JUNE - JULY

2016
Summer Training Report

SUBMITTED BY:
JAIRAM THAKUR
IVth Sem / IInd Year
MECHANICAL ENGINEERING
ROLL NO. 1408131045
PUSA INSTITUTE OF TECHNOLOGY
UCHNJ

PFV
NE
TECHNOLOGY

ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey my thanks to
complete the training here.
I do extend my heartfelt thanks to Mr. Virendra Singh NegI for providing me this
opportunity to be a part of this esteemed organization.
I am extremely grateful to all the technical staff of BTPS / NTPC for their cooperation and guidance that has helped me a lot during the course of training. I have
learnt a lot working under them and I will always be indebted of them for this value
addition in me.
I would also like to thank the training incharge of Pusa Institute Of Technology, Delhi
and all the faculty members of Mechanical Engineering Department for their effort of
constant co- operation, which have been a significant factor in the accomplishment of
my industrial training.

JAI
RAM
THAKUR
PUSA
INSTITUTE
TECHNOLOGY,
NEW DELHI-110012

OF

TRAINING AT BTPS
I was appointed to do 4 week training at this esteemed organization from 13th June to
09th July 2016. I was assigned to visit various division of the plant, which were:
Boiler Maintenance Department (BMD I/II/III)
Plant Auxiliary Maintenance (PAM)
Turbine Maintenance Department (TAM)
These 4 weeks training was a very educational adventure for me. It was really
amazing to see the plant by yourself and learn how electricity, which is one of our
daily requirements of life, is produced.
This report has been made by my experience at BTPS. The material in this report has
been gathered from my textbook, senior student reports and trainers manuals and
power journals provided by training department. The specification and principles are
as learned by me from the employees of each division of BTPS.

JAIRAM THAKUR

ABOUT NTPC
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NTPC Limited is the largest thermal power generating company of India, Public Sector Company. It was
incorporated in the year 1975 to accelerate power development in the country as a wholly owned company of the
Government of India. At present, Government of India holds 89.5% of the total equity shares of the company and
the balance 10.5% is held by FIIs, Domestic Banks, Public and others. Within a span of 31 years, NTPC has
emerged as a truly national power company, with power generating facilities in all the major regions of the
country.
NTPC's core business is engineering, construction and operation of power generating plants and providing
consultancy to power utilities in India and abroad.
The total installed capacity of the company is 31134 MW (including JVs) with 15 coal based and 7 gas based
stations, located across the country. In addition under JVs, 3 stations are coal based & another station uses
naphtha/LNG as fuel. By 2017, the power generation portfolio is expected to have a diversified fuel mix with coal
based capacity of around 53000 MW, 10000 MW through gas, 9000 MW through Hydro generation, about 2000
MW from nuclear sources and around 1000 MW from Renewable Energy Sources (RES). NTPC has adopted a
multi-pronged growth strategy which includes capacity addition through green field projects, expansion of existing
stations, joint ventures, subsidiaries and takeover of stations.

NTPC has been operating its plants at high efficiency levels. Although the company has 18.79% of the total
national capacity it contributes 28.60% of total power generation due to its focus on high efficiency. NTPCs share
at 31 Mar 2001 of the total installed capacity of the country was 24.51% and it generated 29.68% of the power of
the country in 2008-09. Every fourth home in India is lit by NTPC. 170.88BU of electricity was produced by its
stations in the financial year 2005-2006. The Net Profit after Tax on March 31, 2006 was INR 58,202 million. Net
Profit after Tax for the quarter ended June 30, 2006 was INR 15528 million, which is 18.65% more than for the
same quarter in the previous financial year. 2005).

ABOUT BTPS
Badarpur thermal power station started working in 1973 with a single 95 mw unit. There were 2 more units (95
MW each) installed in next 2 consecutive years. Now it has total five units with total capacity of 720 MW.
Ownership of BTPS was transferred to NTPC with effect from 01.06.2006 through GOIs Gazette Notification
.Given below are the details of unit with the year they are installed.
Address:
Telephone:
Fax:
Installed Capacity
Derated Capacity

Badarpur, New Delhi 110 044

(STD-011) - 26949523
26949532
720 MW
705 MW

Location
Coal Source
Water Source
Beneficiary States
Unit Sizes

New Delhi
Jharia Coal Fields
Agra Canal
Delhi
3X95 MW

Units Commissioned

2X210 MW
Unit I- 95 MW - July 1973
Unit II- 95 MW August 1974
Unit III- 95 MW March 1975
Unit IV - 210 MW December 1978

Transfer of BTPS to NTPC

Unit V - 210 MW - December 1981

Ownership of BTPS was transferred to NTPC with effect from
01.06.2006 through GOIs Gazette Notification

BASIC STEPS OF ELECTRICITY GENERATION

The basic steps in the generation of electricity from coal involves following steps:

Coal to steam
5

Steam to mechanical power

Mechanical power to electrical power

COAL TO ELECTRICITY: BASICS

The basic steps in the generation of coal to electricity are shown below:

Coal to Steam
Coal from the coal wagons is unloaded in the coal handling plant. This Coal is transported up to the raw coal
bunkers with the help of belt conveyors. Coal is transported to Bowl mills by Coal Feeders. The coal is pulverized
in the Bowl Mill, where it is ground to powder form. The mill consists of a round metallic table on which coal
particles fall. This table is rotated with the help of a motor. There are three large steel rollers, which are spaced
120 apart. When there is no coal, these rollers do not rotate but when the coal is fed to the table it packs up
between roller and the table and ths 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-Preheaters 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.

I.

BOILER MAINTENANCE DEPARTMENT

Boiler and Its Description

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The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls are made of a web
of high pressure steel tubes about 2.3 inches (60 mm) in diameter. Pulverized coal is air-blown into the furnace
from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the centre. The thermal
radiation of the fireball heats the water that circulates through the boiler tubes near the boiler perimeter. The water
circulation rate in the boiler is three to four times the throughput and is typically driven by pumps. As the water in
the boiler circulates it absorbs heat and changes into steam at 700 F (370 C) and 3,200 psi (22.1MPa). It is
separated from the water inside a drum at the top of the furnace.

Boiler Side of the Badarpur Thermal Power Station, New Delhi

The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion
gases as they exit the furnace. Here the steam is superheated to 1,000 F (540 C) to prepare it for the turbine. The
steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam
turbine that drives the electrical generator.

Schematic diagram of a coal-fired power plant steam generator

AUXILIARIES OF THE BOILER

1. FURNACE

Furnace is primary part of boiler where the chemical energy of the fuel is converted to thermal energy by
combustion. Furnace is designed for efficient and complete combustion. Major factors that assist for
efficient combustion are amount of fuel inside the furnace and turbulence, which causes rapid mixing
between fuel and air. In modern boilers, water furnaces are used.
2. BOILER DRUM
Drum is of fusion-welded design with welded hemispherical dished ends. It is provided with stubs for
welding all the connecting tubes, i.e. downcomers, risers, pipes, saturated steam outlet. The function of
steam drum internals is to separate the water from the steam generated in the furnace walls and to reduce
the dissolved solid contents of the steam below the prescribed limit of 1 ppm and also take care of the
sudden change of steam demand for boiler.
The secondary stage of two opposite banks of closely spaced thin corrugated sheets, which direct the steam
and force the remaining entertained water against the corrugated plates. Since the velocity is relatively low
this water does not get picked up again but runs down the plates and off the second stage of the two steam
outlets.

External View of an Industrial Boiler at BTPS, New Delhi

3. REHEATER
Reheater is used to raise the temperature of steam from which a part of energy has been extracted in high
pressure turbine. This is another method of increasing the cycle efficiency. Reheating requires additional
equipment i.e. heating surface connecting boiler and turbine pipe safety equipment like safety valve, non
return valves, isolating valves, high pressure feed pump, etc: Reheater is composed of two sections namely
the front and the rear pendant section, which is located above the furnace arc between water-cooled, screen
wall tubes and rear wall tubes.

Tubes of a reheater

4. SUPERHEATER
Whatever type of boiler is used, steam will leave the water at its surface and pass into the steam space.
Steam formed above the water surface in a shell boiler is always saturated and become superheated in the
boiler shell, as it is constantly. If superheated steam is required, the saturated steam must pass through a
superheater. This is simply a heat exchanger where additional heat is added to the steam.
5. ECONOMIZER
The function of an economizer in a steam-generating unit is to absorb heat from the flue gases and add as a
sensible heat to the feed water before the water enters the evaporation circuit of the boiler.
Earlier economizer were introduced mainly to recover the heat available in the flue gases that leaves the
boiler and provision of this addition heating surface increases the efficiency of steam generators. In the
modern boilers used for power generation feed water heaters were used to increase the efficiency of turbine
unit and feed water temperature.

An economizer

6. AIR PREHEATER
Air preheater absorbs waste heat from the flue gases and transfers this heat to incoming cold air, by means
of continuously rotating heat transfer element of specially formed metal plates. Thousands of these high
efficiency elements are spaced and compactly arranged within 12 sections. Sloped compartments of a
radially divided cylindrical shell called the rotor. The housing surrounding the rotor is provided with duct
connecting both the ends and is adequately scaled by radial and circumferential scaling.

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An air preheater

7. PULVERIZER
A pulverizer is a mechanical device for the grinding of many types of materials. For example, they are used
to pulverize coal for combustion in the steam-generating furnaces of the fossil fuel power plants.

A Pulverizer

Advantages of Pulverized Coal

Pulverized coal is used for large capacity plants.

It is easier to adapt to fluctuating load as there are no limitations on the combustion capacity.
Coal with higher ash percentage cannot be used without pulverizing because of the problem of large

amount ash deposition after combustion.

Increased thermal efficiency is obtained through pulverization.
The use of secondary air in the combustion chamber along with the powered coal helps in creating
turbulence and therefore uniform mixing of the coal and the air during combustion.

II.

PLANT AUXILIARY MAINTENANCE

1. WATER CIRCULATION SYSTEM

Theory of Circulation

11

Water must flow through the heat absorption surface of the boiler in order that it be evaporated into steam. In drum
type units (natural and controlled circulation), the water is circulated from the drum through the generating circuits
and then back to the drum where the steam is separated and directed to the super heater. The water leaves the drum
through the down corners at a temperature slightly below the saturation temperature. The flow through the furnace
wall is at saturation temperature. Heat absorbed in water wall is latent heat of vaporization creating a mixture of
steam and water. The ratio of the weight of the water to the weight of the steam in the mixture leaving the heat
absorption surface is called circulation ratio.
Types of Boiler Circulating System
i.
ii.
iii.
i.

Natural circulation system

Controlled circulation system
Combined circulation system
Natural Circulation System

Water delivered to steam generator from feed water is at a temperature well below the saturation value
corresponding to that pressure. Entering first the economizer, it is heated to about 30-40C below saturation
temperature. From economizer the water enters the drum and thus joins the circulation system. Water entering the
drum flows through the down corner and enters ring heater at the bottom. In the water walls, a part of the water is
converted to steam and the mixture flows back to the drum. In the drum, the steam is separated, and sent to
superheater for superheating and then sent to the high-pressure turbine. Remaining water mixes with the incoming
water from the economizer and the cycle is repeated.
As the pressure increases, the difference in density between water and steam reduces. Thus the hydrostatic head
available will not be able to overcome the frictional resistance for a flow corresponding to the minimum
requirement of cooling of water wall tubes. Therefore natural circulation is limited to the boiler with drum
operating pressure around 175 kg/ cm2.
ii.

Controlled Circulation System

Beyond 80 kg/ cm2 of pressure, circulation is to be assisted with mechanical pumps to overcome the frictional
losses. To regulate the flow through various tubes, orifices plates are used. This system is applicable in the high
sub-critical regions (200 kg/ cm2).

2. WATER TREATMENT PLANT

As the types of boiler are not alike their working pressure and operating conditions vary and so do the types and
methods of water treatment. 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

12

water. No doubt, this plant has to be engineered very carefully keeping in view the type of raw water to the
thermal plant, its treatment costs and overall economics.

A water treatment plant

The type of demineralization process chosen for a power station depends on three main factors:
i.
ii.
iii.

The quality of the raw water.

The degree of de-ionization i.e. treated water quality.
Selectivity of resins.

Water treatment process is generally made up of two sections:

Pretreatment section.
Demineralization section

Pretreatment Section
Pretreatment plant removes the suspended solids such as clay, silt, organic and inorganic matter, plants and other
microscopic organism. The turbidity may be taken as two types of suspended solid in water; firstly, the separable
solids and secondly the 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 settle able. Long term ability to remain
suspended in water is basically a function of both size and specific gravity.
3. DRAUGHT SYSTEM
There are four types of draught system:

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i.
Natural Draught
ii.
Induced Draught
iii.
Forced Draught
iv. Balanced Draught
4. INDUSTRIAL FANS
ID Fan
The induced Draft Fans are generally of Axial-Impulse Type. Impeller nominal diameter is of the order of 2500
mm. The fan consists of the following sub-assemblies:

Suction Chamber
Inlet Vane Control
Impeller
Outlet Guide Vane Assembly

An ID fan

FD Fan
The fan, normally of the same type as ID Fan, consists of the following components:

Silencer
Inlet Bend
Fan Housing
Impeller with blades and setting mechanism

An FD fan

The centrifugal and setting forces of the blades are taken up by the blade bearings. The blade shafts are placed in
combined radial and axial anti-friction bearings, which are sealed off to the outside. The angle of incidence of the
blades may be adjusted during operation. The characteristic pressure volume curves of the fan may be changed in
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a large range without essentially modifying the efficiency. The fan can then be easily adapted to changing
operating conditions.
Primary Air Fan
PA Fan if flange-mounted design, single stage suction, NDFV type, backward curved bladed radial fan operating
on the principle of energy transformation due to centrifugal forces. Some amount of the velocity energy is
converted to pressure energy in the spiral casing. The fan is driven at a constant speed and varying the angle of the
inlet vane control controls the flow. The special feature of the fan is that is provided with inlet guide vane control
with a positive and precise link mechanism.

Primary air fan

5. COMPRESSOR HOUSE
Instrument air is required for operating various dampers, burner tilting, devices, diaphragm valves, etc: in the 210
MW units. Station air meets the general requirement of the power station such as light oil atomizing air, for
cleaning filters and for various maintenance works. The control air compressors and station air compressors have
been housed separately with separate receivers and supply headers and their tapping.

A compressor house

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Service Air Compressor

The station air compressor is generally a slow speed horizontal double acting double stage type and is arranged for
belt drive. The cylinder heads and barrel are enclosed in a jacket, whih extends around the valve also. The
intercooler is provided between the low and high pressure cylinder which cools the air between tag and collects
the moisture that condenses.

A service air compressor

III.

TURBINE MAINTENANCE DEPARTMENT

TURBINE CLASSIFICATION:
1. Impulse turbine:
In impulse turbine steam expands in fixed nozzles. The high velocity steam from nozzles does work on
moving blades, which causes the shaft to rotate. The essential features of impulse turbine are that all
pressure drops occur at nozzles and not on blades.
2. Reaction turbine:
In this type of turbine pressure is reduced at both fixed and moving blades. Both fixed and moving blades
act like nozzles. Work done by the impulse effect of steam due to reverse the direction of high velocity
steam. The expansion of steam takes place on moving blades.

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A 95 MW Generator at BTPS, New Delhi

MAIN TURBINE:
The 210MW turbine is a cylinder tandem compounded type machine comprising of H.P. and I.P and L.P cylinders.
The H.P. turbine comprises of 12 stages the I.P turbine has 11 stages and the L.P has four stages of double flow.
The H.P and I.P. turbine rotor are rigidly compounded and the I.P. and L.P rotor by lens type semi flexible
coupling. All the 3 rotors are aligned on five bearings of which the bearing number is combined with thrust
bearing.
The main superheated steam branches off into two streams from the boiler and passes through the emergency stop
valve and control valve before entering the governing wheel chamber of the H.P. Turbine. After expanding in the
12 stages in the H.P. turbine then steam is returned in the boiler for reheating.
The reheated steam from boiler enters I.P. turbine via the interceptor valves and control valves and after expanding
enters the L.P stage via 2 numbers of cross over pipes.
In the L.P. stage the steam expands in axially opposed direction to counteract the thrust and enters the condenser
placed directly below the L.P. turbine. The cooling water flowing through the condenser tubes condenses the
steam and the condensate the collected in the hot well of the condenser.
The condensate collected the pumped by means of 3x50% duty condensate pumps through L.P heaters to deaerator
from where the boiler feed pump delivers the water to the boiler through H.P. heaters thus forming a closed cycle.
STEAM TURBINE
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam and converts it into
useful mechanical work.
From a mechanical point of view, the turbine is ideal, because the propelling force is applied directly to the
rotating element of the machine and has not as in the reciprocating engine to be transmitted through a system of
connecting links, which are necessary to transform a reciprocating motion into rotary motion. Hence since the
steam turbine possesses for its moving parts rotating elements only if the manufacture is good and the machine is
correctly designed, it ought to be free from out of balance forces.
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MAIN TURBINE
The 210 MW turbine is a tandem compounded type machine comprising of H.P. and I.P. cylinders. The H.P.
turbines comprise of 12 stages, I.P. turbine has 11 stages and the L.P. turbine has 4 stages of double flow.
The H.P. and I.P. turbine rotors are rigidly compounded and the L.P. motor by the lens type semi flexible coupling.
All the three rotors are aligned on five bearings of which the bearing no. 2 is combined with the thrust bearing

18

The Main Turbine

TURBINE CYCLE
Fresh steam from the boiler is supplied to the turbine through the emergency stop valve. From the stop valves
steam is supplied to control valves situated in H.P. cylinders on the front bearing end. After expansion through 12
stages at the H.P. cylinder, steam flows back to the boiler for reheating steam and reheated steam from the boiler
cover to the intermediate pressure turbine through two interceptor valves and four control valves mounted on I.P.
turbine.
After flowing through I.P. turbine steam enters the middle part of the L.P. turbine through cross-over pipes. In L.P.
turbine the exhaust steam condenses in the surface condensers welded directly to the exhaust part of L.P. turbine.
The selection of extraction points and cold reheat pressure has been done with a view to achieve a high efficiency.
These are two extractors from H.P. turbine, four from I.P. turbine and one from L.P. turbine. Steam at 1.10 and
1.03 g/sq. cm. Abs is supplied for the gland sealing. Steam for this purpose is obtained from deaerator through a
collection where pressure of steam is regulated.
From the condenser, condensate is pumped with the help of 3*50% capacity condensate pumps to deaerator
through the low-pressure regenerative equipments.
Feed water is pumped from deaerator to the boiler through the H.P. heaters by means of 3*50% capacity feed
pumps connected before the H.P. heaters.

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The Turbine Cycle

CONDENSER
There are two condensers entered to the two exhausters of the L.P. turbine. These are surface-type condensers with
two pass arrangement. Cooling water pumped into each condenser by a vertical C.W. pump through the inlet pipe.
Water enters the inlet chamber of the front water box, passes horizontally through brass tubes to the water tubes to
the water box at the other end, takes a turn, passes through the upper cluster of tubes and reaches the outlet
chamber in the front water box. From these, cooling water leaves the condenser through the outlet pipe and
discharge into the discharge duct.
Steam exhausted from the LP turbine washes the outside of the condenser tubes, losing its latent heat to the
cooling water and is connected with water in the steam side of the condenser. This condensate collects in the hot
well, welded to the bottom of the condensers.

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