chhattisgarh state power generation company limited

2014

Deepak Raj Kurrey

APG10910313003

7/7/2014

Chhattisgarh State Power Generation Co. Ltd.

Chapter 1: Chhattisgarh State Power Generation Co. Ltd.

Communication Skills Report Page 5

Acknowledgement

This is chapter 1 of the report on “Chhattisgarh State Electricity

Board.” The data presented inside the report can be used for information

and Industrial Report data.

There may be Compilation Error.



Introduction

Chhattisgarh State Power Generation Co. Ltd. (CSPGCL) is the most important unit of the organization which gives the organization its identity. CSPGCL is the unit which generates electricity for CSEB. It became functional w.e.f. 01.01.2009. This company generates electricity which is further transmitted and distributed.

The company generates electricity by the following Thermal Power Plant (TPP) Hydel Power Plant (HPP)

The company has Thermal Power Plants and Hydel Power Plants which provides electricity by means of Coal and Water, the list is given below as on 11-10-2010

Projects Units & Capacity

Korba Thermal Power Station (East) 4x50MW 2x120MW Dr. Shyama Prasad Mukherjee Thermal Power Station

2x250MW

Hasdeo Thermal Power Station, Korba (West)

4x120MW

Korba West Extension Thermal Power Plant 1x500MW Bhoramdev Co-Generation Plant, Kawardha 1x6MW Mini-Mata Hasdeo Bango Hydel Power Station

3x40MW

Gangrel Hydel Power Station 4x2.5MW Sikasar Hydel Power Station 2x3.5MW Mini/ Micro Hydel Power Station, Korba (West)

2x0.85MW

Total Generation 2424.7MW



The major of electricity generation is done by Thermal Power Plant (TPP), and Hydel Power Plant shares a small portion of it.

One of the TPP is Korba West Extension (1x500MW), which has 4 turbine units to generate 480MW of electricity, but has found that it is generating 20MW more electricity than the actual plan and design. Here is a short technical overview of the plant.



Hasdeo Thermal Power Plant 4x120MW, Korba (West)

Thermal Power Plants generates electricity by the

means of coal as its main energy generating fuel and water

as a major driver and controller in electricity generation. We

will little introduction of the power plant’s major

machineries used in Hasdeo Thermal Power Plant.



The Major organs of the TPP are as a follows

Boiler

Turbine

Generator

Water Treatment Plant

Coal Handling Plant

Ash Handling System

Heavy Fuel Oil Handling System

Compressed Air System

Equipments Cooling System (Water)

Diesel Generating Set

Fire Fighting System

Air Conditioning System

Interlocking & Protection

Here is a short briefing of all the above

COAL HANDLING PLAN – In a TPP, the initial process in

the power generation is “Coal Handling” the overall

processes carried out at a CHP in a coal based thermal power

generating station or TPP is given in short here.

Major Factors

o Coal Companies

o Transport

o CHP Equipment Suppliers and Contractors



Major Issues

o Coal Quality

o Coal Transportation

o Coal Stock

o Component Contractors

Schematic cum Block Diagram of a CHP



The basic layout of Coal Handling Plant is shown by block diagram. The coal is unloaded at various unloading station and transported by conveyors to crushing and screening plant via transfer house. After crushing required quantity of coal is transported to bunker via transfer house and remaining coal is stored in stockyard. This coal is reclaimed as per requirement. From the bunker the coal flows through coal mills to boiler furnace. The main aim of CHP to maintain level of coal in bunkers for smooth coal supply to boiler

There are different streams for transporting of coal. For caring out preventive maintenance schedule one of the stream kept under shutdown. If at the same time breakdown occurs in a machine in other stream, which interrupt the coal supply to boilers. Due this loss of generation will occur.

A plant, which supply of coal to boilers having capacity of 750 tons per hour failed to fulfill need will loss generation of 0.6 MU for one hour. This cost 1.20 Crore of Rupees.

Technical Details

CRUSHER HOUSE

No. of Crusher Four (4) Nos.

Type of Crusher Ring Hammer Type

Capacity 1000 MTPH

Max. Coal size at inlet 200 mm

Motor Rating 750 KW

Belt feeder Nos./capacity 4 Nos./1000 MTPH

Vibrating feeder Nos./capacity 4 Nos./1000 MTPH

Feeder size (MM) 7000 x 1600

TRIPPER

Total Number 6 Nos.

Capacity of tripper conveyer 2000 MTPH (each).

Travel of tripper 165 M.

Travelling speed 0.3 M/sec.

Belt speed 3.15 M/sec.

Motor of tripper 2x5.5 kW



SILOS

Total Nos. 18 Nos.

Cylindrical portion 9.2 M.

Conical 3.485 M

Hyperbolic 3.3 M

Dia. (internal) 7.0 M (cylindrical)

TRACK HOPPERS

No. of Hopper One

Max. Coal lump size 200 mm

Paddle feeder capacity 100 MTPH

CONVEYORS

Conveyor capacity T/hr. 2000 MTPH

Belt speed M/Sec. 2.8/3.15 M/Sec.

Belt Width (Min) 1600 mm

Boiler – In this section, Crushed Coal coming from coal

handling plant are burnt and water is converted into steam

of certain pressure which is capable of rotating the turbine

at 3000 rotation per minute and that is standard speed for

electricity generation in Indian Standard. Detail of boiler

used here:

General Specification Manufacturer – M/s BHEL (C.E. Design) Type – Balanced Draft, Dry bottom, Single drum Controlled

Circulation plus. Type of Firing - Oil Ignition Tilting – Tangential Minimum load at which steam generator can be operated

continuously with complete flame, stability without oil support (& MCR) – 2 Adjacent, Mills at 50% capacity



Minimum load at which the steam generator can be operated continuously with complete flame stability with oil support (% MCR) – 20%

Maximum load for which individual mill beyond which no oil support is required – 50%

Furnace Specification

Type – Controlled Circulation Wall – Water Steam cooled Bottom – Dry Draft – Balanced Tube Arrangement – Membrane Explosion/Implosion – With stand capacity at 67% Yield point – +/-660 mm/wc Residence time for fuel particles in the furnace – 3 seconds Effective volume used to calculate the residence time (M3)



- 14790 Height from furnace bottom ash hopper to furnace roof (M)

- 62. 735 Depth (M) - 15.289 Width (M) - 18.034 Furnace projected area (M2) - 7610 Furnace volume (M3) - 14790

Super Heaters

LTSH pendant Panel – 1

Platen Horizontal Stage – I Type Convection Radiant

Stage II Stage III

Radiant Platen (Drainable/Non- drainable) Non --- Non---- Pendant (Drainable/Non-drainable) Drainable ----------- Horizontal LTSH (--do--) <----------- drainable -----------> Effective heating surface area (m2)/Modified

5903/12500 1350/1660 1465/1730 Total circumferential heating surface area (m2)

5703 ----------- ----------- Total Number of Tubes, Tube pitch (mm)

708 444 408 Parallel to gas flow 101.6 54.00 63.5 Across gas flow 152.4 254.00 762

Method of Joining long tube

<----------------------- Butt weld ---------------------------> Total wt. of tubes (T)/modified

<-------------------------1130/919 --------------------------->

Reheat Emergency temp. Control attemperator

Type - Spray

No. of stages of attemperator - One

Position in the steam circuit - Cold reheats lines

Specification of the Material - SA - 106 Gr - B

Spray nozzle Material - SA- 213T & SS Tips



Economizer

Type - Non Steaming

Water side effective heating - 7810 / 8903.4

Surface area (M2)/ Modified

Gas side effective heating/Modified - 10210/14204.4

Surface area (M2)

Gas flow path area (M2) - 128

Design pressure of tubes Kg/Cm2 - 209.8

OD of Tubes (MM) - 51.00

Actual thickness tubes (MM) - 5.6

Length of Tubes (MM) (approx.) - 2, 15,000/2, 45, 100

Pitch (MM) - 101.6

Total Wt. of Tubes (Kg.) - 4, 82, 200

PRESSURES (STEAM & WATER)

HP Heaters in

Description Unit ----------------------- HP Heaters

MCR 88.72% 70.84% 53.59% out

MCR MCR MCR NCR

Pressure

Superheater Outlet kg/cm2 178 176.08 173.5 171.6 176.4

LTSH Outlet kg/cm2 188.3 184.4 178.9 174.9 185.0

Drum kg/cm2 193.4 188.4 181.6 176.4 189.3

Economizer Inlet kg/cm2 197.2 191.9 184.6 179.1 192.9

Reheater Outlet kg/cm2 43.46 41.05 32.93 24.99 46.60

Reheater Inlet kg/cm2 45.85 43.20 34.66 26.31 49.00



Pressure Drop

Superheater System kg/cm2 15.4 12.3 8.1 4.80 12.9

Reheater kg/cm2 2.39 2.15 1.73 1.32 2.40

Economizer kg/cm2 1.60 1.30 0.80 0.50 1.4

Excluding static head

FUEL

The fuel data on which the guarantees given are as follows:

Description Unit

Fuel Design Coal

Proximate Analysis

Fixed Carbon % 25.00

Volatile Matter % 19.00

Moisture % 12.00

Ash % 44.00

Grind ability Index HGI 58

Higher Heating Value kcal/kg 3500

Size of coal to mill mm 25

Turbine – In this section, the Heat energy is converted

into Mechanical Energy (Rotational Energy). The water

converted into steam is used to rotate the turbine which is

coupled with a large Alternator.

General Specification

Manufacturer : KRAFTWERK UNION, WEST GERMANY Type : Three Cylinder, Reheat, Condensing Turbine Stages : HP 18 Nos. IP 14x2 Nos. LP 6x2 Nos. Nominal Rating : 500 MW Peak Loading : 536.7 MW



Rated Speed : 3000 rpm Max/ Min Speed : 3090 / 2850 rpm Speed exclusion range 400 to 2850 rpm.

Weight (in ton)

HP IP LP

a) Rotor : 11.6 21.8 84.6

b) Cylinder Assembled : 80.0 32.5 86.0

c) Main stop & control valve : 10

d) Reheat stop & control valve : 17

Moments of Inertia (kg/m2)

a) Rotor of HP Cylinder : 713.0

b) Rotor of IP Cylinder : 2145.6

C) Rotor of LP Cylinder : 22981.0

Shaft Lift pump

a) Safety Valve Setting : 200/ 180 ata

b) Pressure limiting valve setting : 180/ 140 ata

c) Pump starts at a turbine speed of : <510 rpm

d) Pump stops at a turbine speed : > 540 rpm

TURBINE OIL PURIFIER SYSTEM

Centrifuge.

Max Capacity : 12500 Liters/hr.

Rated capacity : 8100 liters /hr.

Speed of bowl : 7605 R.P.M.

Oil temp. inlet to electric heater : 550C(through regenerative heat

exchanger)



Oil temp. at outlet to electric heater : 650C

Water temp. in the heater tank. : 90 0C

GENERATOR – In this section, Mechanical energy given to the turbine is converted into Electrical Energy. Here, Turbine rotates the Alternator at 3000 rpm. And electricity is generated of High Ampere. This is later stepped up to high voltage for Transmission using a step-up transformer.

General Specification

Make BHEL (KWU) Type THDF 115/59 Code IEC 34-1, VDE 0530 Cooling, stator winding Directly water cooled, Stator core , rotor

Directly hydrogen cooled.



RATING

Apparent power 588 MVA Active Power 500 MW Power factor 0.85 (lag) Terminal voltage 21 kv permissible variation in + 58 % Voltage. Speed/ Frequency rpm/Hz 3000/50 Stator corrent 16200 Amps.

Hydrogen pressure kg / cm2 4 Short Circuit Ratio 0.48 field current ( Calculated value) 4040 A Field Voltage 340V Class and type of Insulation MICALSTIC (Similar to class F) No. of terminals brought out 6

Resistance in ohms at 20oC Stator winding between terminals u-x 0.001414

v-y 0.0014 17

w-z 0.001420

Rotor winding F1- F 2 0.068293

MAIN EXCITER

Active Power 3780 KW Current 6300 A Voltage 600 V Speed 3000 rpm.

Voltage Regulating System

Type Thyristor 04-2

Maximum output voltage 250 V

Output current for field forcing 152 A

Output current for rated Generator load 88A

Auxiliary Voltages from three phase supply. 220 V

Pilot exciter for thyristor sets 400 Hz.

D. C. Voltage From station for contactors & drives 220V

Power input continuously < O.1 KW



Power input, short time < 1 kw

DC Voltage from Station battery 2x24 for controls Max. 15 A Positive,

and regulation Max. 6A negative

Rated secondary voltage 120v

Power input of Voltage transformer per phase 2 VA

Rated secondary current 5 A

Power input of current transformer per phase 6.5 VA (Plus losses in connecting lead)

Accuracy of control Better than + - 0.5%

Setting range of voltage point potentiometer +58 - 15% of nominal generator voltage.

Setting range of drop compensation or compounding + 0-10% dependent on the and proportional to reactive current* setting of the potentiometer

------------------------------------------------------------------------------------------------

* Direction of reactive current compensating depend on the phase relation which is determined by

connection of CT's to TVR terminals.



TORQUE, CRITICAL SPEEDS

Maximum short circuit torque of stator at line to line single phase short circuit – 1488 kpm

Moment of inertia of generator shaft – 10,000 kgm2 Critical speed (Calculated) nk1 14.4 S-1 (V-GEN)

nk2 30. 1 S-1 (V-EXC)

nk3 39.8 S-1 ( S-GEN)

GENERATOR VOLUME AND FILLING QUANTITIES

Generator volume (Gas Volume) 80 m3

CO2 filling quantity *** 160 M3 (STP) *

H2 filling quantity ** (to 4 bar) 520 M3 (STP) *

* STP = Standard temperature and pressure. 00C and 1.013 bar to DIN 1343.

** Volume required with unit at stand still with the unit on turning gear, the volume will be higher.

*** CO2 quantity kept on stock must always be sufficient for removal of the existing Hydrogen

filling. All values are approximate.

GENERATOR PROTECTIONS

Generators are high quality machines for securing the best possible continuity of power supply. In addition to a suitable technical design and responsible mode of operation, provision has therefore been made for automatic protection facility the following protections have been provided in the 500 MW T. G.

1. Generator Differential protection (87G)

2. Generator Low forward power protection ( 37G )

3. Negative phase sequence protection (46G)

4. Pole slipping protection (98G)

5. Under frequency protection (81G)

6. L.B.B. Protection (50G)

7. Gen field failure protection (40G)

8. Stator Earth fault protection (64 G1 & 64G2)

9. Inter turn fault protection (95 G)

10. Over load protection (51G)

11. Over Voltage protection (59G)

12. Gen. Back up impedance protection (21G)



Specification of Transformer

Generator Transformer

Manufacturer TOSHIBA

Nos. of units 10 Nos. (1 0)

Rating HV & LV (MVA) 200 MVA

Rated Voltage, HV 420 KV

Rated Voltage. LV 21 KV

Rated current, HV 825 Amps

Rated current, LV 9520 Amps

No. of phases 1

Frequency 50 Hz

Type of cooling OF AF

Connection symbol when formed a bank YD5

Impedance at principal tap (75oC) 12.5%

OFF CKT Tap Changer Tapping in 5 equal steps of 2.5% each

……………………………………………………………………………………provided on HV winding to give +5%

to 5%

Temperatures rises Variation of high voltage

o Oil, by thermometer 50oC

o Winding, by resistance 55oC

CTI and WTI, auxiliary contacts settings

o OTI Alarm 85oC

Trip 90oC

o WTI Alarm 105oC

Trip 115oC

Station Transformer

Manufacturer HHE

Nos. off 3

Capacity 20/35/50 MVA

Voltage Ratio 33/11.5/6.9 KV

Vector group DY/nY/n

Unit Auxiliary Transformer

Manufacturer HHE

Nos 6

Capacity 20/25 KVA

Voltage Ratio 21/6.9 KV

Cooling ONAN/ONAF



Percentage impedance 8.5%

C.T. Transformer

Manufacturer HHE

Nos. 2

Capacity 20/25KVA

Voltage Ratio 33/6.9

Vector group DY/n

Percentage impedance 8.5%

Cooling ONAN/ONAF

Ash Water Transformer

Nos. off 2

Capacity 1250 KVA

Voltage Ratio 11KV/433V

Percentage impedance 0.06

Station Service Transformer

Make M/s. ASGM Gmbh

Nos. off 6

Capacity 1600 KVA

Voltage Ratio 6.6 KV/0. 433 KV

Vector group Dynl

Percentage impedance 0.08 + 10%

Unit Service Transformer

Nos. off 6

Capacity 1600 KVA

Voltage Ratio 6.6 KV/433 V

Vector Group DY 1

Percentage impedance 0.08 + 10%

TIE TRANSFORMER

Manufacturer TOSHIBA

Nos of units ONE

Rating 55/75 MVA (30)

Rated Voltage, HV 400 KV

Rated Voltage. LV 34.5 KV



Rated current. HV 1260 Amps

Rated current, LV 108 Amps

No. of phases 3

Frequency 50 Hz

Type of cooling ONAN/ONAF

Connection symbol YND11

Impedance at principle tap 11.74% @750C

Fuel Oil Service Transformer

Manufacturer M/s. Ingra

Nos. off 2

Capacity 1250 KVA

Voltage Ratio 11/0. 433 KV

Vector group DYnl

Percentage impedance 6%

WATER TREATMENT PLANT – Water quality within powers is of critical importance in maintaining efficient operation and in limiting downtimes due to corrosion or maintenance. The major phases and stages where water quality is measured are discussed in this application note along with the parameters measured. Raw water contains organic matter, inorganic salts, bacteria which need to be

removed before being fed to the boiler. It follows the three major steps for the purification of raw water

Disinfection by Chlorination – In this stage, microbiological organism is removed from the water before it is further purified or processed.

Softening of Water – In this stage, the hardness producing inorganic materials like Calcium and Magnesium are removed from the water. Because these substance can cause more consumption of fuel, caustic embrittlement of the boiler leading to blast of boiler. Here Lime soda process is followed where calcium is precipitated into



carbonates and Magnesium into magnesium hydroxide. These are then settled and filtered.

Dechlorination of Water – It is the process of removing residual chlorine from disinfected wastewater prior to use it. Sulfur dioxide is most commonly used for dechlorination. This is done either by o Carbon bed – which is not that much effective, or o Addition of bisulphate, later removed by Anion

exchange process.

Block Diagram of a Water Treatment Plant

The water treatment plant here is established by “Driplex Water Engineering.”



Technical Specification of the Plant as well as its auxiliaries

Pre-treatment Plant

Clarifier-cum-Flocculate:

No. and type One (1)

Rated effluent flow 3000m3/hr.

Effluent Turbidity 20 NTU

Retention Time at rated speed

Floculation Zone 30 min.

Classified Zone 2 hrs. 30 min

O.D. at top 20.6

Bridge revolving Speed 0.038

Gravity Filter

Nos. 2

Flow rate per filter 300 M3/hr.

Surface flow rate 4.845 M3/hr/m2

Filter water reservoir and transfer pump:

Reservoir Capacity 450 M3

Nos. of pump 3 working+1

Standby Capacity of pump 150 M3/hr.

CHEMICAL DOSING SYSTEM

Alum Dosing Pump

Nos. of Tanks 3

Capacity 8 Hrs. each to clarify

Strength of solution 10%

Alum Dosing System

Type Positive displacement

Control 0-100% automatically by pneumatic stroke positioned



Nos. 2 each of 100% cap.

Lime Slaking Tank

Capacity 12 hrs. consumption of clarifiers at 10% strength.

Nos. 2

Lime Slurry Transfer Pump

Nos. 2

Capacity 4M3/hr.

Lime Solution Preparation Tank

Capacity 6 hrs. consumption of clarifier at 6% strength w/v

strength of solution 6%

Nos. 4.

Lime Solution Dosing Pump

Type positive displacement

Control 0-100% automatically by pneumatic stroke positioned

No. 2 each of 100% cap.

Coagulant aid preparation Tank

Nos. 2 each of 100% cap.

Control 0-100% manually by micrometer dial.

Type Positive displacement type.

Chlorination System

Nos. of chlorinators 4

Capacity 10 Kg/hr

Type of Injector Vacuum type

Water Booster pumps 3 Nos. (2 w+1 s) Horizontal, centrifugal type

DEMINERALIZATION PLANT

GENERAL

Nos. of stream 3

Normal Flow through one stream 130m3/hr

D.M. water storage tank 3 Nos. of 2000 m3 each



ANION EXCHANGER

No. off/stream 2

Design flow rate 130 m3/hr.

Shell lining 4.5 mm thick

Shell Material IS - 226

Size WBA 2100 x 4688, SBA 2100 x 5320

Qty. WBA 4.4 m3 - IRA - 93 RE, SBA 5.17 m3-IRA-40 RC

Regeneration NAOH

MIXED BED UNITS

No. off 3

Design flow 130 m3/hr.

Surface flow rate 40 m3/hr/m2

Material IS-226 shell.

Resin Cation + Anion 2 M3+ 2m3, IR-120 = MB + IR 402 MB

REGENERATION SYSTEM

Storage tanks Acid Alkali

No. 4 4

Size Dia & Length 3200 ɸ x 6766 mm 3200mm/6760 mm

Capacity 50 M3 50 M3

Lining RL-4.5 mm RL 4.5 mm

Concentration of chemical 30% 48%

UNLOADING PUMP

Acid Alkali

Nos. 2 2 Type Horizontal Horizontal

Centrifugal Centrifugal

Capacity 20 M3 20M3

TDH MWC 10 10

Neutralization System:

No. of pits 2

Capacity 450 M3



Recirculation cum disposal pump :

Nos. 2/pt (Total 4 nos.)

Capacity 150 M3/hr/at 15 mwc

Duty 3 hrs. every shift

D.M. Tanks:

No. 3

Capacity 2000 M3 each

Size 14 M ɸ x 14.M - Ht.

Material MS I. S. - 226.

Activated Carbon Filter :

No per stream 1

Design Flow rate 145 M3/hr.

Design Surface flow rate 15 M3/hr/m2

Filled Ht. 1200 MM

Supporting Material Graded Gravel- 225 mm (Ht.)

Material of shell IS 2002 Gr. II

Internal painting epoxy.

Cation Exchanger:

No per stream 2

Design Flow rate 130 M3/hr.

Design surface flow rate 35 M3/hr/M2

Filled Ht. WAC-1.00 m, SAC 1.610 M

Qty. of resin WAC -3.46 M3 m3-IRC-84RF, SAC 5.54 M3-IR-120 RF

Regeneration by Hydrochloric Acid

Shell size 2100 mm2 (wac)

Material of shell IS -226 Rubber Lined.

Degasser System:

Nos. of 3

Type Forced draft type

Normal Flow rate 130 M3/hr

Filled Material P.P.N.

CO2 content in effluent 5 PPM (Max.)



Shell material IS – 226

Rubber Lining 4.5 mm thick

Size 2000 ɸ x 5575 ht (Degasser tower)

Ash Handling Plant – Ash is the residue left after the coal is incinerated. In Thermal Power Plant’s coal is generally used as fuel and hence the ash is produced as the byproduct of Combustion. Ash generated in power plant is about 30-40% of total coal consumption and hence the system is required to handle Ash for its proper utilization or disposal.

Ash generated in the ESP which got carried out with the flue gas is generally called Fly ash. Around 80% is the value of fly ash generated. It also consists of Air pre heater ash & Economizer ash (it is about 2 % of the total ash content).

Ash generated below furnace of the steam generator is called the bottom ash. Bottom ash (Bottom ash is 20% of the ash

generated).

Schematic Diagram of an Ash Handling Plant



The ash handling system handles the ash by bottom ash handling system, coarse ash handling system, fly ash handling system, ash disposal system up to the ash disposal area and water recovery system from ash pond and Bottom ash overflow. Description is as follows:

Bottom Ash Handling System – Bottom ash resulting from the combustion of coal in the boiler shall fall into the over ground, refractory lined, water impounded, maintained level, double V-Section type/ W type steel- fabricated bottom ash hopper having a hold up volume to store bottom ash and economizer ash of maximum allowable condition with the rate specified. The slurry formed shall be transported to slurry sump through pipes.

Coarse Ash (Economizer Ash) handling System – Ash generated in Economizer hoppers shall be evacuated continuously through flushing boxes. Continuous generated Economizer slurry shall be fed by gravity into respective bottom ash hopper pipes with necessary slope.

Air Pre Heater ash handling system – Ash generated from APH hoppers shall be evacuated once in a shift by vacuum conveying system connected with the ESP hopper vacuum conveying system.

Fly Ash Handling System – Fly ash is considered to be collected in ESP Hoppers. Fly ash from ESP hoppers extracted by Vacuum Pumps up to Intermediate Surge Hopper cum Bag Filter for further Dry Conveying to fly ash silo. Under each surge hopper ash vessels shall be connected with Oil free screw compressor for conveying the fly ash from Intermediate Surge Hopper to silo. Total fly ash generated from each unit will be conveyed through streams operating simultaneously and in parallel.

Ash Slurry Disposal System – Bottom Ash slurry, Fly ash slurry and the Coarse Ash slurry shall be pumped from the common ash slurry sump up to the dyke area which is located at a distance from Slurry pump house.



Technical Description of Ash Handling System

HOPPER SPECIFICATION

S. No. Description Units

Provided

per Boiler

Ash Collection Rate per

Boiler, Kg/Hr ( Max @

100% BMCR)

Holding

Capacity in

Hrs.

1 Furnace bottom ash hopper 1 32800 Not less than

2 hrs.

2 Economizer 4 8190 8

3 A. H. Hopper

a) Primary

b) Secondary

4

4

2800

5310

8

8

4 E. P. Hopper

1st Row

2nd Row

3rd Row

4th Row

5th Row

6th Row

16

16

16

16

16

16

103000

17560

6210

2555

1170

570

8

8

8

8

8

8

PUMPS SPECIFICATIONS

L. P. Fly Ash water Pumps

No. of Pumps : 4

Location : Ash water pump house

Capacity : 1100 M3/Hz

Head : 65 MWC

Suction : Submerged

RPM : 1500

H. P. Fly Ash Water Pump

No. of Pumps : 3

Suction : Submerged

Capacity : 300 M3/Hr

R.P.M. : 1500 rpm

Head : 95 MWC



Location : Ash water pump house

Motor : 110 KW

Seal Water Pump

Units : 2

Stand-by : 1 Unit

Capacity : 100 M3/hr

Head : 160 MWC

Type : Centrifugal Pumps

Location : Inside Ash Slurry Pump House

R.P.M. : 3000 rpm

Suction : Flooded

Motor : 90 KW

Fly Ash Slurry pump (Refer item for Bottom Ash Slurry Pump)

No. of pumps – Ten (10) size streams (each stream having two pumps in series)

No. of Unit operation – Three (3) streams working and two (2) stand by

Type – Horizontal single stage centrifugal with non-clog impeller

Location – Inside Ash Slurry pump house

Capacity – 1300 M3/Hr

Head – 40 MWC

Motor – 330 KW

Heavy Fuel Oil Handling System – This is the Heart of the boiler of the plant or we can say it is the heart of any fuel based power generation station around the globe. Fuel handling and storage problems can limit the efficiency of the entire boiler.

SOLID FUELS

Solid fuels (including coal, wood, and solid waste) present some of the same handling difficulties. Problems occur unless a free-flowing, continuous supply of fuel that is properly sized for the specific type of combustion equipment is provided. The problems include sizing, shredding or pulverizing, consistency of moisture content, freezing or lumping, dusting, fires in storage due to



spontaneous combustion, and fires in the feed or ash handling systems.

Most problems can be minimized or eliminated through proper selection of fuel handling equipment. Specific types of equipment for handling, storage, and preparation depend on the characteristics of the solid fuel used.

Because the proper equipment is not always available, fuel additives or aids have been used in the attempt to minimize problems. These additives include grinding aids, moisture improvers, dusting aids, freezing inhibitors, and catalysts to minimize combustibles in ash and fly ash handling systems.

LIQUID FUELS

Liquid fuels include waste oils, light oils, heavy oils, and other combustible liquids. Because of the problems of liquid residue disposal, an increasing variety of combustible liquids is being considered and tested. Figures 20-1 and 20-2 illustrate key components found in a typical liquid fuel handling system and fuel oil storage system, respectively.

Problems encountered in the handling, storage, and preparation of liquid fuels include water contamination, sludge formation, resistance to flow, biological growths, instability, and corrosiveness. Generally, these conditions are manifested as excessive strainer plugging, poor flow, increased loading on the fuel pump, heater deposits, fuel line deposits, loss of storage space, burner tip deposits, burner fouling, leakage due to storage tank corrosion, poor atomization, and other combustion problems. Table 20-1 summarizes the nature and cause of problems associated with key liquid fuel handling system components.

Compressed Air System – Air compressors are used to supply process requirements, to operate pneumatic tools and equipment, and to meet instrumentation needs. Only 10-30% of energy reaches the point of end-use, and balance 70-



90% of energy of the power of the prime mover being converted to unusable heat energy and to a lesser extent lost in form of friction, misuse and noise. Compressors are broadly classified as: Positive displacement compressor and Dynamic compressor.

o Positive displacement compressors increase the pressure of the gas by reducing the volume. Positive displacement compressors are further classified as reciprocating and rotary compressors.

o Dynamic compressors increase the air velocity, which is then converted to increased pressure at the outlet. Dynamic compressors are basically centrifugal compressors and are further classified as radial and axial flow types.

COMPRESSED AIR SYSTEM

Manufacturer : Kirloskar Pneumatic

Model Number : T-BTD-BM

Type of compressor : Horizontal Balanced Opposed

Numbers : Eight Units

Instrument Air : 4 Units.

Plant Air : 4 Units

Actual capacity of each compressor : 30.0 Nm3/min

Discharge pressure Kg/cm2 gauge : 8.0

Design ambient temperature : 50 deg C

Design ambient pressure : 0.99753 Kg/cm2

Design ambient humidity : 100%

Exact capacity considering worst : 39.05(at45 deg.C&75%RH)



EQUIPMENT COOLING SYSTEM – Thermoelectric power plants boil water to create steam, which then spins turbines to generate electricity. The heat used to boil water can come from burning of a fuel, from nuclear reactions, or directly from the sun or geothermal heat sources underground. Once steam has passed through a turbine, it must be cooled back into water before it can be reused to produce more electricity. Colder water cools the steam more effectively and allows more efficient electricity generation.

ECW Pumps (D.M. Water)

Nos : 3 (1 standby)

Flow : 2140 M3/hr

Suction Head : 30 MWC

Discharge Head : 50 MWC

MOTOR Rating : 400 KW

Speed : 985 RPM

Plate Type Heat Exchanger

Nos : 2 (1 standard)

Fluid : Primary - Secondary

: D.M. Water - Raw water

In/Out let temp 0C : 44.5/38 - 35/40.92

Flow rate (M3/hr) : 2140 - 2350

Equipment Cooling Water Storage Tank

Elevation : 24.0M

Capacity : 60 M3 for unit No. 4, 50 M3 for unit 5 & 6

Diesel Generator Set – After a blackout (a near total loss of generation and load) takes place, efforts have to be taken to bring back the system to a normal state at



the earliest. It may surprise you to know that this (black starting!) is not an easy task. Once a generator is tripped, restarting it requires a significant amount of power. Power is required for 2 types of activities:

o Survival Power: For emergency lighting, battery chargers etc. Usually the requirement is 0.3% of the generator capacity.

o Startup Power: For starting power plant auxiliaries (pumps etc.) Interestingly, nuclear and thermal units require approximately 8 % of the unit capacity for auxiliaries alone! Therefore, a 500 MW generator requires approximately 40 MW for running its auxiliaries.

Technical Specification

Manufacturer

Engine : Kirlosker Cummins

Alternator & Exciter : NGEF

Control panel : Control & Switchgear Co. Pvt. Ltd.

Battery : Exide

Charge : Logic stat

Engine

Rating at site condition : 750 KVA

Engine type : KTA 3067 G

RPM : 1500 rpm

No. of Cylinders arrangement : 16 cylinder 600 Vee.

Starting time : 30 Sec from Cold

Governor : PSG Motorised

Fuel Oil : HSD as per IS: 1460 grade

Lube Oil : MIL IS2104 C

Guaranteed fuel oil Consumption at 100% : 150 gms/BHP/hr

Lub. oil consumption : 0.62 lit/hr



Mech. Efficiency : 38%

Total Weight : 6 Tons

Alternator

KW : 600

KVA : 750

PF : 0.8

Stator Current : 1043 A

Speed : 1500 rpm

Fire Fighting System – Fire is big threat and cause loss to human life and property. However, disasters due to fire normally remains localized to a particular installation until and unless tripping of the entire power plant causes disturbance in the transmission grid by way of over loading and leading to tripping of other power stations/ transmission lines connected with the grid. The most common cause of the fires is known to be electrical short circuits and fire triggered by the inflammable materials. The damages caused by the fire accidents generally take excessive time for restoration. Analysis of causes of fire incidents reveal that majority of the fires could perhaps be prevented and extent of damage minimized, if fire safety measures were strictly enforced. Early detection of fire and swiftness in fighting it can definitely turn major disaster to minor accidents. In power sector accidents taking place on account of human error or due to malfunctioning of any equipment are also causes of crisis situations. In this plant the following equipments are installed for fire-fighting

Sprinkler System Jockey Pump Hydrant System with Booster Pump

Air Condition System – It is another method equipment cooling in the power station. The major function of air-condition is to optimize the temperature and control



the humidity of the Major components as well as of its auxiliaries.

Compressor

Main Control Room Esp Control Room

Maker Kirlosker Pheumatic Co. Kirlosker Pheumatic Co.

No. off Six (6) Six (6)

Model AC - 1670 AC - 470

No. of Cylinders 16 4

Type Reciprocating Reciprocating

Refrigerant R-22 R-22

Type of Cooling Air Cooling Air Cooling

Condensing temp 20C 4.440C

Operating RPM 1450. 1250 1000

Capacity (TR) 136.96,117.19 25.86

Drive KW at 500C 128.99,111.18 23.27

Condenser

No. off Six (6) Six (6) make Kirlosker Pneumatic Co. KirloskerPneumatic Co. Model 500-9, 500-8 250-70 Over all size OD 640X3419, 640x3114 340 x 2275(MM) Shell Thickness mm 8 6.35 Tube Mat. Copper Copper tube Size dia mm 19 19 Tube Thickness mm 1.41 1.41

Interlocking & Protections

Air PreHeater Interlocking FD Fan Interlocking ID Fan Interlocking PA Fan Interlocking Scanner Fan Logic Seal Air Fan Logic PUL Reviser CC Pump Protection



MFT Conditions Boiler Flame Failure Protection Turbine Protection Generator Protection Earthling and Lightning Protection



Introduction: The Hasdeo Bango Hydel Electric Project is situated at village Machadoli, Katghora, Korba at left bank of Hasdeo River. This Project is designed for multipurpose use. The Project was sanctioned by Planning Commission in March 1984. Hasdeo Bango Dam meets the water requirement of Aluminum Plant, SECL, NTPC, CSPGCL, Korba Town and other industrial units.

Geographical Location: The Hasdeo Bango Hydro Electric Plant is situated at Hasdeo River, the geographical location is at Latitude 22°36’13.69” N & Longitude 82°35’49.95” E [Turbine Floor is at 302.44 Meters from MSL]

Capacity: Three units of 40 MW each.

Commissioning dates:

Unit I - March 1994 Unit II - July 1994 Unit III - November 1994



Salient Features:

Project Cost: Project Cost of Bango Hydel Station was 105.39 Crores (Civil Works: 33.70 Crores, Electrical & Mechanical Works: 71.69 Crores)

Power Evacuation: The Power is evacuated through 132 KV Korba East, Jamnipali, Manendragarh and Bishrampur feeders.

Achievements: National Award with Gold Shield by Ministry of Power, Govt. of India in recognition of outstanding performance during the year of 2006-07.