1 Power House-5

This is the captive power house in the Tata steel. It fulfils two demands of the industry,one of
power generation and other of steam supply. But the main function of this power house is to
provide steam at a pressure of about 16kg/cm^2 and temperature of 758K.

1.1 DM Plant

The purpose of this plant is to convert the water from the lakes or any other water source
and then convert it into demineralised water and then supply that demineralised water to
the power house for the steam preparation. When the water is heated and vaporised it
leaves residual salts on the surface which are bad conductor of electricity which reduces
the efficiency of the boiler. Since the heat transfer between the flue gases and the water
reduces because of the formation of the layer of salts on the surface of the boiler. Here is
the flow chart explaining the process of demineralisation in brief.

water

DMF

Contact tank

PSF

Cartridge filter

Reverse Osmosis

Degrasser Tower

Degrasser storage
tank

Mixed Bed

DM water Tank

The above flowchart gives a brief idea how the process of demineralisation is done. In
demineralisation plant the water is taken from the source and chemical dosing is done on
 the water. The chemicals mixed with water are NaOCl and FeCl3. After that the
chemically treated water is sent to the DMF(Dual Media Filter). In which the particles
size upto 50 microns can be arrested. It genrally arrest sand and anthracite present in the
water. Then the water is sent to the contact tank where where some time is given for the
chemical reaction to take place completely. Then through pumps the water is sent to the
PSF(Pressure Sand Filter) where particles size upto 10 microns can be arrested. Then
after that it is sent to the cartridge filter where final removal of the insoluble particles
takes place. Here particles having size upto 5 microns can be arrested. Then after this th
next step is removal of the totally dissolved solids , for this water through RO pumps are
sent for reverse osmosis. Then the water is sent to the Degasser Tower where H2CO3 is
break down into H2O and CO2. Then through degasser storage tank as per requirement is
sent to power house through Mixed Bed to the DM water tank, which is then converted
into the steam.

1.2 Steam and Power Generation

The demineralised water we got from the DM Plant is then processed and then is
converted into steam at high pressure and high temperature that is 60kg/cm2. The high
pressure steam is then passed through the turbine and converted into low pressure steam
and power is generated. An output of 11kv is generated which then passed though the step
up transformer and stepped up to 30 kv. Here is a flow chart showing the steam and
power generation process in brief.

Air from Atmosphere DM Plant

Chimney
Feed Fans Derator

ATN Boiler feed pump

Economizer
To both boilers

Upper Boiler Drum Superheater

Lower Boiler Drum Attemprature

Turbine

LP Header PRDS
There are three boilers in Power house-5 namely A,B and C. Boiler A has a capacity of 100
tonnes per hour and B and C has a capacity of 60 tonnes per hour each of steam production.

1.2.1Derator

There is one Derator for boiler A and a common Derator for B and [Link] shown in the
flow chart demineralised water enter into the Derator. The function of the Derator is
to remove the dissolved gases from the water. In the derator the slabs are present in
the form as shown below =
Slabs are arranged in
this manner in boiler

The
feed water is splashed on it and hence it get converted into fine particles of water and
hence its surface area increases. The is introduced into the system hence the gaseous
are removed from the water. The gaseous should be removed since the oxygen
presence will cause corrosion of the surface of the boiler.

1.2.2 Boiler Feed Pump

There are three boiler feed pump for boiler A and three boiler feed pump for boiler B and C.
The max pressure that it can give is 90 kg/cm2. There should some minimum pressure which
should be maintained at the inlet of the boiler feed pump that is 2kg/cm2, so as to maintain
the NPSH. There are certain interlocks such that if the pressure at the inlet of the feed pump
goes below 2kg/cm2 the boiler feed pump trips. The pressure of 2kg/cm2 is maintained by
keeping the Derator at a proper height so that the feed water entering the feed pump has
sufficient head.

1.2.3 Economizer

The feed water before sending it to the boiler is preheated in the Economizer. The flue gases
coming out of the boiler is passed through the economizer which heats up the incoming feed
water. And hence the temperature of the feed water increased. This helps in reducing the
work required by the boiler in increasing the temperature. And also using the heat energy of
the flue gases effectively.
1.2.4 Upper and Lower Boiler Drum

The water coming from the feed pump enters the upper boiler drum and from the upper boiler
drum the water enters into the lower boiler drum. The flue gaseous also enter the upper boiler
drum. The internal structure of the boiler can be shown as below.

The flue gaseous entering the boiler should burn properly and a proper colour of flame is to
be maintained that is violet. The pressure inside the boiler should be kept negative and within
a given range that is around -5mm. This is done so if the pressure is in positive value the
flames will come out of the boiler. And if the pressure is kept in more negative value the
outside air can enter the boiler and will cool down the flue gaseous and hence reduce the
effectiveness of heating.