VOCATIONAL TRAINING

REPORT

• SATPURA THERMAL
PLANT
POWER STATION

• SARNI {BETUL}
LOCATION
• MADHYA PRADESH

DURATION • 10/07/17 - 24/07/17

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 A
VOCATIONAL TRAINING REPORT
AT
SATPURA THERMAL POWER STATION
Submitted to:

DEPARTMENT OF MECHANICAL
ENGINEERING
MEDICAPS INSTITUTE OF TECHNOLOGY AND MANAGEMENT
AB ROAD,PIGDAMBER,RAU,INDORE,MADHYA PRADESH.
In a Partial Fulfillment of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
Submitted by:
PIYUSH KHANDAIT
0812ME141105

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 DECLARATION
This report is based on the vocational training I
have undergone in the premises of Satpura Thermal
Power Station (STPS) - A unit of Madhya Pradesh
Power Generating Company Ltd. (MPPGCL) from
10/07/17 to 24/07/17.
This is the original work carried out by me and
has neither been taken from any other source nor
has been submitted to any other institute or
organisation as a fulfillment of any other
curiculum.
The experience of the training was good and I
learned lots of things. I was successfully able to
complete the training.
Date:- Signature

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 ACKNOWLEDGEMENT
I take this opportunity to express my profound
gratitude and deep regards to Mr. Akhilesh Tiwari for
giving me a chance to pursue the training in Satpura
Thermal Power Station , Sarni.

I would like to express my deepest sense of gratitude

and sincere thanks to highly respected Mr. R S Parihar
(SE) for his valuable guidance and monitoring
throughout the training period.

I am obliged to all the members of Satpura Thermal

Power Station , Sarni for their constant assistance and
cooperation.

Lastly I thank almighty, my family and friends for their

constant support and encouragement, without which
this assignment would not have been possible.

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 TABLE OF CONTENTS

S. Topic Page
No No.

1. Declaration 3
2. Acknowledgement 4
3. Organization Introduction 6
4. Installed Capacity 7
5. Operating Cycle 8
6. Coal Handling Plant 9
7. Water Treatment Plant 10
8. Plant Boiler 11
9. Unit Overview 12
10. Turbine & Generator 13
11. Condenser 14
12. Cooling Tower 15
13. Ash Handling Plant 16

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14. Chimney 17
15. Switch Yard 18
16. Conclusion 19

ORGANIZATION INTRODUCTION

Satpura Thermal Power Station is located at Sarni town

near Ghoradongri Railway Station in Betul District of
Madhya Pradesh. The power plant is one of the coal
based power plants of MPPGCL.
Satpura Thermal Power Station has an installed
capacity of 1330 MW. The first unit was commisioned
in October 1967.The water for the plant has been
supplied from nearby Tawa Dam lake area,which
spread in 2893 acres(11.71 km2).The coal for the plant
has been procured by Rail/Road/Belt from Western
Coal Fields.

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The plant comprises of total 11 units of different
capacities. The first 5 units have been dismantelled and
the renovation and maintainance is being carried out.
The rest 6 units are in operating conditions.

INSTALLED CAPACITY

STAGE UNIT INSTALLED DATE OF STATUS TG SET BOILER

NO. CAPACITY COMMISIONING PROVIDER PROVIDER

First 1 62.5 1967 Oct. - GE,USA B&W,USA

First 2 62.5 1968 March - GE,USA B&W,USA

First 3 62.5 1968 May - GE,USA B&W,USA

First 4 62.5 1968 July - GE,USA B&W,USA

First 5 62.5 1970 April - GE,USA B&W,USA

Second 6 200 1979 July Running BHEL BHEL

Second 7 210 1980 Sept. Running BHEL BHEL

Third 8 210 1983 Jan. Running BHEL BHEL

Third 9 210 1984 Feb. Running BHEL BHEL

Fourth 10 250 2013 August Running BHEL BHEL

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Fourth 11 250 2014 March Running BHEL BHEL

OPERATING CYCLE
Coal based thermal power plant works on the principal of
Modified Rankine Cycle.

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 COAL HANDLING PLANT
Many Thermal Power Plant use coal as their main fuel
for the combustion process in boiler. To handle the coal
power station is equipped with CHP. Coal has to be
sized, processed and handled which should be done

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effectively and efficiently. Components and Auxiliaries of
CHP are;
*Coal Yard
*Conveyor Belts
*Zero Speed Switch
*Magnetic Vibrating Feeders
*Trippers
*Electromagnetic Separators
*Crusher
*Bunker
*Hopper
*Rotary Breaker
*Metal Detector
*Scrappers
*Vibrating Screen

WATER TREATMENT PLANT

For the efficiency of the boiler it is very much
important to treat the water before passing it
through the tubes of the boiler. De-mineralized
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water is prepared for the boiler in the power
station. The same has been set up in STPS,Sarni .

RAW WATER CLARIFIER MULTI-GRADE

{STORAGE TANK} FILTER

{ALUM}

ACTIVATED
CARBON
FILTER

WEAK BASE DEGASSER STRONG

ANION TANK ACID
CATION

MIXED DE-
BED MINERALIZED BOILER
WATER

FAMILARIZATION WITH PLANT BOILER

Boiler is a device used for producing steam. There are two
types of boilers:
a). Fire tube boiler
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b). Water tube boiler
In STPS, boiler used is of water tube type. Here the boilers are
manufactured by BHEL . In the boiler, heat energy transfer
takes place through tube walls and drum. The gases lose their
heat to water in the boiler or superheated. The escape heat is
used to heat the water through economizer.
ID and FD fans are used to produce artificial draught. The fuel
oil is used to ignite the boiler and pulverized coal is lifted from
the coal mills by PA fans. Number of mills in this plant are six-
A,B,C,D,E and F respectively.
The accessories which are employed here are:-
1.Superheater
2.Economiser
3.Air Pre-heater
4.Low Pressure Heater
5.High Pressure Heater
6.Deaerator
This on overall basis increases the plant efficiency.

UNIT OVERVIEW

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13 SATPURA THERMAL POWER STATION | MPPGCL | TRAINING REPORT
 TURBINE & GENERATOR( TG)
The Turbine here is manufactured by BHEL So called as the
German Technology Turbine .Turbine is form of heat engine in
which available heat energy in the form of steam is converted
into kinetic energy to rotate the turbine by steam expansion in
suitable shaped nozzles. In this Station there are reaction
turbines.
The turbine consists of three stages:
1.High pressure
2.Intermediate pressure
3.Low pressure
Steam enters the turbine at 350 C with maximum allowable
temp. of 545 C. Cold reheat steam goes to boiler, reheated at
540 C, then fed to medium pressure parts of the turbine. Then,
after cooling it goes to hot well. The shaft is coupled with
generator. The generator converts the kinetic energy of the
rotating shaft to electric energy. Field windings are excited by
D.C. power using exciter. Shaft of generator rotates at 3000
rpm speed.

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 CONDENSER

In condenser, the water passes through various tunes and

steam passes through a chamber containing a large number of
water tubes (about 20000). The steam gets converted into
water droplets, when steam comes in contact with water tubes.
The condensate is used again in boiler as it is dematerialized
water and 5-6 heats the water, which was in tubes, during the
process of condensation. This water is sent to cooling tower.
The main function of the condenser are;

1) To provide lowest economic heat rejection temperature for

steam.

2) To convert exhaust steam to water for reserve thus saving

on feed water requirement.

3) To introduce make up water.

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 COOLING TOWER
It is a structure of height 110m designed to cool the water by
natural draught. The cross sectional area is less at the centre
just to create low pressure so that the air can lift up due to
natural draught and can carry heat from spherical drops. The
upper portion is also diverging for increasing the efficiency of
cooling tower. Hence it is named as natural draught cooling
tower.

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 ASH HANDLING PLANT
Ash is not discharged as such to pollute the land, air and
water, but slurry of ash is made in ash handling plant and this
slurry is dumped in the wasteland, kept for the purpose. The
disposal of ash from a large capacity power station is of same
importance as ash is produced in large quantities. Ash handling
is a major problem.

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i) Manual handling: While barrows are used for this. The
ash is collected directly through the ash outlet door from the
boiler into the container from manually.

ii) Mechanical handling: Mechanical equipment is used

for ash disposal, mainly bucket elevator, belt conveyer. Ash
generated is 20% in the form of bottom ash and next 80%
through flue gases, so called Fly ash and collected in ESP.

iii) Electrostatic precipitator: It is an electronic device.

From air preheater this flue gases (mixed with ash) goes to
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ESP. The precipitator has plate banks (A-F) which are insulated
from each other between which the flue gases are made to
pass. The dust particles are ionized and attracted by charged
electrodes. The electrodes are maintained at 60KV.
Hammering is done to the plates so that fly ash comes down
and collect at the bottom. The fly ash is dry form is used in
cement manufacture.

SWITCH YARD
Switchyard is the area, which feed the grid supply to the
station transformer and fees the grid by the power generator of
the unit. The power supply control is administrated here and the
units consumed and supplies are recorded in the control room.
From here power is evacuated through 440 KV { Itarsi / Indore /
Koradi / Bhilai } lines and 220 KV { Itarsi /Kalmeshwar } lines.

CHIMNEY
The gases produced due to burning of coal are comes out from
chimney. The height of chimney is designed with respect to the
boiler layout. The temp. is also maintained in the chimney. It is
not more than 120 C. If it more than 120 C, then boiler will be
corrupt

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 CONCLUSION
This training focussed upon increasing our knowledge and
interest in toward the Production of Electricity using Coal as a
primary source/fuel. As Electricity is most efficient and
necessary needs to people in these days so its production at
most efficient method with minimum cost and in proper
sequence with less wastage. I learnt how it get produce with

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the help of turbine, generators, cooling towers, water etc. It was
a great experience. It increase my practical skills that’s the
main thing which I learnt in the training session. Thus, I believe
that my training session will be beneficial for various purposes
& hence my efforts will be fruitful.

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