REPORT ON

INTERNSHIP AT

MB Power Madhya Pradesh Limited (MBPMPL)

SUBMITTED BY - PRINCE SHARMA

13 BME0564

ACKNOWLEDGEMENT –

It is often said that life is a mixture of achievements, failures,

experiences, exposures and efforts to make your dream come

true. There are people around you who help you realize your

dream.

I wish to express my sincere gratitude to my Company Guide, Mr.

Nishant Dixit and Mr. Santosh Dubey ,DGM (Mechanical

Department) for there guidance, help and motivation. Apart from

the subject of my study, I learnt a lot from them, which I am sure,

will be useful in different stages of my life.

I would like to thank Mr. Krishna Shukla, Senior Manager (HR)

and Mr. Raghavendra sir (HR) for providing me with this

wonderful opportunity to work at MB power plant.

Above from all, I would like to express my gratitude and sincere

thanks to Mr. Sajjan Kumar Sharma for providing me this lifetime

experience and help me at every step during training period.

Regards,

Prince Sharma

VIT University, Vellore

COMPANY OVERVIEW-

The Hindustan Thermalprojects is all set to change the scenario of power

deficit in India by installing high power thermal power plant. We focus on

generating power through coal- fired power stations in India.

Moving ahead through high investments and a definite raw coal

supply HPPPL is all set to install several high power producing

thermal power plant that will positively impact the grim situation of

development for the lack of electricity.

The arm is developing thermal Power projects with a combined generation capacity of about 5000 MW in the states of Madhya Pradesh & Chhattisgarh. Also the company’s thermal Power project at Anuppur, Madhya Pradesh (2520 MW) is one of the fastest developing projects and its first unit has been commissioned in May 2015. The commissioning of second Unit (600 MW) scheduled to be achieved in early part of 2016.

These thermal power plants are expected to help generate developmental opportunities and address energy shortage in the region.

Anuppur Thermal Powerproject –

The thermal arm is developing 2520 MW coal based Thermal Powerproject in Anuppur district, Madhya Pradesh. The project is planned to be executed in two phases as follows:

Phase - 1 : 1200 MW (2X600 MW) Phase - 2 : 1320 MW (2X660 MW) It is currently implementing the first phase of 1200 MW (2X600 MW) through its SPV (Special Purpose Vehicle) i.e. MB Power Madhya Pradesh Limited (MBPMPL). Coal for the project will be sourced from South Eastern Coalfields and water will be sourced from River Son.

Thermal Power Plant at Anuppur, Madhya Pradesh (2520 MW) is one of the fastest developing projects in India with commissioning in 2014.

INTRODUCTION –

- India is one of the world’s largest consumer of energy

- Conventional sources: Thermal, Hydro and Nuclear.

- Non- conventional: Wind, solar, Geothermal, tidal. - Installed capacity – 1,61,352MW

Thermal = 95151.74MW

Nuclear = 4,120MW

Hydro = 36877.76MW

Solar = 1324.41MW A thermal power plant is a power plant in which the prime mover is stream. Water is heated, turns into steam and spins a turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed and recycled to where it was heated,also called as Rankine cycle.

Main parts of the plant are :

1. Coal handling Plant 2. DM Plant

3. Boiler 4. Super heater

5. Air preheater and Economizer 6. Deaerator

7. Turbine 8. Condenser

9. Cooling towers 10.ESP

11. Smoke stack(Chimney) 12. Generator

13.Control room & Switchyard

COAL HANDLING PLANT (CHP) –

Main objective of CHP are-

To supply the quanta of processed coal to bunkers of Coal mills for Boiler operation.

To Stack the coal to coal yard.

Requirement of coal in MBPMPL is fulfilled from south eastern coalfield and source of transportation is Indian railway. This one is cheap and best facility at doorstep.They receive the coal wagons in the form of rakes (55-60 wagons in each rake).Free time is normally 7 hrs. from Receipt of coal.

Then chemical analysis of coal is carried out. Sample of coal is randomly collected from each rake and detailed chemical analysis, calculation of calorific value is carried out and is confirmed whether it is as per agreement with the coal mines or not.

Basic part of CHP –

1- Wagon Tippler-

These are used to unload the coal wagons into coal hoppers in very less time (e.g. 20 wagons/hr. or more).

Weighing of coal is carried out at wagon tippler.

Normally 55-60 metric ton of coal come in each wagon.

2- Conveyor belt –

Used to transfer the coal.

Synthetic rubber.

4 ply means 4 nylon net in between 2 mm thick rubber coating is used.Width varies from 500 mm -1400 mm.

3. Conveyor belt drive system-

4. Idlers –

These are used to provide motion to conveyor belt. these are connected to motor which control the rotating speed of idlers.Angle between middle idler and the extreme idlers are fixed in between of 20 – 30 degree which prevent coal to move continuously.

5. Interlocking –

Interlocking is used for safety purpose.

If any belt fails all other belts stop working which are interconnected.

6. Magnetic separator –

is used to remove metal particle from coal conveyed through conveyor belt for improving boiler efficiency.

Crushing mechanism in CHP-

Three Stage Crushing System is used in Plant.

1.Double Roll Crusher

2.Rotary Breaker Crusher

3.Impact Crusher

COAL BUNKERS -

Power plant has total of 8 coal bunkers. Coal from impact crusher is transferref to bunkers which is placed just above the coal mill. The main function of coal bunker is to regulate the amount of coal passing in coal mill.

COAL MILL-

Total of 8 coal mill are established which fulfill the coal requirement of boiler. Main function of coal mills are to pulverize the coal before it is passed to boiler. Cold primary air is used to pulverize the coal and this air is supplied directly from PA fan.

From coal mill pulverized coal is transferred to boiler where combustion take place.

BOILER SECTION–

Boiler is a closed vessel in which steam is generated by means of

heat energy. Main fuction of boiler is to convert chemical energy

of fuel into Heat Energy and then transfer heat energy to water for

evaporation & super heating.

Pulverized coal is air-blown into the furnace from fuel nozzles at

the four corners and it rapidly burns, forming a large fireball at the

center. The thermal radiation of the fireball heats the water that

circulates through the boiler tubes near the boiler perimeter. The

water circulation rate in the boiler is three to four times the

throughput and is typically driven by pumps. As the water in the

boiler circulates it absorbs heat and changes into steam at 540 c.

It is separated from the water inside a drum at the top of the

furnace.

Boiler is basically divide into 3 parts-

1 – First pass consist of

Bottom ring header

Drum

Platen super heater

2- Horizontal pass consist of

RH coils

Final Super heater

Roof Tubes

3- Second pass consist of

LTSH

Economiser

WATER WALL BOTTOM RING HEADER

DRUM

CRH IN

REAR ROOF

WATER INLET

SH STEAM OUTLET

EXTENDED

WW

FRONT ROOF

HRH OUT

LTSH

Economiser

Important parts of boiler-

1-Boiler drum-

To Ensure water storage to meet boiler load and to prevent

starvation of tubes. It is a reservoir for providing working fluid

circulation.

2-Economizer-

To Recover The Heat That Is Available In Flue Gas,The boiler

designers always keep the economizer water outlet temperature

to about 25 to 35 degrees below the drum saturation temperature.

This is done to mainly avoid steaming in the economizer.

Economizer alone gives 8% efficiency increase of Boiler.

3- Superheater-

Most of the modern boilers are having super heater and reheater

arrangement. Superheater is a component of a steam-generating

unit in which steam, after it has left the boiler drum, is heated

above its saturation temperature. The amount of superheat

added to the steam is influenced by the location, arrangement,

STEAM AND WATER TEMPERATURE - IN DEG. CENTIGRADE

Feed water ENTERING LEAVING

ECONOMISER 245 289

DRUM 345 350

LTSH 355 426

PLATEN SH 426 520

FINAL SH 520 540

REHEATER 344 540

and amount of super heater surface installed, as well as the rating

of the boiler. The super heater may consist of one or more stages

of tube banks arranged to effectively transfer heat from the

products of combustion.

4- Reheater-

Some of the heat of superheated steam is used to rotate the

turbine where it loses some of its energy. Reheater is also steam

boiler component in which heat is added to this intermediate-

pressure steam, which has given up some of its energy in

expansion through the high-pressure turbine. The steam after

reheating is used to rotate the second steam turbine where the

heat is converted to mechanical energy. This mechanical energy

is used to run the alternator, which is coupled to turbine , there by

generating electrical energy.

AIR PREHEATER-

The remaining heat of flue gases is utilized by air preheater. It is

a device used in steam boilers to transfer heat from the flue gases

to the combustion air before the air enters the furnace. Also

known as air heater; air-heating system. It is not shown in the lay

out. But it is kept at a place near by where the air enters in to the

boiler.

The purpose of the air preheater is to recover the heat from the

flue gas from the boiler to improve boiler efficiency by burning

warm air which increases combustion efficiency, and reducing

useful heat lost from the flue.

DEAERATOR-

A steam generating boiler requires that the boiler feed water

should be devoid of air and other dissolved gases, particularly

corrosive ones, in order to avoid corrosion of the metal.

Generally, power stations use a Deaerator to provide for the

removal of air and other dissolved gases from the boiler feed

water. A deaerator typically includes a vertical, domed deaeration

section mounted on top of a horizontal cylindrical vessel which

serves as the deaerated boiler feed water storage tank.

FORCED DRAUGHT FAN (FD FAN)-

This fan forces the atmospheric air through the boiler furnace and

pushes out the hot gases from the furnace through superheater,

reheater, economizer and air heater to stacks.

INDUCED DRAUGHT FAN (ID FAN)-

Here a fan called ID fan is provided at the outlet of ESP, that is,

just before the chimney.This fan sucks discharges gas into the

chimney.

PRIMARY AIR FAN(PA FAN)-

Primary air fans (PA) are high pressure fans used to supply the

air for the transportation of coal directly to the furnace.

ELECTROSTATIC PRECIPITATOR (ESP) -

It is a device which removes dust or other finely divided particles

from flue gases by charging the particles inductively with an

electric field, then attracting them to highly charged collector

plates. Also known as precipitator. The process depends on two

steps. In the first step the suspension passes through an electric

discharge (corona discharge) area where ionization of the gas

occurs. The ions produced collide with the suspended particles

and confer on them an electric charge. The charged particles drift

toward an electrode of opposite sign and are deposited on the

electrode where their electric charge is neutralized. The

phenomenon would be more correctly designated as electrode

position from the gas phase.

CHIMNEY-

A chimney is a system for venting hot flue gases or smoke from

a boiler, stove, furnace or fireplace to the outside atmosphere.

They are typically almost vertical to ensure that the hot gases flow

smoothly, drawing air into the combustion through the chimney

effect (also known as the stack effect). The space inside a

chimney is called a flue. Chimneys may be found in buildings,

steam locomotives and ships. In the US, the term smokestack is

also used when referring to locomotive chimneys. The

term funnel is generally used for ship chimneys and sometimes

used to refer to locomotive chimneys. Chimneys are tall to

increase their draw of air for combustion and to disperse

pollutants in the flue gases over a greater area so as to reduce

the pollutant concentrations in compliance with regulatory or other

limits.

Boiler Feed Pump -

• The boiler feed pump pumps water into the boiler,

overcoming the boiler pressure of 160 bar to achieve it

• The pump is driven by a steam turbine or an electric motor

• It runs at 7,000 revolutions per minute

Low Pressure Heaters (LPH) -

• Feed water from the condensate extraction pumps passes

through low pressure feed heaters. Steam is used to heat

the feed water

• After the last feed heater, the feed water is at around 160°C.

High Pressure Heaters (HPH) -

• With a similar purpose to the low pressure feed heaters, the

high pressure feed heaters are the last stage of feed water

heating before the feed water enters the boiler system at the

economizer

• Feed water leaving these heaters is at 250°C

TURBINE SECTION -

Turbine is very important part of a power plant whose rotatory

motion helps in rotating the generator and generation of

electricity. It extracts thermal energy from pressurized steam, and

converts it into rotary motion. The steam turbine is a form of heat

engine that derives much of its improvement in thermodynamics

efficiency through the use of multiple stages in the expansion of

the steam.

There are total of 4 turbines –

High pressure turbine- Superheated steam is used to drive the

HP turbine.

Intermediate pressure turbine- Reheat steam is used to drive

this.

Low pressure turbine- Remaining steam from IP turbine enters

the LP turbines and drives it. Total of 2 LP turbines are used in

series.

HP turbine is provided with one extraction that help in transfer of

some heat into HP heater which is further used there to preheat

the condensate.

LP turbine is provided with two extraction, one goes to LP

heater and other helps in rotating the BOILER FEED PUMP

TURBINE.

CONDENSER-

Condenser is a device or unit used to condense a substance from

its gaseous to its liquid state, typically by cooling it.

The exiting steam from steam turbine, now a little above its boiling

point, is brought into thermal contact with cold water (pumped in

from the cooling tower) in the condenser. where it condenses

rapidly back into water, creating near vacuum-like conditions

inside the condenser chest.

COOLING TOWERS-

The condensate (water) formed in the condenser after

condensation is initially at high temperature. This hot water is

passed to cooling towers. It is a tower- or building-like device in

which atmospheric air (the heat receiver) circulates in direct or

indirect contact with warmer water (the heat source) and the

water is thereby cooled. We are using INDUCED DRAFT

COOLING TOWER in this plant.

SITE SELECTION

• Transportation network: Easy and enough access to

transportation network is required in both power plant

construction and operation periods.

• Geology and soil type: The power plant should be built in

an area with soil and rock layers that could stand the weight

and vibrations of the power plant.

• Topography: It is proved that high elevation has a negative

effect on production efficiency of gas turbines. In addition,

changing of a sloping area into a flat site for the construction

of the power plant needs extra budget. Therefore, the

parameters of elevation and slope should be considered.

• Water resources: For the construction and operating of

power plant different volumes of water are required. This

could be supplied from either rivers or underground water

resources. Therefore having enough water supplies in

defined vicinity can be a factor in the selection of the site.

IMPORTANCE OF A THERMAL POWER PLANT-

• Fuel used is cheaper

• Smaller space is required compared to hydro power plant

• Economical in initial cost compared to hydro plants and

running costs are less compared to gas plants or diesel

plants

• Thermal plants can be placed near load centers unlike hydro

and nuclear plants. Hence transmission of power losses can

be minimized

• Thermal plants are able to respond to the load demand more

effectively and supports the performance of the electrical

grid

“THANKS TO EACH AND EVERYONE WHO HELP ME

DURING MY TRAINING PERIOD AND TEACH ME SOME

IMPORTANT LESSONS.THIS WAS AN UNFORGIVABLE

EXPIRIENCE”