PRACTICAL TRAINING REPORT

On

Kota super thermal power plant station

BACHELOR OF TECHNOLOGY

( ELECTICAL ENGINEERING)

SUBMITTED TO: SUBMITTED BY:

SAURABH SINGHAL

11610301

E5

Session: 2016-2020
 ACKNOWLEDGEMENT
I would like to thank the entire kota super thermal power station who has provided me this
sessional training.I am thankful to Sr. Engineer Kapeendra Agrawal for their benevolent
guidance & kind cooperation through out my training along with completing this project
report.I also thanks to workers, who were always ready to clarify my doubts & helped me to
increase my knowledge by illus-traiting me to the finer points.I hope that my report will reflect
my technical knowledge &innovativeness, which I gained from kota super thermal power
station.
 Declaration
This report is based on the summer training, I have unde-rgone in the premises of kota super
thermal power stationfrom 24 may 2018 to 30 june 2018. I got the knowledge of equipments
of power station & about the electicity generation.The experience of the training was good
and I learned lots of things. I was successfully able to complete the summer training.
 CONTENTS

 INTRODUCTION

 LOCATION

 EXCELLENT PERFORMANCE

 POWER STATION DESIGN

 COAL HANDING PLANT

 STEPS IN COAL HANDLING

 PULVERIZATION OF COAL
 PULVERIZED COAL FIRING
 ASH DISPOSAL

 EQUIPMENTS ON A THERMAL POWER STATION

 BOILER
 BOILER DRUM
 ECONOMIZER
 AIR PREHEATER
 SUPERHEATER
 STEAM TURBINE
 IMPULSE TURBINE
 IMPULSE REACTION TURBINE
 DEARATOR
 CONDENSER
 ELECTRO STATIC PRECIPITATOR

 FAN USED IN A THERMAL POWER PLANT

 FORCE DRAUGHT FAN
 INDUCED DRAUGHT FANS
  NATURAL DRAUGHT

 COOLING TOWER

 CONCLUSION
 INTRODUCTION

Rajasthan is well on its way for a 'brighter' future, a future that promises electricity to
every city, town and village of the state, a promise of making the state completely self-
dependent in power production. The state plans to add over 1500 megawatts of power
supply to its present capacity in the coming two years. Nine electricity generating units are
being raised under different power projects across the state that will increase the current
capacity of 2,569 MW to 4084 MW. Kota Thermal Power Station is Rajasthan's First major
coal power station. Presently it is in operation with installed capacity of 1240 MW. And one
more unit of 250MW is slated for commissioning in March 2009.

The foundation of seventh unit of Kota Thermal Power Station (KTPS) was laid by Union
Minister of Power, Mr. Sushil Kumar Shinde on December 5, 2006. The unit is expected to
be ready by November, 2007. .After this, the Kota power plant's present capacity of 1045
MW will be expanded to 1240 Mw.
STAGE UNIT NO. COST
CAPACITY( SYNCHRONI
MW) ZING DATE (Rs. crore)

I 1 110 17.01.1983 143

2 110 13.07.1983

II 3 210 25.09.1988 480

4 210 01.05.1989

III 5 210 26.03.1994 480

IV 6 195 31.07.2003 635

V 7 195 30.05.2009 880

Location:

Kota Thermal Power Station is located on the left bank of river Chambal in Rajasthan's
principal Industrial city, Kota. Thermal power station to produce electrical power for
supply undertakings K.S.T.P.S. is designed for ultimate capacity of 1240 MW.
Excellent Performance:

Kota Thermal Power Station of RVUN is reckoned one of the best, efficient and prestigious
power stations of the country. KTPS has established a record of excellence and has earned
meritorious productivity awards from the Ministry of Power, Govt. of India during 1984,
1987, 1989, 1991& every year since 1992-93 onwards. Kota Super thermal power station
have earned Golden Shield award from Union Ministry of power for consistently
outstanding performance during last four years (i.e. 2000-01,2001-02,2002-03,2003-04).
The Golden Shields were presented by H.E. President of India Dr. A.P.J. Abdul Kalam on
24.08.2004. Kota Thermal Power Station of RVUN is reckoned one of the best, efficient and
prestigious power stations of the country. KTPS has established a record of excellence and
has earned meritorious productivity awards from the Ministry of Power, Govt. of India
during 1984, 1987, 1989, 1991& every year since 1992-93 onwards. Kota Super thermal
power station have earned Golden Shield award from Union Ministry of power for
consistently outstanding performance during last four years (i.e. 2000-01,2001-02,2002-
03,2003-04). The Golden Shields were presented by H.E. President of India Dr. A.P.J. Abdul
Kalam on 24.08.2004.

POWER STATION DESIGN :

Power station design requires wide experience. A satisfactory design consists of the
following step:

 Selection of site

 Estimation of capacity of power station.

 Selection of turbines and their auxiliaries.

 Selection of boilers, and their auxiliaries.

 Design of fuel handling system.

 Selection of condensers.

 Design of cooling system.

 Design of piping system to carry steam and water.

 Selection of electrical generator.

Characteristics of a Steam Power Plant : The desirable characteristic for a steam power
plant are as follows:

 Higher efficiency.

 Lower cost.

 Ability to burn coal especially of high ash content and inferior coals.

 Reduced environmental impact in terms of air pollution.

 Reduced water requirement.

 Higher reliability and availability.

COAL HANDLING PLANT

Coal delivery equipment is one of the major components of plant cost. The various
steps involved in coal handling are as follows:

Steps in coal handling:

1. Coal Delivery

2. Unloading

3. Preparation

4. Transfer

5. Outdoor Storage (Dead Storage)

6. Covered Storage (Live Storage)

7. In Plant Handling

8. Weighing and Measuring

9. Furnace

 Coal Delivery

The coal from supply points is delivered by ships or boats to power stations
situated nearto sea or river whereas coal is supplied by rail or trucks to the
power stations which are situated away from sea or river. The transportation
of coal by trucks is used if the railway facilities are not available.
 Unloading :

The type of equipment to be used for unloading the coal received at the
power station depends on how coal is received at the power station. If coal is
delivered by trucks, there is no need of unloading device as the trucks may
dump the coal to the outdoor storage. Coal is easily handled if the lift trucks
with scoop are used. In case the coal is brought by railway wagons, ships or
boats, the unloading may be done by car shakes, rotary car dumpers, cranes,
grab buckets and coal accelerators. Rotary car dumpers although costly are
quite efficient for unloading closed wagons.

Railway wagon
 Preparation :

When the coal delivered is in the form of big lumps and it is

not of proper size, the preparation (sizing) of coal can be achieved by
crushers, breakers, sizers driers and magnetic separators.

 Transfer :
 After preparation coal is transferred to the dead storage by Belt conveyors,
Screw conveyors, Bucket elevators, Grab bucket elevators, Skip hoists, Flight
conveyor.

 Outdoor (Dead) Storage :

It is desirable that sufficient quantity of coal should be stored. Storage of

coal gives protection against the interruption of coal supplies when there is delay in
transportation of coal or due to strikes in coal mines. Also when the prices are low,
the coal can be purchased and stored for future use. The amount of coal to be stored
depends on the availability of space for storage, transportation facilities, the amount
of coal that will whether away and nearness to coal mines of the power station.
Usually coal required for one month operation of power plant is stored in case of
power stations situated at longer distance from the collieries whereas coal need for
about 15 days is stored in case of power station situated near to collieries. Storage
of coal for longer periods is not advantageous because it blocks the capital and
results in deterioration of the quality of coal.

 Indoor (Live) Storage:

Such storage constitutes coal requirements of the plant

for a day. The live storage can be provided with bunkers and coal bins.

 In Plant Handling :

This refers to handling of coal between the final storage to

the firing equipment. In case of simple stoker firing only chutes may be
required to feed the coal from storage bunker to firing units.
  Coal weighing

The cost of the fuel is the major running cost of the plant. It is,
therefore, very necessary to weigh coal at unloading point and also that used as feed to
individual boilers. A correct measurement of coal enables one to have an idea of total
quantity of coal delivered at the site and also whether or not proper quantity has been
burned as per load on the plant.

 PULVERIZATION OF COAL

Coal is pulverized (powdered) to increase its surface exposure thus permitting

rapid combustion. Efficient use of coal depends greatly on the combustion process
employed. For large scale generation of energy the efficient method of burning coal is
confined still to Pulverized coal combustion. The pulverized coal is obtained by grinding
the raw coal in pulverizing mills. The various pulverizing mills used are as follows:

1. Ball mill

2. Hammer mill

3. Ball and race mill

 PULVERIZED COAL FIRING :

Hot air is passed through coal in the feeder to dry the coal. The coal
is then transferred to the pulverizing mill where it is pulverized. Primary air is
supplied to the mill, by the fan. The mixture of pulverized coal and primary air then
flows to burner where secondary air is added. The unit system is so called from the
fact that each burner or a burner group and pulverising constitutes a unit.

 ASH DISPOSAL

A large quantity of ash is, produced in steam power plants using coal.
Ash produced in about 10 to 20% of the total coal burnt in the furnace. Handling of ash is a
problem because ash coming out of the furnace is too hot, it is dusty and irritating to handle
and is accompanied by some poisonous gases.
EQUIPMENTS ON A THERMAL POWER STATION

Boiler:

Boiler is a device meant for producing steam under pressure. Steam boilers are
broadly classified into fire tube and water tube. Generally water tube boilers are
used for electric power station. In water tube boilers, water circulates through the
tubes and hot products of combustion flow over these tubes. In fire tube boiler the
hot products of combustion pass through the tubes, which are surrounded, by
water. But they are more likely to explosion, water volume is large and due to poor
circulation they cannot meet quickly the change in steam demand. Water tube
boilers require less weight of metal for a given size, are less liable to explosion,
produce higher pressure, are accessible and can response quickly to change in
steam demand. Tubes and drums of water-tube boilers are smaller than that of fire-
tube boilers and due to smaller size of drum higher pressure can be used easily.
Water-tube boilers require lesser floor space. The efficiency of water-tube boilers is
more

Boiler is main equipment on a thermal power station. It made up of thousands of

tubes Generally called water walls. And these walls are insulated by the insulating
material. And water is flowing through these tubes. And the height of the boiler is
approx. 55-60 meter. The plant efficiency is mainly depending upon boiler
efficiency.
TECHNICAL SPECIFICATION OF BOILER (2x110MW UNITS)

1. Type : Direct fired, natural circulation balance draft water

Tube bolier

2. No. of Units. : Two.

3. Make : BHEL.

4. Capacity. 375 tones per hour.

5. Steam Pressure. : 139 Kg./Cm2

6. Efficiency : 86.6 %.

7. No. of fans in service.

a) ID fans. : 2 Nos.

b) FD fans. : 2 Nos.

c) PA fans. : 2 Nos.

d) Seal Air fan. : 1 No.

e) Scanner Air fan. : 1 No.

f) Igniter fan. : 1 No.

8. Steam Temperature : 540oC.

9. No. of coal mills in service. : 3 Nos.

 Boiler drum

Boiler drum is on the height of approx. 53 meters. The boiler drum contains
both steam and water, A number of accessories such as water level indicator, safety valve,
automatic alarms, pressure gauge etc. the use of these devices assists in adequate control
and operation of the boiler as also in safety against accidents.
 economizer

The purpose of economizer is to heat feed water so as to recover a part of heat, Which
would otherwise be lost through flue gases.

 Air Preheater:

An Air preheater increases the temperature of the air supplied for

coal burning by deriving heat from flue gases. The air preheater extracts heat from flue
gases and increases the temperature of air used for coal combustion. The principal benefits
of preheating the air are: increased thermal efficiency. The air pre heater is made up of
Buckets, in which 3 layer of buckets are put on each other, in the middle of layer, a motor is
held, which is rotate on its own axis, Air pre heater heat up the air given to the boiler.

 Superheater:

A superheater is a device which superheats the steam; it raises the temperature of steam
above boiling point of water. This increases the overall efficiency of the steam. A
superheater consists of a group of tubes made of special alloy such as chromium-
molybdenum. These tubes are heated by the heat of the flue gases during their journey
from the furnace to the chimney.

 Stream turbine:

The dry and superheated steam from the superheater is fed to the steam turbine through
main valve. It converts Kinetic energy to Mechanical Energy. ( i.e. The heat energy of steam
passing over the blades of turbine is converted into mechanical energy)
Classification of steam turbine:

(A) On the Basis of Principle of Operation :

i) Impulse turbine ii) Impulse-reaction turbine

(1)Impulse Turbine:

If the flow of steam through the nozzles and moving blades of a turbine
takes place in such a manner that the steam is expanded only in nozzles and pressure at the
outlet sides of the blades is equal to that at inlet side; such a turbine is termed as impulse
turbine because it works on the principle of impulse. In other words, in impulse turbine,
the drop in pressure of steam takes place only in nozzles and not in moving blades. This is
obtained by making the blade passage of constant cross- section area As a general
statement it may be stated that energy transformation takes place only in nozzles and
moving blades (rotor) only cause energy transfer. Since the rotor blade passages do not
cause any acceleration of fluid, hence chances of flow separation are greater which results
in lower stage efficiency.

(2) Impulse-Reaction Turbine:

In this turbine, the drop in pressure of steam takes place in fixed (nozzles) as well as
moving blades. The pressure drop suffered by steam while passing through the moving
blades causes a further generation of kinetic energy within the moving blades, giving rise to
reaction and adds to the propelling force which is applied through the rotor to the turbine
shaft. Since this turbine works on the principle of impulse and reaction both, so it is called
impulse-reaction turbine. This is achieved by making the blade passage of varying cross-
sectional area (converging type)
The various advantages of steam turbine are as follows:

 It requires less space.

 Absence of various links such as piston, piston rod, cross head etc. make the
mechanism simple.

 It can be designed for much greater capacities as compared to steam engine. Steam
turbines can be built in sizes ranging from a few horse powers to over 200,000
horse power in single units.

 In steam turbine power is generated at uniform rate, therefore, flywheel is not

needed.

 It can be designed for much higher speed and greater range of speed.

Technical data of steam turbine (210mw)

 Rated Output : 210 MW.

 Rated Speed. : 3000 rpm.

 Main steam pressure. : 150 Kg./Cm2

 Main steam temperature. : 535oC.

 Reheat steam temperature. : 535oC.

 Weight of turbine. : 475 T approx.

 Overall length. : 16.975 Mtrs.approx.

Description of 210 MW Steam Turbine

1) Steam flow :

210 MW steam turbine is a tandem compound machine with HP, IP & LP

parts. The HP part is single flow cylinder and HP & LP parts are double flow cylinders. The
individual turbine rotors and generator rotor are rigidly coupled. The HP cylinder has a
throttle control. Main steam is admitted before blending by two combined main stop and
control valves. The HP turbine exhaust (CRH) leading to reheat have tow swing check
valves that prevent back flow of hot steam from reheated, into HP turbine. The steam
coming from reheated called HRH is passed to turbine via two combined stop and control
valves. The IP turbine exhausts directly goes to LP turbine by cross ground pipes.

2) HP Turbine :

The HP casing is a barrel type casing without axial joint. Because of its
rotation symmetry the barrel type casing remain constant in shape and leak proof during
quick change in temperature. The inner casing too is cylinder in shape as horizontal joint
flange are relieved by higher pressure arising outside and this can kept small. Due to this
reason barrel type casing are especially suitable for quick start up and loading.

3) IP Turbine:

The IP part of turbine is of double flow construction. The casing of IP turbine is

split horizontally and is of double shell construction. The double flow inner casing is
supported kinematically in the outer casing. The steam from HP turbine after reheating
enters the inner casing from above and below through two inlet nozzles. The center flow
compensates the axial thrust and prevents steam inlet temperature affecting brackets,
bearing etc. The arrangements of inner casing confines high steam inlet condition to
admission branch of casing, while the joints of outer casing is subjected only to lower
pressure and temperature at the exhaust of inner casing. The pressure in outer casing
relieves the joint of inner casing so that this joint is to be sealed only against resulting
differential pressure.
4) LP Turbine: The casing of double flow type LP turbine is of three shell design. The
shells are axially split and have rigidly welded construction. The outer casing consists of
the front and rear walls, the lateral longitudinal support bearing and upper part.

 Turbo Generator

Generator is the main part of thermal power station or any power plant. A
generator is a machine which converts mechanical energy into electrical energy. TURBO
GENERATOR manufactured by B.H.E.L. and incorporated with most modern design
concepts and constructional features, which ensures reliability, with constructional &
operational economy.

Cooling medium hydrogen is contained within frame & circulated by fans mounted at either
ends of rotor. The generator is driven by directly coupled steam turbine at a speed of 3000
r.p.m. the Generator is designed for continuous operation at the rated output.

Temperature detectors and other devices installed or connected within then machine,
permit the windings, teeth core & hydrogen temperature, pressure & purity in machine
under the conditions. The source of excitation of rotor windings is Thyristor controlled D.C.
supply. The auxiliary equipment’s supplied with the machine suppresses and enables the
control of hydrogen pressure and purity, shaft sealing lubricating oils. There is a provision
for cooling water in order to maintain a constant temperature of coolant (hydrogen) which
controls the temperature of windings.
Technical data of turbo-generator:

Make KWVC Craftworks, German

Manufacturer BHEL

Rated Capacity 247 MVA

Rated Output 210 MW

Rated Current 9050 Amp.

Rated Terminal Voltage 15.75 KV

Rated Speed 3000 Rpm

Power Factor 0.8 Lagging

Excitation Voltage 310V

 Dearator :

A Dearator is a device that is widely used for the removal of air and
other dissolved gases from the feed water to steam generating boilers. In particular,
dissolved oxygen in boiler feed waters will cause serious corrosion damage in steam
systems by attaching to the walls of metal piping and other metallic equipment and forming
oxides (rust). It also combines with any dissolved carbon dioxide to form carbonic acid that
causes further corrosion. Most Dearator is designed to remove oxygen down to levels of 7
ppm by weight (0.0005 cm³/L) or less.
 Condenser:

The surface condenser is a shell and tube heat exchanger in

which cooling water is circulated through the tubes. The
exhaust steam from the low pressure turbine enters the shell
where it is cooled and converted to condensate (water) by
flowing over the tubes as shown in the adjacent diagram. Such
condensers use steam ejectors or rotary motor-driven
exhausters for continuous removal of air and gases from the
steam side to maintain vacuum.

For best efficiency, the temperature in the condenser must be kept as low as practical in
order to achieve the lowest possible pressure in the condensing steam. Since the condenser
temperature can almost always be kept significantly below 100°C where the vapor
pressure of water is much less than atmospheric pressure, the condenser generally works
under vacuum.

 Electro Static precipitator

To remove fly ash from the flue gases electrostatic precipitators

are used. They have collection efficiency over 99.5%. The efficiency depends on various
parameters such as velocity of flow, quantity of gas, resistivity of ash, voltage of fields,
temperature etc.

Principle of Operation:

The flue gas laden with fly ash is sent through ducts having negatively charged plates which
give the particles a negative charge. The particles are then routed past positively charged
plates, or grounded plates, which attract the now negatively-charged ash particles. The
particles stick to the positive plates until they are collected by periodically rapping.
 Feed Water Heater
In the case of a conventional steam-electric power plant utilizing a drum boiler, the surface
condenser removes the latent heat of vaporization from the steam as it changes states from
vapor to liquid. The heat content (btu) in the steam is referred to as Enthalpy. The condensate
pump then pumps the condensate water through a feed water heater. The feed water heating
equipment then raises the temperature of the water by utilizing extraction steam from various
stages of the turbine.

Preheating the feed water reduces the irreversibility involved in steam generation and
therefore improves the thermodynamic efficiency of the system. This reduces plant operating
costs and also helps to avoid thermal shock to the boiler metal when the feed water is
introduced back into the steam cycle.

Fans used in a Thermal Power Plant

 Force draught fan :

In order to burn the coal and convert it to heat, there should be a supply for large
amounts of air. Air combustion is supplied by force draught. Part of the air (primary air)
goes to the mills picking up the powdered coal. The rest of the air (secondary air) after
passing through the air preheater enters the furnace through the dampers (controlled
openings).

 Induced Draught Fans : The function of induced draught fan is to draw the flue gas
out of the furnace.it is placed near the stack. In an Induced draught system, the blower
 is installed near the base of the chimney and the burnt gases are sucked out of the
boiler, reducing the pressure inside the boiler to less than atmosphere one.

 Natural Draught

The natural draught is provided by the action of chimney or stack and is

used only in small boilers. Its intensity depends upon the average temp. Difference between
the flue gases within the chimney and the outside air and also on the height of the chimney
above the level of the furnace grate. Its weather conditions and boiler operating conditions.
Chimney, in addition of providing natural draught, helps in reducing air pollution too, as it
delivers the products of combustion and fly ash to a high altitude. The height of chimney is
180 meters.

 Cooling tower :

A cooling tower is equipment used to reduce the

temperature of a water stream by extracting heat from water and emitting it to the
atmosphere. Cooling towers make use of evaporation whereby some of the water is
evaporated into a moving air stream and subsequently discharged into the atmosphere. As
a result, the remainder of the water is cooled down significantly. Cooling towers are able to
lower the water temperatures more than devices that use only air to reject heat and are
therefore more cost-effective and energy eff

 STACK :

A flue gas stack is a type of chimney, a vertical pipe, channel or

similar structure through which combustion product gases called flue gases are exhausted
to the outside air. Flue gases are produced when coal, oil, natural gas, wood or any other
fuel is combusted in an industrial furnace, a power plant's steam-generating boiler, or
other large combustion device. Flue gas is usually composed of carbon dioxide (CO2) and
water vapor as well as nitrogen and excess oxygen remaining from the intake combustion
air. It also contains a small percentage of pollutants such as particulate matter, carbon
monoxide, nitrogen oxides and sulfur oxides.
 CONCLUSION

 After the successive completion of my training I got the practical knowledge of

power plant and make my knowledge better than before.

 I hope this training will help me for my career and to enrich my knowledge to
become a good engineer.

 I am very thankful to everyone who helped me directly or indirectly during my

training.

 It was a memorable experience for me to take training.