ABOUT NTPC

NTPC, India's largest power company, was set up in

1975 to accelerate power development in India. It is
emerging as an' Integrated Power Major, with a
significant presence in the entire value chain of
power generation business.
With a current generating capacity of 34,854 MW,
NTPC has embarked on plans to become a 75,000
MW company by 2017.

Presently, NTPC generates power from Coal and

Gas. With an installed capacity of 34,854 MW,
NTPC is thelargest power generating major
in the country.

NTPC BADARPUR

Badarpur thermal power plant started

working with a single 95 MW unit.
There were two more units installed in
next two consecutive years. Now it has
total 5 units with total capacity of 720
MW.
UNIT NUMBER

INSTALLED
CAPACITY(MW)

95 MW

95 MW

95 MW

210 MW

210 MW

Coal to electricity
The basic steps in generation of electricity from coal is
carried out in
three stages:

Coal to steam

Steam to mechanical power

Mechanical power to electrical power

RANKINE CYCLE
Rankine
cycle
is
a
basic
thermodynamic cycle that converts
heat into work.
Rankine cycle describes a model of
operation of steam heat engines
most commonly found in power
generation plants.

T-s diagram of a Rankine cycle operating between pressures 0-06 bar and 50 bar.
there
are 4 stages in rankine cycle each changing the state of fluid.

Process 1-2: The working fluid is pumped from low pressure to high pressure,
as the fluid is in liquid state at this stage it requires more input.

Process 2-3:The high pressure liquid enters the boiler where it is heated at
constant pressure by an external heat source to become a dry saturated vapor.

Process 3-4: The dry saturated vapor expands through a turbine, generating
power. This decreases the temperature and pressure of the vapor, and some
condensation may occur

Process 4-1: The wet vapor then enters a condenser where it is condensed at
a constant pressure and temperature to become a saturated liquid.
In an ideal Rankine cycle the pump and turbine would be isentropic i.e. the
pump and turbine would generate no entropy and hence maximize the net
work output.

Coal Handling Plant

This plant transfers the coal to the

boiler and also stores the coal in
the bunker.
Wagon tipplers are employed to
unload the coal wagons into coal
hopper.
Vibrating screen are used for
controlled removal of coal from
coal hopper.
We receive coal in the form of odd
lumps. These lumps are to be
crushed to required sizes which is
done by the coal crusher.
Electromagnetic
separator
performs the function of separation
of iron and magnetic impurities
from the coal.

Wagon tippler
Vibrating screen
Conveyor belt
Electromagnetic
separator
Coal crusher
Coal bunker

Coal wagons containing coal

Wagon tippler

There are three operational cycles working in CHP:

1.
Normal Bunkering Cycle: Shifting of the coal received from
coal wagons directly to coal bunkers
2.
Coal stacking: when there is no requirement of coal in the
coal bunker even then CHP has to unload the received coal
which is stacked at open ground called yard.
3.
Coal reclaiming: as and when coal wagons are not available,
the requirement of the coal bunker is fulfilled from the stacked
coal. this is called reclaiming cycle.

Boiler Maintenance
Department

Coal from the coal wagons are unloaded in the coal handling plant.
This coal is transported up to the coal bunker with the help of
conveyor belts. coal is taken to the bowl mill by coal feeders. The
coal is pulverized in the bowl mill and ground to powdered form.
The mill consists of the round metallic table on which coal particles
fall. The table is rotated with the help of motor. There are three
large steel rollers which are spaced 120 apart.
When there is no coal, The rollers do not rotate but when but when
the coal is fed to the table it packs up between roller and the table
and these forces the rollers to rotate. Coal is crushed by the
crushing action between the rollers and the rotating table.
This crushed coal is taken away to the furnace through coal pipes
with the help of hot and cold air mixture from P.A. fan. P.A. Fan
takes atmospheric air, a part of which is sent to air-pre heaters for
heating while a part goes directly to the mill for temperature
control. Atmospheric air from F.D. Fan is heated in the air heaters
and sent to the furnace as combustion air.

Water from the boiler feed pump passes through economizer and reaches the boiler
drum. Water from the drum passes through down comers and goes to the bottom ring
header. Water from the bottom ring header is divided to all the four sides of the furnace

Due to heat and density difference, the water rises up in the water wall tubes. Water is
partly converted to steam as it rises up in the furnace. This steam and water mixture is
again taken to thee boiler drum where the steam is separated from water.

Water follows the same path while the steam is sent to super heaters for superheating
and finally goes to the turbine.

Flue gases from the furnace are extracted by induced draft fan .These flue gases emit
their heat energy to various super heaters in the pent house and finally pass through airpreheater and goes to electrostatic precipitators where the ash particles are extracted.

Steam Boiler

Turbine maintainence department

A steam turbine has two main parts:

Stator:it contains fixed blades ,vanes and nozzles that directs the
steam into the moving blades carried by rotor.

Rotor : a rotor is a rotating shaft that carries the moving blades

on the outer edges on either discs or drum. The blade rotates as
the rotor revolves.
As the steam passes through the fixed blades or nozzles, it
expands and its velocity increases.

The high velocity jet of stream strikes

the first set of moving blades. The K.E of
the steam changes to mechanical
energy causing the shaft to rotate. The
steam that enters the next row of
moving blades. As the steam flows
through the turbine, its pressure and
temperature decreases while its volume
increases.

The path of steam

Superheated steam

H.P turbine

Reheater

I.P turbine

L.P turbine

Condenser

Condensate Extraction Pump

Ejector

GSC-1

LPH- 1

GSC-2

LPH-2

LPH-3

LPH-4

Deareator

Boiler Feed Pump

HPH-5

HPH-6

HPH-7

Feed Regulating Station

Condenser: To condense the steam.

Condensate extraction pump: The condensate water is drawn

from the condenser by the extraction pump.

Gland steam cooler: Thesealsaround the rotating shaft

onsteam turbinesare many in several ways but all leak a small
amount of steam to theatmosphere. To capture this steam, many
of the seals have small condensers to capture this steam.

Deareator: Adeaeratoris a device that is widely used for the

removal of air and other dissolvedgasesfrom thefeed water to
steam-generatingboilers.

Main Turbine
The 210 MW turbine comprises of H.P, I.P
and L.P cylinders. The superheated steam
from the boiler passes through the
emergency stop valve and control valve
before entering the H.P turbine. After
expanding in the 12 stages in the H.P
turbine the steam returns to the boiler for
reheating. The reheated steam from the
boiler enters the I.P turbine via control
valves and after expanding enters the I.P
turbine in the l.P stage the steam expands
in opposite direction to counteract the
trust and then enters the condenser.
The cooling water flowing through the
condenser tubes condenses the steam
and the condensate is collected in the
hot well of the condenser

Plant Auxiliary Maintenance

Water circulation system: The
water is circulated from the drum
and then comes back to the drum
where the water is separated from
the steam and directed to the super
heater.
Types of water circulation system:
1.
2.

Natural circulation system

Forced circulation system

Ash handling Plant

Hydraulic Ash Handling System: The hydraulic system carries the

ash with the flow of water with high velocity through a channel and finally
dumps into a sump. The hydraulic system is divided into:
Low velocity system
High velocity system
In the low velocity system the ash from the boilers falls into a stream of
water flowing into the sump. The ash is carried along with the water and
they are separated at the sump. In the high velocity system a jet of water
is sprayed to quench the hot ash. Two other jets force the ash into a trough
in which they are washed away by the water into the sump .Hydraulic Ash
handling system is used at the Badarpur Thermal Power station.
Bottom Ash Collection and Disposal
At the bottom of every boiler, a hopper has been provided for collection of
the bottom ash from the bottom of the furnace. This hopper is always filled
with water to quench the ash and clinkers falling down from the furnace.
Some arrangement is included to crush the clinkers and for conveying the
crushed clinkers and bottom ash to a storage site.

WATER TREATMENT PLANT

Water treatment plants used in thermal power plants used in
thermal power plants are designed to process the raw water to
water with a very low content of dissolved solids known as
demineralized water.
Pretreatment Section: Pretreatment plant removes the
suspended solids such as clay, silt, organic and inorganic matter,
plants and other microscopic organism. The suspended solids can
either be separable solids or non-separable solids(colloids). The
coarse components, such as sand, silt, etc: can be removed from
the water by simple sedimentation. Finer particles, however, will
not settle in any reasonable time and must be flocculated to
produce the large particles, which are settleable.

demineralisation

This filter water is now used for demineralizing

purpose and is fed to cation exchanger bed. But before
that it needs to be dechorinated. This can be done in
the following ways:
by passing through activated carbon filter
injecting along the flow of water an equivalent amount
of sodium sulphite through some stroke pumps.
The residual chlorine should be remove as it interferes
with the resin.
A DM plant generally consists of cation, anion and
mixed bed exchangers. The final water from this
process consists essentially of hydrogen ions and
hydroxide ions which is the chemical composition of
pure water. The DM water, being very pure, becomes
highly corrosive once it absorbs oxygen from the
atmosphere because of its very high affinity for oxygen
absorption. Some storage is essential as the DM plant
may be down for maintenance. For this purpose, a
storage tank is installed from which DM water is
continuously used.

Compressor house

Instrument air is required for operating various burners and other

devices etc in the 210 MW units.
INSTUMENT AIR SYSTEM:
Control air compressors have been installed for supplying moisture

free dry air required for instrument.

Air-Drying Unit

Air contains moisture which tends to condense, and causes trouble

in operation of various devices by compressed air. Therefore
drying of air is accepted widely in case of instrument air. The
absorption towers are adequately filled with specially selected
silica gel and activated alumina while one tower is drying the air.

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