Kota Thermal Power Station

Training 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 Date of synchronization on coal Date of declaration of
on oil 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
 Air and gas

Cooling
tower

Feed water
Coal and ash
Detail Working of
KTPS
Coal Handling
Coal is supplied By wagon tripler
Through rail By means of two
The coal is drawn
Track by own trains Belts coal is transferred
Into underground hopper To the Conveyer

From nozzle Now coal is fed to Mills Now coal is transferred to

coal Is Coal is taken
to Coal nozzle Where coal is Crushing house and
discharged to
In wind box assembly Crushed in pulverized stored
furnace form to bunkers
There are two types of Mills in KSTPS
 Bowl Mills-  Tube mills-
 Grinding chambers in form of Bowl  Constantly rotating tube around 20
 Centrifugal force is used to move rpm
coal against grinder  Side at which gas gear is mounted
 FD fan is used to dry the coal & is known as driving end
drive it to furnace  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 boiler
Deriving 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

Flow chart Steam is passed Steam now

for turbine through falls on moves
nozzle Turbine blade the turbine

Parts of
Turbine
A.) Nozzle
B.) Blade • The rotor shaft is made of steel, blade is fixed on it
C.) Rotor • Steam is entered from left and right inlets
shaft • 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 required
for 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 KTPS

KW : 210 Kw
PF : 0.85
KVA : 247000
RPM : 3000
Hz : 50hz
Coolant :Water + H2
Parts of Generator
Stator Frame –
Welded construction of plate
Used 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 electrical
loss
Stator Bars –
Each stator half coil bar is composed of alternate strip of double glass covered and bars
copper 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 turns
Semi hold silver alloy copper of rectangular cross section is used, insulated by epoxy
Glasses laminated stripes CONT……
Rotor bearing-
Specially designed bearing electronic apparatus to indicate the location of unbalance
pole 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 for
External 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 – I
1 FAN CONRTOL DESK
a. Induced Fan draft
b. Forced Fan
c. Primary air Fan
2. PRESSURE DESK
a. Furnace pressure
b. Primary Air Heater Pressure
CP – II
1 FUEL CONTROL DESK
a. Coal air flow
b. oil pressure
c. temp of mill
d. flow of air
e. differential pressure of mill CONTD…..
CP – III
1. STEAM AND WATER DESK
a. Drum Level control
b. Flow of Steam and Water
c. Pressure of steam and water
d. Temp of steam and water
CP – IV
1. TURBINE DESK
a. Pressure Control
b. Load control
c. Speed control
d. Valves control
CP – V
1. GENERATOR CONTROL DESK
a. Voltage Control MVAR
b. Stator rotor Temp
c. 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
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