Thermal Power Simulator Training Essar Power Gujarat Ltd,

Jamnagar

Vedant Pravin Sumaria (R630212061)

Ishaan (R6302120

Kanishk Anand Sharma (R630212067)

Kulkarni Singh (R6302120

Md. Amjad Hussain (R630212030)

Acknowledgement

At the outset, We are grateful to Mr. Indranil Ghosh, for giving us theopportunity to do our Industrial Training in ESSAR POWER GUJARATLIMITED. We would like to thank our mentors Mrs. Vinti Gupta(DeputyManager-L&D,EPGL), Mrs. Bhakti Peshkar(Deputy Manager-L&D,EPGL)and Mr. Vijay Anand( Manager-L&D, EPGL) for their extensive help andguidance throughout the training. We would also like to thank Mr. N.B Soni(Head Of Department, Electrical, Power and Energy Department, UPES)whoimparted us with his valuable guidance and suggestions during the entiretraining session.

About Plant

• Salaya power project is located in the Jamnagar district of Gujarat, India.

• It is a 3,120MW coal-fuelled thermal power plant proposed to be built over three

phases (phase I - 1,200 MW, phase II - 1,320MW, phase III - 600 MW).

• The project is being developed by Essar Power, a subsidiary of Essar Energy.

• The 1,200MW phase I of the project, Salaya I, was completed in June 2012 with an

investment of $1.1bn.

• Salaya I includes two 600MW generating units.

• Phase II and III of the project are currently under construction.

Salaya Power Project Details

• The Salaya power project site is spread over an area of 330ha.

• Coal for the plant is transported through a 17km-long conveyer from Essar's own

jetty established for importing coal.

• Salaya I will use coal imported from the Aries coal mine in Indonesia, which was

acquired by Essar in April 2010.

• The proposed phase II of the project, Salaya II, will include two 660MW units.

• It will also use imported coal as fuel but the source of coal for Salaya II has not

been decided yet.

• Phase III of the project, Salaya III, will be a petroleum coke and thermal coal-based

power plant.

• It will use circulating fluidized-bed combustion (CFBC) technology and consist of

four 150MW generating units.

• The plant will use petroleum coke purchased from Essar's Vadinar refinery located

near the plant.

Salaya I Plant Makeup

• The two generating units of Salaya I plant feature a pulverized boiler,cooling tower and transformer yard.

• Coal is milled and fed with air into the burners. Heated coal converts thewater passing through the boiler pipes into superheated steam. Thegenerated steam spins the turbine generator to create electricity, with thelow-pressure steam then sent through a condenser and converted back toliquid water for reuse in the boiler.

• The plant uses seawater for cooling purposes. Flue gases generating by theplant are sent through an electrostatic precipitator (ESP) that captures fly-ash particles.

• Other facilities at the plant include a coal stockyard, coal mills, a DM plant,a desalination plant, a 400kV switchyard, a main control room and anadministration building.

About The 2x600 Mw Simulator

• Simulator provides an interface to execute power plant operation on a simulated

machine. The interface is mostly graphical, which allows the users to control or

limit the execution of a command. This gives practical hands on experience to the

user. 2x600 MW Operator Training Simulator at Essar Power Learning Centre

(EPLC) is the replica of the control units running at 600MW thermal power plant.

• Thermal power plant simulator is an effective tool for operational training used for

safe, efficient and economical thermal power plant operation. The associates, who

are meant for operating 600 MW thermal power plants, can get themselves trained

in the simulator before operating an actual plant.

• The 2x600 MW Simulators installed are the replication of the Unit 1 & 2 of M/s

Essar Power Gujarat Limited, Salaya. These units were commissioned in the year

2011 and 2012 respectively and both of the units have been operating up to their

fullest capacity. These simulators, developed by ABB India, have been used to train

operating personnel of the thermal power stations located at Salaya as well as

Mahan.

Advantages of Simulator Training

• Highly Efficient Learning

• No Fuel Cost On Account Of Training

• No Wastage Of Equipment Time

• Risk Free Training

• High Retention Level Of Plant

• Improved Sharpness Of Operators

• Test Bed

Capacity 2 x 600 MW

Fuel Source Imported Coal

Fuel Requirement 4 million tone/hr.

Mode of Transportation Belt Conveyers

DM Water Source DM Plant

Land Requirement 330 Acres

Main Contractor Harbin Power, China

Power Evacuation GETCO (400kV)

Boiler 1 & 2 Harbin Boiler Group

Turbine Harbin Boiler Group

Generator Harbin Boiler Group

DM Plant Thermax

Electricity Balance of Plants AREVA

HP Heaters 3

LP Heaters 4

CEP (2 Working + 1 Stand By) 3

Super heaters 4

BFP ( 2 TDBFP + 1 MDBFP) 3

Chimney 1( 275m high)

Reheaters 2

Downcomers 6

Primary Separators 112

Secondary Separators 162

Dryers 148

Safety Valves for Drum 6

Overview of EPGL

Reheater Outlet 2

Reheater Inlet 7

HFO Pumps( 2W +1S) 3

LDO Pumps(1W +1S) 2

HP-IP Turbine 1

LP Turbine 2

Ball Mills(5W + 1S) 6

Periodic Blowdown Tank 2

Continuous Blowdown Tank 1

Dewatering Tank 3

Settling Tank(Ash) 1

Primary Air Fan 2

Forced Draught Fan 2

Induced Draught Fan 2

ESP Hoppers 20

CW Pump 2

Cooling Tower 24

Condensers 2

DM Water Storage Tank (2000m3) 2

DM Feed Tank (1250m3) 2

HDO Tank (1000m3) 1

LDO Tank (500m3) 1

Compressors in Compressor house 3

Surge Silos 6

Ash Silos 2

Settling Tank(DM Plant) 2

Types of Superheaters

• Low Temperature Superheater

• Divisional Superheater

• Pendant Superheater

• Final Superheater

Types of Reheaters

• Low Temperature Reheater

• Platen Reheater

• Final Reheater

Collection of Ash

Ash Collection (Tons) Field No.

2045 1st

365 2nd

66 3rd

18 4th

5 5th

Boiler

• Boiler is steam generator. It convert water into high pressure and high temperature

steam

• In Essar power plant Salaya Subcritical type of boiler is used.

• A subcritical steam generator is a type of boiler that operates at subcritical pressure

• Main steam flow:- 2060 TPH

• Main steam outlet pres.:- 17.50 MPa

• Main steam outlet temp.:- 541°C

• Feed water pres.:- 19.492 MPa

• Feed water temp. :- 281.7 °C

• Reheat steam flow :- 1725.9 TPH

Boiler Side View

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

• And main output shaft is coupled with electrical generator

• Turbine divided into 3 Stage

I. HP (High Pressure Turbine)

II. IP (Intermit Pressure Turbine)

III. LP (Low Pressure Turbine)

• Rated Output :- 600 MW

• Rated Speed :- 3000 RPM

• Steam pressure :- 16.7 MPa

• Steam temperature :- 538 °C

• Direction of rotation :- Clockwise

Generator Specifications

Parameter Value

MW Rating 600MW

Rated Voltage 20KV

Rated Stator current 20377 A

Rated Speed 3000 RPM

Rated Frequency 50 Hz

Station Transformer• ST is used supply station common load such as Coal handling, DM plant, etc.

• Transformer used in Salaya power plant is three winding transformer

• Specification

Parameter Value

Rated MVA 70 MVA

Voltage 20/11/33KV

Frequency 50Hz

Number Phase 3

Vector Group Dyn11yn11

Unit Auxiliary Transformer• Unit Transformer supply separate unit load such as Boiler auxiliary, Cooling

tower and Turbine auxiliary etc.

• Specification

Parameter Value

Rated MVA 45MVA

Rated Voltage 20/11.5KV

No. Of Phase 3

Vector Group Dy11

Generator Transformer

• As an essential element of all nuclear, thermal or hydraulic power stations.

• GT are step-up transformer with delta connected LV side and star connected HV

side

• In Essar power Salaya OLTC is used and GT consist of three single phase

transformer unit.

Specification

Parameter Value

Rated MVA 250MVA

Rated Voltage at no load 21/420KV

Vector Group YNd1

Type Of cooling ONAN/ONAF/OFAF

Day Wise Plan

• Day 1: Thermal Power Plant Theory, Main Circuits and Coal Handling Plant

• Day 2: Simulator Training- Back Charging, Lube Oil Systems, Cooling water cycle,

drum filling and other auxiliaries.

• Day 3: Simulator Training- Boiler and Turbine Start Up, Purging, Load raising,

Synchronizing; Site Visit- Scheme Tracing, Positions of different auxiliaries,

Switchyard, Control and Operation room.

• Day 4: Simulator Training: Practice with the roles of each operator changed; Expert

Session- Session on Material of Constructions from Senior Vice President of Essar;

Site Visit- Junction House 18, Metal Detector, Surge Silos, conveyer belts, settling

tank, Cation and anion exchanger, DM feed tank.

• Day 5: Simulator Training- Shutdown Process.

• Day 6: Simulator Training- Start up of Plant and load raising to 200 MW; , Trip

Conditions; Site Visit- Cooling Tower, forebay, Cooling water pumps, platen heat

exchanger; Test; Expert Session- Conversation with Chief Operating Officer of the

plant

Main Circuits

The main circuits in a plant include:

Feed Water and Steam Flow Circuits

Coal and Ash Circuit

Air and Gas Circuit

Cooling water Circuit

Feed Water and Steam Flow Circuits

Boiler feed water is the operating medium in the water-steam circuit of a thermal

power plant and consists of recycled condensate from the water-steam circuit and

conditioned makeup water. As it flows through the piping of the steam generator, it is

heated and converted into high-purity steam that drives the turbines, thus generating

electricity via the coupled generators. The very high temperatures in the steam

generator lead to corrosion and deposits that severely reduce the efficiency of the

power plant

Coal and Ash Circuit

This circuit deals mainly with feeding the boiler with coal for combustion

purposes and taking care of the ash that is generated during the combustion

process and includes equipment and paraphernalia that is used to handle the

transfer and storage of coal and ash.

Air and Gas Circuit

We know that air is one of the main components of the fire triangle and hence

necessary for combustion. Since lots of coal is burnt inside the boiler it needs a

sufficient quantity of air which is supplied using either forced draught or induced

draught fans. The exhaust gases from the combustion are in turn used to heat the

ingoing air through a heat exchanger before being let off in the atmosphere. The

equipment which handles all these processes fall under this circuit.

Cooling water Circuit

This part of the thermal power plant deals with handling of the cooling water

required in the system. Since the amount of water required to cool the

outgoing steam from the boiler is substantial, it is either taken from a nearby

water source such as a river, or it is done through evaporation if the quantity

of cooling water available is limited.

Coal Handling Plant

• Coal is brought through trucks from seashores. There is a 9 kms. Distance between plant and seashore.

• Screw Conveyers are under construction for this purpose.

• Stockyard is divided into 4 parts. It is common for both EPGL (Essar Power Gujarat Limited) and VPCL

(Vadinar Power Company Limited).

• 2 Stockyards are for EPGL

• 2 Stockyards are for VPCL

• 3 Yard Conveyers

• 18 Junction Houses

• 3 Stacker Reclaimer

Bunkers for each unit 6

Volume per Bunker 658 m3

Stacking Density of Coal 0.802 t/m3

Operating time of stored coal at BMCR 10.04 Hrs.

Boiler Coal Consumption 2668 t/hr.

Coal Amount 2630 tones

Efficient Volume Per Bunker 526 m3

Stacker and Reclaimer Description Rating

Rated Capacity(S) 2500 TPH

Rated Capacity(R) 1850 TPH

Design Capacity(S) 2750 TPH

Design Capacity(R) 2035 TPH

Travel Length 630 m

Stock Pile Height 10 m

Stock Pile Base 42m/64m

Rail Gauge 8 m

Boom Length 36 m

Angle of Repose 37o

Max. Sleeve Angle +_ 105o

Incoming Power 11 kV, 3 Phase, 50 Hz.

Power Feeding Mid-Point of travel

Junction House:-

• Hoppers

• Vibro-feeders

• Rod Gates

• Pulleys

• Motors

• Fluid Couplings

• Gear Boxes

Pulleys:-

• Bend Pulley

• Head Pulley

• Tail Pulley

• Take up Pulley

• Snub Pulley

• Drive Pulley

Conveyer Switches:-

• Pull Cord Switches

• Belt Sway Switches

• Zero Speed Switches

• Chute Jam Switches

Types of Idlers:-

• 35o Carrying Idlers

• 200 Transition Idlers

• 10o Transition Idlers

• 2 Metal Detectors and 1 Magnetic Separator

for each Conveyer Belt.

Travelling Tripper:-

• It is situated on the Bunker Conveyers

having capacity of 1000 TPH for both

conveyers.

Simulator Screens

Plant parameter monitoring as well as plant equipment operation can be, as

they are done in actual plant, through the following screens:-

Steam Plant Overview

Electrical charging of EHV Switch-yard and auxiliaries Power supply

Boiler Water System

Air and gas line-up

Turbine and its auxiliaries

Fuel oil System

Boiler Light up

Opportunity of Learning

• Cold Startup procedures

• Warm Start-up

• Hot Start-up

• Steam Plant Overview

• Scheme Tracing of a Power Plant and various

equipments.

• Electrical Charging of EHV Switchyard and Aux

power supply.

• Boiler Water System

• Air and Gas path line-up

• Cooling Water path establishment

• Turbine and it's Auxiliaries

• Fuel Oil System

• Boiler Light-up

• Synchronization

• Load Raising

• Coal Mill Operation and Changeover

• Power Plant shut down

• Emergency/Special Operations

Power Generation Data

1st Unit

• Power Generation- 545 MW

• Coal – 218 TPH

• Coal Mills A, B, C, E, F are in Service

• Coal Bunker Level

A- 66%

B- 52%

C- 66%

D- 92%

E- 70%

F- 73%

2nd Unit

• Power Generation- 545 MW

• Coal – 218 TPH

• Coal Mills A, B, C, E, F are in Service

• Coal Bunker Level

A- 58%

B- 81%

C- 72%

D- 63%

E- 72%

F- 55%

Hydrogen Pressure and Purity

3.87 kg/cm2 and 96.88%

Few Pictures of Essar Power, Jamnagar

Plant Layout Design

BTG Block

Consists of Switch Yard, TG building, Boiler Buildings

and Chimney

Boiler Side View

Boiler Pressure Parts

Boiler Drum and Riser Tubes

Furnace Levels

LP Heaters

Transformer Yard

SwitchYard

DM Plant