1 A MINI PROJECT REPORT ON THERMAL POWER PLANT FAMILIARISATION Submitted in partial fulfillment for the award of the degree Of BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING Submitted By B.MOUNIKA 13J41A0311 Under the Supervision of RAHUL ASSISTANT ENGINEER MALLA REDDY ENGINEERING COLLEGE (Autonomous) Maisammaguda, Dhulapally(Post via Kompally), Secunderabad. 500 100
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A MINI PROJECT REPORT ON
THERMAL POWER PLANT FAMILIARISATION
Submitted in partial fulfillment for the award of the degree
Of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING Submitted By
B.MOUNIKA 13J41A0311
Under the Supervision of
RAHUL
ASSISTANT ENGINEER
MALLA REDDY ENGINEERING COLLEGE
(Autonomous)
Maisammaguda, Dhulapally(Post via Kompally), Secunderabad. 500 100
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MALLA REDDY ENGINEERING COLLEGE (Autonomous)
Maisammaguda, Dhulapally(Post via Kompally), Secunderabad- 500018.
It is a matter of great pleasure and priviledge for me to
present this report of 15 days on basis of practical knowledge gained by me during practical training at Dr.N.T.T.P.S , Vijayawada
during session 2016-2017. I with full pleasure converge my hearties thanks to Head of Mechanical Department, Malla Reddy Engg
College and to my guide Rahul , Assistant Engineer, Training institute Dr .N.T.T.P.S.
B.MOUNIKA
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CHAPTER-1
Dr. NARLA TATA RAO THERMAL POWER STATION
1.1 GENERAL:
Dr. Narla Tata Rao Thermal Power Station (Vijayawada Thermal Power Station) is located on the left bank of river Krishna with in a distance of 2 KM and is in between Ibrahimpatnam – Kondapalli Villages and 16 KMs of the North side of Vijayawada City in Krishna District.
The site lies at an elevation of about 26.5 Mtrs. Above the mean–sea-level.
Dr. Narla Tata Rao Thermal Power Station (Vijayawada Thermal Power Station) complex
consists of four stages. For Stage-I, II & III each stage consists of 2 x 210 MW Units and for Stage-IV the unit is of 500 MW rating. Stage-I, II, III & IV Units are commissioned as detailed
below:
Stage No. Unit No. Capacity Date of Commissioning
I 1
2
210 MW
210MW
01-11-1979
10-10-1980
II 3
4
210 MW
210MW
05-10-1989
23-08-1990
III 5
6
210 MW
210MW
31-03-1994
24-02-1995 IV 7 500 MW 06-04-2009
The total capacity of the station is 1760MW.
Dr. Narla Tata Rao Thermal Power Station (Vijayawada Thermal Power Station) is a unique one in the country, unique in its layout and numerous facilities provided for easy operation and maintenance.
The large reservoir created by the PRAKASAM Barrage provides an efficient Direct
Circulation Cooling Water System and also other requirements of the plant.
Originally the Dr. Narla Tata Rao Thermal Power Station (Vijayawada Thermal Power Station) is linked to Singareni Collieries Company Limited (S.C.C.L.) for supply of coal. The
average distance of S.C.C.L. coal fields by train is about 250 KM.
Dr.NTTPS, Stage-II,. III & IV are linked to Talcher Coal Fields in Orissa to meet the increased demand. The average distance of Talcher Coal Fields by train in 950 KMs.
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1.2 SPECIAL DESIGN FEATURES OF Dr.NARLA TATA RAO THERAML
POWER STATION (Vijayawada Thermal Power Station) :
STAGE-I:
The Coal bunkers and Mills are located in between the Boiler house and ESPs unlike usual arrangement elsewhere in the country, of placing the bunkers and mills in between the Turbine
House and Boiler. Thus, the Turbine House is completely isolated from the Mils to ensure dust – free atmosphere in the Turbine House and also to ensure easy accessibility of Mils of
maintenance. Multiple Flue Chimney is also a new feature at this Power Station.
STAGE – II & III:
1) The Second and Third Stage Boilers, Turbines and Generators are of a completely new design
TOWER Type Boilers of Single pass design manufactured by M/s B.H.E.L. under
collaboration with M/s. Stein Industries (France), KWU Turbines and Generators of West Germany design are installed in the Second and Third Stages.
2) TOWER TYPE BOILERS:
Among the advantages: Drainable heat exchangers and their edge over Two Pass Boilers
when using high ash content coals, lesser erosion of the heating surfaces compared to Two Pass Boilers etc. The spacing of the tubes and velocity of gases can be suitably adjusted at the Design
stage to achieve better results. Maintenance of this Boiler could be faster as there is no need for scaffolding or sky climber for maintenance of Super Heaters and Economizer.
3) DIRECT FIRED TUBE MILLS:
The Tube Mills can run for a very long time (Several thousand hours) without stopping as the forged balls are fed into the running mill while a vertical Bowl Mills is prone to frequent shut
downs due to its design consisting of several moving and wear parts with in system. Moreover the mill rejects system is completely dispensed with.
4) 6.6 KV Vacuum Circuit Breakers – Free from oils and Maintenance.
5) DISTRIBUTED DIGITAL CONTROL SYSTEMS (DCS):
Several advantages are there with Distributed Digital Control System as compared to conventional Hardwired system.The performance of the plant right from its commissioning has been highly satisfactory.
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STAGE –IV ( 1 x 500 MW):
The 7th Unit of Dr. N.T.T.P.S. with an installed capacity of 500 MW was synchronized with
grid on 06-04-2009. The commercial operation of the above unit was commenced form 28-01-2010.
Details of Capital / Investments made on each Stage:
SNo Stage Amount spent in crores
1 I ( 2 X 210 MW ) 193.00
2 II ( 2 X 210 MW ) 533.33
3 III ( 2 X 210 MW ) 840.00
4 IV ( 1 X 500 MW ) 2100.00
1.3 ALTERNATIVE COOLING WATER SYSTEM (A.C.W.S.):
The scheme of Alternative Cooling Water System was constructed in 2003-04 to facilitate repair works at Prakasam Barrage.
It is facilitating to deplete the reservoir level at PRAKASAM Barrage to still level i.e.
El+13.73 Mtrs. for about 3-4 months every year; during these months, the water requirement of Dr. N.T.T.P.S. is to be met by the Alternative Cooling Water System.
The Alternative Cooling Water System commissioned in March’2004 mainly consists of (a)
River Water Pump House at Bhavanipuram on the bank of River Krishna, to pump 1100 cusecs of water into existing cooling water canal (b) Three Nos. induced draft cooling towers in Dr. N.T.T.P.S premises to bring down the temperature of Hot Water to normal temperature so as to
re-circulate the same by adding into inlet canal through energy dissipation system and (C) Hot Water Pump House near Cooling Towers in Dr. N.T.T.P.S. premises to pump 1000 cusecs of
Hot Water into 3 cooling towers from Budameru Diversion Canal.
The Alternative Cooling Water System was completed at a cost of Rs.85 Crores. It was commissioned in March’2004.
1.4 Environment:
APGENCO is striving hard to maintain greener and cleaner atmosphere in and around the
Power House premises. 1,25,000 Nos. trees have been planted so far and further plantation on regular basis is being done. Ash is being issued free of cost for the users like, Cement / Asbestos industries and brick manufacturers. 2Nos. Brick manufacturing units at Dr. Narla Tata Rao
Thermal Power Station (Vijayawada Thermal Power Station) each with a capacity of 15,000 bricks per day for beneficial utilization of fly ash, have been in operation. So far utilization of
Ash up to 62% is achieved. APGENCO is advocating utilization of ash for better yield in agricultural sector and soil conservation and improving its fertility. Fly ash is being issued in
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large scale to farmers in Eluru, Nuziveedu and Ibrahimpatnam. The station has bagged ‘Green tech’ environment award for its best environment practices in the plant for the year 2013.
1.5 Performance:
The high level performance of Dr. N.T.T.P.S. has been a benchmark for the Power Sector in India; Winning & Awards at National level has been a routine for this unique power station. The station has received Meritorious Productivity Awards from the Government of India for the last
21 years consecutively and also Gold Medals for 12 years in a row. It has also got incentives for its Economic operation by improved Specific Oil Consumption / Auxiliary Consumption for 12
consecutive years.
His Excellency Dr. A.P.J. ABDUL KALAM, Hon’ble PRESIDENT OF INDIA presented a GOLD SHIELD to Dr. Narla Tata Rao Thermal Power Station (Vijayawada Thermal Power
Station) on 24-08-2004 at New Delhi in recognition of its outstanding performance for the period from 2000-01 to 2003-04.
In the year 2004-05, Capital overhaul works of Unit-I were carried out.
For the year 2005-06 V.T.P.S. was awarded Bronze Shield under Comprehensive Performance Award Scheme of GOI by the Hon’ble Prime Minister Sri Manmohan Singh on 21-
03-2007. Bronze shield could be bagged inspite of backing down of generation on the units to the tube of 692 MU to comply with the load dispatch instructions.
For year 2006-07 & 2008-09 also Dr. N.T.T.P.S. has bagged Bronze shield in recognition of
outstanding performance from the Ministry of Power, Govt. of India.
DR. Narla Tata Rao Thermal Power Station (Vijayawada Thermal Power Station) has accredited for ISO 9001:2008 Certification by M/s Lloyds Register Quality Assurance n May,
2010.
Dr. Narla Tata Rao Thermal Power Station (Vijayawada Thermal Power Station) continues to maintain its prominence among the best performing power stations in the Country.
Distinciton of Unit – V:
Unit-5 has recorded all time high financial year generation of 1818.35 MU with a PLF of
98.84% in 2009-10. This is the highest PLF ever achieved by any single unit of APGENCO in any financial year.
Unit III has established a grand record of 441 days of uninterrupted running from 14-12-
2004 to 28-02-2006 and proved its reliability as one of the best units in the country.
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Unit-I has also proved its unmatched reliability even after 27 years of service, by running continuously for 238 days from 09-12-2005 to 05-08-2006.
Dr. NARLA TATA RAO THERMAL POWER STATION Stage-V (1x800MW)
APGENCO has taken up the proposal for establishment of 1x800 MW Thermal Power
Project at Dr. NTTPS complex as a expansion unit. The unit is a coal based plant with super critical technology which is highly efficient and environment friendly, thus
minimizing Sox and NOXEmissions, ash generation.
APEGNCO and GoAP entered into MoU on 13-01-2012 during the Partnership Summit-2012 to take up 800 MW Unit at Vijayawada.
Detailed project Report for the project is ready.
The land requirement of the project is 315 acres. 85 acres of the land is readily available
for main plant and the additional land of 230 acres for the ash dyke will be acquired.
GoAP approval was received vide Lr.No. 1990 / Power.I(1)/2012-5, dt.30-01-2013.
Source of water is existing CW canal for the Dr. NTTPS and the water requirement for the project is 2000 M3 / hr.
A letter addressed to CEA for pre qualification and fixing inter-se priority on 26-05-2012.
The proposal for issue of coal linkage for 4.72 million tones per annum has been sent to
Ministry of coal vide letter dated 07-05-2012 along with the necessary application fee of Rs.5.0 lakhs.
Board approved to take up the project in 116th & 117th board meetings.
Airport Authority of India of issued of NOC for chimney on 03-10-2012.
TOR issued vide Lr.No. J-13012/26/2012-IA.II(T); dt.26-09-2012.
Entered PPA with APDISCOMs on 22-01-2013.
Public hearing was conducted on 10-01-2014.
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CHAPTER-2
COAL HANDLING PLANT
General Layout & Basic Idea
A control system of station basically works on Rankin Cycle. Steam is produced in Boiler is
exported in prime mover and is condensed in condenser to be fed into the boiler again. In
practice of good number of modifications are affected so as to have heat economy and to
increase the thermal efficiency of plant.
The Thermal Power Station is divided into four main circuits :
Fuel and Ash Circuit.
Air and Gas Circuit.
Feed water and Steam Circuit.
CoolingWater Circuit.
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2.1 Fuel & Ash Circuit:-
Fuel from the storage is fed to the boiler through fuel handling device. The fuel used in KSTPS
is coal, which on combustion in the boiler produced the ash. The quantity of ash produced is
approximately 35-40% of coal used. This ash is collected at the back of the boiler and removed
to ash storage tank through ash disposal equipment.
2.2 Air and Gas Circuit :-
Air from the atmosphere is supplied to the combustion chamber of Boiler through the action of
forced draft fan and induced draft fan. The flue gas gases are first pass around the boiler tubes
and super heated tubes in the furnace, next through dust collector (ESP) & then economizer.
Finally, they are exhausted to the atmosphere through fans.
2.3 FeedWater and Steam Circuit:-
The condensate leaving the condenser is first heated in low pressure (LP) heaters through
extracted steam from the lower pressure extraction of the turbine. Then its goes to dearator
where extra air and non-condensable gases are removed from the hot water to avoid pitting /
oxidation. From deaerator it goes to boiler feed pump which increases the pressure of the water.
From the BFP it passes through the high pressure heaters. A small part of water and steam is lost
while passing through different components therefore water is added in hot well. This water is
called the make up water. Thereafter, feed water enters into the boiler drum through economizer.
In boiler tubes water circulates because of density difference in lower and higher temperature
section of the boiler. The wet steam passes through superheated. From superheated it goes into
the HP turbine after expanding in the HP turbine. The low pressure steam called the cold reheat
steam (CRH) goes to the reheater (boiler). From reheater it goes to IP turbine and then to the LP
turbine and then exhausted through the condenser into hot
2.4 Cooling Water Circut:-
A large quantity of cooling water is required to condense the steam in condenser and marinating
low pressure in it. The water is drawn from reservoir and after use it is drained into the river
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CHAPTER-3
C0AL HANDLING PLANT
3.1 INTRODUCTION:-
Coal is the prime fuel for a thermal power plant.Hence adequate emphasis needs to be given for its proper
handling and a storage . Also,it is equally important to have a sustained flow of this fuel to maintain
uninterrupted power generation. Coal is transported to the power station by rail or road from the
mines.Loading as well as unloading of the wagons is automatic while the wagons are moving at a
predetermined speed. Coal is unloaded from wagons into track hopper . From the track hopper conveyor
takes coal to crusher for crushing.
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CONSTITUENTS OF COAL :-
CARBON :- 42.9%
HYDROGEN :- 2.96%
NITROGEN :- 0.91%
SULPHUR :- 0.33%
TRANSPORTATION OF COAL :-
BY RAILWAY
80-90% of the requirement is fulfilled by this way.
Safe mode of transport and fast delivery
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Demurrage calculations on Coal Rakes :-
We receive the coal wagons in the form of rakes [55-60 wagons in each rake]
Free time normally 7 hours from receipt of coal.
Free time is calculated from the receipt of written intimation of coal rakes from APGENCO
to the railway.
Rate of demurrage is Rs.100/wagon/hr.
ANALYSIS OF COAL :-
Sample of coal is randomly collected from each rake and detaled chemical analysis,calculation of
calorific value is carried out and is confirmed whether it is carried out and is agreementwith the coal
mines or not.
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Coal is received from singareni collaries and talcher (Orissa state).Coal wagons are received by rakes
of 58 wagons.The railways engine will place the loaded rake inside the Dr.NTTPS,at a sliding point
(placement point) and take away the empty wagons. Coal is also received in bottom discharge wagons
B.O.B.R – Bogies open bottom rapid discharge wagons.These wagons are unloaded on a track hopper
and from there,fed on to the underneath conveyers,by the paddle feeders, which will scoop the coal
from the hopper platform on to the running conveyer.
The coal handling plant can broadly be divided into three sections :-
1) Wagon Unloading System.
2) Crushing System.
3) Conveying System.
3.2 WAGON UNLOADING SYSTEM:-
3.2.1Wagon Tripler :-
It unloads the coal from wagon to hopper. The hopper, which is made of Iron , is in the form of net so that
coal pieces of only equal to and less than 200 mm. size pass through it. The bigger ones are broken by
the workers with the help of hammers. From the hopper coal pieces fall on the vibrator. It is a
mechanical system having two rollers each at its ends.
The rollers roll with the help of a rope moving on pulley operated by a slip ring induction motor with
specification.
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Figure 3.1 WagonTripler
Rated Output. : 71 KW.
Rated Voltage. : 415 V.
Rated Current. : 14.22 Amp
Rated Speed. : 975 rpm
No. of phases. : 3
Frequency. : 50 Hz.
No. of Wagon Tripler : 5
The four rollers place themselves respectively behind the first and the last pair of wheels of the wagon.
When the motor operates the rollers roll in forward direction moving the wagon towards the “Wagon
Table”. On the Wagon table a limit is specified in which wagon to be has kept otherwise the triple would
not be achieved.
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3.3 CRUSHING SYSTEM:-
3.3.1Crusher House:-
It consists of crushers which are used to crush the coal to 20 mm. size. There are 10 Coal Crushers in
N.T.T.P.S.
There are mainly two type of crushers working in NTTPS:-
PrimaryCrushers i.e. i) Rail crushers or ii) Rotarybreaker.
SecondaryCrushers. i.e. Ring granulators.
3.3.1.1 PrimaryCrushers:-
Primary crushers are provided in only CHP stage 3 system, which breaking of coal in CHO Stage 1 &
Stage 2 system is done at wagon tripler hopper jail up to the size (-) 250 mm.
3.3.1.2 SecondaryCrusher:-
Basically there are four ways to reduce material size : impact attrition , Shearing and Compression. Most
of the crushers employ a combination of three crushing methods. Ring granulators crush by compressing
accompanied by impact and shearing.The unique feature of this granulator is the minimum power
required for tone for this type of material to be crushed compared to that of other type of crushers.
3.4 Construction& Operation:-
Secondary crushers are ring type granulators crushing at the rate of 550 TPH / 750 TPH for input size of
250 mm. and output size of 20 mm. The crusher is coupled with motor and gearboxby fluid coupling.
Main parts of granulator like break plates, cages , crushing rings and other internal parts are made of
tough manganese (Mn) steel. The rotor consists of four rows of crushing rings each set having 20 Nos. of
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toothed rings and 18 Nos. of plain rings. In CHP Stage 1 & 2 having 64 Nos. of ring hammers. These
rows are hung on a pair of suspension shaftmounted on rotor discs. Crushers of this type employ the
centrifugal force of swinging rings stroking the coal to produce the crushing action. The coal is admitted
at the top and the rings stroke the coal downward. The coal discharges through grating at the bottom.
3.5 CONVEYING SYSTEM
3.5.1 Stacker Reclaimer :-
The stacker re-claimer unit can stack the material on to the pipe or reclaim the stack filed material and fed
on to the main line conveyor. While stacking material is being fed from the main line conveyor via
Tripler unit and vibrating feeder on the intermediate conveyor which feds the boom conveyor of the
stacker cum reclaimer. During reclaiming the material dis discharged on to the boom conveyor by the
bucket fitted to the bucket wheel body and boom conveyor feeds the material on the main line conveyor
running in the reverse direction.
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CHAPTER-4
ASH HANDLINGPLANT
This plant can be divided into 3 sub plants as follows:-
1) Coarse ash removal system
2) Fly ash handling system
3) Bottom Ash handling system
4.1COARSE ASH REMOVAL SYSTEM :-
Ash collected in four nos. of economizer hoppers will be removed once in a shift. The coarse ash hoppers
are divided in to 2 groups and each group of hoppers is operated one by one in sequence.
Each coarse ash hopper is provided with one number manually operated hopper isolation valve,
pneumatically operated valve, expansion joint and feeder ejector.
OPERATION OF CAR SYSTEM :-
The removal of coarse ash starts,as soon as removal of bottom ash is complete.Each group of coarse ash
hoppers are operated one by one in sequences.In auto mode of operation,the first group feeder ejector
water valve opens first.Knife gate valve connected to that group next,if adequate water pressure is
available.While closing,the knife gate valve closes first then feeder ejector water valve closes.Water valve
of next group in sequences opens,when the water valve,which was open,use fully closed.
Manual operation is also possible through the “close-open” control switch provided, “collect-Bypass”
switches are also provided for by passing any group of hoppers,When ash is not desired to be removed
during any particular operating cycle.
4.2FLY ASH HANDLING SYSTEM :-
Fly Ash Handling System, the major objective is to collect and transport the fly ash from the ash hoppers
of the ESP to the Fly ash silo or to the Ash Slurry making tank. Generally the power plants prefer Dry
Fly ash Disposal instead of making Ash Slurry from the Fly ash and the reason is that the fly ash collected
from the ESP Bottom Hopper is very fine and suitable for Cement making, if we are making slurry of it
then it will not be suitable for Cement making and economically also it is very good if you are selling the
Ash to the Cement Plants. So these are the reasons why most of the plants are going for Fly ash Disposal
instead of Slurry Disposal (Ash Water).
Slurry Type Fly Ash Disposal System: This is one of the simplest system for ash disposal from ESP
hopper to the slurry pond.High Pressure water and fly ash is mixed below the ESP hopper and below in
the diagram you can see that tapping for mixing of water is provided.
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Dry Type Fly Ash Disposal System: Fly Ash from the ESP Hoppers is collected in the Ash Vessels and
from there it is transported to the Fly Ash Silos by the help of Compressed air and from the Ash Silos, the
ash is transported to the Bulkers(Sealed Vessel Trucks).
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ESP Hopper: Hopper is a large conical type container used for dust or ash collection. After the field
charging in ESP we go for hammering of collecting plates and the fly ash deposited on the collecting
plates gets stored in the hopper. To ensure free flow of ash into the ash vessels from the hopper, the lower
portions of the hoppers are provided with electric heaters. Because if the temperature of the ash falls
below the ash fusion temperature then the ash will form big clusters and may choke the entire conveying
system.
Dome valve: It is situated between the ESP hopper and Ash vessel; it is a special type of valve which is
highly leak proof. It consists of a dome type structure with a rubber seal which is continuously getting
supply from the compressed air.
Air Vent Line: To remove the trapped air from the vessel, we use vent line and due to this line air from
the vessel is transported to Hopper and ash come down. It basically does two things, first of all by
removing the air from the vessel, it is removing the back-pressure from the Vessel and simultaneously it
is pressurizing the ash hopper.
Compressor: A compressed air station is set up in the plant. The compressed air station provides air for
the pneumatic conveying system and purging of fabric filters as we already explained in ESP. After
compressing the air, we have to remove all the moisture content from the air. To remove the moisture
from air we use Adsorbent Air Drier (AAD) and Refrigeration Air Drier (RAD).The pressure of the
compressor is depended on the system design.
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Ash Vessels: Ash vessels are present just below the ESP hoppers with the Dome Valve assembly.They
are supposed to contain the fly ash for a certain amount of time which will be carried to the fly ash
silos.Their ash holding capacity is depended on the conveying capacity of the ash line to the Ash Silos.
Fly Ash Silo: Fly Ash Silos store the fly ash generated by the Boiler in the maximum continuous
operating conditions (BMCR).The bottom of each fly ash silo is equipped with two ash discharging
chutes. One ash discharging chute is used for discharging the comprehensively used dry fly ash and the
other one is connected with a wet mixer, discharging the wet fly ash. The wet ash mixer is just a back-up
for the dry ash disposal system. Each fly ash silo is equipped with the bag filters and bag filter cleaning
facilities with exhaust fans.
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(Fly Ash Silos)
Air extraction fan: It is used to create a negative pressure inside the vessel of the silo and the air goes out through the bag filters.
Extractor: It is used to evacuate the Air from the Bulkers (Closed Vessel Truck), which
is connected to the ash disposal chute and the discharge is connected to ash vessel.
Diverting and dump valve: If one ash silo will not work we divert the line into another silo with the help of diverting valve and to dump the ash into ash silo dump valve is used.
Wet Fly Ash Disposal System:Up to the hopper part it is same as that of Dry Fly Ash handling system. After the hopper instead of going into the vessel, the ash gets mixed with a high Pressure
water and this mixture goes to a slurry tank for further pumping. The slurry formed is further pumped through a series of pumps or a single GEVO pump for dumping in the Ash yard. For
mixing of fly ash with water, a tapping is provided for High Pressure water below the hopper.
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4.3Bottom ash handling System :-
The bottom ash quantity is around 20% of the total Ash generation and there are mainly two
types of bottom ash disposal systems.
Dry Type Bottom Ash Disposal Wet Ash Slurry Disposal
Dry Type Bottom Ash Disposal: First of all we will discuss about the Dry type bottom ash
disposal system.
Submerged Scrapper Conveyor: Submerged Scraper Conveyor is used for cooling and
transmitting the hot bottom ash. The scraper conveyor used to send the bottom ash to the bottom ash silo. The Bottom ash hoppers are partially filled with water in order to avoid the direct impact of the Clinkers due to free fall. Whatever the ash, falling on the SSC conveyor is getting
scrapped by the scrappers to the clinker grinder.
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(Submersed Scrapper Conveyor)
Clinker Grinder: A clinker grinder is provided at the outlet of SCC to control the bottom ash size as in the bottom ash there will be some big clinkers and to make the ash of even size we use
a clinker grinder.The output of the bottom ash after the clinker grinder is around 25mm to 50mm,it is adjustable.
Drag Conveyor: It transmits the crusher output to the bottom ash silo. It is same as that of scrapper conveyor. Just for conveying purpose for the bottom ash.
Bottom ash silo: Each boiler is equipped with a bottom ash silo. It is used for storing the bottom
ash for a period of time and then it is dumped in the trucks for disposal.
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Slurry Type Bottom Ash Disposal:
Here the bottom ash from the 2nd pass of the Boilers goes to the Clinker Grinder in the 1st pass
by the help of high pressure water and from the Clinker Grinder all the ash goes to a slurry sump for further pumping.
For general mankind, today an Eco friendly industry is must. As far as air pollution is concerned now a
days various flue gases filter are there in service. The choice depends on the size of suspended particle
matter. These filters are E.S.P. Fabric filter high efficiency cyclone separations and sitelling room. Fop fly
ash , where the particle size vary from 0.75 microns to 100 micron use gradually use E.S.P. to purify the
flue gases due to its higher efficiency & low running cost etc. In an ESP the dust lidder gas is passed
through an intense electric field, which causes ionization of the gases & they changed into ion while
traveling towards opposite charged electrode get deposited as particles and thus dust is electric deposited
an electrode creating the field.
ESP works on the principle of electrostatic attraction. In this phenomenon a negatively charged particle or
molecule is attracted to a positively charged molecule. In ESP, the flue gas passes into a chamber where
the individual particles of fly ash are given an electrical charge (Negative Charge) by the absorption of a
negative ion from a high voltage Negative DC ionizing field. So for that we have to provide a high
voltage of DC in a chamber where a high voltage negative corona will generate and all the particles will
be ionized.
Ionization of gases and charging of dust particles with the help of corona generation.
Movement of the particles to the collector plates & their Deposition
Removing particles from the collecting surface with the help of hammer.
Construction of ESP:
The ESP consists of two set of electrodes,
Thin wires called discharge or emitting electrodes
Collecting electrodes in the form of plates
The emitting electrodes are placed in between two plates (Collecting plates) and the emitting electrodes
are connected to the negative polarity of a high Voltage of DC source. The collecting electrodes are
connected to the positive of the source and grounded.
COMPONENTS OF ESP :-
Gas distribution screen: It is located at the inlet of the ESP. It is used to give an even distribution of gas over the precipitator’s entire cross sectional area.
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Collecting System:
Above we already explained about collecting system, basically used for the deposition of all the charged particulate matters. The upper edges are provided with hooks, which are hung from support welded to the roof structure.
The Lower end of every plate has a shock receiving provision. Collecting system are connected to the positive of the source and grounded.
Emitting System:
Emitting system is used for emit the ion to charge the particulate matter. Mostly it is a wire in
shape.
Rapping mechanism: Rapping mechanism is used in order to release/remove the deposited dust
particles from the collecting plate. It is of two types:
CERM: CERM stands for collecting electrode rapping mechanism. It consist tumbling hammer which is used to hammer the shock bar. Shock bar mounted at collecting plate lower end. When hammer hit the shock bar dust particles release from the collecting plate.
EERM: EERM stands for emitting electrode rapping mechanism. During ESP operation a fraction of the dust will be collected on the emitting electrode. it is therefore necessary to rap the emitting electrodes. The rapping mechanism for EERM is located on the roof.
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(Emitting Electrode Rapping Mechanism)
(Collecting Plate Rapping Mechanism)
Hopper:
Hopper is a large container used for dust or ash collection and lower portions of hoppers are
provided with electrical heaters.They are pyramidal in shape.
Electrical system:
As we know that ESP action required corona generation, Due to this we required high voltage DC (25kV-80kV).So we use rectifier transformer, who steps-up and rectifies the voltage.
Bag filter:
Flue gas (fine particles) enters the bag house and passes through fabric bags, which act as filter.
The bags are woven or felted cotton, synthetic or glass fiber material. Bags are supported by cages.
The separated fly ash is collected in a hopper from where this can be removed through mechanical screw conveyor or pneumatic conveying system.(Bag fabric = P84+ PTFE)
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5.2 CONTROLLER :-
Now a day micro-processor based intelligent controllers are used to regulate the power fed to the HVR.
The controls the firing / ignition angle of the thyristor connected in parallel mode. Input out waves of the
controller and HVR are also shown above, which clearly indicates that average power fed to ESP field
can be controlled byvariation of thefiring angle of thyristor. The output of controller with respect to time
is also controlled by microprocessor, so that ESP operation is smooth and efficient . The chars are as
shown: As can be seen in the event of spark between electrode the output of controller is reduced to zero
for few millisecond for quenching the spark. Controller also takes place care of fault in KVR and gives a
trapping and non-trapping alarm as per the nature of fault.
5.3 HIGH VOLTAGE RECTIFIER TRANSFORMER:-
HVR receives the regulated supply from controller. It steps up to high voltage rectifier. The D.C. supply
is fed to E.S.P. field through its negative bushing. The positive bushing so connected to earth through
small resistance which forms a current feed back circuit. A very high resistance column is also connected
with negative bushing . It forms the voltage feed back circuit. These two feedback are used in the
controller for indication and control purpose.
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5.4 E.S.P. FIELD:-
The field consists of emitting and collecting electrodes structure which are totally isolated from each
other and hanging with the top roof of field. The emitting is also isolated from the roof through the
support insulators which are supporting the emitting electrode frame works and also the supply to these
electrodes is fed through support insulators. The collecting electrodes are of the shape of flat plates. By
several similar plates which the emitting electrodes are of the shape of spring. Strong on the emitting
frame work with the help of hooks in both theends. The ash depositing on these electrode is rapped down
by separate wrapping mechanism happens at the bottom of the field. From these hoppers ash is
evacuated by ash handling system and dispose to the disposal area. The wrapping system is
automatically controlled with the help of the programmable metal controller, located in the ESP
auxiliaries control panels.
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CHAPTER-6
BOILER
A boiler (or steam generator) is a closed vessel in which water, under pressure is converted into steam. It
is one of the major components of a thermal power plant. A boiler is always designed to absorb maximum
amount of heat released in process of combustion. This is transferred to the boiler by all the three modes
of heat transfer i.e. conduction, convection and radiation.
FLOW CHART:-
Feed Water from Economizer → Boiler Drum → Low Temperature Super heater → Radiant
Super heater →Final Super heater → High pressure Turbine →Re-heater → Intermediate
Pressure Turbine →Low Pressure Turbine → Steam condenses in Condenser
6.1 Boilers are classified as:-
6.1.1 Fire tube boiler: -
In this type the products of combustion pass through the tubes which are surrounded by water.
These are economicalfor lowpressure only.
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6.1.2Water tubeboiler:-
In this type of boiler water flows inside the tubes and hot gases flow outside the tubes. These tubes are
interconnected to common water channels and to steam outlet.
water tube boilers have many advantages over the fire tube boiler
High evaporation capacity due to availability of large heating surface.
Better heat transfer to the mass of water.
Better efficiencyof plant owing to rapid and uniform circulationof water in tubes.
Better overall control.
Easy removal of scale from inside the tubes.
In NTTPS, Natural circulation, tangentially fired, over hanged type, Water tube boilers are used. Oil
burners are provided between coal burners for initial start up and flame stabilization. Firstly, light oil
(diesel oil) is sprayed for initialization then heavy oil (high speed diesel oil) is used for stabilization of
flame. Pulverized coal is directly fed from the coal mills to the burners at the four corners of the furnace
through coal pipes with the help of heated air coming from PA fan. Four nos. of ball mills of 34MT/hr.
capacity each have been installed for each boiler. The pressure inside boiler is -ive so as to minimized the
pollution and looses & to prevent the accidents outside the boiler.
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For ensuring safe operation of boilers, furnace safe guard supervisory system (FSSS) of combustion
engineering USA designed has been installed. This equipment systematically feed fuel to furnace as per
load requireme. The UV flame scanners installed in each of the four corners of the furnace, scan the flame
conditions and in case of unsafe working conditions trip the boiler and consequently the turbine. Turbine -
boiler interlocks safe guarding the boiler against possibility furnace explosion owing to flame failure.
6.2 Furnace:-
Furnace is primary part of the boiler where the chemical energy available in the fuel is converted into
thermal energy by combustion. Furnace is designed for efficient and complete combustion. Major factors
that assist for efficient combustion are the temperature inside the furnace and turbulance, which causes
rapid mixing of fuel and air. In modern boilers,water-cooled furnacesare used.
6.3 PULVERISED FUEL SYSTEM:-
The boiler fuel firing system is tangentially firing system in which the fuel is introduced from wind
nozzle located in the four corners inside the boiler.
The crushed coal from the coal crusher is transferred into the unit coalbunkers where the coal is stored for
feeding into pulverizing mill through rotary feeder The rotary feeders feed the coal to pulverize mill at a
definite rate. Then coal burners are employed to fire the pulverized coal along with primary air into
furnace. These burners are placed in the corners of the furnace and they send horizontal streams of air and
fuel tangent to an imaginary circle in the center of the furnace. Figure6.2 Pulverised System
6.4 Fuel Oil System:-
The functional requirement of the fuel burning system is to supply a controllable and uninterrupted
flammable furnace input of fuel and air and to continuously ignite and burn the fuel as rapidly as it is
introduced into the furnace. This system provides efficient conversion of chemical energy of fuel into heat
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energy. The fuel burning system should function such that fuel and air input is ignited continuously and
immediately upon its entry into furnace.
The Fuel air (secondary air) provided FD fan, surrounds the fuel nozzles. Since this air provides covering
for the fuel nozzles so it is called as mantle air. Dampers are provided so that quantity of air can be
modulated. Coal burners distribute the fuel and air evenlyin the furnace.
Ignition takes place when the flammable furnace input is heated above the ignition temperature. No
flammable mixture should be allowed to accumulate in the furnace. Ignition energyis usuallysupplied in
the form of heat.This ignition energyis provided by oil guns and by igniters.
6. 5 Boiler Drum :-
The drum is a pressure vessel. Its function is to separate water and steam from mixture (of steam & water)
generated in the furnace walls. It provides water storage for preventing the saturation of tubes. It also
houses the equipment needed for purification of steam. The steam purification primarily depends on the
extent of moisture removal, since solids in steam are carried by the moisture associated with it. The drum
internals reduce the dissolved solids content of the steam to below the acceptable limit. drum is made up
of two halves of carbon steel plates having thickness of 133 mm.
The top half and bottom half are heated in a plate heating furnace at a very high temperature and are
pressured to form a semi cylindrical shape. The top and bottom semi cylinders with hemispherical dished
ends are fusion welded to form the boiler drum. The drum is provided with stubs for welding all the
connecting tubes i.e. down comer stubs, riser tubes stubs and super-heater outlet tube stubs.
Boiler drum is located at a height of 53m from ground. The drum is provided with manholes and manhole
covers. Manhole is used for facilitating the maintenance person to go inside the drum for maintenance.
The drum form the part of boiler circulating system i.e. movement of fluid from the drum to the
combustion zone and back to boiler drum. Feed water is supplied to the drum from the economizer
through feed nozzles. Water from the drum goes to water walls through six down comers.
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Main parts of boiler drum are:-
1. Feed pipe
2. Riser tube
3. Down comer
4. Baffle plate
5. Chemical dosing pipe
6. Turbo separation
7. Screen dryer
8. Drum level gauge
6.6 DraftSystem:-
The combustion process in a furnace can take place only when it receives a steady flow of air and has the