A PRACTICAL TRAINING SEMINAR ON PRESENTED BY: MUKESH KUMAR VII SEM. (ELECTRICAL ENGG.) 11ESKEE066 SURATGARH SUPER THERMAL POWER STATION SUBMITTED TO Mrs. RIDA QURESHI Mr. MANISH NAULAKHA

1. Introduction 2. Land 3. Water conducting system 4. Block diagram of thermal power plant 5. Boiler 6. Economizer 7. Super heater and Reheaters 8. Air preheaters 9. Turbines 10. Condenser 11. Coal and ash handling plants 12. Generator CONTENTS

Introduction 1. Suratgarh thermal power station is the first super thermal power Station of Rajasthan with total installed capacity of 1500 MW. 2. Suratgarh super thermal power station is located 27 km away from Suratgarh town in Ganganagar Dist. on the left bank of IGNP at Up Stream of Suratgarh Barrage. 3.This station is operated and maintained by Rajasthan Vidhyut Utpadan Nigam Limited.

S.S.T.P.S. is designed in six stages STAGE I-1x250 MW STAGE II-1X250 MW STAGE III-1X250 MW STAGE IV-1X250 MW STAGE V 1X250 MW STAGE VI-1X250 MW STAGE VII- 1X660MW(Under construction) STAGE VIII- 1X660MW(Under construction) Total Power Generation MW

LAND : Total Land 5020 BIGHA Plant Area 3810 BIGHA Colony Area 431 BIGHA Railway Site 425 BIGHA Water conducting 354 BIGHA system

WATER CONDUCTING SYSTEM: a)Length of Intake Canal = 1.6 Km b)Capacity of each Decilting Pump = 3.14 Kw*3(30M³/Hr.) c)Intake Pump House = 90 Kw*6(1250M³/Hr.)Each Pump d)Raw Water Pump House = 7 lacks M³

BLOCK DIAGRAM OF THERMAL POWER PLANT

BOILER

BOILER PARAMETERS:- Height of boiler 60 meters Height of chimeny 220 meters Foundation depth 8.5 meters Furnace Depth meters Furnace Width meters Total Water Flow T/Hr. Steam Flow T/Hr. Steam Temperature 540ºC Coal Requirement for 250MW 160 T/Hr. Primary Air for pulverized fuel T/Hr. Secondary Air for ignition (Combination) T/Hr. Total Air T/Hr. Steam Pressure 156 Kg /cm²

Flue gases coming out of the boiler carry lot of heat. An economizer extracts a part of this heat from flue gases and uses it for heating feed water. This use of economizer results in saving coal consumption and higher boiler efficiency Economizer

Super heater : Super heater is a component of a steam- generating unit in which steam, after it has left the boiler drum, is heated above its saturation temperature Reheater : Some of the heat of superheated steam is used to rotate the turbine where it loses some of its energy Super heater and Reheaters

After flue gases leave economizer, some further heat can be extracted from them and used to heat incoming heat. Cooling of flue gases by 20 degree centigrade increases the plant efficiency by 1%. Air preheaters may be of three types  Plate type  Tubular type  Regenerative type Air preheaters

TURBINE. In a Thermal Power Plant generally 3 turbines are used to increase the efficiency. High Pressure Turbine(HPT): The superheated steam is directly fed to this turbine to rotate it. Intermediate Pressure Turbine(IPT): The out put from the HPT is reheated In a reheated(RH) and used to rotate IPT. Low Pressure Turbine(LPT): The Exhausted steam from the IPT is directly fed to rotate the shaft of LPT. HPTIPTLPT RH Steam Shaft Super Heater Condenser Generator HPTIPTLPT

High pressure turbine: The HP turbine consists of 25 reaction stages. The moving and stationary blades are inserted into appropriately shapes into inner casing and the shaft. Intermediate pressure turbine : The steam from HP turbine after reheating enters the inner casing from above and below through two inlet nozzles. The IP turbine consists of 20 reaction stages per flow. The moving and stationary blades are inserted in appropriately shaped grooves in shaft and inner casing. Low pressure turbine: Steam admitted to LP turbine from IP turbine flows into the inner casing from both sides through steam inlet nozzles.

 HP turbine having 25 Blades & Single flow.  IP turbine having 17 Blades & Single flow.  LP turbine having 8 Blades& Double flow. TURBINE SPECIFICATION Inlet/Outlet Pressure And Temperature 1. H P Turbine Steam Inlet/outlet pressure -150 Kg/Cm²/39.69 Kg/Cm² A inlet/outlet Temperature - 537*C/346*C 2. I P Turbine Steam Inlet pressure Kg/Cm² a. Outlet pressure Kg/Cm² b.Exhaust Temp *C 3. LP Turbine Steam Inlet pressure Kg/Cm² a.Exhaust Temp. - 49*C

MOVING BLADES

FIXED BLADES

Rotor Layout

CONDENSER  The condenser does the job of condensing the steam exhausted from turbine. Steam after rotating steam turbine comes to condenser. Condenser refers here to the shell and tube heat exchanger (or surface condenser) installed at the outlet of every steam turbine in Thermal power stations of utility companies generally.

In S.S.T.P.S. surface condenser is used. A surface condenser consists of an airtight cylindrical shell having a chamber at each end. Water tube extends between the chambers. The shell is made of welded steel plate construction and the tubes are made of copper zinc alloy. Cooling water flow through the tubes. The steam is admitted from the top and gets condensed due to contact with the tube surface. The condensate leaves from the bottom. For efficient operation, the temperature rise in the cooling water passing through the condenser should be around 10degree C. Condenser Used In S.S.T.P.S.

1. COAL HANDLING PLANT (CHP) COAL & ASH HANDLIG PLANT The function of CHP is automatic feeding of coal to the boiler furnace. The coal is transported to the power station by rail. One rail (rack) consists of 58 or 59 boxes with 60 – 70 tones coal loaded in each box. There are 6-7 racks of coal are used.About tonnes coal required per day for whole unit.

The main equipments of CHP are: 1.Wagon trippler: - A tripler is a equipment that is used for unloading the coal from box by lifting and tilting the box. 2.Side arm charger: - It is used for pushing or carrying the loaded or empty boxes. 3.Conveyors: - Different sized and diff. Capacity conveyors are installed for feeding the coal from Tripler to bunkers. 4.Crusher: - Crushers are provided for crushing the coal in desired sizes. 5.Primary crusher:2 6.Secondary crusher:8 7.Stacker cum re-claimer:2 8.Stacker/Reclaimer: - The stored coal is stacked or reclaimed by the stacker/reclaimer. 9.Bunkers: - Crushed coal is led to the mills via canonical shaped bunkers. 10.Coal feeders: - Coal feeder delivers the coal from the bunkers to the mill. 11.Pulverization of coal:- Pulverizing mills In modern TPS’s coal is pulverized i.e. ground to dust likesize. Pulverization is a means of exposing a large surface area to the action oxygen and consequently helping the combustion. mill used for one unit in which one standby. Mill is 4.7met in dia. &7.2 met in length.

Raw coal from bharat coal ltd. Dhanbad & bilaspur(MP) To SSTPS from gudla via a single railway track Wagon tippler hoppers Crusher house bunkers Raw coal feeders Coal mills (pulverization) Boiler furnace ( tangential firing of pulverized coal)

Useful Heat Value Of Different Grade Of Coal. GRADE U.H.V A >6200 Kcal/kg B kcal/kg C kcal/kg D kcal/kg E kcal/kg F kcal/kg U.H.V = [A+M] Where A=% of ash M =% Inherent moisture

2. ASH HANDLING PLANT (AHP)  Coal contains a considerable amount of ash. The percentage of ash in the coal varies from about 5% in good quality coals to about 40% in poor quality coals.  Generally poor quality coal is used in steam power plant, so the plant produces hundred tones of ash daily.  For removal of ash from the boilers and its disposal to the suitable site is quite difficult.  Ash handling comprises the following operation: 1.Removal of ash from the furnace ash hoppers. 2.Transfer of ash to a fill or storage 3.Disposal of stored ash.

In S.S.T.P.S. Hydraulic System Is Used For Ash Handling. Hydraulic system: In this system stream of water carries ash along with it in a Closed channel and disposes it of to the proper site. This is the healthy clean dustless and completely enclosed system. In this system the hoppers below the boilers are fitted with water nozzles both at the top and on sides. The top nozzles quench the ash while the side ones provides the driving force for the ash. The ash and water then flow along a trough to a receiving hopper or sump where the ash is separated from the water. The water is used again while the ash is sent out through the carriages.

 TWO POLE TYPE; WITH CYLINDRICAL ROTOR  BASIC PRINCIPLE :FARADAY’s LOW OF MAGNETIC INDUCTION  COOLING:  STATOR WINDING-DIRECT WATER COOLING  ROTOR WINDING – HYDROGEN COOLING GENERATOR: MECHANICAL ENERGY ELECTRICAL ENERGY

The Synchronous Generator is used to Generate power by connecting the shaft of the Turbine to the shaft of the generator which cuts the magnetic flux producing Emf. The Generated Voltage will generally 11KV to 20 KV max. The Generated Voltage is stepped up by connecting Step up transformer and is transmitted and is also used for Auxiliary purposes. Generator Bus Duct Generator Transformer 20KV to 400KV SYNCHRONOUS GENERATOR UAT 20Kv to 6.KV Unit Auxiliary Transformer: This transformer is used to step down the produced voltage and use for Auxiliary purpose.