Training Report on Thermal Power Plant,panki kanpur

8/12/2019 Training Report on Thermal Power Plant,panki kanpur

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ACKNOWLEDGEMENTI am extremely thankful to the members of Panki Thermal

Power Station (PTPS), Kanpur for their kind support and

Co-operation during my 4 weeks of training period. I would

like to acknowledge Er.B.P Srivastava(Assistance Engineer

of CHD Departments) for giving me this fortunate chance to

learn the various applications of mechanical engineering in

real life. I express my sincere gratitude towards him for hiswonderful guidance in the department and making me

understand the various stages of thermal power generation. Ialso express my respectful gratitude towards all other

engineers and technical staff at CHD for their help and

guidance during my training period.

Finally, I thank all those who have helped me in the successof my training program. They have added a lot to my

knowledge.

Ravi Kant

B.Tech (Mechanical Engineering)

2ND

Year

ACME COLLEGE OF ENGINEERING

Muradnagar, Ghaziabad


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CERTIFIC TEIt is certified that Ravi Kant,student of 2ndYear B-Tech.

Mechanical Engineering at ACME COLLEGE OF

ENGINEERING, Muradnagar, Ghaziabadhas worked onthe Project on Panki Thermal Power Station, Panki, Kanpur

under my guidance and supervision. He has shown sincere

efforts and keen interest during preparation of this project

report. My best wishes are with him, his efforts and his future

endeavours.

Date: Er.B.P Srivastava

25/07/2013 Assistant Engineer

Place: Coal Handling Division

Kanpur Panki Thermal Power Station,

Panki, Kanpur


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Power Consumption In India

The energy sector holds the key in accelerating the economicgrowth of India. The energy demands for developing country

like India keep on continuously growing. Energy is a driving

force behind rapid economic growth of the country. India ranks

tenth in the world in total energy consumption. It is first

requirement of energy to accelerate the development of thesector to meet its growth aspirations.

The pattern of energy production put coal and oil again ontop. These account for 65% of the entire

generation. Renewable energy ranks bottom of the total

production just before the Nuclear energy. The distribution of

energy resource like hydro power is skewed towards North-

eastern states of the country as 70 % of the total hydro

potential is located in the Northern and North-eastern region.


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Panki Thermal Power Station

(PTPS), Kanpur [U.P]

Panki Thermal Power Station is an Electricity GenerationStation where Electricity Generated through the steam

operation on Turbine & Steam is generated by Coal Firing so it

is a Typical Coal fired Electricity Generation Station.

It is Located about 16 Kms Away from Kanpur Railway Station,was Started with two units (1

st& 2

nd) of 32 MW each.it was

established in 1968.

After Generating Power for about 28-29 years, 2*32 MW unitshad completed their Rated Life So they were closed on 30

th

November 1995 & 18th

April 1997 respectively.

So In 1976-77, Two Units (3rd& 4thof 2*110 MW each)Manufactured, Installed Bharat Heavy Electronics Ltd. These

units were established in 1976 & 1977 respectively.

Unit 3rd& 4thhave been debated to 105 MW each by theCentral Electricity Authority (C.E.A) on 11

thJanuary 1990.

So presently there are two units (3rd& 4thof 105 MW each)working at PTPS.


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About Steam Thermal Power

Station

Process:- A steam power plant is a power plant in which prime

mover is steam driven. Water is heated, turns into

steam and spins a steam turbine (Impulse & reaction),

which drives an electrical generator. When the turbine

turns, electricity is generated and given as output by the

generator, which is then supplied to the consumers

through high-voltage power lines.

Process Diagram at Steam Power Plant


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Fossil Fuel Power Station

Previously we discussed that steam is prime driven object in

steam power plant so in the case we needed steam for

power generation ;so this steam is generated by boiling the

water in boiler & this boiling is done by burning of Fuel.

FOSSIL FUEL POWER STAION:-A fossil fuel power station is a power station that burns

fossil fuels such as coal, natural gas or petroleum (oil) to

produce electricity.

Fuel +

oilFurnace

Turbine Generator


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Coal fired Steam Power Plant

Coal Fired Power Station:-A coal Fired power station is that type of Fossil Fuel power

station in which coal is used as a Fuel. In the Steam Power

Plant There is a Separate Unit for Coal Handling System.

There are basically Five main units of a thermal powerplant:

1. Coal Handling Plant (C.H.P)

2. Water Treatment Plant (W.T.P)

3. Boiler Maintenance Division (B.M.D)

4. Turbine Maintenance Division (T.M.D)

5. Generator


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Coal Handling Plant

COAL HANDLING & DELIVERING SYSTEM:-

In a coal Based Thermal Power Plant, the initial process in the

power generation is Coal Handling so in this article I will

discuss the overall Process Carried out a coal handling plant

in a coal based thermal power generating station.

The huge amount ofcoalis usually supplied through

railways. A railway siding line is taken into the power station

and the coal is delivered in the storage yard. The coal is

unloaded from the point of delivery by means of wagon

tippler. It is rack and pinion type. The coal is taken from the

unloading site to dead storage by belt conveyors. The belt

deliver the coal to 0 meter level & further moves to transfer

point. The transfer points are used to transfer coal to the

next belt. The belt elevates the coal to breaker house. It

consists of a rotary machine, which rotates the coal and

separates the light dust from it through the action of gravity

and transfer this dust to reject bin house through belt.

Now the main sources of coal are CCL and BCCL. Which have

contract with government to continuously supply of coal to

the power plant.
http://electrical-engineering-portal.com/siemens-co2-capture-technology-ready-for-big-projectshttp://electrical-engineering-portal.com/siemens-co2-capture-technology-ready-for-big-projectshttp://electrical-engineering-portal.com/siemens-co2-capture-technology-ready-for-big-projectshttp://electrical-engineering-portal.com/siemens-co2-capture-technology-ready-for-big-projects


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Auxiliaries Of Coal Handling

PlantThe belt further elevates the coal to the transfer pointand it

reaches the crusher through belt. In the crushera high-speed

3-phase induction motoris used to crush the coal to a size of

50mm so as to be suitable for milling system. Coal rises from

crusher house and reaches the dead storage by passing

through transfer point.

Equipment used in a coal handling plant

1. Pull cord switch

Pull cord switch also known as Rope Operated Emergency

Switch is used as safety switch to stop the conveyor belt in

case of an emergency by pulling the Rope. Pull cord switch ismounted on the walkway side of the conveyor belt,

preferably at about every 30 meters. When the rope is pulls

from any side, the switch gets operated. Unless and until the

handle is reset manually position, the switch remains in

operated condition. NC contacts of all pull cord switches are

wired in series and further connected to PLC. When anyswitch along the belt operates, the contact opens and

conveyor is stopped.

2. Vibrating feeder

The coal stored in a huge hub is collected on the belt through

vibrations created by the vibrating feeder.

3. Flap gates
http://electrical-engineering-portal.com/construction-of-3-phase-ac-induction-motorshttp://electrical-engineering-portal.com/construction-of-3-phase-ac-induction-motorshttp://electrical-engineering-portal.com/construction-of-3-phase-ac-induction-motors


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These are used to channelize the route of coal through

another belt in case the former is broken or unhealthy. The

flap gates open let the coal pass and if closed stop its

movement.

4. Magnetic separator

These are used to separate the ferrous impurities from the

coal.

5. Metal detector

These are detect the presence of any ferrous and non-ferrous

metal in the coal and sends a signal to a relay which closes to

seize the movement of belt until the metal is removed. It

basically consists of a transmitter and a receiver.

The transmitter consists of a high frequency oscillator, which

produces an oscillations of 1500 Hz at 15V. The receiver

receives this frequency signal. If there is any presence of

metal in the coal. Then this frequency is disturbed and a

tripping signal is send to relay to stop the conveyor belt

6. Belt weightier

It is used to keep an account of the tension & support on the

belt carrying coal and is moves accordingly to release tensionon the belt.

7. Reclaim hopper

Reclamation is a process of taking coal from the dead storage

for preparation or further feeding to reclaim hoppers. This is

accomplished by belt conveyors


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Steam Generation Process

from CoalSTEAM GENERATION FROM COAL:-

1. Tipplers

Coal from the coal wagons is unloaded in the coal handling

plant. This unloading is done by the Tipplers. This coal is

transported up to the raw coal bunkers with the help ofconveyor belts.

2. Coal Crushing

Although coal can be burned in solid form on grates, it is

more usual to break it up before feeding it to the combustion

chamber. The treatment depends on the nature of the coal.

Some coals lend themselves to being ground down to a very

fine powder (called pulverized fuel (PF)) which is then carried

to the burners by a stream of air. Other coals are fed to

impact mills (Formally called Milling System) which use flails

or hammers to break up the material before it is propelled to

the burners by an air stream. The type of mill to be used on a

particular plant will be determined by the process


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Preparation of FuelEngineers and it is the task of the control engineer to provide

a system which is appropriate. To do this it is necessary to

have some understanding of how the relevant type of mill

operates.

Various types of pulverized-fuel mill will be encountered, but

two are most commonly used:

The Pressurized or vertical-spindle ball mill horizontal-tube mill

AT PTPS Vertical spindle ball mill is used.

Vertical-spindle ball millsFigure shows the operating principle of a typical ball mill,

such as the

Babcock 'E' mill. In this device, the coal that is discharged

from the storage hoppers is fed down a central chute onto a

table where it is crushed by the crushing actions between the

rollers and rotating tables rotating steel balls. Air is blown

into the crushed coal and carries it, via adjustable classifier

blades, to the PF pipes that transport it to the burners. Theair that carries the fine particles of coal to the burners is

supplied from a fan called a 'primary-air fan'. This delivers air

to the mill, which therefore operates under a pressure which

is slightly positive with respect to the atmosphere outside.

Because of this and because of its other constructional


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features, this type of mill is properly called a 'vertical-spindle,

pressurized ball mill'.


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Air supply systems for Ball

millsAs stated above, the crushed coal in a pressurized ball mill is

propelled to the burners by a stream of warm air for proper

drying & obtaining a particular temperature of coal. Figure

shows the arrangement for doing this: cool air and heated air

are mixed to achieve the desired temperature.


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Fuel Burning3. Grate- It is the platform in Furnace upon which Fuel is

burnt & it is made of Cast Iron Bars. The Bars are so arranged

that air may pass on to the Fuel for combustion. The area of

the grate on which the fire rests in a coal or wood fired boiler

is called Grate surface.

4. Furnaces

It is a chamber formed by the space above the grate & belowthe boiler shell, in which combustion takes place. It is also

called a fire Box.

This crushed coal is taken away to the furnace through coal

pipes with the help of hot and cold air mixture from P.A Fan.

P.A Fan takes atmospheric air, a part of which is sent to Air

pre-heaters for heating while a part goes directly to the millfor temperature control. Atmospheric air from F.D Fan is

heated in the air heaters and sent to the furnace as

combustion air.

F.D (Force draught) Fan:-Force Draught Fan is mainauxiliary of Furnace which Provides Oxygen for Proper

Combustioning of Fuel. It Takes Suction FromEnvironment. It is an Axial Flow Fan.


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Oil Handling System

Oil Handling Plant:-

In Thermal Power Station Fuel Oil play a vital role. Oil burners

besides initial lighting up are also used to provide effective

ignition of the coal associated with P.F Burners and to

stabilize the flame .The Burners can provide enough heat to

carry on boiling operation of the boilers for the initial startingperiod. It can provide 10-15% of the maximum load. At Lean

Period or when it is desired to Run the Boilers at OFF Load

Condition oil Burners are used. The main supplier of oil to the

power plant is Indian oil. Which have contract with the

government to supply oil.

Fuel oil used in Power Stations Are:-

# Heavy Furnace Oil (H.F.O)

# Light Diesel Oil (L.D.O)

# High Speed Diesel Oil (H.S.D)

# Low Sulphur High Stock Oil (L.S.H.S)

At Panki Thermal Power Station L.D.O is used as Fuel Oil.


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Water Treatment Plant

(W.T.P)

The Water Treatment plant is required at the water from

canal cant be directly Used in Boiler for Thermal Electricity

Generator water is converted into steam at High Pressure &It is allowed to force Turbine Rotated and the electricity is

Generated. Therefore water is the basic requirement to the

thermal Power plant. Generally in the Thermal Power Plant Is

Employed to Refine the Water.

Necessity of Water Treatment:-

Natural Water Contains Solid, Liquid & Gaseous Impuritiesand Therefore this water cant be used for Generation of

Steam in the Boiler, The different Effect introduced due to

use Of Unrated Water in the boiler. So the water impurities

should be removed before itsused as a stream. The

following procedure is used in WTP for minimizing the

hardness & removing the impurities:-Flocculate Plant:-

Here Alum is added is added to water to precipitate

Dust Particles in Water. Aluminium in Alum neutralizes

Charge Dust Particle & this gives Result to a heavy Complex

Compound Which is settled down. Bleaching Powder &

limestone along with chloride is also added in this


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flocculation Tank to remove temporary hardness & chloride

also removes Bacteria & Organic matter.

This is Called flocculate plant because, all the mixing and

processing is done in flocculation plant where flocculation

Mechanism is also happens.

Auxiliaries of W.T.P

Sand Filter-

These Stages of sand filter are putt across the flow so as to

remove other Suspended Particle, if any.

Activated Carbon filter-

This Filter is employed for removal of Bacteria and organic

material. Here anthracite (Coal) is uses for Filter.

Cation Exchanger-

At this stage ions are observed by ion exchanger method, HCl

and negative resin are principle ingredient of this chemical

filter

Anion Exchanger:-

Here Negative Ions are observed by Carefully Formulated by

positive resin.


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B.M.D & Its Supporting

Auxiliaries

Tubes that hang in the hottest part of the combustion gases

as they exit the furnace. Here the steam is superheated to

1,000F (540 C) to prepare it for the turbine. The steamgenerating boiler has to produce steam at the

high purity, pressure and temperature required for the

steam turbine that drives the electrical generator. The

generator includes the

economizer, The Boiler Shell Setting Grate The furnace with its steam generating tubes

Necessary

safety valves are located at suitable points to avoidexcessive boiler pressure. The air and flue gas path

equipment include:

Forced draft (FD) fan Air preheater(APH)


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boiler furnace induced draft (ID) fan Fly ash collectors (electrostatic precipitator or bag

house) and the flue gas stack.

The steam produced is used for Producing Mechanical

work by expanding it in steam engine or steam turbine.

According the Process Boiler is of two type-

1. Water Tube Boiler-In water Tube boilers, Watercirculates through the tubes and hot products of

Combustion Flow over These tubes.

2.Fire Tube BoilerIn this fire flows in the tubes & tubes

is surrounded by water, Fire tube boilers have low Initial

cost in compare to Water Tube Boiler.

At PTPS Water Tube Boilers Are Used.

Boilers are also called Steam GeneratorBoiler


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B.M.D & Its Supporting

AuxiliariesBoiler Shell or Boiler Drum:-The Shell or drum Consist of one

or more Steel Plates bent into cylindrical Form land Riveted

or welded together. The shell end are closed with the end

plates. Its second or down plate made morethicker than

upper because all load applied on this. It is the main drum

which Received D.M Water from Boiler Feed Pump Passing

through High Pressure Heater & Economizer at an operating

Pressure of 183kg/cm2 From Boiler Drum. The Water runs

through the tubes. These Tubes are known as down comers.

Setting- the Primary Function of setting is to continue Heat to

the Boiler by the Passes of gases taking From FD Fan .It is

made from Brickwork.

Grate- It is the platform in Furnace upon which Fuel is burnt

& it is made of Cast Iron Bars. The Bars are so arranged that

air may pass on to the Fuel for combustion. The area of the

grate on which the fire rests in a coal or wood fired boiler is

called Grate surface.

Furnaces-It is a chamber formed by the space above thegrate & below the boiler shell, in which combustion

takes place. It is also called a fire Box.

Mountings-The Items Such as Stop Valve, Safety valve,

Water level Gauges,


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Fusible Plug, Blow off cock, Pressure Gauges, Water

level Indicator etc. are the mountings and a boiler cant

work safely without these.

Path away Accessories or Integral Part of Boilers:-

Economizer:-Economizer is an important boileraccessory. The work of Economizer is preheating of Feed

water of boiler and to less Fuel consumption Furnace.

Preheating of feed Water is done by Flue Gases which is

comes from after burning of Fuel in the CombustionChamber. The Temperature of Feed Water at inlet of

economizer is in Range of 160-1800C

And after Leaving it, It becomes 2100C.It is located in

Rear Side of Boiler.

Rotating Air Pre Heater: - The Purpose of Air Preheateris to recover heat of the Flue Gases Which is at aConsiderably High as PA Fans Temperature. It rotates at

the Speed of 176 rpm. The Heat of the flue gases is

absorbed by Heating Surface of air pre heaters and then

transfer to the cool air coming From P.A Fans.

LPH (Low Pressure Heater):-it takes Extraction fromTurbine & gives these Extraction to Condensate WaterCycle for Preheating of this water. It is situated at

4meter level on Turbine Side.

HPH (High Pressure Heater):- Its work same as LPH toPreheat of Feed water by bleeding of Turbine.

Dearator:-Work of Dearator is to Dearate of Watermeans to Remove Dissolve Gases from DM water & to


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Give Proper Suction to Boiler Feed Pump. It is situated at

27meter level in Boiler side.

Boiler Feed Pump:-Its work is to take suction fromdearator and give it to Boiler Drum on High

Pressure(183Kg/cm2).Cycle of Dearator to boiler drum is

called Feed Water cycle. It is situated at 0 meter level on

Turbine side.

F.D (Force draught) Fan:-Force Draught Fan is mainauxiliary of Furnace which Provides Oxygen for Propercombustioning of Fuel. It Takes Suction From

Environment. It is an Axial Flow Fan.

ID fan (Induced Draft Fan):-basically pulls out flue gasfrom the furnace of boiler. It is located between dust

precipitators (ESPs) and Chimney. Obviously it handles

hot air/dust. Whereas, FD fan (Forced Draft Fan)supplies the required air into the furnace for

combustion of fuel. It handles air at normal

temperature. The capacity/power rating of ID fan will be

more than that of FD fan.

Chimney:-When Coal burns in Furnace then ProduceSmoke, Flew Gases which content NO,SO2,CO,C etc. thatash is send in to Electro Static precipitation and ash

comes out with water but some Ash is sucked by I.D fan

which send into chimney with the smoke so the some

which is passing through Chimney is Black.

Super Heater:-The Function of a super heater is toIncrease the Temperature of Steam above Its Saturation


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point. The Super heater is very important accessory of a

Boiler & used in both in Fire Tube & Water Tube Boiler.

Turbine Maintenance

Division (T.M.D) Steam Turbine

Steam turbines are used in all of our major coal fired

power stations to drive the generators or alternators,

Which produce electricity. The turbines themselves are

driven by steam generated in Boilersor Steam

Generatoras they are sometimes called.

Energy in the steam after it leaves the boiler is

converted into rotational energy as it passes through

the turbine. The turbine normally consists of several

stages with each stage consisting of a stationary blade

(or nozzle) and arotating blade.

Stationary blades convert the potential energy of the

steam (temperature and pressure) into kinetic

energy (velocity) and direct the flow onto the rotatingblades. The rotating blades convert the kinetic energy

into forces, caused by pressure drop, which results in

the rotation of the turbine shaft. The turbine shaft

is connected to

generator, which produces the electrical energy. The


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rotational speed is 3000 rpm for Indian System (50 Hz)

systems and 3600 for American (60 Hz) systems.

T.M.DIn a typical larger power stations, the steam turbines are

split into three separate stages, the first being the High

Pressure (HP), the second the Intermediate Pressure (IP)

and the third the Low Pressure (LP) stage, where high,intermediate and low describe the pressure of the

steam.

After the steam has passed through the HP stage, it is

returned to the boiler to be re-heatedto its original

temperature although the pressure remains greatly

reduced.The reheated steam then passes through theIP stage and finally to the LP stage of the turbine.

A distinction is made between "impulse" and "reaction

turbinedesigns based on the relative pressure drop

across the stage. There are two measures for pressure

drop, the pressure ratio and the percent reaction.

Pressure ratio is the pressure at the stage exit divided bythe pressure at the

stage entrance. Reaction is the percentage is entropic

enthalpy drop across the rotating blade or bucket

compared to the total stage enthalpy drop. Some

manufacturers utilize percent pressure drop across

stage to define reaction.


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Generator

Generator:-

An electric Generator is a machine which converts

Mechanical Energy (or Power) into Electrical Energy.

This Energy Conversion is based on the principle of the

production of dynamically induced e.m.f is Produced init according to faradays law, Whenever aconductor is

moving in a magnetic Field then it cuts Magnetic Flux

and there were an E.M.F (Electro magnetic Force)

Produced ,which is Called Induced E.M.F.

e=N*d/dt


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Overall Process

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Training Report on Thermal Power Plant,panki kanpur

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