Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Report
On
“Study of Boiler and Thermal Plants”
At
NPTC & KBUNL
Kanti, Muzaffarpur, Bihar.
2017-2018
Vocational Training Report
On
“Boiler and Thermal Plants”
At
National Thermal Power Plant, Kanti, Muzaffarpur.
Submitted by:
Name: Sawan Kumar.
Roll no: 16900714088.
College: Academy of Technology.
Duration: 24.06.2017 – 21.07.2017.
Certificate
__________________________
Mr. Suraj Kumar Santosh
Deputy Manager,
Mechanical Maintenance Department,
NTPC, Muzaffarpur.
(I)
ACKNOWLEDGEMENT
Sawan Kumar.
Vocational Trainee
24.06.2017 – 21.07.2017
(II)
Abstract
Any thermal power plant is converting the chemical energy of fossil fuel (coal)
into electrical energy. The process involved for this conversion is based upon
the Modified Rankine Cycle. The major components that are used to accomplish
the modified Rankine cycle are:
All components of a power generating cycle are vital and critical in operation.
In Modified Rankine Cycle, the two most important aspects that is added are
reheating & regenerative heating. By reheating we used to send the steam
coming from exhaust of the turbines back to the reheater of the boiler so that its
enthalpy increases and more work can be done by this steam the other purpose
is to make steam dry so that no harm will be done to the blades of the turbine.
In NTPC, Kanti, we have three turbines in Tandem coupling namely one H.P
Turbine, one I.P Turbine & one L.P Turbine coupled with the generator to
which is synchronized with the grid to produce electricity at 50Hz.
In all my modesty, I wish to record here that a sincere attempt has been made
for the presentation of this project report. I also trust that this study will not only
prove to be of academic interest but also will be able to provide an insight into
the area of technical management.
(III)
Contents
1. Certificate (I)
2. Acknowledgement (II)
3. Abstract (III)
4. Introduction (1)
5. History of Boiler (2-3)
6. Types of Boiler and its classification (3-7)
7. Basic components of Boiler (8)
(i) Economiser (9)
(ii) Pre-heater (10)
(iii) Super-heater (10)
(iv) Re-heater (11)
(v) De-super heater (11)
(vi) Condenser (12)
(vii) Cooling Tower (13)
(viii) Fan & Draught system (13)
(ix) Ash handling system (14)
(1)
History of Boiler
The steam-generating boiler’s roots go back to the late 1700s and early
1800s with the development of the kettle-type boiler, which simply boiled
water into steam. The water was placed above a fire box and then boiled
into steam. It wasn’t until around 1867, with the development of the
convection boiler that the steam-generating industry began.
The Stirling Boiler Company, owned by O.C. Barber and named for the
street (Stirling Avenue) the facility was on in Barberton, Ohio, also began
making boilers in 1891. Their eighth Stirling boiler design was called the
H-type boiler (“h” being the eighth letter in the alphabet) and had a brick
setting design. The Stirling boiler was much larger than the Babcock &
Wilcox boiler and used three drums to help circulate the water and steam
flow throughout the boiler.
In 1907, the Stirling Boiler Company merged with the Babcock & Wilcox
Company. They renamed their boiler the H-type Stirling, and it became
one of best-selling boilers of its time, probably because of its ability to
produce up to 50,000 pounds of steam per hour.
(2)
However, they were not the only boiler manufacturers during the late
1800s. The Grieve Grate Company and the American Stoker Company
were also making boilers of similar all-brick-wall design. They both used
a travelling or screw-type grate at the bottom of the boiler to transport the
fuel (lump coal) across the inside of the boiler. As the fuel traveled across
the inside of the boiler, it was burned and the ash or un-burned fuel would
drop into a hopper. These two companies later formed the Combustion
Engineering Company in 1912. The new Combustion Engineering
Company offered their version of the Grieve and American Stoker boilers
and called it the Type E stoker boiler.
(3)
Fire-tube Boilers
In fire-tube boilers, combustion gases pass through the
inside of the tubes with water surrounding the outside of
the tubes. The advantages of a fire-tube boiler are its
simple construction and less rigid water treatment
requirements.
The disadvantages are the excessive weight-per-pound of
steam generated, excessive time required to raise
steam pressure because of the relatively large volume of
water, and inability to respond quickly to load changes,
again, due to the large water volume.
Relatively inexpensive
Easy to clean
Compact in size
Available in sizes from 600,000 btu/hr to 50,000,000 btu/hr
Easy to replace tubes
Well suited for space heating and industrial process applications
Not suitable for high pressure applications 250 psig and above
Limitation for high capacity steam generation
(4)
Water-tube Boilers
In a water-tube boiler, the water is inside the
tubes and combustion gases pass around the
outside of the tubes. The advantages of a water-
tube boiler are a lower unit weight-per-pound of
steam generated, less time required to raise
steam pressure, a greater flexibility for
responding to load changes, and a greater ability
to operate at high rates of steam generation.
Water-tube boilers:
(5)
Other types of Boiler are:
1. Cast iron boilers.
2. Steam and Condensate boiler system.
3. Hydronic (Hot water) boiler system.
Cast iron boilers are made in three general types: horizontal-sectional, vertical-
sectional, and one-piece. Most of the sectional boilers are assembled with push
nipples or grommet type seals, but some are assembled with external headers
and screw nipples. Horizontal-sectional, cast iron boilers are made up of
sections stacked one above the other, like pancakes, and assembled with push
nipples. Vertical-sectional, cast iron boilers are made up of sections standing
vertically, like slices in a loaf of bread. One-piece cast iron boilers are those in
which the pressure vessel is made as a single casting.
(6)
In common facility heating applications, the condensate system is at
atmospheric pressure and the system is arranged to drain the condensate to a
central condensate receiver, or into local smaller receivers that pump the
condensate back to the central condensate receiver.
(7)
Basic components of Boiler are:
Furnace
Economiser
Air – Preheater
Super Heater
Re-heater
De-Super heater
Condenser
Cooling tower
Fan or draught system
Ash handling system
Furnace: A boiler furnace is the first pass of the boiler in which the
combustible products pass to the super heater
and second pass of boiler. The
combustion process is a
continuous process, which
takes place in the first pass of
the boiler and control by the
fuel input through coal
feeders. It is a radiant type and
water cooled furnace and
enclosure is made up of water
wall.
(8)
Requirement should be satisfied by the furnace:
1. Proper installation, operation and maintenance of fuel burning equipment.
2. Sufficient volume for combustion requirement.
3. Adequate refractoriness and insulation.
Economiser:
It is located below the LPSH in the boiler and above pre heater. It is there to
improve the efficiency of the boiler by extracting heat from flue gases to heat
hot water and send it to the boiler drum.
Advantages:
1. Fuel economy: It is used to save fuel and increase overall efficiency of
the boiler plant.
2. Reducing size of the boiler: A the feed water is preheated in the
economiser and enter boiler tube at elevated temperature. The heat
transfer area required for evaporation reduced considerably.
(9)
Air-preheater: The heat carried
out with the flue gases coming out of
economiser are further utilize for
preheating the air before supplying
to the combustion chamber. It is
necessary equipment for supply of
hot air for drying the coil in
pulverized fuel system to fascinate of
fuel in the furnace.
[Image by:slideshare.net]
Super-heater:
[Image by:slideshare.net]
The steam generated by the boiler is usually wet or at the most dry saturated
because it is in direct contact with water. So, in order to get superheated
steam, a device known as super heater has to be incorporated with the boiler.
The function of the super-heater system is to accept dry saturated steam from
the steam drum and to supply superheated steam at the specific final
temperature of 540°C by means of a series of heat transfer surfaces arranged
within the boiler gas passes.
A super-heater is a surface type heat exchanger generally located in the
passage of hot flue gases.
The dry saturated steam from the boiler drum flow inside the super-heater
tubes and in this way its temperature is increased at same pressure.
Types of super-heater:
1. Primary super-heater
2. Secondary super-heater
3. Final super-heater
(10)
Re-heater:
heater:
Power plant furnaces may have a
re-heater
heater section containing tubes
heated by hot flue gases outside
the tube. External steam from the
high pressure turbine is re-routed
re
to go inside the re-heater
re tube to
pick up more energy to go drive
intermediate or lower pressure
turbines.
[Image by: cleanenergysystem.org]
De-super
super heater:
(11)
Condenser:
The condenser condenses the steam from the exhaust of the turbine into the
liquid to allow it to be pumped. If the condenser can be made is reduced and
efficiency of the cycle increases.
Functions:
1. To provide lowest economic heat rejection temp for steam.
2. To convert exhaust steam to water for reserve thus saving on feed water
requirement.
3. To introduce make up water.
(12)
Cooling tower:
(13)
Ash handling system:
The dispersed of ash from a large capacity power station is of same
importance as ash is produced in large quantities. Ash handling is a
major problem:
1. Manual handling: While barrows as used for this. The ash is collected
directly through the ash outlet door from the boiler into the container
from manually.
2. Mechanical handling: Mechanical equipment is used for ash disposal,
mainly bucket elevator, belt conveyer. Ash generated is 20% in the
form of bottom ash and next 80% through flue gases so called fly-ash
and collected in ESP.
3. Electrostatics precipitator: From air pre-heater, this flue gases (mixed
with ash) goes to ESP. The precipitator has plate blanks (A-F) which
are insulated from each other between which the flue gases are made
to pass. The dust particles are ionized and attracted by charged
electrodes. The electrodes are maintained at 60KV.
(14)
Thermal Power Plant
(15)
WORKING PRINCIPLE
Coal based thermal power plant works on the principal of Modified
Rankin Cycle.
Process 1-2
Working fluid is pumped from low to high pressure.
Process 2-3
High pressure liquid enters a boiler where it is heated at constant
pressure by an external heat source to become a dry saturated
vapour.
Process 3-4
The dry saturated vapour expands through a turbine, generating
power.
Process 4-1
The wet vapour then enters a condenser where it is condensed at a
constant temperature to become a saturated liquid.
Process 3-3’
After the vapour has passed through H.P. it is reheated before
passing through I.P. turbine.
this prevents the vapour from condensing during its expansion
which can seriously damage the turbine blades, and improves the
efficiency of the cycle
(16)
Modified Rankine cycle means reheat rankine cycle or regenerative
rankine cycle. The efficiency of modified Rankine cycle is improved.
Reheat rankine cycle means after the steam expanded from turbine again the
steam is reheated and sent to another turbine for expansion. The remaining
cycle is similar to normal rankine cycle.
(17)
PROCESS OF GENERATION OF ELECTRICITY
NTPC, Kanti is a Thermal Power Plant. The functioning of every thermal power
plant is based on the following processes: -
1. Coal to Steam.
2. Steam to Mechanical Power
3. Power Generation, Transmission & Distribution.
STEP-1
Coal To Steam
Coal and Water are primary inputs to a
thermal power plant. This process of
conversion of water to steam by using the
heat energy produced by burning coal for
producing heat takes place in the boiler
And its auxiliaries. Coal burns in a furnace
located at the bottom part of the boiler. Feed
water is supplied to the boiler drum by boiler
Feed pumps, where water is heated and
converted into saturated steam
This is further superheated in the super
heaters.
[Image by: power.eng.com]
STEP-2
Steam To Mechanical Power
This is the most important process of a power plant. The superheated
Steam produced in the boiler at high pressure and temperature is feed
to the turbine. The steam expands in the turbine giving up heat energy, which is
transformed
rmed into mechanical energy on turbine shaft. Thus,
Mechanical power is obtained from the turbine shaft.
STEP-3
Power Generation, transmission & Distribution
Mechanical power produced at the shaft of the turbine is used to
Rotate the rotor of an electrical generator that produces electric
power. The electric power produced by the generator is boosted to a
higher voltage by a generator transformer to reduce the transmission
losses.
This power at EHV i.e. 400 kV is transmitted and distributed by EHV
transmission lines.
(18)
LIGHT UP PROCESS
STEP-1
STEP-2
The pulverized coal and air discharge from the coal burners is directed
towards the centre of furnace to form fire ball.
STEP-3
The secondary air heating system supplies secondary air for combustion
in the furnace around the pulverized coal burners and through auxiliary
air compartments, directly adjacent to the coal burner compartments.
STEP-4
(19)
Components of Coal Fired Thermal Power Station:
Coal Preparation
Fuel preparation system: In coal-fired power stations, the raw feed
coal from the coal storage area is first crushed into small pieces and
then conveyed to the coal feed hoppers at the boilers. The coal is next
pulverized into a very fine powder, so that coal will undergo complete
combustion during combustion process.
Pulverizer: is a mechanical device for the grinding of many different
types of materials. For example they are used to pulverize coal for
combustion in the steam-generating furnaces of fossil fuel power
plants. There are six mills located adjacent to the furnace at 0 m level
.These mills pulverize coal to desired fineness to be fed to the furnace
for combustion. The main structure of the pulverisering mill is
fabricated from mild steel in three cylindrical sections, the bottom
section (the mill housing support )which support the entire unit and
encloses the mill drive gear unit, a center section (the mill
housing)that contains the rotary grinding element and upper section
(the classifier housing )comprising an accommodate the gas loading
cylinders of the mill loading gear .A platform around the upper section
provide an access to an inspection door and to the top of the mill
routine maintenance and is served by detachable ladder . The grinding
element comprises of 3 rotatory rollers.
Types of Pulverisers:
Ball and Tube mills
Ring and Ball mills
MPS; Ball mill
Demolition
Dryers: They are used in order to remove the excess moisture from coal
mainly wetted during transport. As the presence of moisture will result in
fall in efficiency due to incomplete combustion and also result in
CO emission.
Magnetic separators: Coal which is brought may contain iron particles.
These iron particles may result in wear and tear. The iron particles may
include bolts, nuts wire fish plates etc. so these are unwanted and so are
removed with the help of magnetic separators. The coal we finally get
after these above process are transferred to the storage site.
Purpose of fuel storage is two –
Fuel storage is insurance from failure of normal operating supplies to
arrive.
(20)
Storage permits some choice of the date of purchase, allowing the
purchaser to take advantage of seasonal market conditions. Storage of
coal is primarily a matter of protection against the coal strikes, failure of
the transportation system & general coal shortages.
There are two types of storage:
Live Storage (boiler room storage): storage from which coal may be
withdrawn to supply combustion equipment with little or no remanding is
live storage. This storage consists of about 24 to 30 hrs. of coal
requirements of the plant and is usually a covered storage in the plant
near the boiler furnace. The live storage can be provided with bunkers &
coal bins. Bunkers are enough capacity to store the requisite of coal.
From bunkers coal is transferred to the boiler grates.
Dead storage- stored for future use. Mainly it is for longer period of
time, and it is also mandatory to keep a backup of fuel for specified
amount of days depending on the reputation of the company and its
connectivity.
There are many forms of storage some of which are –
(21)
TYPES OF PUMP
Air Extraction Pump (AEP): The function of the air extraction pump is
to raise and maintain the vacuum conditions in the turbine main
condensers, and to remove air and other non-condensable gases vented to
the condenser from various parts of the turbine and feed water heating
system.
Boiler Feed Pump (BFP): Boiler feed pump is the most critical
component of a power plant. It is a rotary machine, which is coupled to a
motor through variable speed coupling or turbo coupling.
Feed water supplied to the boiler drum should have high pressure which
is achieved when passed through boiler feed pump. Whenever the
pressure of water is to be raised, BFP is used. The discharge pressure of
a boiler feed pump is approx. 150 kg/sq. cm.
(22)
TYPES OF TURBINE
(23)
IMPORTANT CONTROL LOOPS IN A THERMAL
POWER PLANT
Process: The equipment whose present level, pressure and other values is
to be measured is known as process.
Set Point: The required value of parameter is set by the manual which is
to be maintained in order to protect the process from damage.
(24)
Comparator: It compares the signal between set point and measured
value. If the two values differ from one another, an error signal is
generated and sent to the controller.
The required drum level is set at the set point. The present drum level is then
measured which is done by capacitor type transmitter. Two tapping, one at the
bottom in water while other at the top in steam, is made and allowed to flow to
the transmitter. Since, the two elements are in different states, steam is
condensed and collected in a constant head unit (CHU) before going to the
transmitter where the present drum level is measured and converted to current
signal between 4-20 mA. This set value and measured value are then compared
in a comparator and an error signal, if any, is generated and sent to controller
which finally directs the final control element to control the drum level. Here,
the final control element is a control valve through which a fluid passes that
adjusts the size of the flow passage as directed by a signal from controller to
modify the rate of flow of the fluid. Hence, the drum level is controlled.
(25)
D.P. Across Feed Control Station:
In order to maintain the linear characteristics of the feed regulating valves under
different loads, the differential pressure (D.P.) control loops maintains a fixed
differential across the regulating valves and BFP discharge pressure is varied by
changing BFP motor speed through hydraulic scoop tube device which is the
final control element here. The D.P. across feed station (comparator) is sensed
and is fed to the controller. The controller are automatically adjusted as function
of steam flow to achieve stable condition. The reserve Boiler Feed pump scoop
tube automatically follows the running pump scoop tube and the change over to
the reserve BFP takes place with the scoop tube in the same position of the
scoop tube.
Combustion Control :
The combustion control proposed for this boiler comprises of the following
loops:
a. Master pressure control
b. Pulverized coal flow control
c. Combustion air flow control
d. Oxygen trim control
e. Mill temperature and air flow control
(26)
UNIT CONTROL DESK & PANELS
The operation of each unit is envisaged from the central unit control
room. It is located in the control bay at 9.0m TG floor. It is
adequately illuminated and is centrally air conditioned. For
operational convenience, the control room front wall has complete
glass paneling for TG hall view and the two double doors for entry
from TG hall.
The control board has a special profile with three sloping surfaces for
mounting a large fascias, instruments and controls. The automatic
control station and drive control switches & Indications are located on
the first sloping surface. The process indicators/recorders and
ammeters are mounted on the second sloping surface and the alarm
annunciation window fascias are mounted on the top i.e. third sloping
surface.
(27)
ADVANTAGES OF COAL BASED THERMAL POWER PLANT
(28)
Conclusion
The training at NTPC, Kanti was altogether an exotic experience, since work,
culture and mutual co-operation was excellent here. Moreover fruitful result of
adherence to quality control, awareness of safety and employees were fare
which is much evident here.
(29)
References
Modern power station practice-Volume B & Volume C.
www.ntpc.co.in
http://indianpowersector.com/home/powerstation/thermal-power-plant/
https://en.wikipedia.org/wiki/Boiler
https://en.wikipedia.org/wiki/Thermal_power_station
https://en.wikipedia.org/wiki/Rankine_cycle
nptel.ac.in/courses/112106133/Module_5/2_Rankinecycle.pdf
en.wikipedia.org
www.mechanicalengineerings.wordpress.com
www.electrical4u.com
(30)