APPENDIX 1

TRAINING REPORT

A SEMINAR REPORT

Submitted by

KOTTE HEMANTH KUMAR REDDY

In partial fulfillment for the award of

Diploma
IN
Electrical & Electronics Engineering Department

UNDER THE GUIDENCE OF

MUJEEB

GOVERNMENT POLYTECHNIC, VIJAYAWADA

STATE BOARD OF TECHNICAL EDUCATION

AND

TRAINING, ANDHRA PRADESH.

Electrical&ElectronicsEngineering(SHIFT-A) 1
 APPENDIX 2

GOVERNMENT POLYTECHNIC, VIJAYAWADA

BONIFIDE CERTIFICATE

Certified that this seminar report “DR. NARLA TATA RAO THERMAL POWER

STATION ”is the benefited work of “KOTTE HEMANTH KUMAR REDDY &

PIN NO:(21013-EE-003)” submitted in partial fulfillment of the requirements for the

award of the Diploma in Electrical & Electronics Engineering from SBTET, A.P.

Signature of the industrialtrainingincharge Signature of the industrial training Guide

Name: P.VENKATA NAGENDRA BABU Name: MUJEEB

Designation : A.D.E, Stage-2, Academic Designation: Lecture

EM&MRT

Signature of head of department

B.BHIMA NAIK
EEE

Electrical&ElectronicsEngineering(SHIFT-A) 2
 ABSTRACT

The Andhra Pradesh Power Generation Corporation, shortly called as APGENCO has many power
plants and Dr Narla Tata Rao Thermal Power Station operates from the city of Vijayawada.

Dr Narla Tata Rao Thermal Power Station, which is otherwise called as Vijayawada Thermal Power
Plant (VTPS) is situated in the city of Vijayawada. This is a coal-based power projects functioning
under the Andhra Pradesh Power Generation Corporation, established in 1958. It is actually situated on
the left bank of the Krishna River at a distance of about 2 kms. It is well-placed in between the
Ibrahimpatnam and Kondapalli Villages. It lies at an elevated level of about 26.5 meters above sea
level.The efficient working of a thermal power plant is generation of electricity in it. It is a
complexstructure involving a number of stages working simultaneously for the production of electricity.
The most important and the necessary parts of the thermal plant are boiler, turbine, condenser and
generator. The efficiency of a thermal plant depends upon the effective working of these parts.
In this we learnt about the whole process of power generation by the co-ordination of various auxiliary
systems. We saw that the major losses in are mainly due to steam leaks in boiler tubes
and condenser. The effective transfer of steam from boiler to condenser and reuse it as feed water
greatly improves the efficiency of a power plant.
Thus, I conclude that the working of a thermal power plant does not entirely rely upon the boiler and
generator but, the co-ordination of various systems together get the efficient generation.

Electrical&ElectronicsEngineering(SHIFT-A) 3
 ACKNOWLEDGEMENT

We feel it a pleasure duty to express our profound sense of gratitude to our training guide
P.V.NAGENDRA BABU,(A.D.E) stage-2,EM&MRT,for this valuable guidance,tireless efforts
keen interest and encouragement throughout the course. we express our profound test of gratitude to
Sr.vijaya saradhi , principal of Government Polytechnic Vijayawada. For providing necessary facilities
making the project a reality.

we express our profound test of gratitude to Sr. Dr.BHIMA NAIK , Head of Electrical and Electronics
Engineering, Government Polytechnic Vijayawada

Electrical&ElectronicsEngineering(SHIFT-A) 4
 APPENDIX -3
TABLE OF CONTENTS
CHAPTER NO. TITTLE PAGE NO
ABSTRACT

ACKNOWLEDGEMENT

1. ELECTRICAL MAINTENANCE ( 8-14)

1.1 EXCITER
1.2 BATTERIES
1.3 TRANSFORMERS
1.4 BUSBARS
1.5 SWITCH YARD

2. BOILER MAINTENANCE (15-24)

2.1 BOILER INTRODUCTION
2.2 TYPE OF BOILERS
2.3 GENERAL ARRANGE MEET OF BOILER
2.4 BOILER ELEMENTS
2.4.1 BOILER TUBES/WATER WALLS
2.4.2 BOILER FURNACE
2.4.3 ECONOMIZER
2.4.4 SUPER HEATER
2.5 AT TEMPERATURE
2.6 THE BOILER DRUM
2.7 ASH HANDLING EQUIPMENTS
2.8 AIR PREHEATERS

Electrical and electronics engineering(shift -A) 5

 3. RELAYS (25-33)
3.1 RELAYS
3.2 PROTECTION SYSTEM
3.3 CIRCUIT BREAKER
3.4 PERFORMANCE TEST ON POWER PLANT
3.5 MEASUREMENTS IN POWER PLANT
3.6 ELECTROSTATIC PRECIPITATOR
3.7 UCB

4. COAL HANDLING (34-38)

4.1 INTRODUCTION
4.2 COAL HANDLING PLANT
4.3 DESCRIPTION OF WAGON TIPPLER
4.3.1 WAGON TIPPLER
4.3.2 BELT CONVEYOR SYSTEM
4.3.3 COAL TO STEAM PROCESS
4.3.4 STACK AND RECLAIM
4.3.5 CRUSHER HOUSE

5. THERMAL POWER PLANT (39-44)

5.1 INTRODUCTION
5.2 UNIT OVERVIEW
5.2.1 BOILER
5.2.2 STEAM TURBINE
5.2.3 CONDENSER
5.2.4 BOILER FEED PUMP
5.2.5 FURNACE
5.2.6 DRUM
5.2.7 SUPER HEATER
5.2.8 AIR PREHEATERS
5.2.9 RAW COAL MILLS

Electrical and electronics engineering (shift -A) 6

 5.2.10 MILLS
5.2.11 FLAME SCANNERS
5.2.12 IGNITER AIR FANS
5.2.13 SCANNER AIR FANS
5.2.14 FANS
5.2.15 CONDENSATE EXTRACTION PUMPS
5.2.16 ECONOMIZER
5.2.17 CHIMNEY
5.2.18 COOLING TOWER

CONCLUSION (45)

REFERENCE (46)

Electrical and electronics engineering (shift -A) 7

 CHAPTER -1
ELECTRICAL MAINTENANCE

1.1Excitor
The exciter supplies direct current to the field winding of the generator, at whatever voltage is required to
overcome the resistance of the winding. The rating of the exciter is specified as its output power, current, and
voltage corresponding to the rating (or maximum capability, if different) of the generator, recognizing the
temperature of the generator's field winding. The exciter rating may have some margin over this requirement,
as defined when the generator is designed.
Over the years, many types of exciters have been used, but the type most commonly used was the comutator-
type dc generator. This is very rarely used for new generators today. A new turbine generator is usually
supplied with one of the following types of exciter: (1) shaft-driven alternator with solid-state diode rectifiers,
(2) solid-state thyristor rectifiers supplied by a transformer deriving its power from the power system or from
within the generator (the latter is a form of self-excitation), or (3) shaft-driven alternator with its output
winding on the rotor, its output rectified by rotating solid-state rectifiers, commonly called a “brushless
exciter.”
In addition to its normal function of providing the proper level of direct current to the generator's field
winding as required for the apparent power being supplied, the terminal voltage, and power factor of
the generator load, the exciter must also be able to produce a ceiling voltage (which is higher than rated
exciter voltage) and to operate at that condition for a specified brief period, as required by the voltage

Electrical&ElectronicsEngineering(SHIFT-A) 8
 response ration which is part of the excitation system specification. The voltage response ratio is a measure of
the change of exciter voltage in 0.5 sec when a change in this voltage is suddenly demanded.
When the exciter is a rotating machine driven by the generator shaft, it becomes part of the turbine generator
shaft system and must be designed to accommodate axial motions due to thermal expansion of the turbine and
generator rotors, and vertical motions of the generator shaft due to bearing oil film and thermal expansion of
the generator bearing support.

1.2Batteries
The need for energy storage in electricity networks is becoming increasingly important as more generating
capacity uses renewable energy sources which are intrinsically intermittent. The spinning reserve of large
networks is becoming less able to maintain power quality with increased renewable inputs and the strategies
needed to optimise renewable input without curtailment or other measures are driving a move to energy
storage. Electrochemical energy storage in batteries is attractive because it is compact, easy to deploy,
economical and provides virtually instant response both to input from the battery and output from the network
to the battery. There are a range of battery chemistries that can be used and lead batteries offer a reliable, cost-
effective solution which can be adapted for different types of energy storage applications
A battery storage power station is a type of energy storage power station that uses a group of batteries to
store electrical energy. Battery storage is the fastest responding dispatchable source of power on electric grids,
and it is used to stabilise those grids, as battery storage can transition from standby to full power in under a
second to deal with grid contingencies.
Lead-acid battery cells consist of spongy lead anode and lead acid cathode, immersed in a dilute sulfuric
acid electrolyte, with lead as the current collector. During discharge, lead sulfate is the product on both
electrodes. Sulfate crystals become larger and difficult to break up during recharging, if the battery is
overdischarged or kept discharged for a prolonged time period. Hydrogen is produced during charging,
leading to water loss if overcharged.

Electrical&ElectronicsEngineering(SHIFT-A) 9
 Lead-acid batteries are a mature technology, with over a century of operation. They are the most widely used
electrical energy storage technology worldwide. Their popularity is a result of their wide availability and
reasonably low cost. The disadvantages of the lead-acid batteries are their weight, low specific energy and
specific power, short cycle life, high maintenance requirements, hazards associated with lead and sulfuric acid
during production and disposal, and capacity drop at low temperatures.

1.3Transformer
A power plant transformer is a device used for generating electrical power from one voltage level to another.
It does this process while maintaining the same frequency but usually different voltage levels. A transformer
uses electromagnetic induction as a mechanism and transforms the voltage. Power plants employ power
station transformers of various types, sizes, and ratings. Power plant transformers are made up of primary and
secondary coils joined to form a closed magnetic circuit. The system transfers energy from the primary coil’s
electrical voltage level into the magnetic field within the transformer’s coils. Then these coils induce a current
within its opposite polarity onto the secondary coil.Energy suppliers use power plant transformers in industrial
settings. They should have an alternating current applied to one of their windings, creating either an increase
or decrease in voltage. Further features come with different numbers of windings, depending on their
applications. Professionals often employ two-winding (with three wires) power plant transformers when using
them for transmission purposes.

Power plant transformers, as their name suggests, are primarily designated on power plants or substations.
These are high voltage (115kV & above) units that handle larger electrical loads. Power companies employ
power transformers for the transmission and distribution of electrical energy. They use the principle of
primary and secondary coils to transfer large power loads without using excessive voltages.A power station

Electrical&ElectronicsEngineering(SHIFT-A) 10
 transformer is an essential component in modern industrial plants as well as traditional electric utility
companies. They provide backup support during emergencies or when a load increases suddenly, for example,
peak hours. Additionally, they also protect substation equipment from overloads and short circuits.

1.4Bus bars
A busbar is a metallic bar in a switchgear panel used to carry electric power from incoming feeders and
distributes to the outgoing feeders. In simple terms, busbar is a electrical junction where incoming and
outgoing currents exchange. Electrical Busbar consists the number of lines electrically, which are operating at
the same voltage and frequencies. Generally, copper or aluminum conducting material is used in the
construction of bus bars.Bus bars are arranged in a different configurations, any particular arrangement of bus-
bar is to achieve adequate operating flexibility, sufficient reliability and minimum cost.The circuit
breakers are arranged to get the maximum availability to plant operations. Electrical busbars are conductors or
a group of conductors used for collecting electric power from incoming feeders. From there, they distribute
the power to the outgoing feeders. In laymen’s terms, it is a type of electrical junction where all incoming and
outgoing electrical currents meet. The bus bar system has an isolator and the circuit breaker which works as
follows. In the event of a fault, the circuit breaker trips and the faulty section of the busbar is easily
disconnected from the circuit.

Busbars have several benefits and are crucial in electrical distribution systems. This is especially the case
when simplifying the process of electrical power distribution, reducing overall cost while allowing for greater

Electrical&ElectronicsEngineering(SHIFT-A) 11
 flexibility. Here is a brief breakdown of the primary benefits of busbars. Busbars may be more expensive than
a wiring harness but they last longer and don’t require regular replacement. They distribute power more
efficiently, thus, reducing energy consumption which is particularly important for many 21st century
businesses. They’re also easily adaptable for renewable energy integration while offering extreme versatility
for easy customisation for many purposes. Busbars can withstand external weather conditions well, making
them the perfect solution for electrical substations .

Power grid

Electrical power
to the grid is the
output power gen
erated by
a power
plant through the
use of
a fuel or primary
energy
flow of energy.
The power output
by these plants
are in the form electricity and fed to the grid via electrical transmission in order to meet society's electrical
needs. These needs are constantly changing, so it is important for most of these power plants to
be dispatchable in order to meet these fluctuations. An electrical power grid is an interconnected network
that delivers the generated power to the consumers. It is, sometimes, also called as an electrical power
system. A power grid consists of generating stations (power plants), transmission system and distribution
system.

Power generating stations are located at feasible places - according to the availability of the fuel, the dam site
or an efficient location for renewable sources. Hence, they are often located quite away from the populated
areas. This is very practical since the transmission of electrical power over longer distances is a lot much
economical than the relative transmission of any other fuel. Also, a hydroelectric plant must be located
according to an appropriate dam site or a wind power plant may be located off-shore to harvest additional
energy from the wind. Thus, a long distance transmission system is needed to transmit the generated
electricity to the populated areas. And a distribution system is needed to distribute the power to every
consumer at appropriate voltages.

A power grid can be divided into three stages: Power generation, transmission and distribution.

Electrical&ElectronicsEngineering(SHIFT-A) 12
 1.5Switch yard
A station in the power transmission system at which electric power is transformed to a conveniently used form. The
station may consist of transformers, switches, circuit breakers, and other auxiliary equipment. Its main function is to
receive energy transmitted at high voltage from the generating station, by either step-up or step-down the voltage to a
value appropriate for local use and provide facilities for switching. Substations have some additional functions. Its
provide points where safety devices may be installed to disconnect circuits or equipment in the event of trouble.
Some substations, such as power plant switchyards are simply switching stations where different connections can be
made between various transmission lines.

A switchyard is the set of facilities outside a power plant in which voltage is transformed and electricity flow is directed
onto transmission lines. The switchyard comprises transformers plus a series of large switches, breakers, and other
protective devices that can usually be manually or remotely opened and controlled to energize or de-energize specific
transmission circuits leaving the plant. To disconnect a transmission line leaving the plant, the appropriate switches or
breakers are opened in the switchyard at the plant. To connect a line the same switches or breakers are closed.Many
switchyards contain a station bus that serves as a convenient point to make modular connections in the future if more
transmission lines are installed. The station bus commonly consists of a series of busbar or bus duct – high-power
conductors commonly used in switchyards and substations to carry large amounts of power. The point where power is
transferred from the power plant to the transmission line is often referred to as a station bus.The main function of
switchyard is to transmit & distribute the power at incoming voltage from the generating station and provide facilities of
switching by the help of switchgears. Earlier we have explained about the various types of switchgears in our previous
article.Switchyard is the point in the power network where transmission lines and distribution feeders or generating
units are connected through circuit breakers and other switchgears via bus bars and transformers. Switchyard acts as
interface between the power plant electrical system and electrical grid.

Electrical&ElectronicsEngineering(SHIFT-A) 13
Electrical&ElectronicsEngineering(SHIFT-A) 14
 CHAPTER -2
BOILER MAINTENANCE

2.1 BOILER INTRODUCTION:

A boiler is an enclosed vessel that provides a means for combustion heat to be transferred
to water until it becomes heated water or steam. The hot water or steam under pressure is then usable for
transferring the heat to a process. Water is a useful and inexpensive medium for transferring heat to a
process. When water at atmospheric pressure is boiled into steam its volume increases about 1,600
times, producing a force that is almost as explosive as gunpowder.This causes the boiler to be an
equipment that must be treated with utmost care. The boiler system comprises of: a feed water system,
steam system and fuel system. The feed water system provides water to the boiler and regulates it
automatically to meet the steam demand. Various valves provide access for maintenance and repair. The
steam system collects and controls the steam produced in the boiler. Steam is directed through a piping
system to the point of use. Throughout the system, steam pressure is regulated using valves and checked
with steam pressure gauges. The fuel system includes all equipment used to provide fuel to generate the
necessary heat. The equipment required in the fuel system depends on the type of fuel used in the
system. The water supplied to the boiler that is converted into steam is called feed water.

2.2 TYPE OF BOILERS:

Generally boilers are classified as follows ;
(i)Firetube Boilers
(ii)Watertube Boilers
(i)Firetube Boilers:
In a fire tube boiler, hot gases pass through the tubes and boiler feed water in the shell side is
converted into steam. Th schematic of a firetube boiler is as shown in fig.7. Fire tube boilers are
generally used for relatively small steam capacities and low to medium steam pressures. As a guideline,
fire tube boilers are competitive for steam rates up to 12,000 kg/hour and pressures up to 18 kg/cm2.The
advantages of a firetube boiler are its simple construction and less rigid water treatment requirements.
These boilers are commonly used for small capacity, low pressure applications in industrial process
plants.

Electrical and electronics engineering (shift -A) 15

 Fig.7 schematic of a firetube Boiler

Fire tube boilers are classified as follows.

l. External furnace:
(i) Horizontal return tubular (ii) Short fire box (iii) Compact.
2. Internal furnace:
(i) Horizontal tubular(a) Short firebox ( b) Locomotive (c) Compact (d) Scotch.
(ii) Vertical tubular.
(a) Straight vertical shell, vertical tube (b) Cochran (vertical shell) horizontal tube.

(ii)Watertube Boilers:
In a water tube boiler, boiler feed water flows through the tubes and enters the boiler drum.
The circulated water is heated by the combustion gases and converted into steam at the vapour space in
the drum. A typical arrangement of a two pass water tube boiler is as shown in fig.8,9.These boilers are
selected when the steam demand as well as steam pressure requirements are high as in the case of
process cum power boiler / power boilers. Most modern water boiler tube designs are within the
capacity range 4,500 – 120,000 kg/hour of steam, at very high pressures.

Fig.8 Typical sideview of a two pass water tube boiler

Electrical and electronics engineering (shift -A) 16

11
Various advantages of water tube boilers are as follows:
(i) High pressure of the order of 140 kg/cm2 can be obtained.
(ii) Heating surface is large. Therefore steam can be generated easily.
(iii) Large heating surface can be obtained by use of large number of tubes.
(iv) Because of high movement of water in the tubes the rate of heat transfer becomes large resulting
into a greater efficiency.
Water tube boilers are classified as follows:
1. Horizontal straight tube boilers
(a) Longitudinal drum (b) Cross-drum.
2. Bent tube boilers
(a) Two drum (b) Three drum (c) Low head three drum (d) Four drum.
3. Cyclone fired boilers
4.Type of passing
(a) Tower (b)Two Pass

BOILER
Manufacturer BHEL,CE(USA) Design

Type Radiant,Raheat,Natural Circulation,Single Drum,Semi-Out-

Door,Balanced Draft And Direct Fired

Type Of Firing Tilting,Tangential

Type Of SH Pendent,Platen,Horizontal

Total Water Content Of Boiler 321.5t(Including RH)

Table.3 Exemplary technical data of Boiler.

Electrical and electronics engineering (shift -A) 17

 2.3GENERAL ARRANGE MENT OF BOILERS:

Electrical and electronics engineering (shift -A) 18

 2.4BOILER ELEMENTS
The main components in a boiler system are Furnace,Economiser, Superheater, Reheator,
Attemperator . In addition, there are sets of controls to monitor water and steam flow, fuel flow, airflow and
chemical treatment additions.

2.4.1 BOILER TUBES/WATER WALLS:

Boiler tubes are usually fabricated from high-strength carbon steel. The tubes are welded to
form a continuous sheet or wall of tubes. Often more than one bank of tubes is used, with the bank closest to the
heat sources providing the greatest share of heat transfer. They will also tend to be the most susceptible to
failure due to flow problems or corrosion/ deposition problems. Larger central station type boilers have water
cooled furnaces. The combustion space of a furnace is shielded wholly or partially by small diameter tubes
placed side by side. Water from the boiler is made to circulate through these tubes which connect lower and
upper headers of boiler. General types of boiler furnace tubes are vertical and spiral type ant they are as shown
in fig.11

2.4.2BOILER FURNACE :
Boiler furnace is the place where the combustion of the fuel takes place. An inside view of a
coal fired furnace is as shown in fig10. In coal fierd thermal power plants the mixture of coal powder from the
pulverizer mills and oil is burnt with hot air from the airpreheater in the furnce and the generated heat is
transferred to the boiler water walls.

Fig.10 Inside view of the boiler furnace Fig11. A spiral tube boiler furnace

2.4.3 ECONOMIZER:
Economisers are the last stage of the feed water system. They are designed to extract heat value
from exhaust gases to heat the steam still further and improve the efficiency of the boiler.They are simple
finned tube heat exchangers. A typical design of an economizer is as shown in fig.12,14.Not all boilers have
economizers. Usually they are found only on water tube boilers using fossil fuel as an energy conservation
measure. A feed water economiser reduces steam boiler fuel requirements by transferring heat from the flue gas

Electrical and electronics engineering (shift -A) 19

 to incoming feed water. By recovering waste heat, an economiser can often reduce fuel requirements by 5 per
cent to 10 per cent and pay for itself in less than two years.

Fig.12 A typical design of the Economizer Fig. 13.A typical design of the Superheater

2.4.4 SUPERHEATERS:
Superheater converts the saturated steam to the super heated stem by taking the combustion
heat and it is One of the most important accessories of a boiler. A typical design of super heater is as shown in
fig.13.The arrangement of super heater inside the boiler is as shown in fig.14.It effects improvement and
economy in the following ways ,The super heater increases the capacity of the plant, Eliminates corrosion of the
steam turbine, Reduces steam consumption of the steam turbine. There are different types of superheaters are
there and they are as follows ,see fig.
Types of Super Heaters:
▪ Plate Super heaters.
▪ Pendant Super heaters.
▪ Radiant Super heaters.
▪ Final Super heaters.

Electrical and electronics engineering ( shift -A) 20

 Fig.14 General arrangement of Superheater, Reheater, Economizer in side the boiler

The main function of reheater is to reheat the exhaust steam coming from the high pressure turbine. This
reheated steam will be transferred to the intermediate turbine. The functioning of the reheater is same as the super heater.
The general design of reheater is as shown in fig.15.

Fig. 15 General design of a Reheater Fig. 16 Coal supply connections to Burners

Burners are used to burn the pulverised coal. The main difference between the various burners lies in
the rapidity of air-coal mixing i.e., turbulence. For bituminous coals the turbulent type of burner is used whereas
for low volatile coals the burners with long flame should be used. A typical arrangement of tangential burners
and generated fire ball inside the furnace is as show in fig.17&18 respectively. The fuel i.e pulverized coal will
be came from the pulverizer mills and their connections are shown in fig.16.
The various types of burners are as follows :

Electrical and electronics engineering (shift -A) 21

 1. Long Flame Burner (U-Flame Burner).
2. Short Flame Burner (Turbulent Burner).
3. Tangential Burner
4. Cyclone Burner

Fig. 17 Topview of the fireball inside the furnce Fig.18 Typical arrangement of tangential tliting burners

2.5 At Temperatures:
Attemperation is the primary means for controlling the degree of superheat in a superheated
boiler. Attemperation is the process of partially de-superheating steam by the controlled injection of water into
the superheated steam flow. The degree of superheat will depend on the steam load and the heat available, given
the design of the superheater. The degree of superheat of the final exiting steam is generally not subject to wide
variation because of the design of the downstream processes. In order to achieve the proper control of superheat
temperature an attemperator is used. A direct contact attemperator injects a stream of high purity water into the
superheated steam. It is usually located at the exit of the superheater, but may be placed in an intermediate
position. Usually, boiler feedwater is used for attemperation.

2.6 THE BOILER DRUM:

Steam drum is where feed-water from economizer is fed, saturated steam is separated from
the boiling water and the remaining water is circulated above. The drum is also used for chemical water
treatment and blow down to reduce solids in the water. Steam drums are provided in all modern generators
except the once-through types. The drum should stand the flow rate changes and prevent the carryover of water
towards the supper-heater which may lead to distortion or burnout. The steam drum is as shown in fig.19.

Electrical and electronics engineering (shift -A) 22

 Fig. 19.Boiler drum

(i)Steam Drum Functions:

The steam drum is a key component in natural, forced and combined circulation boilers. The functions of a
steam drum in a subcritical boiler are:
▪ Mix fresh feed water with the circulating boiler water.
▪ Supply circulating water to the evaporator through the down comers.
▪ Receive water/steam mixture from risers.
▪ Separate water and steam.
▪ Remove impurities.
▪ Control Water Chemical Balance By chemical feed and continuous blowdown.
▪ Supply saturated steam
▪ Store water for load changes (usually not a significant water storage)
▪ Act as a reference point for feed water control

(ii)Boiler Drum Principle:

Feed water from the economizer enters the steam drum. The water is routed through the steam drum
sparyer nozzles, directed towards the bottom of the drum and then through the downcomers to the supply
headers. This recovery boiler operates by natural circulation. This means that the difference in specific gravity
between the down coming water and uprising water / vapor mixture in the furnace tubes induces the water
circulation. Drum internals help to separate the steam from the water. The larger the drum diameter, the more
efficient is the separation. The dimensioning of a steam drum is mostly based on previous experiences. A
drawing of a steam Water and steam in a steam drum travel in opposite directions. The water leaves the bottom
of the drum to the down comers and the steam exits the top of the drum to the superheaters. Normal water level
is below the centerline of the steam drum and the residence time is normally between 5 and 20 seconds.
A basic feature for steam drum design is the load rate, which is based on previous
experiences. It is normally defined as the produced amount of steam (m3/h) divided by the volume of the steam
drum (m3). Calculated from the residence time in the steam drum, the volumetric load rate can be about 200 for
a residence time of almost 20 seconds in the pressure of about 80 bar. The volumetric load rate increases when

Electrical and electronics engineering (shift -A) 23

 the pressure decreases having its maximum value of about 800. As can be thought from the units, the size of the
steam drum can be calculated based on these values.

(iii)Technical Data:

STEAM DRUM
Material SA-229

Elevation Of Drum 53340 mm

Overall Length 15000 mm aprox

Shell Thickness 170/135 mm

Design Metal Temperature 354

Lowest Water Level Permitted 25sec

Table. 4 Exemplary technical data of boiler drum

2.6 ASH HANDLING EQUIPMENT:

Mechanical means are required for the disposal of ash. The handling equipment functions are
collecting the dust, soot and flyash from the furnace and gently transferring it to the ash pond and cement
industries. The simple ash handling and dust colleting system is as shown in fig.20

Fig.20 Ash Handling And Dust Collections System

2.7 AIR PREHEATERS :

DESCRIPTION:

The airpreheater (or air heater) consists of plates or tubes having hot gases on one s
and air on the other. The heat in the flue gas leaving the boiler or economizer is recovered by the incoming air,
thereby reducing the flue gas temperature and increasing efficiency. There are generally two types of air
preheaters, tubular and regenerative The general schematic of a regenerative airpreheater.

Electrical and electronics engineering (shift -A) 24

 CHAPTER - 3
RELAYS

3.1Relays
A relay is automatic device which senses an abnormal condition of electrical circuit and closes its contacts.
These contacts in turns close and complete the circuit breaker trip coil circuit hence make the circuit breaker
tripped for disconnecting the faulty portion of the electrical circuit from rest of the healthy circuit.
Types of protection relays are mainly based on their characteristic, logic, on actuating parameter and operation
mechanism. Based on operation mechanism protection relay can be categorized as electromagnetic relay,
static relay and mechanical relay. Actually, a relay is nothing but a combination of one or more open or closed
contacts. These all or some specific contacts the relay change their state when actuating parameters are
applied to the relay. That means open contacts become closed and closed contacts become open. In an
electromagnetic relay, these closing and opening of relay contacts are done by the electromagnetic action of a
solenoid. In the mechanical relay, these closing and opening of relay contacts are done by mechanical
displacement of different gear level system.In static relay it is mainly done by semiconductor switches like
thyristor. In digital relay on and off state can be referred as 1 and 0 state.

Electrical&ElectronicsEngineering(SHIFT-A) 25
 Based on Characteristic the protection relay can be categorized as:

1. Definite time relays

2. Inverse time relays with definite minimum time(IDMT)
3. Instantaneous relays.
4. IDMT with inst.
5. Stepped characteristic.
6. Programmed switches.
7. Voltage restraint over current relay.
An electrical generator can be subjected to either internal fault or external fault or both. The generators are
normally connected to an electrical power system, hence any fault occurred in the power system should also
be cleared from the generator as soon as possible otherwise it may create permanent damage in the generator.

3.2Protection system
In a thermal power plant, electricity is produced from heat coming from the combustion of products such as
gas, coal or fuel-oil. These products are stored on open areas or tanks and are routed to the combustion plants
by metal pipes.
There are several high points in thermal power plants, like chimneys that can sometimes reach 250 meters
high. These are the points where lightning will preferentially strike ; for these structures, there is a risk of side
flashes even if a lightning rod is settled at the top. In case of lightning impact, the lightning current will flow
to the ground through the various conductive parts (concrete rebars, metal structure), closest to the point of
impact. The risks on these high structures are the same as for down conductors of a lightning rod : touch
voltage and step voltage, with the added risk of falling concrete blocks. It is usually known that without
protective measures, people within a radius of 3 m around the conductive parts at ground level are in a
dangerous situation (this risk increases with height, especially near the point of strike). Protection of the
technical staff may be considered by : 

Electrical&ElectronicsEngineering(SHIFT-A) 26
 procedures restricting access to high points,  lightning warning system, which effectively reduces the risk for
human and also reduces other risks and thus reduces the lightning protection level required for the plant, 
Isolating people from the earthing system.

3.3Circuit breaker
Air blast circuit breaker is the most common type of circuit breaker used in thermal power plants. These
breakers use compressed air to quench the arc that occurs when the breaker opens, making them the most
efficient and effective type of circuit breaker.

Oil circuit breakers have several advantages over other types of circuit breakers. The advantage is that it can
be used for very high voltage applications. Another advantage is that they are less likely to be damaged by the
high currents that can occur in thermal power plants.

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 Gas circuit breakers are usually used in thermal power plants to protect high voltage equipment from
over current damage. It is also used to protect against over voltage conditions.

Minimum Oil Circuit Breaker is a safety device used in thermal power plants to protect circuit breakers from
overheating damage. When the circuit breaker oil temperature reaches its minimum value, the MOCB opens
the circuit and cuts off the flow of current.

The function of the VCB is based on the arc principle. When an arc forms between two conductors, it is
quickly extinguished by the vacuum. Because the vacuum prevents the arc from continuing to burn.

SF6 is an inert gas. That is, it is non-reactive and does not interact with other chemicals. This is ideal for use
in circuit breakers as it does not corrode or react with circuit breaker components.

3.4Performance tests on thermal power plant

The efficiency calculations for all the equipment used in circulating fluidized-bed (CFB) boiler and pulverized
coal boiler power plants will be covered in-depth in this seminar. All the processes, operational and
maintenance activities, capital projects, technical options, potential initiatives and incentives to implement
upgrades/repairs for increasing the power plant equipment efficiency will also be covered in detail. This
seminar will also provide a thorough explanation of CFB and pulverized coal boiler technology including
hydrodynamics, combustion, emissions, design considerations, gas-solid separators, design of CFB and
pulverized coal boiler components, management of solid residues, materials, stoichiometric calculations, and
model for sulfur capture. The operation, maintenance, testing, and refurbishment options of all the equipment

Electrical&ElectronicsEngineering(SHIFT-A) 28
 and systems used in CFB and pulverized coal power plants will be covered in detail including, boilers,
superheaters, reheaters, turbines, condensers, feedwater heaters, deaerators, pumps, compressors, fans, electric
generators, instrumentation and control systems, and governing systems, etc. All the factors which affect CFB
and pulverized coal boiler power plant efficiency and emissions will be explained thoroughly. All the methods
used to calculate the heat rate of CFB and pulverized coal power plants will be covered in detail. All the areas
in CFB and pulverized coal boiler power plants where efficiency loss can occur will be explained. This
seminar will also provide up-dated information in respect to the following methods used to improve CFB
boiler and pulverized coal boiler power plant heat rate:
Conducting a performance test is a great opportunity to get into the details about the performance of your
power plant. Depending of the extension of your power plant performance analysis, there will be a set of
preparations to ensure the accuracy of your test and to minimize its test uncertainty.

The instructor relies on a highly interactive training method to enhance the learning process. This method
ensures that all the delegates gain a complete understanding of all the topics covered. The training
environment is highly stimulating, challenging, and effective because the participants will learn by case
studies which will allow them to apply the material taught to their own organization.

3.5 Measurements in thermal power plant.

 Fuel gas measurement: Thermal mass flowmeters are used to measure the flow rate of fuel
gases, such as natural gas or coal gas, used to generate electricity in the power plant. Accurate
measurement of the fuel gas flow is important for optimizing the combustion process and
maximizing the efficiency of the power plant.
 Boiler feedwater measurement: Thermal mass flowmeters are also used to measure the flow
rate of boiler feedwater, which is used to generate steam to power the turbine. Accurate
measurement of the flow rate of the boiler feedwater is important for optimizing the steam
production process and maximizing the efficiency of the power plant.
 Flue gas measurement: Thermal mass flowmeters can also be used to measure the flow rate of
flue gases, which are the gases produced during the combustion process. Accurate

Electrical&ElectronicsEngineering(SHIFT-A) 29
 measurement of the flue gas flow is important for monitoring the performance of the power plant
and ensuring compliance with emissions regulations.
 Steam distribution: Thermal mass flowmeters can be used to measure the flow rate of steam
being distributed to various parts of the plant, such as the turbine or heat exchangers.
 Fuel flow measurement: Thermal mass flowmeters can be used to measure the flow rate of
fuel, such as coal, natural gas, or oil, being supplied to the boiler.
 Cooling water: Thermal mass flowmeters can be used to measure the flow rate of cooling water
being supplied to the condenser or other cooling systems.

3.6 Electrostatic precipitator

An electrostatic precipitator aka ESP is an electro-mechanical tool. The device filters out particles such as
fumes, fly ash and suspended dirt from the gas stream before releasing them out of the chimney. The key
principle of the devices is to use a very high voltage negative charged electrostatic force. This negative charge
is derived from a TR set (Transformer Rectifier set).
The three important parts of an ESP are – Emitting Set or Negative Electrodes Set, Collecting Set or Positive
Electrodes Set, and Rapping Mechanism. Let’s have a quick look at each of them.

The set gets negatively charged via TR set. Different kinds of insulators at various intersection points are used
to keep the set separate from the ESP. As the electrodes get charged, they generate an electric field around
them. This is known as the Corona effect.

This part of the ESP is meant for collecting desired particles. There is a notion that the set is positively

Electrical&ElectronicsEngineering(SHIFT-A) 30
 charged. But it is not. It is attached to the ground to get zero charges. As zero is higher than negative, the
collecting set works as a positive electrode. This flat-plated set is positioned in front of the emitting set.

Rapping is the process of forceful periodical elimination of particles by vibrating or hammering the body. The
mechanism helps to bring down the collected particles clung to the collecting or emitting set. The rappers may
vary from device to device based on their size and make.

The flue gas emitted from the boiler furnace contains suspended impurities. Thus, the gas can’t be directly
exhausted into the atmosphere because of government norms. ESP is used to separate the particles from the
flue gases. It uses the mechanism of high discharge. The flue gases pass between two plates. They are charged
with high voltage DC. This high voltage charges the particles in the flue gas, and they get accumulated on the
plates. Now the plates are vibrated so the particles can fall and get collected at the bottom. The waste product
is disposed of in landfills.

Electrostatic precipitation is an effective way to filter fine particles from the flowing air or gas. The device can
manage a huge quantity of air. But it doesn’t slow the rate of flow notably owing to the low-pressure drop
through its filter. The mechanism is quite simple. The unclean gas supplied by two electrodes flows through
the tube. The shape of the electrodes depends on the precipitator allotted. T, bars, or metal
wires. Out of the two plates, one is charged by high negative voltage. It causes the particulates in the burn to
get a negative charge as they flow along with this plate. The next one carries a high positive voltage of equal
amount. This is because opposite charges attract. The negatively charged soot elements are pulled in toward
the positive electrode and get fixed to it. The plates should be cleaned so the collected dust can be removed.

Usually, all ESPs follow the same mechanism. However, the types vary depending on the amount of pollution,
smoke composition, and shaped particles.

The efficiency of the device is over 99.5%.

Electrostatic precipitators are extremely effevtive, and are capable of removing more than 99%
of particulate matter. Since 1940, emissions of particulate matter smaller than 10 micrometers have
been reduced by a factor of 5. However, this high level of effectiveness comes at a high cost - about
2-4% of a power plant's electrical energy output goes into operating electrostatic precipitators and
other systems used to remove particulate matter.
The effectiveness of a certain precipitator is determined by how well the specific device deals with
the unique features and problems of the plant it is used at. Additionally, precipitator effectiveness is
also determined by the temperature and moisture content of the flue gas.

Electrical&ElectronicsEngineering(SHIFT-A) 31
 3.7 UCB
Now a day’s the demand for higher reliability and efficiency is increasing in thermal power plant. Power plant
requires continuous inspection & monitoring after regular intervals. There may be chances of errors while
measuring at various stages by human workers. Thus to increase reliability the automation is needed so that
overall efficiency of power plant gets improved. The automation is developed by using PLC (Programmable
Logic Controller) and SCADA (Supervisory Control and Data Acquisition system) which reduces the errors
caused by human workers. PLC is programmable logic control. It is used for implementing various function

Electrical&ElectronicsEngineering(SHIFT-A) 32
 such as sequencing, timing, counting, logic, arithmetic control through analog and digital input output
modules. In order to store the program in PLC it must be interfaced to computer via interfacing unit. The
programmed can be implemented through various languages. In this paper ladder logic is used for
programming. SCADA system is used to supervise a complete process.

The output of different sensors is given to the PLC which takes necessary action to control the parameter.
SCADA and PLC are interfaced by using communication cable. The alarm system is also provided to inform
the operator. SCADA is used to monitor water level, temperature, pressure using different sensors and
corresponding output is given to the PLC, for controlling these parameters. The sensors used are pressure
sensor, temperature sensor, and water flow level sensor. The pressure is measured and control at turbine too.
Boiler is one of the most important units in thermal power plant. Boilers are used to generate the steam at a
pressure of 66Kg/cm2 and 900oC, this steam is used to rotate the Turbine at speed of 7700 RPM. Turbine is
coupled with generator via a reduction gearbox. Gearbox is used to reduce the speed from 7700 to 1500 RPM.
Once the generator rotates at its rated speed, with excitation it starts generating the Power. This power will be
supplied to plants for their production and for self-consumption.

Electrical&ElectronicsEngineering(SHIFT-A) 33
CHAPTER -4

Coal Handling

34
 COAL HANDLING

4.1INTURDACTION
Vijayawada thermal power station is linked to Sincere Collieries Company Limited (S.C.C.L) for supply of coal.
The average distance of S.C.C.L Coalfields by train is about 250KM and stage 2&3 are linked to Talcher
coalfields in Orissa to meet the increased demand. The average distances of Talcher coalfield by train 950KM.
In power plants the type of coal used is Bituminous.

4.2Coal Handling Plant

Coal is received from singareni collieries and talcher. Coal wagons are received by rakes of 58 wagons.
The railway engine will place the loaded lake inside the VTPS at a siding point and take away the
empty wagons. Coal is also received in bottom discharge wagons. These wagon are unloaded on a
track hopper and from there, fed onto the underneath conveyors, by the paddlefeeders which will scoop
the coal from the hopper platform onto the running conveyor.

The size of the coal is reduced to 40 mm size particles .These are transported to bunkers using 14A,B type belt
conveyers.

Electrical&ElectronicsEngineering(SHIFT-A) 35
 4.3 Description of Wagon Tippler

4.3.1 Wagon tipplers

It is a mechanical drive tippler. The drive is having 1no motor, 1 no break system and 1no gear box andone

set of 2nd reduction gears

Fig; 4 WAGON TIPPLER

4.3.2 Belt conveyor system

The belt conveyor is for conveying coal from the feeding point to the discharge point. That is up to the next transfer
point or finally to its destination i.e. up to the bunkers.
Drive motor is provided at the discharge end and coal is fed onto the conveyor belt at its tail end .Coal fed to the
next conveyor belt from the discharge point is connected by chutes fabricated with MS plates fixed with linear
plates. Feeding is changed by operating the rack and pinion gates/plape gates, from one conveyor to the other. The
maximum slope allowed on the conveyor gallery or tunnel is 14 degrees. This system consists of idlers, pulleys,
conveyor belting, drive reducers, take ups, scrapper etc;

Electrical&ElectronicsEngineering(SHIFT-A) 36
 FIG: 5 BELT CONVEOR

4.3.3 Coal To Steam Process

Coal from the coal wagons is unloaded in the coal handling plant. The coal is transferred up to the raw coal
bunkers with the help of belt conveyors. Coal is then transported to mills through feeders where the coal is
pulverized to powder form. This crushed coal is taken away to the furnace through the coal pipes with the
help of hot and cold air mixture from PA fan. PA 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
FD fan is heated in the air heaters and sent to the furnace as combustion air.
Water from the boiler pump passes through economizer and reaches the boiler drum water from the
drum passes through the down corners and goes to bottom ring header. Water from the bottom ring
header is divided to all four sides of the furnace. Due to heat and density difference the water raises up
in the water wall tubes. Water is partly converted to steam as it raises up in the furnace. This steam and
water mixture is taken to the boiler drum where steam is separated from water. Water follows the same
path, while the steam is sent to the super heater for super heating. The super heaters are located inside
the furnace and the steam is superheated and finally it goes to the turbine Flue gases from the furnace
are extracted by induced draft fan, which maintains balance draft in the furnace with forced draft fan.
These flue gases emit their heat energy to various super heaters in the pent house and finally pass
through air pre heaters and goes to electrostatic precipitator, where the ash particles are extracted.
Electrostatic precipitator consists of metal plates which are electrically charged. Ash particles are
attracted onto these plates, so that they do not pass through the chimney to pollute the atmosphere.
Regular mechanical hammers blows cause the accumulation of the ash to fall to the bottom of the
precipitator, where they are collected in a hopper for disposal. This ash is mixed with water to form
slurry and is pumped to ash pond.

4.3.4Stack and Reclaim

Machines are used to put coal out to the stockpile and reclaim coal from the stockpile. Water is
sprayed on coal to stop them from getting burnt when in storage yard due to internal heat upor
sun heat. Coal when powdered is heated and being lifted by hot air that is sent into the

Electrical&ElectronicsEngineering(SHIFT-A) 37
 In the thermal power plant coal handling system, Conveyors leading to crusher house have facility for

“mills” This goes and burns inside the furnace producing ash and converting the water in the
pipelines into steam

Fig:6 Stacker and reclaimer

4.3.5CRUSHER HOUSE
manual stone picking, at a suitable location after penthouse. In line magnetic separators are also provided
at discharge end of conveyors for removal of remaining metallic ferrous tramp from the coal before it
reaches the crushers. Coal sampling unit is provided to sample the uncrushed coal. The size of the coal
received is normally (-) 300 mm which may, however, depend on coal tie up. The received coal is sized in
crushers (ring granulators) from (-) 300 mm to (-) 20 mm. Screens (vibrating grizzly type or roller screens)
provided upstream of the crushers screen out (-) 20 mm coal from the feed and ( ) 20 mm coal is fed to the
crushers. A set of rod gates and rack and pinion gates is provided before screens to permit

Fig:7 Crusher

Electrical&ElectronicsEngineering(SHIFT-A) 38
CHAPTER -5
THERMAL POWER PLANT

39
 INTRODUCTION OF THERMAL POWER PLANT

5.1.INTRODUCTION
Electricity lights our homes and runs our machines. It claims as much importance as the basic
necessities like air, water, food & shelter. It is the very life of modern civilization.

Power is generated from various resources such as coal, water, gas, diesel, etc. Out of all thermal, hydral
and nuclear power generation have gain importance because of their availability in abundance in nature
64% of the total installed capacity from thermal power plants. Dr. Narla Tatarao Thermal Power
Station (Dr. NTTPS) is one of the leading thermal power plants in India. It is located amidst the
Eastern Ghats on the bank of River Krishna at Ibrahimpatnam Village, Krishna District, A.P. It has six
operating stations each with an installed capacity of 210MW taking an input of 3000tones/unit/day and

One 500MW station taking an input of 6500.

Sub-Bituminous coal is used as primary fuel. The efficiency of the plant is 34.5%. Daily coal
consumption is around 24500tones/unit/day.

We have choose 500MW Station to prepare a Study project on Auto Control loops used in Thermal
Power Stations.

Plant Specifications:
TYPE : THERMAL PLANT
CAPACITY : 500MW
OUTPUT : ELECTRICAL POWER
BY-PRODUCTS : ASH AND FLUE GASES

Load Specifications:
Two pole Synchronous Generator with water + Hydrogen cooled
POWER : 524.204 MW, TG VWO, 3% make up
CURRENT : 16200 AMP
VOLTAGE : 21 KV
EFFICIENY : 98.64%
P. F : 0.85 LAG
Rated Excitation : 4040 Amp / 340 V
Short circuit ratio : 0.48

Electrical&ElectronicsEngineering(SHIFT-A) 40
 5.2 UNIT OVERVIEW

Electrical&ElectronicsEngineering(SHIFT-A) 41
 5.2.1 BOILER
Water is evaporated into steam inside the boiler necessary heat is obtained by burning coal in boiler
furnace to save time and economize fuel consumption feed water is preheated in economizer. Flue gases
from the boiler provide heat to feed water. They are also used to preheat air before they flow to
chimney. A modern boiler produces steam at the rate of 300 to 400 tons per hour at 130 to 140 bar
absolute pressure and 5400C by burning the coal at the rate of 200 tons per hour.

5.2.2 STEAM TURBINE

This is a prime mover and the main power unit of the plant. Steam from super heater is admitted into the
turbine through nozzle. It expands over the blades of turbine rotor pressure falls and thus heat in steam
drops. This drop in enthalpy (heat energy) is converted in to mechanical energy. As a results turbine
shaft rotates at high rotational speeds and this shaft connected to generator.

5.2.3CONDENSER
Condenser is placed at the exhaust end of turbine so that the exhaust steam from turbine is discharged
into it. Condenser condenses the steam making use of certain cooling medium such as water. Condensed
steam is called condensate this is recirculated to boiler as feed water.

5.2.4BOILER FEED PUMP

The main aim of feed pump is to send condensate from hot well to boiler and also increase the pressure
of the condensate.

5.2.5FURNACE
A boiler furnace is that space under or adjacent to a boiler in which fuel is burned the
combustion products pass into the boiler properly. It provides a chamber in which the combustion
reaction can be isolated and confined so that the reaction remains a controlled force.

5.2.6 DRUM
The drum is a pressure vessel. The boiler drum forms a part of the circulation system of
drum serves two functions: a. It separates steam from the mixture of water and steam. B. The drum
houses all equipment used for purification of steam after being separated from water. This purification
equipment is commonly referred to as the drum internals. The boiler drum is made of carbon steel
plates
5.2.7 SUPER HEATER
Super heaters are usually classified according to the shape of the tube banks and position of the header,
also according to whether they receive heat by radiation or convection, although in some instance it may
be a combined of both methods. The super heaters increase the heat energy in the steam supplied to
steam turbines and to ensure that the dry steam supplied until it reaches the last stage of LPT.

Electrical&ElectronicsEngineering(SHIFT-A) 42
 5.2.8 REHEATER
Increased capacity of generators necessitates increased capacity units. The steam entering high pressure
turbine does some work due to steam expanding through various stages. The steam exhaust in high
pressure turbine is again admitted in the reheated circuit to reheat the steam at constant pressure to raise its
temperature to almost equal to super heated steam. The heat energy in the steam is increased in
the reheated and this reheated steam is admitted into IPT and steam is expanded doing some additional
work before exhausting into condenser from LPT.

5.2.9 RAW COAL MILLS

The most efficient way of utilizing coal for steam generation is to burn it is in pulverized form. In
pulverized fuel firing method the coal pulverized to a fineness of 70% to 80% by hot primary air through
pipes directly to burners. The motives behind the development of pulverized fuel firing systems are:
a. Efficient utilization of cheaper and low grade coals.
b. Flexibility in firing with ability to meet fluctuating loads.
c. The ability to use higher combustion air temperature there by increasing the overall efficiency of the
steam operator.

5.2.10 MILLS
To pulverize (Grind) the coal prior to admission into the furnace for effective combustion.

5.2.11 FLAME SCANNERS

To monitor the flame inside the furnace (Furnace safe guard supervision system–FSSS).

5.2.12 IGNITER AIR FANS

To supply cold secondary air for cooling the igniters.

5.2.13 SCANNER AIR FANS

To supply the air for cooling the scanners.
5.2.13 AIR HEATERS
Air heater is a heat transfer surface in which air temperature is raised by transferring heat from other media
such as flue gas. Since air heater can be successfully employed for reclaim heat from flue gas at low
temperature levels than is possible with economizer. The heat rejected to chimney can be reduced to higher
extent thus increasing the efficiency of the boiler. For every 200C drop in flue gas temp, the boiler
efficiency increased by about 1%.

5.2.14 FANS
The purpose of the fan is to move air/gas continuously against moderate pressure. Fans are used in boiler
for different applications such as supplying air for combustion, removal of combustion products, and air
for cooling of equipment working in hot zone set. Fans are designed according to the fans they do in the
boiler, e.g. Induced draft fan, forced draft fan, primary air fan etc.

Electrical&ElectronicsEngineering(SHIFT-A) 43
 1. Primary Air fan [PA fan]
The primary air has two functions, drying the coal and transportation into the furnace. Boiler provided
with two no’s of primary air fans. Each PA fan is provided with blade pitch control for controlling the
loading on fans. Outlet damper for isolation to facilitate start up or maintenance of fan.

2. Forced Draft fan: [FD fan]

The function of FD fan is to supply excess air required for complete combustion. Boiler is provided with
two no. of forced draft fans. Each FD fan is provided with blade pitch control for controlling the loading
on fans. Outlet damper for isolation to facilitate start up/maintenance of fan.

3. Induced Draft fan [ID fan]

The function of induced draft fan is to suck the gases out of furnaces and throw them into stack. Boiler
is provided with two no. of induced draft fans. Each ID fan is provided with regulating damper control
and scoop control for controlling the load on fans, inlet/outlet gates for isolation to facilitate start
up/maintenance of fan. Flue gas inter connection with damper is provided before ESP in order to
maintain balanced flow through both the APH second pass when only one ID fan is running.

5.2.15 CONDENSATE EXTRACTION PUMPS

The function of these pumps is to pump the condensate to the desecrator through ejectors, gland steam cooler, drain
cooler and LP heaters. In a 210MW unit 3pumps are installed, having a pumping capacity of 50% each. Two pumps are
for normal operation and one is stand by. Since the suction is at a negative pressure, the special arrangements have been
made for providing sealing to glands.
5.2.16 ECONOMISER
An economizer is device in which the waste heat of the flue gases is utilized for heating the feed water.

5.2.16 GENERATOR
Generator is used to convert the mechanical energy into electrical energy.

5.2.17 CHIMNEY
A chimney is an industrial structure used to ventilate hot flue gases from the furnace to the outside living
atmosphere.

5.2.18 COOLING TOWER

Cooling tower is a heat removal device that uses water to transfer process waste heat into the
atmosphere

Electrical&ElectronicsEngineering(SHIFT-A) 44
 CONCLUSION
Here in this project we experienced the efficient working of a thermal power plant
and generation of electricity in it. It is a complex structure involving a number of
stages workingsimultaneously for the production of electricity.
The most important and the necessary parts of the thermal plant are boiler, turbine,
condenser and generator. The efficiency of a thermal plant depends upon the effective
working of these parts.
In this we learnt about the whole process of power generation by the co-ordination of
various auxiliary systems. We saw that the major losses in are mainly due to steam leaks
in boiler tubes and condenser. The effective transfer of steam from boiler to
condenser and reuse it as feed watergreatly improves the efficiency of a power plant.
Thus, I conclude that the working of a thermal power plant does not entirely rely upon the EM &
MRT and generator but, the co-ordination of various systems together get the efficient generation

Electrical & Electronics Engineering (SHIFT-A) 45

 REFERENCES.

1. We referred from ESPPE (energy source and power plant engineering).

2. We referred from T E-1 (thermal engineering).
3. We referred from some thermal power plant books in APGENCO, Dr.NTTPS .

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