<p> A REPORT ON 5 Days STUDENTS WORKSHOP ON 5 DAYS Hands-on Workshop “Familiarization of Thermal Power plant and its related Automation “ was organized from 14th March,2017 to 18th March,2017 AT KOLAGHAT THERMAL POWER STATION VISIT</p><p>NAME – Sayani Mukherjee</p><p>ROLL NO - EE2015/002</p><p>DEPARTMENT – Electrical YEAR - 2017</p><p>A Five Days Hands on Student Workshop On Familiarization of Thermal Power Plant and Its Related Automation Organized by: IEEE Student Branch of RCCIIT and Department of Electrical Engineering in collaboration with WBPDCL Financially sponsored by TEQIP-II Date-14th to 18th March Acknowledgement I take this opportunity to express my profound and deep regards to Prof. Alok Kole (HOD of Electrical Department & Counselor of IEEE student branch RCCIIT) for his guidance and constant encouragement throughout the workshop and visit. I also want to thank Er. T. M. Joardar (Ex. DGM of KTPS) , Er. Sanjib Bera (Sr.Manager BkTPP) , Er. Mahitosh Maji (Ex-GM of BkTPP) , Er. Sujit Bose (Ex-GM WBPDCL) and Er. B.R.Sarkar (DGM of KTPS) for their cordial support, valuable information and guidance. Lastly, I thank almighty, coordinators, classmates and the staff members of Kolaghat Thermal Power Station for the valuable information provided by them.</p><p>Thanking you, Sayani Mukherjee Kolaghat Thermal Power Station(KTPS) Address : P.O – Mecheda, Dist.-Purba Medinipur Sl No Units Capacity (MW) 1 Unit-I 210 2 Unit-II 210 3 Unit-III 210 4 Unit-IV 210 5 Unit-V 210 6 Unit-VI 210 Total Capacity 1260</p><p>Overview : It is situated at Mecheda 55 Km from Kolkata.The plant is within 1 Km distance from Mecheda railway station. KTPS is coal fired thermal power plant, consisting of 1260 MW units of 210 MW each. Ash is disposed to total 6 No.s of Ash ponds. KTPS has won quite a few prestigious recognition for operation excellence from Govt. of India over the years. Boiler : A boiler is a closed vessel in which water or other fluid heated. The heated or vaporized fluid exits the boiler for use in various processes or heating applications, including boiler based power generation, cooking & sanitation. Types of Boiler:</p><p> Fire Tube Boiler </p><p> Water Tube Boiler Furnace : A furnace is a device used for heating. The name derives from Latin fornox, oven. The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot blowers, water lancing and observation ports for observation of furnace interior. The coal is ground to a fine powder, so that less than 2% is +300 micrometer and 70-75% is below 75 microns, for a bituminous coal. Boiler Operation: The water enters the boiler through a section in the convection pass called the economizer. From the economizer it passes to the steam drum. Once the water enters the steam drum it goes down to the downside the steam drum. The steam separators and dryers remove water droplets from the steam drum. Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fire ball at the center. The thermal radiation of the fireball heats the water that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the boiler is three to four times the throughout and is typically driven by pumps. As the water in the boiler 700˚F(370˚C)and 3200 psi(22,000 kPa). It is separated from the water inside a drum at the top of the furnace. The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to 1000˚F(540˚C)to prepare it for the turbine. Boiler Drum: Boiler drum is a part of a boiler where the dematerialized water is stored and is inserted into the boiler. It is also houses the steam that is formed in the boiler. Water stored in the drum comes down to the top of the boiler and forms Water Ring which is then inserted into the boiler through the water walls. Water Walls are basically tubes along the walls of the furnace, it is here where the water is converted into the steam at 1300˚C and then the produced steam is taken back to the boiler drum. The pressure of boiler drum is 150kg/sq.cm and must be always maintained. Water in the drum comes from the feed control station via economizer. </p><p>Turbine : A turbine is a rotary mechanical device that extracts energy from a fluid flow and convert it into useful work. Types of Turbine:</p><p> Steam Turbine  Gas Turbine</p><p> Transonic Turbine</p><p> Contra-rotating Turbine</p><p> Statorless Turbine</p><p> Ceramic Turbine</p><p> Shrouded Turbine</p><p> Shroudless Turbine</p><p> Water Turbine Turbine casing:- The turbine assembly comprises of three types of casing. 1. High Pressure Casing 2. Intermediate Pressure Casing 3. Low Pressure Casing Other Turbine Components:-  Rotor  Blades  Sealing Glands  Emergency Stop Valves  Coupling  Bearing  Barring Gear  Turbine Lubrication Oil System Introduction of Water Treatment of Thermal Power Plant In a thermal power plants, plenty of water is needed for generation of electricity. There are two purposes: 1. As a Working Fluid 2. As a Cooling Water Treatment of water for boiler feed: Boiler feed water treatment for high pressure boilers are almost standard. Raw water is classified and filtered for removal of un-dissolved impurities and demineralised for removal of dissolved salts.</p><p>DM Plant- A DM plant generally consists of cation, anion, and mixed bed exchangers. Any ions in the final water from this process consist essentially of hydrogen ions and hydroxide ions which recombine to form pure water. Very pure DM water becomes high corrosive once it absorbs oxygen from the atmosphere because of its very high affinity for oxygen.</p><p>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 cooler, the pressure of the exhaust steam is reduced and efficiency of the cycle increases. The surface condenser is a shell and tube heat exchanger in which cooling water is circulated through the tubes.</p><p>Economizers- These are heat exchange devices that heat fluids, usually water, up to but not normally beyond the boiling point of that fluid. Economizers are so named because they can make use the enthalpy in fluid steams that are hot. But not hot enough to be used in a boiler, thereby recovering more useful enthalpy and improving the boiler’s efficiency. Air and Flue Gas Path Induced Draft (ID) Fan – This fan is used to create negative pressure in the furnace i.e. furnace pressure is lower than the atmospheric pressure, as a result of which the fire ball inside the furnace cannot come of the furnace.ID fans also drives the flue gas throughout its path and above processes and finally rejects it out of the chimney. It sucks air from inside the furnace rejects it to the atmosphere. Force Draft (FD) Fan- Force Draft (FD) fans purpose is to provide a positive pressure to a system. This basic concept is used in a wide variety of industries but the term FD Fans is most often found in boiler, typically through a preheater to increase overall boiler efficiency. Air Preheater – The flue gas produced as result of combustion of fossil fuel in the furnace is taken to the air-preheater. </p><p>Chimney- A chimney is a structure which provides ventilation for hot flue gases or smoke from a boiler, stove, furnace or fireplace to the atmosphere. Chimneys are typically vertical, or as near as possible to vertical, to ensure that the gases flow smoothly, drawing air into the combustion in what is known as the stack, or chimney. Coal Handling Plant Coal: Coal is the basic raw material used on large scale throughout the world. A fossil fuel ,coal forms when dead plant matter is converted into peat. Handling Plant : In a coal based thermal power plant , the initial process in the power generation is “coal handling”. Coal is extracted from the ground of coal mining , either under gounded by shaft mining. The huge amount of coal supplied through railways. Few rail siding line is taken into the power station and the coal is delivered into the storage yard. The coal is unloaded from the point of delivery by means of wagon tippler. The belt delivers the coal to 0m level to the pent house. The transfer points are used to transfer coal to 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. The belt further elevates the coal to the transfer point 7 and it reaches the crusher through belt. In the crusher a high speed 3-phase induction motor is used to crush the coal to a size of 50mm so as suitable for milling system. Coal rises from crusher house and reaches the dead storage by passing through transfer point 8. Components of Coal Handling Plant: 1. Stockpile 2. Stack 3. Reclaimer 4. Crush House 5. Tipplers 6. Pull chord switch 7. Vibrating feeder 8. Flap gates 9. Magnetic separator 10. Metal detector 11. Belt weightier 12. Reclaim hopper Coal Mill: A pulveriser or grinder 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 the thermal power plants. The Mill consists of feeder, Mill for pulverization of coal and classifier. The stacked coal in the bunker is dropped to the feeder automatically; the feeder is housed with a conveyor belt system with motors and pulleys. The flow of coal is maintained by the speed/rpm of the conveyor belt of the feeder. Ash Handling Plant  What is Ash?</p><p>Ash is the residue remaining after the coal is incinerated.  What is Ash handling?</p><p>Ash handling refers to the method of collection, conveying, interim storage and load out of various types of ash residue left over from solid fuel combustion processes. A. Bottom Ash Handling System B. Air Pre heater Ash Handling System C. Fly Ash Handling System D. Ash Slurry Disposal System Generator- E=4.44/ø f N volts Where E= emf induced; Ø=Strength of magnetic field f =Frequency in cycles per seconds N = no. of turns Generator Components –</p><p> Rotor</p><p> Stator Transformer –</p><p> It is static device which transfers electric powers from one circuit to the other without any change in frequency, but with a change in voltage and corresponding current levels also.</p><p> The step up generator transformers are ONAN/ANOF/AFOF cooling type.</p><p> Here the transformers used are to transfer electric power from 15.75KV to 220KV are provided to the national grid. Switching Yard- What is Switching Yard? The switch yard is a junction connecting the Transmission & Distribution system to the power plant. It means collection of electrical equipment where high voltage electricity is switched using of various component. Equipments of Switch Yard 1. Isolator 2. Circuit Breaker Conclusion The five days hands on workshop had been concluded in a very efficient way. We have acquired through knowledge about generation, transmission and distribution of power. Kolaghat Thermal Power Station is one of the largest power station in Eastern India , had been acting as a pioneer in power generation over a decade. This report has covered the mechanical ,electrical overview and various cycles and processes of power generation and details of control and instrumentation required in thermal power plant. </p>