NATIONAL THERMAL POWER CORPORATION

TALCHER SUPER THERMAL POWER STATION

KANIHA,ORISSA
 ACKNOWLEDGEMENTS

This training report at NTPC/TSTPS could not have been

completed without the guidance of Mr. S. Sinha (HR, Employee
Development Centre) and S.N. Dutta (DGM, Chemistry Department)
at NTPC /TSTPS.
I sincerely thank all the EDC faculties and all other
executives for their effective guidance with relevant information
about the power plant engineering of TSTPS plant.
I heartily thank Mr. A. Samanta (Sr. Manager, O&M,
BMD), Mr. P.K. Sahoo (Sr. Manager, CHP), Mrs. Bidisha Sen
(Senior Chemist), for their solicitous support and cooperation with the
relevant power plant information.

Yours sincerely,
TANMAY DATTA (Sr. no.-293/EDC/VT),

JADAVPUR UNIVERSITY
INTRODUCTION
 1. PLANT OVERVIEW- NTPC/TSTPS

The NTPC History

Founded on November 7, 1975, NTPC Limited (Formerly
National Thermal Power Corporation) is the largest power
generation company in India. With a current generating capacity of
31,134 MW, NTPC has embarked on plans to become a 75,000 MW
company by 2017.
The total installed capacity of the company is 31134 MW
(including JVs) with 15 coal based and 7 gas based stations, located
across the country. In addition under JVs, 3 stations are coal based
and another station uses naphtha/LNG as fuel. By 2017, the power
generation portfolio is expected to have a diversified fuel mix with
coal based capacity of around 53000 MW, 10000 MW through gas,
9000 MW Hydro generation, about 2000 MW from Nuclear sources
and around 1000 MW from Renewable Energy Sources (RES).
Pursuant to a special resolution passed by the Shareholders at the
Company‟s Annual General Meeting on September 23, 2005 and the
approval of the Central Government under section 21 of the
Companies Act, 1956, the name of the Company “National Thermal
Power Corporation Limited” has been changed to “NTPC
Limited” with effect from October 28, 2005. The primary reason for
this is the company‟s foray into hydro and nuclear based power
generation along with backward integration by Coal India.
At the present with a generation of about 1, 50,000 MW from all
sources the power plants are able to meet only about 60 to 75% of
this demand on a yearly average. A fixed 11% deficit of power has
been seen to exist in every state in India at average.
NTPC at a Glance(Coal Based projects)

Sl.No. City State Capacity

[Mw]
1 Singrauli Uttar Pradesh 2000
2 Korba Chattisgarh 2100
3 Ramagundam Andhra Pradesh 2600
4 Farakka West Bengal 1600
5 Vindhyachal Madhya Pradesh 3260
6 Rihand Uttar Pradesh 2000
7 Kahalgaon Bihar 2340
8 NCTPP, Uttar Pradesh 1330
Dadri
9 Talcher, Orissa 3000
Kaniha
10 Unchahar Uttar Pradesh 1050
11 Talcher Orissa 460
Thermal
12 Simhadri Andhra Pradesh 1000
13 Tanda Uttar Pradesh 440
14 Badalpur Delhi 705
15 Sipat-II Chattisgarh 1000
Total 24885
 Sales

INSTALLED CAPACITY
NTPC'S GENERATION

Fig. NTPC’s Generation

The basic requirements of a conventional power station are

decided on the type, size and other essential specifications of the
station to be constructed. The general factors include Site
Requirements, Geology, Water for Power Transmission, Climatic
conditions, Proximity of Airfields, Fisheries and Marine Life,
Personnel Requirement, Amenities.
The NTPC/TSTPS set up in the year 1989 (Stage#I, 2x500
MW), is located at a distance of 180 Km from Bhubaneshwar in
district Angul has a present generation capacity of 3000 MW. The
Stage#I (2x500 MW) units had been erected by Alstom & ABB. Later
additional 2000 MW capacity had been proposed and erected under
BHEL, with present nomenclature as Stage#II (4X500 MW). The
salient features include:
Salient Features
Total land
acquisition
Coal source 1. Lingaraj mines/Mahanadi coal
fields/Talcher(Coal India)
2. Neyveli
3. Indonesia & Australia(Imported coal,
anthracite quality)
Water Source Brahmani River
Transport Merry Go Round(MGR)system through rail
system wagons
Effluents Into ash ponds at Derang and abandoned
Discharge excavated mines in Talcher

Beneficiary States from NTPC/TSTPS

BENEFICIARY STATES FROM STAGE # I NTPC/TSTPS (2X500 MW). All are 400
kV AC transmission lines.

STAGE # I
Sl. Beneficiary Electricity Load %
No. State Board Allocation Sharing
1. Bihar BSEB 327 MW 35.4%
2. Jharkhand JSEB 43 MW 5.7%
3. West Bengal WBSEB 90 MW 9.1%
4. Orissa GRIDCO 318 MW 31.8%
5. Sikkim SEB 24 MW 2.4%
6. West Bengal DVC 3.1 MW 0.31%
7. Other States --------- 163 MW 16.3%
 BENEFICIARY STATES FROM STAGE # II NTPC/TSTPS (4X500MW). The
generated power from Stage # II is supplied to the Southern Grid by a 2000
MW HVDC (+ 500 kV Bipole) transmission link (1374 km) from Talcher to Kolar
in Karnataka.

STAGE # II
Sl. Beneficiary Electricity Load %
No. State Board Allocation Sharing
1. Andhra APSEB 248 MW 21.5%
Pradesh
2. Karnataka KSEB 373 MW 18.8%
3. Kerala KERALA SEB 424 MW 21.35%
4. Tamil Nadu TN-SEB 495.6 MW 24.85%
5. Pudicherry PUDICHERRY 63.2 MW 3.3%
6. Orissa OSEB 200 MW 10%

Each unit of TSTPS generates 500 MW at 21 kV and is connected to

the 400 kV grid through a bank of 3 numbers 200 MVA 21/ (420/ 3)
kV step up transformers.
 2. SALIENT FEATURES-TECHNICAL

Raw Material Source

Coal
 According to design, the required calorific value of coal is
3500 Kcal/kg.
 Presently coal available has calorific value of 2800-3200
Kcal/kg in average, received from the Talcher mines, 29 km
from site and the imported coal.
 60,000 tons of coal is required each day to run the 6x500
MW units.
 Coal received from MCL, are of 200 mm dimension in
average.

Water
 Water pumped from Brahmani River from pump house, 9
km from site.
 5000 tons/hr raw water is pumped into the system.
 5 nos. of raw water pumps operating in parallel has rated
power of 418 kW and pumping rate of 2300 𝑚3 /hr each.
 Make up water required is 7-8 tons/hr.

DM Plant Processing
 Raw water processed here and supplied as DM water for
steam generation, and for cooling as Cooling Water, for
plant uses as service water and for drinking water.
 Has 3 DM water storage tanks, 4 degasser water pumps, 4
bulk storage tanks for acid (HCl) and 2 bulk storage tanks
 for alkali(NaOH), 3 gravity filter beds(240 𝑚3 /hr each), 3
clarified water makeup pumps(1800 𝑚3 ) for Stage#II.
 Approximately 1200 kg of HCl and 600kg of NaOH and
other chemicals are required per day.

3.POWER PLANT TECHNOLOGY

A modern pulverized coal-fuelled electrical generation facility
generally uses the most commonly encountered Rankine-based
thermodynamic cycle. This facility generates electricity by producing
steam in a steam generator and expanding the steam through a turbine
generator. The steam is then condensed in a condenser and the
condensed liquid is used again in the steam generator.
RANKINE CYCLE: A BASIC
OVERVIEW
 The figure below depicts the basic path of the working fluid (in
our case water and steam) in a Rankine cycle

STEAM
GENERATOR TURBINE

PUMP

CONDENSER

Fig. Basic layout of a Rankine cycle showing path of the working

fluid
 In a conventional pulverized coal fuelled power plant steam is
generally used as the working fluid. There are several reasons behind
it. To start with:
 Steam/water has got the highest specific heat.
 It has also got a very high heat transfer coefficient thereby
making heat transfer with the hot flue gases an efficient process.
 It‟s easy to control and distribute.
 It‟s cheap and inert.

A brief overview of the properties of steam on the T-S diagram

has been given below

Properties of Steam 374.15 C ,

221.2 bar (a)

Fig. Properties of steam (T-S) diagram

 Working of Basic Rankine Cycle

Fig. Basic Rankine Cycle (Sub-Critical)

The basic Rankine cycle consists of following basic stages

mentioned as follows:
 Raising the pressure of liquid water in pump.
 Sensible heat addition in the economiser at constant pressure
leading to rise of temperature.
 Latent heat addition in the evaporator (water walls) at constant
pressure whereby phase transformation from water to steam
takes place.
 Superheating in the superheaters at constant pressure.
  Work is done in the turbines by expansion of steam in various
stages of the turbine.
 Heat rejection at constant pressure in the condenser.

REHEATING

That increasing the boiler pressure increases the thermal

efficiency of the Rankine cycle, but it also increases the moisture
content of the steam to unacceptable levels. Then it is natural to ask
the following question:
How can we take advantage of the increased efficiencies at higher
boiler pressures without facing the problem of excessive moisture at
the final stages of the turbine?
Two possibilities come to mind:
 Superheat the steam to very high temperatures before it enters
the turbine. This would be the desirable solution since the
average temperature at which heat is added would also increase,
thus increasing the cycle efficiency. This is not a viable solution,
however, since it requires raising the steam temperature to
metallurgically unsafe levels.
 Expand the steam in the turbine in two stages, and reheat it in
between. In other words, modify the simple ideal Rankine cycle
with a reheat process. Reheating is a practical solution to the
excessive moisture problem in turbines, and it is commonly used
in modern steam power plants. The T-s diagram of the ideal
reheat Rankine cycle and the schematic of the power plant
operating on this cycle are shown in the following figure.
 Fig. Ideal Reheating in Rankine Cycle

REGENERATION

A careful examination of the T-s diagram of the Rankine cycle

redrawn in the Fig. below reveals that heat is transferred to the
working fluid during process 2-2‟ at a relatively low temperature. This
lowers the average heat addition temperature and thus the cycle
efficiency.
 Fig. Rankine Cycle

To remedy this shortcoming, we look for ways to raise the

temperature of the liquid leaving the pump (called the feedwater)
before it enters the boiler. One such possibility is to transfer heat to
the feed water from the expanding steam in a counter flow heat
exchanger built into the turbine, that is, to use regeneration. This
solution is also impractical because it is difficult to design such a heat
exchanger and because it would increase the moisture content of the
steam at the final stages of the turbine.

A practical regeneration process in steam power plants is

accomplished by extracting, or “bleeding,” steam from the turbine at
various points. This steam, which could have produced more work by
expanding further in the turbine, is used to heat the feed water instead.
The device where the feed water is heated by regeneration is called a
regenerator, or a feed water heater (FWH).
 Regeneration not only improves cycle efficiency, but also
provides a convenient means of deaerating the feed water (removing
the air that leaks in at the condenser) to prevent corrosion in the
boiler. It also helps control the large volume flow rate of the steam at
the final stages of the turbine (due to the large specific volumes at low
pressures). Therefore, regeneration has been used in all modern steam
power plants since its introduction in the early 1920s.

A feed water heater is basically a heat exchanger where heat is

transferred from the steam to the feed water either by mixing the two
fluid streams (open feed water heaters) or without mixing them
(closed feed water heaters). An ideal regenerative Rankine cycle with
OFWH is shown in the following figure.

Fig. Ideal Regenerative Rankine Cycle

OFFSITES
 WATER TREATMENT PLANT

Cause of Water Treatment

 Raw water contains many dissolved minerals and organic
materials.
 At high temperature certain minerals left scaling on the tube
metal of the boiler and cause permanent damage.
 Some dissolved minerals leads to corrosion of tube metals.
Some leads to foaming.
 At high pressure and temperature an element, silica can be
carried away with steam causing damage to turbine low pressure
stage.
 A Thermal Power Station needs water of varying quality for
different process and hence the requirement.
 The performance and life expectancy of the station greatly
depends on water chemistry compliance.

Type of water treatment

The type of demineralization process chosen for a power station
depends on three main factors:
 The quality of the raw water.
 The degree of deionisation i.e. treated water quality
 Selectivity of resins.
Different water qualities in use at NTPC-Stations
 Condenser cooling…..Raw water/ Clarified & post-chlorinated
water.
 BA flushing – Raw water.
 Boiler feed water…..Conditioned DM water.
 ESP / Channel flushing…..Raw/ Clarified water.
 Other aux. cooling…..Clarified water.
 H2 generation plant…..DM water.
 Drinking water…..Filtered & post-chlorinated water.
 DM plant operation…..Filtered water.

Steps of treatment process

 Aeration of raw water
 Adding chemicals for bacteria removal
 Adding chemicals for sedimentation of suspended particles
 Flocculation
 Filtration
 Ion Exchange process
 Water treatment process is generally made up of two sections :
 Pretreatment section
 Demineralization section
Pre Treatment Process
 Pretreatment plant removes the suspended solids.
 The coarse components, such as sand, silt etc, can be removed
from the water by simple sedimentation.
 The non-separable solids (colloids) will not settle in any
reasonable time and must be flocculated to produce the large
particles which are easily settled.
 Flocculation is obtained by gentle and prolonged mixing which
converts the submicroscopic coagulated particle into discrete,
visible & suspended particles.
 This operation is done by flash mixer in the clari-flocculator.
 Proper pre treatment reduce loading on anion and cation
exchanger.

Raw water to Clarified water

Aerator
Raw water bay

RW make up
pumps

Clarified Clariflocculator Cl2 dosing

water Pershall
flume
Lime dosing

Alum dosing

Flash
18 June 2011 PMI Revision 00 mixer 7

Fig. Motion of Water in a Clari-Flocculator

 Clarification zone Flocculation zone

18 June 2011 PMI Revision 00 9

Clarified Water to Filtered Water

GF Bed
Clarified water Sand filters

FW DW
sump sump

Clari-flocculator
Cl2 Post-
chlorination
DW
Cl2 House FW pumps
pumps

Filtered water

To Township for
DM water
DM PLANT drinking water
for Plant
18 June 2011 PMI Revision 00 10
purpose Turbidity & Free Cl2 check
Demineralization Plant (DM Plant)

FW water

ACF WAC SAC

Degasser

WBA SBA MB

CST

18 June 2011 PMI Revision 00 12

CIRCULATING WATER SYSTEM

Circulating Water Scheme

 Circulating water pump house
 Intake channel
 Trash rack
 Chlorination plant
 Traveling water screen
 Connecting pipe line to condensed
 Outlet channel
 Cooling tower
Types of CWCT systems

Open Loop system:

Water is abundant…
Reduction in the APC..

Steam from Turbine

Cold Water
Condenser
Pump
Hot water

River Flow

19 June 2011 PMI Revision 00 8

Cooling Water Scheme

Reservoir/ River Canal Intake

Trash rack
Cooling tower

TWS
CT pumps

Hot Pond CW pumps

18 June 2011 PMI Revision 00 9
Condenser
Cooling Tower
 Cooling tower is the most important equipment for closed cycle
water recirculation system.
 The efficiency of cooling tower has direct effect on condenser
vacuum and in turn, the heat rate of the station.
 1oC rise in cold water temperature in a 200 MW unit
corresponds to 5 mm vacuum loss leading to 7.5 Kcal/kWh
losses in heat rate and in 500 MW, 5.74 Kcal/kWh losses in heat
rate.

Types of cooling Tower

 Wet type:-Wet type cooling towers are of two types
 Natural Draft
 Mechanical Draft
 Forced draft
 Induced draft
Both of these can be counter flow type or cross flow type.

 Dry type

Natural Draft Cooling Tower

 It produces air flow through utilization of stack or chimney
effect. Pressure difference causing air flow is given by
p=(𝜌𝑜𝑢𝑡𝑒𝑟 - 𝜌𝑖𝑛𝑛𝑒𝑟 )H.g
 The fill is located in the lower portion of shell with upper 85 to
90% of shell empty which is used to create chimney effect.
  They are more suitable in the area of high relative humidity ratio
and low temp.
 They may be of cross flow or counter flow.

Mechanical Draft Cooling Tower

 Forced draft
 Advantage:-fan is subjected to less severe condition
 Disadvantage:-recirculation more
 Induced draft
 Advantage:-min recirculation
 Disadvantage:-fan is subjected to warm humid condition.
 FUEL OIL SYSTEM

Purpose of Fuel Oil

 Initial firing of the Boilers
 Flame stabilization
 Low load operation
Types of Fuel Oil
 Light diesel oil (LDO)
 High speed diesel oil (HSD)
 Heavy Fuel oil (HFO)
 Low sulphur heavy stock (LSHS)

Use of Different Types

LDO & HSD normally used in
 Auxiliary boiler
 Igniter for certain boiler design.
HFO generally used for during startup of boiler at low loads

HYDROGEN GENERATION

Purpose Of Hydrogen In Thermal Power Station

 Cooling of generator rotor
 It is most suitable coolant
 Higher specific heat
 Lower mass
 Better circulation
 Good thermal conductivity
Hydrogen Generation Process
 Electrolysis of water
 Electrochemical Cell
 Natural Hydrogen Extraction
COAL HANDLING PLANT
(CHP)
 As coal is the prime input for a thermal power plant, adequate
emphasis needs to be given for its proper handling and storage. It is
equally important to have a sustained flow of this fuel to maintain
uninterrupted power generation.
Coal is usually delivered to the facility by unit trains, although
barges and tracks are also used. The coal handling system unloads the
coal then stacks, reclaims, crushes and conveys it to storage silos near
the steam generator. Coal is fed from the storage silos, pulverized to a
powder and blown into the steam generator. Within the steam
generator, pulverized coal is mixed with air and combusted and the
combustion energy is used to produce steam.

Grades of Coal
Grade Useful Heat Value Corresponding Ash% Gross Calorific Value
(UHV) (Kcal/Kg) + Moisture % at GCV (Kcal/ Kg) (at 5%
(60% RH & 40O C) moisture level)

A Exceeding 6200 Not exceeding 19.5 Exceeding 6454

B Exceeding 5600 but not 19.6 to 23.8 Exceeding 6049 but

exceeding 6200 not exceeding 6454
C Exceeding 4940 but not 23.9 to 28.6 Exceeding 5597 but
exceeding 5600 not exceeding. 6049
D Exceeding 4200 but not 28.7 to 34.0 Exceeding 5089 but
exceeding 4940 not Exceeding 5597

E Exceeding 3360 but not 34.1 to 40.0 Exceeding 4324 but

exceeding 4200 not exceeding 5089
F Exceeding 2400 but not 40.1 to 47.0 Exceeding 3865 but
exceeding 3360 not exceeding. 4324
G Exceeding 1300 but not 47.1 to 55.0 Exceeding 3113 but
exceeding 2400 not exceeding 3865

13 June 2011 PMI Revision 00 3

 Coal Transportation System
 Daily on an average around 30,000 ton of coal is required for a
typical 2000 MW Station.
 Each Super Thermal Power Project has been linked to a
particular coal mine to meet its coal requirements.
 The required coal is supplied through rail wagon. If the power
station is away from coal mines then it is fed through Indian
Railway system otherwise for pit head station it is done through
Merry Go Round railway system.
 Merry Go Round (MGR) system is a private, fully fledged
Railway system of NTPC used for hauling the required coal
from mines to its Thermal Power Plants.
 Each coal rake consists of Bottom open Broad Gauge wagons
(BOBR) hauled by one/two locomotive.
 Modern Multi Aspect Colour Light Signalling (MACLS) system
with panel interlocking is provided for the safety of the r ake
movement.

Main Features of MGR Loading System

 This system calls for high-speed load-outstation at the mines.
 It consists of one or two loading silos depending upon the coal
requirement of the linked power station.
 The capacity of the silos for the NTPC project varies between
2400 ton and 4000 ton.
 The silos are cylindrical and fed by twin belt conveyors.
 For accurate weighing of coal to each wagon, load cells are
provided with silos.
 A sampling unit suitable size coal is provided at the feed point
of the loading silo to collect samples for quality analysis.
 The loading operation of the coal rake takes place while it is
moving under the silo at a speed of 0.8 km per hr.
 Wagons are provided with bottom discharge ho ppers fitted with
pneumatically operated automatic door actuating mechanism.
 Line side equipment is installed by the track hopper for
initiating the opening of doors in groups of 10-14 wagons. The
unloading operation of 60 ton per load wagon takes about 2 0/30
seconds.

Fig. Loading of coal in Railway wagons

Main Features of Coal Unloading System
 At NTPC end, coal is unloaded in the Track hoppers.
 Track Hopper, normally of 200-250m length.
 After placing the wagons on the hopper, electrical pulse is given
to the pneumatic device for opening the bottom doors.
 Coal rushes down due to its own weight.
 When the track hopper is empty, it takes only 20 seconds for
unloading one wagon i.e. 60 tons.
 This coal falls on a „T‟ table, over which a paddle feeder runs
and pushes the coal on to a conveyor.

Fig. Coal Unloading in Track Hoppers

 Coal Handling System
 Coal handling system consists of three coal paths, first, direct
conveying of coal from track hopper to boiler bunkers; second,
from track hopper to stockyard; third, from stockyard to boiler
bunkers.
 It also provides arrangement for separation of material
impurities, crushing of coals, coal sampling etc.
 The capacity of the coal handling system for super thermal
stations varies from 1200 to 2000 ton/hr, normally, for a stage of
1000 MW.
 The storage facilities at the stockyards have been provided only
for crushed coal.

Fig. Coal Handling Plant Layout

 Track Hopper

Paddle Feeder

Conveyor Belts

Suspended Electromagnetic
Separator

Conveyor Belts

Electromagnetic Metal
Detector

Vibro Grizzly Feeder

Ring Hammer Crusher

Only Fine Coal~20 mm, by-passed

Conveyor Belts

Mills/Pulverizers

Fig. Block Diagram Representation of Coal Transport within the

CHP
Coal Handling System Equipments
Paddle Feeder
 Below track hopper paddle feeder arrangement is provided to
unload coal to coal conveyors.
 The 200 mm coal as received at the track hopper is fed to the
crusher house through 1A & 1B conveyors.

Vibrating Screen
The function of the vibrating screen is-
 To send the coal having size of less than 20mm to belt feeder
through the bypass chute bypassing the crusher.
 To send the coal of more than 20mm size to the crusher.

Crushers
 To crush the coal from 200 mm to 20 mm size received from
vibrating screen crusher hammers are used, which are made of
Manganese Steel.
 Hammer row -4(stage 1)
 Row-1 & 2 =18 hammer each
 Row-3&4=20 hammers each
 No of hammer in each Crusher-
 stage-1 = 76 hammers
 stage-2 = 92 hammers
 Normally these crushers have a capacity of around 600 tons per
hour.
 Fig. Constructional Features of a Crusher

Conveyor Belts
 Made of different layers or piles of fabric duck with rubber
protected by a rubber cover on both sides & edges.
 Fabric ducks are designed to withstand tension created in
carrying the load.
 Nylon rubber cover protects the fabric duck.

Fig. Conveyor Belts

Idlers
 Idlers consist essentially of rolls made out of seamless steel
tubes enclosed fully at each end fitted with stationary shaft,
antifriction bearing and labyrinth sealing.
 Types

Troughing Idlers- shape the belt to

support a moving load without
spill ag e or damage to the belt .

Impact Idlers- abs orb the shock of

falling material at loading and
transfer points to protect belt from
damag e.

Positive Action Troughing

Trainers -automatically maintain
troughing side alignment in one-way
conveyors.

Return Idlers–support the empty belt

during the return run.

Positive Action Return Trainers -

automatically maintain return belt
alignment on one-way conveyors.
Pulleys

 Made of mild steel

 Rubber coating is used

to increase friction
factor between belt &
pulley (rubber
. lagging)

Drive Unit
 Motors coupled to reduction gear with the help of flexible/fluid
coupling on the high speed shaft of the Gear Box.
 Flexible coupling on the input side.

Take Ups
 Facilitates necessary tension for the drive to operate the belt.
 Provides sag at a point where required horse power will be at
minimum and load will move with least disturbance over idlers.

Skirt Board
 Used with chutes at trail end.
 Guides material centrally on the belt while loading until it has
settled down on the belt.
Scrappers
 Placed at discharge pulley in order to clean the carrying side of
belt.
 It avoids the wear of return idlers due to build up material.

Stacker-cum-Reclaimer
 This is used for stacking and reclaiming the coal from stock
yard. Generally two stacker claimers have been provided at each
of the NTPC's projects. Their normal capacity is 200 tons per
hour and maximum design capacity is 450 tons per hour.
 The stacker reclaimer generally consists of (a) Bucket Wheel or
Digging Wheel, (b) Boom Conveyor. While the belt conveyor
carrying the coal for the stock yard is in the same direction but
the direction of the boom conveyor with respect to stacking and
reclaiming is opposite.

Fig. Stacker-cum-Reclaimer
Magnetic Separator
 Any ferrous material on the conveyor will be lifted from the
moving conveyor.
 No tripping involved.
 MS is interlocked with conveyor start up.
 When ferrous metal is picked up, the MS is moved from the
conveyor, de-magnetized and the metal piece is removed.

Metal Detector
 Any Metal with an area of 100 sq. cm will be detected.
 Conveyor is tripped after detection.
 MD is not having interlock with start up.
 A sandbag is dropped near the Metal piece for easy location.

Trippers

 Trippers stack
material at desired
bunker.

 These are provided

with wheels which
move on rails
parallel to conveyor.
 BOILER
AND
BOILER AUXILIARIES
 BOILER
A boiler is a heat transfer instrument whereby heat energy is
transferred to the working fluid by burning fuel. The heated working
fluid is then expanded in a turbine for gaining mechanical energy
which is subsequently transformed to electrical energy using a
generator. Boilers generally have high thermal capacity. In general
boilers can be classified as:
 Fire tube boilers
 Water tube boilers
However limiting of maximum pressure in fire tube boilers from
strength of materials point of view and other design problems have
led to their replacement by water tube boilers.
Modern water tube boilers can be classified in a number of ways.
Based on whether the boiler operates in subcritical or critical zone of
water boilers can be classified as critical or subcritical boilers. Based
on circulation system they can be classified as:
 Natural circulation type
 Forced circulation type
The steam generator has to produce steam at highest purity, and at
high pressure and temperature required for the turbine. Water must
flow through the heat absorption surface of the boiler in order that it
be evaporated into steam Natural circulation is the ability of water
to circulate continuously, with gravity and changes in temper ature
being the only driving force known as „thermal head.‟
The ratio of the weight of water to the weight of steam in the
mixture leaving the heat absorption surfaces is called Circulation
Ratio.
 Cold feed water is introduced into the steam drum where, because
the density of the cold water is greater, it descends in the 'downcomer'
towards the lower bottom ring header, displacing the warmer water up
into the front tubes.
Continued heating creates steam bubbles in the front tubes, which
are naturally separated from the hot water in the steam drum, and are
taken off.

Fig. Natural Circulation in Downcomer Riser Circuit

However, when the pressure in the water-tube boiler is increased,

the difference between the densities of the water and saturated steam
falls, consequently less circulation occurs. To keep the same level of
steam output at higher design pressures, the distance between the
Bottom ring header and the steam drum must be increased, or some
means of forced circulation must be introduced.
Therefore natural circulation is limited to boiler with drum
operating pressure around 175 Kg/cm2 .
 Again based on number of circulations they can be classified as:
 Once through type
 Multiple pass type

In addition to mechanisms for heat addition to the working fluid

modern boilers also incorporate regenerative heating processes i.e.
methods to use heat from outgoing flue gas to heat the incoming air in
case of pulverized coal fuelled boilers, feed water heating etc. There
are also reheating mechanisms in modern boilers.
In NTPC TSTPS Stage# I boilers are once through type
subcritical boilers, while the Stage# II boilers are drum type, forced
circulation, subcritical type boilers.
Stage# I Boiler Specification
Fig. STAGE-I Boilers
Fig. STAGE-II Boilers
 Fig. Arrangement of Boiler Auxiliaries

FUEL SYSTEM
Fuel-Oil System
The purpose of fuel-oil system is to establish initial boiler light
up. It also supports the furnace flame during low load operation. The
Fuel-Oil system consists of
 Fuel oil Pumps
 Oil heaters
 Filters
 Steam tracing lines
The objective is to get filtered oil at correct pressure and
temperature.
 In the burners atomization is very important. Atomization breaks
the fuel into fine particles that readily mixes with the air for
combustion. Oil should be divided up into small particles for effective
atomization. The advantages of atomization are:
 Atomizing burners can be used with heavier grades of oil.
 Can be adapted to large applications because of large capacity
range.
 Complete combustion is assured by the ability of the small
particles to penetrate turbulent combustion.

Classification of Oil Burners

Oil burners are classified according to the method used for
atomization, as follows:
 Air-atomized burners
 Steam-atomized burners
 Mechanically atomized burners
Air atomizing systems are not recommended for heavy oil system
as they tend to chill the oil and decrease atomization quality.

Steam Atomization
This system uses auxiliary steam to assist in the atomization of
the oil. The steam used in this method should be slightly superheated
and free of moisture. As in the air atomizing system, the steam used
for atomizing as well as heating the fuel as it pass through the tip and
into the furnace. The main advantages of steam atomizing burners
over other are:
 Simplicity of its design
 Initial cost of installation is low
  Low pumping pressure
 Low preheating temperature.
Disadvantage of this system is that steam is used in atomizing
process.

Oil Burners
The types of oil used in the oil burners are:
 Light Diesel Oil
 Heavy fuel oil
 Low sulphur heavy stock (LSHS).
Heavy oil guns are used for stabilizing flame at low load carrying.
Warm up oil guns are used for cold boiler warm up during cold start
up and igniter are used for start up and oil flame stabilizing.

Oil Guns
The guns used in this system have two main components for
atomization. They are:
 Mixing plate
 Spray Plate.
These are as shown in the following figure.
 Fig. Oil Gun

Fig. Oil Gun Compartment

Coal Mill & Feeder
We generally use pulverized coal as fuel in boilers. The main
reason behind using pulverized coal as fuel is as follows:
 Efficient utilization of cheaper low grade coals.
 Flexibility in firing with ability to meet fluctuating loads.
 Elimination of breaking losses.
 Better response to automatic control.
 Ability to use high combustion air temperature; increasing the
overall efficiency of boiler.
 High availability.
 It leads to better burning of coals and less wastage as coal is
very finely powdered and is well mixed with air facilitating
combustion.

Components
The Major components of this system are:
 Coal Preparation Equipments
 Feeders
 Mills
 Coal Firing Equipments
 Burners
Feeders
Feeders are mainly of two types. Volumetric and Gravimetric
these two are further classified as follows:
 Volumetric Type feeder
 Chain Feeder
 Belt Feeder
 Table type belt Feeder
 Gravimetric Feeder

Fig. Chain Feeder

Fig. Gravimetric Feeder

Mills
Mills are systems where coal is crushed to “200 mesh” size i.e.
pulverized and then it‟s carried by primary air to the boiler through
coal pipes and coal nozzles for firing. There it‟s mixed with
secondary air and the pulverized coal is fired.

Classification of Mills

CLASSIFICATION OF MILLS

VERTICAL SPINDLE TUBE

BOWL/ PRESSURIZED
BALL & RACE

XRP E MILLS MPS

(BHEL) (BABCOCK)

Classification of Mills Based on Speed

 Bowl Mill
Bowl mills are medium speed mills. They are used in Stage# II
boilers. The following are the features of a bowl mill.
 Grinding chamber
 Classifier mounted above it
 Pulverization takes place in rotating bowl
 Rolls rotating free on journal do the crushing
 Heavy springs provide the pressure between the coal and the
rolls
 Rolls do not touch the grinding rings
 Tramp iron and foreign material discharged.
The figure below shows a bowl mill.

Fig. A Bowl mill

Ball & Tube Mills
Ball and tube mills are low speed mills. They are used in Stage# I
boilers. The common features of a ball tube mill are as follows:
 Operate at 17 to 20 Rpm
 Coal Feed from both end of the Tube
 Small Ball of 30,40, 50 mm Sizes are used
 Hot air blown to move coal to classifiers at two elevations in
boiler furnace
 No Maintenance for long periods
 Better availability so no spare mill required
 Always a reserve of coal so there is no spark produced between
Steel balls
 Consumption of power is more
 High Foundation and Initial cost of Equipment
A common Ball & Tube Mill is shown in the following figure.

Fig. Ball & Tube Mill

 Mill Dampers and air system
 Pulverized Fuel temperature to be maintained 90 0C.
 All Shut off valves are required to be kept wide open during
operation.
 Mill bearing is to be kept clean and no dust should enter.
 Low Primary air flow will cause unstable flame and high flow
result in high mill reject.
 Burners & Burner Arrangement
Firing System
 Direct Firing System: Coal is fed to the mill at controlled
quantity. Hot air (temperature controlled) is permitted to flow
through the mill. The air dries the coal and picks up the milled
product and flows through the classifier rejecting higher size
particle. The fine coal is carried through the coal burner to the
combustion chamber.
 Indirect Firing System: Mills are operated independent of
boiler loading and pulverized coal is stored in the intermediate
bunker. From the bunker it is taken to combustion chamber with
the help of primary air fan. Boiler loading is controlled by the
amount of pulverized fuel fed to boiler.
At NTPC TSTPS direct firing system is used in both the stages.

Fig. Direct Firing System

 Coal Burners
 Coal burners comprise of coal nozzle, steel tip, seal plate and
tilting link mechanism.
 Housed in coal compartment in all four corners of the furnace
and connected with coal pipes.
 One end (outlet) is rectangular and another end is cylindrical.
 The burner can be tilted on a pivot pin.
 The nozzle tip has separate coal and air passages.
 Coal and air passages are divided into several parts.
Methods of Fuel Firing
 Vertical Firing: A number of rectangular fan shaped nozzles
are set across the width of the furnace in an arch. Pulverized fuel
mixture ignites under the arch and is directed vertically
downwards to the bottom of the furnace where the gases are
made to turn upwards to pass through the combustion chamber
this gives a long path to the flame and is particularly suitable for
coals of low volatile content.
 Horizontal Firing: Horizontal firing with the turbulent type of
burner is set up usually in the front (front wall fired) or rear
walls of the furnace. Burner consists of an inner cone for
primary air and fuel which is given a rotary motion as it passes
through the burner.
 Impact Firing: This is the arrangement with the type of burner
used with slag tap furnaces where the ash is kept in a molten
state on the furnace floor and tapped off as and when necessary.
 Corner or tangential Firing: Burners are set at each corner of
the furnace and are directed to strike the outside of an imaginary
circle in the centre of the furnace.
In NTPC TSTPS all the boilers are corner fired.
Fig. Corner firing
 AIR & DRAFT SYSTEM
Major Fans in Boiler Draft System
 PA Fans
 FD Fans
 ID Fans
Primary Air/Mill Seal Air System
Ambient air is drawn into the primary air ducting by two 50%
duty, motor driven axial reaction fans.
Air discharging from each fan is divided into two parts, one
passes first through an air pre-heater then through a gate into the P.A
bus duct. The second goes to the cold air duct. The mix of both is
used to carry the pulverized coal to the boiler

Components of PA Fan
 Suction Bend With volume Measurement instruments
 Fan housing with Guide Vanes
 Main Bearings (Anti Friction)
 Rotor with impeller with adjustable blade with pitch control
 Guide vane housing with guide vanes
 Diffuser with pressure measurement instruments
Secondary Air System
 Ambient air is drawn into the secondary air system by two 50%
duty, motor driven axial reaction forced draft fans with variable
pitch control.
 Air discharging from each fan passes first through a air
preheated then through a isolating damper into the secondary air
bust duct.
 The cross over duct extends around to each side of the boiler
furnace to form two secondary air to burner ducts.
 At the sides of the furnace, the ducts split to supply air to two
corners. Then split again to supply air to each of nineteen
burner/air nozzle elevations in the burner box.

Induced Draft System

 There are three induced draught fans per boiler, two operating
and one standby
 In 500 MW fans are single-stage, double-inlet centrifugal fans.
Principal fan elements of the fan are:
 Housing
 Inlet dampers
 Rotor with Bearing
 Shaft Seal
ID Fan
 The rotor consists of shaft and assembled impeller and runs in
two sleeve bearings that are arranged outside of the housing.
 The impeller consists of a centre disc and two cover discs that
are reinforced by forged rings. The bent blades are welded into
position between the impeller discs.
 The blades are protected by screwed - on wear plates.
 The shaft is of hollow design. The fan shaft has been rated so
that the maximum operating speed is below the critical speed.
Impeller and shaft are connected by means of a flange. This
screwing is protected by wear plates.
 The fan housing is sealed by means of two-part labyrinth seals.
 Bearings are lubricated with oil.

Fig. ID Fan
 Other Fans in The System
 Igniter Air Fan: Provide combustion air to the igniters. Take
suction air from the atmosphere and supplies air to the igniter
wind box.
 Scanner Air Fan: Supplies cooling air to flame scanners.
Normally there are two fans taking suction from FD Fan
discharge duct.
 Mill Seal Air Fan: Seal air fans provide air for the sealing of
Mill bearing. Suction is from cold Primary air and pressure is
boosted up to maintain the differential pressure

Variation of Pressure in Boiler

Furnace Pressure At Various Points in Boiler

250

200

150

100

50
Furnace Pressure

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
-50

-100

-150

-200

-250

-300
Points in Boiler
 AIR AND FLUE GAS PATH TYPICAL 500 MW BOILER
TO MILLS

PAPH-A

PRIMARY
SCAPH-A
PA FAN -A

ECO BYPASS TO ESP

AEROFOIL

SCAPH-A
SECOND
SAPH-A
AA205 AA203 AA202

AA201
AA204
FD FAN -B
SA HDR
HORIZONTAL S.H

ECONOMISER -1

ECONOMISER -2
PANELETTE S.H

ECONOMISER-3

HOT PA HDR
PLATEN S.H

RE HEATER

COMBUSTION
DIVISION

CHAMBER
HOT

AA204 AA201

AA205 AA203 AA202

SAPH-B

SCAPH-B
FD FAN-A

SECOND
AEROFOIL

ECO BYPASS TO ESP

COLD SEC. AIR BIPLANE DAMPER
COLD PRIM AIR
PRIMARY
SCAPH-B

HOT PRIMARY AIR DIVERTER DAMPER

PAPH-B

HOT SEC. AIR

FLUE GAS

PNEUMATICALLY O/P
KNIFE EDGE GATE
TO MILLS
MOTOR O/P LOUVER
DAMPER
PA FAN -A
PNEUMATICALLY O/P
LOUVER DAMPER

13 June 2011
MOTOR O/P GATE PMI Revision 00 15
 Air Pre-Heaters
The primary and secondary airs are heated up in air pre-heaters by
utilizing the heat of the outgoing flue gases.
APH (Air P re-Heater) is the last heat exchanger in the boiler
flue gas circuit. To achieve maximum boiler efficiency maximum
possible useful heat must be removed from the gas before it leaves the
APH. However certain minimum temperature has to be maintained in
the flue gas to prevent cold end corrosion.

Air Pre-Heater Functions

An air pre-heater heats the combustion air where it is
economically feasible. The pre-heating helps the following:
 Igniting the fuel easily.
 Improving combustion.
 Drying the pulverized coal in pulverizer.
 Reducing the stack gas temperature and increasing the boiler
efficiency.
There are three types of air heaters:
 Recuperative
 Rotary regenerative
 Heat pipe

Advantages by use of APH

 Stability of Combustion is improved by use of hot air.
 Intensified and improved combustion.
 Permitting to burn poor quality coal.
  High heat transfer rate in the furnace and hence lesser heat
transfer area requirement.
 Less un-burnt fuel particle in flue gas ensures improvement of
both combustion and efficiency.
 Intensified combustion permits faster load variation and
fluctuation.
 In the case of pulverized coal combustion, hot air can be used
for heating the coal as well as for transporting the pulverized
coal to burners.
 This being a non-pressure part will not warrant shut-down of
unit due to corrosion of heat transfer surface which is inherent
with lowering of flue gas temperature.

Types of Air Pre-heater

Air Pre-heaters are generally of the following type:
 Recuperative
 Regenerative
 Plate type Air-Heater
 Steam Air Pre-Heater
 Langsdorm type
 Rothemuhle type
 Tri sector Air-Heater
 Tubular Air Heaters (Recuperative)
Recuperative or tubular pre heaters are a kind of cross flow heat
exchangers where air flowing in tubes exchange heat with the hot flue
gas as shown in the figure below.

Fig. Recuperative Air Pre Heaters

Regenerative Air Pre-Heaters

These are also sometimes called rotary type air pre-heaters. These
APH have the following characteristics:
 Rotates with a low speed: 0.75 rpm.
 Weight: 500 tons.
 This consists of: rotor, sealing apparatus, shell etc.
 Rotor is divided into 12 or 24 sections and 12 or 24 radial
divisions.
  Each sector is divided into several trapezoidal sections with
transverse division plates.
 Heat storage plates are placed in these sections.

The Material used in APH for heat storage

 Material used Cold end in the basket is a special type of steel
(corten steel (trade name)) which has high resistance to the low
temperature sulphur corrosion, thus prolonging operational life.
 In the hot end mild steels are used
 The optimal geometric shape is usually corrugated and sizes
are determined based on design modelling and experimental
data. The turbulence of air and gas flow through the package
increases the heat transfer rate.

BYPASS SEAL RADIAL SEAL

HOT END AXIAL

SEAL

COLD END HOT INTERMEDIATE

Fig. Air Pre-Heater

Stationary-Plate Type Air Pre-Heater
In a stationary-plate type Air Pre-Heater the heat storage elements
are static but the air/gas flow section rotates. The storage plates are
placed in the stator.

Tri-Sector Type Air Pre-Heaters

It‟s special type of air Pre-heater which is used mainly in power
plants generating lower than 500MW. Here both primary and
secondary airs are heated together by outgoing flue gas in separate
chambers as shown in the following figure.
 Fig. Tri-Sector Type Air Pre-Heater

APH Performance
Boiler efficiency decreases generally on account of APH
performance degradation. This also affects ESP, ID & FD fan
loadings & at times unit capability. Factors affecting APH
performance are as follows:
 Excess air level / No of Mills in service
 Primary Air to Secondary Air ratio
 Moisture in coal/ Air ingress level
 Performance of upstream ash evacuation system
 Procedure for cleaning, soot blowing & regular maintenance etc.
Electrostatic Precipitator
It is a device which captures the dust particles from the flue
gas thereby reducing the chimney emission.
Precipitators function by electrostatically charging the dust
particles in the gas stream. The charged particles are then attracted to
and deposited on plates or other collection devices. When enough dust
has accumulated, the collectors are shaken to dislodge the dust,
causing it to fall with the force of gravity to hoppers below. The dust
is then removed by a conveyor system for disposal or recycling

Location of ESP
The ESP is located, in the flue gas path, after the economizer and
Air Pre-Heaters, and just before the ID fan. It‟s placed in the said
manner so that we can extract maximum amount of fly ash from the
flue gas ensuring that maximum heat can be obtained and utilized,
from the outgoing flue gas, at the same time. The position of the ESP
has been shown in the figure below.

Fig. Location of ESP

Theory of Precipitation
Electrostatic precipitation removes particles from the exhaust gas
stream of Boiler combustion process. Six activities typically take
place:
 Ionization - Charging of particles
 Migration - Transporting the charged particles to the collecting
surfaces
 Collection - Precipitation of the charged particles onto the
collecting surfaces
 Charge Dissipation - Neutralizing the charged particles on the
collecting surfaces
 Particle Dislodging - Removing the particles from the
collecting surface to the hopper
 Particle Removal - Conveying the particles from the hopper to
a disposal point

Fig. ESP
 Fig. Process Steps of ESP

Components of ESP
 Discharge Electrodes
 Power Components
 Precipitator Controls
 Rapping Systems
 Purge Air Systems
 Flue Gas Conditioning
 Emitting Electrodes
 Collecting Electrodes
 High Voltage Equipment
 Rapping Mechanism
 Hoppers
  Heaters
 ALI
 Gas Distribution Screen
 Segregating Gates

Components and their function

 Discharge Electrodes: Discharge electrodes emit charging
current and provide voltage that generates an electrical field
between the discharge electrodes and the collecting plates. The
electrical field forces dust particles in the gas stream to migrate
toward the collecting plates. The particles then precipitate onto
the collecting plates. They are typically supported from the
upper discharge frame and are held in alignment between the
upper and lower discharge frames. The upper discharge frame is
in turn supported from the roof of the precipitator casing. High-
voltage insulators are incorporated into the support system.
 Collecting Plates: Collecting plates are designed to receive and
retain the precipitated particles until they are intentionally
removed into the hopper. Collecting plates are also part of the
electrical power circuit of the precipitator. These collecting plate
functions are incorporated into the precipitator design. Plate
baffles shield the precipitated particles from the gas flow while
smooth surfaces provide for high operating voltage. Collecting
plates are suspended from the precipitator casing and form the
gas passages within the precipitator
 Power Supplies and Controls: The power supply system is
designed to provide voltage to the electrical field (or bus
section) at the highest possible level. The voltage must be
controlled to avoid causing sustained arcing or sparking between
the electrodes and the collecting plates. Electrically, a
 precipitator is divided into a grid, with electrical fields in series
(in the direction of the gas flow) and one or more bus sections in
parallel (cross-wise to the gas flow). When electrical fields are
in series, the power supply for each field can be adjusted to
optimize operation of that field. Likewise, having more than one
electrical bus section in parallel allows adjustments to
compensate for their differences, so that power input can be
optimized. The power supply system has four basic components:
 Automatic voltage control
 Step-up transformer
 High-voltage rectifier
 Sensing device

 Gas distribution System: For creating similar gas and dust

conditions Uniformity is desired in the following parameters:
 Gas velocity
 Gas temperature
 Dust loading
Gas distribution devices, which ensure this, consist of turning
vanes in the inlet ductwork, and perforated gas distribution plates in
the inlet and/or outlet fields of the precipitator.
 Rapping Systems: Rappers are time-controlled systems
provided for removing dust from the collecting plates and the
discharge electrodes. Rapping systems are actuated by electrical,
or by mechanical means. Rapping methods include
 Discharge Electrode Rapping: Discharge electrodes should
be kept as free as possible of accumulated particulate
 Collecting Plate Rapping: Remove the bulk of the
precipitated dust
 Hoppers: Precipitator hoppers are designed to completely
discharge dust load on demand. Typically, precipitator hoppers
are rectangular in cross-section with sides of at least 60-degree
slope. These hoppers are insulated from the neck above the
discharge flange with the insulation covering the entire hopper
area. In addition, the lower 1/4- 1/3 of the hopper wall may be
heated. Discharge diameters are generally 200-300mm. The fly
ash handling system evacuates the fly ash from the hoppers, and
transports the fly ash to reprocessing or to disposal. The ash
handling system are designed and operated to remove the
collected fly ash from the hoppers without causing re-
entrainment into the gas flow through the precipitator. The
design of the ash handling system allow for flexibility of
scheduling the hopper discharges according to the fly ash being
collected in these hoppers.

Fig. ESP Hopper

 Ductwork: Ductwork connects the precipitator with upstream

and downstream equipment. The design of the ductwork takes
into consideration the following:
  Low resistance to gas flow
 Gas velocity distribution
 Minimal fallout of fly ash
 Minimal stratification of the fly ash
 Low heat loss
 Structural integrity

Dust Removal
Dust is removed by Rapping Mechanism by Mechanical Impulses
or by vibration of plates periodically.

Fig. General Layout of an ESP

Disposal of Fly Ash
The disposal of fly ash collected in ESP can be done by two
methods either by wet mode or by dry mode. In dry mode the MHV
(Material Handling Valve) is opened along with stop valve and the
ash is transferred to the silos.
For wet disposal of fly ash the vacuum breaker is closed and the
vacuum pump starts operating. Once sufficient vacuum is present fly
ash comes in through MHV. The water and fly ash coming from
WHWV and WSV to the wetting head respectively mix and forms
slurry which is then collected in the collector tank and finally to ESP
trench. The collector tank is provided with baffles to prevent erosion
due to falling of ash.
Fig. Flue Gas Path
 WATER PATH IN BOILERS
The circulation of water inside the boiler is generally along a
fixed path. The heat is added to the water as it passes through
economizers, steam drums, water walls, superheaters, reheaters etc.
These components have been discussed as below.

Economizers
The feed water first enters the boilers through economizers. Boiler
economizers are feed-water heaters in which the heat from waste
gases is recovered to raise the temperature of feed-water supplied to
the boiler. Following are a few of the applications of economizers.
 The economizer preheats the feed water by utilizing the residual
heat of the flue gas.
 It reduces the exhaust gas temperature and saves the fuel.
 Modern power plants use steel-tube-type economizers.
 Design Configuration: divided into several sections : 0.6 – 0.8 m
gap
Economizers considerably improve boiler efficiency. It has been
observed that a 6oC raise in feed water temperature by economizers
corresponds to a 1% saving in fuel consumption. Correspondingly 220
C reduction in flue gas temperature increases boiler efficiency by 1%.
 Fig. Economizer

Location and Arrangement of Economizers

 Ahead of air-heaters
 Following the primary super-heater or re-heater
 Counter-flow arrangement
 Horizontal placement (facilitate draining)
 Supported to prevent sagging, undue deflection and expansion.
 Stop valve and non-return valve incorporated to ensure
recirculation in case of no feed-flow
 Ash hopper below as flue gas takes a turn
Types of Construction
 Plain Tube: Several banks of tubes with either-in-line or
staggered type formation. Staggered arrangement induces more
turbulence than the in-line arrangement. This gives a higher rate
 of heat transfer and requires less surface but at the expense of
higher draught loss.
 Welded Fin-tube: Fin welded design is used for improving the
heat transfer.

Fig. Various types of fins used in economizer

Separators
It‟s used in stage#1 boiler. The main purpose of separators is to
separate water and steam during start up. The saturated water-vapour
mixture coming from the water walls comes to the separators. There
steam and saturated water is separated. The saturated steam goes in
for superheating while the saturated liquid goes down through start
up heat exchanger (S.H.E.) thereby heating the feed water and
moving to the condenser. All these processes take place only during
start up. Once at approximately 40% of full load only steam comes
into the separator and the S.H.E. becomes stops operating as no
saturated water comes into the separator.

Steam Drum
Steam drums are used in Stage# II boilers. After getting heated in
the economizer the feed water enters the steam drum and from there
it‟s taken by downcomers via the BCW (Boiler Recirculation
Water) pump to the bottom ring header of the boiler and the water is
heated in the water wall tubes of the boiler. The saturated water-
vapour mixture so formed enters the steam drum where steam is
separated from saturated water. The steam separated therein is then
sent for further heating into the superheaters while the saturated liquid
is sent for circulation once again through water walls.

The steam drum contains steam separating equipment and internal

piping for distribution of chemicals to the water, for distribution of
feed water and for blowdown of the water to reduce solids
concentration.
The steam drum consists of the following major parts:

1. Primary separators
Consists of baffle arrangement devices which change the direction
of flow of steam and water mixture

2. Secondary separators
Separators employing spinning action

3. Screening dryers
 Fig. Constructional details of a steam drum

Boiler drum level control is critical for both plant protection and
equipment safety and applies equally to high and low levels of water
within the boiler drum. The purpose of the drum level controller is to
bring the drum up to level at boiler start-up and maintain the level at
constant steam load. A dramatic decrease in this level at constant
steam load may uncover boiler tubes, allowing them to become
overheated and damaged. An increase in this level may interfere with
the process of separating moisture from steam within the drum.
Downcomers
 There are six down comers in (500 MW) which carry water
from boiler drum to the ring header.
 They are installed from outside the furnace to keep density
difference for natural circulation of water & steam.
Water Walls
Water walls serve a number of functions. They are enlisted as
follows:
 Heating and evaporating the feed water supplied to the boiler
from the economizers.
 These are vertical tubes connected at the top and bottom to the
headers.
 These tubes receive water from the boiler drum by means of
downcomers connected between drum and water walls lower
header.
 Approximately 50% of the heat released by the combustion of
the fuel in the furnace is absorbed by the water walls.

Tangent tube
The construction consists of water wall placed side by side nearly
touching each other. An envelope of thin sheet of steel called "SKIN
CASING" is placed in contact with the tubes, which provides a seal
against furnace leakage.

Membrane Wall
A number of tubes are joined by a process of fusion welding or by
means of steel strips called 'fins pressurized furnace is possible with
the related Advantages
  Increase in efficiency
 Better load response simpler combustion control.
 Quicker starting and stopping
 Increased availability of boiler.
 Heat transfer is better
 Weight is saved in refractory and structure
 Erection is made easy and quick

Fig. Arrangement of water walls

Spiral Tube Water Walls

A major problem concerning once through boilers as in stage#1
boilers is Departure from Nucleate Boiling (DNB) i.e. high steam
formation rate leading to formation of a gas film near the inner
surface of water walls causing a reduction in heat transfer rate which
leads to overheating of tubes. To solve this problem spiral tube wall
design using inclined boiler tubes, has been conventionally employed
in order to increase mass velocity in tubes to the level required for
maintaining proper heat transfer-nucleate boiling. The accompanying
reduction in the number of tubes increases flow velocity by 2 to 3
times. It‟s widely used in once through type boilers like Stage#I
boilers. But this spiral tube wall design has relatively complicated
structure, higher system pressure loss, and the higher auxiliary power
consumption. Considering these issues, another option is to use rifled
tubes (that promote heat transfer by means of a spirally grooved
internal surface) which have superior heat transfer characteristics.
Steam film is dispersed by means of the grooves on the inside surface
of the rifled tubes, this inhibits film boiling and allows nucleate
boiling to be maintained to a high steam quality level, thereby holding
down metal temperatures.
Superheaters
Superheaters refer to that portion of the steam circuit where the
saturated steam gets superheated and its enthalpy, temperature and
pressure are raised to proper values before it‟s fed into the turbine.
Super heaters are often divided into more than one stage. The
enthalpy rise of steam in a given section should not exceed
 250 – 420 kJ/kg for High pressure. > 17 MPa
 < 280 kJ/kg for medium pressure. 7 Mpa – 17 MPa
 < 170 kJ/kg for low pressure. < 7 MPa

 Superheating is generally carried out as mentioned below.

 Water is heated to raise steam to higher temperature
 Arranged in 3 stages
 LTSH - located above economizer
 Radiant type (div panel) above furnace
 Convective final super heater (pendant/platen superheater)
above furnace in convection path.

Types Of Superheaters
Divisional Panels
 Divisional panels: Flat panels of tubes located in the upper part
of the furnace, where the gas temperature is high.
 The tubes of the divisional panel SH receive very high radiation
as well as a heavy dust burden.
 Mechanism of HT : High Radiation & Low convection
 Fig. Divisional panel

Pendant Superheaters
 Convective super heaters are vertical type (Pendant) or
horizontal types.
 The Pendant SH is always arranged in the horizontal crossover
duct.
 Pendant SH tubes are widely spaced due to high temperature
and ash is soft.
 Transverse pitch : S1/d > 4.5
 Longitudinal pitch S2/d > 3.5.
 The outside tube diameter : 32 – 51mm
 Tube thickness : 3 – 7mm
 Fig. Pendant superheaters

Convective Superheater (Horizontal)

 The horizontal SH are located in the back pass.
 The tubes are arranged in the in-line configuration.
 The outer diameter of the tube is 32 – 51 mm.
 The tube thickness of the tube is 3 – 7 mm.
 The transverse pitch: S1/d = 2 – 3.
 The longitudinal pitch: S2/d = 1.6 – 2.5.
 The tubes are arranged in multiple parallel sets.
 The desired velocity depends on the type of SH and operating
steam pressures.
 The outside tube diameter : 32 – 51mm
 Tube thickness : 3 – 7mm
 Fig. Horizontal convective superheater

Superheater Temperature Control

Basically the control of temperature is to protect the superheater
by preventing the metal temperatures reaching a dangerously high
level reducing mechanical strength and leading to failure. Water
flowing through a tube conducts heat away much more effecti vely
than steam due to its higher specific heat capacity. This means that
tubes carrying water have a metal temperature much closer to the
fluid passing through it.
For superheat temperatures alloys of chrome molybdenum steels
are used (up to 560 oC), difficulties in welding means that there use is
restricted to only within the highest temperature zone and a transition
piece fitted to connect to remaining mild steel tubing.
Superheat temperature control is therefore fitted to ensure
superheat temperature does not exceed design limits.
Locating the Desuperheater
The preferred location of desuperheater, especially for
temperature above 450 deg C is between sections of superheater. The
steam is first passed through a primary superheater where it is raised
to intermediate temperature. It is then passed through the
desuperheater and its temperature reduction is controlled so that, after
continuing through the secondary or final stage of the superheater, the
required constant conditions are maintained at the outlet.

Fig. Position of the Desuperheater

Reheater
The steam is extracted after expansion in hp turbine for reheating
so as to decrease the moisture content in the final stages of the lp
turbine and also to increase the overall work output. The steam
entering for reheat is called CRH (Cold Reheat) steam while the
reheated steam is called HRH (Hot Reheat) steam. This reheating
takes place inside the boiler in reheaters.
The steam from hp turbine is reheated to 540 degree C. The
reheater is composed of three sections mentioned as follows:
 Radiant wall reheater arranged in front & side water walls
 Rear pendant section arranged above goose neck
 Front section arranged between upper heater platen & rear
water wall hanger tubes
The arrangement and construction of a re-heater is similar to that
of a super-heater. In large modern boiler plant, the reheat sections are
mixed equally with super-heater sections.
A few notable characteristics of reheaters are as follows:
 The pressure drop inside re-heater tubes has an important
adverse effect on the efficiency of turbine.
 Pressure drop through the re-heater should be kept as low as
possible.
 The tube diameter: 42 – 60mm.
 The design is similar to convective super-heaters.
 Overall Heat Transfer Coefficient: 90 – 110 W/m2 K.
Steam And Water Circuit In Stage# I Boilers
TURBINE AND TURBINE
AUXILIARIES
 STEAM TURBINE
 A steam turbine is a mechanical device that extracts thermal
energy from pressurized steam, and converts it into useful
mechanical work.
 Classification
 Depending upon the principle of working:
 Impulse turbine
 Reaction turbine
 Depending upon the type of compounding:
 Pressure compounded
 Velocity compounded

Impulse Turbines
  An impulse turbine uses the impact force of the steam jet on the
blades to turn the shaft. Steam expands as it passes through the
nozzles, where its pressure drops and its velocity increases. As
the steam flows through the moving blades, its pressure remains
the same, but its velocity decreases. The steam does not expand
as it flows through the moving blades.
Reaction Turbine
 In the reaction turbine, the rotor blades themselves are arranged
to form convergent nozzles. This type of turbine makes use of
the reaction force produced as the steam accelerates through the
nozzles formed by the rotor.
Velocity Compounded Impulse Turbine
In this type of turbines the expansion is done in no. of stages.
Each stage consists of a moving and a fixed blade. Pressure first drops
in the nozzle and then it remains constant throughout. Whereas
velocity first increases in the nozzle and then in each moving blade
the velocity drops, remaining constant across the fi xed blades only.

Fig. Velocity Compounded Impulse Turbine

Pressure Compounded Impulse Turbine

Here each stage consists of a nozzle and a moving blade. Pressure
drops in the nozzles and remains constant across the moving blades,
whereas velocity increases in the nozzles and drops in the moving
blades.
 TURBINE LAYOUT

 HP turbine is single flow type. That‟s why thrust imbalance

occurs. To balance this axial thrust balancing drum or dummy
piston is used. HPT has 17 stages (TSTPS, Stage# II).
 IP turbine is double flow type and it has got 12 stages (TSTPS,
Stage# II).
 IP turbine is double flow type and it has got 6 stages (TSTPS,
Stage# II). Due to being double flow type, there is no need for
axial thrust balance in case of IPT and LPT.
 Turbine Components
Casing
 HPT has single casing.
 IPT has got double casing. First, inner casing; second, outer
casing.
 LPT has triple shell welded casing.
Rotor
 Rotating part of the turbine.

Fig. Rotor of a Turbine

Blades
 Most costly element of turbine.
 Blades fixed in stationary part are called guide blades/nozzles
and those fitted in moving part are called rotating/working
blades.

Fig. Blades of a Turbine

 Blades have three main parts

 Aerofoil: working part
 Root
 Shrouds
 Shrouds are used to prevent steam leakage & to guide steam to
next set of moving blades.
Sealing System
 Steam is supplied to the sealing chamber at 1.03 to 1.05
Kg/sq.cm absolute pressure and at temperature 130 0C to 150 0C
from the header.
 Air steam mixture from the last sealing chamber is sucked out
with the help of a special steam ejector to gland steam cooler.
 Provision has been made to supply live steam at the front
sealing of H.P. and I.P. rotor to control the differential
expansion, when rotor goes under contraction during a trip or
sharp load reduction.
 Fig. Labyrinth Seal

Stop & Control Valves

 2 main stop valves and 2 control valves located symmetrically.
 The main steam is admitted through the main steam inlet
passing first the main stop valves and then the control valves.
From the control valves the steam passes to the turbine casing.
 Turbine is equipped with emergency stop valve to cut off steam
supply with control valves regulating steam supply.
 Emergency stop valve are actuated by servo motor controlled by
protection system.
 Control valves are actuated by governing system through servo
motors to regulate steam supply.

Couplings
 Shaft is made in small parts due to forging limitation and other
technological and economic reason, so coupling is required
between any two rotors.
  Due to high torque flexible coupling can‟t be used. Hence rigid
coupling is used.
 Coupling is used between
 HPT & IPT
 IPT & LPT
 LPT & Generator
 Generator & Exciter
 MOP & HPT

Bearings
 General bearing---6no.s
 Thrust bearing---1no.
 Bearings are usually forced lubricated and have provision for
admission of jacking oil.

Barring Gear
 The primary function of barring gear is rotate the turbo
generator rotors slowly and continuously during startup and
shutdown periods when changes in rotor temperature occurs.
 Shaft system is rotated by double row blade wheel which is
driven by oil provided by AOP.
 A manual barring gear is also provided with hydraulic gear .
 Barring speed is 210/240 rpm.
 Turbine Vacuum System
Why vacuum is required?
 The steam turbine itself is a device to convert the heat in steam
to mechanical power.
 Enthalpy drop across the turbine decides the work output of the
turbine. For increasing this enthalpy drop across the turbine we
need effective condenser vacuum system.
 By condensing the exhaust steam of turbine, the exhaust
pressure is brought down below atmospheric pressure,
increasing the steam pressure drop between inlet and exhaust of
steam turbine. This further reduction in exhaust pressure gives
out more heat per unit weight of steam input to the steam
turbine, for conversion to mechanical power.

Components of Vacuum System

Condenser

 Steam from last stage of

LPT exhausts in condenser
tube.

 Condensation of steam
takes place here.

 Water is collected in hot

well.
 Fig. Condenser

Components of Condenser
 Condenser shell
 Air zone
 Tube sheets
 Water boxes
 Tubes
CW System

Fig. Part Section of a Natural Draught Cooling Tower

 CW pumps supply cooling water to condensers.

 CW maintains vacuum in condensers.
 CW flows through condenser tubes.
Steam Ejectors
 Air and water vapour are removed from the main steam
condenser, enter the 1st stage ejector and are compressed to the
interstage pressure by means of the high pressure motive steam.
 The load and motive steam are discharged to the inter
condenser and a portion of the water vapor load and motive
steam are condensed by condensate from the main condenser.
 Non-condensable and associated water vapor are removed from
the inter condenser by the 2nd stage ejector.

Fig. Steam Ejector

Vacuum Pumps
 The liquid-ring vacuum pump is a specific form of rotary
positive-displacement pump utilizing liquid as the principal
element in gas compression.
 The working parts of the liquid ring vacuum pump consist of a
multi-bladed impeller mounted eccentrically in a round casing
which is partly filled with liquid. As the impeller rotates, the
liquid is thrown by centrifugal force to form a liquid ring which
is concentric with the periphery of the casing.

Fig. LRVP
 Fig. Schematic of LRVP System

Turbine Condensate System

What is Condensate?
 The steam after condensing in the condenser known as
condensate is extracted out of the condenser hot well by
condensate pump and taken to the deaerator through ejectors,
gland steam cooler and series of LP heaters.

Components of Condensate System

Condensate Extraction Pump
 The function of these pumps is to pump out the condensate to
the deaerator through ejectors, gland steam cooler, and L.P.
heaters. These pumps have four stages and since the suction is at
a negative pressure, special arrangements have been made for
providing sealing.
 Fig. CEP Layout

Gland Steam Condenser

 Increases the temperature of condensate by exchanging heat
with the steam coming from the labyrinth seal glands of
turbines.

Condensate Polishing Unit (CPU)

 Removes cation and anion from the condensate. It has got mixed
bed resin.

D/A Level Controller

 Controls the level of water in deaerator (D/A).
Drain Cooler
 Increases the temperature of condensate by exchanging heat
with the normal drip from LPH-1. Here liquid-liquid heat
exchange takes place.

Low Pressure Heaters (LPH)

 Low Pressure Heater is a component used to pre-heat water
delivered to the boiler. Preheating the condensate water reduces
the amount of energy needed to make steam and thus reduces
plant operation costs. This improves the thermodynamic
efficiency of the system.
 The preheating is done using turbine bleed steam.
 There are 3 low pressure heaters in which LP turbine last
extractions are used.

Fig. Arrangement of L.P. Heaters

Deaerator and Feed Storage Tank (FST)
 The presence of certain gases, principally oxygen, carbon-di-
oxide and ammonia, dissolved in water is generally considered
harmful because of their corrosive attack on metals, particularly
at elevated temperatures. Function of deaerator is to remove
dissolved gases from the feed water (condensate) by mechanical
means. The deaerated water is stored in the Feed Storage Tank
(FST).

Fig. Deaerator and Feed Storage Tank (FST)

 Fig. Deaeration Procedure

Principle of Deaeration
 Henry’s Law: The mass of gas with definite mass of liquid
will dissolve at a given temperature and is directly
proportional to the partial pressure of the gas in contact with
the liquid. This holds within close limits for any gas, which
does not unite chemically with the solvent.

 Solubility Law: Solubility of gases decreases with increase in

solution temperature and/or decrease in pressure.
 FEED WATER SYSTEM

Fig. Layout of Feed Water System

Components of Feed Water System

Boiler Feed Pump
 Gives the required pressure to the feed water before entering
into boiler.
 Horizontal barrel type multi stage pump located at Zero meter
height.
Fig. BFP Layout
  There are three BFPs. Two of them are turbine driven
(TDBFP) and one is motor driven. Motor driven BFP is used
at startup.

Components of BFP
 Booster Pump
 Ensures a Net Positive Suction Head (NPSH) for Main
Feed Pump so as to save the costly Main Pump from any
damage caused due to cavitation.
 Maintains the continuous flow of feed water when the
valve to Economizer is closed.

 Suction Strainers
 Protects the Booster Pump and Main Pump against
catastrophic failure due to entry of coarse particles.

 Hydraulic Coupling
 Used to transmit power from motor to pump as per the
load requirement.

High Pressure Heaters (HPH)

 These are regenerative feed water heaters operating at high
pressure and located by the side of turbine. These are
generally vertical type and turbine bleed steam pipes are
connected to them.
 HP heaters are connected in series on feed waterside and by
such arrangement, the feed water, after feed pump enters the
HP heaters. The steam is supplied to these heaters form the
 bleed point of the turbine through motor operated valves.
These heaters have a group bypass protection on the feed
waterside.
 Feed water flows through the tube spirals and is heated by
steam around the tubes in the shell of the heaters.

Fig. H.P. Heaters Layout

 Feed Regulating Station(FRS)
 In order to ensure security of supply it has been considered
necessary to provide a multiple feed-water regulating valve
arrangement and on 200 MW units there is a 100% regulating
valve. In addition there are two smaller regulating valves for
low load conditions which can also be used for standby duty.

Fig. Schematic of FRS

Drip Pumps
 The bleed steam from the turbine does the work of reheating
in the regenerative heaters and gets condensed. This
condensation is termed as drip/ drain. Drip from the heaters is
further utilized for reheating.
 HP heaters drip is cascaded from the HPH6 to HPH5 and
then to deaerator with the help of the drip pumps.
 AUXILIARY STEAM SYSTEM

Sources
 Auxiliary boiler.
 Station PRDS header (from other running units).
 Under unit running condition steam for turbine auxiliary steam
header is normally taken from extraction lines depending on
load on the turbine.
 Main steam line through pr and temp reducing valves.
 CRH line.

Uses of Auxiliary Steam on Turbine side

 To turbine gland seal header.
 To ejector system of condenser (main as well as starting
ejector).
 To deaerator as pegging steam.
 For flange & stud heating.
 Interconnection to station PRDS header for supplying aux steam
to other units.

Uses of Auxiliary Steam on Boiler side

 Burner atomization, cleaning, scavenging.
 SCAPH charging during cold start up.
 Regenerative air heater sooth blowing.
Uses of Auxiliary Steam in Offsite
 HFO Station: Fuel oil system heating fuel, oil storage tanks,
pipelines, fuel oil heaters.

Fig. Auxiliary Steam Header

ASH HANDLING SYSTEM
What Is Ash?
 Ash is the residue remaining after the coal has been incinerated
to constant weight under standard conditions.
 Ash is oxidized form of the mineral matters present in coal.
 Typical ash composition: SiO2 , Al2 O3, Fe2O3 , CaO, MgO etc.
 Coal with more SiO2 & Al2O3 , Ash MP > 1400ºC
 Coal with more Fe2O3 , CaO & MgO, Ash MP < 1100ºC

Ash Statistics (Stage-II)

Approx. Coal Consumption (500mw) 340 T/Hr.

Proportion Of Ash In Coal 40 %

Approx. Ash Disposal 150 T/Hr.

IN TOTAL ASH :-

Bottom Ash 20 %
Fly Ash 80 %

TOTAL 100 %

APPROX. FLY ASH DISTRIBUTION :-

Eco And Eco-By-Pass Hoppers ≈ 6.25 %

Air Pre-Heaters ≈ 3.75 %

Esp Hoppers ≈ 90 %

TOTAL 100 %
 Fig. Ash Collection

Why Ash Handling?

 Ash content of Indian coal used in power station is about 30 to
40 %.
 A typical 2000 MW station produces around 9000T to 12000T
of ash per day.
 This huge amount of ash needs to be disposed off continuously.
 Necessary care to be taken for preventing pollution.
 Ash handling system take care the above requirement.
Bottom Ash (BA) Handling System
 20 % of the ash falls at the bottom of the furnace known as
Bottom Ash (BA). BA can form slag and clinker depending on
the temperature of the combustion zone and environment inside.
Reducing environment oxygen (Less O 2) reduces ash MP.
 BA can be collected at furnace bottom as Wet or Dry form.
 Wet bottom ash system consists of (i) Trough seal, (ii) BA gate,
(iii) Hopper, (iv) Scrapper Conveyer, (v) Clinker grinder, (vi)
BA trench, (vii) BA tank, (viii) BA pump and (ix) BA pond.
 Dry BA consists of (i) Trough seal, (ii) BA gate, (iii) Hopper,
(iv) Scrapper Conveyer, (v) Clinker grinder and (vi) Silo.
 Trough seal: A channel around the furnace bottom filled with
water where the furnace bottom end is immersed in water. This
is to prevent air ingression in the boiler during operation.

 BA Gate: Each hopper has separate gate to isolate Scrapper

conveyor from running furnace for any repairing at scrapper.
 Scrapper Conveyer: Consists of number of scrapper bars fasten
at both the ends with two chains which can run on chain pulley
and driven by scrapper conveyor motor. The whole conveyor is
submerged in water for wet BA system. Bottom ash after falling
on scrapper is scrapped away by the running conveyor to one
end of the conveyor to clinker grinder.

Fig. Schematic of Dry Bottom Ash Handling System

 Clinker grinder: Any big size ash clinker is crushed to enable to

be carried away by water jet through BA trench.
 BA trench: Through water jet ash slurry is carried away to BA
tank.
 BA pump: Ash slurry handling pump. It carries ash to the BA
pond. Depending on the distance of BA pond two or more BA
pumps connected in series. There are two BA supporting pumps
which are (i) LP BA pump and (ii) HP BA pump.
  BA pond: Finally ash is discharged to ash pond. It is a large area
surrounded by embankment. Ash mixed with water is allowed to
settle for considerable time. Water from top surface is allowed
to go out from the pond through a designed escape route.

Fig. Layout of Bottom Ash (BA) Handling System

Fly Ash (FA) Handling System

 FA is collected from Air Heater hopper, Eco hopper and ESP
hopper.
 Either through Flushing Apparatus or Hydrobactur system.
 In Flushing Apparatus system ash is allowed to fall in flushing
apparatus under gravitation.
  Water jet in flushing apparatus carries away the ash to FA
trench.
 High pressure jets further carries it to FA sump.
 Series pumping carries the ash slurry to FA pond.

Fly Ash Collection in ESP (Stage #2, TSTPS)

First Hopper 80%

Second Hopper 15 %
Third Hopper 3%
Fourth Hopper 0.8 %
Fifth Hopper 0.5 %
Sixth Hopper 0.31 %
Seventh Hopper 0.22 %
Eighth Hopper 0.13 %
Ninth Hopper 0.04 %
TOTAL 100 %

Dry FA Handling System

 Hydrobackter is a vacuum device to collect ash from the hopper.
 Water jet ejectors used for creating vacuum.
 Dry ash thus collected to silo through belt conveyor.
 Dry ash is disposed through road transport to a dry ash disposal
system. Part of it sold for commercial purpose.
 Fig. Ash Disposal System

Ash Utilization
 Fly ash bricks / blocks
 Cellular concrete products
 Concrete and mortar
 In manufacture of cement
 In manufacture of asbestos products
 Road construction
 Embankment/back fills/land development
 Controlled low strength material (CLSM)
 In agriculture
 Mine filling
 Manufacture of fertilizer
GENERATOR AND ITS
AUXILIARIES
 GENERATOR

Generator and its auxiliary can be broadly divided into four main
systems
 Generator
 Stator water system
 Gas system
 Seal oil system

Generators

Fig. Generator assembly

Main Parts of Turbo Generator
 Stator - Stator Frame (Fabrication & Machining)
 Core Assembly - Stator Core, Core Suspension Arrangement
 End Shield
 Stator Winding Assembly - Stator Winding, Winding Assembly,
Connecting Bus bar
 Rotor - Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor,
Rotor Assembly
 Completing Assembly - Bearing Assembly, Shaft Seal
Assembly, Oil Catchers, Insert Cover etc
 Exciter
 Auxiliary System

Specification of the Generator

Rated parameters (At rated H2 pressure and cooling water temp)

Max. Continuous kVA rating : 247000 kVA

Max. Continuous kW rating : 210000 kW
Rated terminal voltage : 15750 V
Rated stator current : 9050 A
Rated power factor : 0.85 lag
Excitation current at MCR conditions : 2600 A
Slip ring voltage at MCR conditions : 310 V
Rated speed : 3000 rpm
Rated frequency : 50 Hz
Efficiency at MCR conditions : 98.49%
Direction of rotation when viewed from slip ring end
: anti clock wise
Phase connection : double star
No. Of terminals brought out of stator :9
Over all stator diameter : 3960 mm
Length of stator : 4580 mm
Length of rotor : 9770 mm

Weight of stator : 175 kg (Heaviest)

Weight of rotor : 42,200 kg
Total wt. of generator : 239 kg

Fig. Main Parts of a Turbo Generator

Turbo Generator Construction
Construction of generator is essentially manufactured of
component parts which are assembled partly at manufacturer‟s works
and partly at site.
It is usual to consider the machine in two major components:

Frame

1. Stator magnet core

Windings
2. Rotor

Stator Body
 Fabricated gas tight steel structure suitably ribbed internally.
 Can with stand explosion pressure of hydrogen air mixture
without any residual deformation.
 Hydrogen gas coolers housed longitudinally inside stator body.
 End shields for closing casing and supporting fan shields and
shaft seals.

Stator core
 It provides path for machine‟s magnetic flux and has slots in
which windings are assembled.
 Made up of segmental, varnish insulated punching of cold rolled
grain oriented silicon steel
  It consists of several packets separated by steel spacers for
radical cooling of the core by hydrogen.
 Thickness of laminations used iss 0.013” – 0.014”. 1-1/2 – 2-
1/2” thick packets separated by radial cooling ducts to provide
passage for hydrogen.
* Core bars are designed to provide elastic suspension of core in
the stator.

Fig. Stator Core Assembly

Stator Winding
 Three phase windings in two layers of individual bars
 Coil groups connected to Connecting Bus bar and finally to
Terminal
 Bushing
  Involute shape at the end of bar helps withstands various forces
 Micalastic Insulation System (VPI process)
 Micalastic good conductor of heat
 Low flammability
 High resistance to moisture and chemical action
 Accommodates thermo-mechanical stresses
 Retains properties even after years of operation

Rotors
Rotors form the centre of the generator. Their relative motion
with respect to the stator causes change in magnetic flux leading to
generation of E.M.F. by virtue of electromagnetic induction.
Following are some of the features of rotors:
 A high strength alloy steel single forging prepared by vacuum
cast steel
 Slots for housing field windings
 Strong coupling for withstanding short circuit forces
 Bending critical speed away ±5% of operating speed
 Supported on two journal Bearings
 Provision of axial fan/compressor for forced ventilation
 Provision of damper wedges for increasing negative sequence
capability of rotor
Field Winding
Field windings are made from hard drawn silver bearing copper.
The rotor windings are held in position against centrifugal forces by
duralumin wedges in slot portion and by non-magnetic steel retaining
rings in overhand portion. Gas pick up system is employed for direct
cooling of rotor winding.
Slot insulation is in the form of u-trough made of glass cloth
impregnated with epoxy resins. Inter turn insulation – layers of perpex
glass cloth glued to each conductor and consolidated in regulated
conditions of temperature and pressure. End windings packed with
blocks of glass laminates to separate and support the coils and to
restrict their movement due to thermal and rotational forces.

Shaft mounted fans and cooling

Two propeller type fans are shaft mounted of either side of rotor
body for circulating cooling gas inside generator.
Special ducts (fins) are also provided in the rotor body, through
which the cooling gas flows to the rotor end windings.

Stator Water System

 Stator water cooling is a closed loop system.
 There are two full capacity single stage centrifugal pumps with
change over facility.
 The pumps are driven by 3Ph. 415V A.C. motors.
 The stator water cooler is shell and tube type heat exchanger.
 DM water flows through shell.
 Thermal capacity of water as liquid is high. Pure water has high
electrical resistance / low conductivity.
 There are two mechanical filters and one magnetic filters
 Mechanical filters are of wire mesh type
 Magnetic filter is having permanent magnet
 The expansion tank is a hermetically sealed container made of
S.S.
 Float valve is there in the expansion tank to maintain water level
in the tank which act as suction storage tank for stator water
pumps.
 Polishing unit (mixed bed ion exchanger) is there to maintain
conductivity of stator water to desired level.

STATOR WATER SYSTEM

EXPANSION FLOW
TANK METERS
GAS TRAP
DIFF PRESS
SWITCH
MAGNET
FILTER FILTERS

FSI
DIFF PRESS. I

CONDUCTIVITY
POLISH UNIT
MAKE
UP
COOLERS

PUMPS
VACUUM
PUMPS 16 June 2011
PMI Revision 00 3

Fig. Stator Water System

 Fig: Cooling Water Header of Water

Gas Cooling
Hydrogen Cooling
Advantages
 High heat transfer co-efficient
 Low density, so low windage-friction loss
 H2 is lightest gas with 0.09 gm / liter while air‟s 1.3 i.e. 14.4
times.
 Thermal capacity of H2 as gas is high.
 Thermal conductivity of H2 is 5 times that of air.
 Disadvantages
 Moisture and dew point in Generator casing
 Explosive mixture with air

Fig. Hydrogen gas system

THDF Cooling Mechanism: Ventilation Scheme

 Gas flow path 1 enters rotor on Turbine end and cools rotor
overhang and slots.
 Gas flow path 2 cools stator core.
 Gas flow3enters rotor on exciter end & cools rotor overhang &
slots, as well as stator core end parts at both the ends.
 Hot gas from all paths returns through air gap to compressor,
and to coolers.

THDF: VENTILATION SCHEME - 2

16 June 2011 PMI Revision 00 30

Fig: THW 210/235: Rotor Shaft

Seal Oil System
Generator shaft seals are supplied with pressurized seal oil to
prevent leakage of hydrogen gas from the generators. This seal oil is
provided by means of a seal oil system which has the following
characteristics:

Fig. Schematic of Seal Oil System

 Oil pressure is kept higher than the gas pressure.

 There are one AC seal oil pp. and one DC seal oil pp. which
feed oil to the seal through cooler and filter.
 Both the seal oil pumps are 100% capacity screw type pump.
 A vacuum pump is provided to maintain vacuum in seal oil tank.
 There is a additional facility to supply seal oil from governing
oil.
 The seal oil pressure to the seal is controlled by DPR which
maintain specified DP between oil and hydrogen.
 Thrust oil is there to hold the seal ring in position against gas
pressure.
 Two seal oil coolers having 100% capacity is provided to cool
the oil.
 Duplex filter is provided in the oil line.
 Vacuum pump evacuates gases from SOT.
SWITCHYARD
What is a Switchyard?
It is a switching station which has the following credits:
 Main link between generating plant and transmission
system, which has a large influence on the security of the
supply.
 Step-up and/or Step-down the voltage levels depending
upon the Network Node.
 Switching ON/OFF Reactive Power Control devices, which
has effect on quality of power.

Bus Switching Schemes

 Bus Bar Schemes
 Single Sectionalized bus
 Main & Transfer bus
 Sectionalized Main bus with Transfer bus
 Sectionalized Double Main & Transfer bus
 Breaker Schemes
 Ring bus
 One and Half breaker
 Double bus Double breaker

Factors effecting the selection of Switching Scheme

 System Security
 Operational Flexibility
 Simplicity of Protection arrangements
 Ability to limit the Short Circuit levels
 Maintenance
 Ease of extension
 Total land area
 Cost
Fig. Single Sectionalized Bus-bar system

Fig. Main & Transfer Bus-bar system

 Fig. Ring Bus system

Fig. One and Half Breaker scheme

 Fig. Switchyard Single Line Diagram

Switchyard Equipments
Isolators
 Operates under no load condition
 Interlocked with breakers and earthswitches
 Should withstand extreme wind pressures
 Motor driven and hand driven
 Local as well as remote operation possible
 Isolates sections for maintenance
  Used to select bus bars
 CT switching for bus bar protection

Fig. Isolator

Voltage Transformers
  The purpose of voltage transformer is to step-down the high
magnitude of voltage to a safe value to incorporate Measuring
and Protection logics.

Current Transformers
 The purpose of voltage transformer is to step-down the high
magnitude of current to a safe value to incorporate Measuring
and Protection logics.

Capacitive Voltage Transformer (CVT)

 Primary voltage is applied to a series of capacitors group. The
voltage across one of the capacitor is taken to aux PT. The
secondary of the aux PT is taken for measurement and
protection.

Fig. CVT Internals

Circuit Breaker
 Makes or automatically breaks the electrical circuits under
loaded condition.

Fig. Air Blast Circuit Breaker (ABCB)

Fig. Principle of arc quenching in ABCB

Earth Switches
 Used to ground sections required for maintenance
 Ground induction voltages
 Interlocked with breakers and isolators
 Can operate from local only
 Motor driven as well as hand driven
 Safety device

Fig. Construction of an Earth Switch

 Fig. Earth Switch of TSTPS

Wave Trap
 Wave trap is used for Protection of the transmission line and
communication between the Substations.
 VHF signal is transmitted from one end to another through the
same power line.
 Sends inter-trip signal to the other end CBs so that fault can be
isolated at the earliest time.

Fig. Basic Arrangement of Wave Trap and Coupling Capacitor

Lightning Arrestors
 The purpose of Lightning Arrestors is to discharge the high
voltage surges in the power system due to lightning to the
ground.
 Apparatus to be protected :
 Overhead lines………Earth/Ground wires (PA=30 deg)
 HV equipment………Las
 Substation…………...Lightning Masts, Earth wires.

Fig. Lightning Arrestor

Overhead Earth Wire

 Protects the O/H transmission line from Lightning strokes.
Bus Bar
 Conductors to which a number of circuits are connected.

Reactive Power Control Devices

 Controls the reactive power imbalance in the grid by switching
ON/OFF the Shunt Reactors, Shunt Capacitors etc.

Current Limiting Reactors

 Limits the Short circuit currents in case of faulty conditions.

Modes of Transmission
AC Transmission
Advantages
 Power can be generated at high voltages.
 Step-up/Step-down is possible.

Disadvantages
 Requires more copper.
 Due to Skin effect, the effective resistance is increased.
 Continuous loss of power due to charging current even
when the line is open.
 Requirement of Transposition of conductors.
DC Transmission
Advantages
 Low cost due to less copper requirement.
 No Stability and synchronizing problems.
 Asynchronous lines (Interregional ties).
 No increase in Fault level if interconnected.
 Less Corona and RI.
 Better Voltage regulation due to absence of Inductance.
 Requires less insulation as the potential stress is less.

Disadvantages
 Higher generation is not possible due to commutation.
 Step-up/Step-down is not possible.
 Limitations in HVDC CBs, switches etc.
\