SUBMITTED BY: GAURAV BHARDWAJ A2305410190 B.

Tech Final Year Amity School Of Engineering & Technology

AKNOWLEDGMENT
With profound respect and gratitude ,I take the opportunity to convey my thanks to complete the training here .I am extremely grateful to all the technical staff of BTPS/NTPC for their cooperation and guidance that has helped me a lot during the course of training .I have learnt a lot working under them and I will always be indebted of them for this value addition in me .I would like to thanks the all the faculty members of Mechanical And Automation Engineering Department for their effort of constant cooperation which have been a signification factor in the accomplishment of my industrial training

CERTIFICATE
This is to certify that GAURAV BHARDWAJ ,Student of final year B. tech Mechanical And Automation Engineering, Amity School Of Engineering And technology, has been successfully completed his Industrial Training at NATIONAL THERMAL POWER CORPORATION, NEW DELHI from 20th May to 29th June 2013. He has competed the whole training as per the training report submitted by him

TRAINING INCHARGE
NTPC, Badarpur, NEW DELHI

TRAINING AT NTPC
I was appointed to do 3 week training at this esteemed organization from 18th may to 6th June; 2013.I was assigned to visit various of the plant, which were:

Boiler Maintenance Department (BMD I/II/III) Primary Auxiliary Maintenance (PAM) Turbine Maintenance Department (TMD) Coal Handling Department (CHD)
These 6 weeks training was a very educational venture for me .It was really amazing to see the plant by yourself and learn how electricity , which is one of our daily requirement of life ,is produced. This report has been made by my experienced at NTPC .The material in this report has been gathered from my textbook ,senior student reports and trainers manuals and power journals provided by training department .The specification and principles are as learned by me from the employees of each division of NTPC

INDEX
ABOUT NTPC ABOUT BTPS ABOUT STEP OF ELECTRICITY GENERATION RANKINE CYCLE BOILER MAINTENANCE DIVISION PRIMARY AUXILIARY DEPARTMENT TURBINE MAINTENACE DIVISION COAL HANDLING DEPARTMENT

ABOUT NTPC
NTPC Limited is the largest thermal power generation company of india ,public sector company.It was incorporated in the year 1975 to accelerate power development in the country as a wholly owned company of the government of india holds 70% of the total equity shares of the company and the balance 30% is held by FIIs,domestic banks, public and others.Within a space of 38 years,NTPC has emerged as a truly national power company,with power generation facilities in all the major regions of the country. NTPCs core business is engineering,construction and operation of power generation plants and providing consultancy to power utility in india and abroad. The total installed capacity of the company is 41184 MW(including JVs) with 16 coal based and 7 gas based stations ,located across the country.In addition under Jvs, 3 stations are coal based & another

station uses naphtha/LNG as fuel. By 2017,the power generation portfolio is expected to have a diversified fuel mix with coal based capacity of around 53000MW, 1000MW through gas, 9000MW through hydro generation ,about 2000MW from nuclear sources and around 1000MW from Renewable Energy Sources.NTPC has adopted a multi-pronged growth strategy which includes capacity addition through Greenfield projects,expansion of existing station ,joint ventures, Subsidiaries and takeover of stations

TOTAL CAPACITY IN MW
41184 NTPC REST OF INDIA 159816

Technological Initiatives Introduction of steam generatio(boilers)of size of 800 MW. Integrated gasification combined cycle(IGCC)technology. Launch of Energy Technology Centre-A new initiative for development of technologies with focus on fundamental R&D. The company sets aside up to 0.5% of the profits for R&D. Roadmap developed for adopting Clean Development. Mechanism to help get Certified Emission Reduction. Corporate Social Responsibility As a responsible corporate citizen NTPC has taken up number of CSR initiatives. NTPC Foundation forms to address Social issues at national level NTPC has framed corporate Social Responsibility guidelines committing us to 0.5% of net profit annually for community welfare.

 The welfare of project affected persons and the local population around NTPC projects are taken care of through well drawn Rehabilitation and Resettlement policies. The company has also taken up distributed generation for remote rural area centre for Power Efficiency &Environment protection. Group on clean Development Mechanism. NTPC is the second largest owner of trees in the country after the forest department JOURNEY OF NTPC NTPC was set up in 1975 with 100% ownership by the government of india .In the last 30 years ,NTPC has grown into the largest power utility in indai. In 1975,Government of india granted NTPC status of navratnabeing one of the nine jewels of india ,enhancing the powers to the board of directors. In 1997 NTPC became a listed company with majority government ownership of 89.5% In 2004 NTPC becomes third largest by market capitalization of listed companies The company rechristened as NTPC Limited in line with its changing business portfolio and transforms itself from a thermal power utility to an integrated power utility In 2005 NTPC is the largest power generation company in india . Forbes Global 2000 for 2008 ranked it 411th in the world. In 2008 NTPC is the largest power generation company in India.Forbes Global 2000 for 2008 ranked 317th in the world. NTPC has also set up a plan to achieve a target of 50,000 MW generation capacity. NTPC has embarked on plans to become a75,000 MW company by 2017 Partnering government in various initiatives Consultant role to modernize and improvise several plants across the country. Disseminate technologies to other players in the sector.

 Consultant role partnership in excellence programme for improvement of PLF of 15 Power Stations of SEBs. Rural Electrification work under Rajiv Gandhi Garmin vidyutikaran. Environment Management All stations of NTPC are ISO 14001 certified Various group to care environmental issues,

ABOUT BTPS
Badarpur thermal power station started working in 1973 with a single 95MW unit. There were 2 more units (95 MW each) installed in next 2 consecutive years ,now it has total five units with total capacity of 720 MW .ownership of BTPS was transferred to NTPC with effect from 01.06.2006 through GOIs gazette notification given below are the details of unit with the year they are installed Address: Telephone: Fax: Installed Capacity Derated Capacity Location Coal Source Water source Beneficiary states Unit sizes Unit commissioned Badarpur,New Delhi-110044 (STD-011)-26949523 26949532 720 MW 705 MW New Delhi Jharia Coal Fields Agra Canal Delhi 3*95 MW 2*210 MW I-95 MW july 1973 II-95 MW-August 1974 III-95 MW March 1975

IV-210 MW December 1978 V-210 MW-December 1981 Transfer of BTPS to NTPC ownership of BTPS was transferred to NTPC With effect from 01.06.2006 through GOIs Gazette Notification

BASIC STEPS OF ELECTRICITY GENERATION

The basic steps in the generation of electricity from coal in involves following steps: Steam to mechanical power Mechanical power to electrical power

COAL TO ELECTRICITY : BASICS

Steps in the generation of coal to electricity are shown below:

Coal

Superheated steam

Turbine torque

A C in STATOR

CHEMICAL ENERGY

THERMAL ENERGY

KINETIC ENERGY

ELECTRICAL ENERGY

Coal to steam
Coal from the coal wagons is unloaded in the coal handling plant. This coal is transported up to thr raw coal bunkers with the help of belt conveyors. Coal is transported to bowl mills by coal feeders. The coal is pulverized in the bowl mill, where it is ground to powder form .the mill consists of a round metallic table on which coal particles fall. This table is rotated with the help of a motor there are three large steel rollers,which are spaced 120 apart.when there is no coal these rollers do not rotate but when the coal is fed to the table it packs up between roller and the table and the forces the rollers to rotate .coal is crushed by the crushing action between the rollers and the rotating table. This crushed coal is taken away to the furnace through coal pipes with the help of hot and could air mixture from P.A. fan. P.A. Fan takes atm air ,a part of which is sent to Air-preheaters for heating while a part goes directly to the mill for temperature control Atmospheric air from F.D. fan is heated in the air heaters and sent to the furnace as combustion air. Water from the boiler feed pump passes through economizer and reaches the boiler drum. Water from thr drum passes through down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat and density difference , the water rises up in the water wall tube .water is partly converted to steam as it rises up in the furnace. This steam and water mixture is taken to thee boiler where the steam is separated from water

1.cooling tower 2.cooling water pump 3.transmission line 4.unit transformer 5.Electric generator 6.Low pressure turbine 7.condensate extraction pum 8.condensor 9.Intermediate pressure turbine

10.steam governor valve 11.High pressure turbine 12.Deaerator 13.feed heater 14.coal conveyor 15.coal hopper 16.Pulverised fuel mill 17.boiler drum 18.Ash hopper

19.superheater 20.Forced draught fan 21.Reeheater 22.Air intake 23.economiser 24.Air preheater 25.precipitator 26.Induced draught fan 27.chimeny stack

Water follows the same path while the steam is sent to superheaters for superheating .the superheaters are located inside the furnace and the steam is superheated (540C)and finally it goes to the turbine, Flue gases from the furnace are extracted by induced draft fan ,which maintains balance draft in the furnace(-5 to -10mm of wcl)with forced draft fan .these flue gases emit their heat energy to various super heaters in the pent house and finally pass through air-preheaters and goes to electrostatic precipitators where the ash particles are extracted .Electrostatic precipitator consists of metal plates, which are electrically charged. Ash particles are attracted on to these plates ,so that they do not pass through the chimney to pollute the atmosphere.

Regular mechanical hammer blows cause the accumulation of ash to the bottom of the precipitator where they are collected in a hopper for disposal.

Steam to Mechanical Power

From the boiler,a steam pipe conveys steam to the turbine through a stop valve and through control valves that automatically regulate the supply of steam to the turbine stop valve and control valves are located in a steam chest and a governor, driven from the main turbine shaft ,operates the control valves to regulate the amount of steam used. Steam ffrom the control valves entees the high pressure cylinder of the turbine, where act as nozzles and direct the steam into a second ring of moving blades mounted as nozzles and direct the steam into a second ring of moving blades mounted on a disc secured to the turbine shaft .The second ring turns the shafts as a result of the forces of steam .The stationary and moving blades together constitute a stage of turbine and in practice many stages are necessary ,so that the cylinder contains a number of rings of stationary blades with ring of moving blades arranged between them .the steam passes through each stages in turn until it reaches the end of the high pressure cylinder and in its passage som of its heat energy is changed into mechanical energy. The steam leaving the high pressure goes back to the boiler for reheating and returns by a further pipe to the intermediate pressure cylinder .Here it passes through another series of stationary and moving blades .Finally, the steam is taken to the low-pressure cylinders ,each of which enters at the centre flowing outwards in opposite directions through the rows of turbine blades through an arrangement called the double flow-to the extremities of the cylinder .As the steam gives up its heat energy to drive the turbine ,its temperature and pressure fall and it expands.because of this expansion the blades are much larger and longer towards the low pressure ends of the turbine .

Mechanical Power to Electrical Power

As the blades of the turbine rotate, the shaft of the generator ,which is coupled to shaft of the turbine , also rotates, It results in rotation of the coil of the generator, which causes induced electricity to be produced.

BASIC POWER PLANT CYCLE

A Simplifies diagram of a thermal power plant

The thermal power plant uses a dual(vapour +liquid)phase cycle. It is a close cycle to enable the working fluid to be used again and again. The cycle used is Rankine Cycle modified to include superheating of steam, regenerative feed water heating and reheating of steam

On a large turbine ,it becomes economical to increase the cycle 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 the heat is added ,is increased and ,by expanding this reheated steam to the remaining 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. Bleed steam extraction:For regeneration system , nos. of non-regulated extractions is taken from HP, IP turbine Regenerative heating of the boiler feed water is widely used in modern power plants ;the effect being to increase temp. at which heat is added to the cycle , thus improving the cycle efficiency.

FACTORS AFFECTING THERMAL CYCLE EFFICIENCY

Initial steam pressure. Initial Steam Temperature. Whether reheat is used or not,and if used reheat pressure and temperature Condenser pressure. Regenerative feed water heating

RANKINE CYCLE
The Rankine cycle is a thermodynamic 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 electric power used throughout the world , including virtually all solar thermal ,biomass ,coal and nuclear power plants. It is named after William John Macquorn Rankine, a Scottish polymath.. 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.

Bleed steam Extraction: For regenerative system, nos. of non-regulated extraction is taken from HP,LP turbine. Regenerative heating of the boiler feed water is widely used in modern power plants; the effect being to increase the average temperature at which heat is added to the cycle ,thus improving the cycle efficiency.

There are four processes in the rankine cycle,each changing the state of the working fluid . these states are identified by number in the diagram to the right

Process 1-2: The working fluid is pumped from low to high pressure , as the
fluid is aliquid at this stage the pump requires little input energy. 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. Process 3-4: the dry saturated vapor expands through a turbine, generating power . this decreases the temperature and pressure of the vapor , and some condensation may occur. Process 4-1: The wet vapor then enters a condenser where it is condensed at a constant pressure and temperature to become a 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.

TO INCREASE CYCLE EFFICIENCY

Lower condenser pressure Must have at least 10C DT between condenser and cooling water or air temperature for effective heat transfer Watch quality at exit to prevent turbine problems (shouldnt go less than about 88%) Superheat the steam more Tmax ~ 620 due to metallurgical considerations Increase boiler pressure (with same Tmax) Pmax ~ 30 MPa Watch quality at exit Reheat cycle

In this variation, two turbines work in series. The first accepts vapor from the boiler at high pressure. After the vapor has passed the first turbine, it reenters the boiler and is reheated before passing through a second , lower pressureturbine. Among other advantages, this prevents the vapor condensing improves the efficiency of the cycle

Regeneration

Preheats steam entering boiler using a feedwater heater, improving efficiency Also deaerates the fluid and reduces large volume flow rates at turbine exit. BOILER MAINTENANCE DEPARTMENT
Boiler and its description
The boiler is rectangular furnace about 50 ft on a side and 130 ft tall.Its walls are made of a web of high pressure steel tubes about 2.3 inches in diameter.pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the centre. The thermal radiation of the fireball heats the water that circulation rate in the boiler is three to four times the throughout and is typically driven by pumps .The water in the boiler circulates it absorbs heat and changes into steam at 370 C and 3,200 psi.

Boiler side of the Badarpur Thermal Power Station, New Delhi

The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Hence the steam is superheated to 540 C to prepare it for the turbine .the steam generation boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator The generator and the furnace with its steam generation tubes and the superheater coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include: forced daft(FD) fan, Air preheater(APH), boiler furnace, induced draft(ID) fan, fly ash collectors and the flue gas stack. For units over about 210 MW capacity, redundancy of key components is provided by installing duplicates of FD fan,APH,fly ash collectors and ID fan with isolating dampers.on some units of about 60 MW ,two boilers per unit may instead be provided.

Specification of boiler
1. Steam temperature i. Drum 341 C ii. Super heater outlet 540 C iii. Reheat inlet 332C iv. Reheat outlet 540C 2. Steam pressure
i. ii. iii. iv. v. Drum design 158.20 kg/cm2 Drum operating 149.70kg/cm2 Super heater outlet 137.00kg/cm2 Reheat inlet 26.35 kg/cm2 Reheat outlet 24.50 kg/cm2

3.

Fuel specification (a)coal i. fixed carbon 38%

ii. Volatile matter 26% iii. moisture 8%

iv.Ash 28% v.Grindability 55HGI vi. High heat 4860 kcal/kg vii.Coal size to mill 20mm (b)oil i. low heat value 10000 kcal/kg ii.Sulphur 4.5% w/w iii. moisture 1% w/w iv flash point 660 C v.Viscosity 1500 redwood at 37.80 C vi.Sp.weight 0.98 at 380C

AUXILIRIES OF THE BOILER

1. FURNACE (a) Furnace is primary part of boiler where the chemical energy of the
fuel is converted to thermal energy by combustion.Furnace is designed for efficient and complete combustion. Major factors that assist for efficient combustion are amount of fuel Inside the furnace and turbulence, which causes rapid mixing between fuel and air. In modern boilers, water furnaces are used.

2. BOILER DRUM
Drum is of fusion-welded design with welded hemispherical ends. It is provided with stubs for welding all the connecting tubes, i.e. downcomers, risers, pipes, saturated steam outlet. The function of steam drum internals is to separate the water from the steam generated in the furnace walls and to reduce the dissolved solid contents of the steam below the prescribed limit of 1ppm and also take care of the sudden change of stam demand for boiler.

3. REHEATER Reheater is used to raise the temperature of steam from which

a part of energy has been extracted in high pressure turbine .This is another method of increasing the cycle efficiency .

4. SUPERHEATER
Whatever type of boiler is used, steam will leave the water at its surface and pass into the steam space. Steam formed above the water surface in a shell boiler is always saturated and become superheated in the boiler shell, as it is constantly. If superheated steam is required, the saturated steam must pass through a superheater. This is simply a heat exchange where additional heat is added to the steam

5. ECONOMIZER
The function of an economizer in a steam generation 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.

6. AIR PREHEATER
Air preheater absorbs waste heat from the flue gases and transfer this heat to incoming cold air ,by means of continuously rotating heat transfer element of specially formed metal plates. Thousands of these efficiency elements are spaced and compactly arranged within 12 sections. Sloped compartments of a rotor is provided with duct connecting both the ends and is adequately by radial and circumferential scaling APH is the last heat exchanger in the boiler flue gas circuit. To achieve maximum boiler efficiency maximum possible useful heat must be removed from the gas before it leaves the APH. However certain minimum temperature has to be maintained in the flue gas to prevent cold end corrosion

FUNCTION OF AIR PREHEATER

An air pre-heater heats the combustion air where it is economically feasible. The pre-heating helps the following: Igniting the fuel. Improving combustion. Drying the pulverized coal in pulverizer. Reducing the stack gas temperature and increasing the boiler efficiency. There are three types of air heaters: Recuperative Rotary regenerative Heat pipe

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- generation furnaces of the fossil fuel power plants

Types of pulverizer i. Ball and tube mills

A ball mill is a pulverizer that consists of a horizontal cylinder, up to three diameter in length ,containing a change of tumbling or cascading steel balls, pebbles or steel rods. A tube mill is a revolving cylinder of up to five diameters in length used for finer pulverization of ore, rock and other such materials; the materials mixed with water is fed into the chamber from end, and passes out the other end .

ii. Bowl mill

it uses tires to crush coal. It is of two types; a deep bowl mill and the shallow bowl mill

AIR AND DRAFT SYSTEM

Need of Draft System
Air needed for combustion Flue are needed to be evacuated Losses due to flow need to be overcome

Major Fans in Boiler Draft System

PA Fans FD Fans

 ID Fans

PRIMARY AIR SYSTEM

Ambient air is drawn into the primary air ducting by two 50% duty, motor driven axial reaction fans. Air discharging from each fan is divided into two parts, one passes first through a air pre-heater then through a gate into the P.A bus duct. The second goes to the cold air duct. The mix of both is used to carry the pulverized coal to the boiler

FORCED DRAFT FAN

Ambient air is drawn into the secondary air system by two 50% duty, motor driven axial reaction forced draft fans with variable pitch control. Air discharging from each fan passes first through a air preheated then through a isolating damper into the secondary air bust duct. The cross over duct extends around to each side of the boiler furnace to form two secondary air to burner ducts. At the sides of the furnace, the ducts split to supply air to two corners. Then split again to supply air to each of nineteen burner/air nozzle elevations in the burner box.

INDUCED DRAFT FAN

The rotor consists of shaft and assembled impeller and runs in two sleeve bearings that are arranged outside of the housing. The impeller consists of a centre disc and two cover discs that are reinforced by forged rings. The bent blades are welded into position between the impeller discs. The blades are protected by screwed - on wear plates. The shaft is of hollow design. The fan shaft has been rated so that max. operating speed is below the critical speed. Impeller and shaft are connected by means of a flange. This screwing is protected by wear plates.

 The fan housing is sealed by means of two-part labyrinth seals. Bearings are lubricated with oil.

TURBINE MAINTENANCE DEPARTMENT Steam Turbine

A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into useful mechanical work.

Classification
IMPULSE TURBINE REACTION TURBINE

Based on Compounding:
Pressure compounded Velocity compounded

IMPULSE TURBINE
An impulse turbine uses the impact force of the steam jet on the blades to turn the shaft. Steam expands as it passes through the nozzles, where its pressure drops and its velocity increases. As the steam flows through the moving blades, its pressure remains the same, but its velocity decreases. The steam does not expand as it flows through the moving blades.

REACTION TURBINE

In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles. This type of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor