INDUSTRIAL INTERNSHIP

INTERNSHIP REPORT

RAYALASEEMA THERMAL POWER PROJECT

A Study Report on RAYALASEEMA THERMAL POWER PROJECT as part

Palli Goutham Reddy

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ABSTRACT

Power constitutes the basic and essential input for rapid economic development.

In fact the country's industrial growth is directly linked with power supply prospects.

. In this modern scenario energy place a vital role both in industrial development,

which in turn leads to the prosperity generation facilities developed

AP to meet growing demand for power.

By using accessories in the boiler. The efficiency of the plant increases. For example the
accessories like Economiser increases the feed water temperature while

super heater increases the temperature of the steam produced the boiler. The air pre

heater increases the inlet air temperature, which enters into the furnace. By increasing

the efficiency of plant more power can be generated with less quantity of fuel.

The main objective of this internship is to analyse the efficiency

Of boiler, by varying the various parameters in boiler

section The work is carried out in RTPP located at muddanur in kadapa dist. AP.

It also deals with various maintenance factors, As well as get to know about mountings and
accessories.

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CONTENTS

CHAPTER NAME

CHAPTER-1 INTRODUCTION

1.1 Introduction

1.2 Essential inputs to the plant

1.2.1 Coal

1.2.2 furnace oil & diesel oil

1.2.3 water

1.2.4 product

1.3 Plant overview

1.3.1 coal plant operation

1.3.2 fuel oil pump house

1.3.3 feeders

1.3.4 mills

1.3.5 fans

1.3.6 Boilers

1.4 Auxiliary systems

1.4.1 cooling pond

1.4.2 condenser

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1.4.3 pumps

CHAPTER-2 BASIC STEAM POWER CYCLES

2.1 Carnot cycle

2.2 Rankine cycle

2.3 Rankine cycle efficiency improved by

a) Increasing boiler efficiency

b) super heating

c) reducing condenser pressure

CHAPTER-3 INTRODUCTION TO STEAM GENERATORS

3.1 Definition

3.2 classification of boilers

3.3 Boilers mountings & accessories

3.4 Performance of boilers.

CHAPTER-4 ACCESSORIES

4.1 Economizer

4.1.1 Importance

4.1.2 Description of economizer

4.1.3 Economizer in RTPP

4.1.4 working of economizer

4.1.5 Specification of economizer in RTPP

4.2 SUPER HEATERS

4.2.1 Functions

4.2.2 Description of super heater

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4.2.3 Classifications

4.3 AIR PRE HEATER

4.3.1 Introduction

LIST OF DIAGRAMS

Figures

1.1. Steam power plant

1.2. Steam power plant overview

1.3. Power generation (BOILER drum)

2.1. Carnot cycle T-s & P-v diagrams

2.2 Rankine cycle

2.2.1. P-v diagram

2.2.2 T-s diagram

2.2.3. H-s diagram

4. Economizer

5. Super heater

6. Air pre heater

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CHAPTER-1

INTRODUCTION

1.1 INTRODUCTION TO RTPP

Rayalaseema Thermal Power Plant is one of the major power generation

facilities developed in Andhra Pradesh to meet the growing demand for power,the

project envisaged the installation of 5 216 mw cool be thermal generation unit's

stage 12.3.4.1he first unit of 210MW commercially came into operation on 25th Nov

1994,the second unit on 30th march 1995, the third unit on 25th Jan 207 and forth unit on

20th Nov 2007 and fifth unit on Jan 2011

The RTPP is located at a distance of 8 km from muddanur, Railway station

of south central railway and on Cher -Mumbai highway the site selected at,an

adequate distance from the populous towns. The water requirements for the project

are met from Mylavaram reservoir river penna, which is 23 km away from the plant.

1.2 ESSENTIAL INPUTS TO THE PLANT

12.1 coal

The project gets its coal from singareni collieries (SSLC) by wagons and

from the charcoal mines (Mahanadi coal fields by ship and wagon. The coal Is used

in RTPP is sub bituminous It is similar to lignite it contains 50% less moisture than

lignite It also contains less than lignite but it has caking power & also used either in

the form of pulverized state

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The coal from singareni mines is of inferior quality upgraded with ash

average content varying between 45%-65% the un crushed coal is stored in stack

yard and crushed coal in separate yard

1.2.2 Furnace oil and diesel oils:

LDO (light diesel oil) used for firing HFO (heavy furnace oil) used for

flame support and stabilization RTPP gets furnace oil and diesel from Indian oil

Corporation by rail.

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1.2.3 Water

The water requirements of the project are met from Mylavaram Reservoir

across penna river situated at a distance 23 km A gravity pipeline I laid to draw 25

causes of water from the reservoir. Approximately 60,000 kilometer of water is

consumed for different purposes of the plant and colony per day product

The plant with four units of each 210mw in stage generates 10.08 MU per

day or nearly 300 for month.

1.3 Paint overview

In this chapter overview of the plant and its components as shown in fig 1.2

1.3.1 Coal plant operation

Coal from the rail wagons is unloaded by charger arm and wagon trippers,

which is driven by hydraulic system. Raw coal is taken on the UCB, from which it is

fed to the crusher. The coal is crushed into a size of 20mm.If any problem occurs in

one path the process is diverted to another path from the motor control cabin itself

1.3.2 Fuel oil pump house: The two types of oil fed to the thermal power plant are

1)Heavy furnace oil. 2)light diesel oil

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1.3.3 Feeders

Coal feeders are located between each bunker and its respective pulveriser
The principle function of a coal feeder is to control the flow of coal to the pulverizes
to meet the steam demand two variations of the belt feeders are

1.Volume feeder

2.Gravimetric feeder

1.3.4 Mills

A mill is one, which grinds down pieces of coal into fine powder which is to

be fed to the boiler furnace the coal after crushing down to 20mm proceeds to this

mill for the further fine crushing

1.3.5 fans

Fans are provided throughout the steam electric generating unit to supply air

on to exhaust flue gas to meet the needs of various systems. In addition fans are used

for building heat and cold to prevent contamination due to inter leakage and cooling

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for a wide variety of equipment from lubricating oil coolers to mechanical draught
cooling towers

Power plant application that require the largest fans for steam generation are
1.Forced draught fan

2. Primary air fan

3. Induced draught fan

1.3.6 Boilers

Steam generation components are

1. Furnace

2. Drum

3. Soot blowers

4. Coal piping burners

5. Igniters&oil burners

The furnace serves as an enclosure for the combustion process. The required steam
capacity and the characteristics of the fuel determine the size of the furnace.

1.3.6.1 Boiler drum

The drum encloses the steam water interfaces in a boiler and provides a
convenient for addition of chemical and removal of dissolved solids from the water
steam system The water for the boiler enters the water tube furnace through down
comes at which the water is converted into steam inside the furnace and this steam is
sent to the boiler drum through upraises, as shown in fig 3

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1.3.6.2 Soot blowers

Soot blower are used for removal of ash deposits from the fireside of heat

transfer surfaces. Wall blowers are used in difficult applications for spot removal of

heavy slag These are operated 2 to 3 times per day.

Coal piping and Burners

Coal piping conveys the pulverized coal and primary air mixture to the

burners. The burners pipe arrangement is determined by the burner arrangement in the

furnace and types of pulveriser.

burners Igniters and oil

Igniters and warm up burners are necessary for flame initialization and less

low stabilization. The initial ignition source is as high-energy spark that starts the

igniters flame which gives ignition to oil burner.

Turbines

The function of the steam turbine is to convert the thermal energy of the

steam generated to electrical energy .The steam turbine converts the thermal energy to

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rotating mechanical energy and the generator converts the mechanical energy to

electrical energy.

1.3.6.3 Valves

The primary function of stop valves is to provide backup protection for

steam turbine. The primary function of control valve is to regulate the steam flow to

the turbine and thus control the output power of steam turbine generator.
1.4 Auxiliary systems
Some of the common auxiliary systems are

Circulating water systems

Most power plants use a circulating water system as the mechanism, which
transfers cycle waste heat from steam cycle to the ambient environment

1.4.1 Cooling pond:

it is the simplest and least expensive alternate method for providing plant
circulating water.

1.4.2 Condenser

The function of the condenser is to condense exhaust steam from the main power
cycle steam turbine.

1.4.3 pumps

1.4.3.1Condensate pumps

The pumps pump the condensate from the condenser hot well to be aerating heater.

1.4.3.2 Boiler feed pumps

A BFP is a pump that supplies feed water to a steam generator for the

production of steam.

Recirculating cooling system

In this system the circulating water to the cooling tower, which rejects heat

to the atmosphere carries waste heat removed from the steam turbine exhaus

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CHAPTER 2
BASIC STEAM POWER CYCLES

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CHAPTER-2

BASIC STEAM POWER CYCLES

2.1.CARNOT CYCLE

Fig 2.1 shows a Carnot cycle on 1-s diagram and p-v diagrams. It contains

of (a)Two constant pressure operations and(2-3) & (b). Two frictionless

adiabatic(1-2)and(3-4).These operations are discussed below

1. Operation (4-1):-1kg of boiling water at temperature T1 is heated to form wet

steam of dryness fraction x1. This heat is absorbed at constant temperature T1 and

pressure p1 during thus operation.

2. Operation (1-2):-During this operation steam is expanded is entropically to

temperature T2 and pressure p2. The point 2' represents the condition of steam after

expansion.

3. Operation (2-3):-During this operation heat is rejected at constant pressure P2

and temperature T2.As the steam is exhausted it becomes wetter and cooled from

2to3.

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4.Operation (3-4):-In this operation the wet steam at 3 is compressed isentropically

till the steam regains its original state or temperature T1 and pressure pl.Thus cycle is

completed.

From T-s diagram

Heat supplied at constant temperature TI(operation(4-1)=Area 4-1-b-a=T1(S1-s4)or T1(S2-S3).

Heat rejected at constant temperature T2( Operation 2-3-area 2-3-a-b=T2(S2-S3).

Since there is no exchange of heat during isentropic operation(1-2)and (3-4)

Net Work done=Heat supplied-Heat rejected

= T1 (S2-s3)-T2(S2-s3)

= (TI-T2)(S2-S3).

Carnot cycle efficiency=Work done Heat supplied

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=(TI-T2)(S2-s3)/TI(S2-S3)

=T1-T2/T1

2 RANKINE CYCLE: Rankine cycle is the theoretical cycle on which the steam:

turbine (or engine) works. The Rankine cycle is shown in fig 2.2 and it comprises the

following processes as shown in fig 2.3

Process 1-2:- Reversible adiabatic expansion in turbine

Process 2-3:-Constant pressure transfers of heat in the condenser

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Process 3-4:-Reversible adiabatic pumping process in the feed pump

Process 4-1:- Constant pressure transfers of heat in the boiler.

Fig 2.3 shows on Rankine cycle on P-V,T-S and H-S diagrams. Considering

one kg of fluid&applying.steady flow equation to boiler, turbine.condenser andpump.

Efficiency=h1-h2/h1-h4.

THE RANKINE CYCLE EFFICIENCY CAN BE IMPROVED BY:

Increasing the average temperature at which heat is supplied.

Decreasing or reducing the temperature the conditions of steam at which heat

Rejected.

This can be achieved by making suitable changes in generation or condensation

a discussed below

1. Increasing boiler pressure

2.Super heating

3.reducing condenser pressure

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CHAPTER 3
STEAM GENERATORS
(BOILERS)

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CHAPTER-3

INTRODUCTION TO STEAM GENERATORS

3.1 DEFINITION OF STEAM GENERATOR

OR

Steam generator popularly known as boiler made of high quality steel in which

steam is generated from water by application of heat.

3.2 CLASSIFICATION OF BOILERS

The boiler is classified as follows:

1. Depending upon the axis of boiler.

A. Horizontal axis boiler.

B. Vertical axis boiler.

c. Inclined type

2.Depending upon the position of water and hot gases.

A.Fire tube boilers

B.Water tube boiler

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3.Depending upon the method of firing.

A.Externally fired

B.internally fired

4.Depending upon the method of circulation of water

A.Forced circulation

B. Natural circulation

5. According to the pressure of boilers

A.High pressure boilers

B. Low pressure boilers

6 According to the position

A. Stationary

B. Portable

7. According to no. of tubes

A. Single tube

B. Multi tube

3.3 BOILER MOUNTINGS AND ACCESSORIES:

Mountings

These are different fittings and devices that are necessary for the operation and
safety or boiler. Usually these are mounted over boiler shells Some of them are.

1. Safety valve

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2 Water level indicator

3.feed check valve

4.pressure gauge

5.blow off cock

6.fusible plug

7.steam stop valve

8.man hole

9.mud holes or slight holes

water level indicator: The function of this is to indicate the level of water in

the boiler.it shows Steam space in red color and water in green color.

Safety valve: The function is to release the excess steam when the pressure of

the steam inside the boiler exceeds to rated pressure.

pressure gauge: The function of this is to measure the pressure exerted inside

the vessel

Feed check valve: To control the supply of water to the boiler and to prevent

the escaping of water from the boiler when the pump pressure is less or pump

is stopped.

Blow off cock: The functions are

1.1t may discharge a portion of water when the boiler is in operation to blow out

mudscale and sediments periodically.

2. It may empty the boiler when necessary for cleaning inspection and repair.

Fusible plug: The function of fusible plug is to protect the boiler against the

damage due to over heating for low level.

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Steam stop valve: To regulate the flow if steam from one pipe to other pipe or

from boiler to steam pipe.

ACCESSORIES: These are auxiliary parts required from steam boiler for their proper

operation and for increase the efficiency. Commonly used accessories are

1.Feed pumps

2. Economizer

3.Air preheater

4.Super heater

5.Steam separator

1. Feed pump:

The function of feed pump is to force the feed water into the boiler drum at high

Pressure.

2.Economizer:

In this waste heat of flue gases is utilized for heating the feed water. It is placed in between
boiler furnace and air preheater.

3. Air Pre heater:

The function of air preheater is to increase the temperature of air, which enters the

Furnace. It is placed between economizer and chimney.

4.Super Heater:

The function of super heater is to increase the temperature of steam above its

ration temperature by utilizing the heat of flue gases. It is placed in the path of

gases.

3.4 PERFORMANCE OF BOILER

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The performance of boiler gives the efficiency of boiler and thus we can calculate
The amount of input to the system and output. The following parameters are used to
represent the performance of boilers. They are

1. Evaporative Capacity:

Evaporative capacity of boiler is the amount of steam generated per hour. It is

presented in following units

Kg of steam per hour

Kg of steam hour/m2

kg of steam/kg of fuel fired

2 Equivalent Evaporation: The amount of steam generated for different boilers is

different and this is not useful in comparing two boilers. To serve that purpose

the term steam equivalent has been introduced. The pressure and temperatures

also different boilers. It is imperative to define all the boilers on a common

base. The standard condition adopted in this is temperature of feed water at

100 degc. The amount of energy needed to water is 225KJ.

The term equivalent evaporation is defined as the amount of water evaporated

From water at 100'c to steam at 100°c.

3.Factor of Evaporation:

The ratio of heat received by 1kg of water under working conditions to that

received by 1 kg of water evaporated from and at 100°c.

4. Boiler Efficiency:

The ratio of heat actually utilized in generation of steam to that heat supplied by

the fuel in the same period.

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CHAPTER 4.1
ACCESSSORIES
ECONOMIZER

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CHAPTER-4

ACCESSORIES

ECONOMISER

"An economizer is a device which extracts a part if heat from the flue gases and used for heating
the feed water.

4.1.1. IMPORTANCE

Use of economizer increases the boiler efficiency, and then the overall

efficiency of the plant increases, For every 6 deg raise in temperature of feed water.

boiler efficiency increases by 1%. The heat of flue gases, which are being wasted, can

be utilized effectively .By using the heat of the flue gases in economizer the fuel supply to the
boiler can be decreased.

4.1.2 DESCRIPTION OF ECONOMISER

The economizer is a feed water heater deriving heat from the flue gases discharged

m the boiler. The greatest item in a boiler is the heat carried away by the flue of the

chimney or stack some of heat being carried away by the flue gases may be recovered

of sent back into the boiler. In the economizer if the path of feed water placed in the

path of flue gases in between the exit from the boiler and enters the chimney, the heat

from the flue gas is transferred to the feed water. The economizers the fuel and steam

rate is increased. It has been found that a rise in temperature of feed water by 6c

improves the boiler efficiency by 1%.

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Economizer is generally placed between the reheater and the air preheater. In

some cases a low temperature economizer is placed after the Air pre heater, such

economizer is called stack cooler and acts as a low pressure feed water heater except

that the heating system is the flue gases instead of steam to bud from the turbine.

Steaming economizer

Non steaming economizer

4.1.3 ECONOMISER IN RTPP:

TYPE: The economizer used in RTPP is grilled hare tubes horizontally spaced economizer.

LOCATION: The economizer is located at the top if the boiler at the height of56.025 to 62 23m
from the ground floor.

Economers are generally placed between the last super heater and reheater and airpreheater.

4.1.4 WORKING OF ECONOMISER

The economizer consists of two sections. The lower section is known as non

steaming economizer and the upper part is known as steaming economizer. The

economizer is placed above the reheater. The hanger plates are used to support

economizer tubes. First the feed water from hot well is sent through header to lower

of the economizer in which the no of tubes is 100. The flue gases from the

combustion chamber are passed over the economizer. The heated water from the

section of the economizer is passed to upper section. The upper section also

consists of tubes. The feed water temperature rises from 230°c to 294deg c.The flue

gases at a temperature of 418deg c give heat from economizer to water. The water from

per section is sent to boiler drum where the steam is generated.

4.1.5 SPECIFICATIONS OF ECONOMISER IN RTPP

TYPE:Grilled bare tube horizontal speed economizer

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Total heat surface area: 7911m2

Number of blocks : 2

Volume of economizer: 25m3

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CHAPTER 4.2
ACCESSORIES
SUPER HEATER

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4.2 SUPER HEATER

FUNCTIONS

The super heater is very important accessory of boiler. the

Function of the super heater is to increase the temperature of steam above the saturation point.

Another function of a super heater is to remove the lost traces of moisture (1-2%) from the steam

coming our boiler.

4.2.1Advantages:

Due to installation of super heater the thermal efficiency of plant increase

Heat of the flue gas is maximally utilized

Losses due to condensation in the cylinders and steam pipes are reduced

Erosion of blade is reduced

Steam consumption rate of engine or turbine is reduced

4.2.2 DESCRIPTION OF SUPER HEATER

The steam produced in boiler in nearly saturated. This as such should not be used

the turbine because the dryness fraction of steam leaving boiler will be low. This

results in the presence of moisture, which causes corrosion of turbine blades .To rise

temperature of steam,superheater used. superheater supplies steam at constant

temperature at different loads. The use of superheated steam increases efficiency.

The super heating of a steam raise overall efficiency as well as avoids too much

condensation in the last stages of the turbine (below 12% ) and also to avoid blade erosion.

The heat of combustion gases from furnace is utilized for removal of moisture

from steam to superheated steam, as shown in fig 4.2

4.2.3 SUPER HEATERS ARE CLASSIFIED AS:

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according to mode of heat reception

Convective superheater: the heat of combustion gases are transferred to

The surfaces of tubes by convection.

Radiant super heater: The heat of combustion gases are transferred to the

Surface of tubes by radiation.

According to the position of heater tubes

Horizontal type

L-shaped type

According to the arrangement of super heater tubes in the boilers

Inner deck

Inner Tube

Inner deck

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CHAPTER 4.3

ACCESSORIES
AIR PRE HEATER

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4.3 Air preheater

INTRODUCTION

Air heater is a heat transfer in which air temperature is raised by

transferring heat from flue gas. Hot air is necessary for rapid and efficient

combustion in the furnace and also for also for drying coal in the milling plant,

s0 on essential boiler accessory, which serves this purpose, is AIR PREHEATER ,as shown in
fig 4.3.1

Air heater is typically located directly behind the boiler where this

receives hot flue gases from the economizer of 20°c in the air temperature

increases the boiler efficiency by 1%.Air preheater recycles the waste heat

back into the boiler and plays a very effective role of moderating ESP performance as well.

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CONCLUSIONS:

1.By using the Economizer

By instaling the economizer in the plant in the plant, the plant efficiency

can increased by 10%

2. By using super heater

By implementing the super heater the efficiency can be increased by (25-30%)

(8-10)% in each stage of super heater

3. By using high grade coal the following parameters can be improved.

➢ Due to calorific value of coal the heat liberated by burning the coal in
combustion chamber.
➢ The fly ash in flue gas is less.
➢ The ash content in high grade fuel is 20 to 25% only.
➢ Mechanical maintenance can be reduced.
➢ The coal mill output can be increased by using high grade coal.
➢ The mass of fuel gas required by the coal mill can be reduced by

removal of moisture in coal & power required can be improved.

➢ The fuel consumption for same power generation can be reduced.

FUTURE SCOPE

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In comparison with plan tube economizer steel finned economizers occupy

space for same thermal performance & draught loss.

The reduction in tube length for similar tube diameter is usually around 4-7. The

results in smaller casing, less structural steel work to support the reduced weght

fewer bends and fewer welds so there is less loss.

1. Economizer needs less maintenance for effective running.

2. The phase change in economizer is not accepted.

3. Generally economizer tubes are made by carbon steel (k=120 to170 w/mk)if

the tubes are made of aluminum a steel (k=205 w/mk) cause improvements in

thermal properties.

4. If the feed water contains minerals& impurities it causes corrosion and scale

formation in the economizer tubes, This corrosion and sealing layers are bad

conductor of heat and electricity, the heat transfer rate will decrease in the

economizer. So the feed water should be demineralised to free from impurities

and foreign matters.

5. The PH of feed water should be maintained between 8 and 9.

6. .The feed water leakage at the pipe joints is avoided by using gaskets.

7. The rate of air supply should be maintained constant for efficient heat transfer.

8. In order to increase the lifespan of furnace tubes they should be made by

special materials like Monel mixed with stainless steel, which prevents

leakages hence increasing the efficient of boiler.

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