ABSTRACT

Power constitutes the basic and essential in put for rapid economic
development.
Infact the country's industrial growth is directly linked with power supply prospects.
In this modern scenario energy place a vital role both i n 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 Economizer 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 analyze 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.

1
 CONTENTS

CHAPTER NAME

CHAPTER-1 INTRODUCTION

1.1 Introduction

1.2 Essentialinputstotheplant

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

2
1.4 Auxiliary Systems

1.4.1 Coolingpond

1.4.2 Condenser

1.4.3 pumps

CHAPTER-2 BASICS TEAMPOWER CYCLES

2.1 Carnot Cycle

2.2 Rankine Cycle

2.3 Rankine Cycle efficiency improved by

a) Increasing boiler efficiency

b) Superheating

c) Reducing condenser pressure

CHAPTER-3 INTRODUCTIONTOSTEAMGENERATORS

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

3
 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 SUPERHEATERS

4.2.1 Functions

4.2.2 Descriptionofsuperheater

4.2.3 Classifications

4.3 AIR PRE HEATER

4.3.1 Introduction

4
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 preheater

5
` CHAPTER-1

INTRODUCTION

INTRODUCTION TO RTPP
Rayala seema 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
stage12.3.4.1hefirst unit of 210MW commercially came into operation on
25thNov1994, the second unit on 30thmarch1995, the third unit on25thJan 2007and
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, whichis23 km away from the plant.

1.1 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 contains50% less moisture than
lignite It also contains less than lignite but it has caking power &also used either in
the form of pulverized state.

6
 The coal from singareni mines is of inferior quality upgraded with ash
average content varying between45%-65%the uncrushed 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.

1.2.3Water

The water requirements of the project are met from Mylavaram Reservoir
across Penna River situated at a distance 23km a gravity pipe line laid to draw25
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 generates10.08 MU per day or nearly 300

7
for month.

8
1.3 Paint Over View

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

1.3.1COAL PLANT OPERATION

Coal from the rail wagons is unloaded by charger Armand 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.Ifany problem occurs
in one path the process is diverted to another path from the motor control cabin
itself.

9
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

1.3.3Feeders

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 through out 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 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

10
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 1. 3

11
 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.
Burner Signiters And Oil

Igniters and warmup burners are necessary for flame initialization and less
low stabilization. The initial lignition source is as high-energy spark that starts the
igniters flame which gives ignition to oil burner.

12
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
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 f unction of control valve is to regulate the steam flow to the
turbine and thus control the output power of steam turbine generator.
1.2 Auxiliarysystems

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 simple stand 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.

13
1.4.3 Pumps

1.4.3.1 Condensate

pumps

The pumps pump the condensate from the condenser hot well to be aerating
heater.
1.4.3.2 Boiler Feed Pumps

ABFP 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 exhaust.

14
 CHAPTER-2

BASICS TEAM POWER CYCLES

2.1. CARNOT CYCLE

Fig 2.1 shows a Carnot cycle on1-s diagram and p-v diagrams. It contains

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

diabatic (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 fractionx1. This heat is absorbed at constant temperature T1and

pressure p1 during thus operation.

2. Operation (1-2):-During this operation steam is expanded is entropic ally 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.

15
4. Operation (3-4):-In this operation the wet steam at 3 is compressed is

entropically till the steam regains its original state or temperature T1and pressure

pl. Thus cycle is completed.

From T-s diagram

Heat supplied at constant temperature TI ( Operation (4-1)=Area4-1-b-a=T1(S1-

s4) orT1(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 is entropic 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

=(TI-T2)(S2-s3)/TI(S2-S3)
16
 =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 fig2.2 and it comprises the following

processes as shown in fig 2.3

17
Process1-2:-Reversible adiabatic expansion in turbine.

Process2-3:-Constant pressure transfers of heat in the condenser.

Process3-4:-Reversible adiabatic pumping process in the feed pump

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

Fig2.3 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 and pump.

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

18
 2.Superheating

3.Reducing condenser pressure

CHAPTER-3

INTRODUCTION TO STEAM GENERATORS

3.1 DEFINITION OF STEAM GENERATOR

Steam boiler or steam generator is defined as a closed vessel in which the water
is converted into the steam required pressure and temperature.

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

19
2.Depending upon the position of water and hot gases.

A.Fire tube boilers

B.Water tube boiler

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

20
 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

2. Water level indicator

3. Feed check valve

4.Pressure gauge

5.Blow off cock

6.Fusible plug

7.Steams top valve

8.Manhole

9.Mud holes or slight holes

21
Safety valve:
The function is to release the excess steam when the pressure of the steam inside
the boiler exceeds to rated pressure.
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.

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 may discharge a portion of water when the boiler is in

operation to blowout mud scale and sediments periodically.

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 overheating for low level.

Steam Stop Valve:

To regulate the flow if steam from one pipe to other pipe or from boiler to

steam pipe.

22
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. Feedpump:

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.

23
3. AirPreheater:

The function of airpreheater is to increase the temperature of air, which

enters the Furnace. It is placed between economizer and chimney.

4.SuperHeater:

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

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:

24
 The amount of steam generated for different boilers is different and this is

not useful in comparing two boilers. To serve that purpose the terms team

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 by1kg 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.

25
 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 degrease in temperature of feed water.

Boiler efficiency increases by1%.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 DESCRIPTIONOFECONOMISER

26
 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 by6c improves the boiler efficiency by 1%.

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

In some cases a low temperature economizer is placed after the Airpreheater, 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 ECONOMISERIN 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 of 56.025to 62
23m from the ground floor.
Economers are generally placed between the last super heater and reheater

27
and airpreheater

4.1.4 WORKINGOFECONOMISER

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. Thefeedwatertemperaturerisesfrom230°cto 294degc.The flue

Gases at a temperature of 418 degc give heat from economizer to water. The water

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

4.1.5 SPECIFICATIONS OF ECONOMISER IN RTPP

TYPE:
Grilled bare tube horizontal speed economizer
Total heat surface area: 7911m2

Number of blocks : 2

Volume of economizer: 25m3

28
 4.2 SUPERHEATER

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.

4.2.1 Advantages:

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 OFSUPERHEATER

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.

29
This results in the presence of moisture, which causes corrosion of turbine

blades.Torise temperature of steam, superheater used. Super heater 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 (below12%) 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 SUPERHEATERS ARE CLASSIFIED AS:

According To Mode of Heat Reception

30
 Convective super heater: 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

31
 4.2 Airpreheater

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, so 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 by1%.Air pre heater recycles the waste heat .Back in to the boiler

and play savory effective role of moderating ESP performance as well.

32
33
 CONCLUSIONS:

1. By using the Economizer

By installing 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 highgrade 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 is20 to25%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.

 The load factor on power plant can improved.

 Increase in overall efficiency of the plant.

 The percentage of pollutants contained in the flue gases coming out of

chimney is less.

34
 FUTURESCOPE

In comparison with plan tube economizer steel finned economizers occupy

space for same thermal performance & draught loss. The reduction in tube

lengthforsimilartubediameterisusuallyaround4-7.The results in smaller casing, less

structural steel work to support the reduced weight 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=120to170w/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 de mineralized to free from

impurities and foreign matters.

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

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

35
1. The rate of air supply should be maintained constant for efficient heat
transfer.

2. In order to increase the life span 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.

36