A

Practical Training Report

Undertaken at

NASHIK THERMAL POWER STATION

EKLAHARE, MAHAGENCO
Dist. Nashik (Maharashtra)
Submitted in Partial Fulfilment of the Requirement
For the Award of Degree of

BACHELOR OF TECHNOLOGY
In

Mechanical Engineering
to
Rajasthan Technical University,
Kota

2014-2015
Submitted to: Dr. JP Bhamu
Associate Professor
Department of Mechanical Engineering

Submitted by: Sagar Mehta

B.Tech. VII Sem
11EEBME753

GOVERNMENT ENGINEERING COLLEGE, BIKANER

August, 2014

ACKNOWLEDGEMENT
It is often said that life is a mixture of achievements, failure, experiences, exposures and
efforts to make your dream come true. There are people around you who help you realize
your dream. I acquire this opportunity with much pleasure to acknowledge the invaluable
assistance of Nasik Thermal Power Station and all the people who have helped me through
the course of my journey in successful completion of the summer training.
I would like to take this opportunity to thank all those who have contributed in this report
directly or indirectly. I offer my thanks to Mr. Santosh Kulkarni (Dy. Executive Engineer),
Mr. N.M. Shinde (Dy.Chief Engineer), Mr. K.M. Mane (Superintendent Engineer), Mr.
Kimbahune Vikrant V. (Power User, EAM), and O.R.Usrete (Sr. Chemist) for providing
whole hearted Co-operation.
I would personally like to my thank Mr. A.P. Netke (Assistant Engineer and Training Incharge) for helping me throughout my training.
I would like to express my sincere gratitude to Mr. Mohd. Yunus Sheikh (HOD,
Department of Mechanical Engineering) and feel deep sense of gratitude towards Dr. JP
Bhamu, Associate Professor in Govt. Engineering College Bikaner, being a constant source
of motivation and guidance. I also like to thank all Faculty and all staff members of
mechanical department of Govt. Engineering College Bikaner.
I want to thank to all Staff and Workers of NTPS for their guidance and co-operation at each
& every step of my training.
I also acknowledge thank to my fellow students for discussing various points during the
course of training which proved very useful in preparing this report. I am grateful to my
friends who gave me the moral support in my times of difficulties. Last but not the least I
would like to express my special thanks to my family for their continuous motivation and
support.

Sagar Mehta
11EEBME753

TABLE OF CONTENTS

S. NO.
1

TOPICS

PAGE NO.

HISTORY OF POWER SECTOR

1.1

INTRODUCTION

1.2

MARKET REFORM

HISTORY OF INDIAN POWER SECTOR

2.1

INTRODUCTION

2.2

PRESENT ENERGY SCENARIO IN INDIA

HISTORY OF THERMAL POWER GENERATION

3.1

INTRODUCTION

3.2

THERMAL POWER GENERATION IN INDIA

NASIK THERMAL POWER STATION

4.1

INTRODUCTION

4.2

INSTALLED CAPACITY

4.3

TRANSPORT

4.4

SHAKTIMAN A SYMBOL OF VISIONARY

RESOURCEFULNESS

STEAM POWER PLANT

10

5.1

POWER PLANT

10

5.2

STEAM POWER PLANT

10

5.3

RANKINE OR STEAM CYCLE

11

THERMAL POWER STATION VIEWS

13

POWER PLANT WATER INTAKE

14

7.1

INTRODUCTION

14

7.2

METHODOLOGY

14

COAL HANDLING PLANT

15

8.1

INTRODUCTION

15

8.2

COAL

15

8.3

TYPES OF COAL

15

8.4

COAL IN INDIA

16

8.5

GENERAL WORKING OF CHP

16

WATER TREATMENT PLANT

18

9.1

INTRODUCTION

18

9.2

WATER TREATMENT PROCESS

18

10

BOILER WATER MONITORING

21

11

BOILER, BOILER OPERATION, MAINTAINANCE AND

22

ITS AUXILIARIES

12

11.1

INTRODUCTION

22

11.2

BOILER MAIN PROCESS

22

11.3

TYPES OF BOILER USED IN POWER PLANT

22

11.4

BOILER MAIN AUXILIARIES

24

11.5

IMPROVING BOILER AND OVERALL

EFFICIENCY OF PLANT

27

11.6

FLUE GAS PATH

27

11.7

BOILER AUXILIARIES SPECIFICATIONS

29

TURBINE,

TURBINE

OPERATION,

MAINTAINANCE

31

AND ITS AUXILIARIES

12.1

INTRODUCTION

31

12.2

WORKING PRINCIPLE OF STEAM TURBINE

31

12.3

TYPES OF STEAM TURBINE

31

12.4

CONSTRUCTION AND STEAM FLOW

31

12.5

VALVES

32

12.6

TURBINE GOVERNING SYSTEM

32

12.7

OIL SUPPLY SYSTEM

33

13

14

15

16

17

12.8

TURBINE MONITORING SYSTEM

33

12.9

FIXED POINTS

33

12.10

STEAM TURBINE STARTS UP

36

12.11

PRECAUTIONS DURING RUNNING

36

12.12

MATERIALS FOR STEAM TURBINE DESIGN

36

GENERATOR

37

13.1

INTRODUCTION

37

13.2

PRINCIPLE OF GENERATION

37

STEAM CONDESING SYSTEM

39

14.1

INTRODUCTION

39

14.2

STEAM CONDENSING SYSTEM COMPONENTS

39

BOILER FEED WATER PUMP

43

15.1

INTRODUCTION

43

15.2

CONSTRUCTION AND OPERATION

43

ASH HANDLING PLANT

44

16.1

INTRODUCTION

44

16.2

TYPES OF COAL ASH

44

16.3

BOTTOM ASH SYSTEM

45

16.4

FLY ASH SYSTEM

45

16.5

AREAS OF FLY ASH UTILIZATION

45

ENERGY CONSERVATION AND ENERGY AUDIT

48

17.1

ENERGY CONSERVATION

48

17.2

AUDIT

48

18

CONCLUSION

49

19

SUGGESTIONS

50

LIST OF FIGURES AND TABLES

S. NO.

FIGURE NAME

PAGE NO.

2.1

Indias Installed Capacity by Source

1.1

2.3

Indian Generation Capacity (in MW)

1.2

2.3

Indias GDP Variation with Energy Consumption

1.3

4.1

Nashik Thermal Power Station

1.4

5.1

Rankine or Steam Cycle

11

1.5

5.2

T-s Diagram of Modified Rankine (Reheat) Cycle

12

1.6

5.3

Energy Conversion in TPS

12

1.7

6.1

Plant Layout

13

1.8

6.2

Typical View of Thermal Power Plant

13

1.9

8.1

Constituents of Coal

15

1.10

8.2

Coal Handling Plant

16

1.11

9.1

Pre-Treatment Plant Flow Diagram

19

1.12

9.2

Softening Plant Flow Diagram

19

1.13

11.1

Tangential Fired Boiler

23

1.14

11.2

Balance Draft Boiler

23

1.15

11.3

Coal and Flue Gas Cycle

26

1.16

12.1

Steam Turbine and Regenerative Heating

33

1.17

12.2

Steam Turbine Rotor

33

1.18

13.1

Turbo-Generator

36

1.19

13.2

Generator Transformer

36

1.20

14.1

Diagram of Typical Water Cooled Condenser

40

1.21

16.1

Electrostatic Precipitator

46

1.22

16.2

Typical View of Ash Handling Plant

47

TABLE NAME
1.23

4.1

Capacity of Units

1.24

8.1

Coal Mill Technical Specifications

17

1.25

8.2

Coal Feeder Technical Specifications

17

1.26

9.1

River Water and Boiler Water Parameters

20

1.27

11.1

Boiler Technical Specifications

23

1.28

11.2

Boiler Parameters

24

1.29

11.3

Required Boiler Auxiliaries

25

1.30

11.4

Flue Gas Parameters at Various Stages

28

1.31

11.5

Materials for Boiler Tubes

29

1.32

11.6

ID Fan Technical Specifications

29

1.33

11.7

PA Fan Technical Specifications

29

1.34

11.8

FD Fan Technical Specifications

30

1.35

11.9

Air Pre-Heater Technical Specifications

30

1.36

12.1

Turbine Technical Specifications

34

1.37

12.2

Oil Pump Technical Specifications

34

1.38

14.1

Condenser Technical Specifications

42

1.39

15.1

BFP Technical Specifications

43

ABSTRACT
A thermal power station is a power plant in which the prime mover is steam driven. Water is
heated, turns into steam and spins a steam turbine which drives an electrical generator. After
it passes through the turbine, the steam is condensed in a condenser and recycled to where it
was heated; this is known as a Rankine cycle. The greatest variation in the design of thermal
power stations is due to the different fuel sources. Some prefer to use the term energy centre
because such facilities convert forms of heat energy into electricity. Some thermal power
plants also deliver heat energy for industrial purposes, for district heating, or for desalination
of water as well as delivering electrical power. A large part of human CO2 emissions comes
from fossil fuelled thermal power plants; efforts to reduce these outputs are various and
widespread. At present 54.09% or 93918.38 MW (Data Source CEA, as on 31/03/2011) of
total electricity production in India is from Coal Based Thermal Power Station. A coal based
thermal power plant converts the chemical energy of the coal into electrical energy. This is
achieved by raising the steam in the boilers, expanding it through the turbine and coupling the
turbines to the generators which converts mechanical energy into electrical energy.

CHAPTER 1

HISTORY OF POWER SECTOR

1.1 INTRODUCTION: The electric power industry provides the production and delivery of electric energy, often
known as power, or electricity, in sufficient quantities to areas that need electricity through
a grid connection. The grid distributes electrical energy to customers. Electric power is
generated by central power stations or by distributed generation.
Although electricity had been known to be produced as a result of the chemical reactions that
take place in an electrolytic cell since Alessandro Volta developed the voltaic pile in 1800, its
production by this means was, and still is, expensive. In 1831, Faraday devised a machine
that generated electricity from rotary motion, but it took almost 50 years for the technology to
reach a commercially viable stage. In 1878, in the US, Thomas Edison developed and sold a
commercially viable replacement for gas lighting and heating using locally generated and
distributed direct current electricity.
Additionally, Robert Hammond, in December 1881, demonstrated the new electric light in
the Sussex town of Brighton in the UK for a trial period. In early 1882, Edison opened the
worlds first steam-powered electricity generating station at Holborn Viaduct in London,
where he had entered into an agreement with the City Corporation for a period of three
months to provide street lighting. In time he had supplied a number of local consumers with
electric light. The method of supply was direct current (DC).
It was later on in the year in September 1882 that Edison opened the Pearl Street Power
Station in New York City and again it was a DC supply. It was for this reason that the
generation was close to or on the consumer's premises as Edison had no means of voltage
conversion. The voltage chosen for any electrical system is a compromise. Increasing
the voltage reduces the current and therefore reduces the required wire thickness.
Unfortunately it also increases the danger from direct contact and increases the required
insulation thickness. Furthermore some load types were difficult or impossible to make work
with higher voltages. The overall effect was that Edison's system required power stations to

be within a mile of the consumers. While this could work in city centres, it would be unable
to economically supply suburbs with power.
The mid to late 1880's saw the introduction of alternating current (AC) systems in Europe and
the U.S. AC power had an advantage in that transformers, installed at power stations, could
be used to raise the voltage from the generators, and transformers at local substations could
reduce voltage to supply loads. Increasing the voltage reduced the current in the transmission
and distribution lines and hence the size of conductors and distribution losses. This made it
more economical to distribute power over very long distances. Generators (such
as hydroelectric sites) could be located far from the loads. AC and DC competed for a while,
during a period called the War of Currents. The DC system was able to claim slightly greater
safety, but this difference was not great enough to overwhelm the enormous technical and
economic advantages of alternating current which eventually won out.
1.2 MARKET REFORM: There has been a movement towards separating the monopoly parts of the industry, such as
transmission and distribution sectors from the contestable sectors of generation and retailing
across the world. This has occurred prominently since the reform of the electricity supply
industry in England and Wales in 1990. In some countries, wholesale electricity markets
operate, with generators and retailers trading electricity in a similar manner to share and
accuracy.

CHAPTER 2

HISTORY OF INDIAN POWER SECTOR

2.1 INTRODUCTION: The Indian Power Industry before independence was controlled firmly by the British . The
first demonstration of electric light in Calcutta was conducted on 24 July 1879 by P W
Fleury & Co. On 7 January 1897, Kilburn & Co secured the Calcutta electric lighting license
as agents of the Indian Electric Co, which was registered in London on 15 January 1897. A
month later, the company was renamed the Calcutta Electric Supply Corporation. The control
of the company was transferred from London to Calcutta only in 1970. Enthused by the
success of electricity in Calcutta, power was thereafter introduced in Bombay. Mumbai saw
electric lighting demonstration for the first time in 1882 at Crawford Market, and Bombay
Electric Supply & Tramways Company (B.E.S.T.) set up a generating station in 1905 to
provide electricity for the tramway. The first hydroelectric installation in India was installed
near a tea estate at Sidrapong for the Darjeeling Municipality in 1897. The first electric train
ran between Bombay's Victoria Terminus and Kurla along the Harbour Line, in 1925. In
1931, electrification of the metre gauge track between Madras Beach and Tambaram was
started.
The power sector in India has undergone significant progress after Independence. When India
became independent in 1947, the country had a power generating capacity of 1,362
MW. Hydro power and coal based thermal power have been the main sources of generating
electricity. Generation and distribution of electrical power was carried out primarily by
private utility companies. Notable amongst them and still in existence is Calcutta Electric.
Power was available only in a few urban centres; rural areas and villages did not have
electricity. After 1947, all new power generation, transmission and distribution in the rural
sector and the urban centres (which was not served by private utilities) came under the
purview of State and Central government agencies. State Electricity Boards (SEBs) were
formed in all the states. Nuclear power development is at slower pace, which was introduced,
in late sixties. The concept of operating power systems on a regional basis crossing the
political boundaries of states was introduced in the early sixties. In spite of the overall

development that has taken place, the power supply industry has been under constant pressure
to bridge the gap between supply and demand.
2.2 PRESENT ENERGY SCENARIO IN INDIA:

The electricity sector in India had an installed capacity of 205.34 Gigawatt (GW) as
of June 2013, the world's fifth largest.

Thermal power plants constitute 70% of the installed capacity, hydroelectric about
15% and rest being a combination of wind, small hydro, biomass,

waste-to-

electricity, and nuclear.

India generated 855 BU (855 000 MU i.e. 855 TW) electricity during 2011-12 fiscal.

Figure 2.1 Indias Installed Capacity by Source

In terms of fuel, coal-fired plants account for 56% of India's installed electricity
capacity, compared to South Africa's 92%; China's 77%; and Australia's 76%. After
coal, renewal hydropower accounts for 19%, renewable energy for 12% and natural
gas for about 9%.

Figure 2.2 Indian Generation Capacity (in MW)

As of January 2012, one report found the per capita total consumption in India to be
778 kWh.

India is the world's fourth largest energy consumer after United States, China and
Russia.

Figure 2.3 Indias GDP Variation with Energy Consumption

CHAPTER 3

HISTORY OF THERMAL POWER GENERATION

3.1 INTRODUCTION: Almost all coal, nuclear, geothermal, solar thermal electric, and waste incineration plants, as
well as many natural gas power plants are thermal. The initially developed reciprocating
steam engine has been used to produce mechanical power since the 18th Century, with
notable improvements being made by James Watt. When the first commercially developed
central electrical power stations were established in 1882 at Pearl Street Station in New York
and Holborn Viaduct power station in London, reciprocating steam engines were used. The
development of the steam turbine in 1884 provided larger and more efficient machine designs
for central generating stations. By 1892 the turbine was considered a better alternative to
reciprocating engines; turbines offered higher speeds, more compact machinery, and stable
speed regulation allowing for parallel synchronous operation of generators on a common bus.
After about 1905, turbines entirely replaced reciprocating engines in large central power
stations.
3.2 THERMAL POWER GENERATION IN INDIA:

Thermal power plants convert energy rich fuel into electricity and heat. Possible fuels
include coal, natural gas, petroleum products, agricultural waste and domestic trash /
waste.

Coal and lignite accounted for about 70% of India's installed capacity.

India's electricity sector consumes about 80% of the coal produced in the country. A
large part of Indian coal reserve is similar to Gondwana coal.

The installed capacity of Thermal Power in India, as of June 30, 2011, was 115649.48
MW which is 65.34% of total installed capacity.

The state of Maharashtra is the largest producer of thermal power in the country.

CHAPTER 4

NASIK THERMAL POWER STATION

4.1 INTRODUCTION: Nashik Thermal Power Plant is located at Eklahare village near Nashik in Maharashtra. The
power plant is one of the coal based power plants of Mahagenco (Maharashtra State Power
Generation Company Limited MSPGCL). Mahagenco has the highest overall generation
capacity and the highest thermal installed capacity amongst all the state power generation
utilities in India. In terms of installed capacity, it is the second highest generation company
after NTPC. Nasik Thermal Power Station comprises of 2x140 MW and 3x210 MW units.
The first 140 MW unit was synchronized on 16thAugust 1970 followed by second unit on
21st of March 1971.The cost of unit including civil work was Rs. 56.5 crores each.
Boilers are front fired type from Babcock Wilcock France. Turbines are also from France.
NTPS Stage-II comprises of three units of 210 MW each of BHEL Make. The first 210 MW
units were synchronized on 26th April 1979 at total project cost of Rs. 94.73 crores. The next
two units i.e. Unit No. 4 and 5 of 210 MW were constructed at the cost of Rs. 143.95 crores
and commissioned on 10th July 1980 and 30thJanuary 1981 respectively. Thus total cost of
Stage-II is Rs. 238.68 crores.
Boilers are corner fired of American design. Turbines are of Russian design.
The power station campus include self contained township with all amenities. The entire
complex measures 472 hectare of land on the bank of river Godavari.
The power station with its auxiliary equipment comprise intake pump house on the bank of
river Godavari, a large raw water reservoir divided in two halves, and reservoir pump house,
Water Treatment Plant for clarified and filter water, cooling towers with canals and CW
pump houses and the power station proper with concrete stack, dust collecting plant, boiler
plant, steel building housing the plant and equipment in bunker bay, heater bay, and turbine
bay. Beyond the turbine bay is the outdoor installation of generator transformers, auxiliary
reserve and unit transformers.
About 100 meters away from the powerhouse stack and further beyond are the installations
for fuel oil day storage and pump houses and bulk storages with pump house. Near the power

station is the coal storage yard and coal handling plant, comprising crusher house, surge and
reclaim hoppers, wagon tipplers, connecting belt conveyor system with inclined belt
conveyors leading to the power station.
NTPS a major driving force since 1971 pouring 910 MW and an apex of Golden triangle
of Mumbai, Pune & Nashik. Industrial house of giants like Mahindra, MICO, VIP, Siemens,
Gabriel, CEAT, Raymond, Crompton Greaves, HAL(Hindustan Aeronautics Limited),
Security Press are HT Consumers more than110 MW. The power plant has got ISO
Certification on April 2002.
4.2 INSTALLED CAPACITY: Nashik Thermal Power Station has an installed capacity of 890 MW. The plant has 5 units
under operation. The individual units have the generating capacity as follows.

Table 4.1 Capacity of Units

Stage

Unit
Number

Installed
Capacity (MW)

Date of
Commissioning

Status

Stage I 1

140

August, 1970

Stopped(under
renovation)

Stage I 2

140

March, 1971

Stopped(under
renovation)

Stage II 3

210

April, 1979

Running

Stage II 4

210

July, 1980

Running

Stage II 5

210

January, 1981

Running

4.3 TRANSPORT: It is on the Bhusawal-Kalyan section of Central Railway. Coal-based thermal power stations
consume large quantities of coal. For example, the Nasik Thermal Power Station consumed
4,626,000 tonnes of coal in 2006-07. Around 80 per cent of the domestic coal supplies in
India are meant for coal based thermal power plants and coal transportation forms 42 per cent
of the total freight earnings of Indian railways.
4.4 SHAKTIMAN A SYMBOL OF VISIONARY RESOURCEFULNESS: NTPS built a scrap metal sculpture "SHAKTIMAN, weighing 27 tones, 17 meter tall one of
its kinds in ASEA recorded in the GUINNES book of records. No doubt its a symbol of
innovative idea emerged in word and sprit, inspiring visitors that wealth from waste can be a
reality.

Figure 4.1 Shaktiman Statue in Guinness Book of World Records In 1991

CHAPTER 5

STEAM POWER PLANT

5.1 POWER PLANT: A power station (also referred to as generating station, power plant, powerhouse, generating
plant) is an industrial facility for the generation of electric power.
Types of energy available for generation of electrical energy are follows.
1. Thermal Energy
2. Solar Energy
3. Atomic Energy
4. Hydro Power
5. Wind Power
6. Tidal Power
7. Geo-Thermal
8. From Gas
5.2 STEAM POWER PLANT: A steam-electric power station is a power station in which the electric generator
is steam driven. Water is heated, turns into steam and spins a steam turbine. After it passes
through the turbine, the steam is condensed in a condenser. The greatest variation in the
design of steam-electric power plants is due to the different fuel sources.
For a steam power plant, practical thermal cycle was suggested by Rankine called Ideal cycle
or Rankine cycle. A steam power plant continuously convert the energy stored in fossil fuels
(Coal, Oil, Natural Gas) or fissile fuels (Uranium, Thorium) into shaft power into shaft work
and ultimately into electricity. The working fluid is water, which is sometimes in liquid phase
and sometimes in the vapour phase during its cycle of operations. Figure below illustrate a
fossil-fuelled power plant as a bulk energy converter from fuel to electricity using water as
working medium. Energy released by burning of fuel is transferred to water by boiler (B) to
generate steam at a high pressure and temperature, which expands in the turbine (T) to a low
pressure to produced shaft work. The steam leaving the turbine condensed into water in the
condenser (C) where cooling water from river or sea circulates carrying away the heat

10

released during condensation. The water (condensate) is then fed back to the boiler by the
pump (P), and the cycle goes on repeating itself.
5.3 THERMAL POWER STATION WORKS ON RANKINE CYCLE
Main Components of TPS
1. Boiler
2. Turbine
3. Condenser
4. Boiler feed pump
5. Generator

Figure 5.1 Rankine or Steam Cycle

11

Figure 5.2 T-s Diagram of Modified Rankine (Reheat) Cycle

Furnace
Chemical to
Heat
Boiler
Heat energy
converts
water to
saturated
Steam

Generator
Mechanical
to Electrical
Energy

Turbine
Kinetic
energy into
Mechanical
Work

Turbine
Heat energy
into Kinetic
Energy

Figure 5.3 Energy Conversions in TPS

12

CHAPTER 6

THERMAL POWER STATION VIEWS

Figure 6.1 Plant Layout

Figure 6.2 Typical View of Thermal Power Plant

13

CHAPTER 7

POWER PLANT WATER INTAKE

7.1 INTRODUCTION: A systematic study has been carried out to assess the water quality at downstream of
Godavari river at Nashik city and its impact on Nashik Thermal Power Station, Eklahare.
Water samples from six sampling stations were collected monthly, during period March 08
April 09 and physic-chemical and chemical parameters were analyzed by the standard
methods. The pollution level over a period of time is increasing on the river water mainly due
to sewage, industrial and other wastewaters are directly discharge in the river. The use of
Godavari river water is, mainly for domestic, industrial, agricultural purpose and huge
amount of water is also utilized by Nashik Thermal Power Station for electricity generation.
The intake water lifted by Nashik Thermal Power Station is from downstream of the
Godavari River i.e. after Gangawadi. For treatment of such contaminated water huge
chemicals are required for production of filtered water (sump water), which leading to high
chemical cost. To overcome from these difficulties due to polluted water, the quality
assessment of intake water of Nashik Thermal Power Station is necessary for cost effective
generation.
7.2 METHODOLOGY: The pumping station consists of a box open on the riverside. Two, equally spaced pillar walls
at the inside base of the box dived the river approach into three equal bay. Trash racks are
provided at the entry of each bay to arrest the floating debris coming with river water. Due to
shifting flow of river water bunds with the help of sand bags are sometimes used to diver the
flow of river water along the pump house. Sand also accumulates in front of pump house. A
dredging arrangement is there to remove the sand from front of the Pump House.
There are four vertical mixed flow type water pumps. These are placed in line in a common
basin behind three partitioned bays. All the pumps are motor driven. Motor operated,
butterfly types discharge valves are provided for the pumps.

14

CHAPTER 8

COAL HANDLING PLANT

8.1 INTRODUCTION: In thermal power plant coal is a principal fuel, hence design & layout of coal handling plant
is important.
8.2 COAL:

Coal is a non renewable solid fuel formed by a series of geochemical process from the
plant remains accumulated together with other sediments.

i.

For calculating usefulness of coal as a fuel it is analyzed by two types

Proximate Analysis: Determines moisture, ash, volatile matter and fixed carbon
percentage

ii.

Ultimate Analysis: Determines carbon, hydrogen, nitrogen, sulfur and oxygen within
coal.

Main constituents of coal are

ffffffigFf
Figure 8.1 Constituents of Coal
8.3 TYPES OF COAL: According to quality (carbon content), the coal may be divided into following classes:

15

i.

Anthracite: - It is the best quality coal and its carbon content is as much as 92% with
a low volatile matter and very little moisture. It is hard and heavy and burns with
great heat.

ii.

Bituminous: - It is also of good quality coal next to Anthracite. Its carbon content is
up to 85%. Coal mined in India, is mainly of bituminous type of Gondwana age.

iii.

Sub-bituminous: -It is a type of coal whose properties range from those of lignite to
those of bituminous coal and are used primarily as fuel for steam-electric power
generation. Sub-bituminous coals may be dull, dark brown to black, soft. They
contain 15-30% inherent moisture by weight and are non-coking.

iv.

Lignite: - It is inferior quality coal, full of moisture and volatile matter. Its carbon
content is less than 50%. It is also known as brown coal.

v.

Peat: - It is the first stage in the formation of coal. It is light and woody and has poor
heating capacity.

8.4 COAL IN INDIA: The common coals used in Indian industry are bituminous and sub-bituminous coal. The
calorific value of Indian coal ranges from 4000-5000 Kcal/kg. Apart from low calorific value,
Indian coal suffers from high ash content (15-45%) which is about 30-40%.The good thing
about Indian coal is its low sulphur content.
8.5 GENRAL WORKING OF CHP

Figure 8.2 Coal Handling Plant

16

Coal Mill: A pulveriser or grinder is a mechanical device for the grinding of many different types of
materials. For example, a pulveriser mill (Coal Mill) is used to produce pulverize coal for
combustion in the steam generating furnaces of fossil fuel power plants.
Types of Coal Mills
i.

Bowl Mill (Medium Speed)

ii.

Ball & Race Mill (Medium Speed)

iii.

Ball and Tube Mill (Low Speed)

TECHNICAL SPECIFICATIONS OF COAL MILL AND COAL FEEDER:Coal Mill

Table 8.1 Coal Mill Technical Specifications
MAKE
CAPACITY
TYPE
HRDGROOVE
IN
MILL
OUTLET T

BHEL

MAKE

BHEL

31.4 T/HR

CAPACITY

320 KW

XRP 763 BOWL MILLS

VOLTAGE

6.6 KV

72 % ( 200 MESH)

CURRENT

37 AMP

SPEED

990 RPM

80-85 C

Coal Feeder
Table 8.2 Coal Feeder Technical Specifications
MAKE
TYPE
CAPACITY

MITSUBHISHI
PIV ROTARY
FEEDER

SPEED

1430 RPM

COAL

3.7 KW

17

CURRENT

7.6 AMP

VOLTAGE

415 V

CHAPTER 9

WATER TREATMENT PLANT

9.1 INTRODUCTION: Nashik Thermal Power Station is situated at the bank of Godavari River at Eklahare Village.
Godavari River is the only source of raw water for Nashik Thermal Power Station for
Electricity Generation and other purpose. Raw water quality at Nashik TPS is much typical
and contaminated due to release of raw sewage, untreated effluents from various Chemical
Industries, various domestic effluents etc. from up-stream. Most of the period during the year,
the water contains impurities beyond removal by way of existing conventional system. Due
to deteriorated Godavari river water quality, separate arrangement of Darna River water for
drinking purpose is made for NTPS colony residents.
9.2 WATER TREATMENT PROCESS: i.

River water contains a lot of impurities such as algae, fungi, dead vegetation and
mineral matter in the form of dissolved solids.

ii.

This water is fed after treatment to boiler water system, cooling water system and for
domestic purpose.

The treatment is done in two stages

i.

First Stage: - Pre-treatment

Maximum impurities except total dissolved solids and colloidal silica are removed in
this treatment.

ii.

Second Stage: - Post Treatment

a) Demineralization: - Perfectly pure water is produced by ion exchange process by

passing the filtered water through the resins. This water is fed to the boiler feed water
system.
b) Softening: - Hardness causing elements such as Calcium and Magnesium are
removed in this process. This water is used for cooling water system.
c) Domestic water: - Chlorination / Bleaching Powder dosing is arranged to the filtered
water so as to make it suitable for drinking purpose.
Average Incoming River water Parameters are

18

Table 9.1 River Water Parameters

Ion

Minimum impurities (ppm)

Maximum impurities (ppm)

TH

90

350

TCL

20

250

Pretreatment Plant: i.

River water is taken at river water inlet chamber at W. T. Plant where the chemicals
such as alum, lime /bleaching powder, PAC etc. are added.

RIVER

RIVER
WATER

Alum,Lime
KmnO4

SETTLING
TANK(STG-1)

PUMP

INTAKE
PAC,Bleaching CLARIFIER
CHAMBER Powder
(STG-2)

RAPID
SAND

FILTERED
WATER

GRAVITY
FILTER

SUMP

Figure 9.1 Pre-Treatment Plant Flow Diagram

Softening Plant: Water is passed through base exchangers where hardness causing elements i.e. calcium and
magnesium are removed to get soft water.

FILTERED
WATER
SUMP

FILTERED
WATER
PUMP

BASE
EXCHANGER

SOFT
WATER

C. T.
POND

Figure 9.2 Softening Plant Flow Diagram

R Na + Ca / Mg
Resin

R Ca / Mg + Na

Hard Water

Soft Water

Regeneration of Base Exchanger resin is done by using Common Salt, Reaction of which is
R- Ca / Mg + NaCl
Salt

R Na + Ca / Mg
Resin

Effluent

Demineralization: Minerals are removed from the filtered water by ion exchange process. Cations (positive
ions) and Anions (Negative ions) are removed from the water one by one using Resin which

19

is an organic material having the capacity to exchange ions in the water with the active group
on the resin.
Chemical reactions in Regular Process are
i.

Reaction in Cation ExchangerNa Cl

Na

Ca CO3

RH

Mg SiO3
ii.

Cl

R ---Ca

Resin

H --- CO3

Mg

SiO3

Reaction in Anion ExchangerCl

H--- SO4

Cl
R OH

SiO3

R--- SO4

Resin

+ OH - H / H2O

SiO3

Chemical reactions during Regeneration Process are

i.

Reaction in Cation ExchangerNa

R ---Ca

Na Cl
+ HCl

R-H

Mg
ii.

Ca Cl2
Mg Cl2

Reaction in Anion ExchangerCl

R ---SO4

Cl
+ NaOH

ROH

Na--- SO4

SiO3

SiO3

Recommended Boiler water parameters Stage II (210 MW)

Table 9.1 Boiler Water Parameters
Drum Operating Pressure

M/S BHEL

Kg / cm2 126 165

Recommendation

Treatment Type

Phosphate

Phosphate

pH at 25 0 C

9.4 - 9.7

9.4 to 9.6

Conductivity at 25 0 C

100

< 35

mhos/cm

20

Parameters at NTPS

CHAPTER 10

BOILER WATER MONITERING

i.

D. M. water which is produced for feeding to boiler water system is having pH 7.0 and
Conductivity less than 1.0 micromhos / cm, Silica - NIL.

ii.

This water is very sensitive and atmospheric CO2 gets immediately mixed with it to
make it acidic which is not desirable, so chemical dosing is done in boiler feed water.

iii.

Dissolved oxygen is also present in the D.M. water which is responsible for corrosion.
85 % of dissolved oxygen is removed in deaerator in feed water system.

iv.

Hydrazine dosing is arranged through L.P dosing pump at BFP suction for scavenging
residual dissolved oxygen in the system water to avoid corrosion of metal surface.

v.

pH of D. M. make up water at condenser is about 6.8 to 6.9 ( which is not desirable ) is

increased to about 8.8 by dosing Ammonia solution along with Hydrazine through L.P.
dosing pump.

vi.

Colloidal Silica (which is not removed in D.M. Plant) gets transformed to active silica at
Temp. Above 250 deg. Cent. And it appears in boiler drum water.

vii.

Silica in the form of silicates is hazardous in boiler water as it gets evaporated to steam
and gets deposited directly on the turbine blades as too hard deposits.

CONCLUSION: i.

The rotation of water is decided by the Govt. as per the agricultural requirement.

ii.

Normally the water cycle is about 10 days per month throughout the year.

iii.

Due to these reasons, water gets contaminated for about 200 days per year.

iv.

Such type of contaminated water has to be treated in W.T. Plant before its utilization
for electricity generation.

v.

Nashik TPS is situated on the downstream of Godavari River and all the waste water
effluents from Nashik City, Nashik Road area, chemical effluent released from MIDC
Industries etc. gets mixed with the Godavari River which lastly comes to NTPS Dam.

21

CHAPTER 11

BOILER OPERATION, MAINTAINANCE AND ITS AUXILIARIES

11.1 INTRODUCTION: Steam boiler or simply a boiler is basically a closed vessel into which water is heated until
the water is converted into steam at required pressure. The utility boilers are large capacity
steam generators used purely for the electrical power generation. In boiler heat energy is
released from the combustion of fossils fuel and heat is transferred to different fluids in the
system and a part of it is lost or left out as unutilized.
The basic working principle of boiler is very simple and easy to understand. The boiler is
essentially a closed vessel inside which water is stored. Fuel (generally coal) is bunt in a
furnace and hot gasses are produced. These hot gasses come in contact with water vessel
where the heat of these hot gases transfer to the water and consequently steam is produced in
the boiler. Then this steam is piped to the turbine of thermal power plant. There are many
different types of boiler utilized for different purposes like running a production unit,
sanitizing some area, sterilizing equipment, to warm up the surroundings etc.
11.2 BOILER MAIN PROCESS: i.

Send DM water to the boiler through boiler drum to boiler tubes.

ii.

Sending fuel (furnace oil and coal) to the boiler through dampers (3000 MT/day).

iii.

Sending required amount of primary (300T/hr) and secondary air (600T/hr) to the
boiler.

iv.

Supplies superheated steam (5400C) of adequate temperature and pressure to turbines.

v.

Extracting flue gases from the boiler and discharging them to atmosphere.

vi.

Removing bottom ash formed as a result of combustion process.

vii.

Removing fly ash from electrostatic precipitator hoppers.

11.3 TYPES OF BOILER USED IN POWER PLANTS: Conventional, Single Drum, Tangentially fired, balanced draught, Natural Circulation,
Radiant Reheat Type, Dry Bottom with Direct Fired Pulverized Coal with Bowl Mill or with
Fuel Oil.

22

Figure 11.1 Corner Fired Boiler

Figure 11.2 Balance Draft Boiler

210 MW BOILERS TECHNICAL SPECIFICATIONS: Table 11.1 Boiler Technical Specifications

BOILER TYPE

TANGENTIALLY FIRED OR CORNER FIRED

COAL

BITUMINOUS COAL

FURNACE

FC

VM

MOIST

37.30%

27.60%

10%

ASH

GRINDABILITY

CV

25%

50 HGI

5000 KCAL/KG

WIDTH

DEPTH

VOLUME

13.8C8M

10.592M

5495 M

TYPE FUSION WELDED TYPE

LIGHT DIESEL OIL

WARM UP OIL

TOTAL

HEATING

22862.10 SQ.M

SURFACE AREA

23

FEED WATER CYCLE: DM Water Feed Storage Tank Boiler Feed Pump HP Heaters LP Heaters Feed
Station Economizer Boiler Drum Boiler Tubes
BOILER PARAMETERS: Table 11.2 Boiler Parameters
MAIN STEAM FLOW @ SH OUTLET

700 T/HR

MAIN STEAM TEMP @ SH OUTLET

540 C

MAIN STEAM PRES @ SH OUTLET

137 KG/CM

REHEAT STEAM FLOW

578.3T/HR

REHEAT STEAM TEMP @REHEAT OUTLET

REHEAT STEAM PRESSURE@REHEAT OUTLET
REHEAT STEAM PRESSURE@REHEAT INLET
FEED WATER TEMP. ECONOMISER INLET

540 C
25.1 KG/CM
27 KG/CM
247 C

11.4 BOILER MAIN AUXILIARIES: Auxiliaries of steam boiler are devices that be installed to the steam boiler, and can make it
operates efficiently. These devices should be maintained and controlled, so steam boiler can
run in good condition. Some of auxiliaries which are installed in steam boiler are:
11.4.1 COAL CYCLE: Coal is pulverized and feed into the boiler in the following steps

Coal mine - unshaped, unsized raw bituminous coal crusher bunker (stack).

Coal bunkers (20mm size coal) coal feeders (controlling input to coal mill) coal
mills.

Powder, pulverized coal lifted by primary air and sending through coal pipes - coal
dampers - to furnace for combustion.

24

11.4.2 FUEL (FO / LDO) OIL CYCLE:

Furnace Oil (FO) / Light Diesel Oil (LDO) Tanks Fuel Oil Pumps Heaters
(Steam) Oil Dampers - Oil Guns To Furnace

Furnace Oil Is Non Explosive, Difficult To Ignite In Bulk, No Spontaneous

Combustion

Expensive Rs. 45-60 Thousand/Kl

Table 11.3 Required Boiler Auxiliaries

BOILER AUXILIARIES

QUANTITY IN NUMBERS

AIR HEATERS

02 NOS.

FUEL OIL PUMPS

03 NOS.

OIL GUNS / IGNITORS

12 NOS. (4 NOS. AT 1 ELEVATION)

COAL MILLS

06 NOS.

PRIMARY AIR FANS

02 NOS.

FORCE DRAFT FANS

02 NOS.

INDUCED DRAFT FANS

02 NOS.

BOILER FEED PUMPS

03 NOS.

EMERGENCY LIFT PUMPS

02 NOS.

SEAL AIR FANS

02 NOS.

SCANNER FANS

02 NOS.

BOTTOM ASH GRINDERS

04 NOS.( 2NOS. FOR ONE PASS)

ELECTROSTATIC PRECIPETATOR

24 ESP FIELDS (48 HOPPERS)

11.4.3 AIR CYCLE:

Primary Air Fans: Mixture cold & hot air supplies to lifting coal to furnace.

Forced Draft Fans: Supplies hot air required for combustion. The function of
forced draft fans is to supply the combustion air initially, when no coal firing is taking
place. But once the coal firing starts, the function of forced draft fan remains only to
supply air required for completing combustion process.

25

Balanced Draft: - Balanced draft is obtained through use of both induced and forced
draft. This is more common with larger boilers where the flue gases have to travel a
long distance through many boiler passes. The induced draft fan works in conjunction
with the forced draft fan allowing the furnace pressure to be maintained slightly
below atmospheric.

Induced Draft Fans: Maintain continuity of combustion and maintain negative

pressure (-ve). Extract flue gases from furnace and discharge them to atmosphere.

Primary Air: - This air lifts the pulverized coal from the coal mills & enters the
boiler with it. The primary air quantity is less with pressure higher so that it can lift
the coal. This air is also used to dry the coal.

Secondary Air: - As air supplied wet coal (Primary air) is less in quantity it is not
sufficient for complete combustion & some quantity of air must be supplied
additionally to complete combustion. This is called secondary air.

Seal Air Fans: - These fans take the suction from cold air duck of primary air system
& their discharge goes to the sealing of gear box of coal mills & its rollers for bearing
sealing.

Scanner Fans: - Scanner fans air supply the cooling air necessary for the cooling of
costly scanner heads. Scanner heads may get damaged if not cooled, leading to outage
of units. These fans take their suction from the discharge of FD in the discharge of
these fans goes to scanner after getting filtered. In case of AC failure when FD fans
trip, there is provision to provide suction to these fans from atmosphere.

Soot Blower System: - The fuel used in thermal power plants causes soot and this is
deposited on the boiler tubes, economizer tubes, air pre heaters, etc. This drastically
reduces the amount of heat transfer of the heat exchangers. Soot blowers control the
formation of soot and reduce its corrosive effects. The types of soot blowers are fixed
type, which may be further classified into lane type and mass type depending upon the
type of spray and nozzle used. The other type of soot blower is the retractable soot
blower. The advantages are that they are placed far away from the high temperature
zone, they concentrate the cleaning through a single large nozzle rather than many
small nozzles and there is no concern of nozzle arrangement with respect to the boiler
tubes.

26

11.5 IMPROVING BOILER AND OVERALL EFFICIENCY OF PLANT:

Economizer: - Absorbs heat from flue gas and add this sensible heat to feed water
before water enters to Boiler. The justifiable cost of the economizer depends on the
total gain in efficiency. In turn this depends on the flue gas temperature leaving the
boiler and the feed water inlet temperature.

Air Pre-Heater: -Flue gases passes through Heater tubes and Cold air passes through
air heater heated up and Hot air used for combustion. An air preheater or air heater is
a general term to describe any device designed to heat air before another process (for
example, combustion in a boiler) with the primary objective of increasing the thermal
efficiency of the process. They may be used alone or to replace a recuperative heat
system or to replace a steam coil.

Super Heaters: - The super heater 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 efficiency. The superheater consists of a superheater header and
superheater elements. Steam from the main steam pipe arrives at the saturated steam
chamber of the superheater header and is fed into the superheater elements.
Superheated steam is more expansive.

Reheater: - The reheater functions similar to the superheater in that it serves to

elevate the steam temperature. Primary steam is supplied to the high pressure turbine.
After passing through the high pressure turbine, the steam is returned to the steam
generator for reheating (in a reheater) after which it is sent to the low pressure turbine.

11.6 FLUE GAS PATH:

Whenever combustion takes place chemical energy converted into heat energy
(depends on CV).

Various gases CO2, SO2, N2, water vapor produced.

Heat carried away through flue gas is used in Air Heater & Economizer to improve
Boiler Efficiency.

Temperature of the flue gases at various stages is given below in the index for (210
MW) Rated output plant. Parameters of flue gas may vary from one plant to other.

27

Table 11.4 Flue Gas Parameters at Various Stages

FLUE GAS PATH

OUTLET

TEMPERATURE

IN C

FURNACE

1123

PLATTERN SUPER HEATER

1010

REHEATER FRONT

823

REHEATER REAR

765

FINAL SUPER HEATER

662

HORIZONTAL SUPER HEATER

479

ECONOMISER

369

AIR HEATER

140

E.S.P.

125

I.D.FAN

120

CHIMNEY

120

COAL AND FLUE GAS CYCLE

Coal from
CHP

Drum
S/H R/H
S/H
Coal
Bunker

Chimney
Boiler

LTSH

FD Fan

HFO

WindBox

Eco

Feeder

ID fan

APH

ESP
Coal Mill
PA Fan

Figure 11.3 Coal and Flue Gas Cycle

28

Materials used for the boiler tubes as per ASME: Table 11.5 Materials for Boiler Tubes
Material

ASTM

Grade

Temperature

Specification

Carbon Steel

SA 210

A1

450oC

Carbon % MO Steel

SA 209

T1

480Oc

1 % Cr, % MO Steel

SA 213

T11

550oC

2 % Cr, 1 % MO Steel

SA 213

T22

580oC

18% Cr, 8 % Ni Stainless Steel

SA 213

T304

Up to 700oC

11.7 BOILER AUXILIARIES SPECIFICATIONS: Table 11.6 ID Fan Technical Specifications

MOTOR
MAKE
CAPACITY

UNIT NO.3
BHEL
1700

UNIT NO.4
BHEL
1300

UNIT NO.5
BHEL
1300

FAN
MAKE
CAPACITY

SPEED
VOLTAGE

990
6.6

990
6.6

990
6.6

CURRENT

175

138

138

TYPE
SPEED
NO. OF
FAN /
BOILER

BHEL
232.5M/SEC
AXIAL
IMPULSE
990 RPM

Table 11.7 PA Fan Technical Specifications

MAKE

BHEL

MAKE

BHEL , KKK

CAPACITY

1250 KW

TYPE

SINGLE SUCTION RADIAL

VOLTAGE

6.6 KV

FAN SIZE

NDF-21 b U#3

FAN SIZE

NDFV-22b U#4&5

CAPACITY

70.33 M/SEC

SPEED

1480 RPM

29

Table 11.8 FD Fan Technical Specifications

UNIT NO.3

UNIT NO.4

UNIT NO.5

MAKE

BHEL

BHEL

BHEL

MAKE

BHEL

CAPACITY

630

750

750

CAPACITY

105.5 M/SEC

SPEED

990

1491

1491

TYPE OF
FAN

AXIAL
IMPULSE

VOLTAGE

6.6

6.6

6.6

FAN TYPE

AN 20e6 U#3

CURRENT

68

79

79

TYPE OF
FAN

IGV
OPERATIO

PNEUMATIC

HYDRAULIC

HYDRAULIC

FAN TYPE

MOTOR

FAN

AXIAL
REACTION
API-18/11
U#4&5

Table 11.9 Air Pre-Heater Technical Specification

TYPE

TRISECTOR ROTARY AIR

PREHEATER(LIUNGSTORM)

SIZE

27 VI 72

MAKE

NO OF AIR HEATERS

CAPACITY

11 KW

INSTALLED POSITION

VERTICAL

VOLTAGE

415 V

1067 MM

CURRENT

22 AMP

HEIGHT
OF
INTERMEDIATE LAYER

457 MM

SPEED

HEIGHT OF COLD END

LAYER
GAS TEMP.

305 MM
141 C

HEIGHT
LAYER

OF

HOT

MAIN DRIVE MOTOR

CROMPTON
GREAVES

END

DRIVE
MOTOR

30

1440 RPM
2 NOS.

CHAPTER 12

TURBINE OPERATION, MAINTAINANCE AND ITS AUXILIARIES

12.1 INRODUCTION: Turbine is an engine that converts energy of fluid into mechanical energy. The steam turbine
is steam driven rotary engine.Steam Turbine Converts the Heat Energy (Kinetic Energy) into
Mechanical Energy.
12.2 WORKING PRINCIPLE OF STEAM TURBINE: i.

A steam turbine works on the principle of conversion of High pressure & temperature
steam into high Kinetic energy, thereby giving torque to a moving rotor.

ii.

For above energy conversion there is requirement of converging /ConvergingDiverging Sections.

iii.

Such above requirement is built up in the space between two consecutive blades of
fixed and moving blades rows.

12.3 TYPES OF STEAM TURBINE: According to the principle of action of the steam, turbine can be classified as:
i.

Impulse Turbine: - In a stage of Impulse turbine the pressure/Enthalpy drop takes

place only in fixed blades and not in the moving blades.

ii.

Reaction Turbine: - In a stage of Reaction Turbine the Pressure/enthalpy drop takes

place in both the fixed and moving blades.

TURBINES IN NTPS NASHIK: 210 MW Turbine at Nashik is three cylinders (HP, IP, LP) Tandem compound with nozzle
governing, condensing & regenerative feed heating type.

The HPT comprises of 12 stages, the first stage being governing stage.

The IPT comprises of 11 stages.

The LPT has 4+4 stages .Steam enters at middle & flows in opposite paths having
four stages.

Turbine rotors are supported on five bearings .The common bearing of HP & IP rotor is a
combined journal & radial thrust bearing. Rest four bearings are journal bearings.
12.4 CONSTRUCTION AND STEAM FLOW: -

31

The turbine is tandem compound machine with HP, IP, & LP parts. The HP part is a
single flow cylinder & IP & LP parts are double flow cylinders.

The individual rotors & generator rotor are connected by rigid couplings.

The HP cylinder has a throttle control. The initial steam is admitted before the blading
by two combined main steam stop & control valves.

The lines leading from the two HP exhaust branches to the re heater are provided with
swing a check valve which prevents hot steam from re heater flowing back in to the
HP cylinder.

The steam coming from the re heater is passed to the IP part via two combined reheat
stop & control valves cross around pipes connect the IP & LP cylinders.

Bleeds are arranged at several points of the turbine.

12.5 VALVES: It is a mechanical device to control the flow of fluid in pipe. Valves are said to be nerve
centre of power plant controlling high pressure steam & water.

The HP turbine is fitted with two initial steam stop & control valves.

A stop & control valve with stems arranged right angle to each other are combined in
a common body.

The stop valves are spring operated single-seat valves, the control valves, are also of
single seat design, have diffusers to reduce pressure losses.

The IP turbine has two combined reheat stop &control valves.

The reheat stop valves are spring loaded single seat valves.

The control valves, also spring loaded, have diffusers. The control valves operate in
parallel & are fully open in the upper load range.

In the lower load range, they control the steam flow to the IP turbine & ensure stable
operation even when turbo set is supplying only the station load.

Both the main & reheat stop & control valves are supported kinematically on
foundation ceiling below the machine floor before the turbo set.

All valves are individually operated by oil hydraulic servomotors.

12.6 TURBINE GOVERNING SYSTEM: -

32

The turbine has an electro-hydraulic governing system backed with a hydraulic

governing system.

An electric system measures & controls speed & output, & operate the control valves
hydraulically in conjunction with an electro hydraulic converter.

The electro hydraulic governing system permits run up control of turbine up to rated
speed & keeps speed swings following sudden load shedding low.

The linear output frequency characteristic can be very closely set even during
operation.

12.7 OIL SUPPLY SYSTEM:

A single oil supply system lubricates & cools the bearing, governs the machine
operates the hydraulic actuators & safety and protective devices & drives the
hydraulic turning gear.

The main pump is driven by the turbine shaft draws oil from the main oil tank.
Auxiliary oil pumps maintain the oil supply on start up & shut down. During turbine
gear operation & when MOP is faulted.

When the turning gear is stared, jacking oil pumps force high pressure oil under the
shaft journals to prevent boundary lubrication.

The lubricating & cooling oil is passed through oil coolers before oil supply.

12.8 TURBINE MONITORING SYSTEM:

In addition to measuring instruments & instruments indicating pressures,

temperatures, valve positions &speed, the monitoring system also includes measuring
instruments & indicators for the following values.

Absolute expansion, measured at the front & rear bearing pedestal of the HP turbine.

Differential expansion between the shafting & turbine casing, measured at several
points.

Bearing pedestal vibrations, measured at all turbine bearings.

Relative shaft vibrations measured at all turbine bearings .absolute shaft vibrations,
obtained from bearing pedestal vibration & relative shaft vibration by calculation.

12.9 FIXED POINTS:

There is no restriction on axial movement of the casings.

33

In designing the supports of the turbine on the foundation, attention is given to the
expansion and contraction of the machine during thermal cycling.

Excessive stresses would be caused in the components if the thermal expansion or

contractions were restricted any way.

The method of attachment of the machine components, and their coupling together,
are also decisive factors in determining the magnitude of the relative axial expansion
between the rotor system & turbine casings, which is given careful attention when
determining the internal clearances in the design.

TURBINE MAIN DATA: Table 12.1 Turbine Technical Specifications

RATED OUTPUT OF TURBINE

210 MW

RATED SPEED

3000 RPM

RATED PRESSUE OF STEAM

EMERGENCY STOP VALVE

BEFORE
130 KG/CM

RATED LIVE STEAM TEMPERATURE

535 C

RATED STEAM PRESSURE

23.20 KG /CM

RATED STEAM PRESS. AF

535 C

STEAM FLOW

616 TON/HR

STEAM FLOW AT VALVE WIDE OPEN

CONDITION
RATED PRESSURE AT THE EXHAUST OF LPT

670 TON/HR

RATED CIRCULATING WATER TEMP.

30 C

RATED QUALITY OF CIRC

27000 M/HR

63.3 MM HG COL

OIL PUMPS: Table 12.2 Oil Pump Technical Specifications

MOTOR
MAKE

PUMP
BHEL,HARIDWAR

MAKE

CAPACITY

200 KW

SPEED

VOLTAGE
CURRENT

6.6 KV
21.8 AMP

HEAD
DISCHARGE

SPEED

985 RPM

34

MATHER & PLATT,PUNE

970 RPM
220 M
200 M/HR

Figure 12.1 Steam Turbine and Regenerative Heating

Figure 12.2 Steam Turbine Rotor

35

12.10 STEAM TURBINE STARTS UP: When warming up a steam turbine for use, the main steam stop valves (after the boiler) have
a bypass line to allow superheated steam to slowly bypass the valve and proceed to heat up
the lines in the system along with the steam turbine. Also a turning gear is engaged when
there is no steam to the turbine to slowly rotate the turbine to ensure even heating to prevent
uneven expansion. After first rotating the turbine by the turning gear, allowing time for the
rotor to assume a straight plane (no bowing), then the turning gear is disengaged and steam is
admitted to the turbine, first to the astern blades then to the ahead blades slowly rotating the
turbine at 10 to 15 RPM to slowly warm the turbine.
12.11 PRECAUTIONS DURING RUNNING: Problems with turbines are now rare and maintenance requirements are relatively small. Any
imbalance of the rotor can lead to vibration, which in extreme cases can lead to a blade letting
go and punching straight through the casing. It is, however, essential that the turbine be
turned with dry steam. If water gets into the steam and is blasted onto the blades (moisture
carryover) rapid impingement and erosion of the blades can occur, possibly leading to
imbalance and catastrophic failure. Also water entering the blades will likely result in the
destruction of the thrust bearing for the turbine shaft. To prevent this, along with controls and
baffles in the boilers to ensure high quality steam, condensate drains are installed in the steam
piping leading to the turbine.
12.12 MATERIALS FOR STEAM TURBINE DESIGN: i.

ii.

Blades

Stainless Steel 403 & 422 (+Cr)

17-4 PH steel (+ Ti)

Super Alloys

Rotor

High Chrome Moley Steel Cr-Mo-V

Low Ni Chrome Steel Ni-Cr-Mo-V

36

CHAPTER 13

GENERATOR
13.1 INTRODUCTION: In electricity generation, a generator is a device that converts mechanical energy to electrical
energy for use in an external circuit. The source of mechanical energy may vary widely from
a hand crank to an internal combustion engine and turbine used in power plants. Generators
provide nearly all of the power for electric power grids.
13.2 PRINCIPLE OF GENERATION: - GENERATION OF AC POWER
The basic requirements for generation of AC power are as follows.
i.

Conductor

ii.

Magnetic field

iii.

Relative speed

Faraday's laws of electromagnetic induction

First Law: - Whenever there is change in magnetic flux associated with a coil, an emf
is induced in it.
Second law: - The magnitude of induced emf is directly proportional to the rate of
change of flux through the coil.
Maximum electric speed to be achieved is 3000 RPM being 50 cycles per sec. is the quality
of electric supply in our India.

Thus maximum speed shall be achieved by 2 poles machine. However multi pole generators
are used for Hydro Power Stations as speed depends upon depth of reservoirs i.e., water
pressure, water head available at first stage of runner of turbine.

37

Figure 13.1 Turbo-Generators

Figure 13.2 Generator Transformer

38

CHAPTER 14

STEAM CONDENSING SYSTEM

14.1 INTRODUCTION: Thermoelectric power plants boil water to create steam, which then spins turbines to generate
electricity. The heat used to boil water can come from burning of a fuel, from nuclear
reactions, or directly from the sun or geothermal heat sources underground. Once steam has
passed through a turbine, it must be cooled back into water before it can be reused to produce
more electricity. Colder water cools the steam more effectively and allows more efficient
electricity generation.
Wet-recirculating or closed-loop systems reuse cooling water in a second cycle rather than
immediately discharging it back to the original water source. Most commonly, wetrecirculating systems use cooling towers to expose water to ambient air. Some of the water
evaporates; the rest is then sent back to the condenser in the power plant. Because wetrecirculating systems only withdraw water to replace any water that is lost through
evaporation in the cooling tower, these systems have much lower water withdrawals than
once-through systems, but tend to have appreciably higher water consumption.
14.2 STEAM CONDENSING SYSTEM COMPONENTS: i.

Condenser

ii.

Cooling tower

iii.

Hot well

iv.

Condenser cooling water pump

v.

Condensate air extraction pump

vi.

Air extraction pump

vii.

Boiler feed pump

viii.

Make up water pump

ix.

Deaerator

x.

Air Ejector

xi.

Drain Cooler

xii.

Feed Water Heaters (HP/LP Heaters)

39

Condenser: The main purposes of the condenser are to condense the exhaust steam from the turbine for
reuse in the cycle and to maximize turbine efficiency by maintaining proper vacuum. As the
operating pressure of the condenser is lowered (vacuum is increased), the enthalpy drop of
the expanding steam in the turbine will also increase. This will increase the amount of
available work from the turbine (electrical output). By lowering the condenser operating
pressure, the following will occur:
a. Increased turbine output
b. Increased Plant efficiency
c. Reduced steam flow

Figure 14.1 Diagram of a Typical Water-cooled Surface Condenser

Hot Well: These are small storage tank of condensate water below condensers. They are maintained at
required level of condensate with the help of Hot Well Level Controller, provided just before
drain cooler. They are also equipped with make-up lines from DM Storage Tank and Surge
Tank.
Suction Well: This is the storage well of condensate water and condensate pump is submerged in this well.
It is provided with continuous vent connection to condenser to maintain the flow of
condensate water from condenser by neglecting its vacuum.

40

Condensate Pump: There are two multistage centrifugal condensate pumps but both are capable of delivering
full load individually. It delivers condensate to SPE.
Cooling Tower: A cooling tower extracts heat from water by evaporation. In an evaporative cooling tower, a
small portion of the water being cooled is allowed to evaporate into a moving air stream to
provide significant cooling to the rest of that water stream.
Cooling Towers are commonly used to provide lower than ambient water temperatures and
are more cost effective and energy efficient than most other alternatives. The smallest cooling
towers are structured for only a few litres of water per minute while the largest cooling
towers may handle upwards of thousands of litres per minute. The pipes are obviously much
larger to accommodate this much water in the larger towers and can range up to 12 inches in
diameter.
When water is reused in the process, it is pumped to the top of the cooling tower and will
then flow down through plastic or wood shells, much like a honeycomb found in a bees nest.
The water will emit heat as it is downward flowing which mixes with the above air flow,
which in turn cools the water. Part of this water will also evaporate, causing it to lose even
more heat.
Steam Packing Exhauster (SPE): This is a surface type heat exchanger which transfers the heat energy of packing steam to the
condensate water and condenses packing steam (drip) in turn, which are drained to the
condenser through an atmospheric drain tank. Its shell is equipped with an Air Blower to
evacuate non-condensable gases to atmosphere.
Air Ejector: It is a double stage twin steam jet ejector which acts as an air pump. Its main function is to
maintain vacuum by pulling out air and non-condensable gases from the condenser. Exhaust
steam from jet ejector are made to pass from inter and after condenser where heat of jet steam
is transferred to condensate coming from SPE.

41

Drain Cooler: The air from condensate water, which is exhausted to atmosphere through a vent condenser.
The bled steam directly condenses and gets mixed with condensate water from heater, and
this is passed to storage tank.
Deaerator: A deaerator is a device that is used for removal of oxygen and other dissolved gases from the
feed water to steam-generating boilers. In particular, dissolved oxygen in boiler feed water
will cause serious corrosion damage in steam boiler systems by attaching to the walls of
metal piping and other metallic equipment and forming oxides (rust).
Feed Water Heaters: This item is installed to improve power generator efficiency by heating supplied water and
reducing breakage due to heat stress from temperature differences in boiler tubes. Because a
single heater consists of cooling areas, condensing areas, and heating areas, this item requires
thoughtful engineering and production.
Feed water heaters are classified as low and high pressure heaters with one heater consisting
of overheating, condensing and overcooling areas, making it difficult to design and produce.
Use one or more low pressure feed water heaters to raise the temperature of condensate from
condensate pump discharge temperature to the de-aerator inlet temperature. Use one or more
high pressure feed water heaters to raise the temperature of feed water from de-aerator outlet
temperature to the required boiler economizer inlet temperature.
Condenser Data: Table 14.1 Condenser Technical Specifications
MAKE
COOLING SURFACE AREA
NO. OF COOLING TUBES
LENGTH OF COOLING TU
DIA.OF COOLING TUBE
NO. OF WATER PATHS FOR EACH
CONDENSER
DESIGNED CONSUMPTION OF COOLING
WATER
QUANTITY OF STEAM CONDENSING
MAIN EJECTOR
STARTING EJECTOR

42

BHEL
14650 M
15652
10M
30/28 MM
2
27000 M/HR
150 TO 500 T/HR
2 NOS.
1 NO

CHAPTER 15

BOILER FEED WATER PUMP

15.1 INTRODUCTION: A boiler feed water pump is a specific type of pump used to pump feed water into a steam
boiler. The water may be freshly supplied or returning condensate produced as a result of the
condensation of the steam produced by the boiler. These pumps are normally high pressure
units that take suction from a condensate return system and can be of the centrifugal
pump type or positive displacement type.
15.2 CONSTRUCTION AND OPERATION: Feed water pumps range in size up to many horsepower and the electric motor is usually
separated from the pump body by some form of mechanical coupling. Large industrial
condensate may also serve as the feed water pump. In either case, to force the water into the
boiler, the pump must generate sufficient pressure to overcome the steam pressure developed
by the boiler. This is usually accomplished through the use of a centrifugal pump. Another
common form of feed water pumps run constantly and are provided with a minimum flow
device to stop over pressuring the pump on low flows. The minimum flow usually returns to
the tank or deaerator.
Boiler Feed Pump Data: Table 15.1 BFP Technical Specifications
MOTOR

PUMP

MAKE

BHEL , HARDWAR

MAKE

BHEL,HYDERABAD

CAPACITY
VOLTAGE
CURRENT
SPEED

4000 KW
6.6 KV
408 AMP
1485 RPM

TYPE
NO.OF STGES
SPEED
LUBRICATION

200 KHI
6
4320 RPM
FORCED

HEAD

1830 MLC

DISCHARGE

430 T/HR

43

CHAPTER 16

ASH HANDLING PLANT

16.1 INTRODUCTION: To generate one unit, as per design we have to burn 0.55 kg coal. But actually we have to
burn 0.65 kg coal.
Indian coal has

Calorific Value- 5000 Kcal/ Kg.

Fixed Carbon 38%

Volatile Matter 26%

Moisture 8%

Ash Content 28%.

16.2 TYPES OF COAL ASH: Coal ash is the residue of the coal combustion process involved in the thermal power plants.
The types of coal ash from coal based thermal power plants are:
i.

Fly Ash: - Collected from different rows of electrostatic precipitator.

ii.

Bottom Ash: - Collected at the bottom of boiler furnace.

iii.

Pond Ash: - Mixture of bottom ash and fly ash as available in ash disposal ponds.

One 210 mw set requires

0.65*5.04*1000=3276 tonne coal per day.
Ash content is 28%
I.e. 3276*0.28=917.28 tonne i.e. 920 tonne.
Out of this 28% ash
Bottom ash 15 to 20% i.e. 138 to 184 tonne
Fly ash 80 to 85% i.e. 734 to 780 tonne
Contents of ash

Silica

Alumina

Iron oxide

44

Calcium

Magnesium

Sulphate

Alkalis

16.3 BOTTOM ASH SYSTEM: It consists following main components:

Bottom ash hopper

Clinker grinder

Ejector feed pump

Hydro ejector

16.4 FLY ASH SYSTEM: The system for all units is identical and following description is applied to both the units the
water compounded bottom ash hopper receives the bottom ash from the furnace from where it
is stores and discharged through the clinker grinder. Two slurry pumps are provided which is
common to all units & used to make slurry and further transportation to ash dyke through
pipeline.
Ash particles are separated by passing through electrical field (Electrostatic Precipitator).
Components in ESP:

Discharge electrode (-ve)

Collecting electrode (+ve )

Rapping mechanism

Fly ash hopper

High tension voltage equipment

16.5 AREAS OF FLY ASH UTILISATION: Fly ash can be used for various applications. Some of the major areas of fly ash utilization are
as follow:

Fly ash bricks

Fly ash cement

Reclamation of waste land

45

Fly ash based components for construction industry.

Sintered aggregate

Wood substitute doors & panels

Granite substitute

Ceramic tiles

Paints & enamels

Reclamation of ash ponds for human settlement

Figure 16.1 Electrostatic Precipitator

Common causes of unsatisfactory performance of ESP are:

Excessive gas volume

Overloading

Ineffective rapping

46

Overfilling of dust hoppers

Poor gas distribution

Flashover and electrical instability

Discharge wire breakage

Fig 16.2 Typical View of Ash Handling Plant

47

CHAPTER 17

ENERGY CONSERVATION AND ENERGY AUDIT

17.1 ENERGY CONSERVATION: Energy conservation means to reduce the quantity of energy that is used for different
purposes. This practice may result in increase of financial capital, environmental value,
national and personal security, and human comfort.
Individuals and organizations that are direct consumers of energy may want to conserve
energy in order to reduce energy costs and promote economic, political and environmental
sustainability.
On a larger scale, energy conservation is an important element of energy policy. In general,
energy conservation reduces the energy consumption and energy demand per capita. This
reduces the rise in energy costs, and can reduce the need for new power plants, and energy
imports. The reduced energy demand can provide more flexibility in choosing the most
preferred methods of energy production. By reducing emissions, energy conservation is an
important method to prevent climate change. Energy conservation makes it easier to replace
non-renewable resources with renewable energy. Energy conservation is often the most
economical solution to energy shortages.
17.2 ENERGY AUDIT: An Energy Audit is a systematic exercise to identify end-uses that consume a significant
amount of energy, estimate the efficiency in each of these end uses and devise methods of
improving efficiency curbing losses and wasteful use or in other words it is an inspection,
survey and analysis of energy flows for energy conservation in a building, process or system
to reduce the amount of energy input into the system without negatively affecting the output.
It attempts to balance the total energy inputs with its use and serves to identify all the energy
streams in a facility. When the object of study is an occupied building then reducing energy
consumption while maintaining or improving human comfort, health and safety are of
primary concern. Beyond simply identifying the sources of energy use, an energy audit seeks
to prioritize the energy uses according to the greatest to least cost effective opportunities for
energy savings.

48

CHAPTER 18

CONCLUSION
It was a knowledgeable experience while taking practical training at NASHIK THERMAL
POWER STATION. It proved an opportunity for encounter with such huge machines like
tippler, turbine, boiler and generator. But there are few factors that require special mention.
From all the study it can be concluded that the Nasik thermal power project of 210X3 units is
fairly organized unit with the latest machinery available. The turbine is a very sophisticated
assembly of machinery which requires specific conditions of steam temperature and pressure
to work efficiently. Any alteration of the specific requirements may prove hazardous to the
turbine. Another interesting yet worrying fact is the quantity of coal consumed which
approximately 3276 tonne per day. The level of pollution is always controlled according the
established norms, but still I consider it to be quite enough. Well, efforts are always
underway in reducing the pollution and improving the efficiency of the plant. All in all, a
thermal power project is very large establishment with many components and it awesome to
see how all the components work in a synchronized manner.
The Electricity Act 2003 and subsequent National Electricity Policy and Tariff Policy have
Opened up several opportunities for the power sector. The Act allows the IPPs and captive
Power producers open access to transmission system, thus allowing them to bypass the SEBs
and sell power directly to bulk consumers. Slowly open access in distribution system is also
being allowed.
Assessment of the financial feasibility of the Proposed Project, delivers satisfactory financial
Parameters as per base financial model. It has also assessed the viability of the project under
the impact of various scenarios, which could be at variance with the base case scenario
assumed.
Company has proposed to set-up 660 MW Coal fired Thermal Power Project based on
Super Critical Technology. State Government has supported this Project and has issued letter
of support to provide all kind of administrative support required.

49

CHAPTER 19

SUGGESTIONS
Power sector is an essential service and in the basis of industrialization and agriculture. It
plays a vital role in the socio-economic development. Therefore, improving efficiency of
these thermal power stations in addition to increasing their PLF (Plant Load Factor) has
become the need of the hour to bring the cost and maximize the generation levels. With this
objective in view, several actions have already been initiated by Ministry of Power (MOP)
and other various agencies like CEA, NTPC, State Electricity Boards, CBIP etc. to improve
the operating efficiency and PLF of thermal power stations.
Now I here make it sort with my suggestions for improving efficiency of power plant and for
various other factors on the basis of what I have learned during my training are:

With the deficit of electricity in our country, there is need of many projects and the
exposure limit should be increased to effectively assist the new projects.

Proper maintenance of ESP must be done with regular maintenance of boilers and
furnaces.

Variable speed motors should be used.

Auxiliaries power reduction.

Use of automatic system for monitoring flue gases.

Completely insulate the steam system.

Turbine driven Boiler Feed Pumps should be used.

The plant is working fine with not many hindrances, but the main concern is the
cleanliness of plant. The plant, especially 140X2 units building of the plant is not
clean enough. What I believe is that cleaner environment might help in improving of
productivity and decrease the rate of breakdowns. This might improve the efficiency
of the unit as lesser number of foreign elements will be present which prevent the
proper functioning of the unit. If the efficiency increases, the coal consumption will
be reduced for the same load and that would provide better profit to the organization.

Recover the portion of heat loss from the warm cooling water existing the steam
condenser.

Reduce air, water, steam and flue gas leakages.

50