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INTRODUCTION
1.1 About NTPC
NTPC Limited (also known as National Thermal Power Corporation Limited) is
an Indian Central Public Sector Undertaking (CPSU) under the Ministry of Power, Government
of India, engaged in the business of generation of electricity and allied activities. It is a
company incorporated under the Companies Act 1956 and a "Government Company" within
the meaning of the act. The headquarters of the company is situated at New Delhi. NTPC's
core business is generation and sale of electricity to state-owned power distribution
companies and State Electricity Boards in India. The company also undertakes consultancy
and turnkey project contracts that involve engineering, project management, construction
management and operation and management of power plants. The company has also
ventured into oil and gas exploration and coal mining activities. It is the largest power
company in India with an electric power generating capacity of 43,803 MW . Although the
company has approx. 18% of the total national capacity it contributes to over 27% of total
power generation due to its focus on operating its power plants at higher efficiency levels
(approx. 83% against the national PLF rate of 78%).
It was founded by Government of India in 1975, which now holds 70% of its equity shares on
13 May 2015.
In May 2010, NTPC was conferred Maharatna status by the Union Government of India. It is
ranked 424th in in the Forbes Global 2000 for 2014
The company has set a target to have an installed power generating capacity of 1,28,000 MW
by the year 2032. The capacity will have a diversified fuel mix comprising 56% coal, 16% Gas,
11% Nuclear and 17% Renewable Energy Sources(RES) including hydro. By 2032, non-fossil
fuel based generation capacity shall make up nearly 28% of NTPCs portfolio.
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1.3 Vision
To be the worlds largest and best power producer, powering Indias growth
1.4 Mission
Develop and provide reliable power, related products and services at competitive prices,
integrating multiple energy sources with innovative and eco-friendly technologies and
contribute to society
Business Ethics
Environmentally & Economically Sustainable
Customer Focus
Organizational & Professional Pride
Mutual Respect & Trust
Motivating Self & others
Innovation & Speed
Total Quality for Excellence
Transparent & Respected Organization
Enterprising
Devoted
NTPC OWNED
COAL
GAS/LIQ. FUEL
TOTAL
OWNED BY JVCs
Coal
Gas/LIQ. FUEL
GRAND TOTAL
Commissioned
Capacity
(MW)
14
07
21
22,395
3,955
26,350
3
1
25
314
740
27,404
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State
1.
Singrauli
Uttar Pradesh
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Korba
Ramagundam
Farakka
Vindhyachal
Rihand
Kahalgaon
NTCPP
TalcherKaniha
Unchahar
Talcher Thermal
Simhadri
Tanda
Chhattisgarh
Andhra Pradesh
West Bengal
Madhya Pradesh
Uttar Pradesh
Bihar
Uttar Pradesh
Orissa
Uttar Pradesh
Orissa
Andhra Pradesh
Uttar Pradesh
2,100
2,600
1,600
3,260
2,000
1,340
840
3,000
1,050
460
1,000
440
Delhi
705
22,395
14. Badarpur
Total (Coal)
Commissioned
Capacity
(MW)
2,000
State
Commissioned
Capacity
(MW)
Anta
Rajasthan
413
Auraiya
Uttar Pradesh
652
Kawas
Gujarat
645
Dadri
Uttar Pradesh
817
Jhanor-Gandhar
Gujarat
648
Kerala
350
Faridabad
Haryana
430
Total (Gas)
3,955
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State
Fuel
1.
Bihar
Coal
500
500
2.
Chhattisgarh
Coal
1980
1000
3.
Barh
Bihar
Coal
1980
4.
Chhattisgarh
Coal
500
5.
Chhattisgarh
Coal
500
6.
West Bengal
Coal
500
7.
Uttar Pradesh
Coal
980
8.
Andhra Pradesh
Coal
1000
9.
Koldam (HEPP)
Himachal
Pradesh
Hydro
800
Uttarakhand
Hydro
600
Uttarakhand
Hydro
520
11,360
State
Fuel
Commissioned
Capacity
(MW)
Coal
120
Rourkela Orissa
Coal
120
Bhilai
Chhattisgarh
Coal
74
RGPPL
Maharastra
Naptha/LNG 740
Total(JV)
1054
27,404
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BFP work
Heating of water to convert it finally to superheated steam in boiler
Expansion in HP turbine
Reheating
Expansion in IP and LP turbine
Cooling in Condenser
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1st
2nd
Total
Unit
Number
Installed
Capacity (MW)
Date of
Commissioning
210
1991 October
210
1992 December
210
1993 March
210
1994 March
490
2010 January
490
2010 July
Six
1820
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Unit
Number
1st
Total
Installed
Capacity (MW)
Date of
Commissioning
GT / ST
130.19
1992 March
GT
130.19
1992 May
GT
130.19
1992 June
GT
130.19
1992 November
GT
154.51
1993 February
ST
154.51
1993 March
ST
Six
829.78
1.8.2 Location
It is located in Gautam Budh Nagar district of Uttar Pradesh about 25 km from Ghaziabad and
about 9 km fromDadri. It is nearly 48 km from New Delhi towards Hapur. The township has an
area of about 500 acres over all. NTPC Dadri is a branch of National Thermal Power
Corporation, which is a public sector now. It is about 20km from Ghaziabad via Badalpur,
Mahawar, Bamabawar, and Akilpur Jagir.
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CHAPTER 2
COAL CYCLE
2.1 Coal Supplied at NTPC Dadri
Coal is supplied to NTPC, Dadri by Piparwar coal mines. The type of coal is Bituminous and
Semi Bituminous with following specifications: Moisture- less than 8%
Volatile matter-17% to 19%
Ash- 35% - 40%
Calorific Value- 4500 to 5300 Kcal/kg
Coal is received in railway box rakes containing 50-60 wagons in each rake.
Capacity of each box wagon is about 55 ton.
The BOX-N type wagons are placed on 2 wagon tippler (one for Stage-I and other for
Stage-II)
The BOBR type wagons are emptied on track hoppers
Wagon Tippler
Track Hopper
Paddle Feeder
Conveyer Belts
Crusher House
Stacker cum Reclaimer
Coal Yard
Coal Bunker
Coal Feeder
Coal Mills
Furnace
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8, Pennsylvenia, USA
Ring Granulators, TKKGN-48093
875 tonnes/hr
800hp (597KW)
6.6kv, 3, 50Hz
743
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BHEL
6
XRP 883
49 T/hr
25 mm
70% through 200 mesh
Ni -Hard Gr II
2.2.12 FURNACE
Furnace is primary part of the boiler where the chemical energy available in the fuel is
converted into thermal energy by combustion. Furnace is designed for efficient and complete
combustion. Major factors that assist for efficient combustion are the temperature inside the
furnace and turbulence, which causes rapid mixing of fuel and air. In modern boilers, watercooled furnaces are used. The boiler fuel firing system is tangentially firing system in which
the fuel is introduced from wind nozzle located in the four corners inside the boiler. The
crushed coal from the coal crusher is transferred into the unit coalbunkers where the coal is
stored for feeding into pulverizing mill through rotary feeder. The rotary feeders feed the coal
to pulverize mill at a definite rate. Then coal burners are employed to fire the pulverized coal
along with primary air into furnace. These burners are placed in the corners of the furnace
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and they send horizontal streams of air and fuel tangent to an imaginary circle in the centre of
the furnace.
Table 2.3 Furnace specifications
Type
Bottom
Furnace projected area
Fuel heat input
Residence time for fuel particles in furnace
Effective volume used to calculate the residence time
Draft
Furnace width
Furnace depth
Furnace height (Ring header to furnace roof)
(viii) Furnace volume
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CHAPTER 3
WATER CYCLE
3.2.4 Deaerater
A Deaerator is a device for air removal and used to remove dissolved gases (mainly O2 and
CO2) from boiler feed water to make it noncorrosive. A Steam generating boiler requires that
the circulating steam, condensate, and feed water should be devoid of dissolved gases,
particularly corrosive ones and dissolved or suspended solids. The gases will give rise to
corrosion of the metal. The solids will deposit on the heating surfaces giving rise to localized
heating and tube ruptures due to overheating. Under some conditions it may give rise to
stress corrosion cracking
Deaerator is a type of open feed water heater in which feedwater comes in direct contact
with the steam extracted from CRH line and IPT exhaust.
These are of three types
Spray type Deaerator
Tray type Deaerator
Spray Cum Tray type Deaerator
In NTPC Dadri, a spray cum tray type Deaerator is used. In this feedwater is first sprayed and
then made to cascade down a series of trays and bled steam flows upwards. Due to this water
gets heated and scrubbed to release the dissolved gases.
. If operated properly, the deaerator will guarantee that oxygen in the deaerated water will
not exceed 7 ppb by weight (0.005 cm3/L)
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Fig 3.4 Deaerator (upper cylinder) and Feed Storage Tank (lower cylinder)
discharge is blocked) the second stage will be triggered. This stage may switch off the boiler
equipment (preventing the boiler from running dry and overheating), trigger an alarm, or
both
Table 3.2 Boiler Feed Booster Pump specifications
BOILER FEED BOOSTER PUMP
Pump type
FA 1B 56
Liquid pumped
Suction temperature
Differential head
Flow rate
Efficiency
Speed
Power
NPSH, required
BHEL, Hyderabad
FK 6 D 30
6
Boiler feed water
2123m
450 m3 / hr
110 m3 / hr
81%
5150 rpm.
2911 kw
24.0 mlc
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3.3.3 Economiser
Economiser is a mechanical device intended to reduce energy consumption, or to perform
another useful function like preheating a fluid. They are devices fitted to a boiler which save
energy by using the exhaust gases from the boiler to preheat the cold water used to fill it (the
feed water). A common application of economizer in steam power plants is to capture the
waste heat from boiler stack gases (flue gas) and transfer thus it to the boiler feed water thus
lowering the needed energy input , in turn reducing the firing rates to accomplish the rated
boiler output .
Table 3.4 Economiser Specifications
Type
Tube Material
OD of Tube, mm
Actual Thickness of Tubes, mm
Length of Tubes, mm
Tube pitch, mm
a) Parallel to gas path
b) Across gas path
Water side effective heating area, m2
Gas side effective heating area, m2
Gas flow path area, m2
Design Pressure of tubes, kg/cm2
Fusion welded
Material specification
Design pressure, kg/cm2 abs.
Max. operating pressure, kg/cm2 abs.
Design temperature, 0C
Overall length of drum mm
O.D. of Drum, mm
Internal dia. of Drum, mm
No. of distribution headers
Normal water level in drum
SA-299
176.4
167.2
354.0
12200
2083
1778
6
250 mm below drum centreline.
3.3.5 Boiler
Boiler is an enclosed vessel in which water is heated and circulated until the water is turned in
to steam at the required pressure. Coal is burned inside the combustion chamber of boiler.
The products of combustion are nothing but gases. These gases which are at high
temperature come in contact with different heat exchangers and vaporize the water inside
them to steam. This steam is further heated in a super heater as higher the steam pressure
and temperature the greater efficiency the powerplant will have in converting the heat in
steam in to mechanical work. This steam at high pressure and temperature is used directly as
a heating medium, or as the working fluid in a prime mover (turbine) to convert thermal
energy to mechanical work, which in turn is converted to electrical energy.
Boilers are classified mainly into two categories as following:
Fire Tube Boiler
In this type the products of combustion pass through the tubes which are surrounded
by water. These are economical for low pressure only.
Water Tube Boiler
In this type of boiler water flows inside the tubes and hot gases flow outside the tubes.
These tubes are interconnected to common water channels and to steam outlet.
At NTPC Dadri there is a water tube boiler in both stage I and stage II
Table 3.6 Boiler Specifications
Manufacturer
Type
Capacity
Boiler Efficiency
FW. inlet temp
Type of firing
Temp and Pressure at outlet of Superheater
Reheater
Water volume
Generating surface (Water walls)
Economiser
Superheater (Drum to SHO heater)
Drum (full)
Reheater
Total water volume of boiler
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3.4.1 Superheater
A Super heater is a device in a steam engine that heats the steam generated by the boiler
again increasing its thermal energy. Super heaters increase the efficiency of the power plant,
and are widely adopted. Here the temperature of the steam is raised above the saturated
temperature of the steam so that even after isentropic expansion in the turbine the wetness
of steam remains in the desired region
In NTPC Dadri, the boiler has in total 14 superheater headers located at various positions in
the boiler. Superheaters are of three types
Low Temperature Superheater
Platen Superheater
Final Superheater
Table 3.7 Superheater specifications
Type
Direction of flow
Effective heating surface
area, m2
Gas flow path area, m2
Total no. of tubes
O.D., mm
Effective length, mm
Gross length, m
No. of elev/section
Tube pitch
(a) Parallel of gas flow,mm
(b) Across gas flow, mm
LTSH Pendant
Horizontal
Convection
Counter
3700
Platen
S.H.
Radiant
Parallel
1097
Final
S.H.
Convection
Parallel
1543
73
480
44.5
26466
34700
4
138.9
203
47.63
8900
10100
7
72
238
44.5
8360
9760
2
96
114.3
57
457.2
95/96
114.3
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3.4.2 Reheater
Reheater is a heater which is used to raise the temperature of steam which has fallen after
the expansion in High Pressure Turbine. This is done so as to increase the efficiency of the
power plant and to maintain the dryness fraction of the steam within the desired limit.
Table 3.8 Reheater Specifications
Type
Max. operating pressure,kg/cm2
Design pressure, kg/cm2
Total circumferential heating suface, m2
Gas flow path area, m2
Space between two banks in direction of gas flow,
mm
Mean effective length per one tube, mm
Gross length per tube, mm
Total no. of tubes
Acutal tube thickness O.D., mm
Tube material
Tube pitch
(a) Parallel to gas flow, mm
(b) Across gas flow, mm
Method of joining long tubes
3.4.4 Condenser
These condensers are heat exchangers which convert exhaust steam from its gaseous to its
liquid state at a pressure below atmospheric pressure. This is done because handling of the
steam is more difficult and requires more power as compared to that for condensed water.
The condenser used is a shell and tube type condenser in which steam is in the shell while
cooling water is in the tubes. After condensing the steam, the cooling water gets heated up
and is sent to the cooling towers to cool it and use it again
Specifications of the condenser used in NTPC Dadri is as follows
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3.5.3 Forebay
After the water is cooled in the cooling tower, it goes to the CW Pump house through
forebay. It connects water from all the four cooling towers in a single channel which finally
becomes the intake of CW Pump house.
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CHAPTER 4
No of stages
Nominal rating
Peak loading
Max./Min. speed
Weight of turbine
HPT
43
643
95
695
16.975m
10.5 (approx.)
IPT
66
756
100
1041
LPT
755
1473.5
668.8
2144.8
2 x 5 m2
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4.3 Generator
The generator works on the principle of electromagnetic induction. There are two
components stator and rotor. The rotor is the moving part and the stator is the stationary
part. The rotor, which has a field winding, is given a excitation through a set of 3000rpm to
give the required frequency of HZ. The rotor is cooled by Hydrogen gas, which has high heat
carrying capacity of low density. If oxygen and hydrogen get mixed then they will form very
high explosive and to prevent their combining in any way there is seal oil system. The stator
cooling is done by de-mineralized (DM) water through hollow conductors. Water is fed by one
end by Teflon tube. A boiler and a turbine are coupled to electric generators. Steam from the
boiler is fed to the turbine through the connecting pipe. Steam drives the turbine rotor. The
turbine rotor drives the generator rotor which turns the electromagnet within the coil of wire
conductors.
Hydrogen gas is used to cool down the rotor.
Lube oil is used to cool the bearings.
DM water is used to cool the stator.
Seal oil is used to prevent hydrogen leakage
Seal oil coolers are present to cool the seal oil
Hydrogen dryer are used which removes the moisture from hydrogen gas and then is
supplied to the generator.
Clarified water in cooling tower is used to cool down the hydrogen gas.
The 210 MW generates 16.5 KV three phase electricity. The voltage is stepped up to 220 KV
with the help of station transformer and is connected to the switch yard. This electricity is
further stepped up to 400KV and then supplied to the grid
Some of the electricity is stepped down to 6.6KV with the help of Unit Auxiliary Transformer
to drive the different auxiliaries in the plant.
4.4 Transformer
It is a static machine which increases or decreases the AC voltage without changing the
frequency of the supply. It is a device that:
Transfer electric power from one circuit to another.
It accomplishes this by electromagnetic induction.
In this the two electric circuits are in mutual inductive influence of each other.
It works on Faradays Law of Electromagnetic Induction (self or mutual induction depending
on the type of transformer).
There are two types of transformers
Station Transformer
It is the transformer which steps up the 16.5KV electricity generated by the generator
to 220KV
Unit Auxiliary Transformer
It is the transformer which steps down some of the electricity to 6.6KV so as to run the
auxiliaries in the plant
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CHAPTER 5
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5.2 Fans
5.2.1 Primary Air Fan (PA Fan)
It is the fan which is used to carry pulverized coal from the coal mills to the furnace. The PA
Fan takes suction from the FD fan outlet from where the air is sent to the air preheaters.
From APH, the heated air is sent to the coal mills. Heating of primary air is done so as to
remove the moisture content from the coal so as to facilitate the combustion process.
Table 5.1 PA Fan specifications
Manufacturer
BHEL
No. per boiler
Type
Medium handled
Location
Orientation
Capacity
Total head developed
Temp. of medium
Speed
Two
NDZV 19 HERKALES Axial double suction
radial discharge simply supported
Clean air from FD fan discharge
Ground mounted on concrete floor
Top delivery with 450 inclined suction
chamber.
77.4 cu.m/sec.
931 mmwc
530c
1480 rpm
BHEL
Two
AP1-19/11
Clean air
Ground mounted on concrete floor
Horizontal axis
144.7 cu.m/sec
334 mmwc.
500c
1480 rpm
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Fig 5.2 Forced Draft Fan (bottom left) and Primary Air Fan (bottom right)
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In NTPC Dadri, a regenerative air preheater is used. Every unit consists of two air preheaters.
It is of two types
Bisector Air Preheater
Trisector Preheater
Here, a trisector type preheater is used. In this the whole circular area is divided into three
sectors of 180 (for flue gas), 120 (for secondary air) and 60 (for primary air)
BHEL
FAA-6x45-69135-2
312.7 cu.m / sec
1360c
Four
Six
32.18 seconds
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0.839 m/sec
99.9%
505 kw
24
144
3456
13.5 m
750 mm
214.48 sq.m/cu.m/sec
Spiral with hooks
Dia 2.7 mm
54 fields
1242
29808
6967.62 m.
5.3.3 Chimney
A Flue gas stack is a type of chimney, a vertical pipe, channel or similar structure through
which combustion product gases called flue gases are exhausted to the outside air. Flue gases
are produced when coal or oil is burnt in the furnace. Flue gas is usually composed of carbon
dioxide (CO2) and water vapour as well as nitrogen and excess oxygen remaining from the
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intake combustion air. It also contains a small percentage of pollutants such as particulates
matter, carbon mono oxide, nitrogen oxides and sulphur oxides. The flue gas stacks are often
quite tall so as to disperse the exhaust pollutants over a greater area and thereby reduce the
concentration of the pollutants to the levels required by government's environmental policies
and regulations.
Table 5.5 Chimney Specifications
No. of fuel
Wind shield material
flue material
Chimney height
Chimney base diameter
Chimney raft diameter
Flue diameter
4 NO.
Reinforced concerete
Steel
220 m
32.975
43.120 m
4.5 m
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CONCLUSION
The industrial training has proved to be quiet fruitful. It provided an opportunity for
encounter with such huge machines. The architecture of the power plant the way various
units are link and the way working of whole plant is controlled make the student realize that
engineering is not just learning the structure description and working of various machines,
but the greater part is of planning proper management.
The practical experience that I have gathered during the overview training of thermal power
plant having a large capacity of 2637 MW in 45 days will be very useful and a stepping stone
in building bright professional career in future life. It gave me large spectrum to utilize the
theoretical knowledge and to put it into practice. The trouble shooting activities in operation
and decision making in case of crisis made me more confident to work in the industrial
atmosphere. Moreover, this overview training has also given a self-realization & hands-on
experience in developing the personality, interpersonal relationship with the professional
executives, staffs and to develop the leadership ability in industry dealing with workers of all
categories. I would like to thank everybody who has been a part of this project, without
whom this project would never be completed with such ease.
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REFERENCES
Thermal Power Plant (Wikipedia)
NTPC Dadri Technical Diary
Power Plant Engineering by P.K. Nag
TMH Publications
Thermodynamics by P.K. Nag
TMH Publications
www.ntpc.co.in
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