THERMAL POWER PLANT INTRODUCTION:The main source of power for steel plant is Thermal Power Pla nt(TPP).

The power which is obtained from TPP is synchronized and given to APSEB , and from APSEB the plant consumes the power that has generated by the TPP and if the plant consumes excess power then they given, they pay the amount to APSE B. The total capacity of thermal plant of steel plant is 286.5 MW, of which 247.5 M W is from main TPP and 39MW from its auxiliary plants. The main plant consists of, three ge nerators of each 60 MW = 180MW and One generator of 67.5 MW The auxiliary plants are, Back Pressure Turbine Station (BPTS) Gas Expansion Turbine Station (GETS) TPP has the following divisions namely, Boilers Turbo-Generators (TG) Turbo-Blowers (TB) Chemical Water Treatment Plant (CWTP) Coal Handling Plant (CHP) Auxiliaries of TPP Boilers:A boiler is a device where the water is converted into steam by utili zing the heat of combustion. This crushed coal is introduced into the furnace an d the different gases and fuels are injected at various heights of the furnace. The boilers are of water tube type. The crushed coal and the fuels are fired at a temperature of 10000C to produce the steam and flue gases. The steam produced in the boilers is supplied to the turbo-blowers, turbo-generators and process ne eds. The efficiency of boilers increases if the flue gases are also utilized eff ectively. The flue gases produced are at a temperature of about 9000C. In TPP, t here are five boilers each rated 330 tons/hr of steam at 540 C and 101 atm. Thes e boilers are multi fuel five types, and they are manufactured by BHEL. Out of f ive, only four boilers are used for full load operation to produce 247.5 MW of p ower. TURBO GENERATORS:Turbo generators are used for the generation of power by the application of mechanical energy. The Turbo generator using in TPP are BHEL mad e. The ratings of the turbo generators are as follows, 60 MW generators STATOR : Voltage -11000 V Current - 3936 A ROTOR : Voltage -300 V Current - 596 A SPEED : 3000 rpm. FREQUECY : 50 HZ COOLANT : AIR CONNECTION: STAR INSULATION : CLASS B 67.5 MW GENERATOR STATOR ROTOR SPEED FREQUECY : : : : Voltage: 11000 V Current: 4429 A Voltage: 367 V Current: 624 A 3000 rpm. 50 HZ 15 MW (each of 7.5 MW) 24 MW (each of 12 MW).

COOLANT : CONNECTION: INSULATION :

AIR STAR CLASS B

Generator stator is lighter in construction, and they support and enclose stator windings, core and hydrogen coolers .Cooling medium hydrogen is contained with in the frame and circulated by the fans mounted at the either ends of the rotor. The generator is driven directly by a coupled stem turbine at 3000 rpm. TURBO BLOWERS:In TPP there are three turbo blowers of which two are in wo rking condition and other is in stand by condition. Each turbo blowers has capac ity 6067 NM Cu/min. AUXILARIES OF TPP: ASH HANDLING PLANT:- The coal using TPP contains nearly 40 % of ash. The removal of this ash is performed by the ash handling plant. The flu gases formed due to combustion of coal is first passed round the boiler tubes, super heater, econom izer, and reheater. Finally the flu gases after passing through Electro Static P recipitator (ESP) is exhausted through chimney. The flu gases after allowed to p ass through ESP leave the ash on electrodes. This ash on electrodes is removed b y rapping mechanism. Now, this ash will fall down to bottom of ESP and it is tra nsported to ash slurry plant after maxing with water in ESP. The waste water fro m ash slurry plant is sent to ash dumping yard. COAL HANDLING:This is important system in TPP, as it handles the fuel for combustion. The coal brought by rails, is unloaded from wagons and then crushed by crushers and magnetic pulley, and pulverized and tran sferred to boilers. The entire transportation is performed by conveyor belt by 3 phase induction motors. CHEMICAL WATER TREATMENT PLANT:This plant in TPP is used to produ ce high purity of De mineralized and soft water. Normal water in boilers is not used as they form scales due to dissolved salts which cause damage and reduces e fficiency. There are six streams of De mineralizing units each capable of produc ing 125 Cu mt /hr each. De mineralized water is used in TPP and SMS (Steel Melti ng Shop). ELECTRO STATIC PRECIPITATOR:This ESP is used to reduce the amount of dust content in flu ga ses, and to leave cleaned gas. The ESP is huge in construction, it consists of i nductor coils connected from top to bottom to the ESP, and in similar way large electrode plates are connected, the plates given positive charge and inductor co ils negative charge .As ash is negatively charged when it passes through electro des, it gets deposited on electrode plates. The ash accumulated is removed by ra pping mechanism in which electrode is beaten by rod like s