Training report on thermal power plant

1. Training Report Of Koderma
Thermal Power Station
SUMIT KUMAR
B.tech , 7th
Semester
Reg no- 11202437
Civil Engineering
Lovely Professional University
DAMODAR VALLEY CORPORATION
BANJHEDIH , JHARKHAND

2. KODERMA THERMAL POWER STATION
BANJHEDIH, JHARKHAND
INDUSTRIAL TRAINING
1 JUNE 2015 TO 30 JUNE 2015
Submitted by:
Sumit kumar
B.tech, 7th Semester
Civil engineering
Reg no: 11202437
Lovely Professional University
Submitted to:
B.GOSWAMI (S.E. CIVIL)
D.V.C, K.T.P.S, KODERMA

3. PREFACE
I have done my vocational training in KODERMA THERMAL POWER
STATION (K.T.P.S) under DAMODAR VALLEY CORPORATION (D.V.C.)
comprising 2 units of 500 MW each. It is a modern thermal power
station having tilting burner corner fired combustion engineering USA
design boiler and KWU West Germany Design Reaction Turbine. Both
these main equipmentshave been designed, manufactured and supplied
by Bharat Heavy Electricals Limited, India. MTPS units have many
special features such as Turbo mill, DIPC (Direct Ignition of Pulverized
Coal) system, HPLP bypass system, Automatic Turbine Run up system,
and Furnace Safeguard Supervisory System.
A student gets theoretical knowledge from classroom and gets practical
knowledge from industrial training. When these two aspects of
theoretical knowledge and practical experience together then a student
is full equipped to secure his best. In conducting the project study in an
industry, students get exposed and have knowledge of real situation in
the work field and gains experience from them. The object of the
summer trainingcum project is to providean opportunity to experience
the practical aspect of Technology in organization. It provides a chance
to get the feel of the organization and its function. The fact that thermal
energy is the major source of power generation itself shows the
importance of thermal power generation in India – more than 60
percent of electric power is produced by steam plant in India.
In steam power plants, the heat of combustion of fossil fuels is utilized
by the boilers to raise steam at high pressure and temperature. The
steam so produced is used in driving the steam turbine coupled to
generators and thus in generating electrical energy Economic growth in
India, being dependent on the power sector, has necessitated an
enormous growth in electricity demand over the last two decades.
Electricity in bulk quantities is produced in power plants.

4. ACKNOWLEDGEMENT
It is a matter of great pleasure and privilege for me to present this
report of 30 days on the basis of practical knowledge gained by me
during practical training at KODEMA THERMAL POWER STATION
(K.T.P.S.), KODERMA (JHARKHAND) during session 1 june 2015 to 30
june 2015.
I with full pleasure converge my heartiest thanks to Er. KESHAW
KRISHNA & Er. K.N DUTTA to support me at each and every step of my
training Schedule. I attribute hearties thanks to all Engineering
departments and Engineers for their Ample Guidance during my
training period. The dissertation has been prepared based on the
vocational training undergone in a highly esteemed organization of
Eastern region, a pioneer in Generation Transmission & Distribution of
power, one of the most technically advanced & largest thermal power
stations in JHARKHAND, the Koderma Thermal Power Station (K.T.P.S),
under DVC. I would like to express my heartfelt gratitude to the
authorities of Koderma
Thermal Power Station for providing me such an opportunity to
undergo training in the thermal power plant of DVC, K.T.P.S. I would
also like to thank the Engineers, highly experienced without whom
such type of concept building in respect of thermal power plant would
not have been possible.

5. INDEX
1. Introduction
 Damodar valley corporation
 Necessity of the power plant
 Koderma thermal power station
 Summary and project highlights
2. Cooling tower
 Introduction of cooling tower
 Design of cooling tower
 Construction of cooling tower
3. Chimney
 Introduction of chimney
 Design of chimney
 Construction of chimney
4. Water treatment
 Introduction of water treatment
 Pre treatment plant
 DM plant treatment
 Waste water treatment
5. Coal handling plant
 Introduction of coal handling plant
 Design of coal handling plant
 Component of coal handling plant

6. INTRODUCTION
Electricity generation is the process of generating electric power from
source of energy. In thermal power plant prime mover is steam driven.
Water is heated, turns into steam and spins a steam turbine which
drives an the process condenser and recycled to where it was heated;
this is known as a Rankin cycle. The greatest variation in the design of
thermal power stations is due to the different fossil fuel resources
generally used to heat the water. Some prefer to use the term energy
center because such facilities convert forms of heat energy into
electrical energy. Certain thermal power plants also are designed to
produce heat energy for industrial purposes of district heating, or
desalination of water, in addition to generating electrical power.
Globally, fossil fueled thermal power plantsproducea large part of man-
made CO2 emissions to the atmosphere, and efforts to reduce these are
varied and widespread. Almost all coal, nuclear, geothermal, solar
thermal electric, and waste incineration plants, as well as many natural
gas power plants are thermal. Natural gas is frequently combusted in
gas turbines as well as boilers. The waste heat from a gas turbine can be
used to raise steam, in a combined cycle plant that improves overall
efficiency. Power plants burning coal, fuel oil, or natural gas are often
called fossil-fuel power plants. Some biomass-fueled thermal power
plants have appeared also. Non-nuclear thermal power plants,
particularly fossil-fueled plants, which do not use co-generation are
sometimes referred to as conventional power plants.
Commercial electric utility power stations are usually constructed on a
large scale and designed for continuousoperation. Electric power plants
typically use three-phase electrical generators to produce alternating
current (AC) electric power at a frequency of 50 Hz or 60 Hz. Large
companies or institutions may have their own power plants to supply
heating or electricity to their facilities, especially if steam is created
anyway for other purposes. Steam-driven power plants have been used
in various large ships, but are now usually used in large naval ships.
Shipboard power plants usually directly couple the turbine to the ship's
propellers through gearboxes. Power plants in such ships also provide
steam to smaller turbines driving electric generators to supply
electricity. Shipboard steam power plants can be either fossil fuel or
nuclear. Nuclear marine propulsion is, with few exceptions, used only in

7. naval vessels. There have been perhaps about a dozen turbo-electric
ships in which a steam-driven turbine drives an electric generator
which powers an electric motor for propulsion. Combined heat and
power plants (CH&P plants), often called co-generation plants, produce
both electric power and heat for process heat or space heating. Steam
and hot water lose energy when piped over substantial distance, so
carrying heat energy by steam or hot water is often only worthwhile
within a local area, such as a ship, industrial plant, or district heating of
nearby buildings.
DAMODAR VALLEY CORPORATION
Damodar Valley Corporation was established on 7th July 1948.It is the
most reputed company in the eastern zone of India. DVC in established
on the Damodar River. The K.T.P.S under the DVC is the largest thermal
plant in JHARKHAND. It has the capacity of 1000MW with 2 units of
500MW each. Withthe introduction of another two units of 500MW that
is in construction it will be the largest in JHARKHAND. Koderma
Thermal Power Station also known as K.T.P.S is located in the Koderma.
It is one of the Thermal Power Stations of Damodar Valley Corporation .
The total power plant campus area is surrounded by boundary walls
and is basically divided into two major parts, first the Power Plant area
itself and the second is the Colony area for the residence and other
facilities for KTPSs͛ employees.
KODERMA THERMAL POWER STATION
This site is located at Banjhedih village in jainagar block of Koderma
District in Jharkhand state. The site is 5 km from River Barakar, on the
tailrace of Telaiya Dam. The nearest railway stations are Herodih and
koderma. Grand chord line of the Eastern Railways passes about 2km
from site.The water requirement of the thermal power plant including
expansion will be from River Barakar above telaiya. A closed cycle
circulating water system is proposed. Make up water requirement for
present stage of the plant is estimated at 4000m3/hr. DVC.

8. NECESSITY OF THE POWER PLANT
“Power to progress”
Energy provides the powers to progress. The natural resources of a
country may be turned into wealth if they are developed, used and
exchanged for other goods this cannot be achieved without energy.
Availability of sufficient energy and its proper use in any country can
result in this people using from substantial level to the highest standard
of living. It has been found that countries whose national output is
mainly agricultural and whose population lives mostly in rural
communities enjoy low per capita growth of energy consumption is
dependent is the extent to which industrial activity forms a part of its
energy usage a distinct changes. Once energy is made suitable in excess
of domestic needs it has been round that it is not used solely as a
consumer good but becomes factor of production.
A growing proportion of energy is being met all over the world the
electricity. This trend will further be stimulated because of increasing
availability of clean electricity. This applies especially to developing
countries because their industrial progress will be based on modern
technologies, which generally use electricity intensively.

9. COOLING TOWER
Introduction to cooling tower
A cooling tower is a heat rejection device which rejects waste heat to
the atmosphere through the cooling of a water stream to a lower
temperature. Cooling towers may either use the evaporation of water to
remove process heat and cool the working fluid to near the wet-bulb air
temperature or, in the case of closed circuit dry cooling towers, rely
solely on air to cool the working fluid to near the dry-bulb air
temperature.
Common applications include cooling the circulating water used in oil
refineries, petrochemical and other chemical plants, thermal power
stations and HVAC systems for cooling buildings. The classification is
based on the type of air induction into the tower: the main types of
cooling towers are natural draft and induced draft cooling towers.

10. If that same plant had no cooling tower and used once-through
cooling water, it would requireabout 100,000 cubic metres an hour and
that amount of water would have to be continuously returned to the
ocean, lake or river from which it was obtained and continuously re-
supplied to the plant. Furthermore, discharging large amounts of hot
water may raise the temperature of the receiving river or lake to an
unacceptable level for the local ecosystem. Elevated water temperatures
can kill fish and other aquatic organisms (see thermal pollution), or can
also cause an increase in undesirableorganismssuch as invasivespecies
of Zebra mussels or algae. A cooling tower serves to dissipate the heat
into the atmosphereinstead and wind and air diffusion spreads the heat
over a much larger area than hot water can distribute heat in a body of
water. Some coal-fired and nuclear power plants located in coastal areas
do make use of once-through ocean water. But even there, the offshore
discharge water outlet requires very careful design to avoid
environmental problems.
Cross section of cooling tower

11. The towers vary in size from small roof-top units to very large
hyperboloid structures that can be up to 200 metrestall and 100 metres
in diameter, or rectangular structure that can be over 40 metres tall and
80 metres long. Smaller towers are normally factory-built, while larger
ones are constructed on site. They are often associated with nuclear
power plants in popular culture. Industrial cooling towers can be used
to remove heat from various sources such as machinery or heated
process material. The primary use of large, industrial cooling towers is
to remove the heat absorbed in the circulating cooling water systems
used in power plants, petroleum refineries, petrochemical plants,
natural gas processing plants, food processing plants, semi-conductor
plants, and other industrial facilities. The circulation rate of cooling
water in a typical 700 MW coal-fired power plant with a cooling tower
amountsto about 71,600 cubicmetresan hour (315,000U.S. gallons per
minute)and the circulating water requires a supply water make-up rate
of perhaps 5 percent (i.e., 3,600 cubic metres an hour).
If that same plant had no cooling tower and used once-through
cooling water, it would require about 100,000 cubic metres an
hour [4] and that amount of water would have to be continuously
returned to the ocean, lake or river from which it was obtained and
continuously re-supplied to the plant. Furthermore, discharging large
amounts of hot water may raise the temperature of the receiving river
or lake to an unacceptable level for the local ecosystem. Elevated water
temperatures can kill fish and other aquatic organisms. A cooling
tower serves to dissipate the heat into the atmosphere instead and wind
and air diffusion spreads the heat over a much larger area than hot
water can distribute heat in a body of water. Some coal-fired
and nuclear power plants located in coastalareas do make use of once-
through ocean water. But even there, the offshore discharge water
outlet requires very careful design to avoid environmental problems.
Petroleum refineries also have very large cooling tower systems. A
typical large refinery processing 40,000 metric tonnes of crude oil per
day (300,000 barrels per day) circulates about 80,000 cubic metres of
water per hour through its cooling tower system.
The world's tallest cooling tower is the 200 metre tall cooling tower
of Niederaussem Power Plant.
Design of cooling tower

12. Some commonly used terms in the cooling tower industry Drift - Water
droplets that are carried out of the cooling tower with the exhaust air.
Drift droplets have the same concentration of impurities as the water
entering the tower. The drift rate is typically reduced by employing
baffle-like devices, called drift eliminators, through which the air must
travel after leaving the fill and spray zones of the tower.
Blow-out - Water droplets blown out of the cooling tower by wind,
generally at the air inlet openings. Water may also be lost, in the
absence of wind, through splashing or misting. Devices such as wind
screens, louvers, splash deflectors and water diverters are used to limit
these losses.

13. Plume - The stream of saturated exhaust air leaving the cooling tower.
The plume is visible when water vapor it contains condenses in contact
with cooler ambient air, like the saturated air in one's breath fogs on a
cold day. Under certain conditions, a cooling tower plume may present
fogging or icing hazards to its surroundings. Note that the water
evaporated in the cooling process is "pure" water, in contrast to the very
small percentage of drift droplets or water blown out of the air inlets.
Blow-down - The portion of the circulating water flow that is removed
in order to maintain the amountof dissolved solidsand other impurities
at an acceptable level. It may be noted that higher TDS (total dissolved
solids) concentration in solution results in greater potential cooling
tower efficiency. However the higher the TDS concentration, the greater
the risk of scale, biological growth and corrosion. Leaching - The loss of
wood preservative chemicals by the washing action of the water flowing
through a wood structure cooling tower.
Noise - Sound energy emitted by a cooling tower and heard (recorded)
at a given distance and direction. The sound is generated by the impact
of falling water, by the movement of air by fans, the fan blades moving
in the structure, and the motors, gearboxes or drive belts.
Approach - The approach is the difference in temperature between the
cooled-water temperature and the entering-air wet bulb temperature
(twb). Since the cooling towers are based on the principles of
evaporative cooling, the maximum cooling tower efficiency depends on
the wet bulb temperature of the air. The wet-bulb temperature is a type
of temperature measurement that reflects the physical properties of a
system with a mixture of a gas and a vapor, usually air and water vapor
Range - The range is the temperature difference between the water inlet
and water exit.
Fill - Inside the tower, fills are added to increase contact surface as well
as contact time between air and water. Thus they provide better heat
transfer. The efficiency of the tower also depends on them. There are
two types of fills that may be used:
Film type fill (causes water to spread into a thin film)
Splash type fill (breaks up water and interrupts its vertical progress)
Costruction of cooling tower

14. Being very large structures, they are susceptible to wind damage, and
several spectacular failures have occurred in the past. At Ferrybridge
power station on 1 November 1965, the station was the site of a major
structural failure, when three of the cooling towers collapsed due to
vibrations in 85mph winds. Although the structures had been built to
withstand higher wind speeds, the shape of the cooling towers meant
that westerly windswerefunnelled into the towers themselves, creating
a vortex. Three out of the original eight cooling towers were destroyed
and the remainingfive were severely damaged. The towers were rebuilt
and all eight cooling towers were strengthened to tolerate adverse
weather conditions. Building codes were changed to include improved
structural support, and wind tunnel tests introduced to check tower
structures and configuration.

15. CHIMNEY
Introtuction of chimeny
A chimney is a structure which provides ventilation for hot flue
gases or smoke from a boiler, stove, furnace or fireplace to the
outside 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, effect.
The space inside a chimney locomotives and ships. In the United States,
the term smokestack (colloquially, stack) is also used when referring
to locomotive chimneys or ship chimneys, and the term funnel can also
be used.
The height of a chimney influences its ability to transfer flue gases to the
external environment via stack effect. Additionally, the dispersion of
pollutants at higher altitudes can reduce their impact on the immediate
surroundings. In the case of chemically aggressive output, a sufficiently
tall chimney can allow for partial or complete self-neutralization of
airborne chemicals before they reach ground level.

16. Design of chimney
A flue liner is a secondary barrier in a chimney that protects the
masonry from the acidic products of combustion, helps prevent flue
gas from entering the house, and reduces the size of an over-sized flue.
Newly built chimneys have been required by building codes to have a
flue liner in many locations since the 1950s. Chimneys built without a
liner can usually have a liner added, but the type of liner needs to match
the type of appliance it is servicing. Flue liners may be clay tile, metal,
concrete tiles, or poured in place concrete. A chimney pot is placed on
top of the chimney to expand the length of the chimney inexpensively,
and to improve the chimney's draft. A chimney with more than one pot
on it indicates that there is more than one fireplace on different floors
sharing the chimney. A chimney cowl is placed on top of the chimney to
prevent birds and other animals from nesting in the chimney. They
often feature a rain guard to prevent rain or snow from going down the
chimney. A metal wire mesh is often used as a spark arrestor to
minimize burning debris from rising out of the chimney and making it
onto the roof. Although the masonry inside the chimney can absorb a
large amount of moisture which later evaporates, rainwater can collect
at the base of the chimney. Sometimes weep holes are placed at the
bottom of the chimney to drain out collected water. A chimney cowl or
wind directional cap is a helmet-shaped chimney cap that rotates to

17. align with the wind and prevent a back draft of smoke and wind back
down the chimney. An H-style cap (cowl) is a chimney top constructed
from chimney pipes shaped like the letter H. It is an age-old method of
regulating draft in situations where prevailing winds or turbulences
cause downdraft and back puffing. Although the H cap has a distinct
advantage over most other downdraft caps, it fell out of favour because
of its bulky design. It is found mostly in marine use but has been
regaining popularity due to its energy-saving functionality. The H-cap
stabilizes the draft rather than increasing it. Other downdraft caps are
based on the Venture effect, solving downdraft problems by increasing
the updraft constantly resulting in much higher fuel consumption.
A chimney damper is a metal plate that can be positioned to close off the
chimney when not in use and prevent outside air from entering the
interior space, and can be opened to permit hot gases to exhaust when a
fire is burning. A top damper or cap damper is a metal spring door
placed at the top of the chimney with a long metal chain that allows one
to open and close the damper from the fireplace. A throat damper is a
metal plate at the base of the chimney, just above the firebox, that can
be opened and closed by a lever, gear, or chain to seal off the fireplace
from the chimney. The advantage of a top damper is the tight
weatherproof seal that it provides when closed, which prevents cold
outside air from flowing down the chimney and into the living space —
a feature that can rarely be matched by the metal-on-metal seal afforded
by a throat damper. Additionally, because the throat damper is
subjected to intense heat from the fire directly below, it is common for
the metal to become warped over time, thus further degrading the
ability of the throat damper to seal. However, the advantage of a throat
damper is that it seals off the living space from the air mass in the
chimney, which, especially for chimneys positioned on an outside of
wall of the home, is generally very cold. It is possible in practice to use
both a top damper and a throat damper to obtain the benefits of both.
The two top damper designs currently on the market are the Lyemance
(pivoting door) and the Lock Top (translating door).
In the late Middle Ages in Western Europe the design of crow-stepped
gables arose to allow maintenance access to the chimney top, especially
for tall structures such as castles and great manor houses.

18. Construction of chimney
As a result of the limited ability to handle transverse loads with brick,
chimneys in houses were often built in a "stack", with a fireplace on
each floor of the house sharing a single chimney, often with such a stack
at the front and back of the house. Today's heating systems have made
chimney placement less critical, and the use of non-structural gas vent
pipe allows a flue gas conduit to be installed around obstructions and
through walls. In fact, most modern high-efficiency heating appliances
do not require a chimney. Such appliances are generally installed near
an external wall, and a non combustible wall thimble allows a vent
pipe run directly through the external wall. On a pitched roof where a
chimney penetrates a roof, flashing is used to seal up the joints. The
down-slope piece is called an apron, the sides receive step flashing and
a cricket is used to divert water around the upper side of the chimney
underneath the flashing Industrial chimneys are commonly referred to
as flue gas stacks and are generally external structures, as opposed to
those built into the wall of a building. They are generally located
adjacent to a steam-generating boiler or industrial furnace and the
gases are carried to them with ductwork. Today the use of
reinforced concrete has almost entirely replaced brick as
a structural component in the construction of industrial
chimneys. Refractory bricks are often used as a lining, particularly if the
type of fuel being burned generates flue gases containing acids. Modern
industrial chimneys sometimes consist of a concrete windshield with a
number of flues on the inside. The 300 metre chimney at Sasol
Three consists of a 26 metre diameter windshield with four 4.6 metre
diameter concrete flues which are lined with refractory bricks built on
rings of corbels spaced at 10 metre intervals. The reinforced concrete
can be cast by conventional formwork or sliding formwork. The height
is to ensure the pollutants are dispersed over a wider area to meet legal
or other safety requirements. A flue liner is a secondary barrier in a
chimney that protects the masonry from the acidic products of
combustion, helps prevent flue gas from entering the house, and
reduces the size of an over-sized flue. Newly built chimneys have been
required by building codes to have a flue liner in many locations since
the 1950s. Chimneysbuiltwithouta liner can usually havea liner added,
but the type of liner needs to match the type of appliance it is servicing.
Flue liners may be clay tile, metal, concrete tiles, or poured in place
concrete.

19. Clay tile flue liners are very common in the United States. However, this
is the only liner which does not meet Underwriters Laboratories 1777
approval and frequently have problems such as cracked tiles and
improper installation. Clay tiles are usually about 3 feet (0.91 m) long,
various sizes and shapes, and are installed in new construction as the
chimney is built. A refractory cement is used between each tile. Metal
liners may be stainless steel, aluminium, or galvanized iron and may be
flexible or rigid pipes. Stainless steel is made in several types and
thicknesses. Type 304 is used with firewood, wood pellet fuel, and non-
condensingoil appliances, types316 and 321 with coal, and type A1 29-
4C is used with non-condensing gas appliances. Stainless steel liners
must have a cap and be insulated if they service solid fuel appliances,
but following the manufacturer's instructions carefully. Aluminium and
galvanized steel chimneys are known as class A and class B chimneys.
Class A are either an insulated, double wall stainless steel pipe or triple
wall, air-insulated pipe often known by its generalized trade name
Metalbestos. Class B are uninstalled double wall pipes often called B-
vent, and are only used to vent non-condensing gas appliances. These
may have an aluminium inside layer and galvanized steel outside layer.
Condensing boilers do not need a chimney. Concrete flue liners are like
clay liners but are made of a refractory cement and are more durable
than the clay liners. Poured in placeconcrete linersare made by pouring
special concrete into the existing chimney with a form. These liners are
highly durable, work with any heating appliance, and can reinforce a
weak chimney, but they are irreversible.
A characteristic problem of chimneys is they develop deposits
of creosote on the walls of the structure when used with wood as a fuel.
Deposits of this substance can interfere with the airflow and more
importantly, they are combustible and can cause dangerous chimney
fires if the deposits ignite in the chimney.
Heaters that burn natural gas drastically reduce the amount of creosote
build-up due to natural gas burning much cleaner and more efficiently
than traditional solid fuels. While in most cases there is no need to clean
a gas chimney on an annual basis that does not mean that other parts of
the chimney cannot fall into disrepair. Disconnected or loose chimney
fittings caused by corrosion over time can pose serious dangers for
residents due to leakage of carbon monoxide into the home

20. WATER TREATMENT PLANT
Introduction of water treatment plant
Besides treating the circulating cooling water in large industrial cooling
tower systems to minimize scaling and fouling, the water should
be filtered to remove particulates, and also be dosed
with biocides and algaecides to prevent growths that could interfere
with the continuous flow of the water. Under certain conditions, a bio
film of micro-organisms such as bacteria, fungi and algae can grow very
rapidly in the cooling water, and can reduce the heat transfer efficiency
of the cooling tower. Bio film can be reduced or prevented by
using chlorine or other chemicals. Another very important reason for
using biocides in cooling towers is to prevent the growth of Legionella,
including species that causelegionellosis or Legionnaires' disease, most
notably L. pneumophila, or Mycobacterium avium. The
various Legionella species are the cause of Legionnaires' disease in
humans and transmission is via exposure to aerosols—the inhalation of
mist droplets containing the bacteria. Common sources of
Legionella include cooling towers used in open recalculating
evaporative cooling water systems, domestic hot water systems,
fountains, and similar disseminators that tap into a public water supply.
Natural sources include freshwater ponds and creeks.

21. French researchers found that Legionella bacteria travelled up to 6
kilometres (3.7 mi) through the air from a large contaminated cooling
tower at a petrochemical plant in Pas-de-Calais, France. That outbreak
killed 21 of the 86 people who had a laboratory-confirmed infection.[20]
Drift (or wind age) is the term for water droplets of the process flow
allowed to escape in the cooling tower discharge. Drift eliminators are
used in order to hold drift rates typically to 0.001–0.005% of the
circulating flow rate. A typical drift eliminator provides multiple
directional changes of airflow to prevent the escape of water droplets. A
well-designed and well-fitted drift eliminator can greatly reduce water
loss and potential for Legionella or water treatment chemical exposure.
Many governmental agencies, cooling tower manufacturers and
industrial trade organizations have developed design and maintenance
guidelines for preventing or controlling the growth of Legionella in
cooling towers. Below is a list of sources for such guidelines
Pre- treatment Plant
(2+1) 2000M3 /hr. capacity raw water pumps installed in intake pump
house located near Telaiya reservoir will supply water to site through
two 100% capacity pipelines through raw water station. 10 days
requirement of raw water will be-stored at site in a reservoir. Raw
water drawn from the reservoir through (1+1) 4000M3 pumps will be
clarified through PLC operated three 200m3 /hr capacity clarification
(one working for each unit with the third as a common standby.)
Alum/Sodium carbonate/lime/polyelectrolyte and chlorine will be
dosed in the pre-treatment plant to accelerate coagulation process. The
filtered water be stored in an adequately sized filtered water tank
(capacity 20,000cum) including 4000 cum dead storage for fire water
requirement. Sludge from the clarifiers and rapid gravity filters will be
taken into sludge sump. The sludge will be pumped to the gravity type

22. sludge thickness. Under flow from the thickness will be pumped to
centrifuge by centrifuge feed pumps. Concentrate from the centrifuges
and supernatant from the thickness will be taken back to the inlet of the
clarifiers Solid cakes from centrifuge will be collected in sludge dumpers
for ultimate disposal. Filtered water will be distributed to various areas
of the plant through dedicated pump sets as follows:-
Four three working + 1 common standby 100M3 /hr. filtered water
pump sets for supply water to the 3 DM plant streams, [2 streams
working and the third stream as standby] each streams having a
capacity of 90 M3/hr.
Three -75 M3/hr (2 working + 1 standby0 capacity potable water pump
sets will water to the needs of the colony and plant potable water.
Chlorine dosing is envisaged on the pump suction lines to ensure
compliance to GOI Public Health standards. Potable water needs for the
colony and the plant area will be met by the 300 M3 capacity RCC
overhead tank.
Bearing Cooling water system:
Demineralised water in a closed is envisaged for all auxiliary equipment
cooling of the power plant this will be re-cooled by filtered water,
circulating on the secondary side of the plate heat exchange (PHE).
Three –two operating plus one standby PHEs will be provided per unit.
A set of three (2 working with one standby) 3000 M3/hr capacity
auxiliary cooling water booster pumps will be used to establish
necessary pressuredifferentialrequired for PHEs. These equipment will
be located suitably in the power plant building at ground ever for each
unit

23. Demineralized water to – make up to closed cycle BCW system will be
conditioned to avoid commission of carbon steel materials 3NOS (2+1)
of 2000 CMH ACWpumpsetutilizingdemineraised water through PHEs
will distribute to various coolers of plant auxiliaries under uniform
pressure .
Makeup water to ACW system will be made available from the DM
water storage tank this will be achieved through three 5 CMH (one for
each unit with a common standby) located near the DM water storage
tank and a typing is taken for make up to both unit ACW tanks.
Demineralization plant:
Assuming an average 3% makeup for the heat cycle; 1.0% makeup for
auxiliary cooling system, and other uses such as makeup to hydrogen
generation plant, and considering regeneration time of 6 hours, a fully
automatic PLC based Dimineralizing plant having three- 100 cum/hr
capacity streams ( 2 normally operating)will be provided to have mixed
bed cutlet nullity as follows:
-Silica less than 0.01 ppm as Sio2 -pH
7.0+0.2-conductivity Less than 0.1 micronhos/cum At 25oC
The filtered water will be pumped to DM plant through activated carbon
filters, cation exchanges, degasifies, anion exchanges and mixed beds all
installed within the DM plant building. The Dm water will be stored in
two – 1500 cum capacity steel plate fabricated vertical cylindrical DM
water storage tanks along with proper breathers and floating PVC ball
arrangementto preventabsorption of atmospheric gases. The DM water
will be used for heat cycle makeup, auxiliary coolingcircuit makeup and
Hydrogen generation plant Dm water from storage tanks will be
transported to the unit condensate storage tanks two numbers each of

24. 500 cum capacity through three nos. 75 CMH capacity pimps. Two 100
per cent capacity boiler fill pump sets common for 2 units will be
installed at DM water storage tanks for initial fill for supplying Dm
water to heat make up as shown on the DM water system.
Chemical Feed System
Unit wise chemical feed system will be provided for feeding (i)
Trisodium phosphate in the boiler drum (high pressure feed system)
and (ii) Neutralizing amines such as ammonia morpholine and
cyclohexylmine in the condensate pump discharge/boiler feed suction
line (low pressure feed system) condensate tank outlet to maintain the
chemical concentration in the drum water and feed water within
permissible limits for trouble – free operation of the plant. The chemical
feed system plant will be located at ground level near each unit between
B/C bays.
Low pressure chemical dosing system of each unit will consist of:-
An adequately sized mixing tank provided with stirrer and a metering
tank.
Two (2) full capacity metering pump sets complete with suction filters,
valves, specialties, and other accessories with pipe work, fittings etc as
necessary Normally, one pump set will run intermittently while the
other pump set will be standby.
High pressure chemical dosing system of each unit will consist of. An
adequately sized mixing tank at a higher level provided with stirrer and
a metering tank for gravity drawlof chemical solution from mixing tank.
Two full capacity (one operating while the other standby) metering

25. pump sets complete with suction filters, valves, specialties and other
accessories with pipework is used for the each unit water drum.
Station Effluent Treatment System
Main plants drains consisting of waste water having light density fine
suspended particles from different areas as well as other effluents such
as boiler blow down, DM plant effluent (i.e.) Regeneration effluent from
DM plant will be neutralized in a neutralization pit before discharge to
setting sump. Bottom ash hopper over-flow, service water drains etc
will be led to adequately size underground waste water settling sumps
and the resulting water will be used for the CHP dust suppression
system.
Effluent from coal handling plant (CHP) primary consisting of coal dust
Aden water from various dust extraction points as well as dust
suppression system and run off water from coal-pile will be led to a
separate setting/guard pond located near the coal yard conveniently.
Effluentsfrom oil unload will be taken to oil-water separate from where
the separated oil willtaken for mixing with coal for burning in the boiler
and the water led to the CHP sump Skimming tank is provided
separately to remove contaminated oil etc.
The effluent water from ash pond & other station waste will be pumped
to the Guard pond: and will be treated to maintain acceptable standards
to Authorities and recycled back to Ash handling plant sump for each
disposal.

26. Condensate polishing system
The Condensate Polishing System will be designed to remove dissolved
and suspended solids corrosion products & other impurities from
condensate during startup, normal operation and periods or condenser
tube leakage to maintain the feed water and stream purity requirements
of the boiler and turbine. The condensate polisher will be located in
condensate feed water cycle between the condensate pump discharge
and the condenser condensate position system will consist of 3X33.3%
units i.e. each vessel having a capacity of 4 5 regeneration
arrangements.
Chemical Laboratory
A chemical laboratory will be provided for the day to resting of water
quality steam quality blow down etc. Compressed Air System
The control air requirement for the 2X500 MW plant will be met by
three-32 Nm3/min. Capacity 8.5 kg/cm2 (g) discharge pressure rotary,
screw type oil free compressors. The requirements of instruments air
for two units will be met by one (1) compressor on automatic mode
while second compressor wick be on load/unload mode and the third
compressors as standby. Each of the compressors will be of rotary
screw type, non-lubricated type complete with intercooler after cooler,
air receiver (dedicated to each compressor) three air drying plants, for
all the 3 compressors associated pipework, instrumentation, etc. the
silica del desiccant Providing dry air having a dew point of (-) 40oC at
atmospheric pressure will have 100% standby air drying adsorption
tower, etc to supply clean dry air to instrumentation and control system.

27. To meet the station service air requirements, four – b32 Nm3/min 8.5
kg/cm2 g discharge pressure rotary, men –lubricating type station air
compressor (same as that of instruments air compressors) will be
provided. While one compressor will be normally working for each unit
oil automatics that third compressor will be load/unload configuration
for the two units and fourth compressor will be standby for both the
unit. These compressors will have suitable interconnection with
instrument air header to improve the availability reliability of the
instrument air system with proper backflow protection i.e providing a
NRV with direction of flow towards instrument air side. Both the
instrument and service air supply networks will cover the entire
operating and maintenance area of both units of the power plant.

28. COAL HANDLING PLANT
Introduction of coal handling plant
It can be called the heart of thermal power plant because it provided the
fuel for combustion in boiler. The coal is brought to the K.T.P.S through
rails there are fourteen tracks in all for transportation of coal through
rails. The main coal sources for K.T.P.S are SECL (South Eastern
Coalfields Limited), NCL (Northern Coalfield Limited). Everyday 6 to 7
trains of coal are unloaded at K.T.P.S. Each train consists of 58 wagons
and each wagons consists of 50 tones of coal. The approximate per day
consumption at K.T.P.S is about 18000 metric tones. It costs
approximate 4.5 crores of rupees per day including transportation
expenses. The coal is firstly unloaded from wagon by wagon triplers
then crushed by crushers and magnetic pulley and pulverized to be
transformed to the boiler. The whole transportation of coal is through
conveyor belt operated by 3-Ø Induction motor.
The coal handling plant can broadly be divided into three sections :-
1) Wagon Unloading System.
2) Crushing System.
3) Conveying System.

29. Design of coal handling plant
It unloads the coal from wagon to hopper. The hopper, which is made of
Iron , is in the form of net so that coal pieces of only equal to and less
than 200 mm. size pass through it. The bigger ones are broken by the
workers with the help of hammers. From the hopper coal pieces fall on
the vibrator. It is a mechanical system having two rollers each at its
ends. The rollers roll with the help of a rope moving on pulley operated
by a slip ring induction motor with specification:
COAL HANDLING PLANT PROCEDURE

30. Generally mostof the thermal power plants uses low grades bituminous
coal. The conveyer belt system transports the coal from the coal storage
area to the coal mill. Now the FHP(Fuel Handling Plant) department is
responsible for converting the coal converting it into fine granular dust
by grinding process. The coal from the coal bunkers. Coal is the
principal energy source because of its large deposits and availability.
Coal can be recovered from different mining techniques like
• shallow seams by removing the over burnt expose the coal seam
• underground mining.
The coal handling plant is used to store, transport and distribute coal
which comes from the mine. The coal is delivered either through a
conveyor belt system or by rail or road transport. The bulk storage of
coal at the power station is important for the continues supply of fuel.
Usually the stockpiles are divided into three main categories.
• live storage
• emergency storage
• long term compacted stockpile.
The figure below shows the schematic representation of the coal
handling plant. Firstly the coal gets deposited into the track hopper

31. from the wagon and then via the paddle feeder it goes to the conveyer
belt#1A. Secondly via the transfer port the coal goes to another
conveyer belt#2B and then to the crusher house. The coal after being
crushed goes to the stacker via the conveyer belt#3 for being stacked or
reclaimed and finally to the desired unit. ILMS is the inline magnetic
separator where all the magnetic particles associated with coal get
separated.
Rated Output. : 71 KW.
Rated Voltage. : 415 V.
Rated Current. : 14.22 Amp.
Rated Speed. : 975 rpm.
No. of phases. : 3
Frequency. : 50 Hz.
The four rollers place themselves respectively behind the first and
the last pair of wheels of the wagon. When the motor operates the
rollers roll in forward direction moving the wagon towards the “Wagon
Table”. On the Wagon table a limit is specified in which wagon to be has
kept otherwise the triple would not be achieved.
CRUSHING SYSTEM:-
Crusher House:-
It consists of crushers which are used to crush the coal to 20 mm. size.
There are mainly two type of crushers working in KSTPS:-
Primary Crushers i.e.
i) Rail crushers
ii) ii) Rotary breaker.
Secondary Crushers. i.e. Ring granulators.
Primary Crushers:-
Primary crushers are provided in only CHP stage 3 system, which
breaking of coal in CHO Stage 1 & Stage 2 system is done at wagon
tripler hopper jail up
to the size (-) 250 mm.
Secondary Crusher:-
Basically there are four ways to reduce material size : impact attrition ,
Shearing and Compression. Most of the crushers employ a combination
of three crushing methods. Ring granulators crush by compressing
accompanied by impact and shearing. The unique feature of this
granulator is the minimum power required for tone for this type of
material to be crushed compared to that of other type of crushers.

32. Construction of coal handling plant
Secondary crushersare ring typegranulators crushing at the rate of 550
TPH/ 750 TPH for input size of 250 mm. and output size of 20 mm. The
crusher is coupled with motor and gearbox by fluid coupling. Main parts
of granulator like break plates, cages , crushing rings and other internal
parts are made of tough manganese (Mn) steel. The rotor consists of
four rows of crushing rings each set having 20 Nos. of toothed rings and
18 Nos. of plain rings. In CHP Stage 1 & 2 having 64 Nos. of ring
hammers. These rows are hung on a pair of suspension shaft mounted
on rotor discs. Crushers of this type employ the centrifugal force of
swinging rings stroking the coal to produce the crushing action. The coal
is admitted at the top and the rings stroke the coal downward. The coal
discharges through grating at the bottom.
CONVEYING SYSTEM:-
Stacker Reclaimer:-
The stacker re-claimer unit can stack the material on to the pipe or
reclaim the stack filed material and fed on to the main line conveyor.
While stacking material is being fed from the main line conveyor via
Tripler unit and vibrating feeder on the intermediate conveyor which
fedsthe boom conveyor of the stacker cum reclaimer. During reclaiming
the material dis discharged on to the boom conveyor by the bucket
fitted to the bucket wheel body and boom conveyor feeds the material
on the main line conveyor running in the reverse direction.
Conveyor belt Specification of Stacker / Reclaimer:-
Belt width. : 1400 mm.
Speed. : 2.2 m/second.
Schedule of motor : All 3-Ø induction motors.
Bucket wheel motor : 90 KW.
Boom Conveyor motor : 70 KW.
Intermediate Conveyor Motor : 90 KW.
Boom Housing Motor : 22 KW.
Slewing assembly. : 10 KW.
Travel Motor : 7.5 KW.
Vibrating Feeder. : 2x6 KW.
Total installed power. : 360 KW.

33. ASH HANDLING PLANT
Introduction of ash handling plant
This plant can be divided into 3 sub plants as follows:-
1) Fuel and Ash Plant.
2) Air and Gas Plant.
3) Ash Disposal and & Dust Collection Plant.
Fuel and ash plant:-
Coal is used as combustion material in KTPS, In order to get an efficient
utilization of coal mills. The Pulverization also increases the overall
efficiency and flexibility of boilers. However for light up and with stand
static load , oil burners are also used. Ash produced as the result of
combustion of coal is connected and removed by ash handling plant. Ash
HandlingPlantat KTPS consists of specially designed bottom ash and fly
ash in electro static precipitator economizer and air pre-heaters
hoppers.

34. Air & Gas Plant:-
Air from atmosphere is supplied to combustion chamber of boiler
through the action of forced draftfan. In KTPS there are two FD fansand
three ID fans available for draft system per unit. The air before being
supplied to the boiler passes through preheater where the flue gases
heat it. The pre heating of primary air causes improved and intensified
combustion of coal. The flue gases formed due to combustion of coal
first passes round the boiler tubes and then it passes through the super
heater and then through economizer . In re-heater the temperature of
the steam (CRH) coming from the HP turbines heated with increasing
the number of steps of re-heater the efficiency of cycle also increases. In
economizer the heat of flue gases raises the temperature of feed water.
Finally the flue gases after passing through the Electro-Static
Precipitator is exhausted through chimney.
Ash Disposal & Dust Collection Plant:-
KSTPS has dry bottom furnace. Ash Handling Plant consists of especially
designed bottom and fly ash system for two path boiler. The system for
both units is identical and following description is applied to both the
units the water compounded bottom ash hopper receives the bottom
ash from the furnace from where it is stores and discharged through the
clinker grinder. Two slurry pumps are provided which is common to
both units& used to make slurry and further transportation to ash dyke
through pipe line. Dry free fly ash is collected in two number of 31 fly
ash hoppers which are handled by two independent fly ash system. The
ash is removed from fly ash hoppers in dry state is carried to the
collecting equipment where it is mixed with water and resulting slurry
sump is discharged
Utilisation:-
Utilisation of coal-ash is always practise than its disposal. There are
various methods of utilisation of coal-ash along with established
engineering technologies some of them are mentioned below:
1. Manufacturing of building materials.
2. Making of concrete.
3. Manufacturing of pozzuolana cement.
4. Road construction etc.

35. HOW MUCH THIS TRAINING WAS HELPFUL TO ME
The Training at the K.T.P.P. was very much helpful to me.
Before the training at this premier plant. I just had the theoretical
knowledgeof variousequipment, devicesand machine. Butafter coming
here and getting supervisory hand and guidance of various senior
engineers, technicians and worker, we have full knowledge of what the
electricity really stands for the equipments and apparatus available
here were beyond imagination until one can see it practically, which
was the main purpose of having the training. We have through much
more and strong knowledge of mechanical and electrical field. On some
apparatuswehad the opportunity to work under guidance and that was
really a big advantage for us.
Last but not the least the co-ordination provided by the technical staff
was very appreciable.