Report on

Industrial Visit to

Reliance Thermal Power Plant, Dahanu

Submitted by: Dr.Ajoy Kumar(Principal)

Bhavesh Kumar Pasi(HOD)

Mayuri Chawan

Neeta Gawde

B.E. Mechanical

Abstract:

After being briefed upon by the various process of the plant, we were guided by one of the staff members through the plant. The plant capacity is 2x250 MW. The coal obtained from Chattisgarh is unloaded at the wagon tippler and then the coal is crushed at the double roll crusher and then in pulveriser to talcum powder size. The coal is carried by hot air to the boiler in which water from Soorya dam is converted to steam. The steam is then transferred to the turbine which is coupled to the generator which produces electricity and the electricity is then stepped up using step up transformer. The exhaust gases is then send to the electrostatic precipitator where ash is removed from flue gases with 100% efficiency. The exhaust gases are passed through the chimney which is the highest chimney in Asia. The overall efficiency is 35% to 37%

Introduction:

Dahanu Thermal Power Station or Reliance Dahanu Thermal Power Station is a coal based thermal power plant located at coastal Dahanu town in Palghar district in the Indian state of Maharashtra. The power plant is operated by Reliance Infrastructure. The plant is located on Mumbai-Ahmedabad rail line and is 120 km away from Mumbai and 20 km away from Mumbai-Ahmedabad-Delhi National Highway 8 (India).

We were well received by the authorities and one of the staff members guided us in our further visit of the Plant.

It is a coal based thermal power plant. It has an installed capacity of 500 MW (2x250 MW). The power plant was commissioned in 1995 and is commercially producing power since 1996.

The Power Generation Process:

Fig. Layout Of DTPS

Major Parts Of DTPS

1. Coal Handling Plant ( CHP )

2. Boiler

3. Turbine

4. Reheater

5. Superheater

6. Turbo-Separator

7. De-superheater

8. Coal Mill

9. Air Preheater

10. Electrostatic Precipitator

11. Ash Handling Plant

12. Fuel-Oil Handling Plant

13. Sulphur Treatment Plant

14. Compressor House

The Heat Source:

Coal is used as the heat source. The required amount of coal is obtained from Chattisgarh coal mines. Coal is brought by means of railway. Coal is then unloaded at the wagon tippler location. Here the coal is unloaded by rotating the wagon through 1700. Unloading of each wagon takes 2 minutes. The wagon is rotated through 170 degrees by means of a gear mechanism which ensures the 170 degree rotation and the rotation is controlled by a controller placed nearby. There is a vertical and a horizontal plate which support the wagon while it rotates through the said angle. The coal consumption is 4000M Tonne.

Crushing of Coal:

The stacked coal is reclaimed as per the requirement. The coal is brought to a double roll crusher. Here it is crushed to a size of 25mm. But for practical use, the coal needs to be further powdered. This is achieved in the Pulveriser. In the pulveriser, the coal is pulverized to the size of Talcum Powder. The crushed coal is carried to the boiler using jet of hot air.

Boiler:

In this Plant, the boiler used is a water tube boiler. The size of the boiler is (13*10) m. It has a height of 60-65m. The boiler tube is made of Carbon Steel. The Boiler is CE made. The boiler operating temperature is 11000 c.

Water for Boiler:

The water used in the boiler to produce steam is obtained from Soorya dam. The Soorya dam is located 32Km away from Dahanu. This water is then treated to remove suspended particles. It is then sent for demineralization. The water passes through the tube in the boiler.

Steam Generated:

The steam is generated inside the boiler. The generated steam has a temperature of 5400c. It has a pressure of 150 kg/cm2.

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Turbine:

The steam from the boiler at a temperature of 5400 c and 150 kg/cm2is passed to the turbine. The turbine operates at a speed of 3000 rpm. The turbine blades are made of chromium or molybdenum or vanadium. There are three types of turbines installed in each unit. The types are High Pressure turbine, Intermediate Turbine and Low Pressure Turbine.

Generator:

The turbine is coupled to a generator. Electric energy generated is then stepped up from 16kV to 220kV using a step up transformer.

Exhaust from Boiler:

The exhaust gases from the boiler is at a temperature of 3400 c and a pressure of 40 kg/cm2. The flue gas is made to pass through a air pre-heater unit. It is reheated to 5370 c. It is then sent to the Intermediate Pressure Turbine and then at a pressure of 37 Kg/cm2 to Low Pressure turbine.

The flue gases from the pre-heater unit are sent to the electrostatic Precipitator unit where the ash is separated from the gases. The efficiency of this separation of ashes is 100%.

The chimney of this plant is the highest chimney in Asia for 250 MW power plant. It has a height of 275.3m.

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Ash from The Exhaust:

The ash from the flue gases is collected in a hopper. This ash is then marketed to various customers who use it for various purposes like cement, brick manufacturing, gardening, road filling,etc. The revenue generated from the ash sales itself is sufficient to fulfill the wages of all the employees.

Cooling:

To perform the function of cooling, Sea water is directly used. There are no cooling towers in the power plant. For using sea water, the pipes are insulated so as to prevent it from rusting.

Governing of Turbines:

For governing of the turbines, an electro hydraulic governor is used.

Sensors Used:

Various sensors are used for the in process control. The various sensors used are RTD, Stroboscope, Pressure sensor, Flow measuring sensor, Hall Effect Sensor, etc.

Overall Efficiency:

The overall efficiency of the plant is 35% to 37%.

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Report on

Industrial Visit to

Madhuban Dam, Silvasa

Submitted by: Dr.Ajoy Kumar(Principal)

Bhavesh Kumar Pasi(HOD)

Mayuri Chawan

Neeta Gawde

B.E. Mechanical

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Abstract:

The Government of Gujarat, Union Territories of Dadra & Nagar Haveli and Daman had constructed Madhuban dam about 40 kms. downstream of Bhugad dam site. The total catchment area of Damanganga basin upto Bhugad dam site is 729 Sq. km., out of which 141 Sq. km. falls in Gujarat State and 588 Sq. km. falls in Maharashtra State. With the commissioning of Madhuban Dam on the downstream side of river Damanganga, a large water front has formed near Dudhani (40 Kms. from Silvassa).

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GENERAL INFORMATION:-

Information

Location Village: Madhuban Tal.:Dharampur, Dist.;Valsad

Purpose Irrigation, water supply and power generation

River Damanganga

Area of catchment 1813 Km2

Mean annual runoff in the catchment 3771.60 Mm3

Mean annual rainfall 2382 mm

Year of commencem ent of construction work 1973-74

Year of completion 1998

COST:-

Cost

Estimated Cost Rs.16051.00 lacs

Expenditure upto March, 1987 Rs. 12189.18 lacs

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VILLAGES UNDER COMMAND:-

Villages under command

a) District b) Taluka c) No. of villages

Valsad Pardi 78

Umargam 37

Dharampur 6

Daman (Union Territory) Daman 26

Ddadara & Nagar Haveli 24

Total 171

GEOLOGY:-

Geology

Name of Scheme District Rock type encountered at the dam site

Damanganga Valsad Amygdaloidal basalt, Porphyritic basalt,

Dolerite, Agglomerate.

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SALIENT FEATURES OF DAMANGANGA PROJECT

1. LOCATION:- NAME OF RIVER :- DAMANGANGA NEAR VILLAGE :- MADHUBAN DISTRICT :- VALSAD DIST. FROM NEAREST RLY. STN. :- VAPI(30kms.)

2. DAM:- MASONARY DAM :- 352.36 MT. LENGTH SPILLWAY :- 191.11 MT. RIGHT EARTHEN DAM :- 1633.00 M.T LEFT EARTHEN DAM :- 755.00 MT. TOP OF DAM :- 85.60 MT.

3. SPILLWAY:- TYPE OF SPILLWAY :- OGEE SHAPE GATED CREST R. L. :- 65.83 MT. No. AND SIZE OF GATE :- 10 Nos. (15.55x14.02M.) ENERGY DISSIPIATION :- ROLLER BUCKET BYEPASS OUTLET :- 2 Nos. SIZE 1.22x1.52 MT. PENSTOCK :- 2 Nos. 1.52x1.352 MT.

4. HYDROLOGY:- CATCHMENT AREA :- 1813 Sq. km. UPTO DAM SITE TOTAL UPTO SEA :- 2290 Sq. km. Avg. ANNUAL RAINFALL :- 2382 mm. MAX. RAINFALL :- 2382 mm. MEAN ANNUAL RUN OFF :- 3771.60 mcm. MIELD AT 50% :- 3771.60 mcm.

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5. RESERVOIR:- FULL RESERVOIR :- 79.86 M. LEVEL (F. R. L.) MAX. WATER LEVEL :- 82.40 M. (H. F. L) LOWEST WATER LEVEL :- 61.60 M. (M. D. D. L.) LIVE STORAGE :- 478.09 mcm.

6. MAIN CANAL:- L.B.M.C. R.B.M.C

CAPACITY :- 405 cusecs 1230 cusecs LENGTH :- 33.40 Km. 45.54 Km. SECTION :- 3.0 m x 1.35 m 4.50 m x 2.60 m No. OF VILLAGES :- 171 Nos. BENIFITED i) WATER SUPPLY:-

(1) GUJARAT :- 400.00 LACS GAL (2) U. T. OF D. & N. H. :- 127.50 LACS GAL (3) U. T. OF DAMAN :- 52.50 LACS GAL

TOTAL :- 580.00 LACS GAL

ii) POWER GENERATION:- (1) RIVER BED :- 2 x 1.50 MW

POWER HOUSE (2) MAIN CANAL :- 1 x 2.60 MW

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