Industrial training Report on Thermal Power Plant of JindaL Steel and Power Limited Raigarh,Chhattisgarh

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1 month Industrial Training Report File
On Power Plant (19/01/2017-17/02/2017)
Submitted To Submitted By
Mr. Rajesh Kumar Agrawal Shani Kumar Singh
AVP-EPS & Power Plant Roll No-1344948
Thermal Power Plant Branch-Mechanical
Jindal Steel and Power Ltd,Raigarh Semester-8th
College-CGC-COE, Mohali
Signature-

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Acknowledgement
It is matter of great pleasure and privilege for me to present this report of One month
industrial training in Power Plant Unit-3.Though this report, I would like to thank numerous
people whose consistent support and guidance is standing pillar in architecture of this
report.
To begin with, my sincere thanks to Ateet Namdeo, AGM-HR & ES of Jindal Steel and
Power Ltd for providing me an opportunity to get acquainted with various activities of
different Plant. I express thanks to Mr. Rajesh Kumar Agrawal, AVP-EPS and Mr. Pinaki Sir
General Manager of Power Plant Unit-3 for extending co-operation to enable me to get
acquainted with the various activities of their department.
I would like to express my sincere thanks towards members of Maintenance &
Operation department for making me a deep knowledge about various activities of Power
plant.
Shani Kumar Singh

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INDEX
1. Introduction of Jindal Steel & Power Limited
2. Facilities at Raigarh Plant Include
3. Introduction of Thermal Power Plant
4. Thermal Power Plant Layout
5. Process and Cycle
6. Major Equipments of Equipments of Thermal Power Plant
 Boiler
 Turbine
 Condensor
 Hot Well
 Condensate Extraction Pump
 Ejector
 Gland Steam Condenser
 Drain Cooler
 LP Heater
 Deaerator
 Boiler Feed Pump
 Cooling Tower
 Ash Handling System

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Introduction of Jindal Steel & Power Limited
 JSPL is an industrial powerhouse with a dominant presence in steel, power, mining
and infrastructure sectors.
 Turnover of approx. US$ 3.3 billion, JSPL is a part of about US$18 billion diversified
Jindal Group conglomerate.
 In terms of tonnage, it is the third largest steel producer in India.
 The company manufactures and sells sponge iron, mild steel slabs, ferro chrome,
iron ore, mild steel, structural, hot rolled plates and coils.
 JSPL operates the largest coal-based sponge iron plant in the world and has an
installed capacity of 3 MTPA (million tons per annum) of steel at Raigarh in
Chhattisgarh.
 JSPL has been rated as the second highest value creator in the world by the
Boston Consulting Group.
 The 11th fastest growing company in India by Business World and has figured in
the Forbes Asia list of Fab 50 Companies.
 In Oman (Middle East), the company has set up a US $ 500 million, 1.5 MTPA
gas-based hot briquetted Iron (HBI) plant. It has now added a 2MTPA integrated
Steel Plant.
 Alongside contributing to India’s growth story the company is driving an
ambitious global expansion plan in Africa, Australia and Indonesia.
 It deploys its resources to improve infrastructure, education, health, water,
sanitation, environment and so on in the areas it operates in. It has won several
awards for its innovative business and social practices.

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Facilities at Raigarh Plant Include
 DRI Plant-4nos. of 500TPD (0.72 Million TPA) and 6nos. of 300TPD rotary kilns (0.72
Million TPA)
 DRI Plant-4nos. of 500TPD (0.72 million TPA) and 6nos. of 300TPD rotary kilns (0.72
million TPA)
 0.8 million TPA Coke Oven Plant
 2.5 million TPA sinter Plant
 1.25 million TPA and 0.42 million TPA Blast Furnace
 2.0 million TPA and 1.25 million TPA steel melting shop
 2 Vacuum degassing Unit
 RH degassing Unit
 1 No. Single strand slab Caster
 1 No. of 6-strand billet-cum-round Caster and 1 No. 6 Strand billet caster
 2 No of 4-strand combi-caster
 Rail and Universal beam Mill(RUBM) (0.75 million TPA)
 Plate-cum-coil MILL(1.0 million TPA)
 Submerged arc furnace(SAF)(0.03 million TPA)
 Oxygen Plant 37683 Nm^3 per hour
 Lime and Dolomite Calcination Plants(0.4165 million TPA)
 358 MW Captive Power Plant(CPP)
 0.7 million TPA medium and light structure mill

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Introduction of Thermal Power Plant
A thermal power station is a power plant in which heat energy is converted to electric
power. In most of the places in the world the turbine is steam-driven. Water is heated, turns
into steam and spins a steam turbine which drives an electrical generator. After it passes
through the turbine, the steam is condensed in a condenser and recycled to where it was
heated; this is known as a Rankine cycle. The greatest variation in the design of thermal
power stations is due to the different heat sources, fossil fuel dominates here, although
nuclear heat energy and solar heat energy are also used. 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.
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,
in the form of hot exhaust gas, can be used to raise steam, by passing this gas through a
Heat Recovery Steam Generator the steam is then used to drive a steam turbine 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.
Power Plant Unit-3, JSPL, Raigarh

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Thermal Power Plant Layout
Almost two third of electricity requirement of the world is fulfilled by thermal power
plants (or thermal power stations). In these power stations, steam is produced by burning
some fossil fuel (e.g. coal) and then used to run a steam turbine. Thus, a thermal power
station may sometimes called as a Steam Power Station. After the steam passes through the
steam turbine, it is condensed in a condenser and again fed back into the boiler to become
steam. This is known as ranking cycle. This article explains how electricity is generated in
thermal power plants. As majority of thermal power plants use coal as their primary fuel,
this article is focused on a coal fired thermal power plant.
The layout of the steam power plant is shown in figure below. It consists of different
circuits. These are: Boiler, Turbine, Gear Box, Generator, Exciter, Condensor, Hot well, CEP,
Ejector, GSC, Drain Cooler, LP Heater, Dearator, and Boiler Feed Pump etc.
Process and Cycle of Thermal Power Plant
In a coal based power plant coal is transported from coal mines to the power plant by
railway in wagons or in a merry-go-round system. Coal is unloaded from the wagons to a
moving underground conveyor belt. This coal from the mines is of no uniform size. So it is
Typical diagram of a coal-fired thermal power station

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taken to the Crusher house and crushed to a size of 20mm. From the crusher house the coal
is either stored in dead storage( generally 40 days coal supply) which serves as coal supply in
case of coal supply bottleneck or to the live storage(8 hours coal supply) in the raw coal
bunker in the boiler house. Raw coal from the raw coal bunker is supplied to the Coal Mills
by a Raw Coal Feeder. The Coal Mills or pulveriser pulverizes the coal to 200 mesh size. The
powdered coal from the coal mills is carried to the boiler in coal pipes by high pressure hot
air. The pulverized coal air mixture is burnt in the boiler in the combustion zone.
Generally in modern boilers tangential firing system is used i.e. the coal nozzles/ guns form
tangent to a circle. The temperature in fire ball is of the order of 1300 °. The boiler is a water
tube boiler hanging from the top. Water is converted to steam in the boiler and steam is
separated from water in the boiler Drum. The saturated steam from the boiler drum is taken
to the Low Temperature Superheater, Platen Superheater and Final Superheater
respectively for superheating. The superheated steam from the final superheater is taken to
the Steam Turbine. In the Turbine the steam pressure is utilized to rotate the turbine and
the resultant is rotational energy. From the HPT the out coming steam is taken to the
Reheater in the boiler to increase its temperature as the steam becomes wet at the HPT
outlet. The outlet of the Turbine is sent to the condenser for condensing back to water by a
cooling water system. This condensed water is collected in the Hotwell and is again sent to
the boiler in a closed cycle. The rotational energy imparted to the turbine by high pressure
steam is converted to electrical energy in the Generator.
Major Equipments & Station of Thermal Power Plant
BOILER-
Boiler is closed vessel in which water is heated to generate steam for power plant or even
other industrial purpose. The function of boiler is to generate steam at desired pressure

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and temperature by transferring heat produced by burning of fuel in a furnace to change
water into steam.
Tubes filled with water are arranged inside a furnace in a number of possible
configurations. Often the water tubes connect large drums, the lower ones containing water
and the upper ones steam and water; in other cases, such as a mono-tube boiler, water is
circulated by a pump through a succession of coils. This type generally gives high steam
production rates, but less storage capacity than the above. Water tube boilers can be
designed to exploit any heat source and are generally preferred in high-pressure
applications since the high-pressure water/steam is contained within small diameter pipes
which can withstand the pressure with a thinner wall.
JSPL uses majorly two types of Boiler 1st is CFBC (Circulating Fluidised Bed Combustion
Boiler) and the 2nd one WHRB (Waste Heat Recovery Boiler).
CFBC Boiler has advantage that its simplified, cost-effective and efficient design provides
improved performance. Benefits include high combustion efficiency, high reliability and
availability, low maintenance costs, reduced erosion, enormous fuel flexibility and low
emissions. CFBC boiler is based on Babcock & Wilcox's unique internal re-circulation CFB
boiler design and employs a patented two-stage particle separation system.
Waste Heat Recovery Boilers (WHRB) is fully packaged smoke tube industrial boilers
equipped with advanced instrumentation to deliver maximum possible heat recovery. These
boilers are ideal to recover heat from gen sets, incinerators, blast furnace exhausts etc. They
enhance the system efficiency and help save fuel and money.
WHRB

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Boiler Accessories
 Feed Water Pump/Boiler Feed Pump
A boiler feed water pump is a specific type of pump used to pump feed water into a
steam boiler. The water may be freshly supplied or returning condensate produced
as a result of the condensation of the steam produced by the boiler. These pumps
are normally high pressure units that take suction from a condensate return system
and can be of the centrifugal pump type or positive displacement type.
 Pressure Reducing Valve
The function of pressure reducing valve is to maintain constant pressure on its
delivery side of the valve irrespective of fluctuating demand of steam from the
Boiler.
 Economiser
The economizer is a device, which serves to recover some of the heat being carried
by exhaust flue gases. The heat thus recovered is utilized in raised temperature in
feed water being supplied to the boiler. If the water is raised and thus there is a
saving in the consumption of fuel. Since superheating result in the increased
efficiency and economy of the steam plant.
 Super Heater
The steam generated by a simple boiler in generally wet or at the most dry
saturated. Steam super heater is a surface heat exchanger in which the wet steam is
first dried at the same temperature and pressure and then raised to temperature
above the saturation temperature at constant pressure. Heat of flue gasses utilized
in super heating the steam and as the super heater is placed in the path of the flue

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gasses, since superheating result in the increased efficiency and economy of the
steam plant.
Boiler Mounting (For Safety Purpose)
 Water level Indicator
The function of the water level indicator is to ascertain constantly and exactly the
level of water in the boiler shell. It is fitted in the front of the boiler from where it is
easily visible to the operator.
 Safety Valve
The function of the safety valve is to permit the steam in the boiler to escape to
atmosp0here when pressure in the steam space in the boiler. The safety valve
operates in the principle that a valve is pressed against its seat through some agency
such as strut, screw or spring by external weight or force, when the steam force due
to boiler pressure acting under the valve exceeds the external force, the valve gets
lifted off its seat and some of the steam rushes out until normal pressure is restored
again.
 Pressure Gauge
Each boiler has to be provided with a pressure gauge, which record the pressure at
which the steam is being generated in the boiler. The gauge is usually mounted at
the front top of the boiler shell or drum. The gauge should to be clearly visible to the
attendant so that he can easily record the pressure reading.
 Steam Stop Valve
The function of the steam stop valve is to shut off or regulate the flow of steam
from the boiler to the steam pipe or from the steam pipe to the engine. When used
for the former purpose, it is called junction valve. Usually the junction valve means a
regulating valve of larger size and a stop valve refers to a regulating valve of smaller
size.
 Feed Check Valve
The feed check valve has the following two functions to perform:
1. To allow the feed water to pass into the boiler.
2. To prevent the back flow of water from the boiler in the events of the failure
of the feed pump.
 Fusible Plug
The function of the fusible plug is to extinguish the fire in the event of the boiler
shell failing below a certain specified limit. We know that when the water on heating
transforms into steam, the level of water in the boiler falls down. If the water is not
replenished and the steam generation continues then the parts, which have been
uncovered by water uncovered by water may get overheated and subsequently are
melted. To safeguard against this eventuality we use fusible plug.

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Turbine
A steam turbine is a device that extracts thermal energy from pressurized steam and uses it
to do mechanical work on a rotating output shaft. Its modern manifestation was invented
by Sir Charles Parsons in 1884. Because the turbine generates rotary motion, it is
particularly suited to be used to drive an electrical generator – about 90% of all electricity
generation in the United States (1996) is by use of steam turbines. The steam turbine is a
form of heat engine that derives much of its improvement in thermodynamic
efficiency from the use of multiple stages in the expansion of the steam, which results in a
closer approach to the ideal reversible expansion process.
Compounding of steam turbines is the method in which energy from the steam is extracted
in a number of stages rather than a single stage in a turbine. A compounded steam turbine
has multiple stages i.e. it has more than one set of nozzles and rotors, in series, keyed to the
shaft or fixed to the casing, so that either the steam pressure or the jet velocity is absorbed
by the turbine in number of stages.
The steam produced in the boiler has sufficiently high enthalpy when superheated. In all
turbines the blade velocity is directly proportional to the velocity of the steam passing over
the blade. Now, if the entire energy of the steamis extracted in one stage, i.e. if the steam is
expanded from the boiler pressure to the condenser pressure in a single stage, then its
velocity will be very high. Hence the velocity of the rotor (to which the blades are keyed) can
reach to about 30,000 rpm, which is pretty high for practical uses because of very high
vibration. Moreover at such high speeds the centrifugal forces are immense, which can
damage the structure. Hence, compounding is needed. The high velocity which is used for
impulse turbine just strikes on single ring of rotor that cause wastage of steam ranges 10%
to 12%. To overcome the wastage of steam compounding of steam turbine is used.

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Condenser
A surface condenser is a commonly used term for a water-cooled shell and tube heat
exchanger installed on the exhaust steam from a steam turbine in thermal power stations.
These condensers are heat exchangers which convert steam from its gaseous to its liquid
state at a pressure below atmospheric pressure. Where cooling water is in short supply, an
air-cooled condenser is often used. An air-cooled condenser is however, significantly more
expensive and cannot achieve as low a steam turbine exhaust pressure (and temperature)
as a water-cooled surface condenser. Surface condensers are also used in applications and
industries other than the condensing of steam turbine exhaust in power plants.
In thermal power plants, the purpose of a surface condenser is to condense the exhaust
steam from a steam turbine to obtain maximum efficiency, and also to convert the turbine
exhaust steam into pure water (referred to as steam condensate) so that it may be reused in
the steam generator or boiler as boiler feed water.
Hot well
A tank or reservoir in which hot water is collected before being recirculated especially
condensed steam about to be returned to a boiler.
In normal thermal stations where make water is about 1% only. The temperature of hot well
is very low.So adding 1% make up does not have any bad effect. This water along with
condensate is then heated in LP heaters, deaerator then in HP heaters then economizer.
Condensate Extraction Pump (CEP)
In industrial steam systems the condensate pump is used to collect and return condensate
from remote areas of the plant. The steam produced in the boiler can heat equipment and
processes a considerable distance away. Once steam is used it turns to hot water or
condensate. This pump and possibly many more around the plant returns this hot water

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back to a make-up tank closer to the boiler, where it can be reclaimed, chemically treated,
and reused, in the boiler, consequently it can sometimes be referred to as a condensate
return pump.
Ejector
Steam jet ejector is used for air removal on surface condensers. They are simple in
operation and rugged in construction, can use a wide range of steam pressures, and will
handle wet or dry mixtures of air, gases, or vapours at a near-perfect vacuum. However,
several ejectors may be required to obtain the desired vacuum.
The steam-air ejector consists of a steam nozzle, a suction chamber, and a diffuser. Steam
enters the nozzle and discharges a jet of high-velocity steam across a suction chamber into a
venture-shaped diffuser. Air or gases to be evacuated enter the ejector suction, become
entrained by the moving jet of steam, and are then discharged through the diffuser, where
the velocity energy is converted into pressure, thereby compressing the mixture to a lower
vacuum. The steam pressure is variable depending on the size of the nozzle used and
vacuum to be produced.
Where lower vacuums are desired, or where it is not economical to do the entire job of
evacuation in one stage, multistage Steam jet ejector are used. Here the discharge of the
primary stages enters the suction chamber of the succeeding stages either directly or
through an inter cooler placed between the stages. Precoolers are sometimes placed ahead
of the first stage Steam jet ejector to remove condensable vapours before they enter the
ejector, thereby reducing its size and steam consumption. Single-stage ejectors are suitable
where moderate vacuum is desired, after which two-stage ejectors are used. Steam jet
ejector of this type requires little maintenance and is relatively trouble-free in operation,

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and, consequently, they have been universally accepted for this operation. The steam-air
ejector has virtually replaced all other forms of air removal devices. In most condenser
installations, the vacuum to be maintained is greater than can be obtained economically by
a single stage ejector. Two-stage Steam jet ejector usually have some type of condenser
between them to condense the steam and condensable vapours from the first stage.
Gland Steam Condenser
The function of the gland steam condenser is to maintain a sub-atmospheric pressure at the
outermost leak-off belt of the glands and thereby prevent the leakage of steam from the
glands into the turbine hall, where it would condense on the walls and plant.
The condenser is vented to the atmosphere via a blower. The small vacuum created by the
blower is sufficient to draw air into the glands where it mixes with steam leaking from the
cylinder; the air is separated in the gland condenser and passed back to the atmosphere via
the vent fans. The steam is condensed and the condensate passes to the main condenser.
Drain Cooler
The drains cooler is a heat exchangers of the shell and tube type. Each is used in some
particular way to recover heat from exhaust steam by heating the feedwater which is
circulated through the units.
The drains cooler receives the exhaust drains from various auxiliary services and condenses
them: the condensate is returned to the feed system. The circulating feed water passes
through straight tubes arranged in tube plates in the drains cooler.
LP Heater

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A feed water heater is power plant component used to pre-heat water delivering to
generating Boiler. In steam power plant feed water heater allows feed water to brought up
its saturation temperature gradually.
They provides efficiency gains by increasing initial temperature of feed water, so there is
less sensible heat addition occurs in Boiler.
Steam is extracted from selected stage of turbine to the shell and tube heat exchangers or
to open water heaters where the steam and feed water are in direct contact.
Deaerator
A deaerator is a device that is widely used for the removal of oxygen and other dissolved
gases from the feed water to steam-generating boilers. In particular, dissolved oxygen in
boiler feed waters will cause serious corrosion damage in steam systems by attaching to the
walls of metal piping and other metallic equipment and forming oxides (rust). Dissolved
carbon dioxide combines with water to form carbonic acid that causes further corrosion.
Most deaerators are designed to remove oxygen down to levels of 7 ppb by weight (0.005
cm³/L) or less as well as essentially eliminating carbon dioxide.

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Boiler Feed Pump
A boiler feed water pump is a specific type of pump used to pump feed water into a steam
boiler. The water may be freshly supplied or returning condensate produced as a result of
the condensation of the steam produced by the boiler. These pumps are normally high
pressure units that take suction from a condensate return system and can be of the
centrifugal pump type or positive displacement type.
Boiler Feed Pumps range in size up to many horsepower and the electric motor is usually
separated from the pump body by some form of mechanical coupling. Large industrial
condensate pumps may also serve as the feed water pump. In either case, to force the
water into the boiler, the pump must generate sufficient pressure to overcome the steam
pressure developed by the boiler. This is usually accomplished through the use of a

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centrifugal pump. Another common form of feed water pumps run constantly and are
provided with a minimum flow device to stop over pressuring the pump on low flows. The
minimum flow usually returns to the tank or deaerator.
Cooling Tower
A cooling tower is a heat rejection device that 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.
Remove heat from the water discharged from the condenser so that the water can be
discharged to the river or recirculated and reused.
Cooling towers are a special type of heat exchanger that allows water and air to come in
contact with each other to lower the temperature of the hot water. During this process,
small volumes of water evaporate, lowering the temperature of the water that's being
circulated throughout the cooling tower. In a short summary, a cooling tower cools down
water that gets over heated by industrial equipment and processes.
The hot water is usually caused by air conditioning condensers or other industrial processes.
That water is pumped through pipes directly into the cooling tower. Cooling tower nozzles
are used to spray the water onto to the "fill media", which slows the water flow down and
exposes the maximum amount of water surface area possible for the best air-water contact.

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The water is exposed to air as it flows throughout the cooling tower. The air is being pulled
by a motor-driven electric "cooling tower fan".
When the air and water come together, a small volume of water evaporates, creating an
action of cooling. The colder water gets pumped back to the process/equipment that
absorbs heat or the condenser. It repeats the loop over and over again to constantly cool
down the heated equipment or condensers.
Ash Handling System
Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag
filters (or sometimes both) located at the outlet of the furnace and before the induced draft
fan. The fly ash is periodically removed from the collection hoppers below the precipitators
or bag filters. Generally, the fly ash is pneumatically transported to storage silos for
subsequent transport by trucks or railroad cars.

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At the bottom of the furnace, there is a hopper for collection of bottom ash. This hopper is
always filled with water to quench the ash and clinkers falling down from the furnace. Some
arrangement is included to crush the clinkers and for conveying the crushed clinkers and
bottom ash to a storage site. Ash extractor is used to discharge ash from Municipal solid
waste–fired boilers.