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Report on Vocational Training

at
National Thermal Power Corporation, Dadri
Bachelor of Technology
Mechanical Engineering

By

UJJAWAL PRATAP SINGH


2012UME1368
Under the supervision of
Mr. Ashish Kumar Purwar
Deputy Manager (AHP), NTPC Dadri
Mr. Surya Pratap Singh
Senior Engineer, NTPC Dadri
Submitted to

Dr. G.D. Agarwal


Dr. Gopal Agrawal
Dr. Rakesh Jain
DEPARTMENT OF MECHANICAL ENGINEERING MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY,
JAIPUR

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ACKNOWLEDGEMENT
An engineer with only theoretical knowledge is not a complete engineer.
Practical knowledge is very important to develop and apply engineering
skills.
It gives me a great pleasure to have an opportunity to acknowledge and to
express gratitude to those who were associated with me during my training at
NTPC.
I am very great-full to Mr. S.L. Soni for providing me with an opportunity to
undergo training under his able guidance. Furthermore, special thanks to Mr.
Atul Kumar Purti for his help and support at NTPC Dadri. Last, but not the
least, I would also like to acknowledge the immense pleasure, brought about
by my friends as they pursued their training along with me. We shared some
unforgettable moments together. I express my sincere thanks and gratitude to
NTPC authorities for allowing me to undergo the training in this prestigious
organization. I will always remain indebted to them for their constant interest
and excellent guidance in my training work, moreover for providing me with
an opportunity to work and gain experience.

THANK YOU

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ABSTRACT
This Project Report has been prepared in fulfilment of Industrial Training to be
carried out in third year of our four year B.TECH course. For preparing the Project
Report, we have visited NTPC Dadri during the suggested duration for the period of
45 days, to avail the necessary information. The blend of learning and knowledge
acquired during our practical studies at the company is presented in this Project
Report.
The rationale behind visiting the power plant and preparing the Project Report is to
study the mechanical overview, various cycles and processes (viz. Steam Generation,
coal handling, turbine functioning) of power generation in thermal power plant.
We have carried out this training under well experienced and highly qualified
engineers of various departments at NTPC Dadri. We have tried our best to cover all
the aspects of the power plant and their brief detailing in this project report.
The main aim to carry out this training is to familiarize ourselves with the real
industrial scenario, so that we can relate with our engineering studies.

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CONTENTS
Certificate.ii
Acknowledgement...iii
Abstract...iv
Contents...v
List of Figures..viii
List of Tables..x
Abbreviationsxi

CHAPTER 1 INTRODUCTION.1
1.1 About NTPC..1
1.2 Strategies of NTPC...2
1.3 Vision.3
1.4 Mission.3
1.5 Core Values3
1.6 Installed Capacity.3
1.7 Working Principle.6
1.8 About NTPC Dadri...7
1.8.1 Installed Capacity...7
1.8.2 Location.8
1.8.3 Coal Source....8
1.8.4 Water Source.8
CHAPTER 2 COAL CYCLE..9
2.1 Coal Supplied at NTPC Dadri..9
2.2 Different Components of Coal Cycle.9
2.2.1 Wagon Tippler.10
2.2.2 Track Hopper10
2.2.3 Paddle Feeder.11
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2.2.4 Conveyer Belts..11


2.2.5 Safety Switches in Conveyers.11
2.2.6 Crusher House..12
2.2.7 Stacker cum Reclaimer...12
2.2.8 Coal Yard...13
2.2.9 Coal Bunker.13
2.2.10 Coal Feeder...14
2.2.11 Coal Mill...14
2.2.12 Furnace..15
CHAPTER 3 WATER CYCLE17
3.1 De-mineralized Water/Steam Cycle..17
3.2 Condensate Cycle...17
3.2.1 Hot Well...18
3.2.2 Condensate Extraction Pump...18
3.2.3 Feed Water Heater...18
3.2.4 Deaerator...19
3.2.5 Feed Storage Tank.19
3.3 Feed Water Cycle...20
3.3.1 Boiler Feed Pump..20
3.3.2 Feed Regulating Station...22
3.3.3 Economiser.22
3.3.4 Boiler Drum...23
3.3.5 Boiler..24
3.4 Steam Cycle.25
3.4.1 Superheater..25
3.4.2 Reheater....26
3.4.3 Steam Lines26
3.4.4 Condenser.26
3.5 Cooling Water Cycle...28
3.5.1 Raw Water Reservoir......28
3.5.2 De-Mineralizing Plant...28
3.5.3 Forebay...29
3.5.4 Cooling Water Pump House....29
3.5.5 Cooling Tower....29
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CHAPTER 4 TURBINE AND GENERATOR..31


4.1 Turbine....31
4.1.1 High Pressure Turbine..31
4.1.2 Intermediate Pressure Turbine..32
4.1.3 Low Pressure Turbine...32
4.2 Electricity Cycle..33
4.3 Generator.....34
4.4 Transformer....35
4.5 Switchyard...36
4.5.1 Circuit Breaker..37
CHAPTER 5 AIR AND FLUE GAS CYCLE.38
5.1 Air Cycles..38
5.2 Fans..39
5.2.1 Primary Air Fan...39
5.2.2 Forced Draft Fan.39
5.2.3 Induced Draft Fan..40
5.3 Flue Gas Cycles..41
5.3.1 Air Preheater.41
5.3.2 Electrostatic Precipitator..42
5.3.3 Chimney...43
5.4 Ash Handling Plant....45
Conclusion47
References48

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LIST OF FIGURES
S.No Figure No.
1
Fig 1.1
2
Fig 1.2
3
Fig 1.3
4
Fig 2.1
5
Fig 2.2
6
Fig 2.3
7
Fig 2.4
8
Fig 2.5
9
Fig 2.6
10
Fig 2.7
11
Fig 2.8
12
Fig 3.1
13
Fig 3.2
14
Fig 3.3
15
Fig 3.4
16
17
18
19
20
21
22
23
24
25
26
27

Fig 3.5
Fig 3.6
Fig 3.7
Fig 3.8
Fig 3.9
Fig 4.1
Fig 4.2
Fig 4.3
Fig 4.4
Fig 4.5
Fig 4.6
Fig 5.1

Title
PLF vs Year graph
Strategies of NTPC
Rankine Cycle (with reheat)
Coal Cycle
Wagon Tippler
Track Hoppers
Coal Sizes
Stacker cum Reclaimer
Coal Bunkers (in Yellow)
Coal Mills (Pulveriser)
Rollers of Coal Mill
Water Cycle
Low Pressure Heater
High Pressure Heater
Deaerator (upper cylinder) and Feed Storage
Tank (lower cylinder)
Boiler Feed Pump
Boiler Drum
Condenser
Natural Draft Cooling Towers
Cooling Tower from inside
High Pressure Turbine
Intermediate Pressure Turbine
Low Pressure Turbine
Generator (Red) and Turbine (Green)
Station Transformer
Switch Yard
Flue Gas Cycle

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2
2
6
10
11
11
12
13
14
15
15
17
19
19
20
22
23
27
30
30
31
32
32
34
36
36
38
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28

Fig 5.2

29
30
31
32
33
34

Fig 5.3
Fig 5.4
Fig 5.5
Fig 5.6
Fig 5.7
Fig 5.8

Forced Draft Fan (bottom left) and Primary Air


Fan (bottom right)
Induced Draft Fan
Air Preheater
Electrostatic Precipitator
Chimney
Hydrobins
Dry Ash Silos

40
41
42
43
44
46
46

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LIST OF TABLES
S.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

Table No.
Table 1.1
Table 1.2
Table 1.3
Table 1.4
Table 1.5
Table 1.6
Table 1.7
Table 2.1
Table 2.2
Table 2.3
Table 3.1
Table 3.2
Table 3.3
Table 3.4
Table 3.5
Table 3.6
Table 3.7
Table 3.8
Table 3.9
Table 3.10
Table 4.1
Table 4.2
Table 5.1
Table 5.2
Table 5.3
Table 5.4
Table 5.5

Title
Installed Capacity of NTPC
Coal Based Plants
Gas Based Plants
Projects Under Implementation
Power Plants with Joint Ventures
NTPC Dadri Coal Based
NTPC Dadri Gas Based
Crusher House
Coal Mill
Furnace specifications
Condensate Extraction Pump specifications
Boiler Feed Booster Pump specifications
Boiler Feed Pump specifications
Economiser Specifications
Boiler Drum specifications
Boiler Specifications
Superheater specifications
Reheater Specifications
Condenser Specifications
Cooling Tower Specifications
Turbine Specifications
Stage I (210MW) Generator specifications
PA Fan specifications
FD Fan specifications
ID Fan specifications
Electrostatic Precipitator specifications
Chimney Specifications

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3
4
4
5
5
7
8
12
15
16
18
21
21
22
23
24
25
26
27
30
33
35
39
39
40
42
44

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ABBREVIATIONS
AHP
APH
BFP
CEP
CHP
CRH
DM
FD FAN
HP TURBINE
HRH
ID FAN
IP TURBINE
LP TURBINE
NRV
PA FAN
RH
SH
SAC
SBA
TPH
T&G
WAC
WBA

ASH HANDLING PLANT


AIR PRE HEATER
BOILER FEED PUMP
CONDENSATE EXTRACTION PUMP
COAL HANDLING PLANT
COLD REHEAT LINE
DEMINERLISATION PLANT
FORCED DRAUGHT FAN
HIGH PRESSURE TURBINE
HOT REHEAT LINE
INDUCED DRAUHT FAN
INTERMEDIATE PRESSURE TURBINE
LOW PRESSURE TURBINE
NON RETURN VALVE
PRIMARY AIR FAN
REHEATER
SUPERHEATER
STRONG ACID CATION
STRONG BASE ANION
TONN PER HOUR
TURBINE AND GENRATOR
WEAK ACID CATION
WEAK BASE ANION

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