Cstps Modofied-131230103858
Cstps Modofied-131230103858
Cstps Modofied-131230103858
Aniket . S.Naphade
Priyadarshini Coll. Of Engg., Nagpur
Deptt. Of Electrical Engg.
(16/12/2013- to- 30/12/2013 )
Table of Contents
1.
OVERVIEW............................................................................................................ 4
2.
3.
4.
5.
6.
1. OVERVIEW
ABOUT MAHAGENCO
Unit
Number
Date of Commissioning
210
1983 August
210
1984 July
210
1985 May
210
1986 March
500
1991 March
500
1992 March
500
1997 October
Total unit 7
2340
Genration of electricity from thermal power stationIn thermal power station, steam driven turbine is a
prime mover of electrical generator . When water is heated in
boiler, turns into steam and spins a steam turbine which drives
an electrical generator. After it passes through the turbine, the
steam is condensed in a condenser and recycled to where it was
heated; this is known as a Rankine cycle.
Following energy conversion steps are used in the thermal
power stationChemical energy of coal
Bitumino
us
Carbon
%
60-80
Moisture
%
Ash
%
2.2-15.9
3.3-11.7
Calorific
valuve
Kcal/kg
Heat
content
Mj/Kg
4200 (for
imported
coal)
3600 (for
W.C.L.)
24-35
Transportation of coalTransportation
Road
Rope way
Railway
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Water tube boilers can be designed to exploit any heat source and
are generally preferred in high pressure applications since the
high pressure water/steam is contained within small diameter
pipes which can withstand the pressure with a thinner wall. Cool
water at the bottom of the steam drum returns to the feed water
drum via large-bore 'downcomer tubes', where it pre-heats the
feed water supply. To increase economy of the boiler, exhaust
gases are also used to pre-heat the air blown into the furnace and
warm the feedwater supply. Such watertube boilers in thermal
power station are also called steam generating units.
In CSTPS , boiler is suspended from top, it is because of when
water tubes are heated . due to heating ,water tubes expands. If
bottom of the boiler is fixed then tubes will expand in upward
direction, above the boiler the boiler draft is fitted. So due to
heavy weight of boiler drum & tube expansion high stares are
developed in boiler. So it may harmful & reduces boiler & its
peripheries life.
Water tube boiler are subjected to the high pressure, heat flux
and temperature so circulation of steam and water gets
important.
A boiler equipped with a combustion chamber which has
a strong current of air (draft) through the fuel bed will increase
the rate of combustion, which is the efficient utilization of fuel
with minimum waste of unused fuel. The stronger movement will
also increase the heat transfer rate from the flue gases to the
boiler, which improves efficiency and circulation. The combustion
rate of the flue gases and the amount of heat transfer to the
boiler are both dependent on the movement and motion of the
flue gases. Hence, due to above reasons draught system holds
high significance.
The difference between atmospheric pressure and the pressure
existing in the furnace or flue gas passage of a boiler is termed
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Economizer-
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Function of primary air fan Carry the pulverized coal to boiler from coal mills.
Remove moisture from coal.
Forced Draft FanFans for boilers force ambient air into the
boiler, typically through a preheater to increase overall
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Cycles of boilerFollowing air cycles are in the boiler Primary air cycle- functions of primary air is follows Carry the pulverized coal from the coal mill to the
combustion chamber of boiler.
Provide oxygen for combustion of coal particles.
Primary air cycle is shown as follows-
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Flue gas cycleFlue gases are formed after combustion of coal. Flue gases
may contain carbo dioxide(co2),water vapors, sulpher
dioxide(so2),and poolution causing gases like carbon monooxide(CO), particulate matter like soot, & fly ash.
These gases are cleaned by using
Electrostatic precipitator for removal of soot & fly ash.
Flue gas cycle is as follows-
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Boiler
Air heater
Electrostatic precipitator
stack
Boiler MaintenanceBlowdownsBoiler blowdown is removal of water from the boiler.
It is done in order to remove the amount of solids in the
water, and is performed as either bottom (sludge) blowdown, or
continuous (surface) blowdown. The blowdown frequency and
duration is primarily determined by the boiler water analysis. The
water quality will vary greatly
based on boiler type and size, amount of condensate return,
and boiler water treatment program.
Water tube cleaningafter burning of coal two types of ash is formed, namely Fly ash.
Bottom ash.
Fly ash is light in weight, and it flue with flue gases. It
may deposite on the water tube surface inside the boiler. Due
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which less heat is absorbed by the water tube & hence efficiency
of the boiler is lowered downHence it is necessary to clean the
boiler water tube surface.
To remove this deposition suit blowing method is used. in this
method steam is forced to flow over water tube & boiler wall at a
pressure of 150kg.following 2 type of suit blower are used Short soot blower.
It is used to clean to boiler walls &
water tube surface near to boiler walls.
Long soot blower
Two soot blower of 10m are used from both
side of boiler.
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4.2 Turbine
Turbine is a device which converts the kinetic energy of the
steam in the mechanical rotational energy of rotor. Steam
from the boiler is passed over the blade of the turbine, which
tends to rotate the shaft of the turbine. Turbine shaft is
mechanically coupled with generator shaft .when turbine
shaft rotate generator shaft also rotate.
Basically turbine is of following type Impulse turbine.
Reaction turbine.
On 5 different basis turbine is classified ,those are as followsType of compounding.
Type of blading.
Division of flow.
Type of steam flow.
Type of exhausting condition.
Turbine used in CSTPS has following features turbine set consist of 3 turbine defined on the basis of
the pressure inside it. These turbines with their type are
as follows High pressure turbine - impulse turbine.
Intermediate pressure turbine Reaction turbine.
Low pressure turbine Reaction turbine.
Condensing type.
Tandom compound.
Tandom compounding means
both impulse & reaction type turbine is used.
Nozzle governing.
Disc & diaphragm type.
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No of stages
H.P. turbine
I.P. turbine
L.P. turbine
12
11
4+4
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Cooling water cycle. Two circulating water pump (C.W. pump)are circulating
water, taken from sump.
Water from the condenser water tube is cooled in cooling
tower.
27000ton water per hour is cooled in one cooling tower.
14 C.T fans are employed in 210MW plant cooling tower.
Temperature in cooling tower should be 28-30degree cel.
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C
o
o
l i n
g
T
o
w
e
r
W
a
t
e
r
s
u
m
p
C
o
n
d
e
n
s
e
r
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Condenser
Hot well
C.E.P - 1
C.E.P - 2
De aerator
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C.E.P - 3
B.F.P.-1
B.F.P.-2
B.F.P.-3
Boiler drum
4.3 Condensor
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25
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Cooling TowerCooling towers are used to cool the water from the
water tube of condenser. Water in water tube take heat from the
steam from the turbine.
Heat from water is transferred by following methodWet cooling methodIn this method evaporation phenomenon is used to transfer
heat.
Dry cooling method-
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4.4 Generator
Generator is an electrical device which converts mechanical
energy into electrical energy. This Energy conversion is based on
the principal of the production of dynamically induced emf.
Whenever conductor cuts magnetic flux, dynamically induced emf
is produced in it according to Faradays Laws of electromagnetic
induction. This emf causes a current to flow if the conductor
circuit is closed.
Synchronous generator ( Alternator) is used to generate A.C
electric power at a constant frequency 50Hz.
In A.C. generator, following are constructional important parts A stationary element called as stator, on which armature
winding is mounted.
A rotating part inside the stator called as rotor. this rotor is
driven by the rotational mechanical energy from the turbine
shaft at a constant speed.
In CSTPS, 210MW unit 2 pole alternator is used which
generate electricity at 3000rpm of frequency 50Hz.
Stator Construction
Stator is a heaviest component of the
entire generator. It contains stator winding & stator body with a
stator core. it is designed to
Withstand high internal pressure, which may arise due to unlikely
event of explosion of hydrogen air mixture without any residual
deformations. Stator body is a totally enclosed gas tight
fabricated structure made up of high quality mild steel and
austenitic steel.
Stator windingStator winding is made up of a hallow
conducting pipe through which water is circulated for cooling
hydrogen gas. The stator winding is placed in open rectangular
slots of the stator core which are uniformly distributed on the
circumference Bus bars are connected to bring out the three
phases & six neutrals. This bus barware connected with terminal
bushings. Both are water cooled, connection is made by brazing
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Two single stage axial flow propeller type fans circulate the
generator cooling gas. Fitted on either sides of rotor body
BearingsThe rotor shaft is supported on pedestal type of
bearings which has spherical seating to allow self alignment. On
the top of bearings pedestal a vent pipe emerges connecting
bearing chamber to the atmosphere for venting out oil vapour or
traces of Hydrogen. A current collector located just above the
rotor shaft and touching it is also mounted on the bearing body to
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give, shaft voltage for rotor earth fault protection. To prevent the
flow of shaft currents slip ring and bearing and connecting pipes
are insulated from earth.
Shaft Seal
The locations where the rotor shaft passes through
the stator casing, are provided with radial seal rings. The seal ring
is guided in the seal body, which is bolted on to the end shield
and insulated to prevent the flow of shaft currents. The seal ring is
lined with babbit on the shaft journal side. The gap between the
seal ring and the shaft is sealed with seal oil. The seal oil is
supplied to the sealing gap from the seal body via radial holes
and an annular groove in the seal ring. To ensure effective
sealing, the seal oil pressure in the annular gap is maintained at
a higher level than the gas pressure within the generator casing.
Following flow chart shows generated electricity route
Generator
Generating transformer
National grid
CoolingIn generator heat is generated due to windage
loss ,Cu losses, friction. The rise in temperature must be
controlled to protect the insulating material . the temperature with
which these insulating material can with stand is decided by the
class of insulating material to which it belongs.
For cooling generator components following cooling systems
are used Hydrogen cooling.
Demineralised water (D.M.) cooling.
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Oil Tank
MOP
SOP
LOP
AC
DC
Governor
Oil cooler
Servomotor Operate
Pump
4 control valve
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function
core
Primary winding
Secondary winding
enclosure
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Excellent flexibility.
Heat resistant.
Moisture resistant.
Brilliant electrical properties.
Resistant to smoke or odour.
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Electrical
Physical
Chemical
Dielectric strength.
Interfacial
water
content.
Specific resistance.
Tension.
Acidity.
Dielectric dissipation
viscosity
sludge
content.
Factor.
Flash point.
To cool this hot oil water cooling arrangement is provided.
Water is circulated through the tubes. This hot water is
cooled naturally.
Transformer accessories
BreatherWhenever electrical power transformer is loaded, the
temperature of the insulating oil increases, consequently the
volume of the oil is increased. As the volume of the oil is
increased, the air, above the oil level in conservator, will come
out. Again at low oil temperature the volume of the oil is
decreased, which cause, the volume of the oil to be decreased
which again causes air to enter into conservator tank. The natural
air always consists of more or less moisture in it and this moisture
can be mixed up with oil if it is allowed to be entered into the
transformer. The air moisture should be resisted during entering
the air into the transformer, because moisture is very harmful for
transformer insulation. A silica gel breather is most commonly
used as a means of filtering air from moisture. Silica gel breather
for transformer is connected with conservator tank by means of
breathing pipe.
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Conservator
It is the important periphery of transformer.
Conservator is a tank which conserves oil. When transformer is
loaded, oil inside it is heated. Due to heating oil expand. To
provide extra volume conservator is employed.
When oil gets cooled it returns to transformer oil tank.
Conservator tank is partially filled with oil.
So, the vaccum space is filled up by the
atmospheric air. A filtering device, called breather is attached with
the conservator to ensure that only dry and clean air can enter
into the transformer. So, a conservator ensures the safety
operation of a transformer. High temperature of oil also leads
to generate sludge, which occurs in the presence of air. If
somehow the transformer is subjected to a major fault, then the
temperature rise becomes quite high and this causes vaporization
of a part of the oil. This oil vapour forms an explosive mixture with
air and can ignite and cause huge damage. So, to prevent the
contact of oil and moisture-enriched air, conservator and breather
assembly is used.
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Fall of oil level means lowering the position of float and thereby
tilting the mercury switch. The contacts of this mercury switch are
closed and an alarm circuit energized. Sometime due to oil
leakage on the main tank air bubbles may be accumulated in the
upper part the Buchholz Container which may also cause fall of oil
level in it and alarm circuit will be energized. By collecting the
accumulated gases from the gas release pockets on the top of the
relay and by analyzing them one can predict the type of fault in
the transformer.
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( sulfur hexafluoride)
CO2
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Station transformer-
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Post treatment.
175000m^3 water is treated in one day in CSTPS.
Pretreatment of water- Pretreatment is used to kill
disease-causing organisms and help control taste and odor
causing substances. A pretreatment chemical could be any
number of oxidants or disinfectant.
In water pre treatment plant the suspending particles
are removed by screening the water. Following flow chart shows
the water treatment process sequenceWater from Erai dam brought pipe lines
Flash mixture
Clariflocculator
Water sump
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Addition of lime
softening can be achieved by adding lime in the
form of limewater, Ca(OH)2, which, in a carbonatation reaction
with CO2, forms calcium carbonate precipitate, reacts next with
multivalent cat ions to remove carbonate hardness, then reacts
with anions to replace the non-carbonate hardness due to
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screening
settling
Chemical dosing
coagulation
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Post-treatment of Water
Pretreated water send for post
treatment. Post treatment method for D.M water & soften water.
Demineralised (D.M.) water PlantDemineralisation
is a process of removing dissolved salts from water by iron
exchange process. In CSTPS, water with no chemical substances
is come from Erai dam. So the better quality D.M water is
obtained. During demineralization process water is passed
through following ion beds-
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De-gaser
De-gaser tank
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element
P.S.F.
Gelatinous
material
A.C.F.
turbidity
8500
S.A.C.
(Ca^+2),
(Mg^+2),
(Na^+2)
(Cl^-), (SO4^2)
silicates
HCl acid
8500
NaOH solution
8500
NaOH
8000
HCL +NaOH
13200
W.B.A.
S.B.A.
M.B.
Any particles
other than
above
Backwash by
filtered water
y
(M^3)
8500
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Strong acid
cation
hardness
Brine solution
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1.
A.
Bottom Ash Handling System
Bottom ash resulting from the combustion of coal in the boiler
shall fall into the over ground, refractory lined, water impounded,
maintained level, double V-Section type/ W type steel- fabricated
bottom ash hopper having a hold up volume to store bottom ash
and economizer ash of maximum allowable condition with the
rate specified. The slurry formed shall be transported to slurry
sump through pipes.
1.
B.
Coarse Ash (Economizer Ash) handling System
Ash generated in Economizer hoppers shall be evacuated
continuously through flushing boxes. Continuous generated
Economizer slurry shall be fed by gravity into respective bottom
ash hopper pipes with necessary slope.
1.
C.
Air Pre Heater ash handling system
Ash generated from APH hoppers shall be evacuated once in a
shift by vacuum conveying system connected with the ESP hopper
vacuum conveying system.
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1.
D.
Fly Ash Handling System
Fly ash is considered to be collected in ESP Hoppers. Fly ash from
ESP hoppers extracted by Vacuum Pumps up to Intermediate
Surge Hopper cum Bag Filter for further Dry Conveying to fly ash
silo.
Under each surge hopper ash vessels shall be connected with Oil
free screw compressor for conveying the fly ash from
Intermediate Surge Hopper to silo. Total fly ash generated from
each unit will be conveyed through streams operating
simultaneously and in parallel.
1.
E.
Bottom Ash slurry, Fly ash slurry and the Coarse Ash slurry shall
be pumped from the common ash slurry sump up to the dyke area
which is located at a distance from Slurry pump house.
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