PRO TREP OJECT PORT

(N.T.P.C C.BADARPUR,NEW WDELHI) )

INDUSTRIALT TRAINING GREPORT T

(SUBMITTEDINPAR RTIALFULFILLMENTOFTHEREQUIR RMENTOFT THECOURSE EOFB.TECH.)

AKENATN.T.P.C.BADAR RPUR,NEW DELHI UNDERTA m13 011to9thJu uly2011 From thMay20

SUBMITTE BY TED Y:
NIT JAIN TIN N G.B. P PANT EN NGINEE ERING C COLLEGE E OK KHLA PH HASE-III I, NE DELH EW HI-11002 20

1|P a g e

A C K NO WL E D G EM E N T
With respectful regards, I take the opportunity to convey my thanks to the management of Badarpur thermal power station division of National Thermal Power Corporation for giving me the opportunity to complete my summer training here. I do extend my heartfelt thanks to Mrs. Rachna Singh Bahal for providing me this opportunity to be a part of this esteemed organization. I am extremely grateful to all the technical staff of BTPS / NTPC for their co-operation and guidance that has helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted of them for this value addition in me. I would also like to thank the training incharge of G.B.P.E.C, Delhi and all the faculty members of Mechanical Engineering Department for their effort of constant co- operation, which have been a significant factor in the accomplishment of my industrial training.

NITIN JAIN G. B.P.E.C. (NEW DELHI)

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Training at BTPS
Iwasappointedtodo27daystrainingatthisesteemedorganizationfrom13thMay2011to 7thJuly2011.Inthese27daysIwasassignedtovisitvariousdivisionoftheplantwhichwere BoilermaintenancedivisionI(BMDI) BoilermaintenancedivisionII(BMDII) BoilermaintenancedivisionIII(BMDIII) Plantauxiliarymaintenancedivision(PAM) Turbinemaintenancedivision(TMD) This27Daystrainingwasaveryeducationaladventureforme.Itwasreallyamazingtosee theplantbymyselfandlearnhowelectricity,whichisoneofourdailyrequirementsoflife, isproduced.ThisreporthasbeenmadebyselfexperienceatBTPS.Thematerialinthis reporthasbeengatheredfrommytextbooks,seniorstudentreport,andtrainermanual providedbytrainingdepartment.Thespecification&principlesareatlearnedbymefrom theemployeeofeachdivisionofBTPS.

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CONTENT
A). THE

COMPANY

InstalledCapacity ProjectProfile BADARPURTHERMALPOWERSTATION Thermalpowerplant

B). BOILER MAINTENANCE DIVISION

MainBoilerBoilerFundamentals Boilers,theirclassificationandtypes CategorizationofBoilers Mainboiler Mainpartsofboiler Boilerdrum Furnace Combustionchamber Scraperconveyor Clinkergrinder Economizer Superheater Airpreheater Pulversingmill Contactmill Ballmill Bowlmill

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Fuelfiring Coal Oil Highpressureair Highpressuresafetyvalve ESP(ElectrostaticPrecipitator) Upgradation&RetrofittingofPollutionControlSystems ResourcesConservation

C). PLANT AUXILIARY MAINTENANCE DIVISION

Compressorhouse Gascompressor Centrifugalcompressor Diagonalormixedflowcompressor Axialflowcompressor Reciprocatingcompressor Rotaryscrewcompressor Diaphragmcompressor FourmaintypesofcompressorsusedattheBTPS DensvevorCompressors Plantcompressors Instrumentcompressors Blastaircompressors Stagedcompression Primemovers Controlstructurepumphouse Ashhandling WTPandgeomiller W.T.P.I&II Geomiller Clarifloculator Page|5

 Mixedbedexchanger ImportantSpecifications Thecoolingtower

D). TURBINE MAINTENANCE DIVISION

Mainturbine Typesofturbine Casingorshaftarrangement Principleofoperationanddesign Operationandmaintenance Speedregulation C.W.boosterpump Condenser Valve Types/Designations Valveparts Bodyandbonnet Ports Disc/rotor/valvemember Seat Stem Bonnet Spring Valveballs Materialofvalve Operativetype Sealingmaterial Condensatepumpgroup Boilerfeedpump

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THE COMPANY
NTPCLimited(formerlyNationalThermalPowerCorporation)wasfoundedonNovember7,1975. Today it is the largest stateownedpowergenerating company inIndia. It is anIndianpublic sectorcompanylistedontheBombayStockExchangealthoughatpresenttheGovernmentofIndia holds84.5%(afterdivestmentthestakebyIndiangovernmenton19thOctober,2009)ofitsequity. InNovember2004,NTPCcameoutwithitsInitialPublicOffering(IPO)consistingof5.25%asfresh issueand5.25%asofferforsalebyGovernmentofIndia.NTPCthusbecamealistedcompanywith Government holding 89.5% of the equity share capital and rest held by Institutional Investors and Public. The issue was a resounding success. NTPC is among the largest five companies in India in termsofmarketcapitalization.

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 InForbeslistofWorlds2000LargestCompaniesfortheyear2010,NTPCoccupies341thplace.The Company has power generating facilities in all major regions of the country. The total installed capacity of the company is 34894 MW (including JVs) with 15 coal based (25,815MW) and 7 gas based (3995MW) stations, located across the country. In addition under JVs, 5 stations are coal based&anotherstationusesnaphtha/LNGasfuel.Itisamongtheworldslargestandmostefficient powergeneration companies. NTPChas embarkedonplans to become a 75,000 MW company by 2017. NTPC has gone beyond the thermal power generation. It has diversified into hydro power, coal mining,powerequipmentmanufacturing,oil&gasexploration,powertrading&distribution.NTPC isnowintheentirepowervaluechainandispoisedtobecomeanIntegratedPowerMajor.

NTPC's share on 31 Mar 2008 in the total installed capacity of the country was 19.1% and it contributed28.50%ofthetotalpowergenerationofthecountryduring200708.NTPChassetnew benchmarks for the power industry both in the area of power plant construction and operations. With its experience and expertise in the power sector, NTPC is extending consultancy services to various organisations in the power business. It provides consultancy in the area of power plant constructions and power generation to companies in India and abroad. Recognising its excellent performance and vast potential, Government of the India has identified NTPC as one of the jewels of Public Sector 'Navratnas' a potential global giant. Inspired by its gloriouspastandvibrantpresent,NTPCiswellonitswaytorealiseitsvisionofbeing"Aworldclass integratedpowermajor,poweringIndia'sgrowth,withincreasingglobalpresence". Page|8

INSTALLED CAPACITY
An overview

NO. OF PLANTS

CAPACITY (MW)

NTPC Owned Coal Gas/Liquid Fuel Total Owned By JVs Coal & Gas Total 6 28 3,364 34,854 15 7 22 27,535 3,955 31,490

Regional Spread of Generating Facilities

REGION

COAL

GAS

TOTAL

Northern Western Southern Eastern JVs Total

8,015 7,520 4,100 7,900 1,424 28,959

2,312 1,293 350 1,940 5,895

10,327 8,813 4,450 7,900 3,364 34,854

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PROJECT PROFILE
Coal Based Power Stations
COAL BASED(Owned by NTPC) STATE COMMISSIONED CAPACITY(MW)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Singrauli Korba Ramagundam Farakka Vindhyachal Rihand Kahalgaon NCTPP, Dadri Talcher Kaniha Feroze Gandhi, Unchahar Talcher Thermal Simhadri Tanda

Uttar Pradesh Chhattisgarh Andhra Pradesh West Bengal Madhya Pradesh Uttar Pradesh Bihar Uttar Pradesh Orissa Uttar Pradesh Orissa Andhra Pradesh Uttar Pradesh

2,000 2,600 2,600 2,100 3,260 2,000 2,340 1,820 3,000 1,050 460 1,500 440

14. Badarpur
15. Total Sipat

Delhi
Chhattisgarh

705
1,660 27,535

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Coal Based Joint Ventures:

COAL BASED (Owned by JVs) STATE COMMISSIONED CAPACITY

1. 2. 3. 4. 5.

Durgapur Rourkela Bhilai Kanti IGSTPP, Jhajjar

West Bengal Orissa Chhattisgarh Bihar Haryana

120 120 574 110 500 1,424

Total

Gas/Liq. Fuel Based Power Stations

GAS BASED (Owned by NTPC) STATE COMMISSIONED CAPACITY(MW)

1. 2. 3. 4. 5. 6. 7.

Anta Auraiya Kawas Dadri Jhanor-Gandhar Rajiv Gandhi CCPP Kayamkulam Faridabad

Rajasthan Uttar Pradesh Gujarat Uttar Pradesh Gujarat Kerala Haryana

413 652 645 817 648 350 430 3,955

Total

Gas Based Joint Ventures:

COAL BASED (Owned by JVs) STATE COMMISSIONED CAPACITY

1.

RGPPL

Maharashtra

1940 1940

Total

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BADARPUR THERMAL POWER STATION

The Badarpur thermal power Station was planned by CWPC Central Water & Power Commission whichwasbifurcated lateronintoCentralElectricityAuthority(CEA)under MinistryofPowerand CentralWaterCommissionduringsixtiestocaterthegrowingneedsofpowerofDelhi.The area was selected which was out of city limits at that time and near the AGRA CANAL for its water requirements.TheareawasfullofstonesofARAVALlHILLS.Coalrequirementsofplantweretiedup withJHARIA/DHANBADcoalminesthroughnearbyTuglakabadrailwaystation. At that time, only three units of 95MW were planned and the work was given to Public Sector Company namely BHARAT HEAVY ELECTRICAL LIMITED (BHEL). Ministry of Power provided Rs.66 crorestoCEAfortheconstructionoffirststageofpowerhousewhichcomprisedthreeunitsof95 MW,linkcanalfromAgraCanal,&dischargecanaltoAgraCanal,CoalHandlingPlant,AshHandling Plant,AshDisposalarea,WaterTreatmentPlantandresidentialarea.Subsequently,twomoreunits wereplannedwithacapacityof210MWeachtakingfullcapacityto705MWatthecostofRs.170 crores.Outofthis705MW,65MWisconsumedbytheplantitselfandrest640MWistransmitted togridsothatitcanbedistributedtotheconsumers.Thepowergeneratedwastobeutilizedby themainbeneficiaryDelhiandtheadjoiningarealikeHaryana,D.P.&Rajasthan. Thelandwasacquiredin1967andworkstartedthereafter.Firstunitof95MWwassynchronizedon 23rdSeptember1973. PowergeneratedisutilisedbythebeneficiarystatesthroughagreementsofpurchasewithNTPC.As CEAwashavingonlyonePowerhousenamelyBTPS,itwasdecidedbytheMinistryofPowertohand over BTPS to NTPC in March 1978 on contract basis. BTPS has scaled many records of plant load factor(PLF)duringlastdecadeandalsoreceivedmanyrewardsfromMinistryofPowerforattaining highest PLF, lowest oil consumption. BTPS also attained ISO 9002 & ISO 14001 for Environment ManagementSystem.BTPShasplantedmanythousandtreesinitsareaforenvironmentcontrol.

Thermal power plant

Thermalpowerplantconvertstheheatenergyofcoaltoelectricalenergy.Coalisburntinaboiler which converts water into steam. The expansion of steam in turbine produces mechanical power whichdrivesthealternator.Thusthemainequipmentinthethermalpowerplantconsistsofboiler, steamturbineandalternator.Toachieveefficientconversionofheatenergyintoelectricalenergya varietyofauxiliaryequipmentareneeded. Page|12

BASIC PRINCIPLE BASIC PRINCIPLE

Thebasicrawmaterialsrequired for theplants are coal, air andwater.Thecoal is brought tothe station by trains from Bihar, A.P, Orissa and M.P. coal is unloaded from the wagon by the help of wagon tipplers. Then coal is transferred from coal handing plant by conveyor belt to the coal bunkers,fromwhereitisfedtothepulverisingmills,whichgrinditasfineasfacepower.Thefinally poweredcoalmixedwithpreheatedairisthenblownintotheboilerbyafancalledPrimaryAirFan, whereitburns,morelikeagasthenasasolidintheconventionaldomesticorindustrialgrate,with additional amount of air called secondary air supplied by a Force Draft Fan. As the coal has been ground so finely, the resultantash is alsoa fine powder. Some of itbinds together to form lumps whichfallintotheashpitsatthebottomofthefurnace.Thewaterquenchedashfromthebottom ofthefurnaceisconveyedtopitsforsubsequentdisposalorsale.Mostoftheash,stillinthefine particle form is carried out of the boiler to the precipitators as dust, where it is trapped by electrodes changed with high voltage electricity. The dust is then conveyed by water to disposal areasortobunkersforsale.WhilethecleanedfluegassespassonthroughI.D.Fantobedischarged up the chimney. The steam which has given up its heat energy is changed back into water in a condensersothatitisreadyforreuse.Thecondensercontainsmanykilometersoftubingthrough whichcoldwaterisconstantlypumped. Coupledtotheendoftheturbineistherotorofthegenerator,alargecylindricalmagnetsothat when the turbine rotates the rotor turns with it, the rotor housed inside the stator having heavy coils of cooper bars in which electricity is produced through the movement of the magnetic field created by the rotor. The electricity passes from the stator windings to the stepup that it can be transmittedefficientlyoverthepowerlineofthegrid. Meanwhiletheheatreleasedfromthecoalhasbeenabsorbedbymanykilometersoftubingwhich linetheboilerwalls.Insidethetubesistheboilerfeedwaterwhichistransformedbytheheatinto steam at high pressure and temperature. The steam, super heated in further tube (Super Heater) passes to the turbine, where it is discharged through nozzles on the turbine blades. Just as the energyofthewindturnsthesailsofthewindmill,sotheenergyofsteam,strikingtheblades,makes theturbinerotate.Loosesheatandisrapidlychangedbacktowater.Butthetwolotsofwater(i.e. boilerfeedwaterandcoolingwater)mustnevermix.Thecoolingwaterisdrawnfromtheriver/sea, buttheboilerfeedwatermustbeabsolutelypure,farpurerthanthewater,whichwedrink.Indeed thechemistryatapowerstationislargelychemistryofwater. Whybothertochangethesteamfromtheturbinebackintowaterifithastobeheatedupagain immediately? The answer lies in the law of physics, which states that the boiling point of water is directly proportionaltopressure.Thelowerthepressure,thelowerthetemperatureatwhichwaterboils. Page|13

Theturbinedesignedwantsaslowboilingpointaspossiblebecausewecanonlyutilizetheenergy from steam when the steam changes back to water we can get no more work out of it. So a condenserisrequiredbywhichrapidlychangingthesteambackintowatercreatesavacuum.The vacuumresultsinamuchlowerboilingpointwhich,inturn,meanswecancontinuegettingwork outofthesteamwetbelow100Catwhichitwouldnormallychangeintowater. To condense the large quantities to steam, huge and continuous volume of cooling water is essential.In mostof thepowerstation, thesamewateris to beused overandoveragain.So the heatwhichthewaterextractsfromthesteaminthecondenserisremovedbypumpingthewater out to the cooling towers. The cooling towers are simple concrete shells acting as huge chimneys creatingadraught(naturemechanicallyassistedbyfans)ofair,thewaterissprayedoutattopof thetowersandasitfallsintothepondbeneathitiscooledbytheupwarddraughtofair.Thecold waterinthepondisthenrecalculatedbypumpstothecondensers,inevitably,however,someofthe waterisdrawnupwardasavaporsbythedraughtanditisthiswaterwhichformsthefamiliarwhile clouds which emerge from the towers seen sometimes.

MOD F ED RANK NE CYCLE The Badarpur Thermal Power Plant works onMODIIFIIEDRANKIINECYCLE . It is a cycle that
convertsheatintowork.Theheatissuppliedexternallytoaclosedloop,whichusuallyuseswater. Process12representstheadmissionofhighpressuresteamintotheenginecylinder, process23isthereversibleadiabaticexpansionofsteaminthecylinderandprocess 34istheexhaustofsteamintocondenser.Networkdoneisrepresentedbythearea1 2341. Observethatthearea365isverysmallandinordertoobtainthissmallwork,thecylindervolume mustbeincreasedfromv6tov3.Thismakescylinderverybulky.Forthisreason,theexpansion processisterminatedatpoint5.Sothatindicatordiagrambecomes12564.Theworklostissmall butthereislargesavingincylindervolume. Process56representsthereleaseofsteamintothecondenser,thuscausingthecylinderpressure todropfromP5toP6.Process64istheexhaustofsteamatconstantpressure.Cycle12564is calledasthemodifiedRankinecycle.

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BMD BOILER MAINTENANCE DEPARTMENT

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Main Boiler - Boiler Fundamentals:

Theobjectiveofthischapteristoacquaintthereaderswiththebasicsofcombustion,Theory,types andclassificationofboilersandanoverviewofthearrangementofvariousBoileraccessories.

PRINCIPLES OF COMBUSTION:
Theprimaryfunctionofoilandcoalburningsystemsintheprocessofsteamgenerationistoprovide controlledefficientconversationofthechemicalenergyofthefuelintoheatenergywhichisthen transferredtotheheatabsorbingsurfacesofthesteamgenerator. The combustion elements of a fuel consist of carbon, hydrogen and usually a small amount of sulphur. When combustion is properly completed the exhaust gases will contain, carbon dioxide, watervapour,sulphurdioxideandalargevolumeofNitrogen,combiningcarbonandhydrogenor hydrocarbons with the oxygen in air brings about Combustion. When carbon burns completely, it resultsintheformationofagasknownascarbondioxide.Whencarbonburnsincompletelyitforms carbonmonoxide. Compositionofair:thesupplyofoxygenforcombustionisobtainedfromair.Thisisasimportantas thesupplyoffuel.Theaveragecompositionofairis 79%nitrogenand21%oxygenbyvolume 77%nitrogenand23%oxygenbyweight Nitrogen does not burn but passes through the combustion chamber to the chimney unchanged exceptingitstemperature. Ignition:Fuelmustbeignitedbeforeitcanburn.Raisingthetemperatureofthefueltoitsignition temperaturebringsaboutcombustion.Thistemperaturevarieswithdifferentfuels. Excess air: The amount of air required to burn any fuel can be calculated if the amount of the elements present in the fuel are known. This amount of air is known as the theoretical air. In practice this quantity is not sufficient to ensure complete combustion and extra air has to be supplied.Thisextraairisknownasexcessair.

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Thelossofcombustiblesandsunburngaslossreducesasexcessair is addedreachmaximum and any further additions of excess air beyond this stage, the boiler losses increase. Thus there is one andonlyonequantityofexcessair,whichwillgivethelowestcombustionloss.Thevalueofexcess airneededdependsuponthefuelused,thetypeoffiringetc. Thefollowingfactorsinefficientcombustionareusuallyreferredtoas"ThethreeT's: Time:Itwilltakeadefinitetimetoheatthefueltoitsignitiontemperatureandhavingignited,itwill also taketimetoburn.Consequently sufficient timemustbe allowed for complete combustionof thefueltotakeplaceinthechamber. Temperature: A fuel will not burn until it has reached its ignition temperature. Preheating the combustionairincreasesthespeedatwhichthisTemperaturewillbereached.Thetemperatureof theflameoftheburningfuelmayvarywiththequantityofairused.Toomuchcombustionairwill lowertheflametemperatureandmaycauseunstableignition. Turbulence:Turbulenceisintroducedtoachievearapidrelativemotionbetweentheairandthefuel particles. It is found that this produces a quick propagation of the flame and its rapid spread throughoutthefuel/airmixtureinthecombustionchamber. Combustionefficiency:Itvarieswithindividualdifferentgradesoffuelwithineachboiler.Theidea tobeaimedatisthecorrectquantityofairtogetherwithgoodmixingoffuelandairtoobtainthe maximumheatrelease.Maximumcombustionefficiencydependson Designoftheboiler Fuelused Skillinobtainingcombustionwiththeminimumamountofexcessair. Thermal efficiency of a boiler is measured by the amount of heat transferred to the water in the boilerbyeachKgoffuelusedandisexpressedasapercentageofthetotalheatenergyinoneKg.of fuel.Thethermalefficiencyisdependentonthefactorsgoverningefficientcombustion. Boilers,theirclassificationandtypes: Boilerisadeviceforgeneratingsteamforpower,processingorheatingpurposes. Boilerisdesignedtotransmitheatfromanexternalcombustionsource(usuallyfuelcombustiontoa fluid)containedwithintheboileritself.

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 The heatgenerating unit includes a furnace in which the fuel is burned. With the advantage of watercooledfurnacewalls,superheaters,airheatersandeconomizers,thetermsteamgenerator wasevolvedasabetterdescriptionoftheapparatus. Boilersmaybeclassifiedonthebasisofanyofthefollowingcharacteristics: Use:Thecharacteristicsoftheboilervaryaccordingtothenatureofserviceperformed. Customarilyboileriscalledeitherstationaryormobile.Largeunitsusedprimarilyforelectricpower generationareknownascontrolstationsteamgeneratororutilityplants. Pressure: To provide safety control over construction features, all boilers must be constructed in accordancewiththeBoilercodes,whichdifferentiatesboileraspertheircharacteristics. Materials: Selection of construction materials is controlled by boiler code material specifications. Powerboilersareusuallyconstructedofspecialsteels. Size:Ratingcodeforboilerstandardizethesizeandratingsofboilersbasedonheatingsurfaces.The sameisverifiedbyperformancetests. Use Pressure Materials Size TubeContent TubeShapeandposition Firing HeatSource Fuel Fluid Circulations Furnaceposition Furnacetype Generalshape Tradename Specialfeatures.

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Tube Contents: In addition to ordinary shell type of boiler, there are two general steel boiler classifications,thefiretubeandwatertubeboilers.Firetubeboilerisboilerswithstraighttubesthat are surroundedbywater and through whichthe productsofcombustion pass.Water tube boilers are those, in which the tubes themselves contain steam or water, the heat being applied to the outsidesurface. Firing: The boiler may be a fired or unfired pressure vessel. In fired boilers, the heat applied is a productoffuelcombustion.Anonfiredboilerhasaheatsourceotherthancombustion. HeatSource:Theheatmaybederivedfrom(1)thecombustionoffuel(2)thehotgassesofother chemicalreactions(3)theutilizationofnuclearenergy. Fuel:Boilersareoftendesignatedwithrespecttothefuelburned. Fluid:Thegeneralconceptofaboileristhatofavesseltogeneratesteam.Afewutilitiesplantshave installedmercuryboilers. Circulation:Themajorityofboilersoperatewithnaturalcirculation.Someutilizepositivecirculation inwhichtheoperativefluidmaybeforced'oncethrough'orcontrolledwithpartialcirculation. FurnacePosition:Theboilerisanexternalcombustiondeviceinwhichthecombustiontakesplace outsidetheregionofboilingwater.Therelativelocationofthefurnacetotheboilerisindicatedby thedescriptionofthefurnaceasbeinginternallyorexternallyfired. The furnace is internally fired if the furnace region is completely surrounded by water cooled surfaces.Thefurnaceisexternallyfiredifthefurnaceisauxiliarytotheboiler. Furnacetype:Theboilermaybedescribedintermsofthefurnacetype. General Shape: During the evaluation of the boiler as a heat producer, many new shapes and designshaveappearedandthesearewidelyrecognizedinthetrade. TradeName:Manymanufacturerscointheirownnameforeachboilerandthesenamescomeinto commonusageasbeingdescriptiveoftheboiler. Page|19

 Special features: some times the type of boiler like differential firing and Tangential firing are described. CategorizationofBoilers: Boilersaregenerallycategorizedasfollows: Steelboilers FireTubetype Watertubetype HorizontalStraighttube MAINBOILER A boiler is a closed vessel in which the heat produced by the combustion of fuel is transferred to waterforitsconversationintosteamofthedesiredtemperature&pressure. Thesteamproducedmaybesuppliedtoturbineforpowergeneration. Theboilerisgenerallyusedforpowerproductionaretwotypes: 1.Cornerboiler 2.Frontfireboiler The boiler mainly has natural circulation of gases, steam and other things. They contain vertical membranewater.Thepulverizedfuelwhichisbeingusedinthefurnaceisfixedtangentially.They consumeapproximately700ton.\hrofcoalofabout1370kg\cm2ofpressurehavingtemperatureof 540c TheboilerusedismanufacturedbyBHELof210MW.Thefirstpassoftheboilerhasacombustion chamberenclosedwithwaterwallsoffusionweldedconstructiononallfoursides.Inadditionthere arefourwaterplatenstoincreasetheradiantheatingsurface. Beside this platen super heater reheater sections are also suspended in the furnace combustion chamber.Thefirstpassisahighheatzonesincethefuelisburninthispass. Page|20

Thesecondpassissurroundedbysteamcooledwallsonallfoursidesaswellasroofoftheboiler.A horizontalsuperheater,aneconomiser&twoairheatersarelocatedinthesecondpass.

MAIN PARTS OF THE BOILER

BOILERDRUM Its main function is to separate steam from water. It is a circular vessel in which water level is maintained at 10" below the centre of the drum. The wet steam enters in the drum through the waterwallofboiler. The drum consists of baffles and thin fine sieves trough which wet steam passes. The baffles provided number of plates in downward slope direction. The wet steam first passes trough these bafflesandafterthatitpassesthroughthinsievesatthetopofdrum. Thewaterdropletsinthesteamfalldownthroughbafflesandsieves.Thepuresteampassestoroot panels. Thewaterindrumisattachedwithdowncomerandrisers.Thewaterintheboilerisfedthroughthe downcomers. Weight123tonnes Lengthl5700mm Innerdiameterl676mm Outerdiameter1942mm Materialcarbonsteel Pressurel50.7g\cm2 Temp342c

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 FURNACE It is the main part of the boiler where the fuel or coal is burnt and produce lots of heat and flue gasestoconvertthewaterintosteam. Height42.797m Lengthl3.868m Width10.592m Volume52l0m3 Tostarttheproductionunit,firstlypulverisedcoalisfedtothefurnacethroughapump. For fuel burning, ignition temperature and pressure are also necessary. The burning of coal completelyandraisethetemperaturetoanapproximatelylevel.Initiallyairandoilarealsofedtoit through F.D. fan and oil gun respectively. Then when the temperature is reached to the required levelcoalstartsburningandproduceslotsofheatandfluegases.Thewatertubeflowinginsidethe boilercontainingwaterturnsintowetsteam.Itisawatertubeboiler. Page|22

COMBUSTIONCHAMBER It is made of seamless steel tubes and walls are joined by fusion weld. Walls on all sides are rectangularincrosssection.Thespacebetweenthewaterwallstubesisoffusionweldedtoforma complete gas tight seal.These are four platenwater walls inthecombustionchamber to increase theheatingsurface.Thefrontandbottomwallsslopedowntowardthecentreoffurnacetoform inclinedsidesofthebottom.Ashfromthefurnaceisdischargedthroughthebottomopeninginto bottomashhopper. SCRAPERCONVEYOR Thescraperconveyorisusedfortwofunctions: Removeashfromthecombustionchamber Provideceilingtoboiler Thescraperconveyerismountedatthebottomoffurnacewhereashiscollectedafterburningthe coalandremovesfromtheboiler.Scraperconveyerisgenerallyusedforremovingheavydust. Capacity20tonnes\hr Bodymildsteel. Linerssailyard Scraperms CLINKERGRINDER Itisanapparatuswhichisconnectedwithscraperconveyerforthepurposeofremovingashfrom the boiler. The heavy long ash pieces are crushed in the clinker grinder so that they can be easily flowoutfromtheboiler. ECONOMISER Itisusedforutilizetheheatoffluegasessinceforimprovingthetemperatureoffeedwatersothat theefficiencyoftheboilerisincreased. Thefluegaswhenleavestheboileritstemperatureishigherthenthetemperatureoffeedwaterso the waste heat of flue gases can be utilized. It is mounted at the second pass of the boiler. It is arrangedbetweenthefeedpumpanddrums. Thetemperaturebeforeenteringtheeconomiseris240degreecentigrade. Thetemperatureafterdischargingtheeconomiseris280degreecentigrade. Page|23

SUPERHEATER It is an apparatus which is used to increase the efficiency of boiler the super heater used are generallyfourtypes: 1.SealingSH 2.LowertemperatureSH 3.RadiantSH 4.FinalSH Thefunctionofsuperheateristoconvertthewetsteamintodrysteam.Thewetsteamfromthe boilerisenteredintothelowtemperaturesuperheaterandthenintoradiantsuperheaterandthen finallyintofinalsuperheaterandpassedtomainsteamline. AIRPREHEATER TheAirpreheaterisusedintheboilerforimprovingefficiencyandtransferringheatfromfluegasto secondary air and primary air. The air entering the boiler furnace is at a low temperature as comparedtothetemperatureofexhaustfluegases.Theairisheatedbytheheatcarriedawayby thefluegasesandgoingasawastethroughchimney.Itissituatedbetweentheeconomiserandthe chimney. The plant efficiency is increase by the air prehearter. It is mounted on the 2nd pass. The APH are usedaretabularAPH.Inthetabulartube,theairpassesdownoutsidethetubesandthefluegases throughthetubesbeforegoingtoIDfanatthebaseofthechimney.

PULVERISING MILL
1.CONTACTMILL Ithasstationaryandpowerdrivenrotatingelementshavingarollingactionwithrespect toeachother.Coalismadetopasstroughtheseelementsagainandagaintillitis pulverized.Hotairiscirculatedwhichtakesawaythefineparticletotheburner. 2.BALLMILL Alargecylinderordrumpartlyfilledwithvarioussizedballisusedinthismill,the cylinderisrotatedatapproximately17to20rpmwhilecoaliscontinuouslyfedintoit, hotairentersthecylindersdriesthecoalduringpulverizationandcarriespulverizedcoal toburner. 3.BOWLMILL Inthebowlmill,crushedcoalispulverizedandfurtherdriedbyhotprimaryair.A portionofprimaryairfromP.A.fandischargesisheatedfromthistypesector. Page|24

FUEL FIRING
Therearemainlythreecomponentswhichareusedinfuelfiring: 1.Pulverisedcoal 2.Highpressureair 3.Oil COAL The coal has various varieties. The coal which is used out they should have high calorific value, produce maximum heat produce less ash and pollution on burning easily available, low cost etc. these features are available in bituminous coal, which is used in the plant. It has about 9095% carbon and its caloric value varies between 36004200. Coal is brought in large pieces, so in first stagethecoalisfinallycrushedsothatitburnscompletely. Thenitissentthefurnacethroughconveyorbelt.Inthefurnacethecoalburnsandproducessteam. Theashwhichgetscollectedinthescraperisremovedtimetotimewiththehelpofwater.Itsmain functionistoproducelotofheatsoasstoconvertwaterintosteam. OIL Oilissuppliedwiththehelpofoilguntocoalsothatthecoalcanbeeasilyburn. HIGHPRESSUREAIR High pressure air is introduced into the furnace so that the coal can be reached at ignited temperature.ThehighpressureairfromfanisintroducedtothefurnacethroughF.Dfan. Thesuccessfullyworkingofanoilfiringequipmentdependsonthefollowing: I.Thecorrectdesignofcontrolflow. 2.Thedesignofcombustionchamber. 3.Thedesignoftheeconomiserwhichmustbeabletoreducethefueltoafinallydividedstay.

HIGH PRESSURE SAFTY VALVE

It is a device which comes into operation when the pressure in the boiler exceeds the working pressure. It discharges some of the steam automatically out of the boiler and brings the pressure downtothenormalworkinglimit.Therearemanytypeofvalvesbutthevalveusedisspringloaded Page|25

safetyvalve.Inthisvalvethevalverestonitsseatundertheactionofspring.Thevalveisfittedon thedrum.Whensteampressureexceedsthenormalworkinglimit,thesevalvesareliftedfromtheir seatsallowingpassageforsteamtoescapeouttillthepressurefallsbelowthespecifiedlimitafter whichthevalveagainrestontheseal.ItismadeupofC.I.

ESP (ELECTROSTATIC PRECIPITATOR)

Whencoalisburntintheboilerashisliberatedandcarriedalongwithfluegasesiftheseashesare exhaustedtotheatmosphere.Itwillcreatepollutionresultinginhealthhazard.Henceitisnecessary toprecipitatethedustfromthefluegasesandinthisprocessisESPfindsplaceinthepowerplant.In 21OMw11OTofcoalburnsperhourandifcoalcontents30%ashthenashcarriedalongwithflue gaseswillbe33Tonns\hr.

ADVANTAGES
1.Higherefficiency 2.Minimumcost 3.Lowmaintenance 4.Largevolumeofashparticle 5.Createslesspollution

DISADVANTAGES
1.Highinitialcost 2.Lossofefficiencywhenflowisabovethedesiredrate 3.Unpredictableefficiency

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UPGRADATION & RETROFITTING OF POLLUTION CONTROL SYSTEMS:

Inordertokeeppacewiththechangingnormsandensurecompliancewithstatutoryrequirements inthefieldofpollutioncontrol,NTPCkeepsanopenmindforRenovationandModernization(R& M)andRetrofittingandUpgradationofpollutionmonitoringandcontrolfacilitiesinitsexisting stations.Itisimportanttomentionthatsuchmodifications/retrofitprogramsnotonlyhelpedin bettermentofenvironmentbutalsoinresourceconservation. High efficiency ElectroStatic Precipitators (ESPs) of the order of 99.5% and above have been providedatNTPCstationsforcontrolofstackparticulateemissions.However,theESPsofanumber of stations were built prior to the promulgation of the Environment (Protection) Act, 1986 and notification of emission control standards under this Act. Remedial measures have already been takenupandimplementedtoimprovetheefficiencyoftheexistingESPsatvariousNTPCstations. ESP performance enhancement programme by adopting advanced microprocessor based Electrostatic Precipitator Management System (EPMS) was installed at its power stations at Singrauli, Ramagundam, Korba, Farakka, Rihand, Vindhyachal and Unchahar. Additional ESPs were retrofittedintheolderpowerstations,namelyatBadarpurandTalcherThermal.Asaresultofthe above retrofits, the emission of Suspended Particulate Matter (SPM) has been brought down appreciably at the above stations and is maintained within the present statutory limit of 150 mg/Nm3. In new projects, the ESPs have been designed for a maximum permissible outlet dust emissionof50mg/Nm3tomeetthelikelystringentemissionnormsinthenearfuture.

RESOURCES CONSERVATION
With better awareness and appreciation towards ecology and environment, the organization is continually looking for innovative and cost effective solutions to conserve natural resources and reducewastes.Someofthemeasuresinclude:

Reductioninlandrequirementsformainplantandashdisposalareasinnewerunits. Capacityadditioninoldplants,withinexistingland. Reductioninwaterrequirementformainplantandashdisposalareasthroughrecycleand reuseofwater. EfficientuseofFuel(Coal,NaturalgasandFueloil)and Reductioninfuelrequirementthroughmoreefficientcombustionandadoptionofstateof thearttechnologiessuchassupercriticalboilers

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PA M PLANT AUXILIARY MAINTENANCE

COMPRESSORHOUSE CONTROLSTRUCTUREPUMPHOUSE ASHPUMPHOUSE WTP COOLINGTOWER

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GAS COMPRESSOR
Agascompressorisamechanicaldevicethatincreasesthepressureofagasbyreducingitsvolume.

Centrifugalcompressors Centrifugalcompressorsusearotatingdiskorimpellerinashapedhousingtoforcethegastothe rimoftheimpeller,increasingthevelocityofthegas.Adiffuser(divergentduct)sectionconvertsthe velocity energy to pressure energy. They are primarily used for continuous, stationary service in industries such as oil refineries, chemical and petrochemical plants and natural gas processing plants. Their application can be from 100 hp (75 kW) to thousands of horsepower. With multiple staging,theycanachieveextremelyhighoutputpressuresgreaterthan10,000psi(69MPa). Diagonalormixedflowcompressors Diagonal or mixedflow compressors are similar to centrifugal compressors, but have a radial and axialvelocitycomponentattheexitfromtherotor.Thediffuserisoftenusedtoturndiagonalflow to the axial direction. The diagonal compressor has a lower diameter diffuser than the equivalent centrifugalcompressor. Axialflowcompressors Axialflow compressors are dynamic rotating compressors that use arrays of fanlike aerofoils to progressively compress the working fluid. They are used where there is a requirement for a high flowsoracompactdesign. Thearraysofaerofoilsaresetinrows,usuallyaspairs:onerotatingandonestationary.Therotating aerofoils,alsoknownasbladesorrotors,acceleratethefluid.Thestationaryaerofoils,alsoknownas a stators or vanes, turn and decelerate the fluid; preparing and redirecting the flow for the rotor Page|29

bladesofthenextstage.Axialcompressorsarealmostalwaysmultistaged,withthecrosssectional area of the gas passage diminishing along the compressor to maintain an optimum axial Mach number.Beyondabout5stagesora4:1designpressureratio,variablegeometryisnormallyusedto improveoperation. Axial compressors can have high efficiencies; around 90% polytropic at their design conditions. However, they are relatively expensive, requiring a large number of components, tight tolerances and high quality materials. Axialflow compressors can be found in medium to large gas turbine engines,innaturalgaspumpingstations,andwithincertainchemicalplants. Reciprocatingcompressors Reciprocating compressors use pistons driven by a crankshaft. They can be either stationary or portable,canbesingleormultistaged,andcanbedrivenbyelectricmotorsorinternalcombustion engines. Small reciprocating compressors from 5 to 30horsepower (hp) are commonly seen in automotiveapplicationsandaretypicallyforintermittentduty.Largerreciprocatingcompressorsup to1000hparestillcommonlyfoundinlargeindustrialapplications,buttheirnumbersaredeclining astheyarereplacedbyvariousothertypesofcompressors.Dischargepressurescanrangefromlow pressure to very high pressure (>5000 psi or 35 MPa). In certain applications, such as air compression,multistagedoubleactingcompressorsaresaidtobethemostefficientcompressors available,andaretypicallylarger,noisier,andmorecostlythancomparablerotaryunits. Rotaryscrewcompressors Rotary screw compressors use two meshed rotating positivedisplacement helical screws to force the gas into a smaller space. These are usually used for continuous operation in commercial and industrialapplicationsandmaybeeitherstationaryorportable.Theirapplicationcanbefrom3hp (2.24kW)toover500hp(375kW)andfromlowpressuretoveryhighpressure(>1200psior8.3 MPa).Theyarecommonlyseenwithroadsiderepaircrewspoweringairtools.Thistypeisalsoused formanyautomobileenginesuperchargersbecauseitiseasilymatchedtotheinductioncapacityof apistonEngine Diaphragmcompressors Adiaphragmcompressor(alsoknownasamembranecompressor)isavariantoftheconventional reciprocatingcompressor.Thecompressionofgasoccursbythemovementofaflexiblemembrane, insteadofanintakeelement.Thebackandforthmovementofthemembraneisdrivenbyarodand acrankshaftmechanism.Onlythemembraneandthecompressorboxcomeintouchwiththegas beingcompressed. TherearefourmaintypesofcompressorsusedattheBadarpurThermalPowerStation. Theseareasfollows: DensvevorCompressors: It is the most important compressor used at B.T.P.S. These are four in number. One Densveyor compressorisconnectedwitheachmill.Itprovidestheprimaryaswellassecondaryairtotheplant. Page|30

These compressors are automatically operated. It carries the coal directly from the mills to the furnace.Thesecompressorsworkunderamaximumpressureof8kgf. Plantcompressors: Thesecompressorsaretwoinnumber.Plantcompressorsaremoisturetypecompressors. Thesearemainlyusedforwashingtheashformedinthefurnaceanddisposingthemoff. Thesecompressorsworkunderamaximumpressureof8kgf. Instrumentcompressors: These are dry type compressors. These are used to operate different instruments. These compressorsarethreeinnumber.Thesealsoworkunderamaximumpressureof8kgf. Blastaircompressors: These compressors are smaller in size and are not as important as the other three types of compressors.ThecoalintheRC(rawcoal)bunkerssometimesstickstothesurfaceofthebunkers duetomoisturecontentinthecoal.Insuchcases,blastaircompressorsareusedtodetachthecoal fromthesurfaceoftheRC(rawcoal)bunkers. TEMPERATURE Compressionofagasnaturallyincreasesitstemperature. In an attempt to model the compression of gas, there are two theoretical relationships between temperature and pressure in a volume of gas undergoing compression. Although neither of them modeltherealworldexactly,eachcanbeusefulforanalysis.Athirdmethodmeasuresrealworld results: Isothermal This model assumes that the compressed gas remains at a constant temperature throughoutthecompressionorexpansionprocess.Inthiscycle,internalenergyisremovedfromthe systemasheatatthesameratethatitisaddedbythemechanicalworkofcompression.Isothermal compression or expansion more closely models real life when the compressor has a large heat exchangingsurface,asmallgasvolume,oralongtimescale(i.e.,asmallpowerlevel).Compressors that utilize interstage cooling between compression stages come closest to achieving perfect isothermal compression. However, with practical devices perfect isothermal compression is not attainable. For example, unless you have an infinite number of compression stages with correspondingintercoolers,youwillneverachieveperfectisothermalcompression. Adiabatic This model assumesthatnoenergy (heat) istransferred toorfromthe gas during the compression,andallsuppliedworkisaddedtotheinternalenergyofthegas,resultinginincreases oftemperatureandpressure.TheoreticaltemperatureriseisT2=T1Rc(k1)/k,withT1andT2indegrees Rankineorkelvins, andk=ratioof specificheats(approximately1.4forair).Risthecompression Page|31

ratio;beingtheabsoluteoutletpressuredividedbytheabsoluteinletpressure.Theriseinairand temperatureratiomeanscompressiondoesnotfollowasimplepressuretovolumeratio.Thisisless efficient, but quick. Adiabatic compression or expansion more closely model real life when a compressorhasgoodinsulation,alargegasvolume,orashorttimescale(i.e.,ahighpowerlevel).In practicetherewillalwaysbeacertainamountofheatflowoutofthecompressedgas.Thus,making aperfectadiabaticcompressorwouldrequireperfectheatinsulationofallpartsofthemachine.For example,evenabicycletirepump'smetaltubebecomeshotasyoucompresstheairtofillatire. PolytropicThismodeltakesintoaccountbothariseintemperatureinthegasaswellassomeloss of energy (heat) to the compressor's components. This assumes that heat may enter or leave the system,andthatinputshaftworkcanappearasbothincreasedpressure(usuallyusefulwork)and increased temperature above adiabatic (usually losses due to cycle efficiency). Compression efficiency is then the ratio of temperature rise at theoretical 100 percent (adiabatic) vs. actual (polytropic). In the case of the fire piston and the heat pump, people desire temperature change, and compressinggasisonlyameanstothatend. STAGEDCOMPRESSION Sincecompressiongeneratesheat,thecompressedgasistobecooledbetweenstagesmakingthe compression less adiabatic and more isothermal. The interstage coolers cause condensation meaning water separators with drain valves are present. In the case of small reciprocating compressors, the compressor flywheel may drive a cooling fan that directs ambient air across the intercoolerofatwoormorestagecompressor. Because of mechanical limitations and to increase efficiency, most compressors utilize staged compression, usually with intercooling between stages. In the case of centrifugal compressors, commercial designs currently do not exceed more than a 3.5 to1 ratio in any one stage. Because rotary screw compressors can make use of cooling lubricant to remove the heat of compression, they very often exceed a 9 to 1 ratio. For instance, in a typical diving compressor the air is compressed in three stages. If each stage has a compression ratio of 7 to 1, the compressor can output343timesatmosphericpressure(7x7x7=343Atmospheres). PRIMEMOVERS Therearemanyoptionsforthe"primemover"ormotorwhichpowersthecompressor:gasturbines power the axial and centrifugal flow compressors that are part of jet engines. steam turbines or water turbines are possible for large compressors, electric motors are cheap and quiet for static compressors. Small motors suitable for domestic electrical supplies use single phase alternating current. Larger motors can only be used where an industrial electrical three phase alternating current supply is available. Diesel engines or petrol engines are suitable for portable compressors andsupportcompressorsusedassuperchargersfromtheirowncrankshaftpower.Theyuseexhaust gasenergytopowerturbochargers Page|32

CONTORL STRUCTURE PUMP HOUSE

TheCSPHisjustlocatedneartheentranceofBTPSattheleftsideoftheway,thebasicworkofCSPH istotreattherawwatercomingfromthelake,thiswaterisfirsttreatedinCSPHandthendelivered totheotherunitssuchasWTPcoolingtowerESPetc. Thewaterisreceivedfromlakeistotallydirtyandfullofhardandthickimpurities.Thewaterisfirst screenedofusingthescreenwashpumprotatingcontinuouslyconsistingoffilter. THECSPHHASFOLLOWINGPUMPS: S.NO. 1. 2. 3. Number of Operating pumpinBTPS pressure CRW (clarify raw water 3 1kg pump) FS(firescreening) 2 6kg HP(highpressurepumps) 6 67kg Name Use Toclarifyrawwater Firefighting 2 used for cooling turbine water, 3 for disposal of ash from ESP and 1 for pressuring low pressurepump Forscreeningoftraveling water ForEPpumphouse Forchlorinationofwater

4. 5. 6.

TWS (traveling water 7 screening) LP(lowpressurepumps) 3 Chlorinepumps 2

7kg 22.5kg

ASH HANDLING
AshutilizationisoneofthekeyconcernsatNTPC.TheAshUtilizationDivision,setupin1991,strives toderivemaximumusagefromthevastquantities ofash producedatitscoalbasedstations.The divisionproactively formulatespolicy,plansandprogrammeforashutilization.Itfurthermonitors the progress in these areas and works at developing new fields of ash utilization. Pumpsusedforashhandling: S.NO. 1. 2. 3. 4. PUMP 1 2 3 4 LUBRICANT Servo57/68oil Servo40oil Servo40oil Servo40oil CAPACITY 1000m3/hr 1300m3/hr 1300m3/hr 1300m3/hr Page|33

ThequalityofashproducedconformstotherequirementsofIS3812.TheflyashgeneratedatNTPC stations is ideal for use in cement, concrete, concrete products, cellular concrete, lightweight aggregates, bricks/blocks/tiles etc. This is attributed to its very low loss on ignition value. To facilitateavailabilityofdryashtoendusersallnewunitsofNTPCareprovidedwiththefacilityof dry ash collection system. Partial dry ash collection systems have also been set up at the existing stationswherethesefacilitiesdidnotexistearlier.Augmentationofthesesystemsto100%capacity presently in progress. is Astheemphasisongainfulutilizationofashgrew,theusageovertheyearsalsoincreased.From0.3 million tonnes in 19911992, the level of utilization during 200607 stood at over 20.76 million tonnes. The various channels of ash utilization currently include use by a number of Cement, Asbestos Cementproducts&ConcretemanufacturingIndustries,LandDevelopment,Roads&Embankments, AshDykeRaising,andBuildingProducts.Areawisebreakupofutilizationfortheyear200607isas under: AreaofUtilization LandDevelopment Cement&Concrete Roads/Embankments AshDykeRaising Bricks MineFilling Others Total NTPChasadopteduserfriendlypolicyguidelinesonashutilisation.Theseincludeactionsidentified for: AshCollection&StorageSystem Facilities&Incentivestousers DirectDepartmentActivities Administrative&Financialaspects. Quantity(inMillionTons) 7.51 7.40 1.76 2.69 0.15 0.61 0.64 20.76

In order to motivate entrepreneurs to come forward with ash utilisation schemes, NTPC offers severalfacilitiesandincentives.Theseincludefreeissueofalltypesofashviz.DryFlyAsh/PondAsh / Bottom Ash & infrastructure facilities, wherever feasible. Necessary help and assistance is also Page|34

offeredtofacilitateprocurementofland,supplyofelectricityetc.fromGovt.Authorities.Necessary technomanagerial assistance is given wherever considered necessary. Besides NTPC uses onlyash basedbricks&portlandpozzolanacement(FAPPC)inmostofitsconstructionactivities.FAPPC(as per IS 1489 Part1) and Fly Ash Bricks (as per IS 12894) have been included in our standard specifications.DemonstrationprojectsaretakenupinareaofAgriculture,Buildingmaterials,Mine fillingetc. NTPCcontinuallystrivestoevolveinnovativeanddiversemeansofashutilizationtofurtherbroaden thescope.Prominentamongthemethodsdevisedsofarare: DryFlyashExtractionSystems Useincement&concrete UseinAshbasedproductsincludingsettingupof AshTechnologyPark LandDevelopment/WastelandDevelopment,Roads&Embankments,Raisingashdykes' Minefilling/Stowing Agriculture

NTPC,AshUtilizationDivisionhasbroughtoutabooklettitled'NTPCGuideforUsersofCoalAsh'for distributionamongstprospectiveentrepreneursandusersofash.Itcoverssalientinformationabout NTPC's power stations, facilities offered for setting up of ash based industry, statistics about ash productionanditsquality,briefwriteupaboutvarioustechnologiesavailableforutilizationofash, listofequipmentmanufacturers,technologysuppliers,agencieswhomaybeapproachedforsetting uptheprojectsetc.

WTP AND GEO MILLER:

W.T.P.-I&II
Theavailabilityofsuitablesupplyofwaterbothforcoolingpurposesandforboilerfeedmakeain one of the basic requirement of the power station the water treatment plant is meeting this requirement the water which is used in the boiler circuit must be in very pure form to avoid corrosion of boiler tube scale formation on the inside surface of various parts and to avoid silica carryover to turbine corrosion tunes leads to its failure and this reduces boiler reliability scale formationleadstoresistancetoheattransferandoverheartingofthetubemetalandthuscauses frequent shut downs. Silica caries over from boiler gets deposited on relatively cold portion of turbine and create resistance to stream flow thrust reducing efficiency of turbine as the working pressureandtemperatureofboilergoeshighwithunitsizeincreasingtherequirementofverypure waterbecomesevenmorestringentthereforethemainobjectoftheWTPistoremoveimpuritiesof water being sent to boiler in order that the steam generated is pure and boiler can give an uninterruptedsurface. Page|35

GEOMILLER
Thenamegiventothisunitisbecause'geomiller'namedcompanybuiltitandstartedit. Itsmainfunctionistomakewaterpureandclean. TherawwatercomingfromCRWgoesintothetankwherealumandchlorineareaddedtoit.With the help of chlorine and alum all the mud and dust settles down and clean water is taken from above. From there it goes to two separate tanks and from there 7 pumps 4 of 100Mw and 3 of 21OMwpowertakesthewatertovarioussectionssuchasWTPI&IIetc.

CLARIFLOCULATOR To the chlorinated raw water chemical are added in the form of solution and through violet turbulence chemical are adequately mixed in a flash mixer tank the water is then lead to central chamberofclarifloculatorhavingrotatorytypeofarrangementherewithslowmotorgiventowater thenewlyformedflewisrepeatedlybroughtintoimpactwithotherflowparticlesandtheyattack themselvestogetherinlargemasseswhichsettlesquicklythewateristhenallowedslowlytocome inotherchamberthealsohasslowrotatingarrangement Page|36

MIXEDBEDEXCHANGER The water from the cation exchangers enters the final treatment unit for removing the traces of impurities remaining in the anion treated water ~e mixed exchanger is milled steel rubber lines pressure vessels externally fitted with manual and pneumatic valve the internal includes and inlet waterdistributor,causticsodadistributorfortheregenerationofanionresins. Specifications: 1).CLARIFLOCULATOR Dimension13715mmdiameter MetalconstructionRCC Flowrate200m3/hr 2).ALUMDISSOLVERTANK 1500mmdiameterx1500mmdeep Metalofconstructionms 3).ALUMSERVICETANK 1370mmdiameterX120deep MetalofconstructionMS 4).CATIONEXCHANGER 4numbers Dimension1676mmdiameter Materialofconstructionms Qty.30%HCL Minimumflow10m3/hr Maximumflow35m3/hr Page|37

 5).ANIONEXCHANGER 4numbers Dimension1676diameter MaterialofconstructionMS Minimumflow10m3/hr Maximumflow35m3/hr Netflowrate25m3/hr 6).MIXBEDEXCHANGER 4numbers Quantity30%HCL+30causticsoda Dimension762diameter Materialofconstructionms Minimumflow2m3/hr Maximumflow26.8m3/hr

THE COOLING TOWER

CIRCULATINGWATERSYSTEMANDCOOLINGTOWER Thecirculatingwaterisuseforthecondensertocondensetheexhauststeamformtheturbinesince sumchangeofstatetakesplacethereforethevacuumiscratedinsidethecondenserforthedegree ofvacuumwilldependupontheextentofcoolingandthusonthequantityofcirculatingwaterand itstemperatureitisthereforedesirablethatthiswatershouldbeoflowtemp.whenthewater is obtainedfromthelake,canal,riveretctherequirementmaybeabout59gallonsperhourperkilo wattoftheplantthis sissumwhathighforcoolingwatersystemthecoolingeffectinthecooling towerdependsuponthewetbulbtemperatureoftheatmosphereandadditionof10%capacityof tower may be required during summer cooling tower are used lager size stations there is a Page|38

temperaturetofavourcoolingtowerevenforthemediumsizestationduetotheotheradvantages isthatclosedapproachthewetbulbtempispermissiblethroughthese. Thecoolingtoweriswoodensteelconcretestructureinsidewhichisprovidedwithanarrangement of wooden check or work perforated trays etc at the bottom is a reservoir for storage of cooled water warm water isfedtothetoweronthetop and isallowedtopassintothesesheetthrough tracewhileairflowsformthebottomoftowertotopthereisagoodcontactofairandwaterwith theresultofthatthelatteriscooledandfillsinthereservoirairpassingoutatthetoptopreventthe escape of water particles drift eliminator are simple construction are made of few rows of blades placesinclinedtoeachotherandprovideazigzagpathofairsystemthemoistureitsdepositedon thebladesandfallsbackinthetank. Page|39

TMD TURBINE MAINTENANCE DEPARTMENT

MAINTURBINE CWPUMP CONDENSER VALVE CONDENSATEPUMP FEEDPUMP

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MAIN TURBINE
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and convertsitintousefulmechanicalwork. It has almost completely replaced the reciprocating piston steam engine (invented by Thomas NewcomenandgreatlyimprovedbyJamesWatt)primarilybecauseofitsgreaterthermalefficiency and higher powertoweight ratio. Also, because the turbine generates rotary motion, it is particularlysuitedtobeusedtodriveanelectricalgenerator;about80%ofallelectricgenerationin the world is by use of steam turbines. it doesn't require a linkage mechanism to convert reciprocatingtorotarymotion.Thesteamturbineisaformofheatenginethatderivesmuchofits improvement in thermodynamic efficiency through the use of multiple stages in the expansion of thesteam(asopposedtotheonestageintheWattengine),whichresultsinacloserapproachto theidealreversibleprocess. Types Steamturbinesaremadeinavarietyofsizesrangingfromsmall1hp(0.75kW)units(rare)usedas mechanical drives for pumps, compressors and other shaft driven equipment, to 2,000,000 hp (1,500,000 kW) turbines used to generate electricity. There are several classifications for modern steamturbines. SteamSupplyandExhaustConditions Thesetypesincludecondensing,nocondensing,reheat,extractionandinduction. Noncondensingorbackpressureturbinesaremostwidelyusedforprocesssteamapplications.The exhaustpressureiscontrolledbyaregulatingvalvetosuittheneedsoftheprocesssteampressure. These are commonly found at refineries, district heating units, pulp and paper plants, and desalinationfacilitieswherelargeamountsoflowpressureprocesssteamareavailable. Condensingturbinesare mostcommonly found in electricalpowerplants.These turbines exhaust steam in a partially condensed state, typically of a quality near 90%, at a pressure well below atmospherictoacondenser. Reheat turbines are also used almost exclusively in electrical power plants. In a reheat turbine, steam flow exits from a high pressure section of the turbine and is returned to the boiler where additionalsuperheatis added. The steamthengoesbackintoan intermediatepressuresectionof theturbineandcontinuesitsexpansion. Extracting type turbines are common in all applications. In an extracting type turbine, steam is releasedfromvariousstagesoftheturbine,andusedforindustrialprocessneedsorsenttoboiler feed water heaters to improve overall cycle efficiency. Extraction flows may be controlled with a valve,orleftuncontrolled.Inductionturbinesintroducelowpressuresteamatanintermediatestage toproduceadditionalpower.

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CasingorShaftArrang gements Thesearrangementsin ncludesinglecasing,tand demcompoun ndandcross compoundturbines.Sing gle casing units are the m most basic sty where a single casing and shaft are coupled to a generato yle g or. Tandem c compound ar used wher two or mo casings are directly coupled toget re re ore a ther to drive a single gen nerator. A cross compoun turbine ar nd rrangement f features two or more sha not in lin afts ne drivingtw woormorege eneratorstha atoftenoperateatdiffere entspeeds.A Acrosscompo oundturbine is typicallyu usedformany ylargeapplic cations. PrincipleofOperation nandDesign An ideal s steam turbine is consider to be an isentropic process, or co red onstant entro process, in opy whichthe eentropyoft thesteament teringthetur rbineisequal ltotheentro opyofthesteamleavingth he turbine.N Nosteamturbineistruly isentropic, however,withtypicalise entropiceffici ienciesrangin ng from20% %90%based ontheapplic cationofthe turbine.The einteriorofa aturbinecom mprisessever ral setsofbla ades,orbuc cketsasthey yaremoreco ommonlyreferredto.One esetofstatio onaryblades is connected dtothecasin ngandonese etofrotating bladesiscon nnectedtoth heshaft.Thesetsintermes sh withcerta ainminimumclearances,w withthesizea andconfigura ationofsetsv varyingtoeff ficientlyexplo oit theexpan nsionofsteam mateachstag ge. TurbineE Efficiency

Schematic dia S agram outlinin the differen between an impulse and a reaction tu ng nce a d urbine

mize turbine efficiency, th steam is e he expanded, ge enerating wo in a num ork, mber of stage es. To maxim Thesestagesarechara acterizedbyh howtheener rgyisextracte edfromthem mandarekno ownasimpuls se on M n ombination o the reactio and impuls of on se or reactio turbines. Most modern steam turbines are a co design.Ty ypically,higherpressures sectionsareimpulsetype andlowerpressurestage esarereactio on type.

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ImpulseTurbines An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These jets contain significant kinetic energy, which the rotor blades, shaped like buckets, convert into shaft rotationasthesteamjetchangesdirection.Apressuredropoccursacrossonlythestationaryblades, withanetincreaseinsteamvelocityacrossthestage. As the steam flows through the nozzle its pressure falls from steam chest pressure to condenser pressure(oratmospherepressure).Duetothisrelativelyhigherratioofexpansionofsteaminthe nozzlethesteamleavesthenozzlewithaveryhighvelocity.Thesteamleavingthemovingbladesis alargeportionofthemaximumvelocityofthesteamwhenleavingthenozzle.Thelossofenergy duetothishigherexitvelocityiscommonlycalledthe"carryovervelocity"or"leavingloss". ReactionTurbines Inthereactionturbine,therotorbladesthemselvesarearrangedtoformconvergentnozzles.This type of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the stator as a jet that fills the entire circumference of the rotor. The steam then changes directionandincreasesitsspeedrelativetothespeedoftheblades.Apressuredropoccursacross boththestatorandtherotor,withsteamacceleratingthroughthestatoranddeceleratingthrough therotor,withnonetchangeinsteamvelocityacrossthestagebutwithadecreaseinbothpressure andtemperature,reflectingtheworkperformedinthedrivingoftherotor. OperationandMaintenance When warming up a steam turbine for use, the main steam stop valves (after the boiler) have a bypasslinetoallowsuperheatedsteamtoslowlybypassthevalveandproceedtoheatupthelines inthesystemalongwiththesteamturbine.Alsoaturninggearisengagedwhenthereisnosteamto theturbinetoslowlyrotatetheturbinetoensureevenheatingtopreventunevenexpansion.After firstrotatingtheturbinebytheturninggear,allowingtimefortherotortoassumeastraightplane (nobowing),thentheturninggearisdisengagedandsteamisadmittedtotheturbine,firsttothe asternbladesthentotheaheadbladesslowlyrotatingtheturbineat10to15RPMtoslowlywarm theturbine. Problems with turbines are now rare and maintenance requirements are relatively small. Any imbalanceoftherotorcanleadtovibration,whichinextremecasescanleadtoabladelettinggo andpunchingstraightthroughthecasing.Itis,however,essentialthattheturbinebeturnedwith dry steam. If water gets into the steam and is blasted onto the blades (moisture carryover) rapid impingement and erosion of the blades can occur, possibly leading to imbalance and catastrophic failure.Also,waterenteringthebladeswilllikelyresultinthedestructionofthethrustbearingfor the turbine shaft. To prevent this, along with controls and baffles in the boilers to ensure high qualitysteam,condensatedrainsareinstalledinthesteampipingleadingtotheturbine. Speedregulation Thecontrolofaturbinewithagovernorisessential,asturbinesneedtoberunupslowly,toprevent damage while some applications (such as the generation of alternating current electricity) require precisespeedcontrol.Uncontrolledaccelerationoftheturbinerotorcanleadtoanoverspeedtrip, whichcausesthenozzlevalvesthatcontroltheflowofsteamtotheturbinetoclose.Ifthisfailsthen Page|43

the turbine may continue accelerating until it breaks apart, often spectacularly. Turbines are expensivetomake,requiringprecisionmanufactureandspecialqualitymaterials. TheturbinesusedinBTPSarelikeasshowninfigure:

The complete turbine assembly is mounted on foundation frames pedestals and sale plate is designedthatthecomponentarefreetoexpandorcontrolutilizescorrectalignmentismaintained duringstartupshutdownandthroughtheworkingtemperaturerange. In 210Mw the pressure is 120kg/cm2 and rotates at 3000rpm. Rated quantity of circulating water throughcondenseris27000cubicmeter/hr. Thehighsuperheatedsteamispassesonthebladesofturbine,sothatitrotatesveryhighspeed andproducesthepowerwiththeattachmentofturbine.Thegeneratorwhichisconnectedwiththe turbineisrotateswiththerotationofturbineandproducedelectricity. InworkingofturbinefirstMS4,MS5,MS6,MS3valvesareopenedthenESV(emergencysteam valve)situatedatrightorleftisopened.ThensteamisenteredinHPT. Theturbinehasagoverningsystemconsistsofmainoilpump(MOP)forsupplyingtheoiltoturbine. Duringtheoperationtheoilbecomesdirty.Forpurifyingtheoil12filteraremaintained.Inwhich6 has thick sieves and another 6 has thin sieves. The dirty oil first passed in thick sieves and then passedtothinsieves.Theoilisprovidedinthemainoiltankwhichcontains28000litreoil. Ithave31stages HPandIParesinglesideforced LPisdoublesideforced HPhave12stages,12movingand12fixedblades IPhave11stages,11movingand11fixedblades LPhave4stages,8movingand8fixedblades

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When steam entered in the turbine control valve 1,2,3,4 are opens. Rotor of turbine is placed betweenthepads,thefirepadsareatthetopofrotorandanotherfireisatthebottomofrotor. When steam passed the turbine some steam are rejected. The rejected steam are collected in intermediatecylinderandpassedtocondenserforreheating,sothatonceagainhighpressuresteam isenteredinthefurnace.Thetrustbearingareplacedinthemiddleofturbine.Duringtheoperation somesteamareleakages.TheleakagesteamarecollectedinglandsteamcoolerandpassedtoLPH toHPtoeconomisertosuperheatertoboilerdrumformakingpuresteam. Theinternaltempoftheturbineis360C. Whentheturbineshutdownitshouldensuredthattherotorisnotsuddenlystoppedinstantlyorin otherwordsitshouldnotbestoppedathighspeed.Sincewhentherotorisstoppedsuddenlythe highpressuresteamforcedonthebladesofturbineanddamagesit. Sowhentherotorisstoppeditstempisabout80'C.Thisisdonewiththehelpofbearinggear.Then theturbineshutdownaleveronbearinggearisdownonrightside.A30KWthreefaceinduction motor running at 730r.p.m. forms the main driving force of bearing gear which gives the slow rotationoftheturbinerotor.

C.W. BOOSTER PUMP

Coolingwaterboosterisusedforcoolingformturbinetoboiler.Ithassingleandsingledischarge. ThepressureofCWboosterpumpis3to4Kg/Cm2.TheCWboosterpumpprovidestherawwater fromturbinetoboilerforcoolingtheplant.Ittakesthewaterfrom CWpumpsandprovidestheplant. In100MWboosterpumphasadoublesuctionandsingledischarge.Itmeanstwowayofinletwater andonewayofoutletwater.Itdischargepressureisverybetween1.5to 2Kg/cm2

CONDENSER
Acondenser involvesthe transformation ofwater vapor to liquid by mechanicalmeans.Although waterisoneofthemostofversatileliquidsonearth,itcanbedifficulttoisolatewatergoingfrom onephasetoanother.Thus,condensersaredevicesinvolvedinthedehumidificationofair.There are generally three methods to dehumidify air; absorption of water vapor by a liquid solution, adsorbentmaterials(silicageloractivatedalumina),andshellandtubeconvection. Page|45

InBTPSthetypeofcondenserusedisasimpleshellandtubecondenser. Thecondenserusedin210mwunithas 17,000pipes Innerdiameterof26mm Outerdiameterof27mm Andare10mlong

Thecondenserusedin95mwunithas 14,800pipes Innerdiameter26mm Outerdiameter27mm Andare10mlong

VALVE
Avalveisadevicethatregulatestheflowofmaterials(gases,fluidizedsolids,slurries,orliquids)by opening, closing, or partially obstructing various passageways. Valves are technically pipe fittings, butusuallyarediscussedseparately. Types/Designations Valves can be categorized into the following design types and although there are hundreds of variationstheyallfitintothesebasictypes: Alsothevalvescanbeclassifiedas: Page|46 ConventionalValve SevereServiceValve Gate Plug Globe Check Butterfly Diaphragm Ball SOLENOID NEEDLE HYDRAULIC

Valveparts BodyandBonnet Themainpartofthevalveconsistsofthevalvebodyandbonnet.Thesetwopartsformthevesselor casingthatholdsthefluidgoingthroughthevalve.Valvebodiesareusuallymetallic.Brass,bronze, castorductileiron,steel,alloysteelsandstainlesssteelsareverycommon.Plasticbodiesareused for relatively low pressures and temperatures. PVC, PP, PVDF and glassreinforced nylon are commonplasticsusedforvalvebodies. Ports Integraltothevalvebodyarethepassagesthatallowflowintoandoutofthevalve.Thesearecalled ports. These ports are obstructed or opened up by the valve member or disc to control the fluid flow.Valveswithtwoorthreeportsarethemostcommon,whilevalveswithmultipleports(upto 20)areusedinspecialapplications.Nearlyallvalvesarebuiltwithsomemeansofconnectionatthe ports.TheseincludeThreads(maleorfemale);BSPorNPTaremostcommon.Compressionfittings, tosuittubes/sorcopper.Glueorcementapplication(especiallyforplastic)almostalwaysasocket type connection (not a butt) Flanges ANSI, BS, DIN, or JIS. (US, British, European, Japanese standards)WeldingeitherSockettypeorButttypewelds. Disc/Rotor/ValveMember Insidethevalvebody,flowthroughthevalvemaybepartlyorfullyblockedbyanobjectcalledadisc or valve member. Although valve discs of some kinds of valves are traditionally discshaped, discs cancomeinvariousshapes.Althoughthevalvebodyremainsstationarywithinthefluidsystem,the discinthevalveismovablesoitcancontrolflow.Aroundtypeofdiscwithfluidpathway(s)inside which can be rotated to direct flow between certain ports is usually called a ball. Ball valves are valves which use spherical rotors, except for the interior fluid passageways. Plug valves use cylindricalorconicallytaperedrotorscalledplugs.Otherroundshapesforrotorsarepossibletooin rotor valves, as long as the rotor can be turned inside the valve body. However not all round or sphericaldiscsarerotors;forexample,aballcheckvalveusestheballtoblockreverseflow,butis notarotorbecauseoperatingthevalvedoesnotinvolverotationoftheball. Seat Thevalveseatistheinteriorsurfaceinthebodywhichcontactsorcouldcontactthedisctoforma seal which should be leaktight when the valve is shut. If the disc moves linearly as the valve is controlled,thedisccomesintocontactwiththeseatwhenthevalveisshut.Whenthevalvehasa rotor, the seat is always in contact with the rotor, but the surface area of contact on the rotor changesastherotoristurned.Ifthediscswingsonahinge,asinaswingcheckvalve,itcontactsthe seattoshutthevalveandstopflow.Inalltheabovecases,theseatremainsstationarywhilethedisc orrotormoves.Thebodyandtheseatcouldbothcomeinonepieceofsolidmaterial,ortheseat couldbeaseparatepieceattachedorfixedtotheinsideofthevalvebody,dependingonthevalve design. Seatscanbeintegraltothevalvebody,thatis"hard"metalorplastic.Nearlyallmetalseatedvalves leak,eventhoughsomeleaksareextremelysmall.

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"Soft" seats can be fitted to the valve body and made of materials such as PTFE or various elastomers such as NBR, EPDM, and FKM. Each of these soft materials is limited by temperature (roughmaximumtemperaturesarelistedbelow) NBR80C EPDM120C FKM170C PTFE200C The advantage of soft seats is that they are more likely to offer 100% tight shutoff when valve is closed. ThereareadvantagesofhardseatedValvesaswellinapplicationswherethereisheavyerosiondue tothematerialflowingfromthepipesthenthemetalseatedvalvesarepreferredoversoftseated valves. MetalseatedValveshavelongerlifeaswell. Gate Valves, Globe Valves, Check Valves are usually hard seated Valves and Butterfly Valves, Ball Valves,PlugValves,DiaphragmValvesareUsuallysoftseatedValves. Though there are some special cases where we do have hard seated Butterfly Valves and Hard seatedBallValvesaswell. Stem The stem is a rod or similar piece spanning the inside and the outside of the valve, transmitting motiontocontroltheinternaldiscorrotorfromoutsidethevalve.Insidethevalve,therodisjoined to or contacts the disc/rotor. Outside the valve the stem is attached to a handle or another controlling device. Between inside and outside, the stem typically goes through a valve bonnet if thereisone.Insomecases,thestemandthedisccanbecombinedinonepiece,orthestemandthe handlearecombinedinonepiece. Themotiontransmittedbythestemcanbealinearpushorpullmotion,arotatingmotion,orsome combinationofthese.Avalvewitharotorwouldbecontrolledbyturningthestem.Thevalveand stemcanbethreadedsuchthatthestemcanbescrewedintooroutofthevalvebyturningitinone direction or the other, thus moving the disc back or forth inside the body. Packing is often used betweenthestemandthebonnettosealfluidinsidethevalveinspiteofturningofthestem.Some valves have no external control and do not need a stem; for example, most check valves. Check valvesarevalveswhichallowflowinonedirection,butblockflowintheoppositedirection.Some refertothemasonewayvalves. Valveswhosediscisbetweentheseatandthestemandwherethestemmovesinadirectioninto thevalvetoshutitarenormallyseated(alsocalled'frontseated').Valveswhoseseatisbetweenthe discandthestemandwherethestemmovesinadirectionoutofthevalvetoshutitarereverse seated (also called 'back seated'). These terms do not apply to valves with no stem nor to valves usingrotors. Page|48

Bonnet Abonnetactsasacoveronthevalvebody.Itiscommonlysemipermanentlyscrewedintothevalve body.Duringmanufactureofthevalve,theinternalpartsareputintothebodyandthenthebonnet isattachedtoholdeverythingtogetherinside.Toaccessinternalpartsofavalve,auserwouldtake offthebonnet,usuallyformaintenance.Manyvalvesdonothavebonnets;forexample,plugvalves usuallydonothavebonnets. Spring Manyvalveshaveaspringforspringloading,tonormallyshiftthediscintosomepositionbydefault butallowcontroltorepositionthedisc.Reliefvalvescommonlyuseaspringtokeepthevalveshut, but allow excessive pressure to force the valve open against the springloading. Typical spring materials include carbon steel (often cad plated), 304 Series stainless steels and for high temperatureapplicationsInconelX750.Springscanbetypical'coil'typesor'bellville"washerstacks orevenbimetallicelementswhichexertaspringforceontemperaturechange. Valveballs Avalveballisalsousedforsevereduty,highpressure,hightoleranceapplications.Theyaretypically made of stainless steel, titanium, Stellite, Hastelloy, brass, or nickel. They can also be made of differenttypesofplastic,suchasABS,PVC,PPorPVDF. Materialofvalve: Castiron Brass Bronze Gunmetal Carbonsteel Caststeel Alloysteel Somesmallpartsaremadeupofstainlesssteel.

Operativetype Handoperatedvalve Electricallyoperatedvalve Hydraulicorpneumaticallycontrolledvalve

Sealingmaterial Gascutsheet Nonmetallic(fiber,asbestos,graphiteandgrease) Metallic (a composite is formed using nonmetallic material as stated above and wires) Glandpacking Rope(circularorrectangularcrosssection,metallicornonmetallic)

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CONDENSATE PUMP GROUP

Itsmainfunctionistotakewaterfromcondenserandsupplytodiameter. Condensatepumphasmainly2typesofpumpsi.e.95Mw&210Mw 100MW 210MW Ithas2shafts Ithas8stages Ithas8impelleroutofwhich2impellerisforemergencyleakpump. Ithasbarrelcoupling Ithas2shafts Ithas4stages Ithas4impeller,3impellermadeofbrassand1impellermadeofmildsteel. Ithasadiffusertokeepthepressureconstant.

BOILER FEED PUMP

B.F.P.takeswaterfromdieter&providesittoboilerdrumpassingthroughH.Pheater. Suctionpressureof100mw8kg/cm2 Suctionpressureof210mw12kg/cm2 Rechargepressureof100mw150kg/cm2 Rechargepressureof210mw150200kg/cm2 R.P.M.of100mw3000 R.P.M.of210mw4000ormore

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In100MWmotorisdirectlycoupledwhereasin210MWmotor&pumparecoupledwithahydraulic gearbox. Inside discharge rate, there is a balancing chamber inside the pump which is used to keep the balanceofrotororthepump.Thepressureofbalancingleadsoffisoutsidethepressureofsection ofthefeedpump.Afterbalancingleakoffthefeedwaterwhichisleftbehindthengoestotheseal watercoolerfromestapingboxthroughpumping.Insealwatercoolercircularcoilismadewhichis fed by hot water & the remaining cooler is filled with cold water & the water in the coil also becomescool.Balancingchamberismadeoftwodiscsoneisbearingdiscandtheotherisbalancing disc.Thebearingdiscisfittedtothebodyandthebalancingdisctotherotatingwithsamespeed.

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