Kota Super Thermal Power Station Industrial Training Report
Kota Super Thermal Power Station Industrial Training Report
INTRODUCTION
For the power generation with 2x110 MW and 3x210 MW of K.T.P.S. authorities are required to be operative to active full operation. The auxiliaries are basically operation either on L.T. System i.e. 415 V 3 power supply is made available to the system after providing the station transformer of 3x50 MVA capacity with voltage 220 KV/ 7.2/7.2 KV & different service transformers of capacity 1.0 MVA, 1.5 MVA, 2.0 MVA, which are located near the load centre as the transformer having the voltage of 6.6 KV /415 V. a control through DC of 220 V. The 415 V power supply is done through a L.T. SWGR (Switchgear) which are located nearby the distribution transformer as well as the load centers. The all in -comers, which are breaker controlled, are having the control the L.T. SWGR are having the control system on 110/ 220 V AC. The 6.6 KV power supply which are either MOCB (Minimum Oil Circuit Breaker) of JYOTI MAKE or Air Circuit Breakers. The 6.6 KV power supply to various draining g equipments i.e. more is made through breakers which are either MOCB of Jyoti make air circuit breaker which are either of voltage makers as well as SF 6 of NGEF make. The LT supply is also controlled through air break circuit breaker, which are either L&T make or English Electric Company of India. The various H.T. motors are switched on / started through on direct ON line (DOL) in order to inverse the availability of equipment at full efficiency without time gap. The 6.6 KV power is distributed through 6.6 KV interconnected Bus System for all the five units with
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Further , the 6.6 KV system which is normally in delta configuration and terms as an unearthed system so also to keep the running motor complete in operating condition in case of any one .phase of motor winding is earthed due to any one reason. Earthling is detected by an protection system with alarm facility to take remedial measures immediately and at the same time to maintain the generation level in the same condition, prior to occurring the earth fault the single phase earth fault is detected in due course till the motor is not earthed to other or another phase. PUBLIC ADDRESS SYSTEM is available through in area of each unit which helps in fast communication for prompt remedial measure. Soot Blowers are there in the boiler area on the furnace side or Zone which helps in blowing the soot / ash deposition regularly of the furnace wall / economizer tubes to keep heat transfer at the required parameter. In April 1973, Central Electricity Authority prepared a Project Report for power station comprising of the two units of each of capacity 110 MW for RSEB subsequently in September, 1975 this was revised by the Consultant Thermal Design Organization , Central Electricity Authority for invention of 2x110 MW units being manufactured by BHEL, Hyderabad in 1st Stage. The planning commission cleared the project report in Sept., 1976 for installation of two units each of 110 MW in first estimated cost of Rs. 143 Crores.
Total Power Generation - 1240 MW* (* To be commissioned shortly in Sept, 2009.) A I E T / D O E E / P T S /02
1.2.2 LAND Land measuring approx. 250 hectares was required for the project in 1976, For disposal of ash tank very near to power station is acquired which the ash in slurry form is disposed off through ash and slurry disposal plants. 1.2.3 COAL Coal India limited owns and operates all the major coal fields in India through its coal producing subsidiary companies viz. Eastern Coal Fields Limited, Western Coal Fields Limited Coal India limited is supply coal from its coal mines of coal producing subsidiaries BCCL, SECL & ECL to Kota Thermal Power Station through railway wagons. The average distances of SECL, ECL & BCCL are 800, 950 and 1350 Kms. respectively. 1.2.4 WATER The source of water for power station is reservoir formed by Kota Barrage on the Chambal River. In case of large capacity plants huge quantities of coal and water is required. The cost of transporting coal and water is particularly high. The transportation of Therefore, as far as possible, the plant must be located near the pit rather than at load centre for load above 200 MW and 375 MW. electrical energy is more economical as compared to the transportation of coal.
1.3 DESIGN FEATURES The satisfactory design consists of the flowing steps.
Estimation of cost. A I E T / D O E E / P T S /03
Selection of site. Capacity of Power Station. Selection of Boiler & Turbine. Selection of Condensing Unit. Selection of Electrical Generator. Selection of Cooling System. Design of Control and instrumentation system. The design of steam power station requires wide experience as the subsequent operation and maintenance are greatly affected by its design. The most efficient design consist of properly sized component designed to operate safely and conveniently along with its auxiliaries and installation.
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CHAPTER 2
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Air from the atmosphere is supplied to the combustion chamber of Boiler through the action of forced draft fan and induced draft fan. The flue gas gases are first pass around the boiler tubes and super heated tubes in the furnace, next through dust collector (ESP) & then economizer. atmosphere through fans. Finally, they are exhausted to the
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Figure 2.1 CROSS SECTIONAL VIEW OF FOUR MAJOR PART FORM A POWER PLANT
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CHAPTER 3
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Meanwhile the heat reloaded from the coal has been absorbed by kilometers long tubes which lies in boiler walls inside the tubes Boiler Feed Water which is transferred into turbine blades and makes them rotate. To the end of the turbine rotor of generator is coupled, so that when turbine rotates the rotor turns with it. The rotor is housed inside the stator having coil of copper bars in which electric is produced through the movement of magnetic field created by rotor. The electricity passes from the stator winding to the transformer, which steps up the voltage so that it can be transmitted effectively over the power line of grid. The steam which has given up its heat energy in changed back into a condenser so that it is ready for reuse. The cold water continuously pumped in condenser. The steam passing around the tubes looses heat and rapidly change into water. But these two types of water ( boiler feed water and cooling water ) must never mix together. The cooling water is drawn from the river but the Boiler Feed Water must be pure than potable water ( DM Water). Now the question arises why do we bother to change steam from turbine to water when it is to be heated up again immediately ? Laws of Physics gives the answer which states that the boiling point of water is related to pressure. The lower the pressure lower the boiling point temperature. Turbine designer wants boiling point temperature as low as possible because it can only utilize the energy from steam when change back to water, he can get no more work out at it. So there is a condenser which by rapidly changing the steam into water a vacuum. The vacuum results in a must power at lower boiling points which in turn mean it can continue getting out of steam will below 1000C at which it would change into water.
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To condense volume of cooling water is huge and continuous volume of cooling water is essential. In most of the power stations , the same water is to be used over and over again, so the heat which the water extract from the steam in the condenser is removed by pumping water out of cooling tower. The cooling tower is simple concrete shell acting of air. The water is sprayed out at top of tower and as it falls into pond beneath it cooled by the upward draft of air. The cold water in the pond is then re-circulated by pumps to condensers. Invariably however some of the water drawn upwards as vapor by the draft.
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CHAPTER 4
SWITCH YARD
220 KV SYSTEM Two 220 KV bus bars have been provided in switch yard and are inter-connected through a bus coupler. Each of the two 110 MW generator is connected to this system through a step up of 125 MVA 240/ 11 KV yard generator transformer. There are two step down transformer each feeding 6.6 KV system ( Station Switchyard ) viz. BS-IS & SB-IB. Each station transformer has two windings one secondary side and is rated for 50/25/25 mva , 270/7/7.2 kva four feeder take off from 220 switch yard, two to SKATPURA ,GSS and other to HEERAPURA , Jaipur GSS. Each of four feeder are provided with bypass isolators which is connected across line breaker and breaker isolator. By closing bus coupler between 220 KV buses and putting line feeders whose breaker required maintenance of any one bus through by pass isolators and all other line feeders whose breaker is by passed is then transformed to bus coupler breaker. A brief description of equipments of 220 KV system is as follows.
4.2 ISOLATOR
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All the isolators are provided in 220KV switchyard and are motor operated. Triple pole double breaker type and power switch yard L&T make these and are rates for 245 KV and 1250 A. The four isolators are provided with earth switch.
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It has larger value of capacitance and will change upto line voltage. If we have to do some work on line, first earth line through earthing isolator for discharging the line capacitance and then work.
Rated Frequency. No. of Phase. Class of Insulation Rated Primary Voltage. Secondary Voltage Wdg.I Wdg.II.
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CHAPTER 5
DC SYSTEM
5.1 INTRODUCTION
D.C. system play important role in all the major industries. We can call it as back bone of industries. It can be utilized and stored during specific duration. Charging the battery initially to keep the batteries trickily charged and to mention the and load in normal time, a separate equipment called charger is a must.
5.2 RECTIFIER
A.C. supply is converted to D.C. by this component only. SCRs. It has two major
classification. The basic components which are use now a days are diodes and
5.3 CLASSIFICATION
Rectifiers are classified as follows: 1) 2) a) b) c) Half wave rectifier. Full wave rectifier. Uncontrolled. Half controlled. Fully controlled.
5.4 FILTER
Filters are used for smoothing the D.C. output voltage from rectifier unit. Chock input filter, and capacitor input filter is two type of filter in chock, input filters, the chock blocks A C ripples if any ripples get through chock, passes through capacitor ( very low xc) which appears to open for D C signals. In capacitor input filter the capacitor following output wave and get charge to peak voltage Vp when rectifier conducts. One output voltage stands to reduce from peak voltage, the capacitor stands discharging and keep voltage almost constant. A I E T / D O E E / P T S /017
Here the charger output voltage is always maintained at constant voltage equal to reference voltage irrespective of charger output current. So some current limitation has to be provided in this mode. This mode will be ideal for keeping the batteries in floating condition and to meet the loads.
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5.7.2
In this charger put current will be maintained at reference current sitting. It do not take care of voltage condition. This mode will be useful for calculating all rating of batteries charged.
5.8 PROTECTIONS
In A C side charges may be provided with overload protection to avoid overload, fuses and single phasing and phase fail protection. Sometime provided with AC under voltage and AC abnormal voltage protection. In DC side, Diodes and SCRs will be provided with semiconductor fuses for fast action on short cut faults. Output will be provided with HRC fuses converted output will be continuously monitored in each link to find the failure.
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CHAPTER 6
TURBO GENERATOR
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6.1.1 THEORY
TURBO GENERATOR manufactured by B.H.E.L. and incorporated with most modern design concepts and constructional features, which ensures reliability, with constructional & operational economy. The generator stator is a tight construction, supporting & enclosing the stator windings, core and hydrogen coolers. Cooling medium hydrogen is contained within frame & circulated by fans mounted at either ends of rotor. The generator is driven by directly coupled steam turbine at a speed of 3000 r.p.m. the Generator is designed for continuous operation at the rated output . Temperature detectors and other devices installed or connected within then machine, permit the windings, teeth core & hydrogen temperature, pressure & purity in machine under the conditions. The source of excitation of rotor windings is thyristor controlled D.C. supply. The auxiliary equipments supplied with the machine suppresses and enables the control of hydrogen pressure and purity, shaft sealing lubricating oils. There is a provision for cooling water in order to maintain a constant temperature of coolant (hydrogen) which controls the temperature of windings.
It is built up of special sheet laminations and whose assembly is supported by a special guide bass. The method of construction ensures that the core is firmly supported at a large number of points on its periphery. The laminations of high quality silicon steel which combines high permeability with low hystersis and eddy current losses. After stamping each lamination is varnished on both sides with two coats. The segment of insulating material is inserted at frequent intervals to provide additional insulation. The laminations are stamped out with accurately fine combination of ties. Laminations are assembled on guide bass of group separated by radial ducts to provide ventilation passage. The ventilation ducts are disposed so as to distribute the gas evenly over the core & in particularly to give adequate supports to the teeth. At frequent intervals during stacking the assembled laminations are passed together in powerful hydraulic press to ensure tight core which is finally kept between heavy clamping plates which are non-magnetic steel. Use of non-magnetic steel reduces considerably by heating of end iron clamping. The footed region of the core is provided by pressing figures of non-magnetic steel, which are welded to the inner periphery of the clamping plates. In order to reduce the losses in the ends packets special dampers are provided at either ends of core. Mostly dampers are provided to prevent hunting in ac machines.
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Stator bars are manufactured as half bars. Each stator half coil is composed of double glass cover and bars of copper transposed in straight portion of Robill Method so that each strip occupies every radial portion in the bar. For an equal length along the bar. They are made in strips to reduce skin effect. The winding The arrangement reduces additional losses due to overhead is in volute shape. The overhung portion of the bar is divided into four quadrants & insulated . damping currents which otherwise be present due to self-induced non-uniform flux distribution in the coil slots. The main distribution for the bar consists of resin rich mica loosed thermosetting epoxy. This has excellent mechanical and electrical properties & does not require any impregnation. Its moisture absorbing tendency is very low and behavior of mica is for superior than any other conventional tape insulation system. Semi-conductor coating is also applied to a part of overhung with a straight overlap of conductive coil in the sides to reduce eddy currents to minimum. Conductor material is electrolytic copper connections brazed with free coating silver alloy to obtain joints , which are both electrically & mechanically sound.
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Stator windings are double star layers, lap wound, three phase, short pitch type. The top & bottom are brazed and insulated at either end to form turns. Several such turns form a phase. Phases are connected to form a double star winding. The end of winding form involutes shape ends, inclined towards machine axis by 20 o, thus form a basket winding with total induced conical angle of 400 . Due to this stray load losses in the stator ends to zero. The arrangement of complete stator winding electrical circuit is viewed from turbine end of generator & rotor windings. Slot numbering is clockwise from turbine end. A thick line identifies the top bar in slot No.1 . End windings will be sealed against movement of short circuit by both axial & peripheral bracing. The later consists of hardened glass laminated blocks inserted between adjacent coil sides in coil overhangs, so that with the coils , they form a continuous rigid ring. Glass cord or top is used lashing the packing of blocks. The complete assembly is secured b y high tensile brass blots. The winding is designed to withstand short circuit stresses. The exposed portion of windings are finally coated. Insulation of individual bars & stator windings at various stress is tested with applied high voltages of AC of Hz.
6.1.7 BEARINGS
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Generator bearings have electrical seats of consists of steel bodies with removable steel pads. The bearings are formed for forced lubrication of oil at a pressure of 2-3 ATM/ From the same pump that supplies oils to the turbine , bearings & governing gears. There is a provision to ensure & measure the rotor bearing temperature by inserting a resistance thermometer in the oil pockets.
6.1.10 APPLICATIONS
RTD & its associated equipments are designed for use with Generator to determine temperature at various parts & places. The equipments consists of two parts :-
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Leads from RTD are brought out to the terminal board by cables through conduits to protect them from physical damage and from contact with high voltage coils. Some RTDs are in stator teeth with 7 spacers, 7 RTDs between the coil sides in stator slots with 7 spacers and 3 RTDs are there in the stator core with spacers. The location of RTDs is in three phases i.e. in the centre of machine, in each region of machine and midway between them. The detectors in the stator slots are distributed uniformly in all three phases. Measurement of temperature of Hydrogen cooling water for Hydrogen coolers & metals is as : Six RTDs are provided at the inlets of each of six individual Hydrogen cooler elements for measurement of temperature of Hydrogen, similarly Six RTDs are provided at the outlets also. One RTD along-with one spacer is provided in the lower part of stator frame for measurement & signalization of hot Hydrogen. Six RTDs are provided at outlets of each of six individual Hydrogen Cooler elements for measurement of temperature of cooling water at the outlet.
6.2 ROTOR
Rotor shaft consists of single piece alloy steel forging of high mechanical and magnetic properties performance test includes :1. Tensile test on specimen piece. A I E T / D O E E / P T S /026
2. 3. 4. 5. 6.
Surface examination. Sulfur prist tests. Magnetic crack detection. Visual examination of bore. Ultrasonic examination.
Slots are milled on the rotor gorging to receive the rotor winding. Transverse slots machined in the pole faces of the rotor to equalize the moment of inertia in direct and quadrilateral axis of rotor with a view minimizing the double frequency.
6.2.3 BEARINGS
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The bearings are self-aligned & consist of slip steel shells linked with special bearing metal having very low coefficient of friction. The bore is machined on an elliptical shape so as to increase the mechanical stability of the rotor. The bearing are pressure lubricated from the turbine oil supply. Special precautions are taken to prevent oil & oil vapor from shaft seals and bearing along the shaft. The circulation of shaft current is liable to damage. The bearing surface is protected by insulation so placed that the bearings, seals & necessary pipes are inclined from the frame.
Generator stator bars are insulated with mica insulation, which is homogeneous in nature and practically impervious to moisture, and reduce time required to draught. The insulation resistance of the stator phase winging against earth and with reference to other phases under hot condition shall not be less than the value obtained automatically. Rin U Rin = = = /(s/100+1000) m 52 rated winding Voltage under test. insulation resistance under hot conditions
Rated o/p of turbo generator. The insulation resistance of entire excitation system circuit. In hot condition must not fall below 0.5 m 52. The insulation resistance in calculated as per the formula : Rin Rin Rv U1 = = = = Rv (U1 +U2) /( U-1) Insulation resistance of exciter () Internal resistance of voltmeter () Voltage measured btw. Slip ring & shaft/ earth(volts).
When starting the drying process, the winding insulation resistance will usually decrease when the drying process becomes effective; the insulation will gradually increase.
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In KSTPS hydrogen cooling system is employed for generator cooling. Hydrogen is used for cooling medium primarily because of its superior cooling properties & low density. Thermal conductivity of hydrogen 7.3 times of air. It also has higher transfer co-efficient. Its ability to transfer heat through forced convection is about 75% better than air. Density of hydrogen is approx. 7/14 of the air at a given temperature and pressure. This reduces the windage losses in high speed machine like turbo-generator. Increasing the hydrogen pressure the machine improve its capacity to absorb & remote heat. Relative cooling properties of air and hydrogen are given below: 1) 2) 3) Elimination of fire risk because hydrogen will not support combustion. Corona discharge is not harmful to insula ? since oxidation is not possible. Smooth operation of machine in view of vertical elimination of wind age noise & the use of heavy gas light enclosure and dirty proby casing. At pressure 0.035 atm. of hydrogen heat carrying capacity is 1. But at 2.0atm. of hydrogen heat carrying capacity is 1.95 to overcome the serious possibility of hydrogen explosion with in the machine and to ensure the safety of operation purity of hydrogen on the generator. Casing must be maintained as high as possible. The purity of hydrogen should be 98% above but should not be less than 98%. In case of hydrogen purity drops below 98% an alarm is provided. 6.2.7.2 HYDROGEN DRYERS Two nos. of dryers are provided to absorb the hydrogen in the Generator. Moisture in this gas is absorbed by silica gel in the dryer as the absorbed gas passes through it. The satural of silica gel is indicated by change in its color from blue to pink. The silica gel is reactivated by heating. By suitable change over from drier to the other on un-interrupted drying is achieved. 6.2.7.3 HYDROGEN FILLING SYSTEM
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The filling operation is carried out in two steps. Scavenging the air by CO2 with
2) 3) 4) 5)
Nos. of thyristor converters. An automatic voltage regulator (AVR). Field suppression equipment. Field flashing equipment.
RECTIFIER TRANSFORMER
This transformer steps down the bus voltage 11 KV to 640 V and has a rating of 1360 KVA. It is dry type, it is however provided with current relays and two temperature sensors. 6.4.2 A THYRISTOR CONVERTOR The thyristor panel and are intended for controlled rectification of AC Input power. 6. Thyristor converter are connected in parallel each rates for continuous current o/p of 20 % of the rated capacity i.e. 20 % reserve. Each thyristor converter consists of 6 thyristor connected in 3-3 , full wave, 6-pulse bridge from and they are cooled by fans provided with a fuse for protection against short circuit. 6.4.3 AUTOMATIC VOLTAGE CONTROLS The AVR is a transistorized thyristor controlled equipment with very fast response. The AVR is also having provision of stator and rotor currents limits and load angle limits for optimum utilization of lagging and leading reactive capacities of generator.
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6.4.4 FIELD SUPRESSION EQUIPMENT The field equipment consists of a field breaker with discharge resistors. The field breakers have 4 main breaking contacts and two discharge contacts, which close before main contact break. (a) (b) (c) (d) (e) A very fast response. Extremely reliable in view of static components. Low maintenance cost. High efficiency. Fast field suppression through field and discharge resistance as well as through thyristor bridge, feeding the Generator field.
6.5 OPERATION
After bringing the speed to operation speed say 3000 r.p.m. , the voltage is slowly built up with the help of excitation system. This action is taken for synchronizing the Generator. 6.5.1 SYNCHRONIZING For synchronizing the Generator to the grid system 5 condition of equality have to be satisfied. These are (I)_Voltage (II) Frequency (III) Phase displacement (IV) Phase sequence (V) Wave form. Wave form and phase sequence of the Generator are determined at the design of each connection SYNCHRONIZING of the generator. 6.5.2 MACHINE CONNECTED TO INFINITE BUS While separating a machine in parallel with grid we will have two condition:(a) Any increase in the power input of the Generator increase its share of electrical loads (b) any excitation in the excitation of Generator increases its of relative load. A I E T / D O E E / P T S /033
Type t.g.p. 234602 h rating: continuous apparent o/p : 137,500 kva active o/p 710,000 kw power factor a ; 0.8 (lagging) rated voltage 1000V +5% rated: current 7220 A , critical speed : 3000 r.p.m. frequency 50 Hz. Phase connection : double star , No. of terminals : 6 . Main dia. of slip ring : 420 . Max. O/p with H 2 cooler including DC component : 9.2 (peak) inherent voltage regulation : 39% efficiency of turbo-Generator including 0.5. Loads 100 75 80 25 % Loads 100 75 80 25 At 0.8 pf lag 98.32 %, 98.29% 98% 97.84% At unity pf 98.8% 98.76% 98.52% 97.56% Reactance: Informative. HYDROGEN COOLER Nos. of elements: Cooling medium: Discharge losses: Quantity of H2: Quantity of water Temp: Cooling cold H2 Temp.: How resistance(H2 side): Inherent voltage regulation: Short circuit ratio: Type: 0.5%. HC-WLL-BS/C46. 34oC, 400C 12 mm. of peak. 39% 6 Water, H2 at 2 ATM. 1500 KW. 30 M3/ sec.
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CHAPTER 7
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.
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(1) 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. (2) 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. 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. Simple impulse steam turbine. The pressure compounded impulse turbine. Simple velocity compounded impulse turbine. Pressure-velocity compounded turbine. Pure reaction turbine. Impulse reaction turbine.
Direction of rotation viewing from Clockwise The front bearing pedestal. Rated steam pressure before Stop valve. Maximum steam pressure before 146 ata 130 ata
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stop valve. Rated temperature of steam before the stop valve. Maximum temperature of steam before the stop valve. Rated pressure of steam MP Casing. Rated pressure of steam before MP Casing. Rated Temp. of steam before MP Casing. Maximum Temp. of steam before MP Casing. Informative heat flow at the economic output. Informative heat rate at the rated output. HP Cylinder 2 row carts wheel + 8 moving wheels. MP Cylinder 12 moving wheels. LP cylinder 4 moving wheels of 2152.5 K Cal/Kwh. 2135 K cal/Kwh 545oC. 535oC. 35 ata 31.6 ata 545oC 535oC
double row design. Quantity of oil for first filling. 1800 liters. A I E T / D O E E / P T S /038
Single flow HP turbine with 25 reaction stages. Double flow IP turbine with 20 reaction stages per flow. Double flow LP turbine with 8 reaction stages per flow. 2 main stop & control valves. 2 steam check valve in 2 reheat stop & control valves,. CRH.
At KSTPS there are 2x110 MW turbines installed for unit 1 & 2 and 3 210 MW turbines installed for units 3, 4 & 5, one 195 MW turbine installed for unit 6 ( Under final stage of construction & generation of power is expected in August, 2003).
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210 MW steam turbine is a tandem compound machine with HP, IP & LP parts. The HP part is single flow cylinder and HP & LP parts are double flow cylinders. The individual turbine rotors and generator rotor are rigidly coupled. The HP cylinder has a throttle control. Main steam is admitted before blending by two combined main stop and control valves. The HP turbine exhaust (CRH) leading to reheated have tow swing check valves that prevent back flow of hot steam from reheated, into HP turbine. The steam coming from reheated called HRH is passed to turbine via two combined stop and control valves. The IP turbine exhausts directly goes to LP turbine by cross ground pipes. 7.4.2 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. 7.4.3 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. The double flow inner casing is supported kinematic ally 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 flow 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.
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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. 7.4.4 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. 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 released from the combustion of fossils fuel and heat is transferred to different fluids in the system and a part of its is lost or left out as unutilized. It is therefore essential to study. The general principal of heat transfer for understanding the design as well as the behavior of boiler during different condition of operation.
Figure 7.1 CROSS SECTIONAL VIEW OF STEAM TURBINE 7.5 Heat transfer modes: There are three modes of heat transfer viz. conduction, convection and radiation, one or more of these modes for which heat source should be at higher temperature than the receiver transfers heat energy hot surface to a heat recover. 7.5.1 CONDUCTION Conduction is the heat transfer from one part of body to another part of the same body or from one body to another in physical contact without appreciable displacement of the particles of the body. 7.5.2 CONVECTION A I E T / D O E E / P T S /041
Convection is the transfer of heat from one point to another within a fluid by mixing of one part with another due to the movement of the fluid. When the movement of fluid is caused solely by the differences in density resulting from temperature differences in density resulting from temperature differences within fluid.
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7.5.3 RADIATION Radiation is the transfer of heat energy from one body to another by electromagnetic waves which can travel even through vacuum when radiation impinges on a body, some of the radian energy will re-radiated, some of it will be transmitted through the body and remainder will be absorbed.
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This is also convection heat transfer section located in a relatively cooler gas temperature zone and preheats the water entering the drum. point of view. The inlet temperature should not be less than 140oC from the low temperature corrosion The outlet temperature should be 35-45oC lower than the saturation point to avoid the streaming tendency in the economizers. 7.7.4 AIR HEATERS The technical developments of the air pre-heater provide regenerative type air heaters. The air temperature required for drying in the case of coal fired boiler decided the size of the air heaters.
1.
Type
2. 3. 4. 5. 6. 7.
: : : : :
No. of fans in service. a) ID fans. b) FD fans. c) PA fans. d) Seal Air fan. e) Scanner Air fan f) Igniter fan. : : : : : 540oC. 3 Nos. service. 70 Nos. : : : 2 Nos. 2 Nos. 2 Nos. : 1 No. 1 No. 1 No.
8. 9. 10.
7.11 FUEL
7.11.1 COAL Type Quantity consumed Type of handing. Ash disposal d: : : : Slack Coal. 3074 tonnes per day. Conveyor. Wet system. A I E T / D O E E / P T S /045
7.11.2 OIL Type Quantity a) HSD 5520 KL per year. * b) Furnace Oil : 28800 KL per year. *No. of chimney / stack.: 1 / 2. Height of Chimney. : 180 Meters. 198 M3/ Sec. : HSD and fuel oil.
The air required for combustion is supplied by two forced draft fans.
Due to
anticipated high abrasion of ID fans impellers. Three ID fans each of 60% capacity have been provided one ID fan to serve as standby. For ensuring safe operation of boilers, furnace safe guard supervisory system (FSSS) of combustion engineering USA designed has been installed. This equipment systematically feed fuel to furnace as per load requirement. The UV flame scanners installed at two elevation in each of the four corners of the furnace, scan the flame conditions and in case of unsafe working conditions but out fuel and trip the boiler and consequently the turbine. flame failure. Facilities have been provided to simultaneously unload and transfer 10 light oil and 40 heavy oil tankers to the designated tanks. Oil preheating arrangement is provided on the tanks floors for the heavy oil tanks. Superheated steam temperature is controlled by attemperation. Re-heater steam temperature is primarily by tilting fuel burners through + 30o and further control if necessary is done by attemperation. Turbine boiler interlocks safe guarding the boiler against possibility furnace explosion owing to
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CHAPTER 8
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It unloads the coal from wagon to hopper. The hopper, which is made of Iron , is in the form of net so that coal pieces of only equal to and less than 200 mm. size pass through it. The bigger ones are broken by the workers with the help of hammers. From the hopper coal pieces fall on the vibrator. It is a mechanical system having two rollers each at its ends. The rollers roll with the help of a rope moving on pulley operated by a slip ring induction motor with specification: Rated Output. Rated Voltage. Rated Current. Rated Speed. No. of phases. Frequency. : : : : : : 71 KW. 415 V. 14.22 Amp. 975 rpm. 3 50 Hz.
The four rollers place themselves respectively behind the first and the last pair of wheels of the wagon. When the motor operates the rollers roll in forward direction moving the wagon towards the Wagon Table. On the Wagon table a limit is specified in which wagon has to be kept otherwise the triple would not be achieved. 8.1.2 CRUSH SYSTEM 8.1.2.1 CRUSHER HOUSE It consists of crushers which are used to crush the coal to 20 mm. size. There are mainly two type of crushers working in KSTPS:Primary Crushers i.e. i) Rail crushers or ii) Rotary breaker. Secondary Crushers. i.e. 8.1.2.2 PRIMARY CRUSHERS A I E T / D O E E / P T S /049 Ring granulators.
Primary crushers are provided in only CHP stage 3 system , which breaking of coal in CHO Stage 1 & Stage 2 system is done at wagon tripler hopper jail upto the size (-) 250 mm. 8.1.2.3 ROLL CRUSHER Type Capacity Feed material Feed size. End Product size Motor rating. Crushers. : : : : : : : 80 5 A breaker. 1350 TPH Rates/ 1500 TPH Design. Rom Coal. (-) 1200 mm. (approx.) (-) 500 mm. 2 Nos. 125 KW , 100 rpm. 225.
8.1.2.4 ROTARY BREAKER Type Capacity Feed Material. Feed size End product size Motor rating. Breaker rpm. : : : : : : : 12 x 21o Rotary Breaker. 800 TPH Rated/ 1000 TPH Design. Coal with rejects. (-) 0-500 mm. (-) 0-200 mm. 125 HP, 1500 rpm. 12
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Basically there are four ways to reduce material size: impact attrition, Shearing and Compression. Most of the crushers employ a combination of three crushing methods. Ring granulators crush by compressing accompanied by impact and shearing. The unique feature of this granulator is the minimum power required for tone for this type of material to be crushed compared to that of other type of crushers.
Belt width. Speed. Schedule of motor Bucket wheel motor Boom Conveyor motor Intermediate Conveyor Boom Housing Motor Slewing assembly Travel Motor. Vibrating Feeder. Total installed power.
: : : : : : : : : : :
1400 mm. 2.2 m/second. All 3- induction motors. 90 KW. 70 KW. 90 KW. 22 KW. 10 KW. 7.5 KW. 2x6 KW. 360 KW.
2) 750 tonne per hour. No. of conveyor. Horizontal length. Angle of induction. Lift(M) (approx.) Belt width. : : : : : 38 28 meters. As per conveyor profile drg. Variable to suit the system. 1400 mm.
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RPM 1480 1480 1470 1480 1480 1480 1470 1485 1485 1470 1470 1470 1470 1490 1490
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S. No 16.
Conveyor 2C
RPM 1490
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Table 8.1
CHAPTER 9
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9.5 CONTROLLER
Now a days micro-processor based intelligent controllers are used to lectrode the output of controller s reduced to zero for few millisecond for quenching the spark. Controller also takes place care of fault in KVR and gives a trapping and non-trapping alarm as per the nature of fault.
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wrapping system is automatically controlled with the help of the programmable metal controller, located in the ESP auxiliaries control panels. The bottom of the hopper is heated up by two avoid any formation to wet mass of fly ash specially during rainy season. The heating effect help the dry ash to flow freely during evacuation. Heaters are controlled with the help of thermostat.
CHAPTER 10
Sodium Sulphate solution of required strength is dosed into different filtered water by mean of dosing pump to neutralize chlorine prior to activated carbon filter. When water passed an activated carbon filter will remove residual chlorine from water. Provision is made for back washing the activated carbon filter. When pressure drop across filter exceeds a prescribed limit from the activated carbon filter the works acid cation unit. The deception water the weak base anion exchanger unit water then enters de-gasified unit where free CO2 is scrubbed out of water by upward counter flow of low pr. air flow through degasified lower and degassed water is pumped to strong base exchanger ( anion exchanger). Arrangement for dosing ammonia solution into de-mineralized water after mixed bed unit has been provided p+1 correction before water is taken in de-condensate transfer pump the DM water to unit condensor as make up.The softening plant is plant designed to produce 100M3 of the softened water per stream. It is used for bearing cooling.
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CHAPTER 11
CONTROL ROOM
11.1 MAIN CONTROL ROOM
In control room various controls are provided simultaneously various measurement are made various relays are provided here. Instrumentation Limited Kota is major supplier of apparatus. There is one unit control from which two adjacent unit of 110 MW each can be controlled. In addition are local panels at the boilers, turbo sets and boiler feed pumps. The operation of unit is basically controlled from unit control room. The operation of various rents and chain are done locally as per requirement. The unit control room has a set of parameters panel for indicating or recording parameter of boilers or turbo sets. The parameters recorded in control room included per pr. and temp. of line steam, reheat steam , feed water, fuel oil flow, mill outlet temp. ,mill differential , turbine speed, control valve operation, turbine shaft , axial shaft , back pressure in condenser , metal temperature etc. There is a data logger to ensure accurate lagging of essential data. The VCB also control panel for one generator and contains exciter synchronizing arrangement. The unit control room also houses most of electronic regulator, relay, recorders and other devices in near side of room. The scheme of control and instruction is provided to control the parameters and safe operation of equipment. Automatic control is provided for combustion for feed water regulation and reheat temp. The combustion control is designed to inlet maintain the desired steam pressure at turbine only variation thereof utilized to very fuel input to the boiler w.r.t. steam pressure. Ratio steam flow maintained automatically. The feed water regulation is based on impulses from drum level, feed water flow to boiler and steam flow for the boiler. A I E T / D O E E / P T S /062
Super heater temp. counted with feed water spray. The furnace draft control of draft fan. The boiler oil system is provided with itself control for ignition control and also provided with safety interlock to prevent operation under low oil pressure and temperature.
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c) d)
Figure 11.1
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CHAPTER 12
PROTECTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Field Protection. Pole Slipping. Plane Overload Protection. Inter-turn Fault Negative Phase Sequence Protection. Reverse Power Protection. Forward Power Protection. Under Frequency & Over Frequency Protection. Generator Voltage Protection. Rotor Earth Fault Protection.
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CHAPTER 13
c) Max. efficiency. BHEL (86.6 + 1) % d) Capacity. e) Steam Pressure f) Steam Temp. g) No. of draft fans in 375 tonnes 1 Hr. 139 Kg./cm2 540oC, i) FD fans 2 Units ( Each boiler) ii) ID fan 2 Units ( Each boiler ). h) No. of Air fans in Service. i) Primary 2 Units. 1 Unit.
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3 Units.
B)
OIL
i) Type. ii) Qty. used. HSD & Furnace Oil. As per requirement & draft conditions.
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CONCLUSION
The first phase of practical training has proved to be quiet fruitful. It provided an opportunity for encounter with such huge machines like wagon tippler .110 MW & 210 MW turbines and generators. 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 lean low technology used at proper place and time can cave a lot of labour e.g. wagon tippler (CHP). But there are few factors that require special mention. 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. 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. There should be strict monitoring of the performance of students and system of grading
SAMEEKSHA VIJAY
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REFERENCE
http://www.mapsofindia.com/kota/industries/super-thermalpower-plant.html
http://en.wikipedia.org/wiki/Thermal_power_station
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