Kota Thermal Power StationTraining Session May,09 – June,09

Submitted By:-

Ankit Kulshreshtha

EC-1

Roll No. 06/N/028

Industry at a glance :-

Location:- On the bank of river Chambal in Kota (Rajasthan)

Produce electricity by coal Having 6 units (presently) producing continuously Produce almost 1024 MW energy ,second to

Suratgardh power plant Get coal from Madhya Pradesh coal fields Have 4 big 180 meters height chimneys to control

suspended particles Record of having 85% power factor, get clearance

from CEA

Unit Details of KTPS

Units Date of synchronization on oil

Date of synchronization on coal

Date of declaration of Commercial Operation

Unit-1 17.1.83 20.1.83 01.04.83

Unit-2 17.7.83 05.8.83 01.04.84

Unit-3 25.9.88 11.12.88 11.03.89

Unit-4 01.5.89 16.10.89 06.03.90

Unit-5 26.3.94 11.10.94 18.07.95

Unit-6 30.07.2003 30.7.2003 01.08.2004

Basic Process of Thermal Power plant

The KTPS working is based on four Sections

Coal and Ash Air and gas Feed water and steam Cooling water

Coal and ash

Air and gas

Feed water

Cooling tower

Detail Working of KTPS

Coal Handling Coal is supplied

Through railTrack by own trains

By wagon triplerThe coal is drawn

Into underground hopper

By means of two Belts coal is transferred

To the Conveyer

Now coal is transferred toCrushing house and

stored to bunkers

Now coal is fed to Mills Where coal is

Crushed in pulverizedform

Coal is taken to Coal nozzle

In wind box assembly

From nozzle coal Is

discharged to furnace

There are two types of Mills in KSTPS

Bowl Mills- Grinding chambers in form of Bowl Centrifugal force is used to move

coal against grinder FD fan is used to dry the coal &

drive it to furnace

Tube mills- Constantly rotating tube around 20

rpm Side at which gas gear is mounted

is known as driving end 3 balls of diff. size is used FD fan is used to dry the coal &

drive it to furnace

Here hot air is used to remove moisture from coal and cold air is used to keep temp below flash point

Power consumed by Coal Mill Motor is 340 MW. There are total 8 motor are installed 6 running 2 on stand by PA fans = 820 Kw

ID fans = 850 kw

FD fans = 300 kw

Burner :- Tangential type

discharge the fuel air mixture tangentially to an imaginary circle in the center of the furnace

burners are placed at the four corners of the furnace

Firing Mechanism-Fuel is introduced from wind nozzle located at lower corner inside the boiler

Boiler :- A apparatus where water is being converted into steam

The water in the tube of boiler get vaporized by heat energy & steam is generated

The boiler weighs about 6000 Mega tons ,height about 50 to 60 meters

Whole height is divided in 13 diff. levels as per burning materials

Boiler Auxileries- To increase efficiency

Economiser –Used to preheat boiler feed water, before entering to boilerDeriving heat from the flue gases The economizer is placed in the main flue gas path between the boiler and the chimney.

The waste flue gases flow outside the tubes and heat is transferred to the water flowing inside

Air Preheater –Tubular type heat exchanger The flue gases coming out of the economizer is used to preheat the air before supplying it

to the combustion chamber. An increase in air temperature of 20 degrees can be achieved by this method. The pre heated air is used for combustion and also to dry the crushed coal

Useful to increase efficiency (20% flue gas incrs 1% capacity)In KTPS Regenerative type is used (Having rotor move at 2.4 RPM )

Boiler Drum –To separate water from steam It is located 54 meter from ground Feed water coming out of Economiser enter to the Boiler Drum

Turbine :-A machine which convert Kinetic energy to Mechanical energy

Steam is passed throughnozzle

Steam now falls on Turbine blade

moves the turbine

Parts of Turbine

A.) Nozzle

B.) Blade

C.) Rotor shaft

Flow chart for turbine

• The rotor shaft is made of steel, blade is fixed on it

• Steam is entered from left and right inlets

• Two stage turbine is used

• Steam is recycled

Auxiliaries of turbine :-

Condenser –Here steam is exited by creating vaccum or very low atm pressure ,the cooling water is directly taken from chambal requirement – as discharge from LPT is Liquid+vapour

Hotwell –It is located below the condenser ,to store condensate ,tank of size 5m in depth & 2 to 3m in dia.makeup of leakage of demineralised water also processed

Deaerator –It removes the dissolved gases like O2 , CO2 etc by means of pagging.requirement- As dissolved gases may corrode Boiler Drum

High Pressure Heater –It raise the temp & pressure of water which is requiredfor further processing i.e. 165 kg/cm and 2500 C

Generator :-Machine that coverts Mechanical energy to the

Electrical energy

Principle-Based on faraday’s law of electromagnetic induction

Statistics of generator at KTPSKW : 210 Kw

PF : 0.85

KVA : 247000

RPM : 3000

Hz : 50hz

Coolant :Water + H2

Parts of Generator

Stator Frame –Welded construction of plateUsed to contain and support the stator core winding, also provide H2 as coolant

Stator core –Built of Segmented ,annealed ,insulated ,high quality ,Silicon Sheet ,to give min electricalloss

Stator Bars –Each stator half coil bar is composed of alternate strip of double glass covered and barscopper transposed in straight position, each strip occupies every radial position

Rotor –It is forged on a single piece of special Cr, Ni & Mo alloy steel ,to get required mech prop.

Rotor Winding It consist of two poles each having concentric coils of several turnsSemi hold silver alloy copper of rectangular cross section is used, insulated by epoxyGlasses laminated stripes CONT……

Rotor bearing-Specially designed bearing electronic apparatus to indicate the location of unbalancepole in magnitude and direction.

Slip Ring –Made of forged steel they are located side by side on exciter side of generator shaft

Generator Terminal Bushing –Have six output 3 larger and 3 shorter ,coming out of bottom, short terminals used forExternal connection ,conduction is through a Cu tube ,H2 as coolant is used.

Bush Gear Assembly –Made of natural composition of Graphite and winding materials, have low friction , self lubricating

Control Room:- Where controlling of various equipment taken

place Setup is done by Instrumentation Limited, kota From one unit control 2 adjacent unit can be controlled + local CS for boilers ,turbo

jets ,boilers CR shows and record various parameters Automatic Scheme for feed water regulation and reheat temp computation is provided One CR have five desks as follows :-CP – I1 FAN CONRTOL DESK

a. Induced Fan draftb. Forced Fan c. Primary air Fan

2. PRESSURE DESKa. Furnace pressureb. Primary Air Heater Pressure

CP – II1 FUEL CONTROL DESK

a. Coal air flowb. oil pressurec. temp of milld. flow of aire. differential pressure of mill CONTD…..

CP – III1. STEAM AND WATER DESK

a. Drum Level controlb. Flow of Steam and Waterc. Pressure of steam and waterd. Temp of steam and water

CP – IV1. TURBINE DESK

a. Pressure Controlb. Load controlc. Speed controld. Valves control

CP – V1. GENERATOR CONTROL DESK

a. Voltage Control MVARb. Stator rotor Tempc. For stator cooling a) Water

b) H2

Facts about KTPS Kota Thermal Power Station has performed

outstanding, from the very beginning, produced outstanding results and has continuously

earned cash prizes and shields. Power station has received meritorious productivity awards

given by the Ministry of power, Government of India, in the years 1984,1987, 1989, 1991 and

continuously thereafter. The 6th unit of Kota Super TPS was

commissioned and synchronized with the grid on 30.7.03 and full load was achieved on coal

firing in less than 10 Hrs. The project was completed in 24 months which is a national

record for this type of generating unit.

Conclusion :-

K.S.T.P.S. is the main super thermal power plant located in principle industry city, Kota.

It has established a record of excellence & earned various productivity award from The Ministry of power, Government of India.

Thank you Query Please