SUMMER TRAINING REPORT

ON
NTPC NOIDA

Submitted to Guru Gobind Singh Indraprastha University, Delhi (India)

in partial fulfilment of the requirement for the award of the degree of
B. TECH
In
ELECTRICAL AND ELECTRONICS ENGINEERING

Submitted by
SHAHBAZ HASNAT
Roll No. 03215004916

DEPTT. OF ELECTRICAL AND ELECTRONICS ENGINEERING

MAHARAJA SURAJMAL INSTITUTE OF TECHNOLOGY

C-4, JANAK PURI, NEW DELHI – 110058
Affiliated to Guru Gobind Singh Indraprastha University, New Delhi
 CANDIDATE’S DECLARATION

I, Shahbaz Hasnat, Roll No. 03215004916, B.Tech EEE (7th Semester) of the Maharaja
Surajmal Institute of Technology, New Delhi hereby declare that the training report on
industrial training programme I undertook at NTPC Noida is an original work and data
provided in the study is authentic to the best of my knowledge. This report has not been
submitted to any other institute of the award of any other degree.

Place: New Delhi Shahbaz Hasnat

Date: 03215004916

i
ii
 ACKNOWLEDGEMENT

I was appointed to do six-week training at this esteemed organization. The training was
very educational.

However, it would not have been possible without the kind support and help of many
individuals and organization. I am highly indebted to Mr. H.C. BAGHEL for their guidance
and constant supervision as well as for providing necessary information regarding the training.

I would like to express my gratitude towards the members of NTPC Limited Noida. For
their kind cooperation and encouragement, and for giving me such attention and time. My
thanks and appreciation also go to my colleague in training and people who willingly helped
me out with their abilities in completing the training.

iii
 PREFACE

NTPC is one of the most important industries for producing the electricity. There are various
divisions in NTPC for various branches like mechanical division, electrical division etc. The
main objective of preparing this report has been to present the operations of BMD, PAM, TMD
of mechanical division in a logical, innovative and manner. The basic theory presented in this
report has been evolved out of simple and readily understood principles. A sincere effort
has been made to maintain physical concepts in various operations. An effort has been made
to give a balanced presentation of this report with the help of figures, different types of data
and related suitable theories as well as concepts. Eventually, again I would like to thank NTPC
Noida.

iv
 LIST OF FIGURES

Figure No. Description Page No.

1.1 NTPC logo 1
2.1 Power Plant Layout 4
2.2 Components of a coal plant 6
2.3 Boiler maintenance department 6
3.1 Boiler circulating system 7
3.2 Natural circulation system 8
3.3 Combined circulation system 8
3.4 Compressor House 10
4.1 Steam Turbine 11
4.2 Steam Cycle 12
4.3 Impulse and Reaction Turbine 13
4.4 Velocity Compounded Turbine 14
4.5 Curtis stage 14
4.6 Pressure Compounded Turbine 15
4.7 Pressure Compounded Impulse Turbine 15
4.8 Three stages of reaction turbine 16
4.9 Velocity diagram for maximum efficiency 17
4.10 Different stages of steam turbine 18
4.11 Turbine Cycle 20
4.12 L.P. Rotor 21
4.13 Turbine bearings 22
4.14 Thrust bearings 22
4.15 L.P. Heaters 22
4.16 Gate Valve 24
4.17 Regulating Valve 25
4.18 Non-Return Valve 25
4.19 Safety Valve 25

v
 LIST OF TABLES

Figure No. Description Page No.

1.1 Installed capacity 1
1.2 Gas-based 2
1.3 Coal-based 2
2.1 Power plant capacity 4

vi
 CONTENTS

Candidate’s Declaration ........................................................................................................... i

Certificate ................................................................................................................................. ii
Acknowledgment .....................................................................................................................iii
Preface ...................................................................................................................................... iv
List of Figures ........................................................................................................................... v
List of Tables ........................................................................................................................... vi

1. Introduction to NTPC
1.1 Introduction ........................................................................................................................ 1
1.2 Power Generation .............................................................................................................. 1
1.3 Installed Capacity .............................................................................................................. 1
1.4 NTPC Power Stations in India.......................................................................................... 2

2. NTPC Dadri Power Plant

2.1 Introduction ........................................................................................................................ 4
2.2 Basic Power Plant Layout ...................................................................................................

3. Plant Auxiliary Maintenance (PAM) Departments

3.1 Theory of Circulation of Water ........................................................................................ 7
3.2 Ash Handling Plant ............................................................................................................ 8
3.3 CSP House .......................................................................................................................... 8
3.4 Water Treatment Plant ................................................................................................... 10

4. Turbine Maintenance Department (TMD)

4.1 Steam Turbine Theory .................................................................................................... 11
4.2 Steam Cycle ...................................................................................................................... 12
4.3 Turbine Classification ..................................................................................................... 12
4.4 Turbine Cycle ................................................................................................................... 19
4.5 Description of Main Turbine .......................................................................................... 20
4.6 Turbine Auxiliaries and their arrangements ................................................................ 23
4.7 Types of valves used and maintained in TMD .............................................................. 24

Conclusion .............................................................................................................................. 26
References ............................................................................................................................... 27

vii
1. Introduction to NTPC

1.1. Introduction

The year 1975 witnessed the birth of an organization that went on to achieve great feats in
performance in a sector that was then, characterized largely by lack of investment, severe
supply shortages and operational practices that mad the commercial viability of the sector
unsustainable.

Figure 1.1 NTPC logo

NTPC symbolized hop of the country suffering from crippling power black-outs, the
Government of India, which was trying to pull an ailing, economy back on the track and he
World Bank, which was supporting the country in many development initiatives. Thus, NTPC
was created not only to redraw the power map of India but also excel in is performance and se
benchmarks for others to follow. It succeeded on both counts. Today with an installed capacity
of 39,174 MW, NTPC contributes one fourth of the Nations Power generation, with only one
fifth of India total installed capacity. An ISO 9001:2000 Certified company, it is world world`s
10th largest power generation in the world, 3rd largest in the Asia. NTPC is number 1
Independent Power Producer (IPP) in the world. Also it is 384th largest company in the world
(Forbes 2011).
It is one of the largest Indian companies in terms of market cap. The corporation recorded
a generation of 222.07 billion unit (BUS) in 2011-2012; through 16 coal based and 7 gas based
power plant spread all over the country and also has 7 plants in joint venture.

1.2 Power Generation

Presently, NTPC generates power from Coal and Gas. With an installed capacity of 55,174
MW, NTPC is the largest power generating major in the country. It has also diversified into
hydro power, coal mining, power equipment manufacturing, oil and gas exploration, power
trading and distribution. With an increasing presence in the power value chain, NTPC is well
on its way to becoming an “Integrating Power Major.”

1.3 Installed Capacity

Be it the generating capacity or plant performance or operational efficiency, NTPC’s Installed

Capacity and performance depicts the company’s outstanding performance across a number of
parameters.

1
 Table 1.1 Installed capacity
NTPC OWNED NO. OF PLANTS CAPACITY(MW)
COAL 23 44,943
GAS/LIQUID FUEL 7 4,017
TOTAL 44 48,645
OWNED BY JVs
COAL AND GAS 10 8,461
TOTAL 54 57,106

1.3. Power Stations in India

Table Error! No text of specified style in document..2 Gas-Based

SR. NO. PROJECT STATE INST. CAPACITY(MW)
1. NTPC ANTA RAJASTAN 413
2. NTPC AURAIYA UP 652
3. NTPC KAWAS GUJARAT 645
4. NTPC DADRI UP 817
5. NTPC JHANOR GUJARAT 648
6. NTPC KAYAMKULAM KERALA 350
7. NTPC FARIDABAD HARYANA 430
TOTAL 3955

Table Error! No text of specified style in document..3 Coal-based

S. NO. PROJECT STATE INST.
CAPACITY
1. SINGRAULI SUPER THERMAL UTTARPRADESH 2000
POWER STATION
2., NTPC KORBA 2,600
CHHATTISGARH

3. NTPC RAMAGUNDAM ANDHRA 2,600

PRADESH
4. FARAKKA SUPER THERMAL WEST BENGAL 2,100
POWER STATION
5. NTPC VINDHYACHAL MADHYA 4,760
PRADESH
6. RIHAND THERMAL POWER UTTAR PRADESH 3,000
STATION
7. KAHALGAON SUPER THERMAL BIHAR 2.340
POWER STATION
8. NTPC DADRI UTTAR PRADESH 1,820
9. NTPC TALCHER KANIHA ORISSA 3,000
10. FEROZE GANDHI UNCHAHAR UTTAR PRADESH 1,550
THERMAL POWER PLANT
11. TALCHER THERMAL POWER ORISSA 460
STATION
12. SIMHADRI SUPER THERMAL ANDHRA 2,000
POWER PLANT PRADESH

2
13. TANDA THERMAL POWER PLANT UTTAR PRADESH 1,760
14. BADARPUR THERMAL POWER DELHI 705
PLANT
15. SIPAT THERMAL POWER PLANT CHHATTISGARH 2,980
16. NTPC ASSAM 750
BONGAIGAON (COMMISSIONING
2013 ONWARDS)
17. NTPC MOUDA (1 UNIT 500 MW IS MAHARASHTRA 1,000
COMMISSIONED IN APRIL 2012 )
18. RIHAND THERMAL POWER UTTAR PRADESH 500
STATION (ERECTION PHASE)
19. NTPC BARH (COMMISSIONING BIHAR 3,300
2013 ONWARDS )
TOTAL 31,995

3
2. NTPC Dadri Power Plant
2.1. Introduction

The NTPC Dadri Thermal Power Plant has an installed capacity of 2637 MW. The main plant
equipment was supplied by M/S. BHEL. The boiler of Stage-1 (4×210) MW units are of
Czechoslovakian design and that of 210 MW units are of Combustion engineering design. The
Turbo-alternators, supplied by M/S BHEL, are of Russian design and Control and
Instrumentation for Stage-1 (3×95) and Stage-2 units (2x490) MW units are mostly of Russian
design. The coal for the plant is sourced from Piparwar Mines, Jharkhand and the source of
water is Upper Ganga Canal.

Table Error! No text of specified style in document..4 Power plant capacity

STAGE UNIT INT. CAPACITY DATE OF STATUS
NUMBER (MW) COMMISSIONING
First 1 210 October, 1991 Running
First 2 210 December, 1992 Running
First 3 210 March, 1993 Running
First 4 210 March, 1994 Running
Second 5 490 January, 2010 Running
Second 6 490 July, 2010 Running

Figure Error! No text of specified style in document..1 BTP

2.2. Basic Thermal Power Plant

In thermal generating plants, fuel is converted into thermal energy to heat water, making steam.
The steam turns an engine (turbine), creating mechanical energy to run a generator. Magnets
turn inside the generator, producing electric energy.

4
Coal, oil and gas are used to make thermal electricity. They all work basically the same way
(with a few exceptions: for example, in an oil- or gas-fired plant, fuel is piped to the boiler).
1. Coal supply — After haulers drop off the coal, a set of crushers and conveyors prepare
and deliver the coal to the power plant. When the plant needs coal, coal “hoppers” crush
coal to a few inches in size and conveyor belts bring the coal inside.
2. Coal pulveriser —the belts dump coal into a huge bin (pulveriser), which reduces the
coal to a fine powder. Hot air from nearby fans blows the powdered coal into huge
furnaces (boilers).
3. Boiler — The boiler walls are lined with many kilometres of pipe filled with water. As
soon as the coal enters the boiler, it instantly catches fire and burns with high intensity
(the temperatures inside the furnace may climb to 1,300° C). This heat quickly boils the
water inside the pipes, changing it into steam.
4. Precipitators and stack — As the coal burns, it produces emissions (carbon dioxide,
sulphur dioxide and nitrogen oxides) and ash.The gases, together with the lighter ash (fly
ash), are vented from the boiler up the stack. Huge air filters called electrostatic
precipitators remove nearly all the fly ash before it is released into the atmosphere. The
heavier ash (bottom ash) collects in the bottom of the boilers and is removed.
5. Turbine and generator — Meanwhile, steam moves at high speed to the turbines,
massive drums with hundreds of blades turned at an angle, like the blades of a fan. As
jets of high-pressure steam emerge from the pipes, they propel the blades, causing the
turbine to spin rapidly. A metal shaft connects the turbine to a generator. As the turbine
turns, it causes an electro-magnet to turn inside coils of wire in the generator. The
spinning magnet puts electrons in motion inside the wires, creating electricity.
6. Condensers and cooling water system — Next, the steam exits the turbines and passes
over cool tubes in the condenser. The condensers capture the used steam and transform
it back to water. The cooled water is then pumped back to the boiler to repeat the heating
process. At the same time, water is piped from a reservoir or river to keep the condensers
constantly cool. This cooling water, now warm from the heat exchange in the condensers,
is released from the plant.
7. Water purification — To reduce corrosion, plants purify water for use in the boiler
tubes. Wastewater is also treated and pumped out to holding ponds.
8. Ash systems — Ash is removed from the plant and hauled to disposal sites or ash
lagoons. Ash is also sold for use in manufacturing cement.
9. Transformer and transmission lines — transformers increase the voltage of the
electricity generated. Transmission lines then carry the electricity at high voltages from
the plant to substations in cities and towns.

5
 Figure 2.2 components of a coal fired thermal plant

Figure Error! No text of specified style in document..3 boiler maintenance department

6
3. Plant Auxiliary Maintenance (PAM) Development

3.1. Theory of Circulation of Water

Water must flow through the heat absorption surface of the boiler in order that it is 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 at 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

Figure 3.1 Boiler circulating system

Types of boiler circulating system:

•Natural circulation system
•Controlled circulation system
•Combines circulation system

Natural Circulation System

In a natural circulation system, Water delivered to steam generator from feed heater is at a
well below the saturation value corresponding to that pressure. Entering first the economizer it
is heated to about 30 to 40˚C below saturation temperature. From economizer the water enters
the drum and thus joins the circulation system. Water entering the drum flows through the
down comer 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 super heating and then sent to the high-pressure turbine.
Remaining water mixes with the incoming water from the economizer and the cycle is
repeated. The circulation in this case takes place on the thermo-siphon principle. The down
comers contain relatively cold water whereas the riser tubes contain a steam water
mixture. Circulation takes place at such a rate that the driving force and the frictional
resistance in water walls are balanced.

7
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
correspondingto 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.

Figure 3.4 Natural Circulation System

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, orifice plates are
used. This system is applicable in the high sub-critical regions (200 kg/cm²).

Combined Circulation System

Beyond the critical pressure, phase transformation is absent, and hence once through system is
adopted. However, it has been found that even at super critical pressure, it is advantageous to
recirculation the water through the furnace tubes and simplifies the start-up procedure. A typical
operating pressure for such a system is 260 kg/cm².

Figure 3.5. Combined Circulation System

8
3.3. Ash Handling Plant

The ash produced in the boiler is transported to ash dump area by means of sluicing type
hydraulic ash handling system, which consists of Bottom ash system, Ash water
system and Ash slurry system.

Bottom ash system

In the bottom ash system, the ash
discharged from the furnace bottom is collected in two water compounded scraper through
installed below bottom ash hoppers. The ash is continuously transported by means of the
scraper chain convey or onto the respective clinker grinders which reduce the lump sizes to the
required fineness. The crushed ash from the bottom ash hopper from where the ash slurry is
further transported to operation, the bottom ash can be discharged directly into the sluice
channel through the bifurcating chute bypass the grinder. The position of the flap gate in the
bifurcating chute bypasses the grinder. The position of the flap gate in the bifurcating chute is
to be manually changed.

Fly ash system

The flushing apparatus are provided under E.P. hoppers, economizer hoppers, air preheaters,
and stack hoppers. The fly ash gets mixed with flushing water and the resulting slurry drops
into the ash sluice channel. Low-pressure water is applied through the
nozzle directing tangentially to the section of pipe to create
turbulence and proper mixing of ash with water. For the maintenance of flushing apparatus
plate valve is provided between apparatus and connecting tube.

Ash water system

High pressure water required for bottom ash hopper quenching nozzles, bottom ash hopper
spraying, clinker grinder sealing scraper bars, cleaning nozzles, bottom ash
hopper seal through flushing, economizer hopper flushing nozzles andsluicing trench jetting
nozzles is tapped from the high-pressure water ring mainly provided in the plant area. Low
pressure water required for bottom ash hopper seal through make up, scraper conveyor make
up, flushing apparatus jetting nozzles for all fly ash hoppers excepting economizer hopper is
trapped from low pressure water ringsmainly provided in the plant area.

3.3. CSP House (Control Structure Pump House)

The control system has following pumps:-

•Chlorine pump-2(for chlorination of water)
•HP pump-6(for boiling of water)
•LP pump-3(for EP pump house)
•Fire pump-1(in case of fire breakdown)
•TWS pump-3(for screening of water)
•CRW pump-3(supply water for water treatment)
This house is known as control house because amount of water to be supplied for
treatment is controlled from this house with the help of these pumps. Generally, 2 CRW pumps
out of 3 pumps remains open similarly, 1 FP ,2 LP,4 HP,1 TWS pumps remains open. If more
water is needed then others pumps are opened.

9
Compressor House
An air compressor is anything that increases the amount of air that is contained within a
particular space. By packing in the air, the air pressure is increased. This creates a force that is
useful for a variety of purposes, such as industrial, manufacturing, commercial and personal
purposes. Another way to group air compressors is by the number of stages they have. A two-
stage air compressor usually is used for heavy-duty use and offers a higher level of
compression than smaller, single-stage air compressors. Two-stage air compressors can
store air for future use and are more energy efficient because they produce more air per unit of
horsepower than single-stage compressors. Also, less heat is generated in a two-
stage compressor, which means that wear on the unit is reduced. Portable
electric air compressors also are available for light-duty applications.

Figure 3.6 Compressor House

3.4. 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 are designed to process the raw water to water with very lowin dissolved solids known
as "dematerialized 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

Actually, the type of demineralization processchosen for a power station depends on three
main factors:
•The quality of the raw water.
•The degree of de-ionization i.e. treated water quality
•Selectivity of resins.
Water treatment process which is generally made up of two sections:
•Pre-treatment section
•Demineralization section

10
4. Turbine Maintenance Department (TMD)

4.1. Steam Turbine Theory

Figure 4.7 Steam Turbine

Operating Principles

A steam turbines two main parts are the cylinder and the rotor. As the steam passes through the
fixed blades or nozzles it expands and its velocity increases. The high-velocity jet of steam
strikes the first set of moving blades. The kinetic energy of the steam changes into mechanical
energy, causing the shaft to rotate. The steam then enters the next set of fixed blades and
strikes the next row of moving blades. As the steam flows through the turbine, its pressure
and temperature decreases, while its volume increases. The decrease in pressure and
temperature occurs as the steam transmits energy to the shaft and performs work.
After passing through the last turbine
stage, the steam exhausts into the condenser or process steam system. The kinetic energy
of the steam changes into mechanical erringly through the impact (impulse) or reaction of
the steam against the blades.

4.2. Steam Cycle

The thermal (steam) power plant uses a dual (vapour+liquid) phase cycle. It is a closed cycle
to enable the working fluid (water) to be used again and again. The cycle used is "Rankine
Cycle" modified to include super heating of steam, regenerative feed water heating and
reheating of steam.
On large turbines, it becomes economic to increase
thecycle efficiency by using reheat, which is a way of partially
overcoming temperature limitations. By returning partially expanded steam to a reheat, the
average temperature at which heat is added is increased and by expanding this re-heated steam
to theremaining stages of the turbine, the exhaust wetness is considerably less than it would
otherwise be conversely, if the maximum tolerable wetness is allowed, the initial pressure of
the steam can be appreciably increased.

11
 Figure 4.8 Steam Cycle

4.3. Turbine Classification

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. A simple impulse turbine
is not very efficient because it does not fully use the velocity of the steam. Many impulse
turbines are velocity compounded. This means they have two or more sets of moving
blades in each stage.

Reaction Turbine
In this type of turbine pressure is reduced at both fixed& moving blades. Both fixed
& moving blades act as nozzles. Work done by the impulse effect of steam due to reversals
of direction of high velocity steam. The expansion of steam takes place on moving blades. A
reaction turbine uses the "kickback" force of the steam as it leaves the moving blades and fixed
blades have the same shape and act like nozzles. Thus, steam expands, loses pressure and
increases in velocity as it passes through both sets of blades. All reaction turbines are pressure-
compounded turbines.

12
 Figure 4.3 Impulse and Reaction Turbine

Compounding

Several problems occur if energy of steam is converted in single step & so compounding
is done. Following are the types of compounded turbine:

Velocity Compounded Turbine

The velocity-compounded impulse turbine was first proposed by C.G. Curtis to solve the
problems of a single-stage impulse turbine for use with high pressure and temperature steam.
The Curtis stage turbine, as it came to be called, is composed of one stage of nozzles as the
single-stage turbine, followed by two rows of moving blades instead of one. These two rows
are separated by one row of fixed blades attached to the turbine stator, which has the function
of redirecting the steam leaving the first row of moving blades to the second row of moving
blades. A Curtis stage impulse turbine with schematic pressure and absolute steam-velocity
changes through the stage. In the Curtis stage, the total enthalpy drop and hence pressure drop
occur in the nozzles so that the pressure remains constant in all three rows of blades.

13
 Figure 4.4 Velocity Compounded Turbine

Velocity is absorbed in two stages. In fixed (static) blade passage both pressure and velocity
remain constant. Fixed blades are also called guide vanes. Velocity compounded stage is also
called Curtis stage. The velocity diagram of the velocity-compound Impulse turbine is shown
in Figure

Figure 4.5 Curtis Stage

The fixed blades are used to guide the outlet steam from the previous stage in such a manner
so as to smooth entry at the next stage is ensured and the blade velocity coefficient may be
different in each row of blades

Work done =

14
 End thrust =
The optimum velocity ratio will depend on number of stages and is given

by
• Work is not uniformly distributed (1st >2nd)
• The first stage in a large (power plant) turbine is velocity or pressure compounded impulse
stage.

Pressure Compounded Turbine

This is basically a no. of single impulse turbines in series or on the same shaft. The exhaust of
first turbine enters the nozzle of the next turbine. Total pressure drop of steam does not take on
first nozzle ring but divided equally on all of them.

Figure 4.6 Pressure Compounded Turbine

To alleviate the problem of high blade velocity in the single-stage impulse turbine, the total
enthalpy drop through the nozzles of that turbine are simply divided up, essentially in an equal
manner, among many single-stage impulse turbines in series.

Figure 4.7 Pressure Compounded Impulse Turbine

15
Pressure drop - takes place in more than one row of nozzles and the increase in kinetic energy
after each nozzle is held within limits. Usually convergent nozzles are used

We can write

where is carry over coefficient

Reaction Turbine

A reaction turbine is one that is constructed of rows of fixed and rows of moving blades. The
fixed blades act as nozzles. The moving blades move as a result of the impulse of steam
received (caused by change in momentum) and also as a result of expansion and acceleration
of the steam relative to them. In other words, they also act as nozzles. The enthalpy drop per
stage of one row fixed and one row moving blades is divided among them, often equally. Thus
a blade with a 50 percent degree of reaction, or a 50 percent reaction stage, is one in which half
the enthalpy drop of the stage occurs in the fixed blades and half in the moving blades. The
pressure drops will not be equal, however. They are greater for the fixed blades and greater for
the high-pressure than the low-pressure stages. The moving blades of a reaction turbine are
easily distinguishable from those of an impulse turbine in that they are not symmetrical and,
because they act partly as nozzles, have a shape similar to that of the fixed blades, although
curved in the opposite direction. The schematic pressure line shows that pressure continuously
drops through all rows of blades, fixed and moving. The absolute steam velocity changes within
each stage as shown and repeats from stage to stage. Figure shows a typical velocity diagram
for the reaction stage.

Figure 4.8 Three stages of reaction turbine indicating pressure and velocity
distribution
Pressure and enthalpy drop both in the fixed blade or stator and in the moving blade or Rotor

Degree of Reaction =

16
 A very widely used design has half degree of reaction or 50% reaction and this is known
as Parson's Turbine. This consists of symmetrical stator and rotor blades.

Figure 4.9 The velocity diagram of reaction blading

The velocity triangles are symmetrical and we have

Energy input per stage (unit mass flow per second)

From the inlet velocity triangle we have,

Work done (for unit mass flow per second)

Therefore, the Blade efficiency

Put then

17
For the maximum efficiency and we get

from which finally it yields

Figure 4.10 Velocity diagram for maximum efficiency

Absolute velocity of the outlet at this stage is axial. In this case, the energy transfer

can be found out by putting the value of in the expression for

blade efficiency

is greater in reaction turbine. Energy input per stage is less, so there are more number
of stages.

Pressure Velocity Compounded Turbine

It is just the combination of the two compounding has the advantages of allowing bigger
pressure drops in each stage & so fewer stages are necessary. Here for given pressure drop the
turbine will be shorter length but diameter will be increased.

Steam Turbines may be classified into different categories depending upon their construction,
the process by which heat drop is achieved depends upon the initial and final conditions of the
steam and their industrial usage.
.

18
According to the direction of steam flow
 Axial turbines
 Radial turbines
According to the number of cylinder
 Single - cylinder turbines
 Double- cylinder turbines
 Three-Cylinder turbines.
•Four-Cylinder turbines.
•Multi - Cylinder turbines
According to the steam conditions at inlet toturbines
 Low-pressure turbines
 Medium -pressure turbines
 High-pressure
 Turbines of very high pressures
 Turbines of supercritical pressures
According to their usage in industry
 Turbines with constant speed of rotation primarily used for driving alternators.
 Steam turbines with variable speed meant for driving turbo blowers, air circulators,
pumps etc.
 Turbines with variable speed: Turbines of this type are usually
employed in steamers, ships and railway locomotives (turbolocomotives)

4.4. Turbine Cycle

Fresh steam from boiler is supplied to the turbine through the emergency stop valve. From the
stop valves steam is supplied to control valves situated on H.P. cylinders on the front bearing
end. After expansion through 12 stages at the H.P. cylinder steam flows back to boiler for
reheating and reheated steam from the boiler cover to the intermediate pressure turbine
trough two interceptor valves and four control valves mounted on the 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 the highest efficiency. These are two extractions from
H.P. turbine, four from I.P. turbine and one from L.P. turbine. Steam at 1.10 to 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.

19
 Figure 4.11 Turbine Cycle

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.

4.5. Description of main turbine

Specification:
 Turbine Main Data
 Rated Power 210MW
 Rated Speed 3000 rpm rated Steam (Pressure) before ESV 130 Kg`/cm2abs
 Rated Steam Temp. Before ESV 5350 C
 Rated Steam pressure Before IV 27 Kg/cm2Abs
 Rated Steam temp. Before IV 5350C
 Rated Steam Flow 670 T/Hr
 HPT Exhaust Pressure 27 Kg/cm2
 HPT Exhaust Temperature 3270C
 Rated circulating water quantity 27000 m3 through condenser
 Condenser back pressure 0.09 Kg/cm2
 Critical Speed 1585, 1881, 2017 & 2489
 Rated condenser cooling water inlet 240C to 330C temperature
 Rated condenser cooling water 1.0 to 1 Kg/cm2
 Pressure-type of governing Hydro mechanical nozzle type governing
type of turbine condensing, tandem compound three cylinder, Horizontal
Nos. of bearing 5 Nos. (for turbine side only & HPC front bearing is combined thrust
& journal bearing Barring gear 3.4 rpm, ac motor of 30kw, 730rpm, 50c/s, 415 V,

20
 220:1 Ratio Location of anchor point of at the middle foundation frame of front
the turbine exhaust part of the L.P. Cylinder.

Construction Details:
 H.P. Cylinder: 12 stages (1stis governing stage) each stage consists of a diaphragm &a
set of moving blades connected on a disc.
 Body: In two valves made of Creep Resistance (Cr-Mo-V) steel
 Studs and Nuts: High Creep Resistance (Cr-Mo-V) steel forgings
 Nozzle and Steam Chest:4 Nos (2 on Top & 2 on sides) made of High Creep resisting
(Cr-Mo-V) Steel casting
 I .P. Cylinder: 11 stages

Main Components of Turbine:

 Emergency Stop Valve: Steam from the boiler is supplied to the turbine through two
emergency stop valves. The emergency stop valve operated by hydraulic servomotor
shuts off steam supply to the turbine when the turbo set is tripped. The
emergency stop valves connected to
the four control valves through four flexible loop pipes of Chromium-Molybdenum-
Vanadium steel.
 H.P. Cylinder: It is made of creep resisting Cr-Mo-V steel casting made of two halves
joined at the horizontal plane. The horizontal joint is secured with the help of studs and
nuts made of high creep resisting Cr-Mo-V steel forgings.
 H.P. Rotor: The H.P. rotor has discs integrally forged with the shafts and is mechanical
forming single Cr-Mo-V steel forging. A special process to prevent abnormal rotor
deflection thermally stabilizes the rotor forging.
 L.P. Rotor: It consists of shrunk fit discs on a shaft. The shaft is a forging of Cr-Mo-
V steel while the discs are of high strength Ni steel forging. The H.P. rotor is
connected by rigid couplings whole the I.P rotor and L.P. rotor are connected by semi-
flexible lens type coupling. The rotors are dynamically balanced to a very precise
degree.

Figure 4.12 L.P. Rotor

 Turbine Bearings: The three turbine rotors are supported on fine bearings. The second
bearing from pedestal side is a combined radial
thrust bearing while all others are journal bearings.

21
 Figure 4.13 Turbine Bearings

 Thrust Bearings: It is Mitchell type with bearing surface distributed over a number of
bearing surfaces. They are pivoted in housing on the side of I.P. rotor thrust
collar. During operation on oil film is forced between pads and thrust collar and there
is a no metal-to-metal contact. A second ring of pads on opposite side of thrust
collar takes the axial thrust as may occur under abnormal conditions.

Figure 4.14 Thrust Bearings

 L.P. Heaters: Turbine is provided with non-controlled extractions which

are utilized for heating the condensate from turbine bleedingsystem. There are four L.
P. heaters. They are equipped with necessary safety valves in steam space level
indicator for visual gauges are present for measurement of steam pressure.

Figure 4.15 L.P. Heaters

 Gland Steam Cooler: Gland steam cooler has been provided to suck and cool t h e a i r
s t e a m m i x t u r e f r o m t h e g l a n d s e a t s . I t e m p l o ys a s m a l l ejector for

22
 which the working medium is steam of low parameters, which can be taken either
from the deaerator or auxiliary source. The pressure and temperature of this steam
should of this steam is retrieved to the fullest possible extent as the gland steam cooler
is also interposed in the condensate heating cycle thereby improving
overall efficiency of the cycle.

 Condensate Pumps: The function of these pumps is to pumps out the condensate to the
desecrator through ejectors, gland steam cooler, and L.P. heaters. These pumps have
four stages and since the suction is at a negative pressure, special arrangements
havebeenmade for providing sealing. This pump is rated generally for 160m3 hr. at a
pressure 13.2 Kg/cm2.

4.6. Turbine Auxiliaries and their arrangements

Feed Water System

The main equipments coming under this system are:
 Boiler Feed Pump: Three per unit of 50% capacity each located in the '0' meter level
in the TG bay.
 High Pressure Heaters: Normally three in number and are situated in the TG bay.
 Drip Pumps: Generally, two in number of 100% capacity each situated beneath the
LP heaters.
 Turbine Lubricating Oil System: This consists of Main Oil Pump (MOP) Starting Oil
Pump (SOP), AC standby oil pumps and emergency DC' oil pump and Jacking Oil
Pump (JOP) (one each per unit).

Boiler Feed Pumps

Boiler feed pump is used to feed water to steam generator boiler drum at desired pressure and
temperature. Boiler feed pump extract water from de-aerator and feed it to the boiler drum via
H.P heaters and economizer. It works with the steam extraction from Intermediate Pressure
(I.P.) turbine exhaust. This pump is horizontal and of barrel design driven by an Electric motor
through a hydraulic coupling. All the bearings of pump and motor are forced lubricated by a
suitable oil lubricating system with adequate protection to trip the pump if the lubrication oil
pressure falls below a preset value. The high-pressure boiler feed pump is very
expensivemachine which calls for a very careful operation and skilledmaintenance. The safety
in operation and efficiency of the feed pump depends largely on the reliable operation and
maintenance. Operating staff must be able to find out the causes of defect at the very beginning
which can be easily removed without endangering the operator of the power plant and also
without the expensive dismantling of the high pressure feed pump. The feed pump consists of
pump barrel, into which is mounted the inside stator together with rotor. The hydraulic part
isenclosed by the high pressure cover along with the balancingdevice. The suction side of the
barrel and the space in the high pressure cover behind the balancing device are enclosed by the
low pressure covers along with the stuffing box casings. The
bracketsof the radial bearing of the suction side and radial and thrust bearing of the discharge
side are fixed to the low pressure covers.
The entire pumps are mounted on a foundation frame. The hydraulic coupling and two claws
coupling with coupling guards are also delivered along with the pump. Water cooling and
oillubricating are provided with their accessories.

23
High Pressure Heaters

These are regenerative feed water heaters operating at

high pressure and located by the side of turbine. These aregenerally vertical type and turbine
bleed steam pipes are connected to them. HP heaters are connected in series on feed water side
and by such arrangement, the feed water, after feed pump enters the HP heaters. The steam is
supplied to these heaters form the bleed point of the turbine through motor operated valves.
These heaters have a group bypass protection on the feed water side. In the event f tube rupture
in any of the HPH and the level of the condensate rising to dangerous level, the group protection
devicediverts automatically the feed water directly to boiler, thus bypassing all the
3 H.P. heaters.
Following fittings are generally provided on the HP heaters
 Gauge glass for indicating the drain level.
 Pressure gauge with three-way cock.
 Air Vent cock.
 Safety valve shell side.
 Seal pot.
 Isolating valves.
 High level alarm switch.

Speed Governor
It is directly coupled to the turbine rotor through
coupling and has been designed to maintain automatically the speed of the turbo set. It
is located with the front pedestals.

Load Limiter
Turbine is equipped with the load limiter used in special cases to limit the opening of valves
by speed governor.

Purpose
To limit the load rising beyond the set point, can be varied over the entire load range.

Turbine Lubricating System

This consists of main oil pump, starting oil pump emergency D.C. oil pump and each
per unit.

4.7 . Types of valves used in maintenance in TMD

Figure 4.16 Gate Valve

24
 Figure 4.17 Regulating Valve

Figure 4.18 Non-Return Valve

Figure 4.19 Safety Valve

Valves are made of cast iron, cast steel, carbon steel alloy steel.
 Cast iron valves: 0-150 0 C temperature (used for water lines).
 Carbon steel valves: 150-4250 C temperature (used for water/steam lines).
 Alloy steel valves: 425-535 0 C (used for steam lines)

25
 CONCLUSION

Electricity sector consists of three parts – Generation, Transmission and Distribution. NTPC
is a power generation public sector company under central government that owns many
thermal power plants in the country and also has a joint venture for several others. The main
sources for power generation are coal and natural gas. At a thermal power plant, there are
dedicated units for coal-handling, generation, super-heating and cooling. The coal is fed to
the power plant using trucks or dedicated railway lines, the super-heater is used to remove
traces of moisture which prevent formation of steam and can also corrode the blades of the
turbine. Dedicated cooling towers are there for reducing the temperature of water before re-
using them or discharging them into water bodies. Thermal power plants have a cheaper
initial cost without any specific topographical requirements but thermal power plants are a
major source of air pollution which is the reason why we are moving towards more
renewable sources of power.

26
 REFERENCES

All the information is this report has been sourced from the following references

 ntpc.co.in
 wikipedia.org
 mapofindia.com
 electrical4u.com
 instructables.com
 electronics.wisc-online.com

27