INDUTRIAL TRAINING ON 1320 MW ENERGY GENERATING

THERMAL POWER PLANT

An Industrial training report Submitted

in Partial Fulfillment of the Requirements
for the Degree of

BACHELOR OF TECHNOLOGY
in

Electrical Engineering
by
Vaibhav Jaiswal (2100100200017)

Department of Electrical Engineering

United College of Engineering & Research, Allahabad (Code 010)

Dr. A.P.J. Abdul Kalam Technical University

Under the Supervision of

Mr. ASHOK KUMAR TIWARI

MEJA URJA NIGAM PRIVATE LIMITED, MEJA,PRAYAGRAJ

Duration : 30 DAYS
 ORGNISATION HISTORY
Meja Urja Nigam Private Ltd (MUNPL), a joint-venture (JV) company formed by
National Thermal Power Corporation (NTPC) and Uttar Pradesh Rajya Vidyut
Utpadan Nigam Ltd (UPRVUNL), is undertaking the Meja Thermal Power Plant
project in Uttar Pradesh, India. The project involves the construction of a 1,320MW
coal-based power plant. It will be executed in two units of 660MW each. The project
will be based on supercritical technology. In January 2011, a letter of intent (LOI) was
issued for the BTG package to Toshiba. In December 2011, however, the award of the
contract was delayed due to a legal dispute between NTPC and Ansaldo Caldaie over
disqualifying the latter in the bulk tendering process. In May 2012, Toshiba was
awarded the BTG Contract of US$315 million. The scope of the contract covers
engineering, procurement, manufacturing, installation, and testing of the steam
turbine generator islands.On June 6, 2012, MUNPL signed US$1,350 million loan
agreement with a consortium of 16 banks led by State Bank of India and syndicated
by SBI Capital Markets Ltd for funding the project and on June 7, 2012, MUNPL
achieved financial closure.On July 11, 2012, Alstom T&D was awarded US$190
million construction contract for 400kV substation.
The scope of work includes engineering, supply, erection, testing and commissioning
works. It also includes delivery of generator transformer, interconnecting
transformers, shunt reactors, circuit breakers, instrument transformers and substation
automation system.On September 1, 2014, MUNPL signed a loan agreement for
US$156.52 million, with State Bank of India (SBI) and Japan Bank for International
Cooperation (JBIC) to set up an export credit line, which will be utilized to finance
the procurement of steam turbine generator equipment from the Japanese firm,
Toshiba Corporation and its subsidiary in India, Toshiba JSW Power System, to
construct the plant. The loan will be co-financed by the Bank of Tokyo-Mitsubishi
UFJ Ltd (BTMU).On December 24, 2014, Tender issued for providing the Ventilation
System of the proposed project with submission deadline as January 30, 2015. As of
March 2015, Project is kept on hold due to legal issues.In June 2017, 68% works
completed on the project.In July 2017, NTPC signed US$1,028million loan
agreement with Power Finance Corporation (PFC).

ii
 ABSTRACT
Industrial training is an important phase of a student life. A well planned, properly
executed and evaluated industrial training helps a lot in developing a professional
attitude. It develop an awareness of industrial approach to problem solving, based on
a broad understanding of process and mode of operation of organization. The aim and
motivation of this industrial training is to receive discipline, skills, teamwork and
technical knowledge through a proper training environment, which will help me as a
student in the field of Information Technology, to develop a responsiveness of the self-
disciplinary nature of problems in information and communication technology.
During a period of one months training at Meja Urja Nigam Private Limited , I was
Stay in the company, and get detailed information about all the sections there, due to
which I came to know how a Maharatna company generates electricity. And we had
to do complete analysis while doing team work with our group members.
Throughout this industrial training, I have been learned new technologies and fully
automation process established in plant ,the process of the production lines and
distribution system of energy through transmission lines hence able to implement
what I have learnt for the past year as a engineering in Electrical and Electronics.

iii
 ACKNOWLEDGEMENT
The Training opportunity I had with MEJA URJA NIGAM PRIVATE LIMITED
(MUNPL), Prayagraj was a great chance for learning and professional development
therefore I consider my self as a very lucky individual as was provided with an
opportunity to be a part of it. I am also grateful for having a chance to meet
professionals who led me through this Training period. Bearing in mind previous I am
using this opportunity to express my deepest gratitude and special thanks to lead
consultant Mrs. Geetika Gupta, HR department (MUNPL) ma’am and Mr. Ashok
Kumar Tiwari , (MUNPL)sir who inspite of being extraordinary busy with his duties
took time out to hear guide and keep me on the correct path.
I will always remain indebted to them for their constant interest and excellent
guidance in my training work, moreover for providing me with an opportunity to
work and gain experience. At last but not least I would thank to all the well
experienced workers in the Plant (regards SP Sir), who constantly provided me
required knowledge at different stages.

VAIBHAV JAISWAL
2100100200017
BRANCH-EE
UCER , NAINI,
PRAYAGRAJ

iv
 DECLARATION
I Vaibhav Jaiswal student of Bachelor of Technology with specification in Electrical
Engineering from United Collage of Engineering and Research hereby declare that
training report submitted on the topic- “INDUSTRIAL TRAINING ON (1320 MW)
ENERGY GENERATING THERMAL POWER PLANT” is the
outcome of my own work and Meja Urja Nigam Private Limited, Prayagraj is
bonafied correct to best of my knowledge and this work has been carried out taking
care of Engineering Ethics.

v
 TABLE OF CONTENT
ORGANISATION HISTORY ii
ABSTRACT iii
ACKNOWLEDGEMENTS iv
DECLARATION v
TABLE OF CONTENTS vi-vii
LIST OF FIGURE viii-ix
CHAPTER 1:- About Meja Urja Nigam Pvt Ltd (MUNPL) 01-03
1.1 Block Diagram Of Thermal Power Plant 03
CHAPTER 2:- COAL HANDLING PLANT (CHP) 04-13
2.1 Equipments Used In Coal Handling Plant 05-07
2.2 Storage of coal 08
2.3 Crusher House 09-10
2.3.1 Crusher 10
2.4 Mill Motors 11-12
2.5 CHP Layout 13
CHAPTER 3:- BOILER 14-21
3.1 Introduction 14-15
3.2 OTHER PROCESS FANS 16-17
3.3 BOILER FEED PUMPS 18-19
3.3.1 Turbine driven boiler feed pump 18
3.3.2 Motor driven boiler feed pump 19
3.4 Economiser 20-21
3.4.1 Working Of Economiser 21
CHAPTER 4:- GENERATION 22-23
4.1 Synchronous Generator 22
4.2 Excitation Transformer 22
4.3 Steam Turbine 23
CHAPTER 5:- WATER TREATMENT PLANT IN
THERMAL POWER PLANT 24-27
5.1 Open Re-circulating Cooling Towers Operation 24
5.2 Water Quality Parameters for Cooling Towers 25

vi
 5.3 Water Treatment Analysis and Methodology 25
5.4 Waste Minimization: ZLD Systems 26-27
CHAPTER 6:- ELECTROSTATIC PRECIPITATORS 28-29
6.1 Electrostatic precipitators (ESP) 28
6.2 Chimney 28
CHAPTER 7:- SWITCHYARD 30-38
7.1 Equipments In Switchyard 30
7.2 Details Of Equipments 31-34
7.3 Meja switchyard have 2 voltage levels 34
7.4 400 KV Lines for power evacuation(6 Nos.) 34
7.5 Metering of lines 35
7.6 400 KV Switchyard Scheme 35
7.7 400KV Switchyard OWS Screen 35
7.8 400 KV TRANSMISSION LINES & BUS 36
7.9 Control And Protection Scheme 36
7.10 Kiosk 37
7.11 Relay And Control Panel 37
7.12 Decentralized Bus bar Protection 38
CHAPTER 8:- TRANSFORMER 39-43
8.1 TYPES OF TRANSFORMER USED IN MUNPL 39-43
8.1.1 Generator transformer 39
8.1.2 Station Transformer 41
8.1.3 Unit transformer 42
8.14 Unit Auxiliary transformer (UAT) 42-43
REFERENCE 44

vii
 LIST OF FIGURE
Figure 1.1 MUNPL power plant 01
Figure 1.2 Block Diagram 03
Figure 2.1 Coal Supply by INDIAN Railways to MUNPL 04
Figure 2.2 Clamp and driven 05
Figure 2.3 Hydraulic Wagaon driven 05
Figure 2.4 Side Arm Charger 06
Figure 2.5 Track Hopper ( BOBD Type) 07
Figure 2.6 Coal storage place 08
Figure 2.7 Crusher house 09
Figure 2.8 Crusher Machine 10
Figure 2.9 Coal Crushing System 10
Figure 2.10 Mill Motor 12
Figure 2.11 CHP layout 13
Figure 3.1 Forced Draft Fan 15
Figure 3.2 Induced Draft Fan 15
Figure 3.3 Primary Fan 16
Figure 3.4 Flue gas recirculation fans 17
Figure 3.5 TDBFP pump 18
Figure 3.6 MDBFP pump 19
Figure 3.7 Economiser 20
Figure 3.8 Working of Economiser 21
Figure 4.1 Synchronous Generator 22
Figure 4.2 Excitation Transformer 23
Figure 4.3 Steam Turbine 23
Figure 5.1 Cooling towers 24
Figure 5.2 Water quality parameters for cooling towers 25
Figure 5.3 Power Plant Colling Tower Operation 27
Figure 6.1 Electrostatic Percipitator 28
Figure 6.2 Chimney 29
Figure 7.1 Meja Switchyard(400/132KV) 30
Figure 7.2 Lightning Arrester 31
Figure 7.3 Capacitance voltage transformer 31
Figure 7.4 Current transformer 31
Figure 7.5 lightning arrester 32
Figure 7.6 Plc coupling unit 32
viii
Figure 7.7 Isolator 32
Figure 7.8 Circuit Breaker 32
Figure 7.9 Power distribution & interconnection 33
Figure 7.10 Interconnecting transformer 33
Figure 7.11 Absorbs reactive power 34
Figure 7.12 OWS Screen 35
Figure 7.13 Transmission lines and bus 36
Figure 7.14 Kiosk 37
Figure 7.15 Relay and control panel 37
Figure 7.16 BDD Protection 38
Figure 8.1 generator transformer 40
Figure 8.2 Specification of generator Transformer 40
Figure 8.3 Station transformer 41
Figure 8.4 Specification of station transformer 41
Figure 8.5 unit transformer 42
Figure 8.6 Unit auxiliary transformer 43

ix
 CHAPTER 1
About Meja Urja Nigam Pvt Ltd (MUNPL)
Meja Thermal Power Station is an coal-based thermal power plant located in Meja
Tehsil in Allahabad district, Uttar Pradesh. The power plant is owned by the Meja
Urja Nigam Private Limited (MUNPL) a joint venture between NTPC Limited
and Uttar Pradesh Rajya Vidyut Utpadan Nigam. The planned capacity of the power
plant is 1320 MW (2x660MW).

Fig 1.1. MUNPL power plant

THE JOINT VENTURE OF:-

AND

10
Meja Urja Nigam Private Limited (MUNPL) a 50:50 Joint Venture between NTPC
Limited and Uttar Pradesh Rajya Vidyut Utpadan Nigam, established in 2008. The
company owns the Meja Thermal Power Station, a 2x660MW coal-based thermal
power plant.
The power plant is located in Meja Tehsil in Prayagraj district, Uttar Pradesh. Both the
units of the power plant have been commissioned. The power generated by the plant is
supplied mainly to Uttar Pradesh along with the states of Uttarakhand, Chandigarh,
Rajasthan, Punjab, J&K, Delhi, Madhya Pradesh and Haryana.
The water for the power plant is taken from river Ganga. The Pumphouse is located at
Bijoura Village. The coal for the power plant is supplied by Northern Coalfield
Limited and Central Coalfield Limited. The power-station is connected to the grid two
double circuit 400 kV lines of UPPTCL and one double circuit 400kV line of PGCIL.

The project will be based on supercritical technology. In January 2011, a letter of

intent (LOI) was issued for the BTG package to Toshiba. In December 2011,
however, the award of the contract was delayed due to a legal dispute between NTPC
and Ansaldo Caldaie over disqualifying the latter in the bulk tendering process. In
May 2012, Toshiba was awarded the BTG Contract of US$315 million.
The scope of the contract covers engineering, procurement, manufacturing,
installation, and testing of the steam turbine generator islands.On June 6, 2012,
MUNPL signed US$1,350 million loan agreement with a consortium of 16 banks led
by State Bank of India and syndicated by SBI Capital Markets Ltd for funding the
project and on June 7, 2012, MUNPL achieved financial closure.On July 11, 2012,
Alstom T&D was awarded US$190 million construction contract for 400kV
substation. The scope of work includes engineering, supply, erection, testing and
commissioning works. It also includes delivery of generator transformer,
interconnecting transformers, shunt reactors, circuit breakers, instrument transformers
and substation automation system.
On September 1, 2014, MUNPL signed a loan agreement for US$156.52 million, with
State Bank of India (SBI) and Japan Bank for International Cooperation (JBIC) to set
up an export credit line, which will be utilized to finance the procurement of steam
turbine generator equipment from the Japanese firm, Toshiba Corporation and its
subsidiary in India, Toshiba JSW Power System, to construct the plant. The loan will

11
be co-financed by the Bank of Tokyo-Mitsubishi UFJ Ltd (BTMU).On December 24,
2014, Tender issued for providing the Ventilation System of the proposed project with
submission deadline as January 30, 2015. As of March 2015, Project is kept on hold
due to legal issues.In June 2017, 68% works completed on the project.In July 2017,
NTPC signed US$1,028million loan agreement with Power Finance Corporation
(PFC).In August 2017, The unit I synchronized with the main grid marking the
completion of construction works.In September 2017, UPRVUN rejected the proposal
form NTPC to take 50% stake in the project.Construction works are underway ob
Unit II and anticipated for completion by June 2018.

12
THERMAL POWER PLANT

1.1 Block Diagram Of Thermal Power Plant

Fig 1.2 Block Diagram

The working principle of thermal power plant operation depends on Rankin Cycle. In
a thermal power plant, coal is coming from coal storage and burnt in the boiler. It
converts water into steam. This steam is expanded in the prime-mover (i.e., turbine)
which produces mechanical power driving the alternator coupled to the turbine. The
steam is expanded again the turbine and usually condensed in the condenser to be fed
into the boiler. But in real practice, the conversion of heat from coal combustion into
electrical energy needs some modern arrangements and improvements, in which it will
run in proper working efficiency. Here are some basic circuit arrangements of the
modern thermal power plant operation.

13
1. Fuel and Ash Circuit:-
The fuel (coal) is transported from supply points to power station by roads, rails or
water and is stored in coal storage plant. Generally, coal is delivered into power station
by rail wagon but in a case of small power plants, it may be transported by road or
water. After that this coal is stored in the coal storage plant. From the coal storage
plant, it is conveyed to the coal handling plant. In the coal handling plant, coal is
pulverised (i.e. crushed into small pieces) to increase its surface tension to help rapid
combustion without using a large amount of excess air. This pulverised coal is taken
into boiler bunkers by conveyer belt. Coal is now stored into the boiler bunker and fall
into the hoppers by gravity. From the hopper, required amount of coal either fall on
the grate or fall into the coal spreaders. If it is fall to the coal spreaders, maximum coal
combustion is done in the air and remaining portion burnt at the rear end of the grate.
The grate is types of boiler, where combustion is controlled by its speed. The grate is
made a move from rear end to front end with the help of spreaders or without
spreaders; it is move from front to rear. The total coal combustion in the grate is
controlled by its speed. After complete combustion of coal, ash is delivered to the ash
storage plant by scrap conveyors for disposal. Generally, it is seen that a 100 MW
power plant which operates 10% to 12% load factor may burn 20,000 tons of coal per
month and ash is produced nearly 2000 to 3000 tons per month. The block diagram
of thermal power plant is shown in figure:-
2. Air and Fuel Gas Circuit:-
The thermal power plant consists of a boiler and other auxiliary equipment which is
required to utilize the air and flue gases. In the above picture, it is seen that air is
coming from the atmosphere by a forced or induced draught fan through the air pre-
heater. In the air-preheater, air is heated by the heat of flue gases which passing to the
chimney. This flue gases are passing through boiler, super heater, air per heater and
finally exhausted to the atmosphere through the chimney. The boiler is an essential
equipment of the thermal power plant operation. In the boiler, heat is produced by
coal combustion, is utilised to convert water into steam at high pressure and
temperature. The steam is the wet condition in the boiler and it is converted dry and
superheated condition by the flue gases when it is passed through the superheater.
Superheated steam means the steam temperature is above the boiling point of water
and this will provide added advantages to the turbine. This steam is increased

14
the overall efficiency of the turbine and protect the turbine's blade from corrosion.
Economiser and air preheater are such type of devices which extract the heat from flue
gases on their way to a chimney and increased the temperature of the feed water.
Economiser is basically a feed water heater which recovers heat from flue gases and
increase the temperature of the fed water before it is supplied to the boiler. Air is also
supplied for the coal burning. Air preheater also extracts the heat from flue gases when
it is passed in it. Air preheater increases the heat of air as well as improves the overall
efficiency of the turbine. It also increases the steam capacity per square meter of boiler
surface. Now this dry and superheated steam is fed to the blades of steam
turbine through the main valve. Here steam energy is converted to the mechanical
energy.

3. Feed water and steam circuit:-

Condensed steam is coming out of the turbine and the condensate is extracted from the
condenser by the condensate extraction pump. Exhaust steam is passed through the
low-pressure feed water heater where its temperature is raised by the bled steam. The
feed water is now pumped by deaerator to high-pressure feed water heater where this
feed water is heated by the heat from bled steam extracted at suitable point of steam
turbine. Deaerator is to reduce dissolved oxygen content in the feed water. Feed water
is pumped into the boiler the boiler and it is passing through the economiser where it is
heated by the heat of flue gases. This will increase the overall efficiency. Some steam
and water are lost when it is passed through the different component of the system.
Turbine is directly coupled to the alternator which converts the mechanical energy of
turbine into electrical energy and delivers the electrical output to the bus bar.

4. Cooling water circuit:-

Cooling water is supplied from a natural source of supply such as river, channel, sea,
etc. This water is circulated through the condenser for condensing the steam. It will
increase the overall efficiency of the plant. The circulating water absorbs heat from the
exhaust steam and becomes hot. This hot water is coming out from the condenser and

15
discharged at a suitable position like a lake, river etc. To ensure the availability of cold
water throughout the year, a cooling tower is used. During the scarcity of water, hot
water of condenser is passed to the cooling tower where it is cooled. The circulation of
cooling water to the condenser is to maintain low pressure in the condenser.

COMPONENTS OF THERMAL POWER PLANT:

Certainly! Let's delve into the details of a boiler in a thermal power plant:

1. Fuel Handling System:

- The fuel, often coal, is received from the coal storage or handling area.
- It is then transported to the boiler by conveyors.

2. Boiler Furnace:
- The furnace is the combustion chamber where the fuel is burned to release energy.
- Grates, stokers, or other mechanisms ensure controlled and efficient combustion.

3. Boiler Shell and Water Tubes:

- The boiler shell is a large cylindrical vessel that contains water and the fuel.
- Water tubes are positioned within the boiler to circulate water and absorb heat.

4. Combustion Chamber:
- The combustion chamber (furnace) is designed to optimize the combustion process,
ensuring efficient heat transfer to the water tubes.

5. Water Walls:
- Water wall tubes form a barrier between the furnace and the boiler interior,
absorbing heat and preventing damage to the boiler.

6. Superheater:
- Superheater tubes are responsible for further heating the steam beyond its
saturation point, increasing its temperature and energy content.

7. Economizer:
- Economizer tubes recover heat from the flue gases, preheating the feedwater before
16
it enters the water tubes.
- This improves overall efficiency by utilizing waste heat.

8. Air Preheater:
- The air preheater heats the combustion air using waste heat from the flue gases.
- Preheating the air enhances combustion efficiency.

9. Boiler Drum:
- The boiler drum stores water and steam.
- Water from the economizer enters the drum, and steam leaves the drum for further
stages in the power generation process.

10. Boiler Feed Pump:

- The boiler feed pump is responsible for supplying water to the boiler.
- It takes water from the feedwater system and delivers it to the boiler drum.

11. Steam Turbine:

- Steam produced in the boiler is directed to a steam turbine.
- The turbine's blades are turned by the high-pressure steam, converting thermal
energy into mechanical energy.

12. Control Systems:

- Modern boilers are equipped with control systems that monitor and regulate
various parameters.
- These include temperature, pressure, fuel flow, and air flow, ensuring optimal
performance and efficiency.

13. Ash Handling System:

- Residual ash from combustion is collected and transported to ash disposal units.
- This system ensures the proper handling and disposal of ash generated during the
combustion process.

17
14. Draught System:
- Draught systems, including forced and induced draught fans, are used to maintain
the necessary flow of air and gases through the boiler for combustion.

15. Instrumentation and Sensors:

- Various instruments and sensors monitor the boiler's performance and safety
parameters.
- These include pressure gauges, temperature sensors, and level indicators.

16. Safety Systems:

- Safety features such as safety valves, pressure relief valves, and emergency
shutdown systems are crucial to prevent accidents and ensure the safety of the boiler.

17. Steam Generation and Distribution:

- Steam generated in the boiler is used to turn the steam turbine.
- After passing through the turbine, steam is condensed back into water in a
condenser and returned to the boiler for the cycle to continue.

18. Chemical Treatment:

- Chemicals are often added to the boiler water to prevent corrosion, scale formation,
and foaming.

19. Maintenance and Inspection:

- Regular maintenance and inspection are essential to identify and address issues
promptly, ensuring the boiler's reliability and longevity.

20. Environmental Controls:

- Systems such as flue gas desulfurization (FGD) or selective catalytic reduction
(SCR) may be employed to control emissions and comply with environmental
regulations.

A well-designed and properly maintained boiler is crucial for the efficient and reliable
operation of a thermal power plant, contributing significantly to the overall power gen.

18
 CHAPTER 2
COAL HANDLING PLANT (CHP)
In a coal based thermal power plant, the initial process in the power generation is

A Coal Handling Plant (CHP) is a facility that washes coal of soil and rock, crushes it
into graded sizes (sorting), and stockpiles grades preparing it for transport to boiler
department of the thermal power plant. The coal handling system in a thermal power
plant is designed to meet the production requirements of the boiler, which ultimately
influences the overall efficiency of the power plant.

Fig 2.1 Coal Supply by INDIAN Railways to MUNPL.

The huge amount of coal is usually supplied through railways. A railway siding line
is taken into the power station and the coal is delivered in the storage yard. The coal
is unloaded from the point of delivery by means of wagon tippler. It is rack and
pinion type. The coal is taken from the unloading site to dead storage by belt
conveyors. The belt deliver the coal to 0m level to the pent house and further
moves to transfer point .The transfer points are used to transfer coal to the next
belt. The belt elevates the coal to breaker house. It consists of a rotary machine,
which rotates the coal and separates the light dust from it through the action of
gravity and transfer this dust to reject bin house through belt.The belt further
elevates the coal to the transfer point and it reaches the crusher through belt. In
19
the crusher a high-speed 3-phase induction motor is used to crush the coal to a size
of 50mm so as to be suitable for milling system. Coal rises from crusher house and
reaches the dead storage by passing through transfer point.

Basic Coal Flow Diagram of Coal Handling Plant In Thermal Power Plant

Certainly! Let's delve into more detail for each point of the Coal Handling Plant (CHP)
in a thermal power plant:

1. Unloading:
Wagon Tipplers: These are large machines used to unload coal from railway
wagons. The wagons are tilted, and the coal is unloaded onto conveyor belts.

2. Conveying:
Conveyor Belts: Coal is transported from unloading points to the storage yard using
conveyor belts. These belts are designed to handle different capacities and types of
coal.

3. Crushing:
20
 Primary Crushers: These machines initially break down the large-sized coal into
smaller pieces.
Secondary Crushers: Further reduction in size is achieved in secondary crushers,
producing a uniform size for feeding to the boilers.

4. Stacking and Reclaiming:

Stacker-Reclaimer Machines: These are large machines that stack the coal in layers
for efficient storage. Reclaimers are used to recover coal from the stockpile and feed it
to the conveyor system.

5. Bunkering:
Bunker Hoppers: Coal from the stockyard is transferred to the bunkers through
hopper systems. The bunkers store coal before it is fed into the boiler.

6. Weighing of Coal:
Weigh Feeders: These devices measure the amount of coal being fed into the boiler
with precision. Accurate weighing is crucial for controlling the combustion process.

7.Pulverizing:
Pulverizing Mills: These mills crush the coal into a fine powder, increasing its
surface area. The pulverized coal is then mixed with primary air and blown into the
boiler for combustion.

8. Coal Feeding to Boiler:

Boiler Feed Pumps:These pumps feed the pulverized coal and air mixture into the
boiler combustion chamber.

9. Ash Handling:
Bottom Ash Handling: The heavier ash particles that do not go up with the flue gases
settle at the bottom of the boiler. They are collected and transported to ash storage or
disposal units.
Fly Ash Handling: The fine ash particles carried away by flue gases are collected
using electrostatic precipitators or bag filters. This fly ash is then transported to ash
21
storage.

10. Dust Extraction System:

Dust Collectors: These systems use filters or cyclones to capture airborne dust
particles, preventing them from being released into the atmosphere.

11. Fire Protection:

Sprinkler Systems: These systems release water in case of a fire to suppress flames
and cool the affected area.
Fire Hydrants and Extinguishers: strategically placed to provide quick access to
water and firefighting equipment.

12. Monitoring and Control:

Control Room: The entire coal handling process is monitored and controlled from a
central control room using advanced control systems. This includes monitoring
equipment status, coal flow rates, and system alarms.

Efficient and effective operation of each component in the Coal Handling Plant is
essential for the overall performance and safety of the thermal power plant. Regular
maintenance, monitoring, and adherence to safety protocols are critical to ensure
continuous and reliable power generation.

22
2.1 Equipments Used In Coal Handling Plant:
a. Wagon Tippler:- Tippler is used for emptying the loaded wagons by tipping it.
Tippler retains wagon from top as well as from side by using clamping devices provided
on it. Apart from that track stops, wheel grippers and different type of limit switches are
provided as features of wagon tippler. Tippler is driven by either Hydraulic drive or by
electro-mechanical drive OR Hydro Mechinical Drive .
Placement of wagon, on tippler platform, is accomplished by wagon marshalling
equipment like Side Arm Charger or Bettle Charger or Pussher Car deppending on Type
of Wagon Tippler application.

Fig 2.2 Clamp and driven. Fig 2.3 Hydraulic Wagaon driven.
b. Side Arm Charger:- Side arm charger is a marshalling device to position the
loaded wagon centrally on tippler platform one by one for unloading operation by
wagon tippler. Side arm charger is a rail mounted machine used to pull the loaded
wagon along with the rake and push out the empty wagon from the tippler platform
after tippling.
The tractive force of the side arm charger shall be suitable for hauling (moving) one
fully loaded rake (58 wagons). Generally, it’s operating/hauling speed is 0.5 m/s.
The full rake of 58 wagons is brought in by locomotive and stopped with the first
wagon within range of the side arm charger. The locomotive is then taken away. The
charger is driven towards the first wagon, its arm is lowered and it is coupled to the
first wagon of the rake. The charger then hauls the rake forward by one wagon length
and stopped. Here the first wagon is decoupled from the rake. The charger then
23
propels the first wagon on to the tippler table centrally, gets decoupled and clears off
the tippler. Now the wagon tippler is ready for operation. In the meanwhile, the side
arm charger moves back to initial position for next cycle. In the next cycle, the rake is
drawn up by the one wagon length, and the previously tippled wagon is ejected
simultaneously.
The side arm charger is run on a separate pair of rails which runs parallel to wagon
tippler rail. Approximate travel length of the charger is 33 meters. Side arm charger’s
movement on the rail is actuated by the rack and pinion arrangement. The pinions are
driven by hydraulic motors. The hydraulic motors are driven from hydraulic pressure
and the hydraulic pressure is generated from a hydraulic power pack (maximum
pressure = 180 bars).

Fig 2.4 Side Arm Charger.

24
c. Track Hopper:- This is the another form of Wagon Tippler,Track Hoppers are
mainly used for coal storage & handling in power plants. The coal is generally
transported from coal mines either by BOBR wagons (Bottom Open Bottom
Discharge), Top open wagons & rarely by trucks. As there is a huge demands of coal
in the industry, so wagons are very scarce in time. If the wagons are delayed during
unloading of coal in power plants, huge demurrage charges are levied. To avoid a
repetitive demurrage charges it is highly recommended to use Track Hoppers for
BOBR wagons.
Track hoppers are used to unload the BOBR wagons in no time. A standard Track
hopper is approximately 210m long. This length of track hopper can accommodate at
least 15 wagons. Each BOBR wagons has a total volume of 57.2 cum carrying
approximately 45Mt of coal (BD 800 Kg/cum). Hence each length of track hopper,
carrying 15 wagons can unload 675Mt of coal in approximately 30minutes. If we try
to unload the same 15 wagons manually, then it will take at least a day. Hence a track
hopper not only increases the productivity of the power plan but can also make huge
savings in the form of demurrage charges.

Fig 2.5 Track Hopper ( BOBD Type)

25
2.2 Storage of coal
The purpose of coal storage is :
(i) To store the coal for a period of 30 to 80 days so that the plant is never required to
be shut-down due to failure of supplies of coal from the place of origin or due to
transport problems.
(ii) Storage of coal permits some choice of date of purchase, it allows the purchaser to
take the advantage of seasonal market fluctuations in prices of coal.
Method of coal storage are :
Outdoor coal storage : In the outdoor storage or dead storage, the coal is usually kept
on ground in the form of a pile exposed to outside weather. The coal is required to be
protected from deterioration and weathering. Coal has tendency to oxidise with
liberation of heat. If the oxidation is rapid, it may lead to spontaneous combustion
particularly with coals having high sulphur content due to reaction between sulphur,
air and moisture.

Fig 2.6 Coal storage place.

26
2.3 Crusher House
The coal handling plant (CHP) in a thermal power station covers unloading of coal, its
crushing, storage and filling of boiler bunkers. Coal unloaded in the wagon tippler
hoppers/ track hoppers is conveyed to crusher house by belt conveyors via pent house
and transfer points depending on the CHP layout. Suspended magnets are provided
onconveyors at pent house for removal of trampIron pieces. Metal detectors are also
providedto detect non-ferrous materials present in thecoal before crushers. In case the
sized coal is received, then the coal is sent directly to stockyard and the crusher is by-
passed.
In CHP crusher work on principle of combination of impact and attrition crushing. In
this type of crushing first coal is break due to impact and further scrub between two
hard surfaces to get desired coal size. Some crushers are work only on principle of
impact crushing. Generally these crushers are used before final crushers.
The output size of coal affects the performance of CHP. Naturally these two hard
surfaces of crusher are critical parts. One of these surfaces are known as grinding
plates and other may known as rings, hammers, etc. The linkage between crusher
rotor and drive assembly are also critical parts. As failure of these linkages will stop
crushing. So its Operation and Maintenance at time to time is very important.

Fig 2.7 Crusher house

27
2.3.1 Crusher
A crusher is a machine designed to reduce large Coal into smaller Coals, gravel, or
rock dust. crushers are machines which use a metal surface to break or compress
materials. Mining operations use crushers, commonly classified by the degree to
which they fragment the starting material, with primary and secondary crushers
handling course materials, and tertiary and quaternary crushers reducing ore particles
to finer gradations. Each crusher is designed to work with a certain maximum size of
raw material, and often delivers its output to a screening machine which sorts and
directs the product for further processing.
Typically, crushing stages are followed by milling stages if the materials need to
befurther reduced. Crushers are used to reduce particle size enough so that the
material can be processed into finer particles in a grinder.

Fig 2.8 Crusher Machine

Fig 2.9 Coal Crushing System

28
2.4 Mill Motors
Introduction Coal continues to play a predominant role in the production of electricity
in the world, A very large percentage of the total coal is burned in pulverized form.
Pulverized coal achieved its first commercial success in the cement industry. At
Wisconsin Electric Power Company, the use of pulverized coal was also shown to be
a viable fuel for electrical power production after World War .I Pulverized coal burns
like gas, can be easily lighted and controlled.
 Coal pulverizer/mill system One of the critical power plant components that is
relied upon to convert the energy stored in coal into electricity is the coal
pulverizer or mill. The coal flow is controlled by the feeder, allowing coal to
flow into the pulverizer mill.The pulverized coal and air mixture is then
transport to the boiler burner panels.
 Boiler Boiler drum Reheater Final Super Platen Super heater heater LTSH
Economizer Coal bunker Wind Box Secondary PA duct air duct Furnace Flue
gas APH duct Coal feeder F D Fan P A Fan Coal Pulverizer
 Pulverizer:- The pulverizer receives the raw coal and reduces it to a very fine,
specified size consist, similar to face powder. There are four primary
principals involved in pulverization: • Drying • Grinding • Circulation •
Classification
 Drying :- The coal that is passing through a pulverizer is entrained by the use
of hot air usually from the air heater. During the pulverization process the
surface area of the coal particles increases dramatically exposing fresh coal to
the entrainment air. The inherent and surface moisture of the coal is reduced
by the exposure to hot air.
 Grinding:- There are three basic types of grinding: 1. Impaction – where the
material to be ground is hit or impacted by an outside force 2. Crushing –
where material is forced between two fixed objects 3. Attrition – where
material is ground by rubbing or friction
 Circulation:- The primary air, is the method of circulating the coal through the
pulverizer. Circulating air is also important in allowing for the removal of
heavy material such as pyrites, extraneous metal, etc. by centripetal force that
otherwise might damage the grinding mechanisms.
29
 Classification:- The circulating air is also used to classify the pulverized coal
product prior to carrying it to the burners. The classifier, located on the top of
a mill returns the over-size material back to the pulverizer but allows the
proper-sized material to pass out of the mill to the burners. classifiers are
critical in providing the desired quality of pulverized coal with the desired
fineness

Fig 2.10 Mill Motor.

30
2.5 CHP Layout

Fig 2.11 CHP layout

31
 CHAPTER 3
BOILER
3.1 INTRODUCTION

32
boiler, also called Steam Generator, apparatus designed to convert a liquid to vapour.
In a conventional steam power plant, a boiler consists of a furnace in which fuel is
burned, surfaces to transmit heat from the combustion products to the water, and a
space where steam can form and collect.
Boiler systems in Thermal Power plants use different types of Centrifugal Fans to
supply air required for combustion, deliver fuel to the burners, circulate the gases for
better heat transfer and remove exhaust gases. Based on the boiler size and airflow
requirement, different types of fans are used with varied capabilities.

Boiler in thermal power plant accumulates the steam and build up a pressure to
expend it in turbine and convert thermal energy to mechanical energy. The generator
which is connected to turbine converts the mechanical energy into electric energy.

Types of boiler

1. Based on Tube Content

 Fire Tube

 Water Tube

2. Base on Operating Pressure

 Ultra-supercritical boiler: Pressure ≥ 27.0MPa or rated outlet temperature ≥ 590 ℃

boiler
 Supercritical boiler: 22.1MPa ≤ Pressure ≤ 27.0MPa

 Subcritical boiler: 16.7MPa ≤ Pressure ≤ 22.1MPa

 Ultra-high pressure boiler: 13.7MPa ≤ Pressure ≤16.7MPa

 High pressure boiler: 9.8MPa ≤ Pressure ≤ 13.7MPa

 Sub-high pressure boiler: 5.4MPa ≤ Pressure ≤ 9.8MPa

 Medium pressure boiler: 3.8MPa ≤ Pressure≤ 5.4MPa

3. Base on Fuel Used

 Solid Fuel Fired

 Stoker Fired Boilers

33
o Pulverized Fuel Boilers
o Fluidized Bed Combustion (FBC) Boilers
 Oil Fired

 Gas Fired Boilers

4. Based on Draught System

 Natural Draught

 Mechanical Draught

o Forced Draught System

o Induced Draught System
o Balanced Draught System

There are two types of boilers are used in sub critical, super critical and ultra-
super critical coal fired thermal power plant:

1. Pulverized coal-fired Boiler

2. Fluidized Bed combustion (FBC) boiler

Note: Both types of boiler are water tube boiler

Pulverized coal-fired Boiler or Pulverized fuel Boiler

34
A pulverized coal-fired boiler is an industrial boiler that generates thermal energy by
burning pulverized coal.

Two types of fans used in a boiler power plant are- A. Draft Fans and B. Other
Process Fans
a. DRAFT FANS:-
Draft fans play an important role in thermal power plants because they are responsible
for maintaining the flow of gases through the boiler system. Two types of Draft fans
are used in the power plants, which are -1. Forced Draft fans and 2. Induced Draft
Fans.
Forced Draft Fans: Forced Draft fans used in a power plant are centrifugal fans,
utilizing radial airflow blading or variable pitch axial fans. Forced Draft Fans (FD)
supply the air necessary for fuel combustion by pushing air through the combustion
air supply system and into furnace. These fans are located at the inlet of boiler to
push high pressure fresh air into combustion chamber, where it mixes with the fuel to
produce positive pressure.
The key difference between a forced draft and an induced draft fan is, FD fan forces
outside air into the heating system whereas an ID fan draws flue gases from the
system out into the atmosphere. Both FD fan and ID fan operate in such a manner that
it balances the air system in the boiler to make the combustion process efficient.
In Power plants, where coal is used as fuel for combustion, FD fans are used as
secondary air fans to regulate proper combustion and maximize the efficiency of the
fuel. A typical FD fan arrangement uses inlet and outlet dampers to control and
maintain the required air pressure inside the system. These fans have a wheel at the
center that is hung on the shaft along with inlet boxes, silencer, filter, and rain
hood.As compared to ID fans, FD fans are more efficient, easier to maintain, and have
cleaner operating conditions. The most common centrifugal fans used as FD fans are
backward curved and airfoil centrifugal fans.

35
 Fig 3.1. Forced Draft Fan.
b. Induced Draft Fans: Induced Draft Fans (ID) exhaust all gaseous combustion
products or flue gases from the boiler, through dust collector and delivers it to the
chimney into the open atmosphere. Hence the ID fans are usually located at the outlet
of the boiler system (between a dust collector and chimney). ID fan creates a negative
pressure or suction to discharge the gases out after combustion from the furnace.
Since ID fans can handle hot flue gases, they have more corrosion and erosion
problems even more used with electrostatic precipitators. The most common type of
ID fans used in a boiler power plant is radial fans and backward inclined blade
centrifugal fans.

Fig 3.2 Induced Draft Fan

36
3.2 OTHER PROCESS FANS:
Other Process fans used in a boiler power plant are -1. Primary Air fans and 2. Flue
Gas Recirculation Fans.
Primary Air Fans: Primary air fans or PA fans are high-pressure fans, used in the
boiler power plants to supply the air for transportation of coal directly from the
pulverizer to the furnace. PA fans give positive pressure upstream of the coal
pulverizer and handle relatively clean air.
In power plants, PA fans supply air for conveying of the pulverized coal from coal
mills to the furnace area. These fans produce pressure upstream of the pulverizer, to
push the coal and air mixture through the pulverizer into the furnace.
Backward Curved Centrifugal Fan is the most common centrifugal fan used as a PA
fan in a boiler power plant.

Fig 3.3 Primary Fan

Flue gas recirculation fans:
Flue gas recirculation fans are used to reduce the flue gas pollution content in the
gases exhausted from thermal combustion processes. Flue gas recirculation fans are
used in a power plant boiler to control steam temperature, furnace heat absorption,
and sagging of the heating surface.
These fans extract gas from the economizer outlet and the pre-heater inlet and then
discharge the gas either to the bottom of the furnace for controlling steam temperature
or to different locations in the furnace.

37
 Fig 3.4 Flue gas recirculation fans
The most common types of gas re-circulation fans used in a boiler power plant are
backward curved centrifugal fans.
As the Backward Curved bladed centrifugal fans are highly useful in the majority of
centrifugal fans used in boiler power plants, let us take a brief idea of ‘Backward
Curved Blade Centrifugal Fans’.
Backward Curved Blade centrifugal fans:
A Backward curved centrifugal fan is characterized by its cylindrical shape, several
large curved blades, and a conical inlet nozzle. It rotates in a clockwise direction. As
the fan rotates, a pressure difference is created on the impeller blades. On the leading,
convex side of the impeller blade, a positive pressure is created as the rotational
motion of the impeller imparts a force in the air. The impeller blade pushes the air
outwards, exiting in a radial direction.
On the concave side of the impeller blade, a negative pressure is created as the fan
rotates, drawing air into the space between the blades. This air is then picked up by
the following blade and forced outwards radically in a continuous process. The
suction side of the impeller blade draws air from the center of the fan, which results in
a directional change of the airflow between the inlet and the exhaust.
A backward curved centrifugal fan works best when medium pressures and medium
volume flows are required. A backward curved fan can be used in a basic mounting
design for use in a plenum chamber or incorporated into a scroll housing to direct the
exhaust flow.

38
3.3 BOILER FEED PUMPS: Generally,There are two types of pumps are used in
thermal power plant for providing water to boiler are-
3.3.1 Turbine driven boiler feed pump: TDBFP stands for TURBINE DRIVEN
BOILER FEED PUMP. These kind of pumps are generally designed for large
capacities. Boiler feed pump is coupled with a smaller turbine and these turbines are
steam driven. Steam is derived from different sources (such as extraction or aux.
steam). These pumps are energy efficient as these pump utilise steam (low energy) as
compared to electricity (high energy) for the same output.
Reason for using Turbo Driven is “ LAW OF CONSERVATION OF ENERGY”
(ie) Energy Can be neither be created nor be destroyed, But can be transferred
from one form to another.
Whenever energy is transfered from one form to another form , there will be
some conversion loss.
So in TDBFP Thermal Energy from fuel —→ Is used to raise steam —→This
steam energy can be converted to kinetic energy in Turbine. if turbine coupled
with pump it can now pump water from deaerator to drum.

Fig 3.5 TDBFP pump

39
3.3.2 Motor driven boiler feed pump :- In MDBFP Thermal Energy from
fuel→ Is used to raise steam →This steam energy can be converted to kinetic
energy in Turbine which is coupled with generator →Now turbines mechanical
energy is converted to electrical energy→ Again it is connected to Motor which
converts electrical into mechanical energy which pumps the feed water from
deaerator to Drum.
 So in TD-BFP only in three stages, energy is converted to pump the
water. But in MD-BFP it takes five stages , energy is converted to pump
the water.
 So energy loss during this conversion is very less in TD-BFP than MD-
BFP, so operating cost will be less in TD-BFP than MD-BFP.
 During Plant initial startup, as there will be non-availability of steam ,
plant will be started from MD-BFP , whose power will imported, once
steam is available, we can switch to TD-BFP and MD-BFP can be in
standby or during TD-BFP in maintenance.

Fig 3.6 MDBFP pump

40
3.4 Economiser
An economiser is a mechanical device which is used as a heat exchanger by
preheating a fluid to reduce energy consumption. In a steam boiler, it is a heat ex-
changer device that heats up fluids or recovers residual heat from the combustion
product i.e. flue gases in thermal power plant before being released through the
chimney. Flue gases are the combustion exhaust gases produced at power plants
consist of mostly nitrogen, carbon dioxide, water vapor, soot carbon monoxide etc.
Hence, the economiser in thermal power plants, is used to economise the process of
electrical power generation, as the name of the device is suggestive of. The recovered
heat is in turn used to preheat the boiler feed water, that will eventually be converted
to super-heated steam. Thus, saving on fuel consumption and economising the process
to a large extent, as we are essentially gathering the waste heat and applying it to,
where it is required. Nowadays however, in addition to that, the heat available in the
exhaust flue gases can be economically recovered using air pre-heater which are
essential in all pulverized coal fired boiler.

Fig 3.7 Economiser

41
3.4.1 Working Of Economiser
The flue gases coming out of the steam boiler furnace carry a lot of heat. Function of
economiser in thermal power plant is to recover some of the heat from the heat carried
away in the flue gases up the chimney and utilize for heating the feed water to the
boiler. It is simply a heat ex-changer with hot flue gas on shell side and water on tube
side with extended heating surface like Fins or Gills.
Economisers in thermal power plant must be sized for the volume and temperature
of flue gas, the maximum pressure drop passed the stack, what kind of fuel is used in
the boiler and how much energy needs to be recovered.
When the water is boiled in steam boiler, the steam is produced which is then super-
heated after which it is passed to the turbines. Then the exhausted steam from turbine
blades, is passed through steam condenser of turbine in which the steam is condensed
and this condensed water then is pre warmed first in feed water heater then in it before
re-feeding in boiler.
It is placed in the passage of flue gases in between the exit from the boiler and the
entry to the chimney. In this a large number of small diameter thin walled tubes are
placed between two headers. The flue gases flow outside the tubes usually in counter
flow.

Fig 3.8 Working of Economiser

42
 CHAPTER 4
GENERATION
4.1 Synchronous Generator:- A synchronous generator is a synchronous machine
which converts mechanical power into AC electric power through the process of
electromagnetic induction.
Synchronous generators are also referred to as alternators or AC generators. The term
"alternator" is used since it produces AC power. It is called synchronous generator
because it must be driven at synchronous speed to produce AC power of the desired
frequency.
A synchronous generator can be either single-phase or poly-phase (generally 3phase).
“(The Generation Voltage in MUNPL is 23.5KV)”.

Fig 4.1 Synchronous Generator

4.2 Excitation Transformer:- Excitation transformers are used to ultimately provide
power to the field windings. This is done through many stages which include an initial
AC stage where the excitation transformers are connected from the secondary side of
the main HV transformer to an AC breaker. Thereafter, the AC power is fed to a
converter which connects to the field windings through a DC breaker and a brushgear
system.
The primary side of this transformer would normally be rated for the same voltage as
the secondary side of the main transformer, usually tens of kilovolts. The secondary
side of this transformer would normally be rated at hunderds of volts.

43
 Fig 4.2 Excitation Transformer.
4.3 Steam Turbine:- A steam turbine is a machine that extracts thermal energy from
pressurized steam and uses it to do mechanical work on a rotating output shaft. Its
modern manifestation was invented by Charles Parsons in 1884. Fabrication of a
modern steam turbine involves advanced metalwork to form high-grade steel alloys
into precision parts using technologies that first became available in the 20th century;
continued advances in durability and efficiency of steam turbines remains central to
the energy economics of the 21st century.
The steam turbine is a form of heat engine that derives much of its improvement in
thermodynamic efficiency from the use of multiple stages in the expansion of the
steam, which results in a closer approach to the ideal reversible expansion process.
Because the turbine generates rotary motion, it is particularly suited to be used to
drive an electrical generator—about 85% of all electricity generation in the United
States in the year 2014 was by use of steam turbines. A steam turbine connected to an
electric generator is called a turbo generator.

Fig 4.3 Steam Turbine

44
 CHAPTER 5
WATER TREATMENT PLANT IN THERMAL POWER PLANT
5.1 Open Re-circulating Cooling Towers Operation:-
1) After accepting heat from turbine steam, the heated cooling water is showered
down the cooling tower for heat rejection.
2) Heat from the steam is rejected mainly from evaporation as air is forced past
falling droplets and films of circulating cooling water.
3) Water leaves the tower through evaporation and drift (small water droplets),
increasing the concentration of minerals and contaminants in the cooling water.
4) To decrease concentration, a portion of cooling water is removed as blowdown
5) Make-up water is added to the cooling stream to compensate for water lost to
blowdown, evaporation, and drift.
6) Cooling is re-circulated through the condenser.

Fig 5.1 Cooling towers

45
5.2 Water Quality Parameters for Cooling Towers

Fig 5.2 Water quality parameters for cooling towers

Cooling water quality can affect power plant performance. Therefore, the criteria for
power plants cooling water are stricter than those for refineries, which do not have
this concern. Water sources must be evaluated for their chemical constituents. Each
constituent or constituent pair should be analyzed individually to determine the
maximum allowable concentration. The concentration limit is typically defined by the
solubility thresholds of one or more constituents. The first three criteria are applicable
to power plants. EPRI developed standards are circled.
5.3 Water Treatment Analysis and Methodology
STEPS DESCRIPTION:-
Step 1: Identify and Characterize the Source Water(s) Chemical analysis of
constituents of concern should be conducted to determine the feasibility of using the
water source(s) for cooling tower operations. Flow profiles are especially useful for
water from multiple sources, which may require further analysis and calculations
Step 2: Evaluate Constituents of Concern Each constituent must be evaluated to
ensure compliance to operational quality criteria and environmentalregulations. The
maximum cycles of concentration (N) should be calculated for each constituent. The
limiting parameter is the one with the lowest calculated N.

46
Step 3: Identify Cooling Tower Design and Operating Impacts Based on the
constituent make-up and evaluation of limiting parameters, the cooling tower design
and operating impactsshould be identified. Capital and operating costs will be affected
by the design
Step 4: Determine the Need for Treatment Treatmentscenarios and alternate options
will be determined based on calculated N values of constituents,source water, limiting
parameters of, situational limitations, and regulation limitations of the constituents.
Step 5: Evaluate Treatment Requirements Pre, side and post treatment plans will be
developed based on previous calculations and evaluations of constituents present in
the source water. Treatment technologies will be chosen and analyzed.
Step 6: Evaluate Disposal Issues Cooling tower blowdown and treatment waste
streams give rise to disposal issues, which must be evaluated. Wastes must be
analyzed for toxicity and hazards and disposed of accordingly.
5.4 Waste Minimization: ZLD Systems
Zero Liquid Discharge (ZLD):- ZLD systems aim for complete recovery of cooling
water, where no wastewater should leave the site and all waste should be converted to
dry form for ultimate disposal. ZLD systems offer the potential for sustainable
cooling and a viable waste treatment option for areas where evaporation ponds are
infeasible or prohibited. Though ZLD is ideal, not all power plants can achieve these
systems, but waste minimization technologies are nonetheless desirable. These
systems are currently limited by high costs, but can be alleviated by development of
higher recovery technologies, such as advanced RO membranes. Conventional ZLD
systems commonly utilize evaporative technologies, which are highly energy
intensive. Increased recovery with increased pre-treatments can reduce water volume
and thereby, lower evaporative costs. However, higher solid waste disposal and
chemical costs will increase may offset any cost benefits of reduced wastewater
volume. With power plant water treatment systems, recovery benefits are often
difficult to balance with costs.

47
Fig 5.3 Power Plant Colling Tower Operation.

48
 CHAPTER 6
ELECTROSTATIC PRECIPITATORS
6.1 Electrostatic precipitators (ESP):- It collect dust in the flue gas produced by
boiler, etc. Mitsubishi Power contributes to air pollution control at thermal power
plants, steel plants , and various industrial plants.
Basic Principle of ESP:-
A high voltage is applied to the discharge electrode, generating a corona discharge
that produces minus ions. The electrically charged dust is accumulated on the
collecting electrode by an electrical field.
The accumulated dust is removed by rapping hammer (dry ESP), scraping brush (dry
ESP), or flushing water (wet ESP).

Fig 6.1 Electrostatic Percipitator.

6.2 Chimney:- A chimney is the tallest structure in the power plant for venting hot
flue gases or smoke from a boiler, stove, furnace, or fireplace to the external
atmosphere. These power plant chimneys are sometimes known as stacks.
In a thermal power plant chimney has two important functions:
a. To carry undesirable combustion or smoke out of the boiler.
b. To provide the draught that feeds air to the fire to keep it burning. The draft of the
chimney comes from the rising hot air.

49
Fig 6.2 Chimney.

50
 CHAPTER 7
SWITCHYARD

2f
Fig 7.1 Meja Switchyard(400/132KV)

7.1 Equipments In Switchyard:-

• Lightning Arrester – Conduct lightning & switching surges to ground.
• CVT – Voltage measurement & PLCC communication.
• Wave Trap – PLCC communication & Protection.
• CT- Current measurement.
• Earth switch- For discharging equipments.
• Isolator- Isolating equipments from main circuit.
• Breaker- Online connection/disconnection of equipment.
• Busbar- Power distribution & interconnection.
• Transformer- Increase/decrease voltage level.
• Reactor- Absorb reactive power in light load condition.

51
7.2 Details Of Equipments:-
a. Lightning Arrester:- Conduct lightning & switching surges to ground.

Fig 7.2 Lightning Arrester.

b. CVT:- Voltage measurement. c. CT:- Current Measurement.

Fig 7.3 Capacitance voltage transformer Fig 7.4 Current transformer

52
d. Wave Trap:- PLCC communication & Protection.

PLC coupling Unit

Fig 7.5 lightning arrester Fig 7.6 Plc coupling unit

e.Isolator:- Isolating equipments from main circuit. f. Circuit Breaker(CB).

Fig 7.7 Isolator Fig 7.8 Circuit Breaker

53
g. 400KV Bus Bar:- Power distribution & interconnection.

Fig 7.9 Power distribution & interconnection.

h. Transformer:- Increase/decrease voltage level.

Fig 7.10 Interconnecting transformer

54
i. Bus Reactor:- Absorbs reactive power.

Fig 7.11 Absorbs reactive power.

7.3 Meja switchyard have 2 voltage levels:-
1. 400 KV
a) Three double circuit lines.
b) There are two main buses (Bus 1 & 2).
c) Interconnecting transformers (ICT-1 & 2).
d) Bus reactor(1 No.)
e) GT-1 & 2 output bay.
2. 132 KV
a) There are four buses (Bus-1,2,3 & 4)
b) Two lines for Bijoura switchyard(132/11kv).
c) Station Transformer (ST-1 & 2).
d) Miscellaneous Service Transformer (MST-1 & 2)
7.4 400 KV Lines for power evacuation(6 Nos.)
1. Meja-Allahabad Line 1 & 2. (PGCIL)
2. Meja-Rewa Road Line 1 & 2. (UPPTCL)
3. Meja-Bara 1 & 2. (UPPTCL)

55
7.5 Metering of lines
1. For 400 KV Allahabad Line- 1 & 2, PGCIL provided a L&T make energy meter
from which reading of each block can be downloaded through a hand held device or
on computer.
2. For 400 KV Rewa road Line 1 & 2 and Bara Line 1 & 2 UPSEB fixed 2( Main &
Check) Securemeter make energy meters for each line.
3. MUNPL have installed Elster make meters. These meters are accessed on a
computer in switchyard for daily generation calculations.
7.6 400 KV Switchyard Scheme:-
400 KV switch yard have one and half breaker scheme. In such type of scheme there
are two main buses and two feeders connected via three breakers it is called one and
half breaker scheme.
Advantages of one and half breaker scheme
1. High reliability. Breaker failure of bus side breakers removes only one circuit from
service.
2. Low space requirement .
3. All switching is done with breakers.
4. Either main bus can be taken out of service at any time for maintenance.
5. Bus failure does not remove any feeder circuits from service.
7.7 400KV Switchyard OWS Screen

Fig 7.12 OWS Screen.

56
7.8 400 KV TRANSMISSION LINES & BUS

Fig 7.13 Transmission lines and bus.

7.9 Control And Protection Scheme

1. Each dia’s all CT,CVT,Breaker,isolator & Earth switch send signals to their
respective kiosk.
2. For line protection there are 2 relays main-1 & 2.
3. For Tie protection there are 2 relays TEED-1 & TEED-2.
4. For bus bar protection there are 2 PUs(a & b) in each kiosk which communicate
through fiber optic cable to 2 CUs(a & b).
5. There are three BCU in each dia which controls operation of their respective
breaker & isolator. All BCUs connected with SAS in control room for their
centralized operation from control room.
57
7.10 Kiosk

Fig 7.14 Kiosk

7.11 Relay And Control Panel

Fig 7.15 Relay and control panel

58
7.12 Decentralized Bus bar Protection

Fig 7.16 BDD Protection

7.13 Line Charging Procedure

Start charging the Line Bay, in communication with remote end sub-station as below:-
1. All PTWs should be cancelled on line & related equipments.
2. Remote end shall provide Charging code from SLDC/ NRLDC.
3. Re-confirm with SRLDC/ NRLDC about charging code.
4. Open earth switch & ensure that earth switch of line at remote end also open, close
Line isolator & inform to SLDC through message.
5. Re-confirm with SRLDC/ NRLDC about charging code.
6. Remote end in contact with Meja, will close CBs and will request Meja to close CB
through message.
7. Ensure that proper voltage condition (in 400 kV range) is available for the Line, as
per CVT signal available in SAS/BCU.
8. Ensure that leakage current in LA is in green zone.
9. Close the Circuit Breaker for the line bay or tie Bay (On Bus-1 or Bus-2).
10.Ensure that proper voltage condition (in 400 kV range) is available for the charged
Busbar, as per CVT signal available in SAS/BCU.

59
 CHAPTER 8
TRANSFORMER
In the power transmitting station of a power plant the voltage is increased and the
current is decreased keeping power equal. So a step up transformer is used. The
alternating current is transmitted from there and then it is made to go through the step
down transformer and reaches our house at 220V.
After the electricity is generated in the generating station, it has to travel large
distances from the stations to the various areas for supply. Now high current will
cause a high heating effect which will melt the wires and cause very high resistive
loss. So this current is transferred through a step up transformer to increase the
voltage and decrease the current keeping the power constant. The high voltage
transmission is more efficient because it allows transmitting a larger portion of the
generated power to the substations which also translates to operational cost savings.
Hence in the power transmitting station of the power plant, a step up transformer is
used. The type of current that is transmitted from the power station is the alternating
current which is also known as the ac current.
From the generating stations, after the current is passed through the step up
transformer, then the current at the high voltage reaches the substations, there the
current is passed through the step down transformer where the voltage is reduced to
an amount of 220V which is supplied to the household. So the voltage at which the
current is available to our household is 220V.
The transformer in which the output voltage is greater than the input voltage is called
a step up transformer. It decreases the current in the output by keeping the power in
the input and output the same. As the power loss in the transmission line is directly
proportional to the square of the current, so by decreasing the current the power loss
decreases.
8.1 TYPES OF TRANSFORMER USED IN MUNPL
8.1.1 Generator transformer :- It is directly connected to generator taking the supply
voltage of 23.5KV from generator to its primary side and step up this voltage to 400
KV and sends it to the switchyard and further power gets transmitted to the grid.

60
 Fig 8.1 generator transformer

Fig 8.2 Specification of generator Transformer

61
8.1.2 Station Transformer :- It takes supply from grid to provide power backup to
the unit running components and devices like (several motors and internal appliances)
when the fault occurs in unit generator or unit generator is not in working condition
i.e. while maintanence of generator is going on.

Fig 8.3 Station transformer

Fig 8.4 Specification of station transformer

62
8.1.3 Unit transformer :- This transformer also directly connected with generator
towards its primary side it is used for providing the supply to the internal operating
motors ,devices and all the electrical and electronics components used inside an unit.
It works by taking the power from the unit generator.

Fig 8.5 unit transformer.

8.1.4 Unit Auxiliary transformer (UAT) :- The Unit Auxiliary Transformer is the
Power Transformer that provides power to the auxiliary equipment of a power
generating station during its normal operation. This transformer is connected directly
to the generator out-put by a tap-off of the isolated phase bus duct and thus becomes
cheapest source of power to the generating station.
It is generally a three-winding transformer i.e. one primary and two separate
secondary windings. Primary winding of UAT is equal to the main generator voltage
rating. The secondary windings can have same or different voltages i.e. generally
11KV and or 6.9KV as per plant layout.
Unit Auxiliary Transformer is nothing but a step down transformer, which is
connected parallel to the generator before the generator circuit breaker. Unit Auxiliary
Transformer Is used to deliver the power to the motor, fans, pumps, lightings etc.

63
Fig 8.6 Unit auxiliary transformer

64
REFERENCE:
 MEJA URJA NIGAM PVT LTD (MUNPL).About MUNPL
https://en.wikipedia.org/wiki/Meja_Thermal_Power_Station

 NTPC Units And Division mailto:https://www.ntpc.co.in/

 The Venture details(UPRUVNL) mailto:https://www.uprvunl.org/

 Information regarding Thermal Power Plant

mailto:https://en.wikipedia.org/wiki/Thermal_power_station

 Various Image of MUNPL is Provided by mailto:https://www.google.com/

 Materials given by mentors and self notes.

65