Sarni Power Plant

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INTRODUCTION

The aim of this report is to share my experience at Satpura


Thermal Power Plan during my training period of four weeks
which are from 6th of June 2022 to 7th of July 2022.

Satpura Thermal Power Plant, Sarni is the highest power


generating company of Madhya Pradesh and it is also known as
M.P.P.G.C.L., Sarni. It is located in Sarni town near
Ghoradongari Railway Station, dist. Betul. It is the one of coal
based plant of MPPGCL. Satpura Thermal Power Station has an
installed capacity of 500 MW. The First unit was commissioned
in October 1967. The Water for the plant has been procured
from nearby Tawa Dam Lake area, which spread in 2,893 acres
(11.71 km2). The coal for the plant has been procured by
Rail/Road/Belt from Western Coal Fields. There are two units
namely 10 & 11 each with of 250 MW generation capacity.

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THERMAL POWER PLANT

A Thermal power plant is a power plant where steam is used


to drive a steam turbine. This turbine is connected to an
electrical generator which produces electricity. After this, the
water is condensed, and may be used again.

“Steam energy first converted into mechanical energy then


converted into electrical energy and then supplied to the
consumer.”

Flow of energy -

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BLOCK DIAGRAM OF THERMAL POWER
PLANT

There are three cycles involves in production of electrical


energy I thermal power plant they are-

⚫ Coal cycle

⚫ Steam cycle

⚫ Electricity cycle

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COAL CYCLE

4
STEAM CYCLE

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Electricity cycle

This is the single line diagram of flow of power from one unit to
different sections of power plant.

We also have one more single line diagram from yard to station
i.e.,

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ABOUT TRAINING

I got the training section of EMD (Electrical Maintenance


Division) at ET&I - 4 .

The training program went for four weeks . Each week we got a
new section allotted to visit and learn about.

In this four weeks-

⚫ Week 1-

➢ HT Motors
➢ HT Switch gears
➢ DG Set (Diesel Generator)

⚫ Week 2-

➢ Transformers
➢ Generator
➢ Switch Yard

⚫ Week 3-

➢ ESP
➢ Battery Charger
➢ DM Plant

⚫ Week 4-

➢ LT Motors
➢ LT Switch gears
➢ Cooling tower

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HT Motor

Depending on the voltage supply motors are classified into


LT & HT Motors.

HT Motors stands for High Tension Motors.

There are a total of 41 HT motors in this power plant


namely-

BFP - 6 (3 each)

ID Fan -4 (2 each)

CW Pump - 5 (3 at a time)

PA Fan - 4 (2 each)

FD Fan - 4 (2 each)

Mill - 12 (4 at a time)

CEP - 6 (3 each)

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BFP (Boiler Fed Pump) -

In a thermal power plant, the boiler feed pump (BFP) is one of


the critical auxiliary machines that are equivalent to the heart of
the plant. In pace with the increases in the capacity of equipment
for thermal power generation, improvements to adapt to higher
temperatures and pressures, and changes in operation method,
BFPs have been improving and advancing. This paper explains
how BFPs have been upsized and made compatible to higher
pressures; main specifications of BFPs; structures and materials
of typical BFPs for conventional supercritical thermal power
plants and for combined-cycle thermal power plants;
characteristics of the shaft seal and bearing; technological
development for higher capacities and performance; actual
development and delivery of 100% capacity.

Rating of BFP are-

KW- 4600 KW
Voltage- 6.6 KV
Amps-468 A
RPM-1493
Efficiency-97%
Ambient Temp.-50
Temp. Rise-70

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ID Fan(Induced Draft Fan)-

The term “Induced Draught (ID) fan” is most commonly


used in the boiler industry, but more generally refers to any
fans that produce negative pressure (i.e. a partial vacuum) in
a combustion air system such as a kiln.

In coal-fired boilers, the ID fan is typically located between


the electrostatic precipitator and the chimney in the flue gas
path..
Rating are-

KW- 2250 KW
Voltage- 6.6 KV
Amps- 252 A
RPM- 746
Efficiency- 96.3
Ambient Temp.-50
Temp. Rise-70
P.F.-0.81

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CW PUMP(Circulating water pump)

CW Pumps are Circulating Water Pumps used in Thermal


Power Plants. These pumps are critical for plant operation.
When these pumps don’t function effectively, the power
output might have to be de-rated.

Rating are-

KW- 1800 KW
Voltage-6.6 KV
Amps-200A
RPM-495
Efficiency-95
Ambient Temp.-50
Temp. Rise-70

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PA FAN (Primary Air Fan)

The main function of the Primary air fan or PA fan is to carry


the pulverized coal to the furnace as fuel for combustion. This
process is used to create the steam that is the primary process in
the thermal power plant. In power plants, the PA fans supply air

for conveying of the pulverized coal from coal mills to the


furnace area. These primary air fans produce a high pressure to
push the coal and air mixture through pulverizer into the furnace.

Rating are-

KW- 1780KW
Voltage-6.6 KV
Amps-183 A
RPM-1492
Ambient Temp.-50
Temp. Rise-70

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FD FAN (Forced Draft Fan)

Forced Draft Fans (FD) supply the air necessary for fuel
combustion by pushing air through the combustion air
supply system and into furnace. These fans are located
at the inlet of boiler to push high pressure fresh air into
combustion chamber, where it mixes with the fuel to
produce positive pressure.
The key difference between a forced draft and an
induced draft fan is, FD fan forces outside air into the
heating system whereas an ID fan draws flue gases from
the system out into the atmosphere. Both FD fan and ID
fan operate in such a manner that it balances the air
system in the boiler to make the combustion process
efficient.

Rating are-

KW- 750 KW
Voltage-6.6 V
Amps-81
RPM-1488
Ambient Temp.-50
Temp. Rise-70

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MILL (Coal Mill/Crusher )-

Coal Mills are used to pulverize and dry to coal before it is


blown into the power plant furnace.
The coal is feed into the coal mill through a central inlet pipe
where gravity is used to lead the coal to the bottom of the mill,
where the grinding table and some heavy rollers pulverizes the
coal to particles. The primary air flow to the furnace is fed
through the mill, with the purpose of heating and lift the coal
particles out of the mill and into the furnace. If the the particles
are too heavy they will drop to the bottom of the mill and will be
pulverized once more.

Rating are-

KW- 450KW
Voltage-6.6 KV
Amps-57
RPM-987
Ambient Temp.-50
Temp. Rise-70

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CEP(Condensate Extraction Pump)

Condensate extraction pumps (CEP) extract the condensate


water from the condenser and pump it through the condensate
polishing system and the LP heaters to the de-aerator feed water
tank. In medium to large size gas-fired combined-cycle power

plants, the CEP are vertical canned type to ensure enough Net
Positive Suction Head Available (NPSHA). In small power
plants, the CEP could also be horizontal end-suction type.

Rating are-

KW- 325 KW
Voltage-6.6 KV
Amps-36 A
RPM-1487
Ambient Temp.-50
Temp. Rise-70

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In each of the above motor we have-

1) Temperature gauge for both driving and non driving end.

2) Heater in each motor to remove moisture when not in use for


long time.

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HT Switch Gear

In an electric power system, switchgear is composed of


electrical disconnect switches, fuses or circuit breakers used
to control, protect and isolate electrical equipment. Switch
gear is used both to de-energize equipment to allow work to
be done and to clear faults downstream. This type of
equipment is directly linked to the reliability of
the electricity supply.

In here the switch gear has following ratings

Each aux. has its own switch gear and each switch gear has
its own set of relays and each use vacuum circuit breaker.

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The relays used here are-

Numerical Relay-

Numeric relays are the evolved form of a static and


electromagnetic relay. They are basically a device used for
measuring electric parameters in an electrical network and
convert them into numerical data which undergoes
mathematical and logical analysis to decide on tripping an
electrical network.

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Time delay relay-

Time-delay, or time-release relays, allow necessary actions to


happen at specific times in an electrical apparatus because
they, in essence, act as a timer. The purpose of time-delay
relays is to start or stop currents from moving in coils and
armatures, the moving parts of electrical mechanisms. They
are designed to allow electrical circuits to release at certain
times. These types of relays are triggered either by the
opening and closing of a signal or by input currents.

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Trip Circuit supervision relay-

Trip Circuit Supervision Relay is provided to monitor the


healthiness of trip coil. As there are two trip coils therefore,
there will be two Trip Circuit Supervision Relays and hence two
different circuits. This Relay has three coils namely RLA, RLB
and main coil (TCS) of the Relay.

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Tripping relay-

Tripping circuit breakers and operating alarms in control and


protection applications usually require more than one relay
contact. Tripping relays are used to multiply the number of
contacts available, provide isolation between the source and
system operating element and meet the required duty.

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Circuit breaker -

The main purpose of a circuit breaker is to open or close the


contacts of the circuit in faulty or normal situation either
automatically or when commanded.

Here we use vacuum circuit breaker with rating-

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DG SET (Diesel generator set)

Here we have 3 DG sets which can be used during


emergency or a power failure condition.

A Diesel Generator (DG Set) is a combination of diesel


engine with electrical generator (often called an alternator) to
generate electricity. DG sets are used in places that have no
connection to power grid, and as emergency power-supply if
the grid fails.

We use battery set to provide power to self for starting of DG


Set the dc voltage given to self is 12 v comes from 24 v two
battery set connected in parallel.
DG Set is crucial to supply power to important pumps like
SOP,JOP,etc.
These DG sets are-

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TRANSFORMERS

There are four types of transformers used here,they are-

1. GT (Generation transformer) - 2
2. UAT (Unit Auxiliary transformer) - 4
3. ST (Station transformer) - 2
4. SST/UST(Station service transformer /unit service
transformer) - 2

A transformer is an electrical device that transfers energy


between two or more circuits through electromagnetic induction.

A varying current in the transformer's primary winding creates a


varying magnetic flux in the core and a varying magnetic field
impinging on the secondary winding. This varying magnetic
field at the secondary induces a varying electromotive force
(emf) or voltage in the secondary winding. Making use of
Faraday's Law in conjunction with high magnetic permeability
core properties, transformers can thus be designed to efficiently
change AC voltages from one voltage level to another within
power networks

The various transformer parts are :


1. Core
2. Winding
3. Insulation
4. Tank
5. Terminals and bushings
6. Transformer oil
7. Oil Conservator
8. Breather
9. Explosion vent
10. Buchholz relay

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Core
The core provides a low reluctance path for electromagnetic flux
and supports the primary and secondary windings. It is made by
stacking thin sheets of high-grade grain-oriented steel which are
separated by thin insulating material. In order to minimize the
hysteresis and eddy currents, the carbon content of the core steel
is maintained below 0.1%. When it is alloyed with silicon, eddy
currents can be reduced.

Winding
Transformer carries two sets of winding per phase – Primary
winding and secondary winding. These winding consists of
several turns of copper or aluminium conductors, insulated from
each other and the transformer core. The type and arrangement
of winding used for transformers depend upon the current rating,
short circuit strength, temperature rise, impedance and surge
voltages.
Out of the primary winding and secondary winding, the one
which is rated for higher voltage is known as High voltage (HV)
winding and the other is known as the Low voltage (LV)
winding

Insulation
Insulation is the most important part of transformers. Insulation
failures can cause the most severe damage to transformers.
Insulation is required between the windings and the core,
between windings, between each turn of the winding and
between all current-carrying parts and the tank. The insulators
should have high dielectric strength, good mechanical properties
and high-temperature withstand ability. Synthetic materials,
paper, cotton etc are used as insulation in transformers.

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Tank
The main tank is a part of a transformer serves two purposes:
1. Protects the core and the windings from the external
environment.
2. Serves as a container for oil and support for all other
transformer accessories.

Tank bodies are made by fabricating rolled steel plates to


containers. They are provided with lifting hooks and cooling
tubes. In order to reduce weight and stray losses, aluminium
sheets are also used instead of steel plates. However, aluminium
tanks are costlier than steel ones.

Terminal and bushings

For connecting incoming and outgoing cables, terminals are


present in transformers. They are mounted upon the bushings and
is connected to the ends of the windings.
Bushings are insulators that forms a barrier between the terminals
and the tank. They are mounted over the transformer tanks. They
serve as a safe passage for the conductors connecting terminals to
the windings. They are made from porcelain or epoxy resins.

Transformer oil
In all oil-immersed transformers, transformer oil provides added
insulation between the conducting parts, better heat dissipation,
and fault detection features. Hydro-carbon mineral oil is used as
transformer oil. It is composed of aromatics, paraffin,
naphthenes, and olefins. Transformer oil has a flashpoint of 310
degrees Celsius

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Oil Conservators

The oil conservator is moved on the top of the transformers and is


located well above the tank and bushings. Normally a rubber
bladder is present in some oil conservators. The transformer oil
expands and contracts with an increase and decrease in
temperature. The oil conservator provides adequate space for oil
expansion. It is connected to the main tank through a pipe. A level
indicator is fitted to the conservator to indicate the oil level inside.

Breather
Breather is present in all oil-immersed transformers that have a
conservator tank. It is necessary to keep the oil-free from
moisture. As the temperature variations cause the transformer
oil to expand and contact, air flows in and out of the conservator
tank. This air should be free from moisture. Breather serves this
purpose.
A breather is attached to the end of the air pipe such that the air
enters and exits the conservator through it. The silica gel present
in the breathers removes moisture from the air and delivers
moisture-free air to the conservator.

Explosion vent
An explosion vent acts as an emergency exit for oil and air gases
inside a transformer. It is a metallic pipe with a diaphragm at
one end, held slightly above the conservator tank. Faults
occurring under oil elevates the pressure inside the tank to
dangerous levels. Under such circumstances, the diaphragm
ruptures at a relatively low pressure to release the forces from
within the transformer to the atmosphere.

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Buchholz relay
Buchholz relay is one of the most important parts of oil-
immersed transformers rated over 500kVA. It is an oil and gas
actuated relay that is used to sense faults occurring in the parts
immersed in the oil.
Short circuits occurring under the transformer oil generate
enough heat to decompose the oil into hydrogen, carbon
monoxide, methane etc. These gases gradually move towards
the conservator tank through the connecting pipe. Buchholz
relay, which is mounted on the pipe connecting the conservator
tank and the main tank, senses these gases and activates the trip
and alarm circuits. The trip circuit opens the circuit breaker
supplying current to the primary winding and interrupts the
current flow.

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GT(GENERATION TRANSFORMER)

These are step up transformers used to step up voltage levels


suitable for transmission through transmission line via switch
yard.
Here we use a step up transformer which step ups 16.5kv to
400kv A.C.

We use two GT one for each unit .

Ratings are-

Rating- 315 MVA , 3 phase 50 Hz


HV voltage- 420 KV
LV voltage- 16.5 KV
Cooling- OFAF
HV Current-433 A
LV Current- 1022.1 A
Temp. Rise of oil- 35 C above ambient 50 C
Temp. Rise of winding- 40 C above ambient 50C
Connection symbol-YNd1

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UAT (Unit Auxiliary transformer)

These are step down transformers connected to the


same supply we get from generator .
It steps down 16.5 KV to 6.6 KV and provide
operational voltage to HT auxiliaries.

We have 4 UAT , 2 for each generation unit.

Ratings are-

Rating HV- 20/16 , 3 phase 50 Hz


Rating LV- 20/16 , 3 phase 50 Hz
HV voltage -16.5 KV
LV voltage - 6.6 KV
Cooling - ONAF/ONAN
HV Current- 699.83/599.85
LV Current- 1673.48/1338.78
Temp. Rise of oil- 50C
Temp. Rise of winding- 55C
Connection symbol- Dyn1

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ST (Station transformer)

These are the step down transformer used to supply power to


HT auxiliaries working in unit.
These transformers step downs 400 KV TO 6.6KV A.C.
It takes supply from switch yard and provide it to unit
auxiliaries
We have 2 ST , 1 for each unit. These ST has two tapped
output i.e., two LV sides .

Ratings are-

Rating HV- 40/50 MVA ,3 phase 50 Hz


Rating LV1- 20/25 MVA , 3 phase 50 Hz
Rating LV2- 20/25 MVA ,3 phase 50 Hz
HV voltage- 400 KV
LV1 voltage- 6.9 KV
LV2 voltage- 6.9KV
Cooling- ONAN/ONAF
HV Current- 72.2 A
LV1/LV2 Current- 2091.8 A
Temp. Rise of oil- 50C
Temp. Rise of winding- 55C
Connection symbol-YN0yn0yn0

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SST/UST(Station service transformer /Unit service
transformer)

These are step down transformers which further steps


down voltage levels from 6.6 KV to 415 V, and
supplies to LT auxiliaries .
We have 2 UST ,1 for each unit.

Ratings are-

Rating- 2000KVA ,3 phase 50 Hz


HV voltage- 6.6 KV
LV voltage- 433 V
Cooling- AN
HV Current- 174.95 A
LV Current- 2555.74 A
Temp. Rise of oil- 90C
Temp. Rise of winding- 50
Connection symbol-Dyn11

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TURBOGENERATOR
An electric generator that is connected to the shaft of a gas
or steam turbine to generate electric power is known as a
turbo generator. Turbo generators with huge steam-powered
mainly provide electricity all over the world.

Here we use steam turbine with HP turbine ,IP turbine,LP


turbine and steam flows through them.

1st steam goes into HP turbine with high pressure and high
temperature that’s why the size of HP turbine is small.
Then steam is sent back to be reheated and then it is sent into
IP turbine and after IP turbine the steam goes directly into
LP turbine.

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Ratings of Turbogenerator-

Power - 250 MVA


Rating - 294100 KVA
RPM- 3000
P. F.- 0.85
Stator voltage-16500V
Stator current-10291A
Rotor voltage-299 V
Rotor current-2497A
Coolant- Hydrogen

Ratings of Brush Exiter -

Power-1350KW Excitation current DC - 36.5 A


Rating DC- 420 Volts RPM- 3000
Current DC - 3200A Coolant- AIR
Excitation voltage DC -106 Volts

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SWITCH YARD

When power is generated it has to be transmitted to the


consumer so that it can be utilized.
Switch yard is a switching station which provide a link between
generation plan and transmission system.
Single line diagram of switch yard

⚫ In switch yard power flows in a BAY.

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The main components of switchyard are

CVT / PT ( Potential Transformer)-


These are used to step down voltage levels for measuring
instruments.
Connected in parallel with line.

36
CT( Current transformer )

These are used to step down current levels for measuring


instruments.
Connected in series with line.

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Isolaters (Line and Pantograph)-

Isolaters are the switches that separates the parts of electrical


powered equipments and operates under no load condition.
Here we use line and pantograph isolaters .
They are mostly motor driven.

Pantograph isolator

Line & earth isolators Rating plate of line isolator

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SF6 Circuit Breaker-
A sulfur hexafluoride circuit breaker uses contacts surrounded
by sulfur hexafluoride gas to quench the arc. They are most
often used for transmission-level voltages and may be
incorporated into compact gas-insulated switchgear. In cold
climates, supplemental heating or de-rating of the circuit
breakers may be required due to liquefaction of the SF6 gas.

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REACTOR-

In electrical engineering, current limiting reactors can reduce


short-circuit currents, which result from plant expansions and
power source additions, to levels that can be adequately handled
by existing distribution equipment. They can also be used in
high voltage electric power transmission grids for a similar
purpose. In the control of electric motors, current limiting
reactors can be used to restrict starting current or as part of a
speed control system.

Reactor and its conservator tank

Reactor rating plate

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BATTERY CHARGER

Battery is a combination of cell either series or parallel,used to


store electrical energy tat can be used in case of emergency .
Here we use battery to operate DC auxiliaries like
SOP,JOP,EOP and scanner air fan.

Output voltage of batteries is 247.7 volts DC with each cell of


2.25 volts at float mode and 2.75 volts at boost mode.
Battery bank of 110 Nos ; lead acid cell with AH per cell of
2250AH.

Input supply of 3-phase ,415 V +_ 10% AC at 50Hz , each


cell has 6 terminals i.e. 3 positive and 3 negative terminals.

⚫ 110 batteries connected in series

⚫ Charger rating plate

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ESP (ELECTROSTATIC PRECIPITATOR)

An electrostatic precipitator (ESP) is a highly efficient


filtration device that removes fine particles, like dust and smoke,
from a flowing gas using the force of an induced electrostatic
charge minimally impeding the flow of gases through the unit.

ESP works on the principle of electrostatic attraction and


corona effect

TR SET

We use TR set for the production of high voltage DC for


establishment of electric field for corona effect to take place.

It is a step up transformer.

Single line diagram of TR set-

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Ratings are-

Rating- 83 KVA
HV voltage- 74030 V
LV voltage- 373.5 V
Cooling- ONAN
HV Current- 1.12 A
LV Current- 222.2 A

There are 36 TR Sets in total.

MOTORS

Here motors are used for rapping purposes and they are-

CERM- They are collecting electrode rapping mechanism


motors. Total 36 , 18 in each ESP
Placed at lower side of ESP.

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GDRM- They are gas distributor rapping mechanism motors.
Total 4 , 2 in each ESP placed in front.
Placed at middle in ESP.

EERM- They are emitting electrode rapping mechanism motor.


Total 36 , 18 in each ESP.
Placed at upper side of ESP

All these motor are of same rating

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HOPPERS

These are the components of ESP which collects dust particles


in it. They are total 72 in numbers with 36 in each ESP.

These hopper have an upper limit and when its reached the ash
is sucked out by a vacuum formed in drainage pipeline.

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FIELD

The set of positive and negative electrode is called field . There


are total 36 in total with 18 in each ESP.
Each fields gets two hopper for collection of dust particles.

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DM PLANT

DM plant stsnds for demineralized water plant , as name suggest


here we produce demineralized water for steam generation and
cooling purposes.

Steam produced by DM water is used to rotate the turbine for


turbogenerator.

When water is taken from reservoir it is added with clorine and


sent to sedimentation tank for removal of large particle and
algae.

Then after water is passed through 5 different tanks for proper


treatment. These tanks are-

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DMF (Duel Media Filter) -used to remove large particles and
primary filtration.

ACF (Activated Carbon Filter) - used to remove small particles.

SAC (Strong Acid Cation)- here we remove cation from water.

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WBA & SBA(Weak Base Anion & Strong Base Anion)- they
both together remove anion ,this is a two stage process.

MB (Mix Bed Filter) - used to remove both remaining anion and


cation.

The water is then filed in DM water tank for further use.

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LT MOTORS

These are the motors operates on 3-phase ,50 Hz ,415 volts AC


supply.These are the LT auxiliaries that are important to keep
HT auxiliaries running.

There are about 250 LT motors in this power plant most of


which are LOP which stands for lubricating oil pump .

Some of the most important LT Motors are-

ACW- It stands for auxiliaries cooling water pump ,this cooling


happens in plate heat exchanger.

With rating-

50
DMCW- It stands for Demineralized cooling water pump , used
in auxiliaries where cooling is done by demineralized water .

With rating-

51
Vacuum Pump- It is used to create vacuum in condenser to
suck steam in condenser to cool the steam.

This motor is manufactured in china.

With rating-

52
AOP- It stands for auxiliary oil pump used to supply oil in
bearing of big auxiliaries ike BFP, Generator etc., for lubricating
and cooling of bearing.

With rating-

53
JOP- It stands for jacking oil pump used to provide a lift or
jack to the shaft of the turbine to prevent it from bending or sag
and also increase bearing life.

With rating-

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LT Switch Gears

Here LT supply came from UST or UAT which is of 415 V ,3-


phase,50Hz

This supply is used to run the auxiliaries operating at 415 V AC,


these LT auxiliaries are necessary for the operation of HT
auxiliaries

The supply from UST & UAT comes into PMCC(Power Cum
Motor Control Centre) and then divide into several MCC(Motor
Control Center).

For protection or switching operation we use air circuit breaker


and SFU(Switch Fuse Unit).

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Air circuit breakers are installed at the point of incomer in
PMCC, each PMCC has a Bus coupler in middle .

In other modules we use SFU for switching operations.

There are three modes in which each modules can be operated


and they are-

LOCAL - by switch gear


FIELD - by local push button
REMOTE - by PCR\

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COOLING TOWER

A cooling tower is a heat rejection device which extracts waste


heat to the atmosphere through the cooling of a water stream to
a lower temperature. Cooling towers may either use the
evaporation of water to remove process heat and cool the
working fluid to near the wet-bulb air temperature or, in the case
of closed circuit dry cooling towers, rely solely on air to cool
the working fluid to near the dry-bulb air temperature

There are three types of cooling towers


1. Natural draft
2. Forced draft
3. Induced draft

Here we use natural draft cooling ,in which hot water is sent to
cooling tower and then sprinkled on heat exchanger

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here air comes from below and meets water in heat exchanger
and cools down as much water as possible remaining steam is
then sent to atmosphere.

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Cool water falls in the form of droplets

Cooled water is then sent to water treatment plant via canals.

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