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Summer Training Report

     @CTPS
               Rohit anand
               10bme0153
               4th semester
               VIT VELLORE
CONTENTS
 About the company
 Introduction
 General layout
 Components
 Coal cycle
 Condensation cycle
 Steam cycle
 Power cycle
 Ash treatment
 exhaust
About The Company
• Damodar valley corporation, popularly known
  as DVC , came into being on July 7, 1948.this
  was first multi-purpose river valley project of
  independent India.
• CTPS: chandrapura thermal power station is
  situated in Bokaro district of Jharkhand. This
  has a installed capacity of 1600 MW.
MISSION                        VISION
• To generate adequate and     • To be the best power utility
  reliable power most            in the country and one of
  economically , efficiently     the best in the world.
  and eco-friendly.
• To spearhead accelerated
  power development by
  planning and implementing
  new power projects
INTRODUCTION
• A thermal power plant converts the heat
  energy of coal into electrical energy. Coal is
  burned in a boiler which converts water into
  steam. The expansion of steam produces
  mechanical power drives alternator coupled
  to turbine
Tpp summer pro rep
COMPONENTS
            main                   auxiliary
   Coal mill           •   FD fan
   Boiler              •   ID fan
                        •   Safety valve
   Turbine
                        •   Gauge valve
   Generator           •   Conveyer
   Condenser           •   Transmission lines
   super heater        •   Air pre-heater
                        •   De-aerator
                        •   Reheater
                        •   ESPs
COAL CYCLE
 Coal stock yard



 Coal conveyer



  Coal hopper



    Coal mill



    furnace
Coal Handling Plant
 Wagon unloading system
 Crushing system
 Conveying system
Unload the coal from wagon for standardization and
selection and then the coal is stored in STOCK YARD.
Through conveyer system , the coal is sent in hopper.
Hopper allows to pass coal pieces<200 mm
From it coal falls on vibrator which is supported by
roller
Tpp summer pro rep
Crushing System
• The gear box: contains worm wheel and worm
  gear which moves the wheel.
• Motor: this provides energy for both worm gear
  and exhaust fan to move.
• Exhaust fan: it sucks the coal dust , mixes it with
  pre-heated air (to maintain coal temperature)
  and send it through pipes in to boiler.
• One coal mill unit sends 8 pipes into boiler.
• Grinding roll fixed with mill body as shown in fig.
  brings coal to 20 mm size.
Coal + Air Supply
 Atmospheric air


Combustion intake


  Air pre heater


     Fd fan


 Coal pulveriser


    Coal +air


  Burner floor         Primary superheater
Air Supply
 DRAFT SYSTEM
Natural
Mechanical
In mechanical systems fans are used to create
draft .
At CTPS balanced draft system is used in
which both FD and ID fans are used
• FD fan-forced draft fan , this creates a negative
  pressure in the boiler and via this pressure
  difference atmospheric air is drawn in the boiler
• ID fan-this sucks the treated flue gas out and
  ejects it through chimney.the mechanical draft is
  created by fan
• Now the pre heated air goes into coal pulverizer
  and then sent into burner floor of boiler where
  through corner firing system(CFS) fire balls are
  made , which burn the coal laden air stream
  coming from below. Thus producing required
  heat for super heating.
Air Pre-heater
• This is a general term to describe any device
  designed to heat air before another
  process(for ex. Combustion in a boiler). The air
  comes through combustion intake pipeline,
  assisted by FD fan.
CONDENSATE CYCLE
   L.P. turbine            River water

Surface condenser           reservoir

  Cooling tower            Alum house      sump


Condensate pump          Water treatment


   De-aerator               Pure water


Feed water heater        Condensate pump


Feed water pump


   economizer
Water Supply
• Majority of water supply for steam generation
  is condensed water. The steam fromL.P.
  turbine is sent into surface condenser which
• Changes the phase from steam to water.
• Now, this water is sent to cooling towers
  which are evaporative coolers used for cooling
  water. these evaporate some part of
  condensed water to reject heat. At CTPS
  cooling towers are of hyperboloid structure
Tpp summer pro rep
DE-aerator                 Feed water heater
• Device for air removal and   • This is used to pre heat
  corrosive dissolved gases      water delivered to a steam
  because corrosion can          generating boiler, improving
  render pipe networks           efficiency. Feed water
                                 heaters allow the water to
  useless and rusty              be brought upto saturatiuon
                                 temperature very gradually.
                                 This reduces costs and help
                                 prevent thermal shocks to
                                 boiler material.
                               •
• Feed water pump: these pumps are high
  pressure units that overcome steam pressure
  to force water into the boiler drum.
• ECONOMIZER :in boilers, these are heat
  exchangers that heat fluids usually water, upto
  its saturation point, they use the energy from
  the heat of flue gas and thus reduce heat in
  put and costs. It is placed in the passage of
  flue gas between outlet and chimney
Make Up Water
• This is additional water added in feed water
  stream . but before that it Is treated in water
  treatment plant
• At CTPS, there are 4 treatment units
• 1)dirty water from reservoir. Sedimentation
  removes majority suspensions particles:
  trough perforations clean water drips into well
  2)
Tpp summer pro rep
• (2) alum is mixed in 2)with water coming from
  1) micelle formation and this micelle is
  removed by mechanical arrangement; by
  forcing this trough a slope.
• 3)clean water comes from 2) into (3) via
  perforations.
• This treated water is sent into feed stream ,
  where it mixes with condensed water, to form
  “final water”.
STEAM CYCLE
• fe   Feed water       Gauge valve
                                       Primary super
                                           heater


                                       Secondary super
       economizer       Ceiling tube
                                           heater


                                           Platen
       Boiler drum      Boiler drum
                                        superheater


       Ring header       Riser tube
                                           turbine



       Water valve      Input header
Tpp summer pro rep
Boiler Operations
 The feed water enters into economizer reaches upto saturation point.
 It is sent into boiler steam drum
BOILER STEAM DRUM
It is reservoir
of water/steam at the top end of the water tubes in the water-tube
boiler. They store the steam generated in the water tubes and act as
a
phase separator for the steam/water mixture. The difference in
densities between hot and cold water helps in the accumulation of
the
“hotter”-water/and saturated –steam into steam drum.
•   The
•   separated steam is drawn out from the top section of the drum.
•   Saturated steam is drawn off the top of the drum. The steam will reenter
•   the furnace in through a super heater, while the saturated water
•   at the bottom of steam drum flows down to the mud- drum /feed water
•   drum by down comer tubes accessories include a safety valve, water
•   level indicator and fuse plug. A steam drum is used in the company of
•   a mud-drum/feed water drum which is located at a lower level. So that
•   it acts as a sump for the sludge or sediments which have a tendency to go
    to bottom
Tpp summer pro rep
Super Heater Tubes
•   At CTPS types of super heater are :
•   Primary -straight pipes
•   Secondary- U shaped
•   Platen      - BENT shaped
•   This all tubing has same function to super
    heat water: to heat the steam extracted from
    drum, increasing it’s thermal energy and
    decreasing the likelihood that it will condense
    in pipe network or in turbine section
• The superheated steam is sent into high pressure turbine, at 540 degree
  celcius and 145 kg per square cm
• And the thin ash particles are collected by ESP and thick ash fall into ash
  hopper below.


• Turbine section:
• A steam turbine is a device that extracts thermal energy from
  pressurized steam and used it to do mechanical work on a
  rotary output shaft. this is a form of heat engine that derives
  much of its improvement in thermodynamic efficiency
  through the use of multi stagesin expansion of steam
POWER CYCLE
 Boiler drum            Surface condener




 h.p. turbine              l.p.turbine




Reheater inlet             i.P turbine




  reheater              Reheater outlet
•   There are three turbines:
•   High pressure          – 5 stages
•   Intermediate pressure-12 stages
•   Low pressure          -9 stages

• Turbine types:(based on stages)
• Impulse turbine: stage is set of moving blade behind the nozzle.
• Reaction turbine: each row of blades is called a stage.

• Blades:
•    in H.P., the blading used is impulse blading because it extracts more work
    from high pressure steam than reaction blading.
• Impulse blading:it is in shape of half moon. As steam impact the
  moving blade, it pushes the blade forward. this causes steam to lose
  velocity without losing pressure.
• The steam coming out from the H.P. turbine gas into reheater through
  inlet and comes back trough outlet attaining thermal energy can be
  extracted in I.P. turbine and L.P. turbine.
• I.P. and L.P. turbines: the steam at low pressure and
  temperature enter into this turbine pair respectively: so
  reaction blading is used
• REACTION BLADING: works on same concept as a jet engine.
  A jet engine is designed to take in air. Each moving reaction
  blade is designed to act as a nozzle.as the steam passes
  trough a reaction blade it causes the reaction blade to be
  propelled forward , resulting in rotation of L.P. turbine rotor
• Intercept valve: this is in H.P. turbine and governs the the
  steam flow amount.
• There is a surface condenser below L.P. turbine, explained in
  water supply previously.
• all the three turbines are mechanically linked trough a rotor
  and the generator is coupled at the end of the system. At
  CTPS it is hydrogen cooled.
Ash Treatment Plant
•   ESP: electro static precipitator is a particulate device that removes particles
    from a flowing gas, using force of an induced electrical charge.automatic
    rapping systems and hopper evacuation system remove the collected
    particulate matter while in line allowing esps to stay in operation for years at a
    time.
•   From the hoppers these are collected in the collector tank.
•    this collector tank has wet line trough which water comes.both ash and water
    are mixed and sent into collector tank. the hydrovactor is vaccum creating
  machine, that creates vaccum by removing water and air ,thus ensuring
  necessary pressure difference.
• A VACCUM BREAKER is like a plate, it maintains and releases vaccum as
  and when required.
• The slury is sent into sump from where it is carried 4 km away from CTPS
  using suitable pumps and pipe network.
Tpp summer pro rep
• There is air washer in conjunction with hydrovactor,
  that cleans air of its dust and susrensions, etc.
• For thick ash, metal or stones which are falling in ash
  hopper below,where they are crushed using grinde.
  Using grinder. Using a power cylinder to open the
  gate and remove the pulverized debris with water
  into sump tank and discharged.
Exhaust Cycle
Flue gas




  ESP              Ash treatment plant




 ID fan




 Flue
exhaust
• The dust and ash are taken into ash treatment
  plant as mentioned earlier.
• The rest flue gas moves through flue gas stack
  which is a type of chimney, a vertical pipe or
  channel for the exhaust gas outlet.

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Tpp summer pro rep

  • 1. Summer Training Report @CTPS Rohit anand 10bme0153 4th semester VIT VELLORE
  • 2. CONTENTS  About the company  Introduction  General layout  Components  Coal cycle  Condensation cycle  Steam cycle  Power cycle  Ash treatment  exhaust
  • 3. About The Company • Damodar valley corporation, popularly known as DVC , came into being on July 7, 1948.this was first multi-purpose river valley project of independent India. • CTPS: chandrapura thermal power station is situated in Bokaro district of Jharkhand. This has a installed capacity of 1600 MW.
  • 4. MISSION VISION • To generate adequate and • To be the best power utility reliable power most in the country and one of economically , efficiently the best in the world. and eco-friendly. • To spearhead accelerated power development by planning and implementing new power projects
  • 5. INTRODUCTION • A thermal power plant converts the heat energy of coal into electrical energy. Coal is burned in a boiler which converts water into steam. The expansion of steam produces mechanical power drives alternator coupled to turbine
  • 7. COMPONENTS main auxiliary  Coal mill • FD fan  Boiler • ID fan • Safety valve  Turbine • Gauge valve  Generator • Conveyer  Condenser • Transmission lines  super heater • Air pre-heater • De-aerator • Reheater • ESPs
  • 8. COAL CYCLE Coal stock yard Coal conveyer Coal hopper Coal mill furnace
  • 9. Coal Handling Plant  Wagon unloading system  Crushing system  Conveying system Unload the coal from wagon for standardization and selection and then the coal is stored in STOCK YARD. Through conveyer system , the coal is sent in hopper. Hopper allows to pass coal pieces<200 mm From it coal falls on vibrator which is supported by roller
  • 11. Crushing System • The gear box: contains worm wheel and worm gear which moves the wheel. • Motor: this provides energy for both worm gear and exhaust fan to move. • Exhaust fan: it sucks the coal dust , mixes it with pre-heated air (to maintain coal temperature) and send it through pipes in to boiler. • One coal mill unit sends 8 pipes into boiler. • Grinding roll fixed with mill body as shown in fig. brings coal to 20 mm size.
  • 12. Coal + Air Supply Atmospheric air Combustion intake Air pre heater Fd fan Coal pulveriser Coal +air Burner floor Primary superheater
  • 13. Air Supply  DRAFT SYSTEM Natural Mechanical In mechanical systems fans are used to create draft . At CTPS balanced draft system is used in which both FD and ID fans are used
  • 14. • FD fan-forced draft fan , this creates a negative pressure in the boiler and via this pressure difference atmospheric air is drawn in the boiler • ID fan-this sucks the treated flue gas out and ejects it through chimney.the mechanical draft is created by fan • Now the pre heated air goes into coal pulverizer and then sent into burner floor of boiler where through corner firing system(CFS) fire balls are made , which burn the coal laden air stream coming from below. Thus producing required heat for super heating.
  • 15. Air Pre-heater • This is a general term to describe any device designed to heat air before another process(for ex. Combustion in a boiler). The air comes through combustion intake pipeline, assisted by FD fan.
  • 16. CONDENSATE CYCLE L.P. turbine River water Surface condenser reservoir Cooling tower Alum house sump Condensate pump Water treatment De-aerator Pure water Feed water heater Condensate pump Feed water pump economizer
  • 17. Water Supply • Majority of water supply for steam generation is condensed water. The steam fromL.P. turbine is sent into surface condenser which • Changes the phase from steam to water. • Now, this water is sent to cooling towers which are evaporative coolers used for cooling water. these evaporate some part of condensed water to reject heat. At CTPS cooling towers are of hyperboloid structure
  • 19. DE-aerator Feed water heater • Device for air removal and • This is used to pre heat corrosive dissolved gases water delivered to a steam because corrosion can generating boiler, improving render pipe networks efficiency. Feed water heaters allow the water to useless and rusty be brought upto saturatiuon temperature very gradually. This reduces costs and help prevent thermal shocks to boiler material. •
  • 20. • Feed water pump: these pumps are high pressure units that overcome steam pressure to force water into the boiler drum. • ECONOMIZER :in boilers, these are heat exchangers that heat fluids usually water, upto its saturation point, they use the energy from the heat of flue gas and thus reduce heat in put and costs. It is placed in the passage of flue gas between outlet and chimney
  • 21. Make Up Water • This is additional water added in feed water stream . but before that it Is treated in water treatment plant • At CTPS, there are 4 treatment units • 1)dirty water from reservoir. Sedimentation removes majority suspensions particles: trough perforations clean water drips into well 2)
  • 23. • (2) alum is mixed in 2)with water coming from 1) micelle formation and this micelle is removed by mechanical arrangement; by forcing this trough a slope. • 3)clean water comes from 2) into (3) via perforations. • This treated water is sent into feed stream , where it mixes with condensed water, to form “final water”.
  • 24. STEAM CYCLE • fe Feed water Gauge valve Primary super heater Secondary super economizer Ceiling tube heater Platen Boiler drum Boiler drum superheater Ring header Riser tube turbine Water valve Input header
  • 26. Boiler Operations  The feed water enters into economizer reaches upto saturation point.  It is sent into boiler steam drum BOILER STEAM DRUM It is reservoir of water/steam at the top end of the water tubes in the water-tube boiler. They store the steam generated in the water tubes and act as a phase separator for the steam/water mixture. The difference in densities between hot and cold water helps in the accumulation of the “hotter”-water/and saturated –steam into steam drum.
  • 27. The • separated steam is drawn out from the top section of the drum. • Saturated steam is drawn off the top of the drum. The steam will reenter • the furnace in through a super heater, while the saturated water • at the bottom of steam drum flows down to the mud- drum /feed water • drum by down comer tubes accessories include a safety valve, water • level indicator and fuse plug. A steam drum is used in the company of • a mud-drum/feed water drum which is located at a lower level. So that • it acts as a sump for the sludge or sediments which have a tendency to go to bottom
  • 29. Super Heater Tubes • At CTPS types of super heater are : • Primary -straight pipes • Secondary- U shaped • Platen - BENT shaped • This all tubing has same function to super heat water: to heat the steam extracted from drum, increasing it’s thermal energy and decreasing the likelihood that it will condense in pipe network or in turbine section
  • 30. • The superheated steam is sent into high pressure turbine, at 540 degree celcius and 145 kg per square cm • And the thin ash particles are collected by ESP and thick ash fall into ash hopper below. • Turbine section: • A steam turbine is a device that extracts thermal energy from pressurized steam and used it to do mechanical work on a rotary output shaft. this is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multi stagesin expansion of steam
  • 31. POWER CYCLE Boiler drum Surface condener h.p. turbine l.p.turbine Reheater inlet i.P turbine reheater Reheater outlet
  • 32. There are three turbines: • High pressure – 5 stages • Intermediate pressure-12 stages • Low pressure -9 stages • Turbine types:(based on stages) • Impulse turbine: stage is set of moving blade behind the nozzle. • Reaction turbine: each row of blades is called a stage. • Blades: • in H.P., the blading used is impulse blading because it extracts more work from high pressure steam than reaction blading.
  • 33. • Impulse blading:it is in shape of half moon. As steam impact the moving blade, it pushes the blade forward. this causes steam to lose velocity without losing pressure. • The steam coming out from the H.P. turbine gas into reheater through inlet and comes back trough outlet attaining thermal energy can be extracted in I.P. turbine and L.P. turbine. • I.P. and L.P. turbines: the steam at low pressure and temperature enter into this turbine pair respectively: so reaction blading is used
  • 34. • REACTION BLADING: works on same concept as a jet engine. A jet engine is designed to take in air. Each moving reaction blade is designed to act as a nozzle.as the steam passes trough a reaction blade it causes the reaction blade to be propelled forward , resulting in rotation of L.P. turbine rotor • Intercept valve: this is in H.P. turbine and governs the the steam flow amount. • There is a surface condenser below L.P. turbine, explained in water supply previously. • all the three turbines are mechanically linked trough a rotor and the generator is coupled at the end of the system. At CTPS it is hydrogen cooled.
  • 35. Ash Treatment Plant • ESP: electro static precipitator is a particulate device that removes particles from a flowing gas, using force of an induced electrical charge.automatic rapping systems and hopper evacuation system remove the collected particulate matter while in line allowing esps to stay in operation for years at a time. • From the hoppers these are collected in the collector tank. • this collector tank has wet line trough which water comes.both ash and water are mixed and sent into collector tank. the hydrovactor is vaccum creating machine, that creates vaccum by removing water and air ,thus ensuring necessary pressure difference. • A VACCUM BREAKER is like a plate, it maintains and releases vaccum as and when required. • The slury is sent into sump from where it is carried 4 km away from CTPS using suitable pumps and pipe network.
  • 37. • There is air washer in conjunction with hydrovactor, that cleans air of its dust and susrensions, etc. • For thick ash, metal or stones which are falling in ash hopper below,where they are crushed using grinde. Using grinder. Using a power cylinder to open the gate and remove the pulverized debris with water into sump tank and discharged.
  • 38. Exhaust Cycle Flue gas ESP Ash treatment plant ID fan Flue
  • 39. exhaust • The dust and ash are taken into ash treatment plant as mentioned earlier. • The rest flue gas moves through flue gas stack which is a type of chimney, a vertical pipe or channel for the exhaust gas outlet.