INDUSTRIAL TRAINING / SEMINAR

A Report
On
Summer Training at NTPC

Submitted by
Name- SIDDHANT GOSWAMI
Registration No.-169106060

Under the Guidance of

Mr. Abhishek Anand
Manager, NTPC

DEPARTMENT OF ELECTRICAL ENGINEERING

SCHOOL OF ELECTRICAL, ELECTRONICS & COMMUNICATION (SEEC) ENGG
MANIPAL UNIVERSITY JAIPUR, JAIPUR – 303007, RAJASTHAN, INDIA

November 2019
 DECLARATION

I hereby declare that the Industrial Training Report entitled ("Title of the project") is an authentic
record of my own work as requirements of 45 days Industrial for the award of degree of B.Tech.
(Electrical Engineering), Manipal University

Siddhant Goswami
Date: 11 November 2019 169106060

Certified that the above statement made by the student is found correct to the best of our
knowledge and belief.

Signatures
Examined by:

1. 2. 3. 4.

Head of Department
(Signature and Seal)
 ACKNOWLEDGEMENTS

The success and final outcome of the project required a lot of guidance and assistance from many
people and I am extremely privileged to have got this all along the completion of my training.
All was possible due to such supervision and assistance from them.

It is an immense pleasure in expressing my deep sense of thanks and gratitude to my trainee MR

ABHISHEK ANAND, Former Head Operations and Management, Manager, NTPC Barh for his
constant guidance and supervision as well as for providing all necessary information during my
training.

I wish to express my sincere thanks to MR SANDIP DAS, Head, Electrical Department, NTPC
Barh, for his cooperation and providing necessary guidance and resources during my training

I wish to express my hearty thanks to DR. AMIT SONI, Professor and Head of Department,
Electrical Engineering, Manipal University Jaipur for his constant support and guidance.

My special thanks and gratitude to MR. MAHIPAL BHUKYA, Assistant Professor,

Department of Electrical Engineering, Manipal University Jaipur, for his valuable guidance and
suggestions to take up the project
 TABLE OF CONTENTS

1. OVERVIEW 6
2. OBJECTIVES OF TRAINING 9
3. LOCATION OF THERMAL POWER PLANT 10
4. GENERATOR 11
5. RANKINE CYCLE 14
6. BOILER MAINTAINANCE DEPARTMENT 17
7. PLANT AUXILIARY MAINTENANCE 26
8. TURBINE MAINTENANCE DEPARTMENT 27
9. SWITCHYARD 30
10. HIGH TENSION SWITCHGEAR 31
11. CONCLUSION 32
 OVERVIEW

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 greenhouse 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 utilization 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 ranked 492nd in the ‘2019, Forbes Global 2000’ ranking of the
World’s biggest companies. Growth of NTPC installed capacity and generation

Fig 1 – A graph comparing the PLF of NTPC vs All India

 Fig 2 – A graph on installed capacity of NTPC, NTPC Group and All India

Fig 3 – Comparison of growth in generation of NTPC, NTPC Group and All India
The total installed capacity of the company is 55,126 MW (including JVs) with 21 coal based, 7
gas based stations, 2 Hydro based station and 1 Wind based station. 9 Joint Venture stations are
coal based and 11 Solar PV projects. The capacity will have a diversified fuel mix and by 2032,
non fossil fuel based generation capacity shall make up nearly 30% of NTPC’s portfolio.

NTPC has been operating its plants at high efficiency levels. Although the company has 15.56%
of the total national capacity, it contributes 22.74% of total power generation due to its focus on
high efficiency.

NTPC is not only the foremost power generator; it is also among the great places to work. The
company is guided by the “People before Plant Load Factor” mantra which is the template for all
its human resource related policies. In 2018, NTPC was recognized as “Laureate” for
consistently ranking among “Top 50 Best Companies to Work for in India” for last 10 years in
the Great Place to Work and Economic Times survey. Besides, NTPC was also recognized as the
best among PSUs and in Manufacturing
 OBJECTIVES OF TRAINING

This report is made to understand how electricity is generated from these power stations, how is
transmitted from these power plants through grid, the electricity that we use in day-to-day life.
And what materials are required for operation of these power plants.

Also it describes about the consideration of site location of a thermal power plant as this is
considered to be the most important factor for setting up large power plants and also the working
of the thermal power plant and the components related to its working.
Another important aspect for any power plant for its smooth functioning and uninterruption is its
regular maintenance which helps in increasing the plant efficiency and also helps the plant
perform for a longer duration.
CONSIDERATION FOR THE LOCATION OF THE LARGE THERMAL
PLANT

The important aspect to be borne in mind during site selection for a thermal power plant is
availability of coal, ash disposal facility, space requirement, nature of land, water, transport
facility, labor, public problems, size of the plant.

Large development in the thermal power generation calls for proper planning in choice of site,
climatic condition, unit size, coal requirements and transport, transmission system etc. It is a
normal practice to consider various alternative sites for locating thermal plant and work out
comparison to arrive at economically feasible location. The preparation of feasibility report for a
thermal station requires study under two headings viz. area selection and site selection. The area
selection study comprises the study of factor given below, which are required for the
establishment of any production oriented industry. Some are also applicable when final choice of
site is made.

•Supply of raw materials, which is the case of thermal station are coal and water, are of extreme
importance.

•Transport facilities to whole the raw materials viz. Coal in this case and the capital equipment.

•Transmission of the power produced to the local centers.

•A labour force of size and quality required but this will not be of ever riding consideration. In
our country the migration of labour from one place to another does not pose very difficult
problems.
•Climatic conditions have also played an important role in area selection.

WORKING OF THE THERMAL POWER PLANT

Steam is generated in the boiler of the thermal power plant using heat of the fuel brunt in the
combustion chamber. The steam generated is passed through steam turbine where part of its
thermal energy is converted into mechanical energy which is further used for generating electric
power. The steam coming out of the steam turbine is condensed in the condenser and the
condensate is supplied back to the boiler with the help of the feed pump and the cycle is
repeated. The function of the Boiler is to generate steam. The function of the condenser is to
condense the steam coming out of the low pressure turbine. The function of the steam turbine is
to convert heat energy into mechanical energy. The function of the condenser is to increase the
pressure of the condensate from the condenser pressure to the boiler pressure. The other
components like economizer, super heater, air heater and feed water heaters are used in the
primary circuit to increase the overall efficiency of the plant.

GENERATOR
 Fig 4: The overall diagram of a Synchronous Generator

Generator is the electrical end of turbo generator set. It is a cylindrical pole synchronous
generator. It is generally known as a piece of equipment that actually converts the mechanical
energy of turbine into electricity. The generation of electricity is based on the principle of
electromagnetic induction.

A generator consists of the following main components and associated system:-

1. Stator
2. Rotor
3. Excitation system
4. Cooling system
5. Sealing system

STATOR

The stator is the component that embodies the armature core and armature winding. It is totally
enclosed gas tight fabricated structure. It is the heaviest load in the whole turbo generator. The
major part of this load is stator core. The stator comprises of an inner frame and outer frame. The
outer frame is a rigid fabricated structure of welded steel plates.
Within this shell is fixed cage of girderbuil circular and axial ribs. The ribs divide the yoke into,
compartments throw which hydrogen/air flow into radial ducts in the stator core and circulates
throw the gas coolers housed in the frame. The inner cage is usually fixed to the yoke by an
arrangement of springs to dampen the double frequency vibration inherent in 2-pole generator.

STATOR CORE

The stator is built up from a large no of vanished insulated punching or thin sections of thin
(generally 0.35 mm to 0.5 mm) steel plates. The use of cooled rolled grain-oriented, loss less
steel iron which the punching are made can contribute to reduction in the weight of stator core
for two main reasons.

1. There is an increase in core stacking factor which improvement in lamination, cold

rolling and in core building techniques.
2. The advantage can be taken of the high magnetic permeance of grain-oriented steel to
work the stator core comparatively high magnetic saturation without fear of excessive
iron loss or too heavy a demand for excitation ampere-turns from the generator rotor.

The slot ventilation holes etc. are punched out in one operation in the stampings and as such
the stampings are rather complicated or accounts of holes and the slots that have to be
produced. The core stampings are assembled in an inner leaved manner on core bars. The
core consists of several pockets separated by steel spacer for radial cooling of the core by
hydrogen.

STATOR WINDING AND INSULATION

Stator core carries the armature winding where the voltage is generated due to
electromagnetic induction. Each stator conductor must be capable of carrying the rated
current without overheating and the insulation must be sufficient to prevent leakage current
flowing between earth and phase.

The stator has a three phase double layer short core type bar winding having two parallel
paths. Each coil side consists of glass insulated solid and hollow conductor with cooling
water passing through the latter in case of water cooled conductors being used in higher
capacity units. Water is fed to and fro the winding throw Teflon tubes.

The stator winding conductors, both solid and hollow, are transposed about a non magnetic
duct, which provide the flow path for the coolant gas in case of H2 cooled generator. In
liquid cooled windings the transposed conductors are rectangular tubes. The transposition can
be done in no. of ways but most commonly used method of transposition is Roebel
arrangement.

The rotor is cast chromium, nickel, molybdenum and vanadium steel ingot and it is further
forget and machined. The rotor forging is then planed and milled to form the teeth. Very
 often a hole is bored throw the center of the axially from one end to the other for inspection.
Slots are then machined for winding and ventilation.

ROTOR
The rotor carries the field windings. Silver bearing copper (containing 0.03 to 0.1 % silver) is
used for the winding with mica as the insulation between conductors. A mechanically strong
insulator such as micanite is used for lining the slots. Later designs of windings for circulation of
the cooling gases throw the actual conductors. When rotating at high speed, centrifugal force
tries to lift the winding out of the slots and duralumin wedges contain them. The end turns
outside the slots are covered by non magnetic steel retaining end rings are secured to a turned
recess in the rotor body. By shrinking or screwing and support at the other end by fitting the
rotor body.

RANKINE CYCLE

The Rankine cycle is a thermodynamics cycle which converts heat into work. The heat is
supplied externally to a closed loop, which usually uses water as the working fluid. This cycle
generates about 80% of all electricity power used throughout the world, including virtually all
solar thermal, biomass, coal and nuclear power plants.
DESCRIPTION: A Rankine cycle describes a model of the operation of a steam heat

Fig 5: Operation of Rankine cycle

that a pump is used to pressurize liquid instead of gas. This requires about 1/100th (1%)as much
energy Engines most commonly found in power generation plants. Common heat sources for
power plants using the Rankine cycle are coal, natural gas, oil, and nuclear.
The Rankine cycle is sometimes referred to as a practical Carnot cycle as, when an efficient
turbine is used, the T-S diagram will begin to resemble the Carnot cycle. The main difference is
as that compressing a gas in a compressor (as in the Carnot cycle).
The efficiency of a Rankine cycle is usually limited by the working fluid. Without the pressure
going super critical the temperature range the cycle can operate over is quite small, turbine entry
temperature are around 30°C. This gives a theoretical Carnot efficiency of around 63% compared
with an actual efficiency of 42% for a modern coal-fired power station. This low turbine entry
temperature (compared with a gas turbine) is why the Rankine cycle is often used as a bottoming
cycle in combined cycle gas turbine power stations. The working fluid in a Rankine cycle
follows a closed loop and is re-used constantly.

Fig 6 – A T-s graph of Rankine cycle

The benefit of this is lost somewhat due to the lower heat addition temperature. Gas turbines, for
instance, have turbine entry temperatures approaching 1500°C.Nonetheless, the efficiencies of
steam cycles and gas turbines are fairly well matched.
i. Process 1-2: The working fluid is pumped from low to high pressure, as the fluid is a
liquid at this stage the pump requires little input energy.
ii. Process 2-3: The high pressure liquid enters a boiler where it is heated at constant
pressure by an external heat source to become a dry saturated vapour.
iii. Process 3-4: The dry saturated vapour expands through a turbine, generating power.
This decreases the temperature and pressure of the vapour, and some condensation
may occur.
iv. Process 4-1: The wet vapour then enters a condenser where it is condensed at a
constant pressure and temperature to become saturated liquid. The pressure and
 temperature of the condenser is fixed by the temperature of the cooling coils as the
fluid is undergoing a phase change.
In an ideal Rankine cycle the pump and turbine would be isentropic, i.e. the pump and turbine
would generate no entropy and hence maximize the net work output. Process 1-2 and 3-4 would
be represented by vertical lines on the T-S diagram and more closely resemble that of the Carnot
cycle.

Boiler Maintenance Department (BMD)

Boiler and Its Description
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 2.3inches (60 mm) in diameter. Pulverized
coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns,
foaming 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 3200 psi
(22.1MPa). It is separated from the water inside a drum at the top of furnace.
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. The
generator includes the economizer, the steam drum, the chemical dosing equipment, and the
furnace with its steam generating tubes and the superheated coils. Necessary safety valves are
located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment
include: forced draft (FD) fan, air preheated (APH), boiler furnace, induced draft (ID) fan, fly
ash collectors (electrostatic precipitator or bag house) and the flue gas stack. For units over about
210MW capacity, redundancy of key components is provided by installing duplicates of the FD
fan, APH, fly ash collectors and ID fan with isolating dampers. On some units of about 60MW,
two boilers per unit may instead be provided.

AUXILARIES OF BOILER
1.1 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.
1.2 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. down comer, 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 1ppm 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.
From the secondary separators the steam flows upwards to the series of screen dryers, extending
in layers across the length of the drum. These screens perform the final stage of the separation.
Once water inside the boiler or steam generator, the process of adding the latent heat of
vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical
reaction of burning some type of fuel.
The steam/vapour is passed through a series of steam and water separators and then dryers inside
the steam drum. The steam separators and dryers remove the water droplets from the steam and
the cycle through the water walls is repeated. This process is known as natural circulation.
The boiler furnace auxiliary equipment includes coal feed nozzles and igniter’s guns, so out
blowers, water lancing and observation ports (in the furnace walls) for observation of the furnace
interior. Furnace explosions due to any accumulation of combustible gases after a trip out are
avoided by flushing out such gases from the combustion zone before igniting the coal.
The steam drum (as well as the super heater coils and headers) have air vents and drains needed
for initial start-up. The steam drum has an internal device that removes moisture from the wet
steam entering the drum from the steam generating tubes. The dry steam then flows into the
super heater coils. Geothermal plants need no boilers incest they use naturally occurring steam
sources.

1.3 WATER WALLS:

Water flows to the water walls from the boiler drum by natural circulation. The front and the two
side water walls constitute the main evaporation surface, absorbing the bulk of radiant heat of the
fuel burnt in the chamber. The front and rear walls are bent at the lower ends to form a water-
cooled slag hopper. The upper part of the chamber is narrowed to achieve perfect mixing of
combustion gases. The water wall tubes are connected to headers at the top and bottom. The rear
water wall tubes at the top are grounded in four rows at wider pitch forming the grid tubes.
1.4 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.

Fig 7 - Reheater

1.5 SUPERHEATER:
Whatever type of boiler is used, steam will leave the water at its surface and passing to 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 super heater. This is simply a heat exchanger where additional heat is
added to the steam.
In water-tube boilers, the super heater may be an additional pendant suspended in the furnace
area where the hot gases will provide the degree of superheat required. In other cases, for
example in CHP schemes where the gas turbine exhaust gases are relatively cool, a separately
fired super heater may be needed to provide the additional heat.

1.6 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.
Use of economizer or air heater or both is decided by the total economy that will result in
flexibility in operation, maintenance and selection of firing system and other related equipment.
Modern medium and high capacity boilers are used both as economizers and air heaters. In low
capacity, air heaters may alone be selected.
Stop valves and non-return valves may be incorporated to keep circulation in economizer into
steam drum when there is fire in the furnace but not feed flow. Tube elements composing the
unit are built up into banks and these are connected to inlet and outlet heaters.

Fig 8 Economizer

1.7 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 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.
Special sealing arrangements are provided in the air preheater to prevent the leakage between the
air and gas sides. Adjustable plates are also used to help the sealing arrangements and prevent
the leakage as expansion occurs. The air preheater heating surface elements are provided with
two types of cleaning devices, soot blowers to normal devices and washing devices to clean the
element when soot blowing alone cannot keep the element clean.

Fig 9 Air Preheater

1.8 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 power plants.

Fig 10 Pulverizer
 PLANT AUXILIARY MAINTENANCE
WATER CIRCULATION SYSTEM
Theory of Circulation:
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 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 weight of the water to the weight of the steam in the mixture
leaving the heat absorption surface is called circulation ratio.

The 3 systems of circulation adopted in boiler are:

i) Natural circulation system
ii) Controlled circulation system
iii) Combined circulation system

1.1 NATURAL CIRCULATION SYSTEM

Water delivered to a steam generator from feed heaters is at a temperature well below the
saturation value corresponding to that pressure. Entering first, the economizer, it is heated to
much nearer the saturation temperature. From economizer the water enters the drum and thus
joins the circulatory system. Water entering the drum flows down through the downcomer and
enters bottom of the water wall tubes. In the water wall tubes a part of the water is converted to
steam and the mixture flows back to the drum. In the drum, the steam is separated. 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 downcomers contain
relatively cold water, whereas the water wall tubes contain a steam water mixture, whose density
is comparatively less. This density difference is the driving force, for the mixture. Circulation
takes place at such a rate that the driving force and frictional resistance are balanced. 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 boiler with drum operating pressure around 175 kg/cm2.
1.2 CONTROLLED CIRCULATION SYSTEM
Beyond 175 kg/cm2 of pressure, circulation is to be assisted with mechanical pumps, to
overcome frictional losses. To regulate the flow through various tubes, orifice plates are used.
This system is applicable in the high sub-critical regions (say 200 kg /cm2)

1.3 COMBINED CIRCULATION SYSTEM

Beyond the critical pressure, phase transformation is absent, and hence a once through system is
adopted. However, it has been found that even at supercritical pressures, it is advantageous to
recirculate the water through the furnace tubes at low loads. This protects the furnace tubes and
simplifies the start-up procedure. A typical operating pressure for such a system is 260 Kg/cm2

ASH HANDLING PLANT

The widely used ash handling systems are:
i. Mechanical Handling System
ii. Hydraulic System
iii. Pneumatic System
iv. Steam Jet System

The hydraulic system carried the ash with the flow of water with high velocity through a channel
and finally dumps into a sump. The hydraulic system is divided into a low velocity and high
velocity system. In the low velocity system the ash from the boilers falls into a stream of water
flowing into the sump. The ash is carried along with the water and they are separated at the
sump. In the high velocity system a jet of water is sprayed to quench the hot ash. Two other jets
force the ash into a trough in which they are washed away by the water into the sump, where
they are separated. The molten slag formed in the pulverized fuel system can also be quenched
and washed by using the high velocity system. The advantage of this system are that its clean,
large ash handling capacity, considerable distance can be traversed, absence of working parts in
contact with ash.
FLY ASH COLLECTION
Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag
filters (or sometimes both) located at the outlet of the furnace and before the induced draft fan.
The fly ash is periodically removed from the collection hoppers below the precipitators or bag
filters. Generally, the fly ash is pneumatically transported to storage silos for subsequent
transport by trucks or railroad cars.

BOTTOM ASH COLLECTION AND DISPOSAL

At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from
the bottom of the furnace. This hopper is always filled with water to quench the ash and clinkers
falling down from the furnace. Some arrangement is included to crush the clinkers and for
conveying the crushed clinkers and bottom ash to a storage site.

WATER TREATMENT PLANT

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 µdematerialized 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.

The type of demineralization process chosen for a power station depends on three main factors:
i. The quality of the raw water.
ii. The degree of de-ionization i.e. treated water quality.
iii. Selectivity of resins.
Water treatment process is generally made up of two sections:
i. Pretreatment section
ii. Demineralization section
PRETREATEMENT 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.

DEMINERALIZATION SECTION
This filter water is now used for dematerializing purpose and is fed to cation exchanger bed, but
enroots being first dechlorinated, which is either done by passing through activated carbon filter
or injecting along the flow of water, an equivalent amount of sodium sulphite through some
stroke pumps. The residual chlorine, which is maintained in clarification plant to remove organic
matter from raw water, is now detrimental to action resin and must be eliminated before its entry
to this bed.
 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.

MAIN TURBINE

The 210MW turbine is a cylinder tandem compounded type machine comprising of H.P, 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 is 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. If the load on a turbine is
kept constant the torque developed at the coupling is also constant. A generator at a steady load
offers a constant torque. Therefore, a turbine is suitable for driving a generator, particularly as
they are both high-speed machines. A further advantage of the turbine is the absence of internal
lubrication. This means that the exhaust steam is not contaminated with oil vapour and can be
condensed and fed back to the boilers without passing through the filters. It also means that
turbine is considerable saving in lubricating oil when compared with reciprocating steam engine
of equal power. A final advantage of the steam turbine and a very important one is the fact that a
turbine can develop many time the power compared to a reciprocating engine whether steam or
oil.
 COAL HANDLING SYSTEM

In the coal handling system, three coal paths are normally available for the direct conveying of
coal. These are:
Path A: From track hopper to boiler bunker.
Path B: From track hopper to stock yard.
Path C: From stock yard to boiler bunkers.
The storage facilities at the stockyards have been provided only for crushed coal. The coal
handling system is designed to provide 100% standby for all equipments and conveyors. The 200
mm coal as received at the track hopper is fed to the crusher house for crushing. Crusher of 50%
capacity is provided and these are preferred to two crushers of 100% capacity because of
increased reliability and possible higher availability. A series of parallel conveyors are designed
thereafter to carry crushed coal directly to the boiler bunkers or to divert it to the stockyard.

Fig 11- Coal Handling System

 SWITCH YARD

A switchyard provides a connection point for transmission lines of the same voltage. Current
electricity forecasts indicate that it is extremely unlikely that the switchyard would be developed
into a substation. Significant increases in power demand from major industrial development in
areas to the east of the Eastern Terminal switchyard site would need to occur for the switchyard
to be developed into a substation.

Fig 12- Switchyard

 HIGH-TENSION SWITCHGEAR:-

OPERATING MECHANISM FOR HIGH TENSION ELECTRIC SWITCH

GEAR

Operating mechanism for high tension electric switch gear comprising hydraulic cylinder means
for reciprocating a rack, a pinion engaged with the rack for rotation thereby, and a three bar
toggle linkage connected between said pinion and the rotary stack of the switch for operating the
switch; said mechanism being characterized by its economy, compactness, foolproof operation,
safety features and power

Fig 13- High Tension Switchgear

 CONCLUSION

This training helped me understand about how the power plants operate and what are the prime
locations for setting up such a large power plant to cope up with huge demand for power
consumption . Also I have an idea about what are the main operating parts of the power plants
and how they are useful in contributing electricity from these power plants. I also get to know
about the various maintenance departments of the power plant and its useful resources required
for its smooth running and functioning.

REFERENCES
1. www.scribd.com
2. www.wikipedia.org
3. www.ntpc.co.in