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NTPC is India’s largest energy conglomerate with roots planted way back in 1975 to accelerate
power development in India. Since then it has established itself as the dominant power major
with presence in the entire value chain of the power generation business. From fossil fuels it has
forayed into generating electricity via hydro, nuclear and renewable energy sources. This foray
will play a major role in lowering its carbon footprint by reducing green house gas emissions. To
strengthen its core business, the corporation has diversified into the fields of consultancy, power
trading, training of power professionals, rural electrification, ash utilisation and coal mining as
well.
NTPC became a Maharatna company in May 2010, one of the only four companies to be
awarded this status. NTPC was ranked 400th in the ‘2016, Forbes Global 2000’ ranking of the
World’s biggest companies.
NTPC is India’s largest energy conglomerate with roots planted way back in 1975 to accelerate
power development in India. Since then it has established itself as the dominant power major
with presence in the entire value chain of the power generation business. From fossil fuels it has
forayed into generating electricity via hydro, nuclear and renewable energy sources. This foray
will play a major role in lowering its carbon footprint by reducing green house gas emissions. To
strengthen its core business, the corporation has diversified into the fields of consultancy, power
trading, training of power professionals, rural electrification, ash utilisation and coal mining as
well.
NTPC became a Maharatna company in May 2010, one of the only four companies to be
awarded this status. NTPC was ranked 400th in the ‘2016, Forbes Global 2000’ ranking of the
World’s biggest companies.
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Figure 1 : Growth In Installed Capacity
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1.2) INSTALLED CAPACITY
Coal 21 40,355
Hydro 1 800
Wind 1 50
Total 42 46,100
Owned By JVs/Subsidiaries
Total 51 53,651
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NATIONAL CAPITAL POWER STATION (NCPS) OR NTPC DADRI
It is the power project to meet the power demand of National Capital Region (India). It has a
huge coal-fired thermal power plant and a gas-fired plant and has a small township located in
Uttar Pradesh, India for its employees. It is located in Gautam Budh Nagardistrict of Uttar
Pradesh about 25 km from Ghaziabad and about 9 km from Dadri. It isnearly 48 km from New
Delhi towards Hapur. NTPC Dadri is a branch of NationalThermal Power Corporation, which is
a public sector now
NTPC Dadri is a unique power plant of NTPC group which has both coal based thermal plant
and gas based the8Urmal plant of 1820 MW and 817 MW respectively and 5 MW solar plant
totaling 2642 MW
The coal-based station mainly meets power requirements of the National Capital Region [NCR],
and the northern grid. With the World Bank funding component, the capital cost of the units is
Rs. 16.69 billion. There are four 210 MW coal based units. The units have a coal-fired boiler and
a steam turbine each. The boiler design is also suitable for 100% operations with heavy furnace
oil firing. For this, three storage tanks, each of capacity 15,000 kL, enough for 10 days
continuous oil firing requirements have been provided for the boilers.
The coal is transported from the Piparwar block of mines of the North Karanpura Coalfields of
Bihar, over a distance of about 1,200 kms., by the Indian Railways bottom discharge, and Box
'N' type of wagons. The coal requirements for the four units are 15,000 M.T. each day, 3.67
million tonnes annually. The station has its own 14 kms. Long rail track from the Dadri Railway
Station, to the site, and a 6 km in-plant track, on electric traction.
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2.2) NATIONAL CAPITAL POWER STATION – STAGE II(2X490MW)
The stage-II (490MW*2) coal based units are scheduled in 2010 to meet the common wealth
games power requirement. The commercial operation of Stage-II Unit-V 490 MW has been
declared w.e.f 31.01.2010 00:00 Hrs. by Shri Sushil Kumar Shinde honourable Minister of
Power .
The On-Grid type solar PV plant at NTPC Dadri, spread over 27.400 Acre, has the 5MW
capacity. The commercial operation was started on 29th March 2013. It has 20,856 PV modules;
each PV module generating a power of 240.944W.One string consists of 24 PV modules and 18
such string connected in parallel to one SCB leading to power O/p of 104.087KW from one
SCB. 5 nos. SCBs are connected to one inverter. Total 10 nos. of inverters are installed giving
total solar power of 5.20435MW.
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Figure 4: PV solar panel
From solar generation to transmission one underground line has been laid having length around
4.2 KM. at the end of the line one 7.5 MVA, 33/220 KV transformer has been installed at
switchyard of Dadri Gas. Here this incoming solar power is sent to 220 KV bus through SF-6
Circuit breaker and other electrical switchgears.
The gas-based station at N.C.P.S. is the country's largest. It has two modules; each module
consists of two gas turbines of 130.19 MW each with one waste heat recovery boiler and one
steam turbine of 154.51 MW capacity. The power from this plant is allocated to Uttar Pradesh,
and also to Delhi, Punjab, Jammu and Kashmir, Haryana, Himachal Pradesh and Rajasthan. The
cost of gas based modules is Rs. 9.75 billion, which includes a German K.f. W. funding . The
modules are fully commissioned. Gas turbines generate power at an efficiency of about 32%
only, and to utilize the rest of this energy, a combined cycle system is adopted. The waste heat
from the gas turbine exhaust is routed through the waste heat recovery boiler, and the steam thus
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generated is utilized in a conventional steam turbine to generate additional power. By this, the
overall efficiency of fuel heat utilization reaches to about 48%.
The source of fuel for this plant is the reserves of South Bassein fields in South Tapi and mid
Tapi delta in the Arabian Sea. The natural gas from South Bassein off shore fields is transported
through a submarine pipeline to Hazira onshore terminal and then through the 1,700 kms. Long
Hazira-Bijapur pipeline via Shahjanpur and Babrala to the project . For the 829 MW project, the
requirement is 3.00 million cubic meters per day (yearly average). It would be worthwhile to
note that within a short span of less than 7 years, both the coal and gas based power cycle
units/modules have been commissioned in a project. Both the projects have diverse modern
technologies, with the latest process controls.
The gas for the power plant is sourced from GAIL HBJ Pipeline, it also supports HSD as
alternate fuel.
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THERMAL POWER PLANT
Components:
1. Boiler
A Boileris an enclosed vessel that provides a means for combustion heatto be transferred into
water until it becomes heated water or steam. The hotwater or steam under pressure is then
usable for transferring the heat to aprocess. Water is a useful and cheap medium for
transferring heat to aprocess. When water is boiled into steam its volume increases about
1,600times, producing a force that is almost as explosive as gunpowder. This causesthe boiler
to be extremely dangerous equipment that must be treated withutmost care.
2. Steam Turbine
Turbine rotary engine that converts the energy of a moving stream of water, steam, or gas into
mechanical energy. The basic element in a turbine is a wheel or rotor with paddles,
propellers, blades, or buckets arranged on its circumference in such a fashion that the moving
fluid exerts a tangential force that turns the wheel and imparts energy to it. This mechanical
energy is then transferred through a drive shaft to operate a machine, compressor, electric
generator, or propeller. Turbines are classified as hydraulic, or water, turbines, steam
turbines, or gas turbines. Today turbine-powered generators produce most of the world's
electrical energy. Windmills that generate electricity are known as wind turbines.
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Technical specification:
Manufacturer : BHEL
Capacity : 490 MW
Type : Two Cylinder
Condensing Reaction
No of Stages HP : 2 x 22
LP : 2x7
Type of governing : Throttle
Double flow,
LP/ HP cylinder : Horizontally
split
NO of shells HP : 2
No of shells LP : 3
Turbine inlet pressure : 61.75 bar
o
Turbine inlet temp. : 528.6 C
Turbine exhaust pressure : 0.1122 bar
No load steam flow : 16 t/hr.
Steam flow at rated condition :
HP : 451.8 t/hr.
LP : 537.8 t/hr.
Critical speed : 3000 rpm
Governing System : Electrohydraulic
Max Noise level : 85 db
HP/ LP bypass : 115 db
No of Stop valves HP : 2
LP : 2
No of control valves HP : 2
HP : 2
Combined stop &
Type of valves : control
Valves.
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3. Daerator:
A deaerators is a device that is widely used for the removal of air andother dissolvedgasesfrom
the feed water to steam generating boilers. In particular, dissolved oxygen in boiler feed
waters will cause serious corrosiondamage in steam systems by attaching to the walls of
metal piping and other metallic equipment and forming oxides (rust). It also combines with
any dissolved carbon dioxide to form carbonic acid that causes further corrosion. Most
deaerators are designed to remove oxygen down to levels of 7 ppb byweight (0.0005 cm³/L)
or less.
4. Heat Exchanger:
Heat exchangers are equipment that transfers heat from one mediumto another. The proper
design, operation and maintenance of heat exchangers will make the process energy efficient
and minimize energy losses. Heatexchanger performance can deteriorate with time, off
design operations andother interferences such as fouling, scaling etc. It is necessary to
assessperiodically the heat exchanger performance in order to maintain them at a high
efficiency level. Heat exchangers may be classified according to their flow arrangement. In
parallel-flow heat exchangers, the two fluids enter the exchanger at thesame end, and travel in
parallel to one another to the other side. In counter- flow heat exchangers the fluids enter the
exchanger from opposite ends. Thecounter current design is most efficient, in that it can
transfer the most heat.See countercurrent exchange. In a cross-flow heat exchanger, the fluids
travel roughly perpendicular to one another through the exchanger.
5. Super Heaters:
Asuper heateris a device in a steam engine that heats the steam generated by the boiler again,
increasing its thermal energy and decreasing the likelihood that it will condense inside the
engine. Super heaters increase the efficiency of the steam engine, and were widely adopted.
Steam which has beensuperheated is logically known as superheated steam; non-superheated
steam is called saturated steam or wet steam .Super heaters were applied tosteam
locomotivesin quantity from the early20th century, to most steam vehicles, and to stationary
steam enginesincluding power stations.
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6. Condensor:
The surface condenser is a shell and tube heat exchanger in which cooling water is circulated
through the tubes. The exhaust steam from the low pressure turbine enters the shell where it
is cooled and converted tocondensate (water) by flowing over the tubes as shown in the
adjacent diagram. Such condensers use steam ejectors or rotary motor-driven exhausters for
continuous removal of air and gases from the steam side to maintain vacuum. For best
efficiency, the temperature in the condenser must be kept as low as practical in order to
achieve the lowest possible pressure in the condensing steam. Since the condenser
temperature can almost always be kept significantly below 100C where the vapor pressure of
water is much lessthan atmospheric pressure, the condenser generally works under vacuum.
7. Economizer:
8. Electric Generator:
In electricity generation, an electrical generator is a device that converts mechanical energy to
electrical energy, generally using electromagnetic induction. The reverse conversion of
electrical energy into mechanical energy is done by a motor and generators have many
similarities.A generator forces electric charges to move through an external electrical circuit,
but it does not create electricity or charge, which is alreadypresent in the wire of its windings.
It is somewhat analogous to a water pump, which creates a flow of water but does not create
the water inside. The sourceof mechanical energy may be a reciprocating or turbine steam
engine, water falling through a turbine or water wheel, an internal combustion engine, a
windturbine, a hand crank, the sun or solar energy, compressed air or any othersource of
mechanical energy.
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Table 4 : Specifications of generator at stage-2 NTPC Dadri
Manufacturer BHEL
Rated Maximum Output 577 KVA
Power Factor 0.85 Lagging
Power Output rating 490MW
Stator Voltage 21 KV
Stator Current 15800 Amp
Rotor Voltage 334 V
Rotor Current 3973 Amp
RPM 3000
Frequency 50 Hz
Connection Y-Y
Phase 3
Coolant Water & Hydrogen
Manufacturer BHEL
Rated Maximum Output 247 KVA
Power Factor 0.85 Lagging
Power Output rating 210 MW
Stator Voltage 16.5 KV
Stator Current 8645 Amp
Rotor Voltage 355 V
Rotor Current 3000 Amp
RPM 3000
Frequency 50 Hz
Connection Y-Y
Phase 3
Coolant Water & Hydrogen
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SWITCHYARD
It is a switching station establishing main link between generating station and transmission
system. It influences the security of power supply.It steps up or steps down the voltage levels
depending on the network node.It switches ON or OFF the reactive power control devices
Current transformers
Potential transformers
Interconnecting transformers(ICT)
Isolators
Circuit breakers
Supports
Earthing switches
Lightening arresters
Wave traps
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Instrument transformers : For stepping-down the electrical parameter
Protection logics.
Potential transformers
Interconnecting transformers(ICT)
Loaded condition.
Earth switch : Used to connect the charged body to ground to discharge the trapped
charge to
Lightning arrestors : Safe guards the equipment by discharging the high currents
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system. The practice is also to install lightening arresters at the incoming terminals
of the line.
Overhead earth wire : Protects the Over Head transmission line from Lightning
strokes.
telemetering.
Reactive Power control devices : Controls the reactive power imbalance in the
Current Limiting Reactors : Limits the Short circuit currents in case of faulty
conditions.
(CVTS)" are used at 220 KV and above. For the lower voltages, electro-magnetic
type of voltage transformer is mostly used. The secondary voltage is 110/3 volts.
power form generating stations to the load centers. The important components of
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Conductor and accessories: The lines may be single circuit or double
line carries double the power than that of a single circuit line. The
steel reinforced
normally of bolted steel lattice type. Angle sections are bolted together
to form a square base lattice structure. The structures are provided with
cross arms through which insulator strings are hung for supporting the
conductors.
lines 5 to 6 discs insulator are used for 132 KV lines, 9 to 10 and for
employed.
Earth wire and accessories: Earth wire is provided for giving protection
conductors for 400KV lines, 2 ground wires are used with reduced
shield angle of 20°. These earth wires are of galvanized stranded steel,
high tensile steel quality. Earth wire is connected to the tower steel.
arrangement.
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The following empirical relationship to phase voltage of the transmission line:
U = 5.5√(0.62 L + 3P/100)
Where,
P=Power to be transmitted in KW
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There are two main buses and one transfer bus for changeover of bus. The Main Bus as well
as Transfer Bus is of 400KV. The generator Transformer steps up the voltage from 20KV to
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GENERATOR & ITS PROTECTION SYSTEMS
A generator is a device that converts mechanical energy to electrical energy for use in an
external circuit. The source of mechanical energy may vary widely from a hand crank to
an internal combustion engine. Generators provide nearly all of the power for electric power
grids.
Water cooled
Air cooled
Hydrogen cooled
Stator-stator frame
End Shield
stator Winding Assembly - Stator Winding , Winding Assembly, Connecting Bus bar
Rotor - Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor, Rotor Assembly
Exciter
Auxiliary System
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The modern generators are generally provided with the following protections:
1. Over load protection: This protection is provided to safeguard the generator from
rise in temperature in the stator winding due to overload. This protection initiates an
alarm to guide the operator for reducing the load. If overload is accompanied by
flow through the generator for phase-to-phase faults, during asymmetrical loading,
due to open circuit on any one phase or during single phase to earth faults.
generator against phase to phase fault or three phase short circuits in the windings; or
inter connected bus ducts between the generator and generator transformer; or the
transformer against phase to phase fault in primary, or phase to earth fault in the
secondary side up to the protected zone. CT-10 & I provide protection through
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4. Loss of excitation protection: Sudden loss of excitation in an alternator makes
the generator to run as an induction generator. Generally all the generators shall be
designed to run as induction generator with a reduced load for a short period but the
rotor will get over-heated from the induced current flowing in the rotor iron
particularly at the retaining rings of the rotor. "Continuous operation of the generator
generator it draws the reactive power from the grid and there may be a voltage dips in
5. Reverse Power Protection: When the input to the prime mover suddenly goes
off and the generator is in service delivering power to the system, the machine will
not cease to function, but would continue to rotate at the same speed; now as motor
deriving the requisite energy from the system to keep the frictional and windage
losses Both the direction and magnitude of the active power between the system and
the machine therefore changes, while the reactive or wattless power controlled by the
field excitation remains unaltered. Although this abnormal condition would not harm
the generator, it could, however damage the prime mover. It has been the general
indicators.
6. Over voltage and over fluxing protection: The generator can develop
dangerously high voltages in the event of mal-operation of AVR or a load throws off
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while generator excitation is under manual control. An overvoltage relay should be
provided to detect this and give an alarm in UCB. Over fluxing of the generator
excitation application while generator is at lower speed. Its persistence can cause
be provided for the backup protection of generator against external three phase and
phase to phase faults in the 400/220 KV system which may be hanging on due to
failure of this own system primary protection. The zone of 216 should be extended
trip the generator after a time delay of 1 to 1.5 seconds so that the generator is tripped
only when 400 KV/220 KV protections has not cleared the faults even in the second
zone.
Table 6 :Following are some Fault Conditions , their effects and Protection
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Other important systems for Generator Protection are:
Seal oil system: Generator shaft seals are supplied with pressurized seat oil to
prevent hydrogen losses at the shaft and ingress of air into the generator. During
normal operation, shaft seals are supplied with seal oil by a separate system,
consisting of hydrogen side seal oil circuit and air side seal oil circuit. The oil used in
seal oil circuit is same as that used in turbine generator journal bearings. During
normal operation, in the air side AC pump draws seal oil from the seal oil storage tank
and feeds it to the seals via cooler and filters which drains towards the air side and
return back to the seal oil storage tank.Similarly H2 side oil pump supplies oil to seal
through a separate strainer and cooler. By dividing the seal oil system into two
separate circuits, hydrogen losses at the seals are kept to a minimum and good
hydrogen purity is also maintained. For the air side seal oil circuit three seal oil pumps
are provided. In the event of failure of one AC pump the second AC pumps
automatically takes over. If both pumps fail the seal oil supply is taken over by the
standby D.C. pump. On the other hand one seal oil pump is used for oil circulation in
H2 side seal oil circuit. In the event of failure of this pump, seal oil in hydrogen side
is derived from air side seal oil circuit. Prolonged operation in this fashion may result
Primary water system: When the turbine generator is on load heat produced in
mineralized water through hollow conductors of the stator windings and passage ways
within the terminals. The losses occurring in the generator stator winding components
e.g. Stator winding, terminal bushings and phase connectors are dissipated directly
through water. The cooling water being in contact with the high voltage winding must
have an electrical conductivity of the order of 0.5 to 1 micro mho/cm. Primary water
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supply system comprises of the following components. Primary water is circulated by
one of the 2X100% duty pump through a strainer type filter with magnet bar and
cooler. The primary water is drawn from the primary water tank and passes to a
primary water manifold (inlet) via coolers and filters and from there to stator bars via
Teflon hoses. The primary water leaving the stator winding is passed through similar
Teflon hoses to anther primary water manifold (outlet) and is then returned to the
primary water tank. A separate flow path from a point before the stator winding inlet
by a multi-stage axial fan located at the turbine end. The fan draws hot gas from the
air gap and delivers it to the coolers where it is cooled and re-circulated. Gas system
air must neither be directly replaced with hydrogen during generate- filling nor the
hydrogen directly replaced with air driving emptying operation. In both the cases CO 2
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CONCLUSION
Industrial training being an integral part of engineering curriculum provides not only
easier understanding but also help acquaint an individual with technology. It exposes
which otherwise could have been exclusive to me. The practical exposure acquired
here will pay rich dividends when I will set my foot as an engineer.
The training at NTPC Dadri was all together an exotic experience, since work, culture
and mutual cooperation was excellent here. Moreover fruitful result of adherence to
quality control awareness of safety of employees were fare which is much evident
here.
All the minor and major sections of thermal project have been visited and also
understood to the best of my knowledge. I believe that this training has made me well
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Bibliography
2. http://www.ntpc.co.in/en/investors/annual-reports
3. http://www.ntpc.co.in/
4. https://en.wikipedia.org/wiki/NTPC_Dadri
7. NTPC Samachar
8. WEB DADR
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