TRAINING

REPORT
Of
CPP
At
ADHUNIK ALLOYS
& POWER LIMITED
(AAPL)
BY:-
Aman Raj
B.Tech (Power Engg.)
Semester 6
National Power Training Institute (NR), New Delhi

1
 ACKNOWLEDGEMENT
I would hereby like to express my profound sense of gratitude to Sr.
General Manager – HR&IR Sanjay Kumar Srivastava for given me the
opportunity to carry out my vocational training at Capacitive Power Plant
under their experienced and highly qualified staff.

I would like to thank my mentor Sir Aman Verma for his invaluable
guidance during the training period.

I would also like to thank Engineers and Operators for their constant
support and invaluable lesson they taught me about the working of a
Power Plant.

I duly acknowledge the help, direct or indirect of the whole department and
staff members of the organization for providing all the facilities for the
training. The knowledge gained herein and the practical experiences learnt
will be invaluable in the long run.

Reviewed By

Aman Verma

Deputy Manager (Operation – CPP)

Certified & Approved by

Sanjay Kumar Srivastava

Sr. General Manager – HR&IR

2
 PREFACE
With day to day advantage of new technology the older machinery are
being replaced by new machinery. Now it has not been the work of semi-
skilled people. It has opened a new horizon for degree holder engineers.
But to do the job properly a suitable training is needed.

The knowledge of entire system is must for an engineer to do the

trouble-shooting in the quickest possible way so that the production does
not get affected.

So for engineering the industrial training is playing a vital role in

developing the practical knowledge. The industrial training is not merely
an academic requirement but a professional necessity too.

With the increasing demand and utilization of electricity an

electrical engineer should be well versed or at least must be familiar with
the generation, transmission and distribution of electricity, at the same
time must be capable of fault detection and elimination.

It is thus the responsibility of an electrical engineer to deal with the

sophistication and make the maximum possible utilization.

3
 CONTENTS
S. NO. Title of Heading Page No.
I Section A
01 About the Company 06
02 Captive Power Plant 07
II Section B (Theory)
03 Overview of Thermal Power Plant 09
04 Rankine Cycle 11
III Section C (Processes of The
CPP)
05 Coal Handling Process 15
06 Coal Feeding 16
07 Air Circulation and Ash Handling 17
Operation
08 DM Water Plant Operation 19
09 DM Water to Steam Circulation 20
10 Steam Circulation 24
11 Oil Circulation 30
12 Cooling Tower 32
13 Power Generation 33
14 Power Distribution 35
15 Appendix 38
16 Conclusion 42

4
SECTION A

5
 ABOUT THE COMPANY
ADHUNIK ALLOYS & POWER LIMITED (AAPL)
Adhunik Alloys & Power Limited, a part of the Adhunik Group, located at Kandra in
Jharkhand, is an integrated steel plant based on Sponge Iron Technology. AAPL has 2 x 350
TPD DRI Plant with an installed capacity of 220,000 M.T.P.A, a Coal Washery of 1,000 TPD, a
30 MW Captive Power Plant, 2 x 30 ton Induction Furnaces and a 2–strand Continuous
Caster and Rolling Mill of 147,700 TPA.

The steel plant is based on green technology, where waste heat recovery of DRI and
washery rejects are used to generate green power. The plant has its own Railway siding. The
Company has also been allotted the North Dhadu Coal block in Latehar district, Jharkhand.
Allotment of iron ore mines is in an advanced stage of necessary approvals and
development. These resources are to be used on a captive basis for the production of steel.

AAPL has adequate land for setting up full–fledged steel manufacturing facilities. It is an ISO
certified company and is concerned about the environment in and around the plant area.
AAPL has also been granted license by the Central Electricity Regulatory Commission, New
Delhi, for inter–state trading of electricity for selling the surplus power.

Driven by the growing demand for steel products for power & telecommunication sector,
construction sector and heavy industry sectors in the country, the promoters signed an
Memorandum of Understanding with the Government of Jharkhand to set up integrated
steel plant in the state in phases. As per the initial plan the promoters have set up two DRI
Kilns each of 350 tonne/day capacity which are in operation. The first kiln started
production from 20th July 2005 and second kiln started production from 27th March 2006.
After successful implementation of the initial phase, the group has taken up second phase
of expansion plan viz. setting up of Integrated Steel Plant for production of high value added
steel products, like Angles, Beams and Flats, to be utilized by the Power &
Telecommunication industries and their ancillaries. The company has recently completed its
second phase expansion as well by setting up 0.15 MT integrated steel plant supported by
Direct Reduced Iron (DRI) plant with an installed capacity of 220,000 M.T.P.A., 30 MW
captive power, private railway siding and a coal feed washery.

The Company has also been allotted North Dhadu Coal block at Dist. Latehar, Jharkhand.
Allotment of iron ore mines is also at various stages of necessary approvals and
development. With captive co–generation of power, private railway siding and captive iron
ore and coal mining rights, the current expansion project shall assist in achieving low
production cost, thereby allowing to withstand fluctuation in sales prices in future due to
cyclic nature of steel industry.

6
 Captive Power Plant
A 30 MW CPP has been set up for power generation from waste heat coming out from the
DRI plants and solid waste coming from coal washery and DRI plants.

The 30 MW Captive Power Plant is generating 12 MW electricity using waste heat from
Adhunik's DRI plant and balance 22 MW solid waste from the DRI plant and coal washery.
The capacity calculation is as under:

Particulars Existing 30 MW

Plant Installed Capacity (MW) 30

No. of Working Hours per day 24

No. of Working Day per year 365

Captive Power Plant will be to ensure availability of adequate electrical energy in a cost
effective manner utilizing primarily off gases and waste by-products of various modules.

7
SECTION B

8
 Overview of a Thermal
Power Plant

Schematic of a Thermal Power Plant

Power plants generate electrical power by using fuels like coal, oil or natural gas. A simple power
plant consists of a boiler, turbine, condenser and a pump. Fuel, burned in the boiler and superheater,
heats the water to generate steam. The steam is then heated to a superheated state in the superheater.
This steam is used to rotate the turbine which powers the generator. Electrical energy is generated
when the generator windings rotate in a strong magnetic field. After the steam leaves the turbine it is
cooled to its liquid state in the condenser. The liquid is pressurized by the pump prior to going back to
the boiler.

Thus the main inputs required by a plant are:

 Coal: Should have high calorific value and low ash content
 Water: De-mineralized water for steam generation
 Air

Steam

Steam power is fundamental to what is by far the largest sector of the electricity-generating industry
and without it the face of contemporary society would be dramatically different from its present one.
We would be forced to rely on hydro-electric power plant, windmills, batteries, solar cells and fuel
cells, all of which are capable of producing only a fraction of the electricity we use.
Steam is produced by boiling of water and it is achieved at atmospheric pressure at 100 degree
Celsius. Let us consider a quantity of water that is contained in an open vessel. Here, the air that
blankets the surface exerts a pressure on the surface of the fluid and, as the temperature of the water is

9
raised, enough energy is eventually gained to overcome the blanketing effect of that pressure and the
water starts to change its state into that of a vapor (steam). If the pressure of the air blanket on top of
the water were to be increased, more energy would have to be introduced to the water to enable it to
break free. In other words, the temperature must be raised further to make it boil. To illustrate this
point, if the pressure is increased by 10% above its normal atmospheric value, the temperature of the
water must be raised to just above 102 °C before boiling occurs.
The information relating to steam at any combination of temperature, pressure and other factors may
be found in steam tables, which are nowadays available in software as well as in the more traditional
paper form. These tables were originally published in 1915 by Hugh Longbourne Callendar (1863-
1930), a British physicist. Because of advances in knowledge and measurement technology, and as a
result of changing units of measurement, many different variants of steam tables are today in
existence, but they all enable one to look up, for any pressure, the saturation temperature, the heat per
unit mass of fluid, the specific volume etc.
Steam becomes superheated when its temperature is raised above the saturation temperature
corresponding to its pressure. This is achieved by collecting it from the vessel in which the boiling is
occurring, leading it away from the liquid through a pipe, and then adding more heat to it. This
process adds further energy to the fluid, which improves the efficiency of the conversion of heat to
electricity.
As stated earlier, heat added once the water has started to boil does not cause any further detectable
change in temperature. Instead it changes the state of the fluid. Once the steam has formed, heat added
to it contributes to the total heat of the vapor. This is the sensible heat plus the latent heat plus the heat
used in increasing the temperature of each kilogram of the fluid through the number of degrees of
superheat to which it has been raised. In a power plant, a major objective is the conversion of energy
locked up in the input fuel into either usable heat or electricity. In the interests of economics and the
environment it is important to obtain the highest possible level of efficiency in this conversion
process.

Air

Air is a very important material that is required for the proper functioning of the whole set-up. ID, i.e.,
Induced Draught and FD, i.e., Forced Draught fans help in proper circulation of air – from atmosphere
to furnace and back to atmosphere. ID fans are also used in Cooling Tower.

10
 Rankine Cycle – The
working Principle
The Carnot cycle postulates a cylinder with perfectly insulating walls and a head which can be
switched at will from being a conductor to being an insulator. Even with modifications to enable it to
operate in a world where such things are not obtainable, it would have probably remained a scientific
concept with no practical application, had not a Scottish professor of engineering, William Rankine,
proposed a modification to it at the beginning of the twentieth century. The concepts that Rankine
developed form the basis of all thermal power plants in use today. Even today’s combined-cycle
power plants use his cycle for one of the two phases of their operation.

The Rankine cycle in a steam-turbine power plant

In the system shown in figure, water is heated in feed heaters (A to B) using steam extracted from the
turbine. Within the boiler itself, heat is used to further pre-warm the water (in the economizer) before
it enters the evaporative stages (C) where it boils. At D superheat is added until the conditions at E are
reached at the turbine inlet. The steam expands in the turbine to the conditions at point F, after which
it is condensed and returned to the feed heater. The energy in the steam leaving the boiler is converted
to mechanical energy in the turbine, which then spins the generator to produce electricity. The
diagram shows that the energy delivered to the turbine is maximized if point E is at the highest
possible value and F is at the lowest possible value.

11
THERMAL EFFICIENCY

12
SECTION C

13
 OVERVIEW
Of
Important Processes of
THE CAPTIVE POWER
PLANT

14
CHP (Coal Handling Process)
Box-Diagram of CHP
 The coal which comes to the plant is in the form of large lumps. Coal needs to be
converted to fine powdered form to be used in boiler for burning. Powdered form
increases the surface area of coal which helps in burning it mostly efficiently. In between
the coal needs to be stocked, tested for the calorific value and then sent in a controlled
right amount to the boiler. All these steps are managed by coal handling plant
 Mixture of coal and charcoal (from DRI plant) generally in equal ratio or as per the
direction provided is taken from the storage site and put into the Ground Hopper.
 The belt conveyer BC-1 conveys the contents to coal crusher which is at a certain height.
 The coal is then crushed to minute size inside a coal crusher with the help of crushing
hammer.
 The crushed coal is then filtered according to the size. Screen size is of 6mm. That is
precisely the size of coal that the AFBC boiler is designed for.
 The 6mm crushed coal is then transferred to belt conveyer BC-3 and it takes the
combustion fuel to the coal bunker.
 The coal that is not smaller than 6mm is again transferred to belt conveyer BC-1 with
the help of BC – 2 from the vibrating screen for the repetition of process unless it is
reduced to 6mm size.

 STOCK AVAILABLE OF THE COAL

As per the requirement generally a company keeps a stock of 1

week of coal. Here at CPP stock as on 12 June 2018, was about
5000 Tons.

According to the power

production, the daily requirement
of coal at CPP is 280 to 300 tons.

So, accordingly as per the

available stock, that would last
for 17 to 18 days.

Ground Hopper

15
Coal Feeding

Coal Feeding block-diagram

 The 6mm coal that is stored in the Coal-Bunker is then taken to different feeders
according to the quality of the coal.
 There are three kinds of coal feeder :-
DCF that stands for Dry Coal Feeder
Screw Feeder
Rotary Feeder
 From the three kinds of feeders the crushed coal is now transferred to
Cumulative feeder that is common header for all the incoming coal.
 From cumulative feeder that crushed coal is now spread into the furnace with
the help of Spreader.

DCF

16
Air Circulation and Ash-Handling Operation

 Furnace requires a large quantity of air for efficient burning of the fuel (coal or oil).
Forced Draft Fan are used to suck in the air required for efficient burning of fuel in
furnace.
 ID Fan is used after the ESP to move the flue gas out through the chimney by
creating an induced draft. Also they are used in cooling tower for cooling the water.

Air supplied to the furnace with the help of FD fans. The block diagram of the path
followed.

Air sucked from the furnace after it had helped in burning and fluidizing the bed of the boiler.

1. Atmosphere air is sucked from with the help of Forced Draft fans. FD-Fans transfer the
sucked atmospheric air to Air-Preheater.

Air Preheater - An air preheater (APH) is any device designed to heat air before another
process (for example, combustion in a boiler) with the primary objective of increasing the
thermal efficiency of the process.

The purpose of the air preheater is to recover the heat from the boiler flue gas which
increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas.
As a consequence, the flue gases are also conveyed to the flue gas stack (or chimney) at a
lower temperature, allowing simplified design of the conveyance system and the flue gas
stack. It also allows control over the temperature of gases leaving the stack (to meet
emissions regulations, for example).It is installed between the economizer and chimney.

From air preheater of which the temperature stands at nearly 140 Degree Centigrade is now
taken to FD – Duct and then is distributed among four compartments. With the help of
combustor header the heated air is now supplied to Furnace from beneath. The air supplied to
the furnace then is used for combustion purpose. They also help to fluidize the bed.

Fluidized Bed Combustion - When air is passed through a fixed or packed bed of particles,
air simply percolates through the interstitial gaps between the particles, As the air flow rate
through the bed is steadily increased, a point is eventually reached at which the pressure drop
across the bed becomes equal to weight of the particles per unit-cross sectional area of the
bed, This critical velocity is called the minimum fluidization velocity at which the bed is said

17
 to be incipiently fluidized. As the air velocity is increased further, the particles are buoyed up
and imparted a violently turbulent fluid like motion, with the drag forces exerted by the fluid
on the particles exceeding their weight. There is a high degree of particle mixing and
equilibrium between gas and particles is rapidly established. This is called a fluidized bed.

The sandy bed of the AFBC boiler is contaminated with silicon and alum. They help to retain
the heat. The temperature inside the boiler is 800-900 Degree Centigrade.

2. The coal after burning leaves ash. This ash is needed to be removed from the boiler as that
might affect the grossly affect the efficiency of the boiler. For that purpose ID or the Induced
draft fans are used. The ID fans handle dust-laden flue gases and so the blades are subjected
to erosion by the fly ash. The ash from the boiler is sucked by ID fans that pass through
Boiler Bank. At the boiler bank heavy ash particles settle. The flue gas that is sucked by ID
fans has really high temperature. The heat could have been wasted. And that could be harmful
for the environment if that heated air is released into the atmosphere. So from boiler bank this
heated flue gas is taken to Economiser.

An Economiser is a heat exchanger which raises the temperature of the feed-water leaving
the highest pressure feed-water heater to about the saturation temperature corresponding to
the boiler pressure. This is done by the hot flue gases exciting the last super-heater or re-
heater at a temperature varying from 370-540 Degree Centigrade. The term “economiser”
was used historically because the throwing away of such high temperature gases involved a
great deal of energy loss. By utilizing these gases in heating feed-water, higher efficiency and
better economy were achieved, and hence the heat exchanger was called “economiser”.

From economiser the flue gases pass through air preheater. From air preheater it goes into the
ESP which is acronym for Electro-Static Precipitator. For the removal of ash content from
flue gas we have Electrostatic Precipitator. It has four large parallel plates to which high DC
voltage is applied. The ash particles in flue gases when pass between them get polarized and
get attracted to the plates. The stuck particles on the plates are removed by rapping
mechanism. It is mechanical process of hitting the plates with hammer. Also there are hoppers
at the lower end of APH, ESP etc. for collection of ash content that may get collected there.
The ash is collected and made into slurry and moved out of the plant.

Bottom Ash Removal

For the removal of the bottom ash that get collected in the furnace, the boiler has a many
funnel shaped structure called Hoppers. The settled ashes at the bottom keep on getting
drifted to the due to funnel shape and get collected. The collected ash is mixed with water to
form slurry and is moved out of the plant.

FD Fan ESP

18
DM Water Plant Operation

Block Diagram for preparation on DM water

 The water from the reservoir is sucked into the raw water handling. The water is sent to the
clarifier. In clarifier alum and lime are added to the water. Alum helps to settle down the solid
particles and lime helps to maintain the pH of the water. Clarifier is actually a big tank in
which the incoming water is mixed with alum and lime and agitated with the help of shaft
with long blade connected to induction motor. The solid particles get attracted towards the
center and get collected in Clarifier Tank from where it is moved out through duct.
 Water is then sent to DMF or the Dual Media Filter. The dual media filter contains coal +
char+ sand. Normal filtration occurs as water passes through the different layers of the
contents.
 From DMF it goes to ACF or the Activated Carbon Filter. It helps to remove smell and dirt
from the water. That is the property of activated carbon to adsorb dirt and foul smell.
 From ACF it goes into the SAC or the Strong Acid Cation. SAC is charged with HCl. It
chemically reacts with the water and helps to remove cation impurities.
 From there it goes into the Degreaser and then into Degreaser tank. It helps to remove
oxygen, carbon-dioxide and other air particles that act as impurities.
 Then we have SBA or the Strong Base Anion charged with NaOH that helps to remove anion
impurities.
 Lastly the water goes into MB or the Mixed Bed that is charged with both acid and base to
remove left over cation and anion impurities.

The water thus obtained is DM-Water. This water is stored in three DM water storage tanks
and from there as per the requirement the water is sent into operation. It is to be noted that
though after so many filtration process minute traces of impurities remain.

19
DM–Water to Steam Circulation

Block Diagram for DM water to Turbine

 With the help of a pump, DM water or the Demineralised water is then transferred to
Deaerator.

The deaerator removes dissolved gases by vigorously boiling the water and agitating it, a
process referred to as 'stripping'. The water entering at the top is mixed with steam which is
rising upwards. The steam, taken directly from the boiler (Pagging steam) and from an
extraction point on the turbine (Bleed steam) at a reduced temperature and pressure, heats a
stack of metal trays and as the water cascades down past these it mixes with the steam and
becomes agitated, releasing the entrained gases. The steam pressurizes the deaerator and its
contents so that the dissolved gases are vented to the atmosphere.

Minimizing corrosion requires the feed-water oxygen concentration to be maintained below

0.005 ppm or less and although the deaerator provides an effective method of removing the
bulk of entrained gases it cannot reduce the concentration below about 0.007 ppm. For this
reason, scavenging chemicals (LP Dozing of Hydrazine + Amine) are added to remove the
last traces of oxygen.

20
 Principle of a deaerator

 From deaerator water by gravitational energy goes into the Boiler Feed Pump. There were
five BFPs. Three were LT BFP and two were HT BFP.

In a thermal power plant, the boiler feed pump (BFP) is one of the critical auxiliary machines
that are equivalent to the heart of the plant. Boiler Feed Pump as the name suggests, finds
application in boiler or reactor vessels to feed water and also control the amount of water fed
to the boiler. It has got significant role in the operation of boilers. Boiler Feed Pump is
selected depending on the capacity of the boiler. The operation of the pump may be
continuous or intermittent and depends on the liquid level control of the boiler.

Boiler Feed Pumps

21
  BFP feeds the water to the boiler. But before entering the boiler drum. The water passes
through economiser where it is preheated before it enters the boiler drum. Water itself
is heated in the economiser to about 200 Degree Centigrade.

The functions of the drum in a water tube boiler are as follows:

1. To store the water and steam sufficiently to meet varying load requirement.
2. To aid circulation.
3. To separate vapour and steam from water-steam mixture, discharge by the riser.
4. To provide enough surface area for liquid vapour disengagement.
5. To maintain a certain desired ppm in the drum water by phosphate injection and
blow down.

AFBC Boiler drum WHRB Boiler drum

 From Boiler Drum, the water comes down with the help of Downcomer for further
heating. From downcomer it gets into the common Bottom Ring Header.
 From bottom ring header the water gets into the furnace inside Bed Coils which is
submerged into the fluidized bed.
 From there the water gets heated and converted to steam and then moves upwards
because of natural circulation. The temperature inside the boiler furnace is 800-900
Degree Centigrade. No furnace is present in WHRB boiler as the heat from the DRI plant is
used to convert DM water to Superheated Steam through. Similar heating process is
carried out like AFBC boiler. Because of so much heat, the density of steam is reduced
and it rises upward to get back into the boiler via Water-Tubes, Top Ring Header and
Riser Tubes.

22
 Water Tubes are bent or straight hollow tubes through which steam water mixture
circulates. There are two types of water tubes, viz. down-comer and riser. This down comer,
riser assembly is also known as Evaporator (or boiler proper). In the evaporator actual state
change from water to steam occurs.

As the name suggests down-comers is the water tubes through which water comes down from
steam drum to mud drum. No vapor bubble should flow along with saturated water from the
drum to the down comers. This will reduce the density difference and the pressure head for
natural circulation.

Risers are the water tubes through which steam water two-phase mixture at saturation
temperature goes up from mud drum to steam drum. Risers are usually close to furnaces,
while the down-comers are away from the furnaces.

 Steam gets separated inside the boiler drum and before it reaches the turbine to make it rotate,
the steam is superheated in super heaters. Primarily it is superheated in Primary Super heater.
 Then it de-superheated to a particular temperature before it is reheated to obtain the rated
value of Super-Heated Steam.
 After passing through de-super heater, it then passes to Secondary Super Heater.
 The Superheated steam thus obtained is at 480 Degree Centigrade at a pressure of 64 Kg
per centimeter cube.

Super-Heater is an important element of the feed water-steam circuit. It is basically a heat

exchanger in which heat is transferred to the saturated steam to increase its temperature. In
high pressure boilers more than 40% of the total heat is absorbed by the super heaters. In
super-heater, the rate of heat absorption is more. Super-heater tubes are exposed to the
highest steam pressure and temperature on the inside and the maximum gas temperature on
the outside. They are made of costliest alloys. An increase in inlet steam temperature gives a
steady improvement in cycle efficiency. Hence, the function of super-heater is to raise the
overall efficiency. In addition, it reduces the moisture content in the later stages of the turbine
and thus increases the turbine internal efficiency. However, the increase in temperature is
limited by the properties of the construction materials of boilers and turbines. Usually the
optimum temperature of steam is maintained 480oC at the turbine inlet.

Furnace

23
Super-Heated Steam Circulation

Super-Heated Steam circulation block diagram

 Super-Heated steam from AFBC boiler and WHRB boiler join a common header.
 The Pressure of the Super-Heated steam is about 64 Kg/cm2.
 The Temperature of the Super-Heated steam is about 840 ℃.
 A tapping is taken from the Super-Heated steam line. The temperature is reduced to 190 ℃
and the pressure is reduced to about 10 Kg/cm2. This Pressurized De-super-heated Steam
System is takes the line to Ejector. There are three ejector line tapping. Two are Main Line
and in between them is Hogger Line.

Ejector – In the condensing operation, the use of ejector is to create vacuum so as to remove
non – condensing steam inside the Condenser and send it to another condenser, i.e. , Gland-
Sealing Condenser. After condensing of the non – condensing steam, the remaining non-
condensed steam is rejected. The rest condensed steam return back to the hot well.

The working principle of the ejector - When a high pressure motive fluid ( steam/liquid)
steam nozzle , this result in a decreasing pressure and increasing velocity of the fluid again
the fluid enters in the diffuser which result in an increasing pressure and decreasing
velocity of the fluid so due to pressure difference vacuum is created in between the nozzle
and diffuser we can say venture throat . So due to pressure difference or vacuum it sucks no
condensable air and fluid from the system. The mixture then enters to an inter condenser
where the steam is condensate. The inter condenser are designed with a special inter
condenser baffles of tubes where heat transfer takes place. The second stage ejector
handles the non-condensate gasses of first stage ejector and through a vent opening to the

24
 atmosphere. The air flow can be measured. The condensate water of steam sends back to
re-use through steam traps.

Hogger Line Ejector - This ejector is known as the starting ejector which is used to pull the
gasses at the time of starting of system. It has high capacity of air extraction. This ejector
operates with parallel with the running ejector till the vacuum reaches 500-600 mm of HG
column, then the hogger ejector is switched off and main ejector will remain in service. The
main disadvantage of this ejector is the steam escaped to atmosphere and can’t reuse.

Main Line Ejector - This is also known as the running ejector which evacuates the air
continuously at the system running condition. This is a multi-stage type ejector. The high
velocity air -water mixture enters to the shell and cooled in the first stage of the shell by
condensate. Steam is thus condensate and the steam air mixture volume reduced and allowed
to second stage of the nozzle. In the second stage the mixture is completely condensate and
the air is vented to the atmosphere. The drains are provided with loops or siphoned to prevent
ingress of air from the atmosphere. Here the condensate seam is again recovered in
condenser and reuse.

Ejector header

Ejector Main Line

Ejector Hogger Line

 Another tapping from the main steam line is provided for charging of De-aerator. The
temperate is reduced to 145 ℃ and pressure is reduced to as low as 1.3 Kg/cm2 before it is
allowed to enter the De-aerator. This steam line is called Pagging Steam. Another tapping
from Turbine itself is used to charge the De-aerator. So pagging steam line(from Main Steam
Line) and bleed steam line ( from turbine), join at a common point and then enter the De-
aerator. Both the lines lines are equipped with NRV so that steam line is only directed
towards De-aerator path and does not enter each other’s line.
 Another tapping is taken from the Main Steam Line before it is made to enter the boiler. This
line is called Dumping Line. This line is provided for emergency purpose. If one needs to stop
main steam line from entering into the turbine, this line is used to send the water directly into
the condenser so that DM-water can be saved instead of wasting it and releasing it into
atmosphere.
 Now the main steam line enters the Turbine at pressure of about 64 kg/cm2 and temperature
840 ℃.

25
Working Principle of Steam Turbine
High pressure steam is fed to the turbine and passes along the machine axis through multiple
rows of alternately fixed and moving blades. From the steam inlet port of the turbine towards
the exhaust point, the blades and the turbine cavity are progressively larger to allow for the
expansion of the steam.
The stationary blades act as nozzles in which the steam expands and emerges at an increased
speed but lower pressure. (Bernoulli's conservation of energy principle - Kinetic energy
increases as pressure energy falls). As the steam impacts on the moving blades it imparts
some of its kinetic energy to the moving blades.
There are two basic steam turbine types, impulse turbines and reaction turbines, whose
blades are designed control the speed, direction and pressure of the steam as is passes
through the turbine.

Impulse Turbines - The steam jets are directed at the turbine's bucket shaped rotor
blades where the pressure exerted by the jets causes the rotor to rotate and the velocity of the
steam to reduce as it imparts its kinetic energy to the blades. The blades in turn change the
direction of flow of the steam however its pressure remains constant as it passes through the
rotor blades since the cross section of the chamber between the blades is constant. Impulse
turbines are therefore also known as constant pressure turbines.

The next series of fixed blades reverses the direction of the steam before it passes to the
second row of moving blades.

26
 Reaction Turbines - The rotor blades of the reaction turbine are shaped more like aero
foils, arranged such that the cross section of the chambers formed between the fixed blades
diminishes from the inlet side towards the exhaust side of the blades. The chambers between
the rotor blades essentially form nozzles so that as the steam progresses through the
chambers its velocity increases while at the same time its pressure decreases, just as in the
nozzles formed by the fixed blades. Thus the pressure decreases in both the fixed and moving
blades. As the steam emerges in a jet from between the rotor blades, it creates a reactive
force on the blades which in turn creates the turning moment on the turbine rotor, just as in
Hero's steam engine. (Newton's Third Law - For every action there is an equal and opposite
reaction).

Turbine-Generator arrangement - The plant employs a 4-pole synchronous generator with

a synchronous speed of 1500 RPM. The output frequency is determined by the relation

Where, N is the rotor speed in RPM

f is the output frequency of generator
P is the number of poles of generator

The generator and the bearings are cooled by oil which is supplied by various oil pumps
AOP, COP etc. The following figure shows the arrangement of turbine and generator set.

Overall turbine and generator arrangement

27
 The turbine rotates with a speed of 4897 RPM.
 When the exhausted steam leaves the turbine, it leaves at a negative pressure of about
-8.5 kg/cm2 and temperature is reduced to as low 53 ℃.
 Now, generator cannot operate at such high RPM so it needs to be reduced. The 4897
RPM is reduced to 1500 RPM. This is achieved by means of Turning-Gears. This is
in turn coupled to common rotor shaft of generator, exciter and PMG.
 Governor is attached to steam turbine, to maintain the speed, as per the requirement.
 The exhausted steam is now transferred to Condenser where it is condensed to return
back into circulation so that

Condenser – The main purpose of the condenser is to condense the exhaust steam
from the turbine for reuse in the cycle and to maximize turbine efficiency by
maintaining proper vacuum. As the operating pressure of the condenser is lowered
(vacuum is increased), the enthalpy drop of the expanding steam in the turbine will
also increase. This will increase the amount of available work from the turbine
(electrical output).
The main heat transfer mechanism in a surface condenser is the condensing of the
saturated steam on the outside of the tubes. Thus for a given circulating water flow
rate, the water inlet temperature to the condenser determines the operating pressure
of the condenser. As this temperature is decreased, the condenser pressure will also
decrease. As described above, this decrease in the pressure will increase the plant
output and efficiency. The non-condensable gases consist of mostly air that has
leaked into the cycle. These gases must be vented from the condenser. The gases need
to be removed because this will increase the operating pressure of the condenser.
This rise in pressure will decrease the turbine output and efficiency

Condenser parts presentation

28
 Super-Heated steam line

Condense
r

Hot-Well

 The condensate is collected in hot-well.

 Another important component is Gland Sealing Condenser.

The function of gland steam condenser is to maintain a sub atmospheric

pressure at the outmost leak off belt of the glands and thereby prevent
leakage of steam to atmosphere.

 The condensate now is sent back to Deaerator. There by the Steam Cycle
continues.

29
Oil Circulation

Block diagram of Oil Circulation

 For balance of plant an oil handling plant is very essential. Oil is required as
lubricant. It is also required for cooling purpose as well.
 Oil Servo Prime 46 is used for the purpose of circulation.
 Oil from Oil Tank is sucked with the help of AOP or the Auxiliary Oil Pump.
 AOP sends the oil to oil cooler first. Oil is cooled up to a temperature to
about 45 ℃.
 Next from Oil Cooler, oil is transferred to Oil Filter.

Oil Filter is of Basket Type. The mesh material is made of stainless steel.
The mesh rating is 25 Microns. Work Pressure is 3 kg/cm2 inside the filter.
The capacity of the oil filter is 870 LPM. Manufactured by Southern
Lubrication (P) Ltd.

 Now from oil filter the oil passes to PRV or the Pressure Relief Valve.
Initially at the suction line the is about 9.4 Kg/cm2. This is reduced to 2.8
Kg/cm2 with the help of PRV.
 And it is then finally sent to General Bearing for cooling and its lubrication.
Steam turbines are provided with General bearings and thrust bearings.
General bearings are at each end of each rotor to support the weight of
the rotor. One thrust bearing is provided for the entire steam turbine to
maintain the axial position of the rotor.

30
Major control valves associated with the steam turbine and their operations are as
follows:
Main Steam Stop (Throttle) Valves: The steam from the steam generator flows to the
main steam stop or throttling valves. The primary function of the stop valves is to
provide backup protection for the steam turbine during turbine generator trips in the
even the main steam control valves do not close. The energy in the main steam and
steam generator can quickly cause the turbine to reach destructive over speed on loss of
the generator load. The main steam stop valves close from full open to full closed in
0.15 to 0.5 s. The stop valves are also closed on unit normal shutdown after the control
valves have closed.
Main Steam Control (Governor) Valves: The steam flows from the stop valves to the
main steam control or governor valves. The primary function of the control valves is to
regulate the steam flow to the turbine and thus control the power output of the steam
turbine generator. The control valves also serve as the primary shutoff of the steam to
the turbine on unit normal shutdowns and trips.

 Another line is taken from Oil Tank with the help of COP or the
Control Oil Pump.
 This oil is filtered in Control Oil Filter. It is then sent to Governor for
the purpose of cooling and lubrication.
 Not only Governor and the General Bearing, other auxiliaries are also
targeted that require cooling and lubrication.
 Finally a common oil outlet header gets the oil back to the oil tank
which is again cooled, filtered and circulated.
 The trip oil is the one used to trip the Turbine, by Closing Stop Valves
and Control valves .The trip oil gets drained when the trip signal is
generated. So Trip oil trips the turbine.

 Overhead Oil Tank is an emergency oil storage tank on the terrace of

the plant. In case the oil system is not working properly. Overhead
Head Oil Tank is drained to reach the parts. For this purpose it uses
Gravitational Energy.

Governor
Turning Gear
Generator

Oil Outlet Header

31
 Cooling Tower
ID Fan

ACWP-2 ACWP-1 CWP-3 CWP-2 CWP-1

Auxiliaries Block Diagram of Cooling Tower

Condenser

In the processes of condensing the steam, the circulating water in the condenser gets
heated. This heated water needs to be cooled down in order to be used again in the
condenser. Here comes the role of cooling tower. The cooling tower takes the
circulating water from the condenser cools it and returns it through the main stream.

The circulating water from the condenser comes from the through large tubes under
high pressure to make it reach a certain height. Water from here gets distributed
among a number of small pipes network just below the Induced Draft fan. The nozzles
at the bottom end of the pipes breaks the water and sprinkles them on the bar layer.
This water falls on the bed in the form of a shower.

 A four cell tower is present at the site.

 Each of the Tower had ID fans, since it is ID fan, it rotates in anti-
clockwise direction.
 There are 5 cooling water pumps. Out of which 2 are ACWP or the
Auxiliary Cooling water pump and 3 is Cooling Water Pump.
 The auxiliary cooling water proceeds to small heat exchangers used
for cooling the pumps and motor bearing frames, and other equipment
 The cooling water from CWP proceeds for circulation in condenser.

32
Power Generation

T
u
r
n
i
n
g
G
e
a
r

Block diagram of Power Generation

 As the Turbine rotates by the Super-Heated steam. It also rotates a

rotor to which it is coupled with,
 The turbine rotates at very high RPM of 4897. This can spoil the
generator as the speed is very high. So the speed needs to be
reduced to the rated 1500 RPM of the generator. This is achieved
with help of gears.
 PMG or the Permanent Magnet Generator rotes by the rotor shaft
giving a AC voltage as output.

The PMG (Permanent Magnet Generator) is a system which is used

for secondary exciting. The PMG provides stable and reliable
electric energy for AVR regardless the generator’s terminal
voltage.

 AVR provides a rated voltage to the exciter.

Excitation current is required to set up the working magnetic flux in

the alternator. This necessary excitation current is provided by the
exciter. It is transferred to the magnetic poles or field winding
through slip ring. The output of the ac exciter is given to diode
wheel. It rectifies the current and feeds it to the field winding
through the slip ring.

33
 A DC current is hence provided to generator rotor. This creates a
magnetic field around the Generator stator. This induces EMF in
Generator Stator. From this output of 11KV is obtained with AC
current of 1968 A at 50 Hz. Earthing for the three phases is also
provided from a stator (star connected) so as to keep the voltage at
11 KV.

Thus the generator converts the rotational energy to electrical

energy. This conversion is based upon the Faraday's Law which
states that relative motion between conductor and magnetic flux
induces EMF in the conductor.

 The AVR or the Automatic Voltage Regulator also acts as a

feedback system and operates the exciter according to the output
from the generator.

Permanent Magnet Generator

Exciter

Automatic Voltage
Regulator

34
Power Distribution

Microcontroller Room bus-bar presentation

 Finally the power generated power is distributed

 The 11kV line from the generator first charges the bus bar to 11kV.
From there multiple lines are taken for distribution and auxiliary
working purpose.

The bus bars are aluminum or copper conductors which carry

electric current in open air to which various connections (feeders,
equipment) can be made.

 A connection is made to the bus bar from the Grid Incomer. In case
the generator trips, the Grid Incomer will provide the necessary
power for use.
 There ATF or the Automatic Transformer with rated power of 2.5
MVA is connected to the bus bar. This provides the rated output
that acts as a rated input for working of the various plant
auxiliaries.
 Connections are also taken from the bus bar to provide 11 kV
supply to DRI feeder, and also supply to the 2 HT pumps.
 Likes various bus bars are interconnected so that incase a part does
not work properly, supply does not get affected and the power is
supplied smoothly.
 ET or the Earthing Transformer connection is also provided to the
bus bar to deal with transient current as it provides a low
impedance path to the ground which otherwise may damage the
loads connected to the system.
 Circuit Breakers are provide at every connection so that working of
one load does not affect the working of the other connected loads.

35
  From the bus bar the supply of 11 kV is supplied to the sub-station
where the voltage is step-up to 33 kV and again the voltage is step-
up to 132 kV for supply to the Grid.

Important components of the grid are :-

Transformer - Transformers are required to step up or step down the voltage level
depending upon the requirement. They are constant flux device. A basic transformer
has two sets of winding namely primary and secondary winding. Ratio of number of
turns in both winding determines whether it is step up or step down transformer.

At the most ground level transformer is just an application of Faraday's Law which
states that EMF is induced in a coil if the magnetic flux linked to it changes.
Alternating current given to primary winding of transformer produces alternating
flux. This alternating flux is linked to the secondary through a common core. The
alternating flux through the turns of the secondary winding induces EMF in the
winding. If the number of turns are greater than the voltage is stepped up, else it is
stepped down.

33/ 11 kV
Transformer

Isolators - Isolators are disconnection switch. They can be controlled from switch
yard or from the control room. These isolators are in open air, so they are used only
in off load condition, i.e,. they are operated only after the circuit breaker is brought
to action. By looking at the position of the isolators we can tell whether it is
connected or disconnected. For repairing purpose circuit breaker is tripped first and
then the isolators contact are removed which isolates the equipment for repair
purpose.

36
 Isolators are of two kinds:-

a.) Center Break Isolator

b.) Center Rotating Isolator

Circuit – Breaker - Circuit Breakers are used for making and breaking of electrical
contacts. These are ON-Load switch.

To open the circuit first the circuit breaker is opened and then isolator is opened. To
close the circuit, first isolator is closed and then the circuit breaker is closed

For the safety of the instruments and economic reasons, we need to keep a record of
the current and voltage at various points in the circuit. Such high voltage and current
is highly unsafe to directly give to the measuring equipment. Their values have to be
lowered down. For this we require CT and PT.

Potential Transformer – It is a Step – Down transformer used for measurement of

voltage and hence be used for safety purpose.PT is connected in parallel to the
circuit. The secondary windings of a potential transformer should not be short-
circuited because since it is a Step-Down transformer, current will be very high, and
that will burn the windings.

Current Transformer – It is a Step – Up transformer used for measurement of

current and protection purpose. CT is connected in series. The secondary winding of
the current transformer if not shorted then it will develop very high voltage across its
secondary winding which may damage transformer insulation.

Lighting Arrester - Lightening arresters protect from surge due to switching the
machines on and off and due to lightening. They have nonlinear resistance whose
conductivity increases with increase in voltage above the safe value. Above the
limiting value of the circuit operation, the resistance path of arrester become
conductive and conduct the surge current to the ground without harming any
equipment.

Wave Trap – It is device that helps in communication between sub-stations. It traps

high frequency communication signal in the HT wire. It provides a high impedance to
high frequency communication and let pass the lower frequency power to the bus bar.

37
 APPENDIX

Turbine/Generator STEAM TURBINE

4897/1500 RPM
Inlet Steam Pressure 64 Kg/cm2
Inlet Steam Temperature 480 ℃
Extraction Steam Pressure 2.4
Exhaust Steam Pressure 0.1
Weight 39000 Kg
Company Shin Nippon Machinery Co. Ltd, Japan

LT-BFP

Pump ( X 3)
Type/Model HAD 80/11
RPM 2970

Bearing
DE/NDE Shell Bearing (Bush Bearing)
LOD BRG – 3310 C3
Capacity 45 m3 / Hr
Head 920 meter

Motor
Capacity 200 kW
Model/Type Induction Motor 3 Phase
Voltage 415 V
Current 323 A
RPM 2983

Bearing DE
DE 6217 + NU 217
NDE NU217 M

HT-BFP

Pump ( X 2)
Type/Model HDA 100/9
RPM 2970
Load – Brg 3310 C3
DE/NDE Shell Bearing
Capacity 88 m3 / Hr
Head 950 m

38
 Motor
Type/Model L – AMA450L2ABAI
Capacity 350 kW
Voltage 1100V
Current 24 A
RPM 2973
EFF 92.7%

Bearing
DE 6319 m/c3
NDE 6319 m/c3

COOLING TOWER AREA

(“TARUNA”)
Type Mechanical
Draft Induced
Flow Counter Flow
Number of Cell 4 (3H)
Capacity 5910 m3 / Hr
Flow Rate/Cell 1970 m3 / Hr
Hot Water Temperature 42℃
Cold Water Temperature 32℃
Change in Temperature 10℃
Wet – Bulb Temperature 27℃

PUMP COOLING (CWP)

Make Mather & Platt

Type Centrifugal (Split Casing Pump)
Flow 2815 m3 / Hr ; Head – 35m
Bearing Type (DE Bush Bearing) Brass
NDE (Bush Bearing) Brass
NDE (Deep Groove Ball Bearing) 6313 C3
Motor
Make ABB
KW 225
RPM 998
AMP 397
Frequency 50 Hz
Volts 415
Bearing Type DE(6322 C3) / NDE(6322 C3)

39
 PUMP COOLING (ACWP)

Make Mather & Platt

Type Centrifugal (Split Casing Pump)
Flow 605 m3 / Hr ; Head – 35 m
Bearing Type DE (6308 ZZ)
NDE 6308 ZZ
Motor
Make ABB
KW 75
RPM 1440
AMP 128
Volt 415 V
Bearing Type DE(6317 C3) / NDE( 6316 C3)

DM WATER
PARAMETER UNIT LIMIT
pH 6.5 – 7.2
Conductivity us / cm <1
Silica ppm < 0.02

FD/ID FAN
FD Fan Quantity 2
Capacity 60 Ton / Hr
Current 283 A
ID Fan Quantity 2
Capacity 120 Ton / Hr
Current 70

40
 GENERATOR
Output 375000 kVA
Standard IS 4722
Number of Phases 3
Number of Poles 4
Voltage (AC) 11 kV
Current (AC) 1968 A
Frequency 50 Hz
Speed 1500 RPM
Limiting Speed 1800 RPM
Power Factor 0.8
Type of Stator Connection Star
Excitation Voltage(DC) 302 V
Excitation Current(DC) 478 A
Altitude < 1000
Company TD Power System – TOKYO

41
 CONCLUSION
MY visit to CPP was from June 11, 2018 to June 26, 2018.

The modernization of world as we see today would not become possible if

electrical power do not come into picture. Today each area of Science &
technology is highly affected by the use of electrical energy. Electrical energy is
the only reliable form of Energy which is easily converted into any form of
energy whether it is Mechanical, Chemical, Light, and Sound etc.

The electrical energy has been used not only in industrial areas but also in
residential and commercial application as well. The reason behind the
popularity of this form of energy is because it can be easily transferred to one
place to another with efficiency.

So at the outset I would like to conclude that there is no doubt without the
development of this form of energy, we would never achieved the faster pace of
growth rate as today the world is growing and this has become possible only
due to the development of power system.

Thank You

42