 INDEX

 Acknowledgement
 Introduction
 DSTPS : Andal 2x500 MW Power Plant
 Coal Handling Plant
 Ash Handling Plant
 DM Plant
 Boiler
 TG Section

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 ACKNOWLEDGEMENT
The successful completion of any task would be incomplete without mentioning the names of
the person who helped us to make it possible. We take this opportunity to express our
gratitude to those who helped us in the completion of the project despite their hectic schedule.

Firstly, we would like to express our sincere gratitude towards Mr.A.Sarkhel for his
guidance.

We are also thankful to following person for their co-operation during our training period----

o MR. A. Sarkar

o Mr.V.N.Sharma

o Mr. Ajoy kumar

o Mr. D.D.Dubey

o Mr.S.N.Dutta

o Mr.M.K.Singh

We also like to express our gratitude to the officials and other staff members of DSTPS , Andal who rendered
their help during our training period .

GROUP MEMBERS:

o PRASENJIT KAR

o SUBHANKAR SAMANTA

o PRATEEK DAS

o PICKON GHOSH

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 Damodar Valley Corporation
The Damodar Valley Corporation, popularly known as
DVC, is the first multipurpose river valley project of
independent India. The corporation came into being on
7th July, 1948 by an Act of Constituent Assembly of
India (Act no XIV of 1948).

The initial focus of DVC were flood control,

irrigation generation, transmission and distribution of
electricity, eco-conservation and afforestation and job
creation for the economic well-being of the people
residing in and around the affected areas. However over
the past few decades, power generation has gained
priority.

Damodar Power Stations At A Glance

Thermal Power Stations:

NAME LOCATION CAPACITY

BOKARO’B’ Bokaro,Jharkhand 630MW(3x210MW)

CHANDRAPURA Bokaro,Jharkhand 390MW(3x130MW)

DURGAPUR(DSTPS) Burdwan,West Bengal 350MW(1x140+1X210MW)

MEJIA Bankura,West Bengal 1340MW(4x210+2x250MW)

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DSTPS : ANDAL 2x500 MW POWER PLANT

This project report on the ‘Vocational Training’ is submitted on the basis of self undergone first –
hand training at Durgapur Steel Thermal Power Station (DSTPS) , from 21ST June ,2012 to 14th July
2012. Here two units ,each of capacity 500MW, are being constructed by M/s BHEL who has been
awarded this contract on Turnkey basis by M/s Damodar Valley Corporation ( DVC) , the owner of
this project , having the head office at Kolkata.

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 NAME OF PROJECT—

2x500MW DURGAPUR STEEL THERMAL POWER STATION

LOCATION—

Andal, Durgapur, District- Burdwan ( West Bengal)

AREA—

The total area of the plant is 3.47sqkm.

COMMUNICATION—

The site is located 0.5km away from NH-2. The nearest railway station is
Andal station which is about 3km away from the site.

SYNOPSIS—

 2km North of Andal and 12km North of Durgapur railway station on Howrah-
Asansol line of eastern railway and about 800m from NH-2 in Burdwan district
of West Bengal.

 Longitude 8712’ to 8714’ and Latitude 2333’ to 2334’.

 Eastern railway at Andal Station is 1.5km from the project site.

 Durgapur reservoir is on Damodar river.

 Land is 1169 acres.

 Rehabilitation is as per DVC R&R Package of 2007

 Requirement is 15000 tonnes per day.

 Source is ECL-Non-Ranigunj.

 Transportation is by rail.

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 Dry fly ash collection is utilized in cement, bricks , concrete block making and
backfilling of abandoned Coal mines , Road embankments.

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 TG SECTION

 TURBINE:-

It is a prime mover which is used to convert the the thermal energy

possesed by the steam into kinetic energy of the blade of the turbine.This

energy is then converted to electric power by a Generater with the help of

Exitor.

 Fluid (steam) turbine pressure and temprature enters the

turbine.It passes through stationary and rotary blades and lossses

it energy((by means of pressure and temperature) to the turbine

rotor and turbine rotor rotates to rotate the generator.

 At the entrance pressure gets converted to velocity( partly) at

stationary nozzle and in subsequent rotary stages pressure as well

velocity drops while transferring the kinetic energy to the rotary

blades. Stationary blade is responsible for guiding the steam and

partial drop in pressure.

 The turbine is coupled with the rotor of the generator which rotates

as the turbine blades rotate so as produce the power output.

 N.B.:- The set of turbine used at Andal site are of the impulse reaction

type.

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  CONTROL VALVE:-

The control valve at the entrance of the turbine

controls the amount of steam entryto the turbine controls the amount of steam
entry to the turbine and in turn LOAD/SPEED.

 STOP VALVE before the control valves shut off the steam entry in case
of emergency which is called "TRIPPING OF MACHINE".

 OPERATION:
The control valves opening and closing is controlled by the demand of
load/speed being generated in the governing system. This governing is electro-
hydraulic. It can be opened at any percent as per requirement. Valves operated
with oil and comparison of signals are in
electronic cards and coupling of these two is done by a solenoid coil and
hydraulic amplifier.

TURBINE TYPES
 HP TURBINE :-

This turbine is characterised by a small size and presence of a

unidirectional increasing moving and fixed blades. Since the steam passes over
the turbine blades resulting in a corresponding decrease in pressure and
enthalpy, the volume of the steam increses and hence, the blade are made
continously increasing in size. The blades ancere of aerofoil section, and are
rimmed throughout thier periphery so as to increase thier strength.
Here, the flow occurs in a single direction , and hence bearings are provided so
as to balance the resultant axial and radial thrusts produced due to flow.
The steam from this turbine goes back to the boiler for reheating via the cold
reheat line. Steam is bled from this line for high pressure heating in the HP
HEATER. Also steam is bled from suitable points of this turbine for use in the
DEAIRATOR.

 IP TURBINE:-

This turbine is usually larger than the HP turbines. Here the blades are placed in
two parts in opposite direction, and hence the blades are bidirectional. The
blades are continously increasing in size in both directions. Here the steam after
reheating in the boiler enters via the hot reheat line by two paths - one from the
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top and another from bottom, at the centre of the turbine ,and then drives
symmetrically and expands in both the direction. This is done so as to balance
the axial thrusts. The steamleaves by two paths and goes to the LP turbines.

 LP TURBINE:-

This turbine is the biggest in size. Its blades are similar in construction and
shape to that of the IP Turbine. Here the steam enters from two directions as
well - but from the front and from the back, for the same purpose.
This turbine is coupled to the generator for electrical power production.

 POWER GENERATION

The turbine shaft is coupled with the generator rotor, which is in turn coupled
With the exitor rotor, further coupled with the PMG (Permanent Magnet). The
rotation of the PMG induces a voltage in its stator part. This induced voltage is
transferred to the exitor stator. In the exitor, magnetic flux lines are cut because
of which AC current is induced in the rotor part of the exitor. in between the
generator and the exitor, a diode is placed for rectification purpose (AC to DC).
This DC current passes through the rotor of the generator, which is responsible
for the formation of a rotating magnetic field. Magnetic flux cutting in voltage
induction in the stator thus producing power transmitted by 3-phase lines.

Number of Stages:

Stages of HIGH PRESSURE TURBINE: 17

Stages of INTERMEDIATE PRESSURE TURBINE: 12 for per

Flow (double flow)

Stages of LOW PRESSURE TURBINE:6 per flow(double flow)

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SPECIFICATION:

Rated output: 500 MW

Rated Speed: 3000 r.p.m.

Inlet Steam Pressure: 166.71 kgf/cm2

Inlet Steam Temperature: 540 0C

Reheat Steam Temperature : 540 0C

Overall Length: 19.94 meters

 TURBINE GENERATION AUXILLIARIES

1) CONDENSER

2) CONDENSATE EXTRACTION PUMP

3) EJECTOR

4) LP HEATER

5) HP HEATER

6) BOILER FEED PUMP

7) DEAIRATOR

 CONDENSER

Condenser is basically a heat exchanger. Steam after moving

through the turbine passes through the condenser. The use of a condenser
enhances the efficiency of the power plant by reducing the exhaust pressure of
steam below atmospheric pressure. The condenser basically condences the
exhaust steam into water. The use of condenser also helps in recycling of this
condensed steam again & again as boiler feed water & this in turn reduces the
capacity of the water softening plant. Air & other non-condensable gases

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present in the exhaust steam are removed when this steam is passed through the
condenser.

Vacuum is maintained inside the condenser to extract maximum energy from

steam as at lower pressure the heat loss is less. To increase the inside vacuum of
the condenser CEP pumps are used in the power plant.
CONDENSATE EXTRACTION PUMP :-

The function of this pump is to extract the condensed steam from the
condenser & deliver it to the ejector

 Specification of CEP :-

1. BHRC 28T type CONDENSATE EXTRAXTION PUMPS (210 MW)

2. PUMP

3. 3 numbers per unit

4. Multistage, vertical turbine centrifugal pump

5. Low specific speed, medium head

6. Medium capacity

7. Discharge 2811T/hr

8. Manometric Head-201m

9. NPSH -3.5m

10. RPM - 1489

11. No. of stages -8

12. HP - 256

13. MOTOR

14. Power - 220kw (300HP)

15. Voltage - 6.6kV

No. of CEP pumps for each boiler unit:- 3

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  EJECTOR:-

It takes out the air & other non-condensable gases from the
condenser & maintained the vacuum level in it.
 LP HEATER:-

Water coming out of the Ejector is heated at low pressure in the

LP Heater. This heating is done by bleeding steam point from the low pressure
turbine.

 SPECIFICATION:

Low pressure Heater- 1:

Shell side Tube side

Design pressure 3 & F.V. kg/cm2 40 kg/cm2 g

Design temp. 155 0C 152 0C

Surface Area : 1312 m2

Weight : 26000 kg

Low pressure heater- 2,3:

Shell side Tube side

Design pressure 4 & F.V kg/cm2 g 40kg/cm2 g

Design temp. 216 0C 152 0C

Surface Area : 1312 m2

Weight: 26000 kg

 DEAIRATOR:-

It is fitted between the LP heater & heater to draw out the dissolved
gases & air present in the feed water. It uses hot steam for this purpose as high
temp. reduces the solubility in the feed water, thus driving them away. This
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steam is bled from the cold reheat line from the HP Turbine.
HP HEATER:-

Water coming out of the Deairator is heated in the HP Heater at

high pressure.

Specification of HP heater:

High pressure heater - 5A & 5B :

Shell Side Tube Side

Design pressure: 24 kg/cm2 g 330kg/cm2 g

Design Temp. 224 0C 244 0C

Surface Area: 964 m2

Wieght : 44500 kg

High pressure heater - 6A & 6B

Shell Side Tube Side

Design pressure 57kg/cm2 g 330 kg/cm2 g

Design Temp. 273 0C 293 0C

Surface Area: 1145 m2

Wieght: 54000 kg

BOILER FEED PUMP:-

Feed water is delivered to the boiler with the help of boiler feed
pump. There are two types of BFP's:

1) MDBFP- Motor Driven boiler feed pumps. Here we have 2 such pumps.
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These pumps are used when the plant is not in full operation.

2) TDBFP- Turbine Driven boiler feed pumps. Here we have a single such
pump. It is used when the plant is in full running condition.

There are B.F.P. in D.S.T.P.S. Two of them are turbine operated and the rest
one is motor operated.

 Specifications of TDBFP:

Type- Centrifugal

Qty: 990m3/hr

Head: 2050 m

Speed : 5465 r.p.m.

Temp: 161.8 0C

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  Specifications of MDBFP:

Normal Speed : 3000 r.p.m.

Set speed : 300 r.p.m.

Speed range : 100-1000 r.p.m.

Parts of a BFP:

1) BOOSTER Pump

2) Hydraulic Coupling

3) Feed Pump

Working of BFP:

Water with more than required NPSH goes to suction branch

into the intake spiral and from here is directed to the first impeller. After leaving
through the impaller it passes through the distributing passages of the diffuser
where it gets certain pressure rise & flows over to guide vanes to the inlet of the
next impeller.

COLLING WATER CYCLE:

VARIOUS PARTS OF A CW CYCLE:

1) CW PUMP AND PUMP HOUSE

2) DUCTS

3) HOTWELL

4) NDCT(Natural Draught Colling Towers)

5) CW RESERVOIR

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  CW PUMPS AND PUMPHOUSE:-

The C.W. Pump house comprises mainly of three parts-

a) Sump area

b) Feed pool

c) Duct area

The Sump is the most important area in the C.W. Pump house.

Here 8 nos. chambers are constructed where CW pumps are placed. The

water in these chambers will be pumped to condenser through C.W.

conduits. The water from the colling tower is conveyed into the feed pool

through the CW duct. Water is stored in the feeed pool and sump area.

Apart from the 8 CW Pumps, we have two AUXILLIARY COLLING

WATER Pumps(ACW Pumps).

 DUCTS:

Ducts are used to transmit the cooling water from the CW Feed

pool or reservoir, to the condenser, and back from the hot well to the cooling
towers.

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  COOLING TOWER

A cooling tower is a semi-enclosed device for evaporative cooling of water by

contact with air. It is a wooden, steel or concrete structure and corrugated
surfaces or troughs or baffles or perforated trays are provided inside the tower.
The hot water coming out of the condenser fed to heat tower on the top and
allowed to tickle in form of hot sheets or drops. The air flows from bottom of
the tower or perpendicular to the direction of water flow and then exhaust to be
atmosphere after effective cooling. To prevent the escape of water with air, draft
eliminators are provided at the top of the towers.

NATURAL DRAFT COOLING TOWER

In natural draft cooling tower, the air flows naturally fan through tower and
provides the required cooling. The shape of the tower is circular in plan and
hyperbolic in profile. It is made of steel reinforced concrete and the bottom of
the tower is 9.4 m above the reference level. The coolong tower breaks the
warm water into a spray or a film of water by forcing it through a nozzle and
exposes it to a flow of air.this film of water is allowed to fall through water
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distributing troughs or fill packs so that more loss of heat takes place from the
water droplets.

the cooled water droplets are accumulated in the reservoir from where it is
passed to cooling water pool. CW pumps forced this water from cw pool to the
condenser which after being heated by the heat of the stream returns to the
cooling tower. In natural draft cooling tower the flow of air through it is
established by chimney action. The flow is created by the density difference
vapour which is lighter than air and the density of high humidity provides
necessary pressure head for creating the flow. The difference in the density is
considerably small so the height of the cooling tower required to create positive
flow of air is considerably large compared with mechanical towers.

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 Specification:-
There are two cooling towers at DSTPS.

Height: 126 meters

Base Diameter: 95.5 meters

Throat Diameter: 49.66 meters

Top Diameter: 56.8 meters

Number of Precast Beam: 1116

Shape: Hyperboloid

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Over the lifetime of structure, it expose to severe frost action in a saturated
state, chemical attacks due to noxious substances in the atmosphere and in the
water and water vapour, biological attacks due to micro-organisms, and the
possibly chemicals attacks due to reintroduced cleaned flue gases. The cooling
towers have following properties:

 High resistance against chemical attacks coating of copolymer in an

acrylic-vinyl resin base.

 High structural density

 High resistance against frost

Advantages:

a. Since no fans are needed, power cost and auxiliary equipments are
eliminated and therefore operating and maintenance costs are consequently
reduced. It gives more or less travel free operation.

b. Hyperbolic tower's chimney shapes creates its own draft assuring efficient
operation even when there is no air.

c. The enlarged top of the tower allows water to fall out of suspension.

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 Disadvantages:

a. Its initial cost is considerably high.

b. Its performance varies with the seasonal changes and RH of the air.

POWER GENERATION SYSTEM

 Generator:-
An alternator is an elertromechanical device that
converts mechanical energy to alternating electrical
energy. Most alternators use a rotating magnetic field. In
principle generator can be called an alternator.
but usually the word refers to small rotating machines
driven by automotive and other internal combustion
engines.

Generally it consists of two parts - stator and

rotor. The shaft runs through the turbines is coupled to
the rotor, which is the large electromagnet inside a
cylinder of copper windings a magnetic field is created
which induces a three phase alternating current (AC) in
the windings.
Transformer:-
A transformer is a device that transforms elone
circuit to another by coupling without requiring relative
motion between its parts.

Several types of Transformer:

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 1. Generator Transformer (GT)
2. Station Transformer (ST)
3. Unit Auxiliary Transformer (UAT)
4. Current Transformer (CT)
5. Potential Transformer (PT)

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