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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.
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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
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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