Académique Documents
Professionnel Documents
Culture Documents
Internship Report
Of
Northern Power Generation Company
Limited
Thermal Power Station Muzaffar Garh(Phase-11)
(Genco-III)
2
Introduction
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 either drives an
electrical generator or does some other works, like ship propulsion. 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 center because such facilities convert forms of heat energy
into electrical energy.
Commercial electric utility power stations are m9ost usually constructed on a very
large scale and designed for continuous operation. Electric power plants typically
use three phase or individual phase electrical generators to produce alternating
current (AC) electric power at a frequency of 50Hz or 60Hz depending on its
location on the world. Other large companies or institutions may have their own
usually smaller power plants to supply heating or electricity to their facilities
especially if heat or stem is created anyway for other purposes.
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Table of contents
1 Introduction 7
2 TPS Muzffar Garh 8
2.1 Installed capacity 8
2.2 Introduction to phase#1 8
2.3 Introduction to phase#2 9
3 Boiler 11
3.1 Water tube boiler 11
3.2 Boiler parameter 11
3.3 Main part of boiler 12
3.4 Boiler protection 16
4 Steam turbine 17
4.1 HP (High pressure) turbine 18
4.2 IP (Intermediate pressure) turbine 18
4.3 LP (Low pressure) turbine 18
4.4 Steam turbine specification 18
4.5 Turbine protection 19
5 FSSS 19
5.1 Decanting area 20
5.2 Fuel oil tanks 20
5.3 First lift pump 20
5.4 Main heaters 21
5.5 Second lift pump 21
6 The generator 22
6.1 Working principle 22
6.2 Main generator parameters 23
6.3 Cooling system of turbo-generator 24
6.4 Protections of generator 27
7 Cycles 29
7.1 Steam cycle 29
7.2 Fuel oil cycle 30
7.3 Air flow cycle 31
7.4 Condensate cycle 32
7.5 Feed water cycle 33
This phase consist of three steam units each capable of generating 210MW
electricity. The supplier started delivery of equipment to site in January,
1989 and after pre-assembly of equipment at site, erection started in July,
1990. Unit#1 was commissioned in September, 1993 and unit#2 in March,
1994.
Main Building:
It contains the turbine hall having a span of 45m and dearator bay, 12m
wide. The stem turbines which drive generators are of three stage
condensing type arranged transversely to the axis of turbine hall. The
operational platform is at elevation 12.6m and a maintenance bay at ground
flour near unit#1. The power plant is designed block principle: boiler-
turbine-generator-unit transformer. The flue gas exhaust section of two
units is connected with a 200m high stack, outer section of which is a 195m
high concrete shell.
Combined Auxiliary Building:
The building is connected with the main building and it houses water
treatment plant to produce 100t/h dematerialized water for the
replenishment of station losses. Hydrogen plant to provide hydrogen for
cooling of generator's r rotor, maintenance shops, laboratories, and central
control room.
Fuel & Oil Facilities:
Fuel oil facilities are constructed for decanting, oil storage, preparation
and supply of fuel to boiler nozzles. It also includes HSD storage as well as
oil facilities for reception, storage, purification and centralized delivery of
turbine oil and insulating oil to power plant.
Hydraulic Structures:
The cooling water used in condensers is re-circulated in closed cycle with
indicated draft cooling towers, the water is being cooled for each unit in two
cooling towers each consisting of eight fans, two cooling towers carry
27,500Cu m/h circulating water for condensers of one unit.
Startup Boiler:
One startup boiler using diesel oil as fuel with steam output of 50t/h is
provided to meet steam requirement for initial start of unit as well as a
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backup of power plant auxiliaries. A separate stack of 30m high has been
constructed for it.
Electrical Part:
The electricity generated at 15.75 KV is brought out from unit transformer
at 220 KV and feed to the national grid via a switch yard. Power plant
auxiliaries are fed at 6.6 KV.
2.3 Phase#2(Units#5 & 6):
It consist of two units of 210MW each having equipment similar to phase#1.
Turbines are placed longitudinally in main building outdoor boiler exhaust
of two units is connected to one stack.
Overview:
There are many different types of power plants including thermal power
plants and hydel power plants. Thermal power plants use fuel such as gas,
HSD, furnace oil or nuclear fuel to produce heat energy that is converted
to electrical energy through a series of intermediate process. Hydel power
plants convert the potential energy of water to electrical power as it follows
from higher to lower elevations.
The "traditional" thermal power plant is the Rankin cycle plant named
after the man who invented the cycle. A power plant cycle is a series of
processes in which a fluid generally water/steam, is used to convert heat
energy to mechanical energy. The Rankin cycle in its simplest form consists
of a boiler, a turbine, a condenser and a boiler feed pump. Early plants had
thermal efficiencies of approximately 25% to 30%. Only 25% to 30% of the
heat energy in the fuel burned in these plants was converted to electrical
energy. The rest was lost in various ways. The Rankin cycle has been
refined considerably over the years and made more efficient by the addition
of components like economizer, feed water heaters, super heaters and re-
heaters. The efficiency of Rankin cycle has also been improved by
increasing the pressure and temperature of the cycle. The laws of
thermodynamics and considerations such as material limitation have
prevented any significant improvement sense then. Power plants commonly
use heat rate of measure efficiency.
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3. Boiler
The boiler is the main part of any thermal power plant. It converts the fuel
energy into steam energy. The fuel may be furnace oil, diesel oil, natural gas
or coal. The boiler may be fire from the multiple fuels. The types of boiler use
in the T.P.S phase#2 is "water tube type"
3.1 Water Tube Boilers:
In water tube boilers, boiler water passes through the tubes while the exhaust
gasses remain in the shell side, passing over the tube surface, since tubes can
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typically withstand higher internal pressure then the large chamber shell in a
fire tube, water tube boilers are used where high steam pressure (as high as
3,000Psi) are required.
Water tube boilers are also capable of high efficiencies and can generate
saturated or superheated steam. The ability of water tube boilers to generate
superheated steam makes these boilers particularly attractive in applications
that require dry, high-pressure, high-energy steam, including steam turbine
power generation.
Type Y1600-12/2150
Stator voltage 6.6KV
Rated current 182A
Rated speed 372rpm
Rated power 1600KW
Connection of stator winding 2Y
Insulation class B
Ambient temperature 50°C
No. of phases 3
Rated frequency 50Hz
Weight 17500Kg
3.3.6 CW Pump:
Type is single stage double suction centrifugal pump.
Type 1400S25-1
Capacity 16000𝒎𝟑 /h
Speed 370rpm
Power 1600KW
Weight 35000Kg
Head 25m
NP SHR 8.5m
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3.3.8 Economizer:
Flue gases from large boilers are typically 450-650°F. Stack economizer
recover some of this heat for pre-heating water. The water is most often
used for boiler make-up water are some other need that coincides with
boiler operation. Stack economizers should be considered as an efficiency
measure when large amounts of make-up water are used (i.e. not all
condensate is return to the boiler or large amount of live steam are used in
the process so there is no condensate to return) or there is a simultaneous
need for large quantity of hot water for some other use. The savings
potential is based on existing stack temperature, the volume of make-up
water needed and the hours of operation.
4. Steam Turbine
Turbine is used to convert the heat energy into mechanical energy.
Turbine used in T.P.S Muzaffar Garh is impulse-reaction steam turbine. The
load requirement is controlled by the steam flow through a governing valve.
Maximum steam at full load is 670t/h. When the load at generator is suddenly
decreased then the rpm (frequency) of the generator is increased and to
decrease the frequency we lower down the steam flow which decreases the
speed and maintains the frequency.
If load is suddenly increased rotor speed becomes slower, to increase the speed,
steam flow is increased.
Steam turbine has three parts.
1. HP turbine
2. IP turbine
3. LP turbine
Generator
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Condenser
Diesel pumps
Recirculation pumps
Recirculation heater
Filters
Control room
o Oil tankers
o Train
For unloading of the fuel from oil tankers and train there is separate
unloading or de-canting station for each. The unload fuel oil is initially stored in
the underground reservoir; from there it is filled in the main storage tanks.
02 pumps are used to fill the main storage tanks from the oil tankers decanting
area. One of them is active (on load) and other is standby.
Usually one storage tank is called service tank, from there furnace oil is supplied
to the units. The furnace oil is filled in the other tanks first and then filled in the
service tank through recirculation pumps (RCP). The oil in the tanks is kept
heated at the temperature 75-80°C. There are total 06 storage tanks for furnace
oil each having a volume of 20,000𝒎𝟑 hence each can store 2,00,00,000 litter.
There are two diesel oil storage tanks each having capacity of 1000ton.
First lift pump takes the furnace oil from the service tank and supplied to the main
heaters. There are total 04 first lift pumps which are operated according to unit
load conditions. The specification of first lift pump motor is as follows:
Connection Star
Power 55KW
Power factor 0.9
Efficiency 90%
Voltage 230/400V
Speed 2950rpm
Current 177/102A
Temperature 270°C
Pressure 11-13bar
5.5 Second lift Pump:
Second lift pumps take the furnace oil from the main heater and supply to boiler
of the units. There are 04 second lift pumps which are operated according to the
unit load conditions.
Power 250KW
Voltage 6.6KV
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Speed 2950rpm
Current 252A
6. The Generator
The generator is a device which converts the mechanical energy into electrical
energy.
If the output electrical energy is AC, it is called alternator. If the output electrical
energy is DC, it is called DC generator. In fact there is no difference between
alternator and Dc generator except the way the output is obtained from the
generator. In alternator the AC supply is produced in the armature and supply is
obtained through slip rings where as in the DC generator are generated AC supply
is obtained from the armature through the spilt rings or commutator which
converts the AC into DC. The following three things are necessary for generation
of electrical energy.
Magnetic field
Conductor
Relative motion between conductor and magnetic field
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In the small generator the magnetic field is being produced in the stator and the
electromotive force is produced in the rotor through Faraday's law of
electromagnetic induction. The electromagnetic are used in the generator to
produce the magnetic field. In the large generator the magnetic field is produced
by the electromagnetic in the rotor and the electromagnetic force is produced in
the stator .the output is taken from the rotor, the rotor must
Have high insulation due to high voltage induction and it must have heavy
insulation which may increase the size of rotor, and require more power for the
prime mover to rotate to this heavy rotor
Armature connection 𝒀
Specification OEA.513.039
Manufacturing date 1993-8-24
Rated capacity 1165KVA
Two types of cooling are used in the turbo generator of TPS phase second.
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Stator cooling
Rotor cooling
The demi water is necessary for the cooling of the stator winding because raw
water is not a pure insulator which may cause the flow of leakage current when
passed through stator winding.
The demi water plant removes the impurities and minerals of the raw water and
make it good insulator whose resistivity is taken at a minimum level of 200K𝛀.cm.
The demi water that process through the stator winding absorbs the heat of stator
winding makes it cool and becomes hot itself. The demi water then passes through
heat exchanger (coolers) where its temperature is decreased by the circulating
water coming from the cooling towers. This demi water is also passed through the
mechanical and magnetic filters before passing through stator winding and
thirstier converts.
When the generator is turned off for a long time for maintenance purpose
hydrogen is released from the generator in the air using special method. Method
involves that firstly fill the generator with CO2 which release the hydrogen in the
air and then in the end air is filled in the generator and CO2 is released in the air.
This method is adopted because if hydrogen is released using air instead of CO2
then it can cause explosion due to oxygen in the air which will meet hydrogen
under pressure in the generator. After maintenance hydrogen gas is refilled in the
generator using the reverse process as described above.
This system is intended to protect against turn-to-turn short circuit of one phase
in the generator stator winding.
This system is intended to reveal and disconnect one phase earth fault of generator
stator winding.
This system is intended to protect the generator against external symmetric short
circuit.
This system is intended to protect against asynchronous mode. One of the elements
of resistance block relay for protection of the unit against external symmetrical
short circuit used.
This system is intended to protect the generator incase of earth fault at one point
of excitation circuit.
This system is intended to backup protection at one phase short circuit in 220KV
network. It is also used to backup unit protection when short circuit at the 220KV
side of the unit.
This system is intended to protect against all kind of short circuit in the exciter
winding and on its leads.
This system is intended to protect against over current in the external system of
the exciter.
7. CYCLES
7.1 Steam Cycle:
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Economizer Environment
Condenser
Dearator
Hot well
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Cond. Pump
Makeup Water
DA Pump
From LP Heater
Dearator
29
To Economizer
HP HP
Heater B Heater A BFP B
BFP A
Make up water