Industrial Summer Training Project Report NTPC, BADARPUR

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ACKNOWLEDGEMENT
I wish to express my appreciation to all those with whom I worked interacted and whose thoughts and insists helped me in increasing my knowledge and understanding of working in an organization. I feel great pleasure in presenting my obligation to Prof. J.D GUPTA who allowed me to undergo training at BTPS.I acknowledge with deep sense of gratitude to Mr. G.D SHARMA(training coordinator) for providing his esteem guidance and vast knowledge to help me complete my training. I would also like to thanks Mrs. RACHNA SINGH BHAL (H.R.), m y instructors of B.M.D.,P.A.M.,T.M.D. and divisions without them I would not be able to perform such a delightful job. And at last I would like to thanks all the people involved in the training who helped me in accomplishing it in such a wonderful way.

NISHTHA SAINI 110839

TRAINING SCHEDULE
DEPARTMENT PERIOD REPORTING OFFICER

B.M.D

P.A.M

T.M.D

CONTENTS
Introduction ABOUT NTPC Power Generation in India Badarpur Thermal Power Station (BTPS)

Objective

Work Done During The Training Period Basic steps of Electricity generation Boiler Maintenance Division (BMD) Plant Auxiliary Maintenance (PAM) Turbine Maintenance Department(TMD)

Inference Bibliography

INTRODUCTION

Thermal power station employs a great no of equipment performing number of complexity process. The ultimate aim being the production of electricity in order to have stable generating conditions always balance has to be achieved so that heat input is equal to electricity output and losses. Efficiency of the plant is expressed in terms of heat rate which is the kilocalories burnt to get 1 kWhr.

ABOUT NTPC Indias largest power company, NTPC was set up in 1975 to accelerate power development in India. NTPC is emerging as a diversified power major with presence in the entire value chain of the power generation business. Apart from power generation, which is the mainstay of the company, NTPC has already ventured into consultancy, power trading, ash utilization and coal mining. NTPC ranked 317th in the 2009, Forbes Global 2000 ranking of the Worlds biggest companies.

The total installed capacity of the company is 31,704 MW (including JVs) with 15 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 53000 MW, 10000 MW through gas, 9000 MW through Hydro generation, about 2000 MW from nuclear sources and around 1000 MW from Renewable Energy Sources (RES). NTPC has adopted a multipronged growth strategy which includes capacity addition through green field projects, expansion of existing stations, joint ventures, subsidiaries and takeover of stations. NTPC has been operating its plants at high efficiency levels. Although the company has 18.10% of the total national capacity it contributes 28.60% of total power generation due to its focus on high efficiency.

POWER

GENERATION

IN

INDIA

NTPCs core business is engineering, construction and operation of power generating plants. It also provides consultancy in the area of power plant constructions and power generation to companies in India and abroad. As on date the installed capacity of NTPC is 27,904 MW through its 15 coal based (22,895 MW), 7 gas based (3,955 MW) and 4 Joint Venture Projects (1,054 MW). NTPC acquired 50% equity of the SAIL Power Supply Corporation Ltd. (SPSCL). This JV Company operates the captive power plants of Durgapur (120 MW), Rourkela (120 MW) and Bhilai (74 MW). NTPC also has 28.33% stake in Ratnagiri Gas & Power Private Limited (RGPPL) a joint venture company between NTPC, GAIL, Indian Financial Institutions and Maharashtra SEB Co Ltd. NTPC has set new benchmarks for the power industry both in the area of power plant construction and operations. Its providing power at the cheapest average tariff in the country.

DESCRIPTION OF BTPS
(BADARPUR THERMAL POWER STATION )

Badarpur thermal power station (BTPS) is designed and engineered by the central water and power commission (CWP). Approved capacity: 705 MW Installed capacity: 705 MW Location: New Delhi Coal source: jharia coal fields a) CCL (central coal fields) b) BCCL (bharat cooking coals ltd.) c) ECL (eastern coal fields ltd.)

Water source: Agra canal Beneficiary state-New Delhi Size of units- 3x95 MW 2x210 MW Commissioning of units: Unit I Unit II Unit III Unit IV Unit V 95 MW 95 MW 95 MW 210 MW 210 MW 1973-75 1974-75 1974-75 1978-79 1981-82

The management of centrally owned BTPC was handed over to NTPC on April 15th 1978. The BTPS under the management of NTPC is generating today at a plant load factor of more than 80% of the total capacity. The turnaround of station has been possible only due to management of station by NTPC. The station was designed and engineered by Central Electricity Authority (CEA) formerly central water and power commission. The plant became operational on July 26th, 1973.presently the station is supplying its entire generation to New Delhi There are 11 feeders in use at present, 2-Okhla, 2-Sarita Vihar, 2-Mahroli, 2-Noida, 2Ballabhgarh, and 1-Alwar.

Site selection of power plant Availability of coal-steam power station should be located near mines so minimum cost of fuel is maintained. However if such facility isnt available then adequate facilities should be made for transportation of coal like railway lines which are provided in case of BTPS Availability of water-a large amount of water is necessary for condenser. Therefore such a plant should be located at the bank of river or near a canal like Agra canal in case of BTPS Means of transportation-the power plant should be well interconnected with roads or railways system for efficient transportation material Land properties-land should be cheap and there should be enough land surrounding the plant so that there may be option of expanding. The land should be able to withstand the load of heavy equipment Nearness to load centers-this is very important factor when considering dc transmission. If an ac system is employed then this factor is less important because ac can be transmitted at high voltage with consequent reduction transmission cost that is why it is possible to install the plant away from load centre provided the conditions are favorable Ash disposal facilities-quantity of ash to be handled is 1500-2000 tons per day the disposal of large quantity of ash from the power station can be into river, sea or lake or can be brought into useful purposes like manufacturing of bricks as done by BTPS or for land filling as recently was used by Delhi metro Distance from populated areas-since there is a lot of coal burnt in the power station there will be a lot smoke and fumes that make surrounding of plant very hazardous

OBJECTIVE

I was appointed to do Six-week training at this esteemed organization from 18 JUNE to 28 JULY, 2010. In these six weeks I was assigned to visit various division of the plant which were:

1. Boiler Maintenance Division I (BMD-I) 2. Boiler Maintenance Division II (BMD-II) 3. Boiler Maintenance Division III (BMD-III) 4. Plant Auxiliary Maintenance (PAM) 5. Turbine Maintenance Department (T.M.D)

The objective of the training at NTPC is to gain experience of three weeks on field, utilize the current engineering concepts, to gain practical knowledge in the field of thermal power generation and understand how an organization works in harmony to produce benefits for both the employees and customers.

BASIC STEPS OF ELECTRICITY GENERATION:

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

Coal to steam:
Coal from the coal wagons is unloaded in the coal h a n d l i n g p l a n t . T h i s C o a l i s t r a n s p o r t e d u p t o t h e r a w c o a l bunkers with the help of belt conveyors. Coal is transported t o B o w l M i l l s b y C o a l f e e d e r s T h e c o a l i s p u l v e r i z e d i n t h e B o w l M i l l , w h e r e i t i s g r o u n d t o a p o w d e r f o r m . T h e m i l l 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 does not rotate but when the coal is fed to the table it packs up between roller and the table and this f o r c e s t h e r o l l e r s t o r o t a t e . C o a l i s c r u s h e d b y t h e c r u s h i n g action between the rollers and rotating table. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold air mixture from P.A. Fan.

Water from the boiler feed pump passes through e c o n o m i z e r a n d r e a c h e s t h e b o i l e r d r u m . W a t e r f r o m t h e drum passes through down comers and goes to bottom ring header. Water from the bottom ring header is divided to all t h e f o u r s i d e s o f t h e f u r n a c e . D u e t o h e a t a n d - t h e d e n s i t y difference the water rises up in the water wall tubes. "Water is partly converted to steam 'as it rises up in the furnace. This s t e a m a n d w a t e r m i x t u r e i s a g a i n t a k e n t o t h e b o i l e r d r u m where the steam is separated from water. Water follows the s a m e p a t h w h i l e t h e s t e a m i s s ent t o s u p e rh ea t e rs fo r superheating. The superheaters are l o c a t e d i n s i d e t h e furnace and the steam is superheated (540"C) and finally it goes to turbine.

Steam to mechanical Power

From the boiler, a steam pipe conveys steam to the turbine through a stop valve (which can be used to shut off s t e a m i n a n e m e r g e n c y ) a n d t h r o u g h c o n t r o l v a l v e s t h a t a u t o m a t i c a l l y r e g u l a t e t h e s u p p l y o f s t e a m t o t h e t u r b i n e where it passes through a ring of stationary blades fixed to the cylinder wall. These act as nozzles and direct the steam i n t o a s e c o n d r i n g o f m o v i n g b l a d e s m o u n t e d o n a d i s c which rotates the blades and its passage of some heat energy is changed into mechanical energy. The thermal (steam) power plant uses a dual ( v a p o u r + l i q u i d ) p h a s e c yc l e . It i s a c l o s e d c yc l e t o e n a b l e t h e w o r k i n g f l u i d ( w a t e r ) t o b e u s e d a g a i n a n d again. The c y c l e u s e d i s " R a n k i n e C y c l e " m o d i f i e d t o i n c l u d e superh e a t i n g o f s t e a m , r e g e n e r a t i v e f e e d w a t e r h e at i n g a n d reheating of steam.

Mechanical to electrical As the blades of the turbine rotate, the shaft of the generator, which is coupled to turbine, also rotates. It results in rotation of the coil of generator, which causes induced electricity to be produced. BASIC POWER PLANT CYCLE:

Factors affecting thermal efficiency: . Initial steam pressure

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

On large turbines, it becomes economical to increase the cycle efficiency by using reheat, which is a way o f partially overcoming temperature l i m i t a t i o n s . B y returning partially expanded steam, to a reheat, the average t e m p e r a t u r e a t w h i c h h e a t i s a d d e d , i s i n c r e a s e d a n d , b y expanding this reheated steam to the remaining stages of the t u r b i n e , t h e e x h a u s t w e t n e s s i s c o n s i d e r a b l y l e s s t h a n i t w o u l d o t h e r w i s e b e c o n v e r s e l y, i f t h e m a x i m u m t o l e r a b l e wetness is allowed, the initial pressure of the steam can be appreciably increased.

Typical diagram of coal based thermal power plant:

The description of some of the components written above is described as follows: 1. Cooling towers

Cooling Towers are evaporative coolers used for cooling water or other working medium to near the ambivalent web-bulb air temperature. Cooling tower use evaporation of water to reject heat from processes such as cooling the circulating water used in oil refineries, Chemical plants, power plants and building cooling, For example : The tower vary in size from small roof-top units to very large hyperboloid structures that can be up to 200 meters tall and 100 meters in diameter, or rectangular structure that can be over 40 meters tall and 80 meters long. Smaller towers are normally factory built, while larger ones are constructed on site. The primary use of large industrial cooling tower system is to remove the heat absorbed in the circulating cooling water systems used in power plants , petroleum refineries, petrochemical and chemical plants, natural gas processing plants and other industrial facilities . The absorbed heat is rejected to the atmosphere by the evaporation of some of the cooling water in mechanical forced-draft or induced draft towers or in natural draft hyperbolic shaped cooling towers as seen at most nuclear power plants.

2.

Electrical

generator

An Electrical generator is a device that converts kinetic energy to electrical energy, generally using electromagnetic induction. The task of converting the electrical energy into mechanical energy is accomplished by using a motor. The source of mechanical energy may be a reciprocating or turbine steam engine, , water falling through the turbine are made in a variety of sizes ranging from small 1 hp (0.75 kW) units (rare) used as mechanical drives for pumps, compressors and other shaft driven equipment , to 2,000,000 hp(1,500,000 kW) turbines used to generate electricity.

3. Turbines There are several classifications for modern steam turbines.

Steam turbines are used in all of our major coal fired power stations to drive the generators or alternators, which produce electricity. The turbines themselves are driven by steam generated in Boilers or steam generators as they are sometimes called.

Electrical power station use large steam turbines driving electric generators to produce most (about 86%) of the worlds electricity. These centralized stations are of two types: fossil fuel power plants and nuclear power plants. The turbines used for electric power generation are most often directly coupled to their-generators .As the generators must rotate at constant synchronous speeds according to the frequency of the electric power system, the most common speeds are 3000 r/min for 50 Hz systems, and 3600 r/min for 60 Hz systems. Most large nuclear sets rotate at half those speeds, and have a 4-pole generator rather than the more common2-pole one.

Energy in the steam after it leaves the boiler is converted into rotational energy as it passes through the turbine. The turbine normally consists of several stage with each stages consisting of a stationary blade (or nozzle) and a rotating blade. Stationary blades convert the potential energy of the steam into kinetic energy into forces, caused by pressure drop, which results in the rotation of the turbine shaft. The turbine shaft is connected to a generator, which produces the electrical energy.

4.

Steam-powered

pumps

Steam locomotives and the steam engines used on ships and stationary applications such as power plants also required feed water pumps. In this situation, though, the pump was often powered using a small steam engine that ran using the steam produced by the boiler. A means had to be provided, of course, to put the initial charge of water into the boiler(before steam power was available to operate the steam-powered feed water pump).the pump was often a positive displacement pump that had steam valves and cylinders at one end and feed water cylinders at the other end; no crankshaft was required.

In thermal plants, the primary purpose of surface condenser is to condense the exhaust steam from a steam turbine to obtain maximum efficiency and also to convert the turbine exhaust steam into pure water so that it may be reused in the steam generator or boiler as boiler feed water. By condensing the exhaust steam of a turbine at a pressure below atmospheric pressure, the steam pressure drop between the inlet and exhaust of the turbine is increased, which increases the amount heat available for conversion to mechanical power. Most of the heat liberated due to condensation of the exhaust steam is carried away by the cooling

medium

(water

or

air)

used

by

the

surface

condenser.

5.Control

valves

Control valves are valves used within industrial plants and elsewhere to control operating conditions such as temperature, pressure, flow, and liquid Level by fully partially opening or closing in response to signals received from controllers that compares a set point to a process variable whose value is provided by sensors that monitor changes in such conditions. The opening or closing of control valves is done by means of electrical, hydraulic or pneumatic systems.

6.

Fuel

gas

stack

A Fuel gas stack is a type of chimney, a vertical pipe, channel or similar structure through which combustion product gases called fuel gases are exhausted to the outside air. Fuel gases are produced when coal, oil, natural gas, wood or any other large combustion device. Fuel gas is usually composed of carbon dioxide (CO2) and water vapor as well as nitrogen and excess oxygen remaining from the intake combustion air. It also contains a small percentage of pollutants such as particulates matter, carbon mono oxide, nitrogen oxides and sulfur oxides. The flue gas stacks are often quite tall, up to 400 meters (1300 feet) or more, so as to disperse the exhaust pollutants over a greater aria and thereby reduce the concentration of the pollutants to the levels required by governmental environmental policies and regulations. When the fuel gases exhausted from stoves ,ovens, fireplaces or other small sources within residential abodes, restaurants , hotels or other stacks are referred to as chimneys.

BMD
BOILER MAINTENANCE DEPARTMENT

BOILER MAINTENANCE DIVISION I (BMD - I) BOILER MAINTENANCE DIVISION II (BMD- II) BOILER MAINTETNANCE DIVISION III (BMD III)

As the name suggests this unit maintains the boiler and checks out its proper functioning. There are 5 boilers 3 of 95 MW and 2 of 210 MW each. Each boiler is considered as one unit.

Structure of units 1, 2, 3 is same and so is of unit 4,5

Units 1/2/3 (95 MW each) 1. I.D Fans 2. F.D Fans 3. P.A. Fans 4. Mill Fans 5. Ball mill fans 6. RC feeders 7. Slag Crushers 8. DM Make up Pump 9. PC Feeders 10. Worm Conveyor 11. Turnikets 2 in no. 2 in no. 2 in no. 3 in no. 3 in no. 3 in no. 5 in no. 2 in no. 4 in no. 1 in no. 4 in no.

Units 4/5 (210 MW each) 1. I.D Fans 2. F.D Fans 3. P.A Fans 4. Bowl Mills 5. R.C Feeders 6. Clinker Grinder 7. Scrapper 8. Seal Air Fans 9. Hydrazine and Phosphorous Dozing 2 in no. 2 in no. 2 in no. 6 in no. 6 in no. 2 in no. 2 in no. 2 in no. 2 in no.

Boiler and its description:

A boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft. (40m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60 mm) in diameter. Pulverized coal is air-burn into the furnace from fuel nozzles at the four corners and it rapidly burn s, forming large fireball at the centre. The thermal radiation of fireball heats the water that circulates through boiler tubes near the boiler perimeter. The water circulation rate is three 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 degree C) and 3200 psi (22.1 MPa) . It is separated from the water inside the drum at the top of the furnace.

Fig : Boiler side of Badarpur Thermal Power Station ,New Delhi The saturated steam is introduced into superheat pendent tubes that hang in the hottest part of combustion gases as they exit the furnace. Here the steam is superheated 1000 F 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 boiler includes the economizer, the steam drum, the chemical dosing equipment, and furnace w i t h i t s s t e a m g e n e r a t i n g t u b e s a n d t h e s u p e r h e a t e r c o i l s . N e c e s s a r y safety valves are located at suitable points to a v o i d e x c e s s i v e b o i l e r p r e s s u r e . T h e a i r a n d f l u e g a s path e q u i p m e n t i n c l u d e : f o r c e d d r a f t ( F D ) fan,air preheater (APH), b o i l e r f u r n a c e , i n d u c e d d r a f t ( I D ) f a n , f l y a s h c o l l e c t o r s (electrostatic precipitator or baghouse) and theflue gas stack .[1][2] [3]

Schematic diagram of typical coal-fired power plant steam generator highlighting the air preheater (APH) location

Specifications:
MAIN BOILER: AT 100% LOAD

Evaporation 700t/hr Feed water temperature 247C Feed water leaving economizer 276C
STEAM TEMPERATURE:

Drum 341C Super heater outlet 540C Reheat inlet 332C Reheat outlet 540C
STEAM PRESSURE: Drum design 158.20 kg/cm2

Drum operating 149.70 kg/cm2 Super heater outlet 137.00 kg/cm2 Reheat inlet 26.35 kg/cm2

Reheat outlet 24.50 kg/cm2

FUEL:COAL DESIGN WORST Fixed carbon 38% 25%

Volatile matter 26% 25% Moisture 8% 9% Grindability 50% Hardgrove 45% Hardgrove
OIL:

Calorific value of fuel oil 10,000 kcal/kg Sulphur content 4.5% W/W Moisture content 1.1% W/W Flash point 66C

AUXILLARIES OF THE BOILER:

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. Height - 42.797mLength - l3.868mWidth - 10.592mVolume - 52l0m To start the production unit, firstly pulverised coal is fed to the furnace through a pump .For fuel burning, ignition temperature and pressure are also necessary. The burning of coal completely and raise the temperature to an approximately level. Initially air and oil are also fed to it through F.D. fan and oil gun respectively. Then when the temperature is reached to the required level coal starts burning and produces lots of heat and flue gases. The water tube flowing inside the boiler containing water turns into wet steam. It is a water tube boiler.
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. 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 1 ppm 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 bythe chemical reaction of burning some type of fuel.

.The water enters the boiler through a section in the convection pass called the economizer. From the economizer it passes to the steam drum. Once the water enters the steam drum it goes down the down comers to the lower inlet water wall headers. From the inlet headers the water rises through the water walls and is eventually turned into steam due to the heat being generated by the burners located on the front and rear water walls (typically). As the water is turned into steam/ vapour in the water walls, the steam/vapour once again enters the steam drum.

EXTERNAL VIEW OF THE BOILER AT BTPS, NEW DELHI

2.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 r a d i a n t h e a t o f the fuel burnt in the chamber. The front and rear w a l l s a r e b e n t a t t h e l o w e r e n d s t o f o r m a w a t e r - c o o l e d s l a g hopper. The upper part of

t h e c h a m b e r i s n a r r o w e d t o a c h i e v e perfect mixing of combustion gases. T h e w a t e r w a l l s t u b e s a r e connected to headers at the top and bottom. The rear water wall stubes at the top are grounded in four rows at a wider pitch forming the grid tubes.
4. REHEATER :

Reheater is used to raise the temperature of s t e a m f r o m w h i c h a p a r t o f e n e r g y h a s b e e n e x t r a c t e d i n h i g h - pressure turbine. This is another method of increasing the cycle efficiency. Reheating srequires additional equipment I.e. Heating surface connecting boiler and turbine pipe safety equipment like safety valve, non-return valve, isolating valves, high pressure feed pump, etc. Reheater is composed to two sections namely front and r e a r p e n d a n t s e c t i o n w h i c h i s l o c a t e d a b o v e t h e f u r n a c e a r c h between water-cooled screen wall tubes and rear wall hanger tubes.

Tubes of Reheater

5. SUPERHEATERS:

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 a n d cannot become superheated in the boiler shell, as it is c o n s t a n t l y i n c o n t a c t w i t h t h e w a t e r s u r f a c e . If superheated steam is required, the saturated steam must pass through a superheater. This is simply a heat exchanger where additional heat is added to the saturated steam .In water-tube boilers, the superheater may bean additional pendant suspended in the furnace area where the hot g a s e s w i l l p r o v i d e t h e d e gr e e o f s u p e r h e a t r e q u i r e d ( s e e F i g u r e 3.4.4). In other cases, for example in CHP schemes where the gas t u r b i n e e x h a u s t g a s e s a r e r e l a t i v e l y c o o l , a s e p a r a t e l y f i r e d superheater may be needed to provide the additional heat.

If accurate control of the degree of superheat is required, as would be the case if the steam is to be used to drive turbines, then an attemperator (desuperheater) is fitted. This is a device installed after the superheater, which injects water into the superheated steam to reduce its temperature.

6. ECONOMISER: The function of an economizer in a steam generating unit is to absorb heat from the flue gases and add as a s e n s i b l e h e a t t o t h e f e e d - w a t e r b e f o r e t h e w a t e r e n t e r s t h e evaporation circuit of the boiler .Earlier economizer were introduced mainly to recover the heat available in flue gases that leaves the boiler and provision of t h i s a d d i t i o n h e a t i n g s u r f a c e i n c r e a s e s t h e e f f i c i e n c y o f s t e a m 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.

An Economiser

Location &Maintenance:
It is usual to locate economizer ahead of air h e a t e r . C o u n t e r f l o w a r r a n g e m e n t i s normally selected so that h e a t i n g s u r f a c e r e q u i r e m e n t i s k e p t m i n i m u m f o r t h e s a m e temperature drop in flue gas. Water flow is from bottom to top so that steam if any formed during the heat transfer can move along with water and the lock up steam which will cause overheating and failure of economizer tube. Manholes and adequate spacing between the banks of tubes are provided for inspection and maintenance works. 7. AIR PREHEATER:

Air preheater absorbs waste heat from the flue gases and transfers this heat to incoming cold a i r , b y m e a n s o f c o n t i n u o u s l y r o t a t i n g h e a t t r a n s f e r e l e m e n t o f specially formed metal plates. Thousands of these high efficiency elements are spaced and compactly arranged within 12 sections. Sloped compartments of a radially divided cylindrical shell called the rotor. The housing surrounding the rotor is provided with duct c o n n e c t i n g b o t h t h e e n d s a n d i s a d e q u a t e l y s c a l e d b y r a d i a l a n d circumferential scaling. Air preheater consists of: .1.Connecting plates. Housing 2. Rotor 3. Bearing 4. Sector plates & Sealing Arrangement .5.Heating surface elements 8. PULVERISER: A pulverizer is a mechanical device for the grinding of many d i f f e r e n t t y p e s o f m a t e r i a l s . F o r e x a m p l e , t h e y a r e u s e d t o pulverize coal for combustion in the steam-generating furnaces of fossil fuel power plants.

Types of Pulverizers
Ball and Tube Mills

A ball mill is a pulverizer that consists of a h o r i z o n t a l r o t a t i n g c y l i n d e r , u p t o t h r e e d i a m e t e r s i n l e n g t h , containing a charge of tumbling or cascading steel balls, pebbles, or rods. A tube mill is a revolving cylinder of up to five diameters in length used for fine pulverization of ore, rock, and other such materials; the material, mixed with water, is fed into the chamber from one end, and passes out the other end as slime.
Ring and Ball Mill

This type of mill consists of two rings separated by a series of large balls. The lower ring rotates, while the upper r i n g p r e s s e s d o w n o n t h e b a l l s v i a a s e t o f s p r i n g a n d a d j u s t e r assemblies. The material to be pulverized is i n t r o d u c e d i n t o t h e center or side of the pulverizer (depending on the design) and is ground as the lower ring rotates causing the balls to orbit between the upper and lower rings. The pulverized material is carried out of t h e m i l l b y t h e f l o w o f a i r m o v i n g t h r o u g h i t . T h e s i z e o f t h e pulverized particles released from the grinding section of the mill is determined by a classifer separator.
MPS Mill

Similar to the Ring and Ball Mill, this mill uses large "tires" to crush the coal. These are usually found in utility plants.
Bowl Mill

Similar to the MPS mill, it also uses tires to crush coal. There are two types, a deep bowl mill, and a shallow bowl mill.
Advantage of pulverized coal Efficient utilization of cheap and low grade coal

Flexibility to meet fluctuating load Elevation of bending lose

An external view of coal pulverizer

MILLING SYSTEM: RC bunker

These are in process storage silos used for s t o r i n g c r u s h e d c o a l f r o m t h e c o a l h a n d l i n g s ys t e m . G e n e r a l l y , these are made up of welded steel plates.' Normally, there are six such bunkers supplying coal of the corresponding mills. These are located on top of the mills so as to aid in gravity feeding of coal.

Rc feeder:
It transports pre crust coal from raw coal bunker to mill. The quantity of raw coal fed in mill can be controlled by speed control of aviator drive controlling damper and aviator change. These are 6 in number.

Ball Mill:
The ball mill crushes the raw coal to a certain height and then allows it to fall down. Due to impact of ball on coal and attraction as per the particles move over each other as well as over the Armor lines, the coal gets crushed. Large particles are broken by impact and full grinding is done by attraction. The Drying and grinding option takes place simultaneously inside the mill.

Mills

There are six mill (25% capacity each), for every 200 .MW unit, located adjacent to the furnace at '0' M level. These mills pulverize coal to the desired fineness to be fed to the furnace for combustion. Mills Six in Fans: all and - It are is running of condition all 3 the types time.

(a)

ID Fans: - Located between electrostatic precipitator and chimney. Type-radical Speed-1490 Rating-300 Voltage-6.6 Lubrication-by oil rpm KW KV

(b)

FD Fans: - Designed to handle secondary air for boiler. 2 in number and provide Type-axial Speed-990 Rating-440 Voltage-6.6 KV rpm KW ignition of coal.

(c)

Primary Air Fans: - Designed for handling the atmospheric air up to 50 degrees Celsius, 2 in numbers, and they transfer the powered coal to burners to Type-Double Rating-300 Voltage-6.6 Lubrication-by Type of operation-continuous suction firing. radial KW KV oil

ESP (ELECTROSTATIC PRECIPITATOR)

When coal is burnt in the boiler ash is liberated and carried along with flue gases if these ashes are exhausted to the atmosphere. It will create pollution resulting in health hazard .Hence it is necessary to precipitate the dust from the flue gases and in this process is ESP f i n d s p l a c e i n t h e p o w e r p l a n t . In 2 1 O M w 1 1 O T o f c o a l b u r n s p e r h o u r a n d i f c o a l contents 30% ash then ash carried along with flue gases will be 33Tonns\hr.
ADVANTAGES

1. Higher efficiency2. Minimum cost 3. Low maintenance4. Large volume of ash particle5. Creates less pollution
DISADVANTAGES

1. High initial cost2. Loss of efficiency when flow is above the desired rate3. Unpredictable efficiency

FUEL FIRING
There are mainly three components which are used in fuel firing:-1. Pulverised coal2. High pressure air 3. Oil
COAL

The coal has various varieties. The coal which is used out they should have high calorific value, produce maximum heat produce less ash and pollution on burning easily available ,low cost etc. these features are available in bituminous coal, which is used in the plant. It has about 90-95% carbon and its caloric value varies between 3600-4200. Coal is brought in large pieces, so in first stage the coal is finally crushed so that it burns completely .T h e n i t i s s e n t t h e f u r n a c e t h r o u g h c o n v e yo r b e l t . In t h e f u r n a c e t h e c o a l b u r n s a n d produces steam. The ash which gets collected in the scraper is removed time to time with the help of water. Its main function is to produce lot of heat so ass to convert water into steam.
OIL : Oil is supplied with the help of oil gun to coal so that the coal can be easily burn. HIGH PRESSURE AIR: High pressure air is introduced into the furnace so that the coal can be

reached at ignited temperature. The high pressure air from fan is introduced to the furnace through F.D fan The successfully working of an oil firing equipment depends on the following:I. The correct design of control flow.2. The design of combustion chamber.3. The design of the economiser which must be able to reduce the fuel to a finally divided stay

PAM
PLANT AUXILIARY MAINTENANCE
. CONTROL STRUCTURE PUMP HOUSE (CSPH) . WATER TREATMENT PLANT (WTP) . ASH PUMP HOUSE (APH) . AIR COMPRESSOR HOUSE

Control Structure Pump House (CSPH) The CSPH is just located near the entrance of BTPS at the left side of the way, the basic work of CSPH is to treat the raw water coming from the lake, this water is first treated in CSPH and then delivered to the other units such as WTP cooling tower ESP etc. The water is received from lake is totally dirty and full of hard and thick impurities. The water is first screened of using the screen wash pump rotating continuously consisting of filter . This unit consists of all types of pumps used in plants for purposes like water supply, ash slurry flow etc. The various types of pumps are:

The CSPH has following pumps :

S. No 1 2 3 4 5 6

Types CRW Pump Fire Fighting Pump Diesel Fire Pump Low Pressure Pump High Pressure Pump TWS Pump

No. 3 2 1 3 6 3

CHARACTERSTICS:
CRW pump is raw water pump used in CSPH, through which raw water is sent into water treatment plant to get demineralised water. Fire Fighting Pumps are used to pacify fire, which occurs most of the time in Coal Handling Plant. These pumps direct the screened or strained water into the areas where fire has started. Diesel Fire Pump is an alternative to Fire fighting pump. It acts as spare. Low Pressure Pump is used to direct treated water into turbines and cooling lines of units 1, 2, 3, 4, 5. In case LP pump is not able to send water up to unit 4 or 5, HP pumps are used. High Pressure Pumps are also used in ash lines, where the ash is directed into slurry pond. Travelling Water Strainer or TWS pump is used to screen the catchable impurities, plastics, dirt through screens placed in the inlet of the Agra canal channel.

WATER TREATMENT PLANT (WTP )

W.T.P.-I&II

The availability of suitable supply of water both for cooling purposes and for boiler feed make one of the basic requirement of the power station . The water treatment plant is meeting this requirement, the water which is used in the boiler circuit must be in very pure form to avoid corrosion of boiler tube, scale formation on the inside surface of various parts and to avoid silica carryover to turbine corrosion tunes leads to its failure and this reduces boiler reliability scale formation leads to resistance to heat transfer and over hearting of the tube metal and thus causes frequent shut downs. Silica car ies over from boiler gets deposited on relatively cold portion of turbine and create resistance to streamflow thrust reducing efficiency of turbine as the working pressure and

temperature of boiler goes high with unit size increasing the requirement of ver y pure water becomes even more stringent therefore the main object of the WTP is to remove impurities of water being sent to boiler in order that the steam generated is pure and boiler can give an uninterrupted surface.

GEOMILLER
The name given to this unit is because 'geo miller' named company built it and started it. Its main function is to make water pure and clean .The raw water coming from CRW goes into the tank where alum and chlorine are added to it. With the help of chlorine and alum all the mud and dust settles down and clean water is taken from above. From there it goes to two separate tanks and from there 7 pumps 4 of 100Mw and 3 of 21OMw power takes the water to various sections such as WTP-I & II etc.

Internal treatment
This final D.M effluent is then either led to hot well of the condenser directly as make up to boilers, or being stored in D.M. Water storage tanks first and then pumped for make up purpose to boiler feed. As the D.M. Water has a good affinity to absorb carbon dioxide and oxygen, and both are extremely harmful to metal surfaces for their destruction like corrosion, these have to b e removed before it is fed to boiler. This is being done in d e s e c r a t o r . S t i l l t h e r e s i d u a l o x yg e n w h i c h i s r e m a i n i n g i n t h e water is neutralized by a suitable doze of hydrazine, at the point a f t e r d e s e c r a t o r . T o h a v e further minimum corrosion, the pH of feed water is to be maintained at a r o u n d 9 . 0 f o r w h i c h p u r p o s e ammonia in suitable doze is added to this make up water at a point along with hydrazine as stated above.

ASH HANDLING HOUSE Ash utilization is one of the key concerns at NTPC. The Ash Utilization Division, set up in 1991, strives to derive maximum usage from the vast quantities of ash produced at its coal-based stations. The division proactively formulates policy, plans and programme for ash utilization. It further monitors the progress in these areas and works at developing new fields of ash utilization.

Pumps used for ash handling :

S.NO 1. 2. 3. 4. PUMP 1 2 3 4 LUBRICANT Servo 57/68 oil Servo 40 oil Servo 40 oil Servo 40 oil CAPACITY 1000 m3/hr 1300 m3 /hr 1300 m3 /hr 1300 m3 /hr

The quality of ash produced confirms to the requirements of IS3812 .The fly ash g e n e r a t e d a t NTPC stations is ide al for use in cement, concrete, concrete products, cellular concrete, lightweight aggregates, bricks/blocks/tiles etc. This is attributed to its very low loss on ignition value. To facilitate availability of dry ash to end-users all new units of NTPC are provided with the facility of dry ash collection system. Partial dry ash collection systems have also been set up at the existing stations where these facilities didno t e x i s t e a r l i e r . A u gm e n t a t i o n o f t h e s e s ys t e m s t o 1 0 0 % c a p a c i t y i s p r e s e n t l y i n progress. As the emphasis on gainful utilization of ash grew, the usage over t h e y e a r s a l s o increased. From 0.3 million tonnes in 1991-1992, the level of utilization during 2006-07stood at over 20.76 million tonnes. The various channels of ash utilization currently include use by a number of cement, asbestoscement products & concrete manufacturing industries , land development , roads and embankments , ash dye raisin & building products .

NTPC has adopted user friendly policy guidelines on ash utilization. These include actions identified for: . Ash collection and storage system .facilities and incentives to users . direct department activities . administrative and financial aspects In order to motivate entrepreneurs to come forward with ash utilisation schemes, NTPCoffers several facilities and incentives. These include free issue of all types of ash viz.Dry Fly Ash / Pond Ash / Bottom Ash & infrastructure facilities, wherever feasible. Necessary help and assistance is also offered to facilitate procurement of land, supply of electricity etc. from Govt. Authorities. Necessary techno-managerial assistance is givenwherever considered necessary. Besides NTPC uses only ash based bricks & portland pozzolana cement (FAPPC) in most of its construction activities. FAPPC (as per IS 1489P a r t - 1 ) a n d F l y A s h B r i c k s ( a s p e r I S 1 2 8 9 4 ) h a v e b e e n i n c l u d e d i n o u r s t a n d a r d specifications. Demonstration projects are taken up in area of Agriculture, Buildingmaterials, Mine filling etc.

NTPC continually strives to evolve innovative and diverse means of ash utilization to further broaden the scope. Prominent among the methods devised so far are : . dry flash extraction systems . use in cement and concrete . use in ash based product including setting up of Ash technology park .agriculture . mine filling / stowing NTPC, Ash Utilization Division has brought out a booklet titled 'NTPC Guide for Userso f Coal Ash' for distribution amongst prospective entrepreneurs and users of a s h . It covers salient information about NTPC's power stations, facilities offered for setting upof ash based industry, statistics about ash production and its quality, brief write-up aboutvarious technologies available for utilization of ash, list of equipment manufacturers,technology suppliers, agencies who may be approached for setting up the projects fly ash system

Air Compressor house

This machine is the reciprocated device machine. Types of compressor : # 1st classification Plant air compressor Tenfold compressor Station air compressor Instrument air compressor Densover air compressor Blaster air compressor # 2nd classification: Single satge compressor Double stage compressor

Multiple stage compressor Our compressor is double stage compressor . 1. Plant air compressors are lubricated compressors. 2. Instrument air compressors are non- lubricated compressors.

Use of air in Plant Instrument air is required for various dampers , burner tilting devices, diaphragm valves etc. at 210 MW units. Station air meets the general requirements of power station such as light oil atomizing air , for cleaning filters , and for various maintanence works. The control air compressors and station air compressors have been housed separately with separate receivers and supply headers and their tapping.Plant air compressors & Densover air is used in Ball mill, ESP system , cleaning work, R.C Feeder , cooling the bearing. Blasting & degassing in air . Hopper operating system , densover valve operating system , HT tank , spray & tier fighting tank , pressurized by air.

A compressor house

Parts of compressor : 1. 2. 3. 4. Crankcase Crankshaft Connecting rods Main bearing & big end bearing

5. Cross head 6. HP &LP cylinder 7. Pistons 8. Valves 9. Intercooler 10. After cooler 11. Oil pump 12. Coupling 13. motor

Specifications of BTD HM compressor 1. Bore LP cylinder = 380 mm HP cylinder = 245 mm 2. Stroke = 125 mm 3. Speed = 980 rpm 4. Piston displacement = 27.60 m3/ min 5. F.A.D at 7kg /cm/sq/g =21.25 m3/min 6. Motor kw =125/135 7. Netweight of compressor = 2900 kgs (app.) 8. Lubricating oil = 25 lt 9. Oil pressure = 2.5 to 4 kg/cm 10. Cooling water flow rate = 180 lt/ min

Reciprocating compressor Reciprocating compressors usepistonsd r i v e n b y a c r a n k s h a f t . T h e y c a n b e e i t h e r stationary or portable, can be single or multi-staged, and can be driven by electric motorso r internal combustion engines. Small reciprocating c o m p r e s s o r s f r o m 5 t o 30horsepower (hp) are commonly seen in automotive applications and are typically for intermittent duty. Larger reciprocating compressors up to 1000 hp are still commonlyfound in large industrial applications, but their numbers are declining as they are replaced by various other types of compressors. Discharge pressures can range from low pressuret o v e r y h i g h p r e s s u r e ( > 5 0 0 0 p s i o r 3 5 M P a ) . I n c e r t a i n a p p l i c a t i o n s , s u c h a s a i r compression, multi-stage double-acting compressors are said to be the most efficient compressors available, and are typically larger, noisier, and more costly than comparable rotary units.

There are four main types of compressor used at badarpur thermal power station . these are as follows : Densover compressor: It i s t h e m o s t i m p o r t a n t c o m p r e s s o r u s e d a t B . T . P . S . T h e s e a r e f o u r i n n u m b e r . O n e Densveyor compressor is connected with each mill. It provides the primary as well assecondary air to the plant. These compressors are automatically operated. It carries thecoal directly from the mill s to the furnace. These compressors work under a maximum pressure of 8kgf. Plant compressor: These compressors are two in number. Plant compressors are moisture type compressors.These are mainly used for washing the ash formed in the furnace and disposing them off.These compressors work under a maximum pressure of 8kgf.Instrument compressors:-These are dry type compressors. These are used to operate different instruments. These compressors are three in number. These also work under a maximum pressure of 8kgf. Blast air compressor: These compressors are smaller in size and are not as important as the other three types of compressors. The coal in the RC (raw coal) bunkers sometimes sticks to the surface of the bunkers due to moisture content in the coal. In such cases, blast air compressors areused to detach the coal from the surface of the RC (raw coal) bunkers.

INDUSTRIAL FANS :
The air we need for combustion in the furnace and the flue gas thatwe must evacuate would not possible without using fans. A fan is capable of imparting energy to the air/gas in the form of a boost in pressure. We overcome the losses through the system by means of this pressure boost. The boost is dependent on dens ity for a givenfan at a given speed. The higher the temperature, the lower is the boost. Fan performance (Max. capability) is represented as volumevs. pressure boost.

ID FAN The induced Draft Fans are generally of Axial -Impulse Type. Impeller nominal diameter is of the order of 2500 mm. The fan consists of the following sub-assemblies Suction Chamber Inlet Vane Control Impeller Outlet Guide Vane Assembly

ID FAN

The outlet guides are fixed in between thec a s e o f t h e d i f f u s e r a n d t h e c a s i n g. T h e s e g u i d e v a n e s s e r v e t o direct the flow axially and to stabilize the draft-flow caused in thei m p e l l e r . T h e s e o u t l e t b l a d e s a r e r e m o v a b l e t yp e f r o m o u t s i d e . During operation of the fan itself these blades can be replaced one by one.Periodically the outlet blades can be removed one at a time to findout the extent of wear on the blade. If excessive wear is noticed the blade can be replaced by a new blade.

FD FAN
T h e f a n , n o r m a l l y o f t h e s a m e t yp e a s ID F a n , c o n s i s t s o f t h e following components: *Silencer *Inlet bend *Fan housing *Impeller with blades and setting mechanism *Guide wheel casing with guide vanes and diffuser

FD FAN

The centrifugal and setting forces of the blades are taken up by the blade bearings. The blade shafts are placed in combined radial andaxial antifriction bearings which are sealed off to the outside. Theangle of-incidence of the blades may be adjusted during operation.T h e characteristic pressure volume curves of the fan may bec h a n g e d i n a large range without essentially modifying theefficiency. The f a n c a n t h e n b e e a s i l y a d a p t e d t o c h a n g i n g operating conditions.The rotor is accommodated in cylindrical roller bearings and an inclined ball bearing at the drive side adsorbs the axial thrust.Lubrication and cooling these bearings is assured by a combinedoil level and circulating lubrication system.

PRIMARY AIR FAN :

P.A. ran if flange mounted design, single stage suction, NDFV type, backward curved bladed radial fan operating on the principleof energy transformation due to centrifugal forces. Some amountof the velocity energy is converted to pressure energy in the spiralc a s i n g . T h e f a n i s d r i v e n a t a c o n s t a n t s p e e d a n d t h e f l o w i s controlled by varying the angle of the inlet vane control. TheSpecial feature of the fan is that is provided with inlet guide vanecontrol with a positive and precise link mechanism.

PRIMARY AIR FAN

TMD
TURBINE MAINTENANCE DEPARTMENT

TURBINE CLASSIFICATION :
IMPULSE TURBINE : In Impulse Turbine steam expands in fixed nozzles.The high velocity steam from nozzles does work on moving bladeswhich causes the shaft to rotate. The essential features of impulset u r b i n e a r e t h a t a l l p r e s s u r e d r o p s o c c u r a t n o z z l e s a n d n o t o n blades.A simple impulse turbine is not very efficient because it doesnot fully use the velocity of the steam. Many impulse turbines arevelocity compounded. This means they have two or more sets of moving blades in each stage.

REACTION TURBINE :
In this type of turbine pressure is reduced at both fixed& m o v i n g b l a d e s . B o t h fixed& moving blades act as nozzles.Work done by the impulse e f f e c t o f s t e a m d u e t o r e v e r s a l s o f direction of high velocity steam. The e x p a n s i o n o f s t e a m t a k e s place on moving blades.

A reaction turbine uses the "kickback" force of the s t e a m a s i t l e a v e s t h e m o v i n g blades and fixed blades have thes a m e s h a p e a n d a c t l i k e n o z z l e s . T h u s , s t e a m e x p a n d s , l o s e s pressure and increases in velocity as it passes through both sets of blades. All reaction turbines are pressure-compounded turbines.

COMPOUNDING:
Several problems occur if energy of steam is convertedin single step & so compounding is done. Following are the typesof compounded turbine: Velocity Compounded Turbine Like simple turbine it has only one set of nozzle & entire steam pressure drop takes place there. The kinetic energy of steam fully on the nozzles is utilized in moving blades. The role of fixed blades is to change the direction of steam jet & to guide it. PRESSURE COMPOUNDED TURBINE This is basically a no. of single impulse turbines inseries or on the same shaft.The exhaust of first turbine enters the nozzle of the next turbine.Total pressure drop of steam does not take on first nozzle ring butdivided equally on all of them. Pressure Velocity Compounded Turbine It is just the combination of the two compounding hasthe advantages of allowing bigger pressure drops in each stage &s o f e w e r s t a g e s a r e n e c e s s a r y . H e r e f o r gi v e n p r e s s u r e d r o p t h e turbine will be shorter length but diameter will be increased. Steam turbines may be classified into different categories depending on their construction, the process by which heat dropi s a c h i e v e d , t h e i n i t i a l a n d f i n a l c o n d i t i o n s o f s t e a m u s e d a n d their industrial usage.

MAIN TURBINE : The 210MW turbine is a tandem compounded typem a c h i n e c o m p r i s i n g o f H . P . & I. P . c yl i n d e r s . T h e H . P . t u r b i n e comprises of 12 stages the I.P. turbine has 11 stages & the L.P. hasfour stages of double flow. The H.P. & I.P. turbine rotor are rigidlycompounded & the I.P. & the I.P. rotor by lens type semi flexible coupling. All the three rotors are aligned on five bearings of whichthe bearing no.2 is combined with thrust bearing.The main superheated steam branches off into twostreams from the boiler and passes through the emergency stopv a l v e a n d c o n t r o l v a l v e b e f o r e e n t e r i n g , t h e g o v e r n i n g w h e e l chamber of the H.P. turbine. After expanding in the 12 stages in the H.P. turbine the steam returned in the boiler for reheating.

The reheated steam from the boiler enter I.P. turbine viainterceptor valves and control valves and after expanding entersthe L.P. turbine stage via 2 numbers of cross over pipes.In the L.P. stage the steam expands in axially oppositedirection to counteract the trust and enters the condenser placedd i r e c t l y b e l o w t h e L . P . t u r b i n e . T h e c o o l i n g w a t e r f l o w i n g throughout the condenser tubes condenses t h e s t e a m a n d t h e condensate collected in the hot well of the condenser.The condensate collected is pumped by means of 3*50% duty condensate pumps through L.P. heaters to deaerator f r o m w h e r e t h e b o i l e r f e e d p u m p d e l i v e r s t h e w a t e r t o boiler t h r o u g h H . P . h e a t e r s t h u s f o r m i n g a c l o s e d c y c l e

Turbine cycle : Fresh steam from boiler is supplied to the turbinethrough the emergency stop valve. From the stop valves steam issupplied to control valves situated on H.P. cylinders on the front bearing end. After expansion through 12 stages at the H.P. cylinder steam flows back to boiler for reheating and reheated steam from t h e b o i l e r c o v e r t o t h e intermediate pressure turbine trough two interceptor valves and four control v a l v e s m o u n t e d o n t h e I. P . turbine.After flowing trough I.P. turbine steam enters the middle part of the L.P. turbine through cross over pipes. In L.P. turbine theexhaust steam condenses in the surface condensers welded directlyto the exhaust part of L.P. turbine.

The turbine cycle

The selection of extraction points and cold reheat pressurehas been done with a view to achieve the highest efficiency. Theseare two extractions from H.P. turbine, four from I.P. turbine ando n e f r o m L . P . t u r b i n e . S t e a m a t 1 . 1 0 t o 1 . 0 3 g / s q c m A b s i s supplied for the gland sealing. Steam for this purpose is obtained f r o m d e a e r a t o r t h r o u gh a c o l l e c t i o n w h e r e p r e s s u r e o f s t e a m i s regulated.From the condenser condensate is pumped with the helpof 3*50% capacity condensate pumps to deaerator through the low pressure regenerative equipments. Feed water is pumped from deaerator

to the boiler through the H.P. heaters by means of 3*50% capacity feed pumpsconnected before the H.P. heaters. TURBINE COMPONENTS: Casing Rotor Blades Sealing System Stop & control valves Coupling & bearings Bearing gear

Condensate System :
This contains the following : Condensate pumps : 3 per unit of 50% capacity each located near condenser hot well. LP Heaters : Normally 4 in no. with 1 located at upper part of the condenser & no.s 2,3,4 around 4m level. Deaerator : one per unit located around 181M level in CD bay.

Condensate Pumps
The function of these pumps is to pumps out the condensate to the desecrator through ejectors, gland steam cooler,a n d L . P . h e a t e r s . T h e s e p u m p s h a v e f o u r s t a g e s a n d s i n c e t h e suction is at a negative pressure, special arrangements have been m a d e f o r p r o v i d i n g s e a l i n g . T h i s p u m p i s r a t e d g e n e r a l l y f o r 160m3 hr. at a pressure 13.2 Kg/cm2.

L.P. Heater
Turbine has been provided with non-controllede x t r a c t i o n s w h i c h a r e u t i l i z e d f o r h e a t i n g t h e c o n d e n s a t e , f r o m turbine bleed steam. There are 410w pressure heaters in which thelast four extractions are used. L.P. Heater-1 has two parts LPH-1Aa n d L P H - 1 B l o c a t e d i n t h e u p p e r p a r t s o f c o n d e n s e r A a n d condenser B respectively. These are of horizontal type with shell and tube construction. L.P.H. 2, 3 and 4 are of similar constructiona n d t h e y a r e m o u n t e d i n a r o w a t 5 M l e v e l . T h e y a r e o f v e r t i c a l construction with brass tubes the ends of which are expanded intotube plate. The condensate flows in the "U" tubes in four passesand extraction steam washes the outside of the tubes. Condensate passes thru' these four L.P. heaters in succession. These heatersare equipped with necessary safety valves in the steam space levelindicator for visual level indication of heating steam condensate pressure vacuum gauges for measurement of steam pressure etc.

DEAERATOR

The presence of cerataion gases principally oxygen , carbondioxide, ammonia dissolved in water is generally considered harmful because of their corrosive attack on metals, particularly at elevated temperatures. One of the most important factor in prevention of internal corrosion in modern boilers and associated plant therefore is that the boiler feed water should be free as far as possible from all dissolved gases especially oxygen. This is achieved by embodying into the boiler feed system deaerating unit , whose function is to remove dissolved gases from feed water by mechanical mens. Particularly the unit must reduce the oxygen content of feed waterto lower values as far as possible , depending upon the individual circumstances. Residual oxygen content in condensate at the outlet of deaerating plant usuassly specified are 0.005/ lt or less.

A DEAERATOR

PRINCIPLE OF DEAERATION It is based on following two laws. H e n r y s Law Solubility

The Deaerator comprises of two chambers: Deaerating column Feed storage tank Deaerating column is a spray cum tray type cylindrical vessel of horizontal constructionwith dished ends welded to it. The tray stack is designed to ensure maximum contact time aswell as

optimum scrubbing of condensate to achieve efficient deaeration. The deaerationcolumn is mounted on the feed storage tank, which in turn is supported on rollers at the twoends and a fixed support at the centre. The feed storage tank is fabricated from boiler qualitysteel plates. Manholes are provided on deaerating column as well as on feed storage tank for inspection and maintenance.The condensate is admitted at the top of the deaerating column flows downwards through thespray valves and trays. The trays are designed to expose to the maximum water surfaces for efficient scrubbing to affect the liberation of the associated gases steam enters from theunderneath of the trays and flows in counter direction of condensate. While flowing upwards through the trays, scrubbing and heating is done. Thus the liberated gases move upwards along with the steam. Steam gets condensed above the trays and in turn heats the condensate. Liberated gases escapes to atmosphere from the orifice opening meant for it. This opening is provided with a number of dlflectors to minimize the loss of steam.

FEED WATER SYSTEM

The main equipments under this system are : Boiler Feed Pump : T h r e e p e r u n i t o f 5 0 % c a p a C i t y e a c h located in the '0' meter level in the TG bay. High Pressure Heaters : N o r m a l l y t h r e e i n n u m b e r a n d a r e situated in the TG bay. Drip Pumps : Generally two in number of 100% capacity each situated beneath the LP heaters. T u r b i n e L u b r i c a t i n g O i l S y s t e m : T h i s c o n s i s t s o f M a i n O i l Pump (MOP) Starting Oil Pump (SOP), AC standby oil pumpsand emergency DC' oil pump and Jacking Oil Pump (JOP) (oneeach per unit). Boiler feed pumps
This pump is horizontal and of barrel design driven byan Electric motor through a hydraulic coupling. All the bearings of pump and motor are forced lubricated by a suitable oil lubricatingsystem with adequate protection to trip the pump if the lubricationoil pressure falls below a preset value.The high-pressure boiler feed pump is very expensivem a c h i n e w h i c h c a l l s f o r a v e r y c a r e f u l o p e r a t i o n a n d s k i l l e d m a i n t e n a n c e . T h e s a f e t y i n o p e r a t i o n a n d e f f i c i e n c y o f t h e f e e d pump depends largely on the reliable operation and maintenance. Operating staff must be able to find out the causes of defect at thevery beginning which can be easily removed without endangeringt h e o p e r a t o r o f t h e p o w e r p l a n t a n d a l s o w i t h o u t t h e e x p e n s i v e dismantling of the high pressure feed pump.

The feed pump consists of pump barrel, into which ismounted the inside stator together with rotor. The hydraulic part is e n c l o s e d b y t h e h i g h p r e s s u r e c o v e r a l o n g w i t h t h e b a l a n c i n g device. The suction side of the barrel and the space in the h i gh pressure cover behind the balancing device are enclosed by the low pressure covers along with the stuffing box casings. The bracketso f t h e r a d i a l b e a r i n g o f t h e s u c t i o n s i d e a n d r a d i a l a n d t h r u s t bearing of the discharge side are fixed to the low pressure covers.T h e e n t i r e p u m p s a r e m o u n t e d o n a f o u n d a t i o n f r a m e . T h e hydraulic coupling and two claws coupling with coupling guardsa r e a l s o d e l i v e r e d a l o n g w i t h t h e p u m p . W a t e r c o o l i n g a n d o i l lubricating are provided with their accessories. HP heater These are regenerative feed water heaters operating ath i g h p r e s s u r e a n d l o c a t e d b y t h e s i d e o f t u r b i n e . T h e s e a r e generally vertical type and turbine bleed steam pipes are connectedto them.HP heaters are connected in series on feed watersideand by such arrangement, the feed water, after feed pump enters t h e H P h e a t e r s . T h e s t e a m i s s u p p l i e d t o t h e s e h e a t e r s f o r m t h e bleed point of the turbine through motor operated valves. Theseheaters have a group bypass protection on the feed waterside.In the event f tube rupture in any of the HPH and the level of theconde nsate rising to dangerous level, the group protection device d i v e r t s a u t o m a t i c a l l y t h e f e e d w a t e r d i r e c t l y t o b o i l e r , t h u s bypassing all the 3 H.P. heaters.

INFERENCE
In these six weeks at BTPS, I gained practical experience and earned quite a lot of

Information regarding thermal power engineering. The thermal plant consists of various units. All the main plant running equipments were divided into units, which were further sub divided into more specific units for their maintenance and efficient working. For my six week training, I was assigned the work of three units, which were BMD and PAM & TMD. Boiler and turbine are the most important part of the power plant, without which the power plant cannot run. This plant produces 705 MW of electricity, with the help of its 5 units. 3 units of 95 MW each and 2 units of 210 MW each. The 95 MW units were the first ones to be established followed by the 210 MW units in the later years. As for the unit PAM, it is equally important. It takes care of all the auxiliary processes going on in the plant. It provides water to all the parts of the plant with the help of pumps present in CSPH. Also it produces DM water from raw water by passing it through water treatment plant. The ash or the waste produced on burning is taken care of, by Ash handling plant. The compressed air required in any part of the plant is provided by the unit comprising of the compressor, also known as compressor house. The fuel used was coal which was pulverized with the help of bowl and ball mills. This pulverized coal was the fuel burnt in the furnace to produce heat, which then heated the water to superheated steam. This superheated steam was passed into the turbine rotor, thus rotating the turbine shafts. To ensure the quality of steam generated a process named as reheating is taken into account, which increases the dryness fraction of steam or makes it superheated. Thus as the rotor rotates, it also runs the generator, which produces electricity. This electricity is then sent to GT junction (Generator- Transformer), through which the electricity is passed into the switching yard. After which it is distributed into various grids. process. Thus I learned a lot during my training and hope to use this knowledge in the future.

BIBLIOGRAPHY

NTPC Trainer Manual , By Training Department Senior Student Training Report , NTPC Badarpur Library , New Delhi NTPC slides , By- NTPC training Department