NTPC

PROJECT REPORT
Summer Training

PROJECT REPORT
ON

FEROZE GANDHI UNCHAHAR

THERMAL POWER STATION

Reporting Officer:
Mr. Bimal Shah
(HR-EDC)

FGUTPS, UNCHAHAR

Submitte
d by:

................
B.Tech(FINAL
YEAR)

Contents
1.

Introduction of NTPC

2.

Introduction about Project

3.

Production of Electicity

4.

Principal of Steam Power Plant

5.

H.T.Switch gear

6.

L.T.Switch gear

7.

Generators and Transformers

8.

D.C. System

9.

Switch Yard

10.

Coal Handling Plant

11.

Coal Handling Plant Power Distribution

12.

Demineral Plant(DM Plant)

13.

Coal ,Water and Steam Cycle

14.

Conclusion

INTRODUCTION OF NTPC

Established in 1975, NTPC the largest power company of the country has been
consistently powering the growth of India.

With an installed capacity of 30,144 MW, it contributes 28.6% of the nations

power generation with only 18.79% of Indias total installed capacity. An ISO
9001:2000 certified company, it is worlds sixth largest thermal power generator
and second most efficient in capacity utilization.

The corporation recorded a generation of 206.94 billion units (bus) in 2008-09,

an increase of 3.03% over 2007-08, through 13 coal based and 7 gas based
power plants spreads all over the country. Rated as one of the Best companies
to work for in India it has developed in to a multi-location and multi fuel
Company over the past three decades.

Driven by its vision to lead, it has charted out an ambitious growth plan of
becoming a 40,000 MW plus company by 2012.

Following are the other important highlights of 2008-09:

1.

Total Income of Rs.455, 000 million.

2.

Net profit in excess of Rs.78, 274 million

3.

A dividend payment of Rs.126, 865 million to the Govt. of India.

Received highest credit rating AAA by CRISIL and LAAA by ICRA for domestic
bond and international rating for Eurobond.

INTRODUCTION ABOUT PROJECT

The Unchahar Thermal Power Plant located about 125kms from Lucknow. It is
nearly 80kms from Allahabad. The nearest railway station is Unchahar. The
project lies in the Raibareilly District in U.P.Water source for this plant is Sarda
Sahayak Canal. The climate conditions are quite favourable with greenery all
around.The installed capacity is 5 X 210 MW.
The Uttar Pradesh Vidyut Utpandan Nigam Limited started this project in 1981.
This was fully owned by the UP Government. Our late Prime Minister Smt. Indira
Gandhi laid down the foundation stone on 27 TH June 1981. The project was
started with an installed capacity of 420MW (2*210).

Faced with financial crunch of its affairs, the Nigam was not able to operate the
plan continuously at optimum capacity. Resulting in loss of generation the UPSEB
was not able to pay charges to NTPC for energy bought. Then it was decided to
sell of the project to NTPC to augment and continue generation of electricity at
full level and commence actives the expansion project in the interest of power
development.

The governor promulgate Uttar Pradesh Vidyut Utpadan Nigam Limited

(Acquisition and transfer of Undertaking) act. Consideration worth Rs.925 Crore
was decided for takeover.

PLF in 1990-91 was 5.5% and at the time of take-over in 1992-93, it was around
20%. NTPC is managing the project well and the result is PLF of 54.9% in 199293, 68% in 1993-94 and more there after. In the year 2000-2001 it has achieved
85.5%. PLF in March 2009 is highest at 100.03%.
It supplies the produced electricity to region of Uttar Pradesh. The project is a
coal-based thermal power project and the main constituents for production is
coal, oil and water.

The NTPC has total installed capacity of 30, 144 Mega Watts and has the goal to
reach the capacity of 40000 Mega Watts. Today it has project at the following
places: -

1. Northern region station

1.

Singrauli

(5*2000+2*500) Mega Watts.

2.

Rihand

(2*500) Mega Watts.

3.

Unchahar

(5*210) Mega Watts.

4.

Tanda

(4*110) Mega Watts.

2. Southern region station

1.

Ramagundem

(3*200+3*500) Mega Watts.

2.

Kayamkulam

(2*155GT+1*120St) Mega Watts.

3. Western region station

1.

Korba

(3*200+3*500) Mega Watts.

2.

Vindhyanehal

(6*210+2*500) Mega watts.

3.

Kawas

(4*106 GT+2*105 ST) Mega Watts.

4. Eastern region station

1.

Farakka

(3*200+2*500) Mega Watts.

2.

Kahalgaon

(4*210) Mega Watts.

3.

Takher

(4*60+2*110) Mega Watts.

5. Nation capital region station

1.

Dadri coal

(4*210) Mega Watts.

2.

Auta

(3*88 GT+1*149 St) Mega Watts.

3.

Auraiya

(4*110 GT+2*106 ST) Mega Watts.

4.

Faridabad

(2*143 GT+1*144 ST) Mega Watts.

PRODUCTION OF ELECTRICITY

The means and steps involved in the production of electricity in a coal-fired

power station are described below.
The coal, brought to the station by train or other means, travels from the coal
handling plant by conveyer belt to the coal bunkers, from where it is fed to the
pulverizing mills which grinds it as fine as face powder. The finely powdered
coal mixed with pre-heated air is then blown into the boiler by fan called
Primary Air Fan where it burns, more like a gas than as a solid in convectional
domestic or industrial grate, with additional amount of air called secondary air
supplied by Forced Draft Fan. As the coal has been grounded so finely the
resultant ash is also a fine powder. Some of this ash binds together to form
lumps which fall into the ash pits at the bottom of the furnace. The water
quenched ash from the bottom of the furnace is conveyed to pits for subsequent
disposal or sale. Most of ash, still in fine particles form is carried out of the boiler
to the precipitators as dust, where it is trapped by electrodes charged with high
voltage electricity. The dust is then conveyed by water to disposal areas or to

bunkers for sale while the cleaned flue gases pass on through ID Fan to be
discharged up the chimney.
Meanwhile the heat released from the coal has been absorbed by the many
kilometres of tubing which line the boiler walls. Inside the tubes is the boiler
feed water which is transformed by the heat into the steam at high pressure
and temperature. The steam super-heated in further tubes (Super Heater) passes
to the turbine where it is discharged through the nozzles on the turbine blades.
Just the energy of the wind turns the sail of the wind-mill, so the energy of the
steam, striking the blades, makes the turbine rotate.
Coupled to the end of the turbine is the rotor of the generator a large
cylindrical magnet, so that when the turbine rotates the rotor turns with it. The
rotor is housed inside the stator having heavy coils of copper bars in which
electricity is produced through the movement of the magnetic field created by
the rotor. The electricity passes from the stator winding to the step-up
transformer which increases its voltage so that it can be transmitted efficiently
over the power lines of the grid.
The steam which has given up its heat energy is changed back into water in the
condenser so that it is ready for re-use. The condenser contains many
kilometres of tubing through which the colder is constantly pumped. The steam
passing around the tubes looses the heat and is rapidly changed back to water.
But the two lots of water (i.e. boiler feed water & cooling water) must NEVER
MIX. The cooling water is drawn from the river, but the boiler feed water must be
absolutely pure, far purer than the water we drink, if it is not to damage the
boiler tubes. Chemistry at the power station is largely the chemistry of water.
To condense the large quantities of steam, huge and continuous volume of
cooling water is essential. In most of the power stations the same water is to be
used over and over again. So the heat which the water extracts from the steam
in the condenser is removed by pumping the water out to the cooling towers.
The cooling towers are simply concrete shells acting as huge chimneys
creating a draught (natural/mechanically assisted by fans) of air. The water is
sprayed out at the top of towers and as it falls into the pond beneath it is cooled
by the upward draught of air. The cold water in the pond is then circulated by
pumps to the condensers. Inevitably, however, some of the water is drawn
upwards as vapours by the draught and it is this which forms the familiar white
clouds which emerge from the towers seen sometimes.
Why bother to change steam from the turbine back into water if it has to be
heated up again immediately? The answer lies in the law of physics which states
that the boiling point of water is related to pressure. The lower the pressure, the
lower the temperature at which water boils. The turbine designer want as low
boiling point of water as possible because he can only utilize the energy of the
steam when the steam changes back into water he can get NO more work out
of it. So a condenser is built, which by rapidly changing the steam back into
water creates a vacuum. This vacuum results in a much lower boiling point
which, in turns, means he can continue getting work out of the steam well below
100 degree Celsius at which it would normally change into water.

Principle of the Steam Power Plant

The working principle of a steam plant is based upon the

Rankine cycle. Generally steam is taken as the working medium
due to its ability to be stable and that its readily stable. The
flow of steam in the plant can be very easily be understood by
the flow diagram of the plant. A graph plotted between the
temperature and the entropy would indicate the technical
details of the working by the rankine cycle. The entropy of a
system can be understood as an index of degradation of
energy.

PLANT FLOW DIAGRAM

H.T.SWITCH GEAR

OPERATIONG VOLTAGE - 6.6KV

For low voltage circuits fuses may be used to isolate the faulty circuit. For
voltage higher than 3.3 kV isolation is achieved by circuit breaker.

Requirement of circuit breaker:

1.

After occurrence of fault the switchgears must isolate the faulty circuit as
quickly as possible i.e. keeping the delay to minimum.

2.

It should not operate when an over current flows under healthy condition.

Basic principal of operation of circuit breaker:

Circuit breaker consists of a fix contact and sliding contact into which moves
a moving contact. The end of moving contact it attached to a handle that can
be manually operated or may operate automatically with the help of
mechanism that has a trip coil energized by secondary of CT. Under normal
condition the secondary of CT is not energized sufficiently to trip the coil but
under false condition the coil is energized fully to operate the trip coil and the
circuit breaker is operated.

1.

MOCB (Minimum oil circuit breaker)

2.

SF6 (Sulphur hexafluoride circuit breaker)

Here oil and SF6 are used to quench the arc.

L.T SWITCH GEAR

OPERATING VOLTAGE- 415VOLT

TYPES OF CIRCUIT BREAKER: - Air break circuit breaker

Air brake circuit breaker:

The arc interruption process of air- based circuit breaker is based on the natural
deionization of gases by cooling action. The arc is resilient and can be stretched,
and has a resistance, which can be increased both by length and confinement.
Hence the arc resistance is increased by stretching the arc and as the resistance
increases to higher value, the short circuit current drops to zero and arc is
extinguished.
Reducing the phase difference between the system voltage and the short circuit
current assure that when the are current is interrupt at its zero value, the
recovery voltage has very low value at its not allowed to reach 2-3 times the
value of the system peak voltage, a phenomenon that occurs in most cases,
when arc current is interrupted at low power factor.

GENERATORS AND TRANSFORMERS

INTRODUCTIONThe auxiliaries in a plant can be divided into two

categories1.

URGENT AUXILIARIES- the urgent auxiliaries are those, which are

associated with running of unit.

2.

SERVICE AUXILIARIES- the service auxiliaries are those whose loss would
not affect output.

GENERATOR

SPECIFICATIONS-

TURBO GENERATOR (gen1, gen2)

KVA

247000

Pf

0.85

Volts of stator

15750

Amperes of stator

9050

Volts of rotor

310

Amperes of rotor

2600

Rpm

3000

Hz

50

Phase

Connection

YY

Coolant

Water (stator)& hydrogen (rotor)

Gas pressure

3.5kg/cm-sq.

Insulation class

EXCITATION SYSTEM-

1.

STATIC EXCITATION SYSTEM-The generators in stage -1(u-1&u-2) have

this excitation system. Static excitation system has slip ring and carbon
brush arrangement. It consists of step down transformer, converter and
AVR (automatic voltage regulator).

2.

BRUSHLESS EXCITATION SYSTEM The generators in stage -2(U-3, U4& &U- 5) have this excitation system. It has two exciters, one is main
exciter and other is pilot exciter.

GENERATOR PROTECTION-

1.

STATOR PROTECTION- The neutral of star connected winding is

connected to primary of neutral grounding transformer, so that earth fault
current is limited by over voltage relay.

2.

DIFFERENTIAL PROTECTIONIn case of phase-to-phase fault

generator is protected by longitudinal differential relay.

3.

ROTOR PROTECTION- Rotor winding may be damaged by earth faults

or open circuits. The field is biased by a dc voltage, which causes current
to flow through the relay for an earth fault anywhere on the field system.

4.

OVER SPEED PROTECTION Mechanically over speed device that is

usually in the form of centrifugally operated rings mounted on the rotor
shaft, which fly out and close the stop valves if the speed of the set
increase more than 10%.

5.

OVER VOLTAGE PROTECTION

It is provided with an over voltage
relay. The relay is usually induction pattern. The relay open the main
circuit break and the field switch if the over voltage persists.

6.

SEAL OIL SYSTEM

Hydrogen in the generator is under very
high pressure. There is a possibility of this hydrogen to come out of gaps,
which is very hazardous. So, seal oil is used to seal the gaps so that
hydrogen doesnt come out.

7.

LUBRICATION OIL SYSTEM

Turbine lubrication-oil system seeks
to provide proper lubrication of turbo generator bearings and operation of
barring gear. Pumps are used to circulate lubrication-oil inside the
generator. The oil of the lubrication and the governing system is cooled in
the oil coolers. The cooling medium for these coolers is circulating water.

TRANSFORMER

TYPE PF TRANSFORMERS

1. GENRATOR TRANSFORMER: -This is a step up transformer. This supply

gets its primary supply from generator and its secondary supplies the
switchyard from where it is transmitted to grid. This transformer is oil
cooled. The primary of this transformer is connected in star. The
secondary is connected in delta. These are four in number.
2.

STATION TRANSFORMER: -- This transformer has almost the same

rating as the generator transformer. Its primary is connected in delta and
secondary in star. It is a step down transformer. These are 4 in number.

3.

UNIT AUXILIARY TRANSFORMER: -- This is a step down transformer.

The primary receives from generator and secondary supplies a 6.6 KV bus.
This is oil cooled. These are 8 in number.

4.

NEUTRAL GROUNDED TRANSFORMER: -This transformer is

connected with supply coming out of UAT in stage-2. This is used to
ground the excess voltage if occurs in the secondary of UAT in spite of
rated voltage.

SPECIFICATIONS

Generator transformer (GT-1 & GT-2)

KV

15.75/242

MVA

250

Phase

Hz

50

Connections

Y-D 11

Type of cooling

OFAF/ONAF/ONAN

Rated HV and IV (MVA)

250/150/100

Rated LV (MVA)

250/150/100

No Load Voltage HV (KV)

242

No Load Voltage IV (KV)

No Load Voltage LV (KV)

15.75

Line current HV (Amps)

597.14/358.29/238.86

Line current IV (Amps)

Line current LV (Amps)

9175.15/5505.09/3670.66

Temp rise coil oC

50

Temp rise winding oC

55

Neural grounded transformer (NGT)

KVA

1150

Phase

Hz

50

Type of cooling

ONAF/ONAN

No load voltage HV (volts)

6600

No load voltage LV (volts)

250

Line current HV (Amps)

105.9

Line current LV (Amps)

2655.8

Temp rise oil oC

50

Temp rise winding

55

Potential Transformer

KVA

1000

Phase

Hz

50

Type of Cooling

ONAN

No Load Voltage HV (volts) 6600

No Load Voltage LV (volts)

433

Line Current HV (Amps)

87.53

Line Current LV (Amps)

133.5

Temp rise oil oC

50

Temp rise winding oC

55

D.C SYSTEM

INTRODUCTION:

DC system is generally used for control and protection operation, as AC supply is

not fully dependable. To maintain constant supply in case of power failure we use
DC supply.
DC system consists of a battery charger. These are the mode of energy storage.

CHARGING EQUIPMENTS:

The battery charging equipment comprises of trickle charger, quick charger, battery panel, main
distribution board and switch control and signaling board.

CHARGING EQUATION:

In battery PbO2 used as positive plate and Pb as negative plate.

1.

DISCHARGING PROCESS

2.

CHARGING PROCESS

BATTERY CHARGER:

Battery charger normally operates in two modes.

1.

Float charging: It is constant voltage mode and works as a trickle charger.

2.

Boost charging: It is constant current mode and works as a quick charger.

TRICKLE CHARGER:

This charger is fed from three-phase ac supply and gives a dc-stabilized output at rated full load
current. The variation of the dc output voltage is limited to +/- 1% for 0 to 100% load variation and
simultaneously ac voltage variation of +/- 10% of frequency variation of +/- 5% from 50 Hz.

The rectification is obtained through full bridge controlled silicon rectifier. Stack comprising of these
SCR and three diode with the surge suppression RC network connected across each SCR and diode.

SWITCH YARD

As we know that electrical energy cant be stored like cells, so what we generate
should be consumed instantaneously. But as the load is not constants therefore
we generate electricity according to need i.e. the generation depends upon load.
The yard is the places from where the electricity is send outside. It has both
outdoor and indoor equipments.

SINGLE LINE DIAGRAM OF 220KV SWITCH YARD-

OUTDOOR EQUIPMENTS

1.

BUS BAR

2.

LIGHTENING ARRESTER

3.

WAVE TRAP

4.

BREAKER

5.

CAPACITOR VOLTAGE TRANSFORMER

6.

CORONA RING

7.

EARTHING ROD

8.

CURRENT TRANSFORMER

9.

POTENTIAL TRANSFORMER

10.

LIGHTENING MASK

11.

LIGHTENING MOOSE

INDOOR EQUIPMENTS

1.

RELAYS

2.

CONTROL PANELS

CIRCUIT BREAKER:

The code for circuit breaker is 52. An electric power system needs some form of switchgear
in order to operate it safely & efficiently under both normal and abnormal conditions.

Circuit breaker is an arrangement by which we can break the circuit or flow of

current. A circuit breaker in station serves the same purpose as switch but it has
many added and complex features. The basic construction of any circuit breaker
requires the separation of contact in an insulating fluid that servers two
functions:

1.

It extinguishes the arc drawn between the contacts when circuit breaker
opens.

2.

It provides adequate insulation between the contacts and from each

contact to earth.

The insulating fluids commonly used in circuit breakers are:

1.

Compressed air

2.

Oil which produces hydrogen for arc excitation.

3.

Ultra high vacuum

4.

Sulphur hexafluorides

The Specifications of the circuit breaker used are:

MAKE

CROMPTON GREAVES LTD.

TYPE

AIR BLAST CIRCUITREAKER

RATED VOLTAGE

245 KV

RATED LIGHTING IMPULSE

WITHSTAND VOLTAGE
RATED SHORT CIRCUIT BREAKING
CURRENT
RATED FREQUENCY

1050 KV
25 - 40KA
50HZ

RATED NORMAL CURRENT

2000 A TO 4000 A

RATED CLOSING VOLTAGE

220 V DC

RATED OPENING VOLTAGE

220 V DC

LIGHTING ARRESTER:

It saves the transformer and reactor from over voltage and over currents. We
have to use the lightning arrester both in primary and secondary of transformer
and in reactors.
A meter is provided which indicates the surface leakage and internal grading
current of arrester.

1.

Green arrester is healthy

2.

Red arrester is defective.

In case of red we first de-energize the arrester and then do the operation.

AIR BREAK EARTHING SWITCH:

The code of earthling switch is 5, 6, 7.The work of this equipment comes into
picture when we want to shut down the supply for maintenance purpose. This
help to neutralize the system from induced voltage from extra high voltage.
This induced power is up to 2KV in case of 400 KV lines.

The specification of earthling switch is:

MAKE

S & S POWER

TYPE

MADRAS

VOLTAGE

245 KV

CURRENT

10 KA

MOTOR VOLT (AC)

415 VOLTS

CONTROL VOLT (DC)

220 VOLTS

BUS BAR:

Bus bars generally are of high conductive aluminum conforming to IS-5082 or

copper of adequate cross section .Bus bar located in air insulated enclosures
& segregated from all other components .Bus bar is preferably cover with
polyurethane.

1.

Current Transformer (CT):

A current transformer is a type of instrument transformer designed to provide a

current in its secondary winding proportional to the alternating current flowing in
its primary

.
Current Transformer Diagram
Application:

1.

They are commonly used in metering and protective relaying in the electrical power
industry where they facilitate the safe measurement of large currents, often in the
presence of high voltages.

2.

The current transformer safely isolates measurement and control circuitry from the
high voltages typically present on the circuit being measured.

3.

Current transformers are used extensively for measuring current and monitoring the
operation of the power grid. The CT is typically described by its current ratio from
primary to secondary. Often, multiple CTs are installed as a "stack" for various uses
(for example, protection devices and revenue metering may use separate CTs).
Similarly potential transformers are used for measuring voltage and monitoring the
operation of the power grid.

4.

Capacitive Voltage Transformer (CVT):

A capacitor voltage transformer (CVT) is a transformer used in power systems

to step-down extra high voltage signals and provide low voltage signals either for
measurement or to operate a protective relay. In its most basic form the device
consists of three parts: two capacitors across which the voltage signal is split, an
inductive element used to tune the device to the supply frequency and a
transformer used to isolate and further step-down the voltage for the
instrumentation or protective relay as shown in figure below.

The device has at least four terminals, a high-voltage terminal for connection to
the high voltage signal, a ground terminal and at least one set of secondary
terminals for connection to the instrumentation or protective relay. CVTs are
typically single-phase devices used for measuring voltages in excess of one
hundred kilovolts where the use of voltage transformers would be uneconomical.

In practice the first capacitor, C1, is often replaced by a stack of capacitors

connected in series.This results in a large voltage drop across the stack of
capacitors that replaced the first capacitor and a comparatively small voltage
drop across the second capacitor C2, and hence the secondary terminals.

The total number of bays is 22. Out of which we have 3 spare bays.

Bay 1

250 MVA 15.75/242 kV Generator transformer 1

Bay 2

Spare 40 MVA 220/7.1 kV Station Transformer- 3

Bay 3

40 MVA 220/7.1 KV Station Transformer - 1

Bay 4

40 MVA 220/7.1 KV Station Transformer - 2

Bay 6

250 MVA 15.75/242 KV Generator Transformer -2

Bay 7

220 Kv (Chin hut) Luck now Feeder - 1

Bay 8

220 KV Luck now Feeder -2

Bay 9

Bus couplets 220 KV

Bay 10

220 KV Fateful Feeder - 1

Bay 11

220 KV Fateful Feeder - 2

Bay 12

220 KV by Pass Breaker

Bay 13

210 MW Generators -3

Bay 14

40 MVA 220/6.9 KV Station Transformer - 3

Bay 16

210 Mw Generators - 3

Bay 17

220 KV Transfer Bus Coupler- 2

Bay 19

220 KV Kanpur Feeders - 1

Bay 20

220 KV Kanpur Feeders - 2

Bay 21

220 KV Kanpur Feeders - 3

Bay 22

220 KV Kanpur Feeders - 4

COAL HANDLING PLANT

Introduction: -

NTPC Unchahar gets its coal supply mainly from Bihar. Now coal is also coming
from Australia, as coal produced in India is of low grade and ash content is more.
The coal being filled in the wagons of the rail reaches plant. The purpose of this
plant is to convey the coal to the bunker in the size not larger than 20mm.It
handles and transports the coal to the bunker from the wagons by passing
through various conveyors, transfer points, crusher houses, etc.

Type of coal: -

BCCL costs Rs.4/kg

CCl cost Rs.6/kg

Type of unloading the coal: -

1. Manual Unloading: Previously, manpower was used for unloading

the wagons. But it was very time consuming and more workers were required
for the job to be done.

2. Box in (using wagon tippler for unloading): This method is

still used in stage -1of NTPC Unchahar. For this method, Indian Railway grants
10 hours for unloading the 58 wagons. In this method, Wagons are separated
and tippled by using wagon tippler. The Beetle Feeder is used to move the
wagon on wagon tippler. The coal from the wagons gets accumulated in The
Track Hopper. At this time; the size of the coal is approximately 300mm.

3. BOBR: - This method is used in used in stage -2 of NTPC Unchahar. Indian

Railway grants only 2.5 hours for Unloading 58 BOBR wagons. This is an
advanced technology in which we use the compressor system.

In Bottom Open Bottom Release (BOBR) technology the wagons are opened
from side. Pressure is applied by the compressor to open the bottom gates of
the wagon so that the coal gets released over the track hopper and wagon
get unloaded quickly.

Various equipment used in CHP: -

1. WAGON TIPPLER: thermal power

project.

The wagon tippler is a most important device in

The Wagon tippler turns back the wagon at 135-degree angle and the
structure of the wagon tippler is to be very heavy. Upper side of the wagon is
fixed with the many angles for supporting the wagon. When the wagon is
fixed on the Platform then whole platform is turned back and the coal fall
down in the wagon tippler hopper. The unloading time of the Rack is 6hours.
Here the type of the rack is Box C / Box N type.

A- WTH, B-VF, C- BC, D- DS are the parts of the wagon tippler.

1.

Wagon Tippler Hopper: The Wagon tippler Hoper is a part of the

wagon tippler where the coal is stored from the wagon tippler. The size of
the coal here is less than 300mm.

2.

Vibrating Feeder: The vibrating feeder is used for falling the coal
on the conveyer through Wagon tippler Hoper. Before Wagon tippler Hoper
and Vibrating Feeder the gate is providing to control the flow of the coal.

3.

Beetle Charger: The Beetle charger is a traveling device that is

used to carry the wagon on the wagon tippler platform.

4.

Dust Suppuration: Dust Suppuration is a useful device. When

the wagon are tippling then the dust is mixed in the air and that area
becomes very dusty then Dust Suppuration operates and water flows
through its points and the dust settles down. It is an automatic device.

.
2. PADDLE FEEDER: - They have been installed on conveyors below the
manual
unloading track hopper. There are 6 nos. of paddle feeders, 3 on
each conveyer. 3 Paddle Feeders of each conveyer move to and fro within a
limiting range. The rotating part of the paddle feeder is called as plough
wheel. Plough wheel has 6 blades. By the rotation of the plough wheel, the
coal of the track hopper gets accumulated between the blades and is
discharged on the conveyor below it. The main components of paddle feeder
are:

1.

Plough wheel-It is the rotating part consists of 6 blades. It is attached

with the rotor of 3-phase slip ring induction motor.

2.

Reduction gear boxwheel.

3.

End limit switch (left or right)-It provides the limiting motion of the
paddle feeders.

4.

Anti-collision switch- It provides the prevention from collision between

two paddle feeders.

5.

Interlock system-It is provided for safety purpose. By this, the conveyor

belt moves first then paddle feeder starts.

It is installed to control the speed of plough

3. VIBRATING FEEDER: They have been installed below the track

hoppers of wagon tippler. The coal is accumulated over the vibrating feeder
so by giving vibrations to the vibrating feeder we discharge the coal from
track hopper to the conveyors. Their main purpose is to provide uniform
feeding on the conveyors. The vibrating feeders consist of a tray to which
vibrator body is fixed on the rear end.

4. TRANSFER POINTS: Transfer Point is provided with flap gate and

Conveyer. In transfer Point the coal is transferred from one conveyer to other
conveyer.

1.

Flap Gate: The flap Gate is a two-way device. It consists of two

gates. Both gates cannot operate together. By help of the flap Gate, we
change the way of coal that fall down on the conveyer.

2.

Conveyers: The Conveyer Belt is a moving device. It travels on its

platforms. The shape of the conveyer belt is to be flat but on the platforms
it is to be in curve shape. The coal falls down the conveyer and goes to the
primary Crusher House Platforms. The capacity of conveyer in Stage I is
800MT/ hr. & in Stage II is 1200MT / hr.

Many protecting device provide to the Conveyer--a -Zero Speed Switch, b -Pull Cord Switch, c - Belt Sway Switch

1.

Zero Speed Switch: - The Zero Speed Switch prevents the Conveyer
from over load run. When the conveyer is over loaded, the speed of the
conveyer is reduced and Zero Speed Switch is operated and stops the
conveyer. This device is provided at Head End of the Conveyer. The Zero
Speed Switch is a Centrifugal Switch.

2.

Pull cord Switch: This is a manual protecting device. When the

Worker sees any mistake like big stone or any dangerous fault, pulls this
cord. The Pull Cord Switch is to be operated, and the Conveyer stops.

3.

Belt Sway Switch: The Belt Sway Switch also protects the conveyer.
This device is provided on both side of the conveyer. When the conveyer
leaves its way the switch is operated and the conveyer stops. This is also
an automatic protecting device.

5.

PRIMARY CRUSHER (ROTARY BREAKER): - In Primary Crusher House, the

coal breaks in Rotary Breaker. Here the coal comes from the Transfer point;
breaks here and the stone fall down to a separate place. Coal is converted
from 300mm to 150mm size.
Part of the Primary Crusher House a- Rotary Breaker b- Belt Feeder

1.

ROTARY BREAKER: The Rotary Breaker has a rotating mechanism.

It is rotated on the shaft. The coal come from the conveyer through the
Flap Gate falls down into the rotary breaker. The rotary breaker is to be

rotated and coal moves up and down and collides and hence breaks. The
Rotary Breaker is H.T. 170KW
6.6KV Motor

2.

BELT FEEDER: The Belt Feeder is a small size of the conveyer. It is

used for feeding the coal to the conveyer through Flap Gate.

6.

SECONDARY CRUSHER (RING GRANULATOR): In Secondary crusher

House first the magnetic part separate from the coal and then feed to the
Secondary Crusher. This Crusher breaks the coal in 20mm size and coal is
sent to the Flap Gate and then feeded to the conveyer. The Secondary
crusher is hammer type. H.T. motor are used for breaking of the coal.
Specifications are 700KW 6.6KVMotor.

7.

CROSS BELT MAGNETIC SEPRATORS: They will remove the ferrous

particles, which passes along with the coal. It consists of electromagnet
around which a belt is moving. It is suspended from top, perpendicular to the
conveyor belt at certain height. Whenever any iron particle passes below the
CBMS, it is attracted by the magnet and stick to the cross belt below it. The
CBMS capacity is of 50kg.

8.

METAL DETECTOR: The purpose of installation is to detect any

metallic piece passing through the conveyor. Whenever the pieces pass below
the search coil of the metal detector, it gives the trip command to the
conveyor. Simultaneously, sand bag marker will fall on the conveyor belt so
that the metal can be searched easily and removed.

9.

STACKER/RECLAIMER: It is a very important device. The whole

Structure of it is called Super Structure. It stacks the excessive coal and
reclaims the coal on its requirement. It is a two-way device. It consists of
following main parts.

1.
Stacker: - The Stack is a position (1). When the rack comes, the
excessive coal is send to the stacker through the conveyer from Secondary
Crusher house. The coals are stacked at the Secondary Crusher Coal Heap.
The coal falls down from the stacker through Boom Conveyer.

2.
Reclaimer: The Reclaimer is position (2). When the rack is
not coming and there is a shortage of coal, then reclaiming is to be started

and the coal is lifted from the Secondary Crush Coal Heap and feeded to
the bunker.

3.
Boom Conveyer: The Boom conveyer is a Bi-directional
conveyer. It moves clockwise & anticlockwise direction. In stacking
position, it is moving in clockwise direction and in the reclaiming position
its moving in anticlockwise direction. They are provided with Center Chute
and End Chute on the both end.

4.
Boom hoist: The Boom hoist is a link of the Super Structure.
The hoist is moved up and down. For controlling the up & down position,
limit switch is provided.

5.
Slew drive: The Slew Drive moves at 180-degree. When the
coal is stored on both the side of the track of travel, then the Slew Drive
moves and lifts or fall the coal from Boom Conveyer. For control the
rotation of Slew Drive, the limit switch is provided.

6.
Bucket wheel: - The Bucket Wheel is used when there is a
requirement of the coal. It is a rotary device. It is always rotated in
anticlockwise. In the Reclaiming position, the Center Chute is to be up and
End Chute of the Boom Conveyer is fixed on the conveyer. The Bucket
Wheel rotates; when the Bucket of the wheel is full with coal and the
wheel is rotated the coal fall down on the Boom conveyer and the coal is
send to the Super Structure.

7.
Travel: It is a slip ring induction motor driven system. The
Super Structure moves on it. The normal speed of the Travel is 10 meter /
minute. It moves on its track from one end to other end.

10.

TRANSFER TOWER: Here the coal is send to the Tipper. Transfer

Tower is provided with a coal sampler.

11.

TIPPER: The Tipper is a three-way device to feed the coal in

Bunker. It is moveable device. It is move on its track.

12.

BUNKER: - Here the coal is collected from the tipper and stored. The
capacity of the bunker for Stage-I is 4800MT & Stage-II is 8700MT

COAL HANDLING PLANT POWER DISTRIBUTION SYSTEM

STAGE-1
S.NO

DRIVE
(CONVEYOR)

RATINGS (KW)

TYPE-F.L

MCC-1
1

CON1/A/B/C/D

75

NR-3 134A

CON2A/B (P)

125

BKR 228A

CON2A/B (S)

75

NR-3 143A

CON10A/B

125

BKR 228A

P/F 1-6 LCC

PLOUGH WHEEL

22

NR-34A

LONG TRAVEL

5.5

RV-11A

PCRD

2.2

NR-5A

SPEED CONTROL

0.25

RV-0.6

10

B/F-1, (PCH)

22

NR-2,37A

22

NR-2 37A

SF-2 100A

MCC-2
11

B/F-2 (PCH)

12

SUSPENDED MAG.

SF-1 63A

13

LIGHTING BOARD

SF-3 250A

14

DE-1 (SCH)

FSU-2 250A

15

MAG.SEP.(SCR)

SF-2 63A

16

VIB.SCREEN-1,
2(SCH)

37

NR-3 64A

17

CON-3A/B

160

BKR 269

18

CON-4A/B

55

NR-3 96A

19

B/F-4 (SCH)

22

NR-2 37A

MCC-3

20

CBMS-3 TP-8

63A

21

TT-1

63A

22

DE-4(BUNKER)

63A

23

DE-3(BUNKER)

250A

24

CON5A/B

110

BKR 195A

25

CON6A/B

125

BKR 228

26

CON7A/B

90

159A

27

CON8A/B(P)

160

BKR 269

28

CON8A/B(S)

75

BKR 134

29

CON9A/B

90

159A

30

CON12

125

BKR 228A

31

BEETLE
1,2

32

BAGOB TRIPLER-1,2 71

RV-126A

33

VIB.FEEDERS
1,2,3,4

SF-63A

CHARGER 55

STAGE 2

RV-98A

Equipment

Conv14

Conv15

KW

2*95

2*140

Conv16

2*115

Conv17

65

Conv18

160

Conv19

115

Conv20

315

Conv21

140

Conv22

140

Conv23

2*110

Conv24

110

Conv25

110

Conv26

2*115

R.B

160

Crusher

450

STAGE-2

S.No.

Drive (conveyor) Ratings (KW)

Type-F.L

CON14A/B

2*95

161

CON15A/B

2*140

237

CON16A/B

2*115

195

CON17A/B

65

115

CON18A/B

160

269

CON19A/B

115

195

CON20A/B (HT)

315

34

CON21A/B

140

237

CON22

140

237

10

CON23

2*110

182

11

CON24A/B

110

182

12

CON25A/B

110

182

13

CON26

2*115

195

14

R.B

160

269

15

CRUSHER (HT)

450

54

16

BELT FEEDER (SCH) 18.5

1,2

35

17

BELT FEEDER (PCH) 25

4,5

47

18

PADDLE FEEDER
7,8,9,10

45

80

19

S/R-2 BOOM
CONVEYOR

75

127

20

S/R-2 BUCKET
WHEEL

75

127

21

S/R-2 SLEW/TRAVEL
MOTOR 7.5(DC)

22

VGF 1,2,3,4

37

65

23

SWP 1A/B

115

195

24

SWP 2A/B

32

25

SUMP-PUMP

15

TERMS

FULL FORM

CBMS

Cross belt magnetic

separator

ILMS

Inline magnetic separator

PF

Paddle feeder

TT

Transfer tower

TP

Transfer point

MD

Metal detector

SM

Suspended magnet

RB

Rotary breaker

VGF

Vibro grizzly feed

RPG

Rack and pinion get

CR

Crusher rotary

RH

Reclaim hopper

VS

Vibrating screen

BF

Belt feeder

FG

Flap gate

TC

Telescopic chute

WT

Wagon tippler

PH

Pent house

PCH

Primary crusher house

SCH

Secondary crusher house

S/R

Stacker/Reclaimer

CO

Conveyor

CHP

Coal handling plant

TH

Track hopper

MCC

Motor control center

LCS

Local control switch

PCS

Pull card switch

BSS

Belt swag switch

ZSS

Zero speed switch

VF

Vibrating feeder

VF.

Vibrating fan

SOME IMPORTANT FACTS

Coal handling plant area

200acrs

Length of conveyor stage-1

13km

Length of conveyor stage-2

13.5km

M.U.T.H coal capacity stage -1

2800 M.T

New track hopper coal capacity stage

-2

5400M.T

Primary yard coal capacity stage -1

2.5 lac M.T

Secondary yard coal capacity stage -1 1.5 lac M.T

Secondary yard coal capacity stage-2

1.8 lac M.T

Bunker capacity stage -1

400*12=4800 M.T

Bunker capacity stage-2

730*12=8760 M.T

Coal used in 24 hrs(4 unit)

12000 M.T

Total plant area

970acrs

Total township area

280acrs

Coal import

CCI, BCCL

Water source

Sharda and dalmau canal

Power line (220kv)

Uncr-Lko(2 lines), Uncr-Fatehpur(2

lines), Uncr-Kanpur(4 lines)

Power export

Delhi, Punjab, Rajesthan, UP, Haryana,

Chandigarh, J & K, HP

DEMINERAL (DM) PLANT

INTRODUCTION: --

Water is required in plant for many purposes like for formation of steam, for
removal of ash, for safety during fire, etc. But the water required for the
formation of steam should be perfectly devoid of minerals because if minerals
are present in the steam and the steam strike the blades of the turbine, then due
to being high in pressure it produces scars or holes on the turbine blades.

PURIFICATION OF WATER: Water is purified in DM plant through a chain of processes as under: --

1.

Carbon filter
Water taken from the river is first sent to the
carbon filter for the removal of carbon contents in the water.

2.

Strong acid cation exchanger

After passing through the carbon
filter, water is sent to the strong acid cation exchanger, which is filled with
the concentrated HCL. The acid produces anions, which get combined with
the cations present in the water.

3.

Strong base anion exchanger

After that the water is sent to the
strong base anion exchanger, which is filled with the concentrated
NaOH.The base produces cations, which get combined with the anions
present in the water.

4.

Mixed bed exchanger And then water is sent to the chamber of mixed
bed exchanger where the remaining ions are removed. This is the last
stage of purification.

COAL, WATER & STEAM CYCLES

COAL CYCLE

C.H.P Plant
Boiler section

1.

Bunker

R.C Feeder

Pulverization mill

R.C Feeder: It is an induction motor driven device, which determine the

Quantity of coal enter in the pulverize mill.

2.

Pulverization mill:

Pulverization means exposing a large surface area

to the action of oxygen .Two Types of mill are used in the plant.

1.

Ball mail:

A ball mill operates normally under

suction. A large drum partly filled with steel balls, is used in this mill .The
drum is rotated slowly while coal is fed in to it .The ball pulverize the coal
by crushing. This type of mill is used in stage-1.

2.

Contact mail:

This mill uses impact principle. All the grinding

elements and the primary air fan are mounted on a single shaft. The flow
of air carries coal to the primary stage where it is reduced to a fine
granular state by impact with a series of hammers. This type of mill is
used in stage-2.

WATER CYCLE

D.M Plant
Hot well
C.E.P Pump
1, 2, 3
Derater
Boiler Feed Pump
Heater 5, 6
Feed Regulating station
Boiler Drum.
1. DERATER:
1.

Feed strong tank of water

Low Pressure Heater

High Pressure
Economizer

2.

To produce sufficient pressure before feeding to B.F.D.

3.

Filter the harmful chemicals.

2. FEED REGULATING STATIONS:

1.

Control the quantity of water in to boiler drum.

3. ECONOMISER:
2.
Flux gases coming out of the boilers carry lot of heat. An
economizer extracts a part of this heat from the flue gases and uses it for
heating the feed water.

4. DRAFTS SYSTEM:

3.
In forced draft system the fan is installed near the base of the boiler
furnace. This fan forces air through the furnace, economizer, air preheater
and chimney.
4.
In an induced draft system, the fan is installed near the base of
Chimney.

STEAM CYCLE

Boiler Drum
Ring Header
Boiler Drum (Steam chamber)
Super
Heater
H.P Turbine
Repeater
I.P Turbine
L.P Turbine
condenser

1.

BOILER:
Boiler drum consists two chambers water chamber, steam
chamber. Before Entering in super heater the steam is going in to boiler
drum, where the boiler drum filtered the moisture and stored in to water
chamber.

2.

SUPER HEATER:
The function of super heater is to remove the last
traces of moisture from the saturated steam leaving the tube boiler. The
temperature is approx.530 oC.

3.

TURBINE:
Steam turbine converts the heat energy in to mechanical
energy and drives the alternator. The velocity attained during expansions
depends on initial and final heat content of the steam. Turbine having
number of stages in which the pressure drops takes place.

Conclusion

On completion of my vocational training at Feroze Gandhi

Unchahar Thermal Power Project, Unchahar I have come to
know about how the very necessity of our lives nowadays i.e.,
electricity is generated. What all processes are needed to
generate and run the plant on a 24x7 basis.
NTPC Unchahar is one the plants in India to be under
highest load factor for the maximum duration of time and that
to operating at highest plant efficiencies. This plant is an
example in terms of working efficiency and management of
resources to all other thermal plants in our country. The
operating plf of the NTPC as compared to the rest of country is
the highest with 87.54% the highest since its inception.
The training gave me an opportunity to clear my concepts from
practical point of view with the availability of machinery of such
large rating.

Acknowledgements

Everything that happens in the world is an out come of interaction of various

factor, some of which are favourable while other not. Always for a desired result,
the number of favourable factors is more. This work is NO exception to this fact. I
acknowledge that Ive been fortunate enough to get the support, mentally and
physically in everything that I do.

First of all I would like to thank Shri Munish Jauhari, Honourable DGM
(EMD),NTPC Unchahar who led the entire team of FGUTP for functioning of
each department in a modernized and techno-commercial atmosphere to make
the project touch such peaking performance.

I would give our special thanks to Mr. Bimal Shah (HR-EDC) and Mr.A.K.Singh (Sr
Engg), for giving his very kind permission to undergo the training programme
under the able guidance of NTPC engineers. We would thank Mr .M V Sathe
(Supdt
Engg.),
Mr.
K.K.Singh
(HT
Switchgear),Mr.K.M.Gupta(HT
Switchgear),Mr.J.K.Sahu (LT Switchgear), Mr.H.Mukherjee (Motor Maintenance),
Mr.Rakesh(Supdt.,Switchyard) & Mr.Verma(CHP) under whose able guidance I
completed my training. All these people were of immense importance regarding
the knowledge and supports for the well furnished equipments. Special gratitude
towards Mr.Ranjeet Prasad Singh who provided us the best moral support which I
was in need for.

I greatly acknowledge the help and the mental strength provided by our entire
family for encouraging me and providing me knowledge & guidance related with
every deptt. of NTPC, FGTUP.

At last I conclude by thanking all the employees of NTPC, FGTUP (both executives
& workers) who helped me in making our training a boon for me.

Mayur
Btech Final Year, Electrical Engineering
Motilal Nehru National Institute of Technology,Allahabad.