NTPC

PROJECT REPORT
Summer Training

PROJECT REPORT
ON

NTPC BARH PATNA

Submitted by:
MD ASHGAR ANSARI
Roll No. 1415340071

Submitted to:
Mr. YOGESH KUMAR
(Advisor)

DEPARTMENT OF MECHANCAL

SKYLINE INSTITUTE OF ENGINEERING &

TECHNOLOGY, GREATER NOIDA
 Acknowledgements

Everything that happens in the world is an out come of interaction of various factor, some of which
are favourable while other not. Always for a desired result, the number of favourable factors is
more. This work is NO exception to this fact. I acknowledge that I’ve been fortunate enough to get
the support, mentally and physically in everything that I do.

First of all I would like to thank Mr. Yogesh Kumar (Advisor) who led the entire team of FGUTP for
functioning of each department in a modernized and techno-commercial atmosphere to make the
project touch such peaking performance.

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

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

Professor J.M. Giri Mr. YOGESH YADAV

HOD Assistant Professor

Department of Mechanical Department of Mechanical
Engineering Engineering
SIET, Gr.Noida SIET ,Gr.Noida
 Contents
1. Introduction of NTPC

2. Introduction about Project

3. Production of Electricity

4. Principal of Steam Power Plant

5. H.T.Switch gear

6. L.T.Switch gear

7. Generators and Transformers

8. D.C. System

9. Switch Yard

10. Coal Handling Plant

11. Coal Handling Plant Power Distribution

12. Demineral Plant(DM Plant)

13. Coal ,Water and Steam Cycle

14. Conclusion

INTRODUCTION OF NTPC

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

With an installed capacity of 30,144 MW, it contributes 28.6% of the nation’s power generation with
only 18.79% of India’s total installed capacity. An ISO 9001:2000 certified company, it is world’s sixth
largest thermal power generator and second most efficient in capacity utilization.

The corporation recorded a generation of 206.94 billion units (bus) in 2008-09, an increase of 3.03%
over 2007-08, through 13 coal based and 7 gas based power plants spreads all over the country.
Rated as one of the “Best companies to work for in India it has developed in to a multi-location and
multi fuel Company over the past three decades.

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

Following are the other important highlights of 2008-09:

1. Total Income of Rs.455, 000 million.

2. Net profit in excess of Rs.78, 274 million

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

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

INTRODUCTION ABOUT PROJECT

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

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

The governor promulgate Uttar Pradesh Vidyut Utpadan Nigam Limited (Acquisition and transfer of
Undertaking) act. Consideration worth Rs.925 Crore was decided for takeover.

PLF in 1990-91 was 5.5% and at the time of take-over in 1992-93, it was around 20%. NTPC is
managing the project well and the result is PLF of 54.9% in 1992-93, 68% in 1993-94 and more there
after. In the year 2000-2001 it has achieved 85.5%. PLF in March 2009 is highest at 100.03%.

It supplies the produced electricity to region of Uttar Pradesh. The project is a coal-based thermal
power project and the main constituents for production is coal, oil and water.

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

1. Northern region station

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

2. Rihand (2*500) Mega Watts.

3. Unchahar (5*210) Mega Watts.

4. Tanda (4*110) Mega Watts.

2. Southern region station

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

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

3. Western region station

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

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

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

4. Eastern region station

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

2. Kahalgaon (4*210) Mega Watts.

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

5. Nation capital region station

1. Dadri coal (4*210) Mega Watts.

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

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

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

 PRODUCTION OF ELECTRICITY
The means and steps involved in the production of electricity in a coal-fired power station are
described below.

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

Meanwhile the heat released from the coal has been absorbed by the many kilometres of tubing
which line the boiler walls. Inside the tubes is the boiler feed water which is transformed by the
heat into the steam at high pressure and temperature. The steam super-heated in further tubes
(Super Heater) passes to the turbine where it is discharged through the nozzles on the turbine
blades. Just the energy of the wind turns the sail of the wind-mill, so the energy of the steam,
striking the blades, makes the turbine rotate.

Coupled to the end of the turbine is the rotor of the generator – a large cylindrical magnet, so that
when the turbine rotates the rotor turns with it. The rotor is housed inside the stator having heavy
coils of copper bars in which electricity is produced through the movement of the magnetic field
created by the rotor. The electricity passes from the stator winding to the step-up transformer which
increases its voltage so that it can be transmitted efficiently over the power lines of the grid.

The steam which has given up its heat energy is changed back into water in the condenser so that it
is ready for re-use. The condenser contains many kilometres of tubing through which the colder is
constantly pumped. The steam passing around the tubes looses the heat and is rapidly changed back
to water. But the two lots of water (i.e. boiler feed water & cooling water) must NEVER MIX. The
cooling water is drawn from the river, but the boiler feed water must be absolutely pure, far purer
than the water we drink, if it is not to damage the boiler tubes. Chemistry at the power station is
largely the chemistry of water.

To condense the large quantities of steam, huge and continuous volume of cooling water is
essential. In most of the power stations the same water is to be used over and over again. So the
heat which the water extracts from the steam in the condenser is removed by pumping the water
out to the cooling towers. The cooling towers are simply concrete shells acting as huge chimneys
creating a draught (natural/mechanically assisted by fans) of air. The water is sprayed out at the top
of towers and as it falls into the pond beneath it is cooled by the upward draught of air. The cold
water in the pond is then circulated by pumps to the condensers. Inevitably, however, some of the
water is drawn upwards as vapours by the draught and it is this which forms the familiar white
clouds which emerge from the towers seen sometimes.
 Principle of the Steam Power Plant

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

PLANT FLOW DIAGRAM

 H.T.SWITCH GEAR

OPERATIONG VOLTAGE - 6.6KV

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

Requirement of circuit breaker:

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

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

Basic principal of operation of circuit breaker:

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

1. MOCB (Minimum oil circuit breaker)

2. SF6 (Sulphur hexafluoride circuit breaker)

Here oil and SF6 are used to quench the arc.

 L.T SWITCH GEAR

OPERATING VOLTAGE- 415VOLT

TYPES OF CIRCUIT BREAKER: - Air break circuit breaker

Air brake circuit breaker:

The arc interruption process of air- based circuit breaker is based on the natural deionization of
gases by cooling action. The arc is resilient and can be stretched, and has a resistance, which can be
increased both by length and confinement. Hence the arc resistance is increased by stretching the
arc and as the resistance increases to higher value, the short circuit current drops to zero and arc is
extinguished.

Reducing the phase difference between the system voltage and the short circuit current assure that
when the are current is interrupt at its zero value, the recovery voltage has very low value at its not
allowed to reach 2-3 times the value of the system peak voltage, a phenomenon that occurs in most
cases, when arc current is interrupted at low power factor.
 GENERATORS AND TRANSFORMERS

INTRODUCTION-

The auxiliaries in a plant can be divided into two categories-

1. URGENT AUXILIARIES- the urgent auxiliaries are those, which are associated with running of
unit.

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

GENERATOR

SPECIFICATIONS-

TURBO GENERATOR (gen1, gen2)

KVA 247000

Pf 0.85

Volts of stator 15750

Amperes of stator 9050

Volts of rotor 310

Amperes of rotor 2600

Rpm 3000

Hz 50

Phase 3

Connection YY

Coolant Water (stator)& hydrogen (rotor)

Gas pressure 3.5kg/cm-sq.

Insulation class B
 EXCITATION SYSTEM-

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

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

2. BRUSHLESS EXCITATION SYSTEM –The generators in stage -2(U-3, U-4& &U- 5) have this
excitation system. It has two exciters, one is main exciter and other is pilot exciter.

GENERATOR PROTECTION-

1. STATOR PROTECTION- The neutral of star connected winding is connected to primary of

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

2. DIFFERENTIAL PROTECTION- In case of phase-to-phase fault generator is

protected by longitudinal differential relay.

3. ROTOR PROTECTION- Rotor winding may be damaged by earth faults or open circuits. The
field is biased by a dc voltage, which causes current to flow through the relay for an earth
fault anywhere on the field system.

4. OVER SPEED PROTECTION – Mechanically over speed device that is usually in the form of
centrifugally operated rings mounted on the rotor shaft, which fly out and close the stop
valves if the speed of the set increase more than 10%.
5. OVER VOLTAGE PROTECTION – It is provided with an over voltage relay. The relay is usually
induction pattern. The relay open the main circuit break and the field switch if the over
voltage persists.

6. SEAL OIL SYSTEM – Hydrogen in the generator is under very high pressure.
There is a possibility of this hydrogen to come out of gaps, which is very hazardous. So, seal
oil is used to seal the gaps so that hydrogen doesn’t come out.

7. LUBRICATION OIL SYSTEM – Turbine lubrication-oil system seeks to provide

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

TYPE PF TRANSFORMERS—

1. GENRATOR TRANSFORMER: -- This is a step up transformer. This supply gets its primary
supply from generator and its secondary supplies the switchyard from where it is
transmitted to grid. This transformer is oil cooled. The primary of this transformer is
connected in star. The secondary is connected in delta. These are four in number.

2. STATION TRANSFORMER: -- This transformer has almost the same rating as the
generator transformer. Its primary is connected in delta and secondary in star. It is a step
down transformer. These are 4 in number.

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

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

4. NEUTRAL GROUNDED TRANSFORMER: -- This transformer is connected with

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

Generator transformer (GT-1 & GT-2)

KV 15.75/242

MVA 250

Phase 3

Hz 50

Connections Y-D 11

Type of cooling OFAF/ONAF/ONAN

Rated HV and IV (MVA) 250/150/100

Rated LV (MVA) 250/150/100

No Load Voltage HV (KV) 242

No Load Voltage IV (KV)

No Load Voltage LV (KV) 15.75

Line current HV (Amps) 597.14/358.29/238.86

Line current IV (Amps)

Line current LV (Amps) 9175.15/5505.09/3670.66

Temp rise coil oC 50

Temp rise winding oC 55

Neural grounded transformer (NGT)

KVA 1150

Phase 3

Hz 50

Type of cooling ONAF/ONAN

No load voltage HV (volts) 6600

No load voltage LV (volts) 250

Line current HV (Amps) 105.9

Line current LV (Amps) 2655.8

Temp rise oil oC 50

Temp rise winding 55

Potential Transformer

KVA 1000

Phase 3

Hz 50

Type of Cooling ONAN

No Load Voltage HV (volts) 6600

No Load Voltage LV (volts) 433

Line Current HV (Amps) 87.53

Line Current LV (Amps) 133.5

Temp rise oil oC 50

Temp rise winding oC 55

 D.C SYSTEM

INTRODUCTION:

DC system is generally used for control and protection operation, as AC supply is not fully
dependable. To maintain constant supply in case of power failure we use DC supply.

DC system consists of a battery charger. These are the mode of energy storage.

CHARGING EQUIPMENTS:

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

CHARGING EQUATION:

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

1. DISCHARGING PROCESS

2. CHARGING PROCESS

BATTERY CHARGER:

Battery charger normally operates in two modes.

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

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

TRICKLE CHARGER:

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

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

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

SINGLE LINE DIAGRAM OF 220KV SWITCH YARD-

OUTDOOR EQUIPMENTS

1. BUS BAR

2. LIGHTENING ARRESTER

3. WAVE TRAP

4. BREAKER

5. CAPACITOR VOLTAGE TRANSFORMER

6. CORONA RING

7. EARTHING ROD

8. CURRENT TRANSFORMER

9. POTENTIAL TRANSFORMER

10. LIGHTENING MASK

11. LIGHTENING MOOSE

INDOOR EQUIPMENTS

1. RELAYS

2. CONTROL PANELS
 CIRCUIT BREAKER:

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

Circuit breaker is an arrangement by which we can break the circuit or flow of current. A circuit
breaker in station serves the same purpose as switch but it has many added and complex features.
The basic construction of any circuit breaker requires the separation of contact in an insulating fluid
that servers two functions:

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

2. It provides adequate insulation between the contacts and from each contact to earth.

The insulating fluids commonly used in circuit breakers are:

1. Compressed air

2. Oil which produces hydrogen for arc excitation.

3. Ultra high vacuum

4. Sulphur hexafluorides
The Specifications of the circuit breaker used are:

MAKE CROMPTON GREAVES LTD.

TYPE AIR BLAST CIRCUITREAKER

RATED VOLTAGE 245 KV

RATED LIGHTING IMPULSE

WITHSTAND VOLTAGE 1050 KV

RATED SHORT CIRCUIT BREAKING 25 - 40KA

CURRENT

RATED FREQUENCY 50HZ

RATED NORMAL CURRENT 2000 A TO 4000 A

RATED CLOSING VOLTAGE 220 V DC

RATED OPENING VOLTAGE 220 V DC

LIGHTING ARRESTER:

It saves the transformer and reactor from over voltage and over currents. We have to use the
lightning arrester both in primary and secondary of transformer and in reactors.

A meter is provided which indicates the surface leakage and internal grading current of arrester.

1. Green – arrester is healthy

2. Red – arrester is defective.

In case of red we first de-energize the arrester and then do the operation.
 AIR BREAK EARTHING SWITCH:

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

The specification of earthling switch is:

MAKE S & S POWER

TYPE MADRAS

VOLTAGE 245 KV

CURRENT 10 KA

MOTOR VOLT (AC) 415 VOLTS

CONTROL VOLT (DC) 220 VOLTS

BUS BAR:

Bus bars generally are of high conductive aluminum conforming to IS-5082 or copper of
adequate cross section .Bus bar located in air –insulated enclosures & segregated from all other
components .Bus bar is preferably cover with polyurethane.

1. Current Transformer (CT):

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

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

Current Transformer Diagram

Application:

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

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

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

4. Capacitive Voltage Transformer (CVT):

A capacitor voltage transformer (CVT) is a transformer used in power systems to step-down extra
high voltage signals and provide low voltage signals either for measurement or to operate a
protective relay. In its most basic form the device consists of three parts: two capacitors across
which the voltage signal is split, an inductive element used to tune the device to the supply
frequency and a transformer used to isolate and further step-down the voltage for the
instrumentation or protective relay as shown in figure below.
 The device has at least four terminals, a high-voltage terminal for connection to the high voltage
signal, a ground terminal and at least one set of secondary terminals for connection to the
instrumentation or protective relay. CVTs are typically single-phase devices used for measuring
voltages in excess of one hundred kilovolts where the use of voltage transformers would be
uneconomical. In practice the first capacitor, C1, is often replaced by a stack of capacitors connected
in series.This results in a large voltage drop across the stack of capacitors that replaced the first
capacitor and a comparatively small voltage drop across the second capacitor C2, and hence the
secondary terminals.

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

Bay 1 250 MVA 15.75/242 kV Generator transformer – 1

Bay 2 Spare 40 MVA 220/7.1 kV Station Transformer- 3

Bay 3 40 MVA 220/7.1 KV Station Transformer - 1

Bay 4 40 MVA 220/7.1 KV Station Transformer - 2

Bay 6 250 MVA 15.75/242 KV Generator Transformer -2

Bay 7 220 Kv (Chin hut) Luck now Feeder - 1

Bay 8 220 KV Luck now Feeder -2

Bay 9 Bus couplets 220 KV

Bay 10 220 KV Fateful Feeder - 1

Bay 11 220 KV Fateful Feeder - 2

Bay 12 220 KV by Pass Breaker

Bay 13 210 MW Generators -3

Bay 14 40 MVA 220/6.9 KV Station Transformer - 3

Bay 16 210 Mw Generators - 3

Bay 17 220 KV Transfer Bus Coupler- 2

Bay 19 220 KV Kanpur Feeders - 1

Bay 20 220 KV Kanpur Feeders - 2

Bay 21 220 KV Kanpur Feeders - 3

Bay 22 220 KV Kanpur Feeders - 4

 COAL HANDLING PLANT

Introduction: -

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

Type of coal: -

BCCL costs Rs.4/kg

CCl cost Rs.6/kg

Type of unloading the coal: -

1. Manual Unloading: - Previously, manpower was used for unloading the wagons. But it
was very time consuming and more workers were required for the job to be done.

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

3. BOBR: - This method is used in used in stage -2 of NTPC Unchahar. Indian Railway grants only
2.5 hours for Unloading 58 BOBR wagons. This is an advanced technology in which we use the
compressor system.

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

1. WAGON TIPPLER: - The wagon tippler is a most important device in thermal power
project.

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

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

1. Wagon Tippler Hopper: - The Wagon tippler Hoper is a part of the wagon tippler
where the coal is stored from the wagon tippler. The size of the coal here is less than
300mm.

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

3. Beetle Charger: - The Beetle charger is a traveling device that is used to carry
the wagon on the wagon tippler platform.

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

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

1. Plough wheel-It is the rotating part consists of 6 blades. It is attached with the rotor of 3-
phase slip ring induction motor.

2. Reduction gear box- It is installed to control the speed of plough wheel.

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

4. Anti-collision switch- It provides the prevention from collision between two paddle feeders.

5. Interlock system-It is provided for safety purpose. By this, the conveyor belt moves first then
paddle feeder starts.

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

4. TRANSFER POINTS: - Transfer Point is provided with flap gate and Conveyer. In transfer
Point the coal is transferred from one conveyer to other conveyer.

1. Flap Gate: - The flap Gate is a two-way device. It consists of two gates. Both gates
cannot operate together. By help of the flap Gate, we change the way of coal that fall down
on the conveyer.
2. Conveyers: - The Conveyer Belt is a moving device. It travels on its platforms. The shape
of the conveyer belt is to be flat but on the platforms it is to be in curve shape. The coal falls
down the conveyer and goes to the primary Crusher House Platforms. The capacity of
conveyer in Stage – I is 800MT/ hr. & in Stage –II is 1200MT / hr.

Many protecting device provide to the Conveyer---

a -Zero Speed Switch, b -Pull Cord Switch, c - Belt Sway Switch

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

2. Pull cord Switch: - This is a manual protecting device. When the Worker sees any
mistake like big stone or any dangerous fault, pulls this cord. The Pull Cord Switch is to be
operated, and the Conveyer stops.

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

5. PRIMARY CRUSHER (ROTARY BREAKER): - In Primary Crusher House, the coal breaks in Rotary
Breaker. Here the coal comes from the Transfer point; breaks here and the stone fall down to a
separate place. Coal is converted from 300mm to 150mm size.

Part of the Primary Crusher House – a- Rotary Breaker b- Belt Feeder

1. ROTARY BREAKER: - The Rotary Breaker has a rotating mechanism. It is rotated on the
shaft. The coal come from the conveyer through the Flap Gate falls down into the rotary
breaker. The rotary breaker is to be rotated and coal moves up and down and collides and
hence breaks. The Rotary Breaker is H.T. 170KW 6.6KV Motor
2. BELT FEEDER: - The Belt Feeder is a small size of the conveyer. It is used for feeding the coal
to the conveyer through Flap Gate.

6. SECONDARY CRUSHER (RING GRANULATOR): - In Secondary crusher House first the

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

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

8. METAL DETECTOR: - The purpose of installation is to detect any metallic piece passing through
the conveyor. Whenever the pieces pass below the search coil of the metal detector, it gives the
trip command to the conveyor. Simultaneously, sand bag marker will fall on the conveyor belt so
that the metal can be searched easily and removed.

9. STACKER/RECLAIMER: - It is a very important device. The whole Structure of it is called

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

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

2. Reclaimer: - The Reclaimer is position (2). When the rack is not coming and there
is a shortage of coal, then reclaiming is to be started and the coal is lifted from the
Secondary Crush Coal Heap and feeded to the bunker.
 3. Boom Conveyer: - The Boom conveyer is a Bi-directional conveyer. It moves
clockwise & anticlockwise direction. In stacking position, it is moving in clockwise direction
and in the reclaiming position its moving in anticlockwise direction. They are provided with
Center Chute and End Chute on the both end.

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

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

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

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

10. TRANSFER TOWER: - Here the coal is send to the Tipper. Transfer Tower is provided with
a coal sampler.

11. TIPPER: - The Tipper is a three-way device to feed the coal in Bunker. It is moveable
device. It is move on its track.

12. BUNKER: - Here the coal is collected from the tipper and stored. The capacity of the bunker for
Stage-I is 4800MT & Stage-II is 8700MT
COAL HANDLING PLANT POWER DISTRIBUTION SYSTEM
STAGE-1

S.NO DRIVE (CONVEYOR) RATINGS (KW) TYPE-F.L

MCC-1

1 CON1/A/B/C/D 75 NR-3 134A

2 CON2A/B (P) 125 BKR 228A

3 CON2A/B (S) 75 NR-3 143A

4 CON10A/B 125 BKR 228A

5 P/F 1-6 LCC SF-2 100A

6 PLOUGH WHEEL 22 NR-34A

7 LONG TRAVEL 5.5 RV-11A

8 PCRD 2.2 NR-5A

9 SPEED CONTROL 0.25 RV-0.6

10 B/F-1, (PCH) 22 NR-2,37A

MCC-2

11 B/F-2 (PCH) 22 NR-2 37A

12 SUSPENDED MAG. SF-1 63A

13 LIGHTING BOARD SF-3 250A

14 DE-1 (SCH) FSU-2 250A

15 MAG.SEP.(SCR) SF-2 63A

16 VIB.SCREEN-1, 2(SCH) 37 NR-3 64A

17 CON-3A/B 160 BKR 269

18 CON-4A/B 55 NR-3 96A

19 B/F-4 (SCH) 22 NR-2 37A

 MCC-3

20 CBMS-3 TP-8 63A

21 TT-1 63A

22 DE-4(BUNKER) 63A

23 DE-3(BUNKER) 250A

24 CON5A/B 110 BKR 195A

25 CON6A/B 125 BKR 228

26 CON7A/B 90 159A

27 CON8A/B(P) 160 BKR 269

28 CON8A/B(S) 75 BKR 134

29 CON9A/B 90 159A

30 CON12 125 BKR 228A

31 BEETLE CHARGER 1,2 55 RV-98A

32 BAGOB TRIPLER-1,2 71 RV-126A

33 VIB.FEEDERS 1,2,3,4 SF-63A

STAGE 2

Equipment KW

Conv14 2*95

Conv15 2*140

Conv16 2*115

Conv17 65
Conv18 160

Conv19 115

Conv20 315

Conv21 140

Conv22 140

Conv23 2*110

Conv24 110

Conv25 110

Conv26 2*115

R.B 160

Crusher 450
 STAGE-2

S.No. Drive (conveyor) Ratings (KW) Type-F.L

1 CON14A/B 2*95 161

2 CON15A/B 2*140 237

3 CON16A/B 2*115 195

4 CON17A/B 65 115

5 CON18A/B 160 269

6 CON19A/B 115 195

7 CON20A/B (HT) 315 34

8 CON21A/B 140 237

9 CON22 140 237

10 CON23 2*110 182

11 CON24A/B 110 182

12 CON25A/B 110 182

13 CON26 2*115 195

14 R.B 160 269

15 CRUSHER (HT) 450 54

16 BELT FEEDER (SCH) 1,2 18.5 35

17 BELT FEEDER (PCH) 4,5 25 47

18 PADDLE FEEDER 45 80
7,8,9,10

19 S/R-2 BOOM CONVEYOR 75 127

20 S/R-2 BUCKET WHEEL 75 127

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

22 VGF 1,2,3,4 37 65

23 SWP 1A/B 115 195

24 SWP 2A/B 32

25 SUMP-PUMP 15
TERMS FULL FORM

CBMS Cross belt magnetic separator

ILMS Inline magnetic separator

PF Paddle feeder

TT Transfer tower

TP Transfer point

MD Metal detector

SM Suspended magnet

RB Rotary breaker

VGF Vibro grizzly feed

RPG Rack and pinion get

CR Crusher rotary

RH Reclaim hopper

VS Vibrating screen

BF Belt feeder

FG Flap gate

TC Telescopic chute

WT Wagon tippler

PH Pent house

PCH Primary crusher house

SCH Secondary crusher house

S/R Stacker/Reclaimer

CO Conveyor

CHP Coal handling plant

TH Track hopper

MCC Motor control center

LCS Local control switch

PCS Pull card switch

 BSS Belt swag switch

ZSS Zero speed switch

VF Vibrating feeder

VF. Vibrating fan

SOME IMPORTANT FACTS

Coal handling plant area 200acrs

Length of conveyor stage-1 13km

Length of conveyor stage-2 13.5km

M.U.T.H coal capacity stage -1 2800 M.T

New track hopper coal capacity stage -2 5400M.T

Primary yard coal capacity stage -1 2.5 lac M.T

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

Secondary yard coal capacity stage-2 1.8 lac M.T

Bunker capacity stage -1 400*12=4800 M.T

Bunker capacity stage-2 730*12=8760 M.T

Coal used in 24 hrs(4 unit) 12000 M.T

Total plant area 970acrs

Total township area 280acrs

Coal import CCI, BCCL

Water source Sharda and dalmau canal

Power line (220kv) Uncr-Lko(2 lines), Uncr-Fatehpur(2 lines), Uncr-

Kanpur(4 lines)

Power export Delhi, Punjab, Rajesthan, UP, Haryana,

Chandigarh, J & K, HP
 DEMINERAL (DM) PLANT

INTRODUCTION: --

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

PURIFICATION OF WATER: -

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

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

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

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

4. Mixed bed exchanger – And then water is sent to the chamber of mixed bed exchanger
where the remaining ions are removed. This is the last stage of purification.
COAL, WATER & STEAM CYCLES

COAL CYCLE

C.H.P Plant Bunker R.C Feeder Pulverization mill Boiler section

1. R.C Feeder: It is an induction motor driven device, which determine the Quantity of coal
enter in the pulverize mill.

2. Pulverization mill: Pulverization means exposing a large surface area to the action of
oxygen .Two Types of mill are used in the plant.

1. Ball mail: A ball mill operates normally under suction. A large

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

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

D.M Plant Hot well C.E.P Pump Low Pressure Heater 1, 2, 3 Derater
Boiler Feed Pump High Pressure Heater 5, 6 Feed Regulating station
Economizer Boiler Drum.

1. DERATER:

1. Feed strong tank of water

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

3. Filter the harmful chemicals.

2. FEED REGULATING STATIONS:

1. Control the quantity of water in to boiler drum.

3. ECONOMISER:

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

4. DRAFTS SYSTEM:

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

4. In an induced draft system, the fan is installed near the base of Chimney.
 STEAM CYCLE

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

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

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

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

On completion of my vocational training at Feroze Gandhi Unchahar

Thermal Power Project, Unchahar I have come to know about how the very
necessity of our lives nowadays i.e., electricity is generated. What all processes
are needed to generate and run the plant on a 24x7 basis.

NTPC Unchahar is one the plants in India to be under highest load factor
for the maximum duration of time and that to operating at highest plant
efficiencies. This plant is an example in terms of working efficiency and
management of resources to all other thermal plants in our country. The
operating plf of the NTPC as compared to the rest of country is the highest
with 87.54% the highest since its inception.

The training gave me an opportunity to clear my concepts from practical point

of view with the availability of machinery of such large rating.