DVC Andal VT Report

Training Report 2014
1 | P a g e

VOCATIONAL TRAINING
DSTPS, DVC ANDAL

Project Report
Submitted by:
Satyaki Dutta
Department of Mechanical Engineering
Jadavpur University

Under the guidance of
Mr. P. K. SIKDAR
Dy. Chief Engineer (M), DVC, DSTPS

2 | P a g e

The dissertation has been prepared based on the vocational training undergone in a highly
esteemed organisation of Eastern region, a pioneer in Generation Transmission &
Distribution of power, one of the most technically advanced thermal power stations in India,
the Durgapur Steel Thermal Power Station (D.S.T.P.S), under DVC. We would like to
express our heartfelt gratitude to the authorities of Durgapur Steel Thermal Power Station for
providing us such an opportunity to undergo training in the thermal power plant of DVC,
DSTPS.
I would also like to thank the highly experienced Engineers, without whom such type
of concept building in respect of thermal power plant would not have been possible. Some of
them are:
1) Mr. P.K.Sikdar, Dy. CHIEF ENGINEER (M), DVC, DSTPS
2) Mr. M.K.Singh, SE (M), CHP, DVC, DSTPS
3) Mr. A. Kumar, SE (M), BOILER & AUXILIARIES, DVC, DSTPS
4) Mr. S.N.Dutta, SE (M), TURBINE & AUXILIARIES, DVC, DSTPS
5) Mr. V.N.Sharma, SE (M), OPERATION SUPERINTENDENT, DVC, DSTPS

INTRODUCTION
DVC (Damodar Valley Corporation) a legacy to the people of India, emerged as a
culmination of attempts made over a whole century to control the wild and erratic Damodar

3 | P a g e

river. The river spans over an area of 25,000 sq. kms covering the states of Bihar (now
Jharkhand) & West Bengal. The Corporation came into existence on 7th July, 1948 as the
first multipurpose river valley project of independent India.
DSTPS or Durgapur Steel Thermal Power Station is one of the eight thermal coal
based power plants of DVC, situated at Andal , Durgapur in the district of Burdwan , West
Bengal , India having co ordinates 2334'48"N , 8712'19"E.

TECHNICAL SPECIFICATION OF DSTPS
INSTALLED CAPACITY: -
1) Total number of Units: - 2 X 500 MW (unit 1 to 2)

4 | P a g e

2) Total Energy Generation: - 1000MW
3) Source of Water: - Damodar River
4) Sources of Coal: - BCCL, CCL with FSA (Fuel Supply Agreement)
5) Sources of Oil :- Indian Oil Corporation
OVERVIEW OF A THERMAL POWER PLANT
In a Thermal Power generating unit, combustion of fossil fuel (coal, oil natural gas) in Boiler
generates heat energy. This heat energy transforms water steam at high pressure and
temperature. This steam is utilised to generate mechanical energy in a Turbine. This
mechanical energy, in turn is converted into electrical energy with the help of an Alternator
coupled with the Turbine. The production of electric energy utilising heat energy is known as
thermal power generation.
The heat energy changes into mechanical energy following the principle of Rankine reheat-
regenerative cycle and this mechanical energy transforms into electrical energy based on
Faradays laws of electromagnetic induction.
General Layout of Thermal Power Station

OVERVIEW OF A THERMAL POWER PLANT


5 | P a g e

1. Cooling tower 12. De-aerator 23. Economiser
2. Cooling water pump 13. Feed heater 24. Air pre heater
3. Transmission line (3-phase) 14. Coal conveyor 25. Precipitator
4. Unit transformer (3-phase) 15. Coal hopper 26. Induced draught fan
5. Electric generator (3-phase) 16. Pulverised fuel mill 27. Chimney Stack
6. Low pressure turbine 17. Boiler drums
7. Condensate extraction pump 18. Ash hopper
8. Condenser 19. Super heater
9. Intermediate pressure turbine 20. Forced draught fan
10. Steam governor valve 21. Re-heater
11. High pressure turbine 22. Air intake

COAL HANDLING PLANT
INTRODUCTION

6 | P a g e

What is CHP??
CHP is (C- Coal, H- Handling, P- Plant) a plant which handles the coal from its receipt to
transporting it to Boiler and store in Bunkers. It also processes the raw coal to make it
suitable for Boiler Operation.
BASICS OF OPERATION
0mm.

en this coal is fed to the coal mill for pulverization.

area.
OBJECTIVE OF CHP: Objective of CHP is to supply the quanta of processed coal to
bunkers of Coal mills for Boiler operation and to stack the coal to coal storage area. Coal is
a hard black or dark brown sedimentary rock formed by the decomposition of plant material,
widely used as a fuel. A piece of coal called Coal Lumps. Mostly E and F grade coal used in
India. In brief we can say that receipt of coal from coal mines, weighing of coal, crushing it
to required size and transferring the quantity of coal to various coal mi
the responsibility and duty of the CHP and its staff.
Fig: COAL HANDLING PLANT

LIST OF MAJOR EQUIPMENT/ SYSTEM OF COAL HANDLING PLANT OF
DSTPS UNIT
NO: 1, 2, UNDER THE CONTRACTORS SCOPE OF WORK.

7 | P a g e

1. Track unloading hopper and accessories :

(A) RCC Track Hopper 1 (Length 250 M width - 6M), Capacity 5500MT
(B) Steel grating over hopper 300MM X 300 MM Mesh
(C) Track Hopper Beams all sides (except bottom) and inclined portion of inner
surface all through lined with replaceable SAILHARD/ SAILMA Plates.
(D) Concrete table top all through lined with 16MM thick SAILHARD/SAILMA Plates
(removable).
(E) Paddle Feeders 4 Nos. (Each of Capacity 900 TPH)
2. Belt conveyors and accessories:-

Capacity 1600 TPH (rated) Design 1760 TPH, Troughing Angle 35.
A) 2 nos.1400 mm belt conveyors(Horizontal) 1A and 1B each of approximate
length 302mtrs. complete with belting, idlers, pulleys, speed reducer, drives
and motors, tension devices, cleaning devices, pulleys and coupling, hold backs,
transfer chutes and accessories for carrying coal of 350 mm and down lump size.
B) 2 nos. 1400 mm belt conveyors (inclined) nos. 2A and 2B each of approx length
109mtrs. complete with usual accessories
C) 2 nos. 1400 mm belt conveyor(Horizontal) no. 3A and 3B each of approx length
308 mtrs. respectively with all usual accessories mentioned in 2 (A) including in-
line Magnetic separators ,Metal Detector ,suspended magnet at head end along with
non-magnetic pulleys and belt weighers. To carry crushed coal of 350 mm and down
up to Crusher house discharging to Roller screen.
D) 2 no. 1400 mm belt conveyor(Horizontal) no. 4A/4B of approximate length 250 mtrs.
with usual accessories inter connecting conveyor no5 to 6.
E) 2 nos. 1400 mm belt conveyors(inclined) no. 5and 6 each of approx 450 mtrs. with
usual accessories for carrying coal (20mm and down) from transfer points to
conveyor no. 7A and 7B.
F) 2 nos. 1400 mm belt conveyors(inclined) no. 7A and 7B each of approx. length 250
mtrs. with usual accessories to discharge coal to conveyor belt 8A and 8B.
G) 2 Nos. 1400 mm belt conveyors(Horizontal) no 8A & 8B each of approx. length-360
mtrs with usual accessories for feeding coal to belt conveyors no. 10A and 10B
each of approx. length 680 mtrs. with usual accessories mentioned in 2 (A)
including in-line Magnetic separators ,Metal Detector ,suspended magnet at head
end along with non-magnetic pulleys. for transfer of coal to conveyor no 11A/11B.

8 | P a g e

H) 02 Nos. 1400 mm belt conveyors(Horizontal) no 11A & 11B each of approx. length-
200 mtrs with usual accessories for feeding coal to belt conveyors no. 12A and 12B
each of approx. length 140mtrs. with usual accessories mentioned in 2 (A)
Accessories fitted with Conveyors. Conveyors 11A/11B also transfer the coal to bunker
conveyor B1 and B2 each of approximate length 80 mtrs. Belt conveyors no. 12A and
12B also transfer the coal to bunker conveyor B3 and B4 each of approximate length 80
mtrs. There are 4 nos of travelling tripper for transferring the coal from bunker
conveyors B1,B2,B3 and B4 to coal bunkers.Belt wiper units, pull cord type
emergency switches, belt sway limit switches, foundation plate, anchor bolts,
fasteners etc. counter weight, one zero speed switches for each conveyor, brakes and
hold-backs, steel structures/CGI sheet enclosure for all outdoor conveyors.
4. Crusher House Equipment:
a) Ring type Granulator Crusher (900 TPH rated each) 4nos. with motors and fluid
couplings.
b) Roller screen (900 TPH rated each) . with motors and fluid couplings to receive coal
from Conv. # 3A/3B& discharge to Cr- 1, 2, 3 and4.Coal sampling unit
c) Linear actuator operated flap gates, belt feeders ,rack and pinion gate ,rod gates etc. One
number rack and pinion elevator, Vibration monitoring and vibration isolation system
5. Traveling Stacker-cum-Reclaimer: Stacker-cum-Reclaimer for Stacking and reclaiming
mounted on Conv. no. 5 & 6 with all accessories like tripper Unit, boom conveyor,
bucket wheel control panel etc. 2 nos.
6. Track hopper Maint. Bay, Wagon tippler, tunnel area and sump pump pits.
7. Coal bunkers for Unit 1,2, with ten hoppers in each Unit, each capacity of 600 MT.
8. Structure, Structural steel construction etc. for conveyor frames, head frames, stringers,
hand rails, walk ways, safety guards, stairs etc.
9. a) Travelling tripper 4 nos.
b) Magnetic separators 4nos.
c) Metal detectors 4
nos.
d) Coal samplers 2 nos.
e) Belt weighers 4 nos(2 nos. in crushing side and 2 nos. in feeding side)

10. Air pollution control system:
a)Ventilation system Ventilation system in Track Hopper, wagon tippler,MCC(3 nos),TP1
b)Dust extraction system DE In all Bunkers and crusher house
c) Dust suppression system-Dry fog system in all TPs and wet system in track hopper and

9 | P a g e

crushed coal stock pile area.

COMPRESSOR - 2nos for BOBR opening.

Pump house A
DS pump-6 nos
SWS pump-2nos
CWS pump-2 nos
DEWS pump-2nos
WSS pump-2 nos
DFS pump-2 nos
Compressor for DFS -2
nos

Pump house B
DFS pump-2 nos
SWS pump-2nos
CWS pump-2 nos


10 | P a g e

WATER TREATMENT PLANT

Raw water supply: Raw water received at the thermal power plant is passed through Water
Treatment Plant to separate suspended impurities and dissolved gases including organic
substance and then through De-mineralised Plant to separate soluble impurities.
Deaeration: In this process, the raw water is sprayed over cascade aerator in which water
flows downwards over many steps in the form of thin waterfalls. Cascading increases surface
area water to facilitate easy separation of dissolved undesirable gases (like hydrogen
sulphide, ammonia, volatile organic compound etc.) or to help in oxygenation of mainly
ferrous ions in presence of atmospheric oxygen to ferric ions.
Coagulation: Coagulation takes place in clariflocculator. Coagulant destabilises suspended
solids and agglomerates them into heavier floc, which is separated out through sedimentation.
Prime chemicals used for coagulation are alum, poly-aluminium chloride (PAC).
Filtration: Filters remove coarse suspended matter and remaining floc or sludge after
coagulation and also reduce the chlorine demand of the water.
Chlorination: Neutral organic matter is very heterogeneous i.e. it contains many classes of
high molecular weight organic compounds. Humic substances constitute a major portion of
the dissolved organic carbon from surface waters. They are complex mixtures of organic
compounds with relatively unknown structures and chemical composition.


11 | P a g e

DM (Demineralised Water) Plant: In De-mineralised Plant, the filter water of Water
Treatment Plant is passed through the pressure sand filter (PSF) to reduce turbidity and then
through activated charcoal filter (ACF) to adsorb the residual chlorine and iron in filter water.


12 | P a g e

BOILER & AUXILIARIES
Boiler
Working principle of Boiler (Steam Generator): In Boiler, steam is generated from
demineralised water by the addition of heat. The heat added has two parts: sensible heat and
latent heat. The sensible heat raises the temperature and pressure of water as well as steam.
The latent heat converts water into steam (phase change). This conversion is also known as
boiling of water, which is dependent on pressure and corresponding temperature.
Thermodynamically, boiling is a process of heat addition to water at constant pressure &
temperature. The quantity of latent heat decreases with increase in pressure of water and it
becomes zero at 221.06 bars. This pressure is termed as Critical Pressure. The steam
generators are designated as sub-critical or super critical based on its working pressure as
below critical or above critical pressure. The steam, thus formed is dry & saturated. Further,
addition of heat raises the temperature and pressure of steam, which is known as superheated
steam. The differential specific weight between steam and water provides the driving force
for natural circulation during the steam generation process. This driving force considerably
reduces at pressure around 175 Kg/cm
2
and is not able to overcome the frictional resistance
of its flow path. For this, forced or assisted circulation is employed at higher sub-critical
pressure range due to the reason of economy. But, at supercritical pressures and above,
circulation is forced one (such boiler is called once through boiler).

Fig: BOILER


13 | P a g e

Important parts of Boiler & their functions:
Economizer:
Feed water enters into the boiler through economizer. Its function is to recover residual heat
of flue gas before leaving boiler to preheat feed water prior to its entry into boiler drum. The
drum water is passed through down-comers for Circulation through the water wall for
absorbing heat from furnace. The economizer recirculation line connects down-comer with
the economizer inlet header through an isolating valve and a non-return valve to protect
economizer tubes from overheating caused by steam entrapment and starvation. This is done
to ensure circulation of water through the tubes during initial lighting up of boiler, when there
is no feed water flow through economizer.
Drum:
Boiler drum is located outside the furnace region or flue gas path. This stores certain amount
of water and separates steam from steam-water mixture. The minimum drum water level is
always maintained so as to prevent formation of vortex and to protect water wall tubes
(especially its corner tubes) from steam entrapment / starvation due to higher circulation ratio
of boiler.
Superheater:
Superheaters (SH) are meant for elevating the steam temperature above the saturation
temperature in phases; so that maximum work can be extracted from high energy (enthalpy)
steam and after expansion in Turbine, the dryness fraction does not reach below 80%, for
avoiding Turbine blade erosion/damage and attaining maximum Turbine internal efficiency.
Steam from Boiler Drum passes through primary superheater placed in the convective zone
of the furnace, then through platen superheater placed in the radiant zone of furnace and
thereafter, through final superheater placed in the convective zone. The superheated steam at
requisite pressure and temperature is taken out of boiler to rotate turbo-generator.
Reheater:
In order to improve the cycle efficiency, HP turbine exhaust steam is taken back to boiler to
increase temperature by reheating process. The steam is passed through Reheater, placed in
between final superheater bank of tubes & platen SH and finally taken out of boiler to extract
work out of it in the IP and LP turbine.
De-superheater (Attemperator):
Though superheaters are designed to maintain requisite steam temperature, it is necessary to
use de-superheater to control steam temperature. Feed water, generally taken before feed
water control station, is used for de-superheating steam to control its temperature at desired
level.


14 | P a g e

Technical data of the Boiler:
Manufacturer - M/s BHEL (C.E. Design)
Type Balanced Draft, Dry bottom, Single
Drum Controlled Circulation plus.
Type of FIRING Tilting TANGENTIAL
Minimum load at which steam generator can be
operated continuously with complete flame, stability
without oil support (& MCR)
2 adjacent, Mills at 50% capacity.
Minimum load at which the steam generator can be
operated continuously with complete flame stability
with oil support (% MCR)
20%

Maximum load for which individual mill beyond which
no oil support is required
50%


15 | P a g e

TURBINE & AUXILIARIES

Steam turbine converts the heat energy to mechanical energy and drives the alternator. The
velocity during expansion of steam depends on the initial and final heat content of the steam .
The turbines consist number of stages where the pressure drop takes place .

MAIN COMPONENTS OF TURBINES AND AUXILIARIES:

1. Turbine
2. Generator and Exciter
3. Condenser
4. LP and HP heater
5. Deareator
6. Boiler Feed Pump
7. Condensate extraction pump
8. Auxiliary oil pump

1. Turbine: A turbine is a series of fixed and rotating blades that extract the mechanical and
thermal energy from the steam. According to pressure of steam flow turbines can be
classified as

1. High Pressure Turbine
2. Intermediate pressure Turbine and
3. Low pressure turbine.

The specifications are given below:

16 | P a g e

2. Generator and Exciter: The Generator generates electrical power by the interaction of the
rotating magnetic fields of the stator and rotor. The Exciter supplies direct current power to
the electromagnet to produce the magnetic field within the generator.


17 | P a g e

Fig: Turbine & Generator

18 | P a g e

3. Condenser: After expansion at the turbine the wet vapour comes to condenser and
condensed to liquid water. The condenser used in DVC is a surface condenser which
of consist a large no of small diameter tubes. the cooling water passes through
individual tubes and steam flows over and around the tube bundles. The condensate is
collected at the bottom of the condenser known as the Hotwell.

4. LP and HP Heater : Both LP and HP heater are used to increase the temperature
of water or wet steam which enters the boiler, for increasing the mean temperature of
heat addition in the boiler to increase the overall efficiency.

5. Deareator: Deareator is used for the removal of oxygen and other dissolved gases
from the feed water to boilers.

6. Boiler feed pump: Boiler feed pump extracts water from de-aerator and feed it to
the boiler drum via H.P heaters and economizer. This is usually accomplished through
the use of a centrifugal pump. BFP is two types
Turbine driven boiler feed pump: It works with the steam extraction from
Intermediate Pressure (I.P.) turbine exhaust.
Motor driven boiler feed pump: It works with a motor as the name specifies
7. Condensate extraction pump: It extracts the condensate from the condenser and
sends it to the feed water tank after passing it through LP heater and deareator .

8. Auxiliary oil pump: Auxiliary oil system pump is used to supply oil at the start-up
of the steam turbine generator. It supplies the hydraulic oil system required for steam
turbine's main inlet steam stop valve, the governing control valves, the bearing and
seal oil systems, the relevant hydraulic relays and other mechanisms.


19 | P a g e

AIR AND FLUE GAS SYSTEM

AIR SYSTEM
Correct amount of air is the most essential ingredient for Combustion. More air or less air
both makes the combustion process inefficient.
Forced Draft Fan supplies most of the Combustion air. This fan takes air from the atmosphere
and blows it into the furnace through air ducts. The Air Heater heats the air before it enters
the Furnace.
Air Heater utilises the heat of the hot flue gases that leave the boiler to heat the combustion
air. Hot air improves the efficiency of combustion. The Air Heater works on the regenerative
principle. Steel plates alternatively placed in the hot flue gas path and then in the air path
heats the cold air entering the Air Heater.
Primary Air Fan supplies the air to the pulverisers for drying and transporting coal. This air
called the Primary air also is heated in the Air Heater.
FLUE GAS SYSTEM.
Coal burns in the furnace giving out heat and forming flue gases.
Induced Draft Fan. The hot flue gases from the furnace is drawn out by the Induced draft
fan. The gases passes through the various heating surfaces of the boiler, the Electrostatic
Precipitator and discharges to the atmosphere at the top of the stack. Induced Draft Fan
provides the energy for this flow of flue gases. The Induced Draft Fan is normally located
adjacent to the Stack.
Electrostatic Precipitators capture the fly ash in the flue gases without letting them out into
the atmosphere. High voltage electrodes placed in the gas path ionise the ash particles which
collects on collecting electrodes and falls into ash hoppers.
Stack or the Chimney disperses the hot gases and any other particles at a great height. The
height enables a very large dispersion area and regulates emission concentrations at ground
levels to the level acceptable to humans and vegetation. Stack heights for large power plants
are around 250 to 280 meters.
Balanced Draft. The Forced Draft fan and the Induced Draft fan operate in such a way that
the air pressure in the furnace is at zero pressure ie: at atmospheric pressure. This is called the
Balanced Draft system.


20 | P a g e

ASH HANDLING PLANT

INTRODUCTION
Ash is the residue remaining after the coal is incinerated. The composition of ash are SiO
2,
Al
2
O
3
, Fe
2
O
3
, CaO, MgO etc . In Thermal Power Plants coal is used as fuel and hence the
ash is produced as the byproduct of Combustion. Ash generated in power plant is about 30-
40% of total coal consumption and hence the system is required to handle Ash for its proper
utilization or disposal. The ash produced is two types , Fly ash and Bottom ash.
Ash generated in the ESP which got carried out with the flue gas is generally called
Fly ash. It also consists of Air pre heater ash & Economiser ash (it is about 2 % of the total
ash content). Ash generated below furnace of the steam generator is called the bottom ash.


21 | P a g e

ASH HANDLING SYSTEM
The ash handling system handles the ash by bottom ash handling system, coarse ash
handling system, fly ash handling system, ash disposal system up to the ash disposal area and
water recovery system from ash pond and Bottom ash overflow. Description is as follows:
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 pipe.
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.
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.
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.
Ash Slurry Disposal System
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.


22 | P a g e

The practical experience that I have gathered during the overview training
of large thermal power plant having a large capacity of 1000 MW for Unit#
I to II in two weeks will be very useful as a stepping stone in building bright
professional career in future life. It gave me large spectrum to utilize the
theoretical knowledge and to put it into practice. The trouble shooting
activities in operation and decision making in case of crisis made me more
confident to work in the industrial atmosphere. Moreover, this overview
training has also given a self realization & hands-on experience in
developing the personality, interpersonal relationship with the professional
executives, staffs and to develop the leadership ability in industry dealing
with workers of all categories. I would like to thank everybody who has
been a part of this project, without whom this project would never be
completed with such ease.


23 | P a g e

DVC Andal VT Report

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DVC Andal VT Report

Uploaded by

Copyright:

Available Formats

Training Report 2014

You might also like