Training report On power plant

Power plant consists of four unit 1.Coal plant 2.Boiler 3.Turbine 4.D.M. plant

COAL PLANT

coal
coal "mineral of fossilized carbon" since the 13th century)[1] is a combustible black or brownish-black sedimentary rock usually occurring in rock strata in layers or veins called coal beds or coal seams. The harder forms, such as anthracite coal, can be regarded as metamorphic rock because of later exposure to elevated temperature and pressure. Coal is composed primarily of carbon along with variable quantities of other elements Types of coal

Peat, considered to be a precursor of coal, has industrial importance as a fuel in

some regions, for example, Ireland and Finland. In its dehydrated form, peat is a highly effective absorbent for fuel and oil spills on land and water. It is also used as a conditioner for soil to make it more able to retain and slowly release water.

Lignite, or brown coal, is the lowest rank of coal and used almost exclusively as
fuel for electric power generation. Jet, a compact form of lignite, is sometimes polished and has been used as an ornamental stone since the Upper Palaeolithic.

Sub-bituminous coal, whose properties range from those of lignite to those of

bituminous coal, is used primarily as fuel for steam-electric power generation and is an important source of light aromatic hydrocarbons for the chemical synthesis industry. Bituminous coal is a dense sedimentary rock, usually black, but sometimes dark brown, often with well-defined bands of bright and dull material; it is used primarily as fuel in steam-electric power generation, with substantial quantities used for heat and power applications in manufacturing and to make coke.

"Steam coal" is a grade between bituminous coal and anthracite, once widely
used as a fuel for steam locomotives. In this specialized use, it is sometimes known as "sea-coal" in the US. Small steam coal (dry small steam nuts or DSSN) was used as a fuel for domestic water heating.

Anthracite, the highest rank of coal, is a harder, glossy black coal used
primarily for residential and commercial space heating. It may be divided further into metamorphically altered bituminous coal and "petrified oil", as from the deposits in Pennsylvania.

Graphite, technically the highest rank, is difficult to ignite and is not commonly
used as fuel it is mostly used in pencils and, when powdered, as a lubricant.

Coal plant handling

Coal plant handling means properly handles the coal from its receipt to transferring it to bunkers. Collection hoppers and have slanted bottoms which allow coal to easily spill out onto a conveyor belt. Within the plant coal is transported by means of conveyors into whats known as a breaker building. This building lives up to its name because it

contains a very large machine whose job it is to break the chunks of raw coal that have been harvested from mines into smaller chunks which the boiler can work with. Once broken down, the coal will go to one of two places, either directly into silos or coal bunkers in the power plant building for short term storage, or into an outside storage pile, usually a prominent feature of a power pla t due to its formidable size. The coal pile can

be several stories tall and much larger than a football field. It acts as a reserve supply should the regular delivery of coal be interrupted by labor strike, natural disaster, or equipment failure. When necessary, the coal is removed from the pile and sent into the plant to fill the coal silos. Coal from the silos is used to feed the power plant boilers.

Coal Power Plant Fundamentals Feeding The Furnace

Figure 1 Feeding Coal To A Power Plant Furnace

Now you could have the coal spill down a chute directly from the silo into the mill, bypassing the coal feeder entirely, but thats really not a good idea. Just think how difficult it would be to chew if you tried to stuff an entire plate of food into your mouth at once. Just as your mouth requires to be fed in mouth-sized amounts, the coal mill must be fed coal in a size that it can handle. Its the job of the spinning wheel inside the coal feeder to keep coal flowing in measured amounts to the mill. You see, the wheel is attached to a variable speed motor, and depending on how quickly the furnace needs to be fed, the wheel will either turn faster or slower. Once inside the mill, the coal is ground up before moving on to the furnace. The coal mill contains massive steel parts capable of pulverizing chunks of coal into a fine black powder. This pulverized coal is then propelled by means of an exhauster towards the burners. The exhauster sits next to the coal mill and both are often driven by the same electric motor. The exhauster is connected to the top of the mill by a pipe, and another pipe connects the exhauster to burners on the furnace. The exhauster acts like a big vacuum cleaner, sucking coal powder out of the mill, then blowing it through pipes leading to the burners. Finally, the powder ignites within the furnace, heating the water inside the boiler.

 BOILER
A boiler or steam generator is a device used to create steam by applying heat energy to water. A boiler or steam generator is used wherever a source of steam is required. The form and size depends on the application We are using water tube boiler in NAHAR FABRICS or the generation of steam.

The steam generator or boiler is an integral component of a steam engine when considered as a prime mover. However it needs be treated separately, as to some extent a variety of generator types can be combined with a variety of engine units. A boiler incorporates a firebox or furnace in order to burn the fuel and generate heat. The generated heat is transferred to water to make steam, the process of boiling. This produces saturated steam at a rate which can vary according to the pressure above the boiling water. The higher the furnace temperature, the faster the steam production. The saturated steam thus produced can then either be used immediately to produce power via a turbine and alternator, or else may be further superheated to a higher temperature; this notably reduces suspended water content making a given volume of steam produce more work and creates a greater temperature gradient in order to counter tendency to condensation due to pressure and heat drop resulting from work plus contact with the cooler walls of the steam passages and cylinders and wire-drawing effect from strangulation at the regulator. Any remaining heat in the combustion gases can then either be evacuated or made to pass through an economiser, the role of which is to warm the feed water before it reaches the boiler. Components of a boiler are:

1.SUPER HEATER 2.ECONOMISER 3.STUDDED TUBES 4.WATER WALL TUBES 5.HEAT EXCHANGERS 6.FINNED TUBES

7.HEADERS 8.WASTE HEAT BOILERS 9.WATER WALL PANEL

Boiler Fittings and Mountings: A number of items must be fitted to steam boilers, all with the objective of improving: Operation. Efficiency.

Safety.

Some of these are: 1.Safety valves 2.Safety valve regulations 3.Boiler stop valves 4.Feedwater check valves 5.Bottom blowdown

TURBINE
A turbine is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. A turbine is a turbomachine with at least one moving part called a rotor

assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades so that they move and impart rotational energy to the rotor.

Theory of operation

Fig: (Schematic of impulse and reaction turbines, where the rotor is the rotating part, and the stator is the stationary part of the machine.)

A working fluid contains potential energy (pressure head) and kinetic energy (velocity head). The fluid may be compressible or incompressible. Several physical principles are employed by turbines to collect this energy: Impulse turbines change the direction of flow of a high velocity fluid or gas jet. The resulting impulse spins the turbine and leaves the fluid flow with diminished kinetic energy. There is no pressure change of the fluid or gas in the turbine blades

(the moving blades), as in the case of a steam or gas turbine, all the pressure drop takes place in the stationary blades (the nozzles). Before reaching the turbine, the fluid's pressure head is changed to velocity head by accelerating the fluid with a nozzle. Pelton wheels and de Laval turbines use this process exclusively. Impulse turbines do not require a pressure casement around the rotor since the fluid jet is created by the nozzle prior to reaching the blading on the rotor. Newton's second law describes the transfer of energy for impulse turbines. Reaction turbines develop torque by reacting to the gas or fluid's pressure or mass. The pressure of the gas or fluid changes as it passes through the turbine rotor blades. A pressure casement is needed to contain the working fluid as it acts on the turbine stage(s) or the turbine must be fully immersed in the fluid flow (such as with wind turbines). The casing contains and directs the working fluid and, for water turbines, maintains the suction imparted by the draft tube. Francis turbines and most steam turbines use this concept. For compressible working fluids, multiple turbine stages are usually used to harness the expanding gas efficiently. Newton's third law describes the transfer of energy for reaction turbines.

Types

Steam turbines are used for the generation of electricity in thermal power plants, such as plants using coal, fuel oil or nuclear power. They were once used to directly drive mechanical devices such as ships' propellers (for example the Turbinia, the first turbine-powered steam launch,[2]) but most such applications now use reduction gears or an intermediate electrical step, where the turbine is used to generate electricity, which then powers an electric motor connected to the mechanical load. Turbo electric ship machinery was particularly popular in the period immediately before and during World War II, primarily due to a lack of sufficient gear-cutting facilities in US and UK shipyards. Gas turbines are sometimes referred to as turbine engines. Such engines usually feature an inlet, fan, compressor, combustor and nozzle (possibly other assemblies) in addition to one or more turbines. Transonic turbine. The gasflow in most turbines employed in gas turbine engines remains subsonic throughout the expansion process. In a transonic turbine the gasflow becomes supersonic as it exits the nozzle guide vanes,

although the downstream velocities normally become subsonic. Transonic turbines operate at a higher pressure ratio than normal but are usually less efficient and uncommon.

Contra-rotating turbines. With axial turbines, some efficiency advantage can be obtained if a downstream turbine rotates in the opposite direction to an upstream unit. However, the complication can be counter-productive. A contra-rotating steam turbine, usually known as the Ljungstrm turbine, was originally invented by Swedish Engineer Velocity compound "Curtis". Curtis combined the de Laval and Parsons turbine by using a set of fixed nozzles on the first stage or stator and then a rank of fixed and rotating blade rows, as in the Parsons or de Laval, typically up to ten compared with up to a hundred stages of a Parsons design. The overall efficiency of a Curtis design is less than that of either the Parsons or de Laval designs, but it can be satisfactorily operated through a much wider range of speeds, including successful operation at low speeds and at lower pressures, which made it ideal for use in ships' powerplant. In a Curtis arrangement, the entire heat drop in the steam takes place in the initial nozzle row and both the subsequent moving blade rows and stationary blade rows merely change the direction of the steam. Use of a small section of a Curtis arrangement, typically one nozzle section and two or three rows of moving blades, is usually termed a Curtis 'Wheel' and in this form, the Curtis found widespread use at sea as a 'governing stage' on many reaction and impulse turbines and turbine sets. This practice is still commonplace today in marine steam plant. Pressure compound multistage impulse, or "Rateau". The Rateau employs simple impulse rotors separated by a nozzle diaphragm. The diaphragm is essentially a partition wall in the turbine with a series of tunnels cut into it, funnel shaped with the broad end facing the previous stage and the narrow the next they are also angled to direct the steam jets onto the impulse rotor.

DEMINERALIZATION PLANT
Ion exchange technology is used to remove salts (cations and anions) from the water Soluble chemical compounds, when dissolved in water, become ionized; that is their molecules dissociate into positively and negatively charged components called ions.

Consider common table salt, sodium chloride. In its solid form, this compound consists of one sodium atom (Na) and one chlorine atom (Cl) tightly coupled together (NaCl). When dissolved in water, however, the compound splits into two ions, Na and Cl.
Ion Exchange

A process in which Contaminant ions are exchanged from water is called ion exchange. This process occurs in ion exchange resin Initially, resin is loaded with hydrogen (H ) ion for cations and hydroxide (OH-) ion for anions. As water passes through the resin, the contaminant ions in the water displace the loaded ions from the sites on the resin. This is because the resin has a greater affinity for the contaminant ions. Affinity for most resins is based loosely on ionic size and charge
Regeneration

Over a period of time most of the cation resin gets converted into Ca, Mg, Na form and it has no Hydrogen Ions (H ) to replace Ca, Mg, Na ions and the anion resin gets converted into Cl, SO4, SiO2 form and it has no Hydroxyl Ions (OH-) to replace Cl, SO4, SiO2 ions.. This is called the resin exhaustion or end of service cycle. The exhausted resin has to be brought back into Hydrogen (H ) Hydroxyl (OH-) form to continue the process and use it again and again. The procedure of converting exhausted resin into Hydrogen (H ) Hydroxyl (OH-) form is called regeneration
Separate Bed DM Systems

Ion exchange occurs across at least two different columns. The first is a cation column, which is filled with resin loaded with positive hydrogen ions (H ). As water passes through this column, the positively charged impurities in the water are exchanged for the hydrogen ions A similar exchange takes place in the second column, the anion column. This column is filled with resin loaded with negative hydroxide ions (OH-). As the now cation-free water from the cation column passes through, any negatively charged contaminants are removed from the water and replaced by hydroxide ions from the resin. The water now has a neutral pH. hydroxide [OH-] and hydrogen [H ] ions

exchanged in the columns combine, forming water [H2O) Mixed Bed Systems In a Mixed Bed System water is purified by removing all ions in one pass through an ion exchange bed. The bed consists of cation and anion resins in mixed condition, so that ions are actually removed in the same two step ion exchange process. All the traces of Cations and Anions of the dissolved solids and silica in the water are replaced by Hydrogen ion (H) and Hydroxyl Ion (OH-) respectively. We get very high purity demineralized water at the outlet of the MB.