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A Practical Training Report On Submitted in partial fulfillment for the award of the degree of BACHELOR OF ENGINEERING In Mechanical Engineering Submitted by:- Patel Vishal V. Patel Harshad B. 110750119018 110750119001 SEM: - VII SEM:- VII Shankersinh Vaghela Bapu Institute Of Technology, vasan, Gandhinagar Gujarat Technology University

TPS training report Gandhinagar, coal base power plant

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Page 1: TPS training report Gandhinagar, coal base power plant

A Practical Training Report

On

Submitted in partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING In

Mechanical Engineering

Submitted by:-

Patel Vishal V. Patel Harshad B. 110750119018 110750119001

SEM: - VII SEM:- VII

Shankersinh Vaghela Bapu Institute Of Technology,

vasan, Gandhinagar

Gujarat Technology University

Page 2: TPS training report Gandhinagar, coal base power plant

PREFACE

A student gets theoretical knowledge from classroom and gets practical knowledge from industrial training. When these two aspects of theoretical knowledge and practical experience together then a student is full equipped to secure his best. In conducting the project study in an industry, students get exposed and have knowledge of real situation in the work field and gains experience from them. The object of the winter training cum project is to provide an opportunity to experience the practical aspect of Technology in any organization. It provides a chance to get the feel of the organization and its function.

The fact that thermal energy is the major source of power generation itself shows the importance of thermal power generation in India – more than 60 percent of electric power is produced by steam plant in India.

In steam power plants, the heat of combustion of fossil

fuels is utilized by the boilers to raise steam at high pressure and

temperature. The steam so produced is used in driving the steam

turbine coupled to generators and thus in generating ELECTRICAL

ENERGY

Page 3: TPS training report Gandhinagar, coal base power plant

1. INTRODUCTION TO THE POWER PLANT Electricity is the only form of energy which is easy to produce, easy to transport, easy to use and easy to control. So, it is mostly the terminal of energy for transmission and distribution. Electricity consumption per capita is the index of the living standard of people of place or country.

Electricity Demand and Supply in India: India is facing energy shortages of 11% of demand and even higher peak shortages of 14%Demand-supply gap is more acute in Western region (where 70% of the Project’s power will be supplied) with energy deficit at 16% and peak deficit at 21% Capacity additions of 160,000 MW required in the next 10 years to meet India’s power demand. New capacity need to be added using a combination of coal, hydro, gas, nuclear and wind projects Types of Power Plants: Electricity in bulk quantities is produced in power plants, which can be of the following types:

Thermal

Nuclear

Hydraulic

Gas turbine

Geothermal

Page 4: TPS training report Gandhinagar, coal base power plant

India’s Installed Capacity (233930 MW)

Page 5: TPS training report Gandhinagar, coal base power plant

2. A VIEW OF GANDHINAGAR TPS

Page 6: TPS training report Gandhinagar, coal base power plant

3. DIAGRAM OF A TYPICAL COAL-FIRED THERMAL

POWER STATION

1. Cooling tower 10. Steam Control valve 19. Superheater 2. Cooling water pump 11. High pressure steam turbine 20. Forced draught (draft) fan 3. transmission line (3-phase) 12. Deaerator 21. Reheater 4. Step-up transformer (3-phase) 13. Feed water heater 22. Combustion air intake 5. Electrical generator (3-phase) 14. Coal conveyor 23. Economiser 6. Low pressure steam turbine 15. Coal hopper 24. Air preheater 7. Condensate pump 16. Coal pulveriser 25. Precipitator 8. Surface condenser 17. Boiler steam drum 26. Induced draught (draft) fan 9. Intermediate steam turbine 18. Bottom ash hopper 27. Flue gas stack

Page 7: TPS training report Gandhinagar, coal base power plant

1. COAL YARD.

In the coal yard the wagon full of coal is emptied automatically.

In this first the wagon is sprayed of water.

Then the wagon is clamped by horizontal and vertical clamp.

Then the dc motors rotates the bridge and the coal is emptied from

the wagon.

The floor is at 40m depth.

Then the bridge came into original position.

The rack pulls out the wagon from the track.

The rack is worked by motor.

Page 8: TPS training report Gandhinagar, coal base power plant

2. COAL CRUSHER.

The coal crusher is used to crush the coal.

From the floor the rack pull out the coal.

In the crusher there is one mill which crack the large stone of coal.

There is magnet used to pull out the metal particles present in the

coal.

There is always 2 gates are used.

One in working condition while another is in stand by.

From the crusher the coal is stored in the bunker or either on the

ground.

The continues water is sprayed on the coal.

Due to property of the coal the coal burn in the air so the water

spray is required.

The JCB is used to supply coal to bunker from ground storage.

3. BUNKER

The bunker is the one type of storage.

The belt is used to pull out the coal from crusher.

The depth of the bunker is 12m.

8m cylindrical and 4m conical shape.

From the bunker the coal enters into the feeder.

From the feeder the coal enter into the coal mill.

Page 9: TPS training report Gandhinagar, coal base power plant

4. COAL MILL

The coal needed to be fine particles to burn efficiently.

The size of the coal particles are 200-400 mesh.

The mesh is unit which is described as the parts per square inch.

Here the bowl type coal mill used.

The saucer type bed is rotating with the help of motor.

From the feeder the centrally located pipe feed the coal into mill.

The roller is used to crush the coal.

While the coal crushed from the mill is of size of 200-400 mesh.

The P.A. Fan blows the air from the bottom and fly out the crushed

coal into the boiler from the mill.

The 4 pipe is used as outlet.

The metal particles and another heavy particles are diffused away

at bottom.

The excitation force is provided to the roller from behind.

The nitrogen shock absorber tank is also used to absorb the shock

on the roller.

The lubrication is required in the roller.

The lubrication pump is existing there.

The coal is prevented to enter into the bearing so seal pump is also

used.

The speed of the coal crushed in the mill is managed by managing

the speed of the feeder.

Coal is grounded to powdery form in bowl mill. This finely

grounded coal is known as pulverized coal. Bowl mill consists of a

round metallic table and three rollers. Rotating table is made to

rotate with the help of a motor. There are three large rollers which

are at a spacing of 120°.When there is no coal these rollers does

not rotate but when coal is fed to the table it packs between the

Page 10: TPS training report Gandhinagar, coal base power plant

table and the roller and this forces the rollers to rotate. Coal is

crushed by the crushing action between table and rollers.

This pulverized coal is taken to the burner in coal pipes with the

help of hot and cold air mixture from primary air (PA) fan.

TECHNICAL DATA:

No. of coal mills: 6 Nos.

Maximum capacity : 45 TPH

Mill speed : 26.4 rpm

No. of coal Bunkers : 6 Nos

Mill type : Medium speed vertical grinder roller

Coal fineness : 75 μ

Capacity of coal feeder : 50 TPH

Outlet PA / Coal temp. : 85° C

Fig. coal mill inside view

Page 11: TPS training report Gandhinagar, coal base power plant

Fig. coal mill inside view

Page 12: TPS training report Gandhinagar, coal base power plant

5. BOILER

Now that pulverized coal is put in boiler furnace.

Boiler is an enclosed vessel in which water is heated and

circulated until the water is turned in to steam at required

pressure.

Coal is burned inside the combustion chamber of boiler.

The products of combustion are nothing but gases.

These gases which are at high temperature vaporize the water

inside the boiler to steam.

Sometimes this steam is further heated in a super heater as

higher the steam pressure and temperature the greater efficiency

the engine will have in converting the heat in steam in to

mechanical work.

This steam at high pressure and temperature is used directly as a

heating medium, or as the working fluid in a prime mover to

convert thermal energy to mechanical work, which in turn may

be converted to electrical energy.

Although other fluids are sometimes used for these purposes,

water is by far the most common because of its economy and

suitable thermodynamic characteristics.

There are two types of boiler in the power plant subcritical &

supercritical 330MW unit have subcritical boiler and 660MW

unit have supercritical boilers.

Page 13: TPS training report Gandhinagar, coal base power plant

Rankine Cycle

• The “efficiency “of the thermodynamic process is the heat energy

fed into the Rankine cycle is converted into electrical energy.

• Heat energy input to the Rankine cycle is kept constant, the output

can be increased by selecting high pressures and high

temperatures.

• The key components are supercritical once through boiler and high

pressure & high temperature steam turbine.

Fig. Rankine cycle

1 – 2 > CEP work

2 – 3 > LP heating

3 – 4 > BFP work

4 – 5 > HP heating

5 – 6 > Eco. WW

6 – 7 > superheating

7 – 8 > HPT work

8 – 9 > Reating

9 – 10 > IPT work

10 – 11 > LPT work

11 – 1 >Condensing

Page 14: TPS training report Gandhinagar, coal base power plant

Boiler design:

Fig. Boiler inside View

Page 15: TPS training report Gandhinagar, coal base power plant

Boiler Components: Water Walls

Separator

Economiser

Superheater

Reheater

A DETAILED VIEW OF SUPERCRITICAL BOILER

Fig Detail view of Boiler

Page 16: TPS training report Gandhinagar, coal base power plant

Water Walls /Evaporator

• The furnace circuitry consists of a lower section with optimized,

vertical rifled tubes that extend up to transition headers located at

an elevation below the furnace nose.

• The transition headers are interconnected to provide pressure

equalization to minimize flow unbalances and provide circuit flow

stability.

• Above the transition header location, vertical smooth bore tubes

extend up to the furnace roof, and also form the furnace exit screen

and part of the vestibule side walls.

• The tube panels that form the furnace enclosure are of Monowall

type construction. Risers pipes extend from the furnace enclosure

upper headers and are routed to a collection manifold from which

the flow is directed to a final evaporator zone that forms the

furnace nose, vestibule floor and approximately half of the

vestibule sidewalls.

• The furnace enclosure tube size and spacing were selected to

provide a low mass flux (nominally 1000 kg/m2-s at full load) to

provide a “natural circulation” flow characteristic (as will be

described in a subsequent section) to accommodate radial heat

absorption variations around the perimeter of the furnace.

• Tube sizes and spacing, membrane fin sizes, and materials are all

selected to provide for base load service as well as the defined

cyclic operation of the plant.

• The final evaporator zone that forms the furnace nose, vestibule

floor, and part of the vestibule sidewalls is provided to act as a

buffer circuit to minimize tube temperature differentials between

the furnace evaporator walls and the adjacent HRA enclosure

superheater panels during start-up and transient conditions.

• The interface between evaporator and superheater tubes is

positioned near the center of the vestibule to avoid structural

discontinuities such as enclosure corners where stress

concentrations are the greatest.

Page 17: TPS training report Gandhinagar, coal base power plant

• From the vestibule enclosure, steam is directed to four in-line

steam/water separators connected in parallel, which are part of the

start-up system, which is described below.

Fig Boiler wall

Page 18: TPS training report Gandhinagar, coal base power plant

SEPARATOR

• Subcritical boilers are consisting of drum arrangement and

supercritical boilers are consisting of separator. The separators are

once through arrangement.

ECONOMISER

• An economizer is a heat exchanger which raises the temperature of

the feedwater leaving the highest pressure feed water heater to

about the saturation temperature corresponding to the boiler

pressure.

• This is done by the hot flue gases exiting the last superheater or

reheater at a temperature varying from 370`C to 540`C. The

throwing away of such high temperature gases involved a great

deal of energy loss.

• By utilizing these gases in heating feedwater, higher efficiency and

better economy were achieved.

• The flue gases coming out of the boiler carry lot of heat. An

economiser extracts a part of this heat from the flue gases and uses

it for heating the feed water before it enters into the steam drum.

• The use of economiser results in saving fuel consumption and

higher boiler efficiency but needs extra investment. In an

economizer, a large number of small diameter thin walled tubes are

placed between two headers. Feed water enters the tubes through

the other. The flue gases flow outside the tubes.

Page 19: TPS training report Gandhinagar, coal base power plant

Fig. Economizer

Page 20: TPS training report Gandhinagar, coal base power plant

SUPERHEATER

• The superheater is a heat exchanger in which heat is transferred to

the saturated steam to increase its temperature. It raises the overall

cycle efficiency.

• In addition it reduces the moisture content in the last stages of the

turbine and thus increases the turbine internal efficiency.

• In modern utility high pressure boilers, more than 40% of the total

heat absorbed in the generation of steam takes place in the

superheaters. So, large surface area is required to be provided for

superheating of steam.

Fig. Super heater

Page 21: TPS training report Gandhinagar, coal base power plant

Fig. Inside View of super heater in Boiler

Page 22: TPS training report Gandhinagar, coal base power plant

REHEATER:

• Some of the heat of superheated steam is used to rotate the turbine

where it loses some of its energy.

• Reheater is also steam boiler component in which heat is added to

this intermediate-pressure steam, which has given up some of its

energy in expansion through the high-pressure turbine.

• The steam after reheating is used to rotate the second steam turbine

where the heat is converted to mechanical energy.

• This mechanical energy is used to run the alternator, which is

coupled to turbine, there by generating electrical energy.

• Fig. Reheater

Page 23: TPS training report Gandhinagar, coal base power plant

Main Steam, water, air flow of plant

Page 24: TPS training report Gandhinagar, coal base power plant

DRAUGHT SYSTEM

Large amount of air is required for combustion of fuel. The gaseous

combustion products in huge quantity have also to be removed

continuously from the furnace. To produce the required flow of air or

combustion gas, a pressure differential is needed. The term “draught” or

“draft” is used to define the static pressure in the furnace, in the various

ducts, and the stack.

The function of the draught system is basically two folds:

• To supply to the furnace the required quantity of air for complete

of fuel.

• To remove the gaseous products of combustion from the furnace

and throw these through chimney or stack to the atmosphere.

• There are two ways of producing draught:

• Natural draught

• Mechanical draught

Natural Draught: The natural draught is produced by a chimney or a

stack. It is caused by the density difference between the atmospheric air

and the hot gas in the stack.

Mechanical Draught: Mechanical draught is produced by fans.

Induced and Forced Draught Fans:

• Big fans may be used for sucking and throwing out the flue gas

through the chimney, thereby creating adequate draught inside the

furnace.

• Such Fans are termed as Induced Draught Fans. Forced draught

Fans may also be deployed for supply of required quantity of

Page 25: TPS training report Gandhinagar, coal base power plant

combustion air and maintaining a positive draught inside the

furnace.

• The flue gas will be pushed out the stack with the draught pressure

available in the furnace.

FORCED DRAUGHT FAN:

• Air drawn from atmosphere is forced into the furnace, at a pressure

higher than the outside atmosphere, by big centrifugal fan or fans

to create turbulence and to provide adequate Oxygen for

combustion.

• Hence the system is known by the name Forced draught system

and the fan, used to push through combustion air under pressure, is

called Forced Draught Fan. F D fan is normally located at the front

or sideways of the furnace.

Fig. FD Fan

Page 26: TPS training report Gandhinagar, coal base power plant

INDUCED DRAUGHT FAN:

• Instead of drawing atmospheric air and pushing through furnace, a

centrifugal fan can be deployed to draw out the air from the

furnace and throw out through the chimney, thereby creating

negative pressure in the combustion zone and maintain the

negative draught through out the furnace.

• The system is called Induced Draught system and the fan deployed

for this purpose is known as Induced Draught Fan.

• In the Induced Draught system, the fan is fitted at back end of the

furnace or near the base of the chimney.

• Due to the negative pressure created inside the furnace, by the

action of the fan, flue gas will not come out of combustion space

i.e. Furnace.

• The entry of air to Boiler is regulated through air registers and

dampers.

• For similar capacity boilers, the size of an induced draught fan will

be more than the size of the forced draught fan required for a

forced draught system.

• This is because the products of combustion is always much higher

in volume than the volume of combustion air handled by the forced

draught fan.

• Further the flue gas is hotter and the density is less. Hence the

volume is much more.

• According to Charles Law, when a gas is heated the volume will

proportionately increase at constant pressure, with the raise in

temperature.

• According to Boyles Law, if pressure inside a vessel is increased,

the volume will proportionately decrease and the vice-versa is also

true (P ∝ 1/V).

Page 27: TPS training report Gandhinagar, coal base power plant

Fig. ID Fan

Page 28: TPS training report Gandhinagar, coal base power plant

PRIMARY AIR FAN:

• These are the large high pressure fans which supply the air needed

to dry and transport coal either directly from the coal mills to the

furnace or to the intermediate bunker.

• These fans may be located before or after the milling equipment.

The most common applications are cold primary air fans, hot

primary air fans.

• The coal primary air fan is located before air heater and draws air

from the atm. And supplies the energy required to force air through

air heaters, ducts, mills and fuel piping.

• With a cold air system like this the FD fan may be made smaller as

PA fan supply part of combustion air.

• For primary air fans boosts the air pressure from air heaters for

drying and transporting coal from pulverisers in these systems the

total air has to be handled by FD fans and each mill will be

provided with a primary air fan at the mill inlet side the primary

fan in these case has to handle hot air probably with some amount

of fly ash carried from the air pre-heater.

AIR PREHEATER:

• Air preheater are in generally divided into following two types:

Recuperative

Regenerative

• In Recuperative APH, heat is directly transferred from the hot

gases to the air across the heat exchanging surface.

• They are commonly tubular, although some plate types are still in

use. Tubular units are essentially counter-flow shell-and-tube heat

exchangers in which the hot gases flow inside the vertical straight

tubes and air flows outside.

Page 29: TPS training report Gandhinagar, coal base power plant

• Baffles are provided to maximize air contact with the hot tubes.

• Regenerative APH are also known as storage type heat exchangers,

have an energy storage medium, called the matrix, which is

alternately exposed to the hot and cold fluids. When the hot flue

gases flow through the matrix in the first half of the cycle, the

matrix is heated and the gas is cooled. In the next half of the cycle

when air flows through the matrix, air gets heated and the matrix is

cooled. The cycle repeats itself.

Fig. Air Preheater

DEAERATOR:

• A steam generating boiler requires that the boiler feed water should

be devoid of air and other dissolved gases, particularly corrosive

ones, in order to avoid corrosion of the metal.

• Generally, power stations use a Deaerator to provide for the

removal of air and other dissolved gases from the boiler feed

water. A deaerator typically includes a vertical, domed deaeration

Page 30: TPS training report Gandhinagar, coal base power plant

section mounted on top of a horizontal cylindrical vessel which

serves as the deaerated boiler feed water storage tank.

Fig. Deaerator

Page 31: TPS training report Gandhinagar, coal base power plant

6. STEAM TURBINE:

INTRODUCTION:-

• Turbine is a machine in which a shaft is rotated steadily by impact

or reaction of current or stream of working substance (steam, air,

water, gases etc) upon blades of a wheel.

• It converts the potential or kinetic energy of the working substance

into mechanical power by virtue of dynamic action of working

substance. When the working substance is steam it is called the

steam turbine.

Fig. Inside View of Turbine

Page 32: TPS training report Gandhinagar, coal base power plant

PRINCIPAL OF OPERATION OF STEAM TURBINE:-

• Working of the steam turbine depends wholly upon the dynamic

action of Steam. The steam is caused to fall in pressure in a

passage of nozzle: doe to this fall in pressure a certain amount of

heat energy is converted into mechanical kinetic energy and the

steam is set moving with a greater velocity.

• The rapidly moving particles of steam, enter the moving part of the

turbine and here suffer a change in direction of motion which gives

rose to change of momentum and therefore to a force.

• This constitutes the driving force of the machine. The processor of

expansion and direction changing may occur once or a number of

times in succession and may be carried out with difference of

detail.

• The passage of steam through moving part of the commonly called

the blade, may take place in such a manner that the pressure at the

outlet side of the blade is equal to that at the inlet inside.Such a

turbine is broadly termed as impulse turbine.

• On the other hand the pressure of the steam at outlet from the

moving blade may be less than that at the inlet side of the blades;

the drop in pressure suffered by the steam during its flow through

the moving causes a further generation of kinetic energy within the

blades and adds to the propelling force which is applied to the

turbine rotor. Such a turbine is broadly termed as impulse reaction

turbine.

• The majority of the steam turbine have, therefore two important

elements, or Sets of such elements.

• These are the nozzle in which the system expands from high

pressure end a state of comparative rest to a lower pressure end a

status of comparatively rapid motion.

• The blade or deflector, in which the steam particles changes its

directions and hence its momentum changes .

• The blades are attach to the rotating elements are attached to the

stationary part of the turbine which is usually termed the stator,

casing or cylinder.

Page 33: TPS training report Gandhinagar, coal base power plant

• Although the fundamental principles on which all steam turbine

operate the same, yet the methods where by these principles

carried into effect very end as a result, certain types of turbine have

come into existence.

1. Simple impulse steam turbine.

2. The pressure compounded impulse turbine.

3. Simple velocity compounded impulse turbine.

4. Pressure-velocity compounded turbine.

5. Pure reaction turbine.

6. Impulse reaction

Fig Turbine Stage

Page 34: TPS training report Gandhinagar, coal base power plant

7. DESCRIPTION OF STEAM TURBINES:-

HP TURBINE:-

• The HP casing is a barrel type casing without axial joint. Because

of its rotation symmetry the barrel type casing remain constant in

shape and leak proof during quick change in temperature.

• The inner casing too is cylinder in shape as horizontal joint flange

are relieved by higher pressure arising outside and this can kept

small. Due to this reason barrel type casing are especially suitable

for quick start up and loading.

• The HP turbine consists of 25 reaction stages. The moving and

stationary blades are inserted into appropriately shapes into inner

casing and the shaft to reduce leakage losses at blade tips.

Fig. HP Turbine

IP TURBINE:-

• The IP part of turbine is of double flow construction. The casing of

IP turbine is split horizontally and is of double shell construction.

Page 35: TPS training report Gandhinagar, coal base power plant

The double flow inner casing is supported kinematically in the

outer casing.

• The steam from HP turbine after reheating enters the inner casing

from above and below through two inlet nozzles.

• The centre flows compensates the axial thrust and prevent steam

inlet temperature affecting brackets, bearing etc.

• The arrangements of inner casing confines high steam inlet

condition to admission branch of casing, while the joints of outer

casing is subjected only to lower pressure and temperature at the

exhaust of inner casing.

• The pressure in outer casing relieves the joint of inner casing so

that this joint is to be sealed only against resulting differential

pressure.

• The IP turbine consists of 20 reaction stages per flow. The moving

and stationary blades are inserted in appropriately shaped grooves

in shaft and inner casing.

Fig. IP Turbine

LP TURBINE:-

• The casing of double flow type LP turbine is of three shell design.

The shells are axially split and have rigidly welded construction.

Page 36: TPS training report Gandhinagar, coal base power plant

• The outer casing consist of the front and rear walls , the lateral

longitudinal support bearing and upper part.

• The outer casing is supported by the ends of longitudinal beams on

the base plates of foundation.

• The double flow inner casing consist of outer shell and inner shell.

The inner shell is attached to outer shell with provision of free

thermal movement.

• Steam admitted to LP turbine from IP turbine flows into the inner

casing from both sides through steam inlet nozzles.

Fig. LP Turbine

LOSSES IN STEAM TURBINE: • Friction losses

• Leakage losses

• Wind age loss( More in Rotors having Discs)

• Exit Velocity loss

• Incidence and Exit loss

• Secondary loss

• Loss due to wetness

• Loss at the Bearings (appx 0.3% of total output)

• Off design losses

Page 37: TPS training report Gandhinagar, coal base power plant

MAIN LOSSES IN TURBINE: FRICTION LOSS:

• It is more in Impulse turbines than Reaction Turbines,because impulse

turbines uses high velocity of steam and further the flow in the moving blades of the Reaction turbines is accelerating which leads to better and

smooth flow(Turbulent flow gets converted to Laminar flow)

LEAKAGES LOSS:

It is more in Reaction turbines than Impulse turbines because there is

Pressure difference across the moving stage of reaction turbines which

leads to the Leakages. In Impulse turbine such condition is not there.

• Leakage loss predominates over friction losses in the High

Pressure end of the Turbine

• Friction Losses predominates over the Leakage's Loss in the Low

Pressure end of the Turbine.

• It is observed that the Efficiency of The IP Turbine is the

maximum followed by The HP and LP Turbine.

Page 38: TPS training report Gandhinagar, coal base power plant

8. CONDENSER:

• Steam after rotating steam turbine comes to condenser. Condenser

refers here to the shell and tube heat exchanger (or surface

condenser) installed at the outlet of every steam turbine in Thermal

power stations of utility companies generally. These condensers

are heat exchangers which convert steam from its gaseous to its

liquid state, also known as phase transition.

• In so doing, the latent heat of steam is given out inside the

condenser. Where water is in short supply an air cooled condenser

is often used.

• An air cooled condenser is however significantly more expensive

and cannot achieve as low a steam turbine backpressure (and

therefore less efficient) as a surface condenser.

• The purpose is to condense the outlet (or exhaust) steam from

steam turbine to obtain maximum efficiency and also to get the

condensed steam in the form of pure water, otherwise known as

condensate, back to steam generator or (boiler) as boiler feed

water.

Fig. Condenser

Page 39: TPS training report Gandhinagar, coal base power plant

9.COOLING TOWERS :

• The condensate (water) formed in the condenser after condensation

is initially at high temperature. This hot water is passed to cooling

towers.

• It is a tower- or building-like device in which atmospheric air (the

heat receiver) circulates in direct or indirect contact with warmer

water (the heat source) and the water is thereby cooled.

• A cooling tower may serve as the heat sink in a conventional

thermodynamic process, such as refrigeration or steam power

generation, and when it is convenient or desirable to make final

heat rejection to atmospheric air.

• Water, acting as the heat-transfer fluid, gives up heat to

atmospheric air, and thus cooled, is recalculated through the

system, affording economical operation of the process

COOLING TOWER:

• Inlet water temperature : 60 °C

• Outlet water temperature : 35 °C

Page 40: TPS training report Gandhinagar, coal base power plant

Fig. Cooling Tower

Page 41: TPS training report Gandhinagar, coal base power plant

10. ELECTROSTATIC PRECIPITATOR(ESP) :

• It is a device which removes dust or other finely divided particles

from flue gases by charging the particles inductively with an

electric field, then attracting them to highly charged collector

plates. Also known as precipitator.

• The process depends on two steps. In the first step the suspension

passes through an electric discharge (corona discharge) area where

ionization of the gas occurs. The ions produced collide with the

suspended particles and confer on them an electric charge.

• The charged particles drift toward an electrode of opposite sign

and are deposited on the electrode where their electric charge is

neutralized. The phenomenon would be more correctly designated

as electrode position from the gas phase.

Fig. ESP

Page 42: TPS training report Gandhinagar, coal base power plant

Fig.ESP

Page 43: TPS training report Gandhinagar, coal base power plant

11. SMOKE STACK/CHIMNEY: • A chimney is a system for venting hot flue gases or smoke from a

boiler, stove, furnace or fireplace to the outside atmosphere.

• They are typically almost vertical to ensure that the hot gases flow

smoothly, drawing air into the combustion through the chimney

effect (also known as the stack effect).

• The space inside a chimney is called a flue. Chimneys may be

found in buildings, steam locomotives and ships.

• In the US, the term smokestack (colloquially, stack) is also used

when referring to locomotive chimneys.

• The term funnel is generally used for ship chimneys and

sometimes used to refer to locomotive chimneys. Chimneys are tall

to increase their draw of air for combustion and to disperse

pollutants in the flue gases over a greater area so as to reduce the

pollutant concentrations in compliance with regulatory or other

limits.

• These are 220M tall RCC structures with single / multiple flues

inside the concrete shells. The height of these chimneys varies

depending on the location of power plant.

Fig. Chimney

Page 44: TPS training report Gandhinagar, coal base power plant

12. GENERATOR:

• An alternator is an electromechanical device that converts

mechanical energy to alternating current electrical energy.

• In principle, any AC generator can be called an alternator, but

usually the word refers to small rotating machines driven by

automotive and other internal combustion engines.

• Generator is connected with the all HP, IP and LP turbines so

when the turbines rotates by the pressure of the steam the generator

also rotate and due to magnetic field it generates electricity.

• In 330MW unit the generator is connected with one HP turbine,

one IP turbine and one LP turbine but In 660MW unit the

generator is connected with one HP turbine, one IP turbine and two

LP turbine.

Fig. Generator

Page 45: TPS training report Gandhinagar, coal base power plant

CONCLUSION:

• The first phase of practical training has proved to be quiet fruitful.

It provided an opportunity for encounter with such hardworking

engineers.

• The architecture of the power plant the way various units are

linked and the way working of whole plant is controlled make the

student realize that engineering is not just learning the structured

description and working of various machines, but the greater part

is of planning proper management.

• It also provides an opportunities to learn low technology used at

proper place and time can cave a lot of labour But there are few

factors that require special attention. Training is not carried out

into its tree sprit.

• It is recommended that there should be some project specially

meant for students where presence of authorities should be

ensured. There should be strict monitoring of the performance of

students and system of grading be improved on the basis of work

done.

• However training has proved to be quite fruitful. It has allowed an

opportunity to get an exposure of the practical implementation to

theoretical fundamentals.