Ennore Thermal Power Station
Ennore Thermal Power Station
Ennore Thermal Power Station
IN
ENNORE THERMAL POWER STATION
BY
J.MARTIN MANOJ
R.RAHUL
G.PRADEEP
M.SHANMUGAM
G.THANESH
B.RAJESH KUMAR
VISIT DETAILS
STATION
DATE OF VISIT
DURATION OF VISIT
: 18-05-2015 TO 22-05-2015
: 5 DAYS
CONTENT
1. HISTORY
2. FEATURES
3. CAPACITY
4. Thermal power generation EfficiencY
5. Feed water heating and deaeration
6. Boiler operation
7. Superheater
8. Steam condensing
9. Reheater
10.
Steam turbine generator
11.
Stack gas path and cleanup
12.
Fly ash collection
13.
Bottom ash collection and disposal
14.
Barring gear
15.
Generator cooling
16.
Developments
History
Ennore Thermal Power Station was constructed to serve the purpose of
energy generation in the year 1970. It is one of the four major thermal power
plants of Tamil Nadu established by TANGEDCO. Presently it has an installed
capacity of 450-MW. The necessary coal arrives through ship to the Ennore
Port.However the construction of the 1000 MW plants in the premise began in
the year 2007.The Station presently consists of two 60-MW and three 110MW units. A 500-MW coal based unit is proposed and its development started
in the month of November 2007.The total cost of the venture was 270 crores.
Features
The Power Station has been a major provider of electricity in the state
and its production capacity has been improved over the years.The Ennore
Power Station has also garnered various awards from the
TANGEDCO.However power deficit seems to be playing an important role for
the recent decision.It also has a special treatment plant to dispose the ash
slurry in a proper way.
Coal for ETPS is received from MCL (Talchar and Ib Valley), Orissa and
ECL, Raniganj, West Bengal. The plant load factor (PLF) for the year 2008
2009 was 49.17 percent.
ETPS has total installed capacity of 450 M.W , comprising 2 X60 M.W
and 3X110 M.W units.
The total cost of the project was 270 crores.
The units are coal based.
Coal for ETPS is received from Mahanadhi coal fields Limited (Talchar &
IB Valley), Orissa and Eastern coal fields Limited, Ranikanj, West Bengal.
As all the units have completed more than 30 years R & M works were
carried out in all
the five units.
Generation and Plant load factor(PLF) for the year 2010-11 is 1396.289
MU and 35.42 %
A thermal power station is a power plant in which the prime mover
is steam driven. Water is heated, turns into steam and spins a steam turbine
which drives an electrical generator. After it passes through the turbine, the
steam is condensed in a condenser and recycled to where it was heated; this
is known as a Rankine cycle. The greatest variation in the design of thermal
power stations is due to the different fossil fuel resources generally used to
heat the water. Some prefer to use the term energy center because such
facilities convert forms of heat energy into electrical energy.[1] Certain thermal
power plants also are designed to produce heat energy for industrial
purposes of district heating, or desalination of water, in addition to
generating electrical power. Globally, fossil fueled thermal power plants
produce a large part of man-made CO2 emissions to the atmosphere, and
efforts to reduce these are varied and widespread.
CAPACITY
Unit Number
Installed
Capacity (MW)
Date of
Commissioning
Status
1.
60
31 March 1970
Running
2.
60
14 February 1971
Running
3.
110
17 May 1972
Running
4.
110
26 May 1973
Running
5.
110
2 December 1975
Running
A thermal power station is a power plant in which the prime mover is steam
driven. Water is heated, turns into steam and spins a steam turbine which
drives an electrical generator. After it passes through the turbine, the steam
is condensed in a condenser and recycled to where it was heated; this is
known as a Rankine cycle. The greatest variation in the design of thermal
power stations is due to the different fossil fuel resources generally used to
heat the water. Some prefer to use the term energy center because such
facilities convert forms of heat energy into electrical energy.
Certain thermal power plants also are designed to produce heat energy for
industrial purposes of district heating, or desalination of water, in addition to
generating electrical power. Globally, fossil fueled thermal power plants
produce a large part of man-made CO2 emissions to the atmosphere, and
efforts to reduce these are varied and widespread.
Diagram of boiler feed water deaerator (with vertical, domed aeration section
and horizontal water storage section).
The water is pressurized in two stages, and flows through a series of six or
seven intermediate feed water heaters, heated up at each point with steam
extracted from an appropriate duct on the turbines and gaining temperature at each
stage. Typically, in the middle of this series of feedwater heaters, and before the
second stage of pressurization, the condensate plus the makeup water flows
through a deaerator that removes dissolved air from the water, further purifying and
reducing its corrosiveness. The water may be dosed following this point with
hydrazine, a chemical that removes the remaining oxygen in the water to below 5
parts per billion (ppb). It is also dosed with pH control agents such as ammonia or
morpholine to keep the residual acidity low and thus non-corrosive.
Boiler operation
The boiler is a rectangular furnace about 50 feet (15 m) on a side and 130
feet (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3
inches (58 mm) in diameter.
Pulverized coal is air-blown into the furnace through burners located at the
four corners, or along one wall, or two opposite walls, and it is ignited to rapidly
burn, 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. As the
water in the boiler circulates it absorbs heat and changes into steam. It is separated
from the water inside a drum at the top of the furnace. The saturated steam is
introduced into superheat pendant tubes that hang in the hottest part of the
combustion gases as they exit the furnace. Here the steam is superheated to
1,000 F (540 C) to prepare it for the turbine.
Plants designed for lignite (brown coal) are increasingly used in locations as
varied as Germany, Victoria, Australia and North Dakota. Lignite is a much younger
form of coal than black coal. It has a lower energy density than black coal and
requires a much larger furnace for equivalent heat output. Such coals may contain
up to 70% water and ash, yielding lower furnace temperatures and requiring larger
induced-draft fans. The firing systems also differ from black coal and typically draw
hot gas from the furnace-exit level and mix it with the incoming coal in fan-type
mills that inject the pulverized coal and hot gas mixture into the boiler.
Plants that use gas turbines to heat the water for conversion into steam use
boilers known as heat recovery steam generators (HRSG). The exhaust heat from
the gas turbines is used to make superheated steam that is then used in a
conventional water-steam generation cycle, as described in gas turbine combinedcycle plants section below.
Superheater
Fossil fuel power plants often have a superheater section in the steam
generating furnace. The steam passes through drying equipment inside the steam
drum on to the superheater, a set of tubes in the furnace. Here the steam picks up
more energy from hot flue gases outside the tubing and its temperature is now
superheated above the saturation temperature. The superheated steam is then
piped through the main steam lines to the valves before the high pressure turbine.
Nuclear-powered steam plants do not have such sections but produce steam
at essentially saturated conditions. Experimental nuclear plants were equipped with
fossil-fired super heaters in an attempt to improve overall plant operating cost.
Steam condensing
The condenser condenses the steam from the exhaust of the turbine into
liquid to allow it to be pumped. If the condenser can be made cooler, the pressure of
the exhaust steam is reduced and efficiency of the cycle increases.
The condenser generally uses either circulating cooling water from a cooling
tower to reject waste heat to the atmosphere, or once-through water from a river,
lake or ocean.
From the bottom of the condenser, powerful condensate pumps recycle the
condensed steam (water) back to the water/steam cycle.
Reheater
Power plant furnaces may have a reheater section containing tubes heated
by hot flue gases outside the tubes. Exhaust steam from the high pressure turbine
is passed through these heated tubes to collect more energy before driving the
intermediate and then low pressure turbines.
Steam turbine generator
boiler where the steam is reheated in special reheat pendant tubes back to 1,000 F
(540 C). The hot reheat steam is conducted to the intermediate pressure turbine
where it falls in both temperature and pressure and exits directly to the long-bladed
low pressure turbines and finally exits to the condenser.
The generator, 30 feet (9 m) long and 12 feet (3.7 m) in diameter, contains a
stationary stator and a spinning rotor, each containing miles of heavy copper
conductorno permanent magnets here. In operation it generates up to 21,000
amperes at 24,000 volts AC (504 MWe) as it spins at either 3,000 or 3,600 rpm,
synchronized to the power grid. The rotor spins in a sealed chamber cooled with
hydrogen gas, selected because it has the highest known heat transfer coefficient of
any gas and for its low viscosity which reduces windage losses. This system requires
special handling during startup, with air in the chamber first displaced by carbon
dioxide before filling with hydrogen. This ensures that the highly explosive
hydrogenoxygen environment is not created.
The power grid frequency is 60 Hz across North America and 50 Hz in Europe,
Oceania, Asia (Korea and parts of Japan are notable exceptions) and parts of Africa.
The desired frequency affects the design of large turbines, since they are highly
optimized for one particular speed.
The electricity flows to a distribution yard where transformers increase the
voltage for transmission to its destination.
The steam turbine-driven generators have auxiliary systems enabling them to
work satisfactorily and safely. The steam turbine generator being rotating
equipment generally has a heavy, large diameter shaft. The shaft therefore requires
not only supports but also has to be kept in position while running. To minimize the
frictional resistance to the rotation, the shaft has a number of bearings. The bearing
shells, in which the shaft rotates, are lined with a low friction material like Babbitt
metal. Oil lubrication is provided to further reduce the friction between shaft and
bearing surface and to limit the heat generated.
Stack gas path and cleanup
As the combustion flue gas exits the boiler it is routed through a rotating flat
basket of metal mesh which picks up heat and returns it to incoming fresh air as the
basket rotates, This is called the air preheater. The gas exiting the boiler is laden
with fly ash, which are tiny spherical ash particles. The flue gas contains nitrogen
along with combustion products carbon dioxide, sulfur dioxide, and nitrogen oxides.
The fly ash is removed by fabric bag filters or electrostatic precipitators. Once
removed, the fly ash byproduct can sometimes be used in the manufacturing of
concrete. This cleaning up of flue gases, however, only occurs in plants that are
fitted with the appropriate technology. Still, the majority of coal-fired power plants in
the world do not have these facilities. Legislation in Europe has been efficient to
reduce flue gas pollution. Japan has been using flue gas cleaning technology for
over 30 years and the US has been doing the same for over 25 years. China is now
beginning to grapple with the pollution caused by coal-fired power plants.
Where required by law, the sulfur and nitrogen oxide pollutants are removed
by stack gas scrubbers which use a pulverized limestone or other alkaline wet slurry
to remove those pollutants from the exit stack gas. Other devices use catalysts to
remove Nitrous Oxide compounds from the flue gas stream. The gas travelling up
the flue gas stack may by this time have dropped to about 50 C (120 F). A typical
flue gas stack may be 150180 metres (490590 ft) tall to disperse the remaining
flue gas components in the atmosphere. The tallest flue gas stack in the world is
419.7 metres (1,377 ft) tall at the GRES-2 power plant in Ekibastuz, Kazakhstan.
In the United States and a number of other countries, atmospheric dispersion
modeling studies are required to determine the flue gas stack height needed to
comply with the local air pollution regulations. The United States also requires the
height of a flue gas stack to comply with what is known as the "Good Engineering
Practice (GEP)" stack height. In the case of existing flue gas stacks that exceed the
GEP stack height, any air pollution dispersion modeling studies for such stacks must
use the GEP stack height rather than the actual stack height.
Fly ash collection
Fly ash is captured and removed from the flue gas by electrostatic
precipitators or fabric bag filters (or sometimes both) located at the outlet of the
furnace and before the induced draft fan. The fly ash is periodically removed from
the collection hoppers below the precipitators or bag filters. Generally, the fly ash is
pneumatically transported to storage silos for subsequent transport by trucks or
railroad cars .
Bottom ash collection and disposal
At the bottom of the furnace, there is a hopper for collection of bottom ash.
This hopper is always filled with water to quench the ash and clinkers falling down
from the furnace. Some arrangement is included to crush the clinkers and for
conveying the crushed clinkers and bottom ash to a storage site. Ash extractor is
used to discharge ash from Municipal solid wastefired boilers.
Barring gear
Barring gear (or "turning gear") is the mechanism provided to rotate the
turbine generator shaft at a very low speed after unit stoppages. Once the unit is
"tripped" (i.e., the steam inlet valve is closed), the turbine coasts down towards
standstill. When it stops completely, there is a tendency for the turbine shaft to
deflect or bend if allowed to remain in one position too long. This is because the
heat inside the turbine casing tends to concentrate in the top half of the casing,
making the top half portion of the shaft hotter than the bottom half. The shaft
therefore could warp or bend by millionths of inches.
This small shaft deflection, only detectable by eccentricity meters, would be
enough to cause damaging vibrations to the entire steam turbine generator unit
when it is restarted. The shaft is therefore automatically turned at low speed (about
one percent rated speed) by the barring gear until it has cooled sufficiently to
permit a complete stop
Generator cooling
While small generators may be cooled by air drawn through filters at the
inlet, larger units generally require special cooling arrangements. Hydrogen gas
cooling, in an oil-sealed casing, is used because it has the highest known heat
transfer coefficient of any gas and for its low viscosity which reduces windage
losses. This system requires special handling during start-up, with air in the
generator enclosure first displaced by carbon dioxide before filling with hydrogen.
This ensures that the highly flammable hydrogen does not mix with oxygen in the
air.
The hydrogen pressure inside the casing is maintained slightly higher than
atmospheric pressure to avoid outside air ingress. The hydrogen must be sealed
against outward leakage where the shaft emerges from the casing. Mechanical seals
around the shaft are installed with a very small annular gap to avoid rubbing
between the shaft and the seals. Seal oil is used to prevent the hydrogen gas
leakage to atmosphere.
The generator also uses water cooling. Since the generator coils are at a
potential of about 22 kV, an insulating barrier such as Teflon is used to interconnect
the water line and the generator high-voltage windings. Demineralized water of low
conductivity is used.
Developments
The Ennore Thermal Power Station has been handed over for improvements.
A SEZ project is being discussed at the site. The new project will use the
latest technology to enhance the output.The Proposal also talks about a
super-critical procedural implementation.In recent years due to shortage of
coal in the state, coal is being imported to function the power plant