TARINING REPORT

ON

INDUSTRIAL TRAINING UNDERTAKEN AT

“PANIPAT THERMAL POWER STATION”

SUBMITTED IN PARTIAL FULFILMENT OF

THE REQUIREMENT FOR THE AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY IN INFORMATION TECHNOLOGY

OF KURUKSHETRA UNIVERSITY

KURUKSHETRA

BY

RAHUL

1507551

IT-5

DEPARTMENT OF INFORMATION TECHNOLOGY

N.C. COLLEGE OF ENGINEERING, ISRANA (PANIPAT)

CERTIFICATE

I am submitting my training report detailing the work done during the training at P.T.P.S. Panipat. I have written this report from the sources which have been fully acknowledged.

has worked under my supervision during training report period. I have read this report, it meets expectations and it accurately reflects work done by him.

ACKNOWLEDGEMENT

In every step of achieving any concert, there is need of guidance, inspiration & help for results.

Here I am thankfull to following persons for not only their valuable instructions that they have

given me to prepare this report. But also for their cooperation during training period.

1. Er. R.S. Kataria XEN/Traing Deptt.

2. Er. A.K.Dua XEN/CHP-1st

3. Er. Harminder Singh AEE/CHP-1st

4. Er. R.S. Malik J.E./CHP-1st

I am really thankfull to all other staff of CHP-1st.Their best of help me and provide me

information required for directly or indirectly for completion of this project report.

J.E. CHM-1st

P.T.P.S. Panipat

INTRODUCTION TO HPGCL

Haryana Power Generation Corporation Limited (HPGCL) was incorporated as a company under

Companies Act 1956 On 17th March 1997 and certificate for commencement of business was

granted on 5th August 1997. The business of generation of power of erstwhile Haryana State

Electricity Board was transferred to Haryana Power Generation Corporation Limited on 14 th

August 1998 pursuant to the implementation of power reforms in the state of Haryana. The main

objective of HPGCL is to generate power in the state of Haryana from the existing generating

stations in most efficient manner on commercial lines and sell whole of the power generated

exclusively to Haryana Vidyut Parsaran Nigam Limited and to set up new power projects in the

state sector.

The main objectives of HPGCL are as under

1. To generate power from its existing Generating Stations in the most efficient manner on

commercial lines and to sell the same to distribution companies.

2. To set up new power generation projects.

3. From June 2005 HPGCL is also responsible for the work of power trading i.e.

Procurement of power on long term and short-term basis, signing of power purchase

agreements with power producers/ traders.

INTRODUCTION TO PANIPAT THERMAL POWER STATION

Panipat thermal power station is an undertaking of Haryana vidyut Prasaram nigam. This a coal

based thermal power plant, which produced electricity by using heat energy coal. It was

established in 1979.

It is established in Assan village on jind-Panipat Roud, 14K.m.s from west of Panipat the station

area is spread in 1870 acres, out of which 630 acres is occupied by the power plant, 400 acres is

for residential colony and 840 acres is for the disposal of ash. The inputs of the plant are mainly

water and coal. The water is cleaned and demineralised and then sent to the boiler for the

production of steam.

The output of the plant is electric power. The present capacity of the plant is 1360 MW with a

total investment of Rs. 2500 crore. There are eight units. The capacities of first four units are 110

MW each. The capacity of fifth and sixth units are 210 MW each. Capacities of seventh and

eighth units are 250 MW each.

Panipat Thermal Power Station

Sr.No. Stage No. Unit No. Capacity

Date of

Commissioning

1.

Stage-1 Unit-1 110 MW 01.11.1979

Unit-2 110 MW 27.03.1980

2.

Stage-2 Unit-3 110 MW 01.11.1985

Unit-4 110 MW 11.01.1987

3.

Stage-3 Unit-5 210 MW 28.03.1989

Unit-6 210 MW 31.03.2001

4.

Stage-4 Unit-7 250 MW 28.09.2004

Unit-8

250 MW

28.01.2005

THREE MAJOR INPUT TO POWER STATION

1) WATER

Water for the power station has been taken from nearby Yamuna canal. This water is

lifted by raw water is stored in clear well where it is send to the clarifier to remove

turdibility in water.is stored in the clear well from where it is send to water treatment

plant, cooling water system and the service water system. The water treatment plant is

filtered and dematerialized. The DM water is storage in tanks for use in boiler and filtered

which is not dematerialized is sent plant and colony for personal use with the help of

portable pumps.

2) FUEL OIL

In the power station two types of oils are used for the initial preheating of the boiler.

a) LSHS(Low Sulphate High Stock Oil)

b) High Speed Diesel Oil

c) Heavy Furnace Oil

The high speed diesel oil reaches the power station through the lorry tankers. The

HFO oil is stored in large tankers for the future use in the boiler.

The heavy oil comes in rail tankers. As the oil is heated in bulk storage coils. Heavy

furnace oil os burnt in furnace after the atomizing with steam.

For efficient burnuing o foil, the oil and air is to bemixed thoroughly the oil has to

broken into the finer particles to readily combine with the air f;or combustion. This is

known as the atomization of oil. Atomization of oil can be done in following two

ways.

1. Mechanical pressure atomizing

2. Atomizing through external source

At P.T.P.S. atomizing with steamis done at the higher pressure than the oil is

admitted into the burner for combustion in the furnace.

High speed diesel oil is stored in the storage tanks oil storage yard and is

conveyed to the boiler front a set of pumps and strainers. The atomizing medium

for high oil is compressed air and is supplied from the plant service air system.

Heavy oil is stored in tanks yards and is conveyed to the through a set of pumps

and strainers. The whole length of piping the boiler front is steam traced maintain

the temperature and hence its fluidity so that it can freely flow in the pipelines.

3. COAL

The coal reaches the plant in the railway wagons. The unloading of coal is done

mainly by titling the wagon by tippler. The coal is sent to the storage yard through

the conveyer belts. The curshed coal is sent to the storage yard through the

conveyer belts. The crushed coal from store is sent to the coal dust passes upward

into the direction of flow is changed abruptly. This cause the coarse particle in the

air coal stream to finer coal dust along with primary air leaves the classifier into

the coal transport piping from where it goes to nozzle. Pulverized coal obtained

from coal mill cannot be burnt directly.

ESSENTIAL FEATURE OF THE LOCATION OF A THERMAL POWER

PLANT :-

There are various factors whose consideration is essential while deciding the location of any

thermal power plant. The two essential inputs i.e. water and coal must be easily available. The

raw water should be available near the site i.e. some water source like canal or river must be near

the site. For getting the supply the plant should be connected by rail or road.

SELECTION OF SITE FOR A THERMAL STATION DEPENDS UPON

THE FOLLOWING POINTS :-

1. Nearness to load center

2. Supply of water

3. Availability of coal

4. Land requirement

5. Type of land

6. Transportation facilities

7. Labour supplies

8. Ash disposal

9. Distance from populated area

BRIEF DESCRIPTION OF PLANT LAYOUT:-

A thermal power station is a power plant in which the prime mover is steam driven. Water is

heated; it turns into steam and spins a steam turbine, which drives an electrical generator. After it

passes through the turbine, the steam is condensed in a condenser, this is known as a Rankine

cycle. The greatest variation in the design of thermal power plant is due to the different fuel

sources. Some prefer to use the term energy center because such facilities convert forms of heat

energy into electrical energy.

The basic energy cycle involved in the plant is as follows :

Chemical Energy

(Coal)

Heat Energy

Mechanical Energy

Electrical Energy

Various steps and processes undergone at P.T.P.S. are as follows:

1. Coal handling

2. Combustion

3. Feeding water

4. Ash disposal

1) Coal handling: majority of fuel used at P.T.P.S. is coal. Therefore half of total

station operating cost is of coal and therefore coal handling requires careful

consideration.

Various steps in coal handling are:

i) Delivery of coal: coal may be delivered by rail or road. In Panipat delivery of coal

is mainly through railways.

ii) Unloading: the coal is unload from the rail wagons and sent for preparation.

iii) Preparation: preparation of coal before feeding to the combustion chamber

becomes necessary only if upsized coal is brought to the site and sizing is

desirable for purpose of storage or firing. A coal preparation plant may include:

a) Crusher

b) Sizer

c) Magnetic separation

d) Dryer

iv) Transfer: This means carrying coal from unloading plant to the storage site from

where it is discharged to the firing equipment.

v) Coal weighing: as stated above cost of fuel is major running cost of plant. It is

necessary to weigh coal at the unloading point too and also that used as feed to

individual boiler a correct measurement of coal enable us here an idea of quantity

of coal is delivered at he site.

2) Combustion: fuel is burnt in confined space called furnace. A efficient combustion of

fuel is essential for economic working of plant.

3) Feeding water: natural water that comes to the P.T.P.S. from link canal contains solid,

liquid and gaseous impurities. This water as such can’t be used, therefore the

impurities in raw water have to removed before it is used in boiler.

Even through the main condensate returns to boiler as feed water, make up water is

still required to replace the loss of water due to blow down leakage etc in cycle.

Different impurities in natural raw are as follows:

a) Undisclosed and suspended solid material.

b) Dissolved salt and minerals

c) Dissolved gases such as CO2 and O2.

4) The air is drawn from atmosphere by forced draught fan through air pressure in which

it is heated by heat of gases passing to chimney and then is eliminated. The heat is

admitted to furnace. The flue gases after passing around boiler tubes and super heater

drawn by the induced fan air heater and finally exhausted to atmosphere through

chimney.

5) The chemical energy of the fuel converts the water into steam in the boiler. This

steam is taken from super heater to turbine through different stages. The staff is

coupled with generator or turbo generator and electrical power is generated.

6) The steam from the lpt is taken to condenser where it is consider into H2O. the

condensed water is extracted from the condenser by condensate pumps & then forced

to low pressure feed water heater where its temperature is raised by the heat rom glad

steam.

7) Ash disposal system: for a large rating of power station a huge amount of ash is to be

disposed off. Handling of ash is a problem because ash coming out of furnace is:

1) Very hot

2) Dusty

3) Introduces poisonous gases and corrosive acid when mixed in water.

In the layout of a thermal plant it consists of four circuits. These circuits are as follows:

1) Coal and ash flow cycle

2) Air and gash cycle

3) Water flow process

4) Cooling water cycle

COAL AND ASH FLOW CYCLE

In the cycle coal from the storage is fed to the boiler through coal handling equipment. Ash

produced due to combustion of coal is removed to ash handling system.

Details of processes are shown in following cycle:

RAW COAL (FROM MINES)

COAL TRANSPORTATION (IN OPEN RAILWAYS WAGONS)

COAL UNLOADING (BY WAGON TIPPLERS)

COAL BROKEN TO PIECES

COAL ON CONVEYER BELT(BIG STONES REMOVED

COAL REDUCED TO PIECES(12-20 MM SIZE)

COAL ON CONVEYER BELT(BIG STONES REMOVED

COAL ON BUNKERS

TO COAL MILLS

POWDERED FORM

COAL TO FEEDER

COAL TO FURNACE

IGNITED COAL

ASH

ASH MIXED WATER

ASH HANDLING PLANT

AIR AND GAS CYCLE

Air is supplied to combustion chamber to the boiler drum through the F.D. fan; P.A. fan is used

to carry pulverized coal to the furnace. The exhaust gases are passed through air pre heater and

various economizers and then send to the electrostatic precipitator before being send to chimney

with the help of I.D. fan.

WATER FLOW PROCESS

The raw water taken from canal is send to the clarifier. There dust and salts are removed by

assing alum and ci. This water moves to d.m. plant where the minerals from the water are

removed. Then the water is fed to the boiler for the formation of steam, which is utilized for the

formation of electricity.

Details of processes are shown in following cycle:

RAW WATER(FROM CANAL)

WATER KEPT STANDING

SUSPENDED IMPURITIES SATTLED DOWN

ALUM ADDED TO H2O(SUSPENDED IMPURITIES REMOVED

WATER TO TREATMENT PLANT

CLLURNING OF H2O(SISSOLVED IMPURITIES OF BACTERIA REMOVED

PRESSURE PLANT

ACTIVATED CARBON FILTER

CATION EXCHANGER(POSITIVE IONSREMOVED)

DE GASES( GASES REMOVED)

ANION EXCHANGER

MIXED FILTER BED

STORAGE TANK

DOZING OF SULPHATE HYDRAZINE

pH MAINTAINED

PURE H2O

ECONNOMISER

TO THE BOILER

STEAM

COOLING WATER CYCLE

The quantity of water required for condensing the steam to water us quite a large and is therefore

taken directly from the water source. The water is continuously through the condenser and sent

to the cooling tower for the purpose of cooling.

BOILER AND ITS ACCESSORIES:

The boiler which is used in this unit of PTPS is of natural circulation, wet bottom, tangential

cornered fired balanced draft, radiant direct fired pulverized coal system type. Basically the

boiler is defined as set of units, combined together consisting of a apparatus for producing and

recovering heat by igniting the certain fuel together with the arrangement for transferring heat so

as to make it available water which could be heated and vaporized to steam which can be further

used for generation o electricity with the help of turbine and generator.

ACCESSORIES:

These are some common components which are installed to increase the efficiency of the system

power plant and help in proper working of the boiler unit. These fittings are called as boiler

accessories and given as follows:

1) Furnace:

A boiler furnace is that space under of adjacent to a boiler in which the fuel gets and from

which the combustion products pass into the boiler proper.

ELECTROSATTIC PRECIPITATOR:

These are generally two plate type between boiler and chimney. The precipitator for horizontal

gas flow and is constructed with steel casing. ESP can handle a large volume of gases from

which solid particles are to be removed. Their technical superiority lies in low pressure droop,

high efficiency for small particles size and relatively easy removal of the collected particulates.

There are four steps in process of precipitation:

1. Ionization of gases and charging of dust particles.

2. Migration of particles to the collector.

3. Deposition of charged particles on the collecting surface.

4. Dislodging of particles from the collected surface.

The electrostatic precipitator essentially consists of two sets of electrodes. One in the

form of their wires called discharge or emitting electrodes and the other set known as

collecting electrodes in the form of pipe nor plate. The emitting electrodes are placed in

the center of pipes or midway between two plates and are connected to the negative

polarity of he high voltage DC source of the order of 25-10kv.

PRIME MOVERS

Now days almost steel turbines are employed as thermal power station .According to the action

of steam on the moving plates. There are two types of steam turbine namely:

1. IMPULSE TURBINE

2. REACTION TURBINE

1) IMPULSE TURBINE: In these turbines the steam expense in nozzle only and when

passes over the blades its pressure remains constant. The jet passes over several ring of

moving blades and its kinetic energy is conferred into mechanical energy.

2) REACTION TURBINE: in these turbines steam expands as it flow over the blades. The

blades will there for act as a nozzle. The explanation of steam and blade is utilized to heat

he steam and therefore efficiency will be more thus turbine converts heat energy of steam

into mechanical energy.

DSECRIPTION OF TURBINE

Main technical data

Main specifications

The 110MV steam is a cylinder, impulse type, condensing turbine with one reheat and 8 non

reregulated extractions for regenerating heating of the feed water. The turbine offers high

potential flexibility coupled with quick starting and load changing capacities.

The main technical data of turbine is given below:

Rated output 110MV

Economic output 95MV

Rated speed 3000rpm

Direction of rotation viewing from the front bearing pedestal clockwise

Rated steam pressure before the stop valve 130ata

Maximum steam pressure before the stop valve 146ata

Rated temperature of steam before the stop valve 535 degree c

Maximum temperature of steam before the stop valve 545 degree c

Rated pressure of steam before MP casing 31.6ata

Rated pressure of steam before MP casing 35ata

Rated temperature of steam before MP casing 535 degree c

Maximum temperature of steam before MP casing 545 degree c

Informative heat rate at the economic output 2135 kcal/kwh

Informative heat rate at the rate output 2152.5 kcal/kwh

The three cylinders of the turbine are high medium and low pressure parts. There are two sets of

staff and governing valves arranged on either side of the casing, each set consists of one stop

valve and two governing valve assembled in series. The steam from the boiler is admitted into

the HP casing through two parts and admitted to reheated, where it is reheated to original

temperature. The reheated steam is taken out to the MP casing through combined stop and

interceptor valve arranged either side of the MP casing. The exhaust from the MP casing is taken

directly to the LP casing. The steam after expansion in the LP casing condenses into condenser.

It provides a chamber in which the combustion reaction can be isolated and confined that the

reaction remains a controlled force. In addition, it provides support for encloses for firing

equipment.

The furnace must provide the following:

a. Proper insulation, operation and maintenance of fuel burning equipment.

b. Sufficient volume for combustion requirement.

c. Adequate refractors and insulation.

d. Accessibility to the boiler for the maintenance and repair work that must be handled from

the furnace chamber

The furnace used with the boiler of unit-5 is fusion-welded type with size gives as front

13.8m side 10.135m, height 45m and capacity 2300m3.

BOILER DRUM:

The function of the boiler drum is to separate the water from the steam generated in the furnace

walls and to reduce the dissolved solid contents of the steam to below the preheated limit of

1ppm.

SUPER HEATER:

There are three stages of super heaters besides the side walls. The first stages consists of

horizontal super heater of convention mixed flow type with upper and lower bank located above

economizer assembly in the rear pass. The upper bank terminates into hanger tubes which are

connected to the outlet heater of the first stage super heater.

The second stage super heater consists of pendant plants, which of radiant flow type. The third

dotage super heater pendant spaced is of convention parallel flow type. The super heater is

located at or above 37ml level. The other temperature and pressure of the steam coming out of

the super heater is 550c and 138kg/vm2 receptively.

AIR HEATER:

The air heater is an essential boiler auxiliary, because hot air is necessary for repaired and

efficient combustion in the furnace and also for drying coal in the milling plant. This is either

different from its original purpose, which was to recover waste heat from the flue gases to

increase boiler efficiency in many of the present generation of large boiler. Two sets of air heater

are provides one for the normal duty of pre-heating air into ill for drying out wet coal.

So there are two main types of air heaters in use:

1. Static recuperative plate or tube type.

2. Rotator regenerative type.

In S.R.P. fuel gases is on one side of the tuberator plate and air is on the other side. In

rotator regenerative type gas flow through a closely packed matrix. Matrix may be rotated

to achieve this heat transfer as a continuous process.

SPRING LOADED SAFETY VALVES:

Only this type of values is used in plant. The inlet nozzle is welded to mounting block on the

boiler shell. The upper end of spring is connected to the lever arm in the middle of two valves.

When the boiler pressure rises above that for which the valves set the value opens and release the

steam and when pressure inside the boiler is within limit which is mentioned valve set on its seat

and there is no release of steam.

BOILER DESCRIPTION OF AUXILARIES IN UNIT

There are some auxiliaries which are used in addition to the general equipment used with the

boiler so as to increase the efficiency and capacity of the boiler and thus of the plant. Brief

descriptions of the auxiliaries which are used in addition with the boiler of unit-5 are given

below:

COAL BUNDERS:

These are in process storage used for storing coal from handling system. Generally these are

made up of the welded steal plants with the vibrating arrangement at the outlet to choking of

coal. Normally these are six bunkers supply coal to the corresponding mills. These are located on

the top of the mills so as to add gravity feeding of coal.

COAL FEEDER:

Each mill is provided with a drag link chain feeder to transport raw coal bunkers to the inlet

chute, leading to the mill at a distance rate.

MILLS:

These are six mills for pulverizing which are located adjacent to the desired fineness to be fed to

the furnace for the proper combustion. The mills used in unit-5 are of bowl type. These mills

have a property that they reject the very hard pieces of coal and metal pieces and reject them.

PRIMARY AIR FAN:

The primary air fan are used for handling atmosphere air into temperature of 50C these fans are

located near the boiler and air from these fans mixed with the pulverized coal in the mills and

gets enter into the furnace through the nozzle.

AIR PRE-HEATER:

Air pre-heater transfer heat from flue gasses to cold primary and secondary air by means of

rotating surface element beneath this regenerative type air pre-heater there is exist a steam coil

pre-heater. These located in the secondary pass, the furnace at a height of 16 meter. There is two

such airs pre-heater.

FORCED DRAFTMAN:

Forced draft fan are designed for handling secondary air for the boiler. These fans are located at

zero meter level near the primary fan.

WIND BOX:

This act as distributing media for supplying secondary air to combustion chamber or furnace.

These are generally located on the left and right sides of the furnace while facing the chimney.

BURNERS:

There are twenty four total pulverized coal burners arranged on the corners at a height of

eighteen to twenty six meters and twelve oil burners provided each in between to pulverized fuel

burners. The pulverized coal to the burners at four corners of the furnace. All the nozzle of the

burners interlinked and can be titled at an angle of thirty degree.

INDUCED DRAFT FAN:

These are located between the electrostatic precipitator and chimney. There are hot induced draft

fan for each unit. These are used to create induced draft in the furnace.

SOOT BLOWERS:

Following two types of soot blowers in requisite number are provided :

a. Long retractable soot blowers.

b. Wail blowers.

Steam at pressure of 25Kg/cm2 at 450c is tapped from the LTHS for the purpose of soot

blowing. The soot blowers are used for efficient heat transfer.

ELECTRIC SUPPLY SYSTEM

The electric supply system undergoes many changes from the point of production to the

consumers. A brief description of the various systems in P.T.P.S. as follows:

1) 220KV

220KV system of supply is used for the transmission of electricity, because at high

voltage the current is very small hence the losses are minimized. Therefore transmission

in India is carried out at 220,000volts.

2) 15.75KV

This is the voltage at which the production of electricity takes place i.e. this is output

voltage from turbo generator installed at various units.

3) 6.6KV

This system of supply is used for electricity is used for high tension machinery in the

power plant and also in some industries. The H.T. motors used in the thermal plant itself

include:

1. F.D. fan

2. I.D. fan

3. P.A. fan

4. Raw Water Pump

5. C.W. pump

6. E.P.T. etc.