Vocational Summer Training Report On
Panki Thermal Power Station, Kanpur Submitted to the Department of Coal Handling Division For the Partial fulfilment of the requirements for The degree of Bachelor of Technology In Mechanical Engineering.
Submitted To: Er. B.P Srivastava
Assistant Engineer Coal Handling Division Panki Thermal Power Station, Panki, Kanpur.
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Submitted By: Ravi Kant ACME COLLEGE OF ENGINEERING Muradnagar, Muradnagar, Ghaziabad. Ghaziabad.
ACKNOWLEDGEMENT
I am extremely thankful to the members of Panki Thermal Power Station (PTPS), Kanpur for their kind support and Co-operation during my 4 weeks of training period. I would like to acknowledge acknowledge Er . B.P Srivastava (Assistance Engineer of CHD Departments) for giving me this fortunate chance to learn the various applications of mechanical engineering in real life. I express my sincere gratitude towards him for his wonderful guidance in the department and making me understand the various stages of thermal power generation. I also express my respectful gratitude towards all other engineers and technical staff at CHD for their help and guidance during my training period.
Finally, I thank all those who have helped me in the success of my training program. They have added a lot to my knowledge.
Ravi Kant B.Tech (Mechanical Engineering) ND 2 Year ACME COLLEGE OF ENGINEERING
Muradnagar, Ghaziabad 2|Page
nd It is certified that Ravi , student of 2 Year B-Tech. Ravi K ant Mechanical Engineering at ACME COLLEGE OF ENGINEERING, Muradnagar, Ghaziabad has worked on the Project on “Panki Thermal Power Station, Panki, Kanpur ” under my guidance and supervision. He has shown sincere efforts and keen interest during preparation of this project report. My best wishes are with him, his efforts and his future endeavours.
Date: 25/07/2013
Assistant Engineer
Place: Kanpur
Coal Handling Division Panki Thermal Power Station,
Er. B.P Srivastava
Panki, Kanpur 3|Page
Power Consumption In India
The energy sector holds the key in accelerating the economic growth of India. The energy demands for developing country like India keep on continuously growing. Energy is a driving force behind rapid economic growth of the country. India ranks tenth in the world in total energy consumption. It is first requirement of energy to accelerate the development of the sector to meet its growth aspirations.
The pattern of energy production put coal and oil again on top. These account for 65% of the entire generation. Renewable energy ranks bottom of the total production just before the Nuclear energy. The distribution of energy resource like hydro power is skewed towards Northeastern states of the country as 70 % of the total hydro potential is located in the Northern and North-eastern region.
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Panki Thermal Power Station (PTPS), Kanpur [U.P]
Panki Thermal Power Station is an Electricity Generation Station where Electricity Generated through the steam operation on Turbine & Steam is generated by Coal Firing so it is a Typical Coal fired Electricity Generation Station.
It is Located about 16 Kms Away from Kanpur Railway Station, st nd was Started with two units (1 & 2 ) of 32 MW each.it was established in 1968.
After Generating Power for about 28-29 years, 2*32 MW units th had completed their Rated Life So they were closed on 30 th November 1995 & 18 April 1997 respectively.
So In 1976-77, Two Units ( 3 & 4 of 2*110 MW each) Manufactured, Installed Bharat Heavy Electronics Ltd. These units were established in 1976 & 1977 respectively.
Unit 3 & 4 have been debated to 105 MW each by the th Central Electricity Authority (C.E.A) on 11 January 1990.
rd
rd
th
th
rd
th
So presently there are two units (3 & 4 of 105 MW each) working at PTPS.
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About Steam Thermal Power Station •
Process:-
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A steam power plant is a power plant in which prime mover is steam driven. Water is heated, turns into steam and spins a steam turbine (Impulse & reaction), which drives an electrical generator. When the turbine turns, electricity is generated and given as output by the generator, which is then supplied to the consumers through high-voltage power lines.
Process Diagram at Steam Power Plant
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Fossil Fuel Power Station Previously we discussed discussed that steam steam is prime prime driven object in steam power plant so in the case we needed steam for power generation ;so this steam is generated by boiling the water in boiler & this boiling is i s done by burning of Fuel. •
FOSSIL FUEL POWER STAION:-
A fossil fuel power station is a power station that burns fossil fuels such as coal, natural gas or petroleum (oil) to produce electricity.
Fuel + oil
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Furnace
Turbine
Generator
Coal fired Steam Power Plant •
Coal Fired Power Station:-
A coal Fired power station is that type of Fossil Fuel power station in which coal is used as a Fuel. In the Steam Power Plant There is a Separate Unit for Coal Handling System.
There are basically Five main units of a thermal power
plant:
1. Coal Handling Plant (C.H.P) 2. Water Treatment Plant (W.T.P) 3. Boiler Maintenance Division (B.M.D) 4. Turbine Maintenance Division (T.M.D) 5. Generator
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Coal Handling Plant
COAL HANDLING & DELIVERING SYSTEM:In a coal Based Thermal Power Plant, the initial process in the power generation is “Coal Handling” so in this article I will discuss the overall Process Carried out a coal handling plant in a coal based thermal power generating station. The huge amount of coal 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 coal is taken from the unloading site to dead storage by belt conveyors. The belt deliver the coal to 0 meter level & further moves to transfer point. The transfer points are used to transfer coal to the next belt. The belt elevates the coal to breaker house. It consists of a rotary machine, which rotates the coal and separates the light dust from it through the action of gravity and transfer this dust to reject bin house through belt. Now the main sources of coal are CCL and BCCL. Which have contract with government to continuously supply of coal to the power plant.
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Auxiliaries Of Coal Handling Plant 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 50mm so as to be suitable for milling system. Coal rises from crusher house and reaches the dead storage by passing through transfer point. Equipment used in a coal handling plant 1. Pull cord switch
Pull cord switch also known as Rope Operated Emergency Switch is used as safety switch to stop the conveyor belt in in case of an emergency by pulling the Rope. Pull cord switch is mounted on the walkway side of the conveyor belt, preferably at about every 30 meters. When the rope is pulls from any side, the switch gets operated. Unless and until the handle is reset manually position, the switch remains in operated condition. NC contacts of all pull cord switches are wired in series and further connected to PLC. When any switch along the belt operates, the contact opens and conveyor is stopped. 2. Vibrating feeder
The coal stored in a huge hub is collected on the belt through vibrations created by the vibrating feeder. 3. Flap gates 10 | P a g e
These are used to channelize the route of coal through another belt in case the former is broken or unhealthy. The flap gates open let the coal pass and if closed stop its movement. 4. Magnetic separator
These are used to separate the ferrous impurities from the coal. 5. Metal detector
These are detect the presence of any ferrous and non-ferrous metal in the coal and sends a signal to a relay which closes to seize the movement of belt until the metal is removed. It basically consists of a transmitter transmitter and a receiver. The transmitter consists of a high frequency oscillator, which produces an oscillations of 1500 Hz at 15V. The receiver receives this frequency signal. If there is any presence of metal in the coal. Then this frequency is disturbed and a tripping signal is send to relay to stop the conveyor belt 6. Belt weightier
It is used to keep an account of the tension & support on the belt carrying coal and is moves accordingly to release tension on the belt. 7. Reclaim hopper
Reclamation is a process of taking coal from the dead storage for preparation or further feeding to reclaim hoppers. This is accomplished by belt conveyors
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Steam Generation Process from Coal STEAM GENERATION FROM COAL:1. Tipplers
Coal from the coal wagons is unloaded in the coal handling plant. This unloading is done by the “Tipplers”. This coal is transported up to the raw coal bunkers with the help of conveyor belts. 2. Coal Crushing
Although coal can be burned in solid form on grates, it is more usual to break it up before feeding it to the combustion chamber. The treatment depends on the nature of the coal. Some coals lend themselves to being ground down to a very fine powder (called pulverized fuel (PF)) which is then carried to the burners by a stream of air. Other coals are fed to impact mills (Formally called Milling System) which use flails or hammers to break up the material before it is propelled to the burners by an air stream. The type of mill to be used on a particular plant will be determined by the process
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Preparation of Fuel Engineers and it is the task of the control engineer to provide a system which is appropriate. To do this it is necessary to have some understanding of how the relevant type of mill operates. Various types of pulverized-fuel mill will be encountered, but two are most commonly used:
The Pressurized or vertical-spindle ball mill
horizontal-tube mill
AT PTPS Vertical spindle ball mill is used. Vertical-spindle ball mills
Figure shows the operating principle of a typical ball mill, such as the Babcock 'E' mill. In this device, the coal that is discharged from the storage hoppers is fed down a central chute onto a table where it is crushed by the crushing actions between the rollers and rotating tables rotating steel balls. Air is blown into the crushed coal and carries it, via adjustable classifier blades, to the PF pipes that transport it to the burners. The air that carries the fine particles of coal to the burners is supplied from a fan called a 'primary-air fan'. This delivers air to the mill, which therefore operates under a pressure which is slightly positive with respect to the atmosphere outside. Because of this and because of its other constructional
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features, this type of mill is properly called a 'vertical-spindle, pressurized ball mill'.
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Air supply systems for Ball mills As stated above, the crushed coal in a pressurized ball mill is propelled to the burners by a stream of warm air for proper drying & obtaining a particular temperature of coal. Figure shows the arrangement for doing this: cool air and heated air are mixed to achieve the desired temperature.
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Fuel Burning is 3. Grate- It is the platform in Furnace upon which Fuel is burnt & it is made of Cast Iron I ron Bars. The Bars are so arranged that air may pass on to the Fuel for combustion. The area of the grate on which the fire rests in a coal or wood fired boiler is called Grate surface. 4. Furnaces
It is a chamber formed by the space above the grate & below the boiler shell, in which combustion takes place. It is also called a fire Box. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold air mixture from P.A Fan. P.A Fan takes atmospheric air, a part of which is sent to Air pre-heaters for heating while a part goes directly to the mill for temperature control. Atmospheric air from F.D Fan is heated in the air heaters and sent to the furnace as combustion air. F.D (Force draught)
Fan:-Force Draught Fan is main auxiliary of Furnace which Provides Oxygen for Proper Combustioning of Fuel. It Takes Suction From Environment. It is an Axial Flow Fan.
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Oil Handling System Oil Handling Plant:-
In Thermal Power Station Fuel Oil play a vital role. Oil burners besides initial lighting up are also used to provide effective ignition of the coal associated with P.F Burners and to stabilize the flame .The Burners can provide enough heat to carry on boiling operation of the boilers for the initial starting period. It can provide 10-15% of the maximum load. At Lean Period or when it is desired to Run the Boilers at OFF Load Condition oil Burners are used. The main supplier of oil to the power plant is Indian oil. Which have contract with the government to supply oil.
Fuel oil used in Power Stations Are:# Heavy Furnace Oil (H.F.O) # Light Diesel Oil (L.D.O) # High Speed Diesel Oil (H.S.D) # Low Sulphur High Stock Oil (L.S.H.S) At Panki Thermal Power Station L.D.O is used as Fuel Oil.
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Water Treatment Plant (W.T.P) The Water Treatment plant is required at the water from canal can’t be directly Used in Boiler for Thermal Electricity Generator water is converted into steam at High Pressure & It is allowed to force Turbine Rotated and the electricity is Generated. Therefore water is the basic requirement to the thermal Power plant. Generally in the Thermal Power Plant Is Employed to Refine the Water. Necessity of Water Treatment:Natural Water Contains Solid, Liquid & Gaseous Impurities and Therefore this water can’t b e used for Generation of Steam in the Boiler, The different Effect introduced due to use Of Unrated Water in the boiler. So the water impurities should be removed before it’s used as a stream. The following procedure is used in WTP for minimizing the hardness & removing the impurities:Flocculate Plant:-
Here Alum is added is added to water to precipitate Dust Particles in Water. Aluminium in Alum neutralizes Charge Dust Particle & this gives Result to a heavy Complex Compound Which is settled down. Bleaching Powder & limestone along with chloride is also added in this 19 | P a g e
flocculation Tank to remove temporary hardness & chloride also removes Bacteria & Organic matter. This is Called flocculate plant because, all the mixing and processing is done in flocculation plant where flocculation Mechanism is also happens.
Auxiliaries of W.T.P Sand Filter-
These Stages of sand filter are putt across the flow so as to remove other Suspended Particle, if any. Activated Carbon filter-
This Filter is employed for removal of Bacteria and organic material. Here anthracite (Coal) is uses for Filter. Cation Exchanger-
At this stage ions are observed by ion exchanger method, HCl and negative resin are principle ingredient i ngredient of this chemical filter Anion Exchanger:-
Here Negative Ions are observed by Carefully Formulated by positive resin.
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Mixed Bed Exchanger:-
Here Remaining a negative ion is removed that is extracted through resin. The D.M (De mineralized) water is now ready which has some PropertiesConductivity-0.03 to 0.5 (micro/cm2) PH-6.5 Hardness-NIL
Diagram of W.T.P At PTPS
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B.M.D & Its Supporting Auxiliaries Tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to 1,000F (540 C) to prepare it for the turbine. The steam generating boiler has to produce steam at the high purity, pressure and temperature temperature required for the steam turbine that drives the electrical generator. The generator includes the •
economizer,
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The Boiler Shell
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Setting
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Grate
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The furnace with its steam generating tubes
Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include:
Forced draft (FD) fan
Air preheater(APH)
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boiler furnace
induced draft (ID) fan
Fly ash collectors (electrostatic precipitator or bag house) and the flue gas stack.
The steam produced produced is used for Producing Mechanical work by expanding it in steam engine or steam turbine. According the Process Boiler is of two type1. Water Tube Boiler-In water Tube boilers, Water circulates through the tubes and hot products of Combustion Flow over These tubes. 2.Fire Tube Boiler –In this fire flows in the tubes & tubes is surrounded by water, Fire tube boilers have low Initial cost in compare to Water Tube Boiler.
At PTPS Water Tube Boilers Are Used. •
Boilers are also called Steam Generator
Boiler
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B.M.D & Its Supporting Auxiliaries Boiler Shell or Boiler Drum:- The Shell or drum Consist of one or more Steel Plates bent into cylindrical Form land Riveted or welded together. The shell end are closed with the end plates. It’s second or down plate made more thicker than upper because all load applied on this. It is the main drum which Received D.M Water from Boiler Feed Pump Passing through High Pressure Heater & Economizer at an operating Pressure of 183kg/cm2 From Boiler Drum. The Water runs through the tubes. These Tubes are known as down comers. Setting- the Primary Function of setting is to continue Heat to the Boiler by the Passes of gases taking From FD Fan .It is made from Brickwork.
i s burnt Grate- It is the platform in Furnace upon which Fuel is & it is made of Cast Iron I ron Bars. The Bars are so arranged that air may pass on to the Fuel for combustion. The area of the grate on which the fire rests in a coal or wood fired boiler is called Grate surface. •
Furnaces-It is a chamber formed by the space above the grate & below the boiler shell, in which combustion takes place. It is also called a fire Box. Mountings-The Items Such as Stop Valve, Safety valve, Water level Gauges,
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Fusible Plug, Blow off cock, Pressure Gauges, Water level Indicator etc. are the mountings and a boiler can’t work safely without these. Path away Accessories or Integral Part of Boilers:
Economizer:-Economizer is an important boiler accessory. The work of Economizer is preheating of Feed water of boiler and to less Fuel consumption Furnace. Preheating of feed Water is done by Flue Gases which is comes from after burning of Fuel in the Combustion Chamber. The Temperature of Feed Water at inlet of 0 economizer is in Range of 160-180 C 0
And after Leaving it, It becomes 210 C.It is located in Rear Side of Boiler.
Rotating Air Pre Heater: - The Purpose of Air Preheater is to recover heat of the Flue Gases Which is at a Considerably High as PA Fans Temperature. Temperature. It rotates at the Speed of 176 rpm. The Heat of the flue gases is absorbed by Heating Surface of air pre heaters and then transfer to the cool air coming From P.A Fans.
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LPH (Low Pressure Heater):- it takes Extraction from Turbine & gives these Extraction to Condensate Water Cycle for Preheating of this water. It is situated at 4meter level on Turbine Side.
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HPH (High Pressure Heater):- Its work same as LPH to Preheat of Feed water by bleeding of Turbine.
Dearator:-Work of Dearator is to Dearate of Water means to Remove Dissolve Gases from DM water & to
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Give Proper Suction to Boiler Feed Pump. It is situated at 27meter level in Boiler side.
Boiler Feed Pump:- Its work is to take suction from dearator and give it to Boiler Drum on High Pressure(183Kg/cm2) Pressure(183Kg/cm2).Cycle .Cycle of Dearator to boiler boi ler drum is called Feed Water cycle. It is situated at 0 meter level on Turbine side.
F.D (Force draught) Fan:-Force Draught Fan is main auxiliary of Furnace which Provides Oxygen for Proper combustioning of Fuel. It Takes Suction From Environment. It is an Axial Flow Fan.
ID fan (Induced Draft Fan):-basically pulls out flue gas from the furnace of boiler. It is located between dust precipitators (ESPs) and Chimney. Obviously it handles hot air/dust. Whereas, FD fan (Forced Draft Fan) supplies the required air into the furnace for combustion of fuel. It handles air at normal temperature. The capacity/power capacity/power rating of ID I D fan will be more than that of FD fan.
Chimney:-When Coal burns in Furnace then Produce Smoke, Flew Gases which content NO,SO2,CO,C etc. that ash is send in to Electro Static precipitation and ash comes out with water but some Ash is sucked by I.D fan which send into chimney with the smoke so the some which is passing through Chimney is Black.
Super Heater:-The Function of a super heater is to Increase the Temperature of Steam above Its Saturation
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point. The Super heater is very important accessory of a Boiler & used in both in Fire Tube & Water Tube Boiler.
Turbine Maintenance Division (T.M.D) •
Steam Turbine
Steam turbines are used in all of our major coal fired power stations to drive the generators or alternators, Which produce electricity. The turbines themselves are driven by steam generated in ‘Boilers’ or ‘Steam Generator’ as they are sometimes called. Energy in the steam after it leaves the boiler is converted into rotational energy as it passes through the turbine. The turbine normally consists of several stages with each stage consisting of a stationary blade (or nozzle) and a rotating blade. Stationary blades convert the potential energy of the steam (temperature and pressure) into kinetic energy (velocity) and direct the flow onto the rotating blades. The rotating blades convert the kinetic energy into forces, caused by pressure drop, which results in the rotation of the turbine shaft . The turbine shaft is connected to generator, which produces the electrical energy. The
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rotational speed is 3000 rpm for Indian System (50 Hz) systems and 3600 for American (60 Hz) systems.
T.M.D In a typical larger power stations, the steam turbines are split into three separate stages, the first being the High Pressure (HP), the second the Intermediate Pressure (IP) and the third the Low Pressure (LP) stage, where high, intermediate and low describe the pressure of the steam. After the steam has passed through the HP stage, it is returned to the boiler to be re-heated to its original temperature although the pressure remains greatly reduced. The reheated steam then passes through the IP stage and finally to the LP stage of the turbine. A distinction is made between "impulse" and "reaction turbine’’ designs designs based on the relative pressure drop across the stage. There are two measures for pressure drop, the pressure ratio and the percent reaction. Pressure ratio is the pressure at the stage exit divided by the pressure at the stage entrance. Reaction is the percentage is entropic enthalpy drop across the rotating blade or bucket compared to the total stage enthalpy drop. Some manufacturers manufacturers utilize percent pressure drop across stage to define reaction.
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Generator Generator:-
An electric Generator is a machine which converts Mechanical Energy (or Power) into Electrical Energy. This Energy Conversion is based on the principle of the production of dynamically induced e.m.f is Produced in it according to faraday’s law, “Whenever a conductor is moving in a magnetic Field then it cuts Magnetic Flux and there were an E.M.F (Electro magnetic Force) Produced ,which is Called Induced E.M.F.”
e=N*dφ/dt
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Overall Process
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