Dr.

NARLA TATA RAO THERMAL

POWER STATION

POWER PLANT FAMILIARIZATION -2017

INDUSTRIAL PLANT TRAINING REPORT

COURSE CO-ORDINATOR
MR.

SUBMITTED BY :Kunta Sai vivek

 ACKNOWLEDGEMENT

We wish to extend our profound and sincere thanks to APGENCO/Dr.NTTPS Trg.

management; without their support, this training would have been a distant dream.

We also acknowledge the corporation authority of Vijayawada Thermal Power

Station for their permission to visit the plant and their support. Especially we are
very much thankful to the chief engineers for all detailed information they have
provided about the working and other components of the power plants.
 INDEX
SERIAL NO. NAME OF CHAPTERS

1. Abstract
2. Introduction
3. Purpose of visit
4. Details of TPS
5. Block Diagram of TPS
6. Working of TPS
7. Equipments required in TPS
8. Generator
9. Transformer
10. Switchyard
11. Control Room
12. Cooling
13. Advantages &disadvantages
14. Conclusion
15. Reference
 1.ABSTRACT

A thermal power station is a power generating plant in which heat energy

is converted to electric power. Water is heated, turns into steam and spins a steam
turbine which drives a generator. After passing through the turbine, the steam is
condensed and recycled to boiler where it was heated; this is known as a Rankine
cycle. There are different types of thermal power plant in India based on the type
of fuel used to generate the steam such as coal, gas, diesel, etc. About 75% of
electricity consumed in India is generated by thermal power plants.

More than 51% of India’s commercial energy demand is met through the
country’s vast and massive coal reserves. A coal based thermal power plant
converts the chemical energy of coal into electrical energy. This is done by raising
steam in boiler; expanding it through turbine and the coupling the turbines to
generators converting mechanical energy into three phase AC electrical energy.
 2.INTRODUCTION
Andhra Pradesh Power Generation Corporation Limited is power
generating organization in Andhra Pradesh. It undertakes operation and
maintenance of the power plants and also setting up new power projects
alongside upgrading the project's capacity.

The total installed capacity of APGENCO, after the formation of TSGENCO is

4612.6 MW comprising 2810 MW Thermal, 1797.6 MW Hydro and 5 MW
Solar power stations. The Power Plants of APGENCO include thermal, hydel
and Solar based plants.

The performance of APGENCO thermal power stations in terms of reliability,

availability and maintainability is one of the best in India.

Dr Narla Tata Rao Thermal Power Station Rayalaseema Thermal Power Station

Srisailam dam Tungabhadra dam

 PURPOSE OF VISIT

The main reason to visit the power plant was to understand and get complete
knowledge about practical overview of energy generation plant. Since we are to
study the theoretical working and details about various thermal plants in our
syllabus, this visit helped us to correlate between the various equipments and
parameters used in actual power generation technique with the one given in our
academic books.

The total installed capacity of Dr.NTTPS is 1760 MW. This TPS consist of 6 units
of 210MW capacity and 1 unit of 500MW capacity. We have visited and obtained l
the information about these 6 units of 210MW. Some comparisons of parameters
between 500MW and 210MW details were also presented in detail to us. As soon
as we entered the premises, we noticed the greenery of campus. Almost 30000 to
40000 trees were planted in and around the plant. This training correlated with
physical visualization from frequent plant visits developed a clear understanding of
the layout and functionality of the thermal power plant.
 UNDERSTANDING THERMAL POWER PLANT
The thermal power station converts heat energy of coal into electrical energy. The
coal handling plant supplies coal to the boiler. The ash formed in the boiler is
disposed of by ash handling plant. Air is taken from atmosphere by primary and
forced draft fans and thus air is heated in Air Preheater before fed to the boiler. The
flue gases obtained from combustion of air and fuel will pass through the re-heater,
super heater, and economizer, Air Preheater, electrostatic precipitator and ID fan
before being discharged to the atmosphere through chimney.

The boiler vaporizes water into wet steam which is further heated in super heater
and fed to the high pressure turbine. After expanding the steam is reheated again in
the boiler and fed to the intermediate pressure turbine. The exhaust steam from low
pressure turbine is condensed by condenser as shown in fig and condensate along
with the makeup water is passed through economizer before being fed to the boiler.
In this way electrical energy is produced by rotating turbine using steam which is
coupled to the alternator of required rating.
Coal handling Plant (CHP)

In a coal based thermal power plant, the initial process in the power generation is
“Coal Handling”.

Plant was designed for bituminous coal. Bituminous is second best, hardest form of
coal. Such coals may contain ash, moisture and volatile material, and hence there is
a need for pulverisation. The firing systems also differ for different grades of coal.

The huge amount of coal is usually supplied through railways. A railway siding
line is taken into the power station and the coal is delivered in the storage yard.
The coal is unloaded from the point of delivery by means of wagon tippler. It is
rack and pinion type. The motor used for tippling is a slip ring induction motor.
The coal is taken from the unloading site to Bunker/Stockyard by belt conveyors
and stacker & Reclaimer.
The transfer points or junction towers are used to transfer coal to the next belt. The
belt further elevates the coal to the transfer point and it reaches the crusher through
belt. In the crusher a high-speed 3- phase induction motor is used to crush the coal
to a size of 20mm so as to be suitable for milling system. Coal rises from crusher
house and reaches the Bunker /Stockyard by passing through transfer point.

Magnetic separators: Coal which is brought may contain iron particles. This iron
particle may result in wear and tear. The iron particles may include bolts, nuts,
wire, fish plates etc. This is unwanted and removed with the help of magnetic
separators which are usually placed above the conveyer belts.

Boiler

The water-tube boiler is about 65 feet tall. Its walls are made of a web of high
pressure steel tubes.

Pulverized coal is air-blown into the furnace through burners located at the four
corners and it is ignited to rapidly burn, forming a large fireball at the centre
(tangential firing). The thermal radiation of the fireball heats the water that
circulates through the boiler tubes near the boiler perimeter. As the water in the
boiler circulates it absorbs heat and changes into wet steam. It is separated from the
water inside a drum at the top of the furnace by turbo separators. The saturated
steam is introduced into super heater that hangs in the hottest part of the flue gases
as they exit the furnace. Here the steam is superheated to 540 °C to prepare it for
the turbine.

Boiler auxiliaries are used to increase the efficiency of its working. They are-

A] Economizer: It is located in the boiler. It is there to improve the efficiency of

boiler by extracting heat from flue gases to heat water and send it to the boiler
drum.
Advantages of economizer include:
1. Fuel economy: - Used to save fuel and to increase efficiency of boiler plant.
2. As the feed water is pre heated in the economizer and enter boiler tube at
elevated temperature, it reduces thermal stresses.
3. Optimum usage of heat of the flue gases.
B] Superheater: It super heats the wet steam from the drum to dry super-saturated
steam which then drives the HP turbine.
Advantages:
1. Increases the efficiency
2. Protects the turbine blades from corrosion.
3. Optimum usage of heat from flue gases.

C] Re-heater: it reheats the steam from the HP turbine before sending it to the IP
turbine.
Advantages:
1. Increases the efficiency
2. Protects the turbine blades from corrosion.
3. Optimum usage of heat from flue gases.

D] Pulveriser(Mills): Pulverization is a mechanical process for grinding of

different types of material. For example, they are used to pulverize coal for
combustion in steam generating furnaces of thermal power plants. There are
various types of mills such as ball and Tube mills, Ring and ball mills, demolition.
The pulveriser reduces the coal size to 74 micron which is then sent to the boiler
through the secondary air.
E] Fans : The Pulverised coal from the Mills is lifted to the boiler using Primary
air (PA) Fans . The air from these fans also takes part in combustion of coal by
providing the oxygen. The additional /excess air required for combustion will be
given directly to the boiler using another set of fans called Forced Draught (FD)
Fans. To keep the firing effective, negative pressure is created inside the boiler
using one set of fans called Induced draught (ID) fans.

F] Air Preheater: Air from the PA & FD fans is preheated using the exit flue
gases of the boiler using the Air Preheater and thereby improving the efficiency.

Layout of 210MW two pass boiler and connecting equipment

Steam Turbine

The turbine generator consists of a series of steam turbines interconnected to each

other and a generator on a common shaft. There is a high pressure turbine at one
end, followed by an intermediate pressure turbine, a low pressure turbine, and the
generator. As steam moves through the system and loses pressure and thermal
energy it expands in volume, requiring increasing diameter and longer blades at
each succeeding stage to extract the remaining energy. It is so heavy that it must be
kept turning slowly even when shut down (at 3 rpm) so that the shaft will not bend
even slightly and become unbalanced due to unequal heating. This is so important
that it is one of only six functions of blackout emergency power batteries on site.
Other functions are emergency lighting, communication, station alarms, generator
hydrogen seal system, and turbo-generator lube oil.

Superheated steam of 150 kg/sq.cm &540°C from the boiler is delivered to the
high pressure turbine where it falls in pressure to 39 kg/sq.cm & 320 °C in
temperature through the stage. It exits cold reheat lines and passes back into the
boiler where the steam is reheated in special re-heater tubes back to 1,000 °F
(540 °C). The hot reheat steam is admitted to the intermediate pressure turbine
where it falls in both temperature and pressure and exits directly to the long-bladed
low pressure turbines and finally exits to the condenser.

210 MW Turbine
Condenser

The condenser condenses the steam from the exhaust of the turbine into liquid to
allow it to be pumped. If the condenser can be made cooler, the pressure of the
exhaust steam is reduced and efficiency of the cycle increases. The function of
condenser is

1. To provide lowest economic heat rejection temperature for steam.

2. To convert exhaust steam to water for reserve thus saving on feed water
requirements.
3. To introduce make up water.

The heat absorbed by the circulating cooling water in the condenser tubes must
also be removed to maintain the ability of the water to cool as it circulates. This is
done by pumping the warm water from the condenser that reduce the
temperature of the water by evaporation, by about 11 to 17 °C (20 to 30 °F)—
expelling waste heat to the atmosphere.

Condenser
Ejectors: From the condenser the water then goes to the main air ejector through
the condensate extraction pump to extract non condensing gases. Then the water is
then sent to the low pressure heaters which are 2 in number and is then sent to
Deaerator. These ejectors are used to improve Vaccum in the condenser and also
increase the temperature of the water in the feed water circuit.

Deaerator: Its function is to remove dissolved non-condensable gases and to heat

boiler feed water.

Deareator

Boiler Feed Pump: It is provided for pumping feed water to economiser. There is
also a feed water storage tank to store the water when not needed

Boiler Feed Pump

Generator

The generator voltage for modern utility-connected generators ranges from 11 kV

in smaller units to 22 kV in larger units. The generator high-voltage leads are
normally large aluminium channels because of their high current as compared to
the cables used in smaller machines. They are enclosed in well-grounded
aluminium bus ducts and are supported on suitable insulators. The generator high-
voltage leads are connected to step-up transformers for connecting to a high-
voltage electrical substation (usually in the range of 115 kV to 765 kV) for further
transmission by the local power grid.

The necessary protection and metering devices are included for the high-voltage
leads. Thus, the steam turbine generator and the transformer form one unit. Smaller
units may share a common generator step-up transformer with individual circuit
breakers to connect the generators to a common bus.

Generator Auxilaries: The generator in the 210 MW generates a voltage of

15.75kV of which the auxiliaries in the plant take about 6.6 kV through the unit
auxiliary transformers.

There is also a station transformer which takes power from the grid directly in case
of emergencies. The station transformers are designed to be able to withstand the
entire unit auxiliary’s requirements.
Ash handling plant

Slag and ash falling from the furnace are temporarily stored in the bottom ash silo.
They are then sent to the ash pond using a hydro ejector. Alternatively, they are
sent back to the bottom ash silo to be recycled after going through a submerged
drag chain conveyor or dry ash extraction conveyor.

 Bottom Ash Hopper System utilizing Hydro-ejector’s

 Dry Ash Extraction System.

For the Fly Ash Handling for power plants, pneumatic conveyor system have
world-widely been applied (ESP, Bag Filter, Etc.). The fly ash handling system
transports the ashes pneumatically with the compressed air from blower or air
compressor through it.

Ash Disposal System: The bottom ash, coarse ash and fly ash lead to the common
slurry sump. Wet ash can be used by cement industries and extra wet ash is
disposed in ash ponds which on filling are converted into parks.

Control Room

The control room in this case is of remote control and houses all the necessary
measuring instructions for each panel or alternator and feeder, synchronizing gear,
protective gear, automatic voltage regulator, communication arrangement etc.

Types of Control panel

 Flue gas panel

 Combustion Panel
 Primary Air and coal panel
 Steam panel(boiler)
 Feed Water panel
 Condensate & cooling water panel
 Turbo-supervisory panel etc.
Switch yard
EHV Substation at VTPS:
1) 220 kV Switchyard
2) A) 220 /132 kV SS; B)132 kV SS
3) 400 kV Switchyard

The 220 kV switchgear comprises of the following equipment:.

1) C.T’s And P.T’s
2) Isolator
3) Circuit Breaker
4) Lightning Arrestor
5) Cvt
6) Wave Trap (Included In Plcc)
7) Bus Bars
8) Bus Coupler

Tasks of the switchyard:

 Protection of transmission system
 Controlling the exchange of power
 Maintain the system frequency within targeted limits
 Determination of power transfer through transmission lines
 Fault analysis and subsequent improvements
 Communication

SWITCH YARD
 ADVANTAGES & DISADVANTAGES OF THERMAL POWER STATIONS:

Advantages:

1. Economical for low initial cost other than any generating plant.
2. Land required less than hydro power plant.
3. Since coal is main fuel and its cost is quite cheap than petrol or diesel so
generation cost is economical.
4. These are having easier maintenance.
5. Thermal power plant can be installed in any location where transportation
and bulk of water are available.

Disadvantages:

1. The running cost for a thermal power station is comparatively high due to
fuel maintenance etc.
2. Large amount of smoke causes air pollution. The thermal power station is
responsible for global warming.
3. Overall efficiency of thermal power plant is low like 30%.
 CONCLUSION
After visiting this power station I came to know about the practical generation
process of electrical energy. I understood the function of various components in
thermal power station, their importance, their arrangements and precaution to be
taken for the safety in the power plants. This experience gave us good exposure to
the industries- tied branches of engineering. This visit to Dr.NTTPS was an
exciting experience, since the hard work of APGENCO and mutual cooperation of
their staff and workers is really appreciable. I would like to thank our staff
members for arranging this quality and career building visit.
 REFERENCES

1. www.apgenco.gov.in
2. Google, Wikipedia
3. Course material on Power plant familiarization-APGENCO