DC systems
Advantages of coal based thermal Power Plant
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
Disadvantages of coal based thermal Power Plant
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
Thermocouple
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Thermocouple plugged to a multimeter displaying room temperature in C.
A thermocouple is a junction between two different metals that produces a voltage related
to a temperature difference. Thermocouples are a widely used type of temperature sensorfor measurement and control and can also be used to convert heat gradient into
electricity. They are inexpensive and interchangeable, are supplied fitted with standard
connectors, and can measure a wide range of temperatures. The main limitation is
accuracy: system errors of less than one degree Celsius (C) can be difficult to achieve.
Any junction of dissimilar metals will produce an electric potential related to
temperature. Thermocouples for practical measurement of temperature are junctions of
specific alloys which have a predictable and repeatable relationship between temperature
and voltage. Different alloys are used for different temperature ranges. Properties such as
resistance to corrosion may also be important when choosing a type of thermocouple.
Where the measurement point is far from the measuring instrument, the intermediate
connection can be made by extension wires which are less costly than the materials used
to make the sensor. Thermocouples are usually standardized against a reference
temperature of 0 degrees Celsius; practical instruments use electronic methods of cold-
junction compensation to adjust for varying temperature at the instrument terminals.
Electronic instruments can also compensate for the varying characteristics of the
thermocouple, and so improve the precision and accuracy of measurements.
Thermocouples are widely used in science and industry; applications include temperature
measurement for kilns, gas turbine exhaust, diesel engines, and other industrial processes.
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Principle of operation:-
In 1821, the GermanEstonian physicist Thomas Johann Seebeck discovered that when
any conductor is subjected to a thermal gradient, it will generate a voltage. This is now
known as the thermoelectric effect or Seebeck effect. Any attempt to measure this voltage
necessarily involves connecting another conductor to the "hot" end. This additional
conductor will then also experience the temperature gradient, and develop a voltage of its
own which will oppose the original. Fortunately, the magnitude of the effect depends on
the metal in use. Using a dissimilar metal to complete the circuit creates a circuit in
which the two legs generate different voltages, leaving a small difference in voltage
available for measurement. That difference increases with temperature, and is between 1
and 70 microvolts per degree Celsius (V/C) for standard metal combinations.
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The voltage is not generated at the junction of the two metals of the thermocouple but
rather along that portion of the length of the two dissimilar metals that is subjected to a
temperature gradient. Because both lengths of dissimilar metals experience the same
temperature gradient, the end result is a measurement of the temperature at the
thermocouple junction.
High Static Gauge Pressure Transmitter
The high performance gauge pressure transmitter model EJA440A can be used to
measure liquid, gas, or steam pressure. It outputs a 4 to 20 mA DC signal corresponding
to the measured gauge pressure.
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The EJA Series is available with BRAIN, HART, FOUNDATION fieldbus or
PROFIBUS PA communication protocols.
Features
Excellent performance and stabilityThe EJA series uses a silicon resonant sensor formed from monocrystal silicon, a
perfect material which has no hysteresis in pressure or temperature changes. The sensor
minimizes overpressure, temperature change, and static pressure effects, and thus offers
unmatched long-term stability.
Compact and light-weight designHalf the weight of conventional models thanks to miniaturization of the casing
with the amplifier ASIC, pressure cell structure, and flange. The ASIC uses the minimum
number of parts and improves the reliability of the amplifier.
Fieldbus communication capabilityFieldbus is a digital two-way communication system. It is a revolutionary
technology for configuring instrumentation control systems and a promising successor to
the standard 4 to 20 mA analog communication used in most field instruments today.
EJA series offers two types of fieldbus models, FOUNDATION fieldbus Low Voltage
Mode and PROFIBUS PA devices, which ensure interoperability between Yokogawa and
other manufactures. As for software, the EJA series incorporates two AI function blocks
that compute differential and static pressures to allow flexible configuration of
instrumentation.
Specifications of Gauge Pressure Transmitter
C Capsule D Capsule
Range -0.1 to 32 MPa
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Accuracy 0.12% 0.12%
Certificates FM, CENELEC ATEX, CSA, IECEx
Output 4 to 20 mA DC or FOUNDATION fieldbus or PROFIBUS PA 2-wire system
with digital communication
Ambient temperature -40 to 85 deg C (-40 to 185 deg F) (general use type)
-30 to 80 deg C (-22 to 176 deg F) (with integral indicator)
Process temperature -40 to 120 deg C (-40 to 248 deg F) (general use type)
Maximum overpressure 48 MPa (6750 psig) 60 MPa (8500 psig)
Absolute and Gauge Pressure Transmitter
The general purpose absolute and gauge pressure transmitter EJX510A and EJX530A
feature single crystal silicon resonant sensor and are suitable to measure liquid, gas, orsteam pressure.
The multi-sensing technology provides the advanced diagnostic function to detect such
abnormalities as an impulse line blockage or heat trace breakage.
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The EJX series is available with BRAIN, HART, and FOUNDATION fieldbus
communication protocols.
Specifications :-
Accuracy 0.1%
Supply voltage BRAIN and HART:10.5 to 42 V DC
(10.5 to 30 V DC for Intrinsically safe type)
Ambient temperature -40 to 85 deg C (-40 to 185 deg F) (general use type)
-30 to 80 deg C (-22 to 176 deg F) (with integral indicator)
Process temperature -40 to 120 deg C (-40 to 248 deg F) (general use type)
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