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30-May-2016 Today, was my first day of internship at National thermal power corporation (NTPC). I was very excited though nervous. I was excited as I already had little knowledge about working of powerplant as I had already completed my powerplant engineering course and I wanted to learn more about it and wanted to know things practically. On the first day trainees were asked to go to Employee development Centre (EDC) building. At EDC many trainees were there. Training coordinator came and asked us to sit in a room and gave us a form for one month entry inside NTPC and told us to visit very next day after collecting entry paas. 31-May-2016 Today, I went to EDC building along with many trainee. We were asked to sit in a room and after few minutes a sir came who was from operation and research department was allotted to us by our training incharge. He taught the basic working of powerplant. He told us about rankine cycle and reheat rankine cycle which I already knew as I learnt these cycles in my powerplant engineering course. He gave us basic idea about what we have to learn as a trainee and told us about various department like BMD, PAM , TMD , PAM which we have to visit. 1—July—2016 On day 3, We were again summoned at the EDC building. Sir, told us about how they meet the demand and how electricity is supplied at our homes and cost of one unit production which was Rs 4.60 which was way more than the hydro powerplant as its unit cost was 40 paisa. He told us briefly about transmission and distribution and about electrical things. On the same day, there was session on safety measures to be taken at NTPC. Sir, told us about what to do and what not to. He told us about how small ignorance can lead to a bigger problem and we were asked to our safety helmet and shoes inside NTPC. On the same day our insurance was done. 2—-June—2016 Today, At EDC sir, allotted the department which we have to visit during our internship. The details are as follows:— ¢ Boiler Maintenance Department (BMD) e Plant Auxiliary Maintenance (PAM) e Turbine Maintenance Department (TMD) ¢ Coal Handling Plant (CHP) Today sir, taught us about various cycles like Primary Air Cycle e Seconday Air Cycle * Coal Cycle e Electricity Cycle e Flue Gas Cycle e Condensate Cycle e Feed Water Cycle e Steam Cycle 3-June—2016 Today, it was my first day on Boiler Maintenance Department. All students were divided into the groups. We had to report AGM (BMD). He told us that they have 5 unit, 3 of them were 95 MW each and 2 unit of 210 MW each. He gave description about the boiler that the boiler is a rectangular furnace about 15m on a side and 40 m tall and its walls are made of a web of a high pressure steel tubes about 60 mm in diameter. He then told about difference between ideal rankine cycle and actual rankine cycle and about reheat and regenerative cycle and what effect does it have on efficiency. He told that before coal enters the furnace it is pulverized i.e. broken down into very fine particle and with the help of primary air fan it enters into the furnace and secondary air fan which provides excess air for complete combustion. 4—June-—2016 Today, we again went to the AGM. He summoned one worker and asked him to show us the primary and secondary air fan. We went with him and he showed us both fans. PA fan was having backward curved bladed radial fan and had spiral casing. After viewing fans we went again to sir and he told that coal preheated below its ignition temperature so as to increase efficiency. He also explained that height of the boiler is divided into two parts. First part in which heat is transferred through radiation and by little amount of convection and in second part heat is transfer takes place through convection. He asked us to search on net about how it is done and told that he will ask us about it the very next day. 6-June—2016 Today, sir asked about the question no one answered correctly so he told that air after coming from Air Preheater (APH) is divided into two parts One part directly passes to the pulverized coal and the other passes from Air Preheater (APH) which has sensor which checks the amount of air needed to be heated so as to keep the coal at a temperature below its ignition point. The pulverized coal is sprayed into furnace. He also told why it is pulverized and what its advantages are and told us that air which passes through secondary fan is also preheated in APH. And at last he explained the working of Air Preheater. 7-june-2016 Today, he had meeting so he asked someone to take us to the site and told to show us furnace. We went there he showed us furnace through a manhole. Then after coming back we meet sir he told that coal is not directly fired but first oil and LPG gas is burned after reaching a particular temperature the coal from pulverizer is sprayed using PA fan and in this way process is carried out. He then told that the firing type is tangential. It is done by four burners which are located at the corners of the boilers. They fires in such a way that four flames are tangential to the imaginary circle and because of turbulence rapid mixing of pulverized coal is done and after combustion fly ash and bottom ash is formed. He also told why tangential firing method is better than other firing methods. He told a little about it and Plant auxiliary department will tell us more about it. 8—june-2016 Today, sir told us about water walls and boiler drum. Water from bottom ring header is transferred to water walls. Water walls are basically tubes in the Boiler where water is evaporated to steam and are also called Steam Generating Tubes. These Tubes also form the Walls of the Boiler and are hence called Water Walls. He also told that heat is transferred by radiation as these tubes are very close to furnace. He then explained working of boiler drum and how natural circulation takes place. He told that boiler drum is used to separate water and steam. Water from the drum comes down into the furnace by downcomer and steam is superheated before entering the turbine. 9—-june-—2016 Today, we again had to report to same sir. They told us how they use thermal energy of flue gas. Then he told us about the devices which uses flue gas energy to operate and they are:— » Reheater >» Economizer > Superheater » Air preheater Economi — it absorbs heat from the flue gas and add a sensible heat to the feed water before the water enters the evaporation circuit of the boiler. Superheater:—steam from boiler drum passes through superheater so that it absorb heat from flue gas so that it gets converted into superheated steam. Reheater:— that the steam from hp turbine comes to reheater and it absorbs heat from flue gas and then it is passed to lp turbine. It is used to raise the temperature of steam from which a part of energy has been extracted in high-pressure turbine. Then he asked us to read about air preheater. 10—june-2016 Today, sir told us about air preheater and Electrostatic precipitator. Air preheater is a heat exchanger device that preheat the air coming from primary and secondary air fan. He then explained its working and then he told about ESP. Fly ash along with flue gas is passed through ESP so that this fly ash and dust particle are ionized and gets collected on the collector electrode and then hammering is done on plates so that fly ash comes down and collect at the bottom. 11—june-2016 Today, sir told us about the pulverizer. the pulverizer they use are bowl mill. As pulverized coal enters from the feeder it gets crushed by the pulverizer they use are bowl mill. As pulverized coal enters from the feeder it gets crushed by the three grinders present inside the mill at an angle of 120 deg each. The bowl or the table rotate due to which these grinder rotate. There is also provision to change the angle of the grinders. Coal enters through the centre feed pipe .warm air enters the mill through the airport assembly. As the air enters it is rotated and a cyclone is formed but it is tried to maintain a steady air. then he told the advantages which are >» Lower power consumption » Reliability > Minimum maintenance > Wide capacity 12—june—2016 Today, it was my first day in Plant Auxiliary maintenance (PAM). We were asked to report PAM AGM. He told us many things comes under PAM like e¢ Water Circulation System Ash Handling Plant « Water Treatment Plant e Draught System ¢ Compressor house He told us that he will teach us all the things one by one. Today, he taught us about water circulation system. He told water must flow through the heat absorption surface of the boiler in order that it is evaporated into steam. Basically there he told us about two types of circulating system e Natural circulating system * Forced circulating system Natural circulation system: — In this water delivered to the boiler from feed water is at a temperature well below the saturation value corresponding to that pressure. First water enters into economizer which heat it 30-40 below the saturation temp and then it enters the drum. water entering the drum flows through downcomer and enters a ring header at the bottom where it is converted into steam and again water and steam mixture is sent to drum where steam is separated from water. It occurs naturally as there is difference in density between incoming water from downcomer and rising water and steam mixture which is less dense. So it happens naturally Forced circulating system: — Forced circulation in which a pump in the downcomer provides additional driving force for the circulating flow. The assistance of a pump is usually provided when generating steam at above about 170 bar because, at pressures above 170 bar, the density difference between the downcomer liquid and the liquid—steam mixture in the furnace wall tubes is reduced sufficiently to limit the circulating flow rate. 13—june—2016 Today, he taught us about ash handling system. He told that two types of ash is generated in the process ¢ Bottom ash e Fly ash Bottom ash is generated at the bottom of the boiler, a hopper collects this ash. This hopper is always filled with water to quench the ash and clinkers falling down from the furnace. Some arrangement is included to crush the clinkers and for conveying the crushed clinkers and bottom ash to a storage site. Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag filters (or sometimes both) located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators or bag filters. Generally, the fly ash is pneumatically transported to storage silos for subsequent transport by trucks or railroad cars. 14—june-2016 Today was my third day in PAM department. today, he told us about draught system. He told there are 4 types of draught system He explained them one by one. e Natural draft: When air or flue gases flow due to the difference in density of the hot flue gases and cooler ambient gases. The difference in density creates a pressure differential that moves the hotter flue gases into the cooler surroundings. e Forced draft: When air or flue gases are maintained above atmospheric — pressure. Normally it is done with the help of a forced draft fan. e Induced draft: When air or flue gases flow under the effect of a gradually decreasing pressure below atmospheric pressure. In this case, the system is said to operate under induced draft. The chimneys provide sufficient natural draft to meet the low draft loss needs. In order to meet higher pressure differentials, the stacks must simultaneously operate with draft fans. Balanced draft: When the static pressure is equal to the atmospheric pressure, the system is referred to as balanced draft. Draft is said to be zero in this system. 15—-june-2016 Today he told us about the compressor and their types and advantages. He told control air compressors have been installed for supplying moisture free dry air required for instrument used. instrument air is required for operating various dampers, burner tilting, diaphragm valves. Air drying unit consists of dual absorption towers which are filled specially with silica gel and activated alumina for absorbing moisture from air. service air compressor is a slow speed horizontal double acting double stage type and is arranged for belt drive. Air from L.P. cylinder enters at one end of the intercooler and goes to opposite end wherefrom it is discharged to high pressure cylinder. He also told that demineralized water is used for steam generation. He told that deposition of dissolved salts and suspended impurities will form a scale on the inside wall of different heat— exchangers and thus there will create excessive pressure and thermal stress and The harmful dissolved salts may react thereby can corrode the surfaces. Corrosion damage may occur to turbine blades. 16—june—2016 Today we were asked to report at TMD department. TMD (AGM) sir asked what is turbine I told it is a mechanical device that extracts thermal energy from pressurized steam and converts it into useful mechanical work and then he told about the different types of turbine and difference between them. The 210 MW turbine is a cylinder tandem compounded type machine comprising of H.P., I.P. and L.P. cylinders. The H.P. turbine comprises of 12 stages the I.P. turbine has of 11 stages and L.P. has four stages. The main superheated steam branches off into two streams from the boiler and passes through the emergency stop valve and control valve before entering the governing wheel chamber of the H.P. Turbine. After expanding in the 12 stages in the H.P. turbine then steam is returned in the boiler for reheating. The reheated steam from boiler enters I.P. turbine via the interceptor valves and control valves and after expanding enters the L.P stage. Then he told about the blades he told that blades are the most costly element of the turbine. Blades have three main parts:— > Aerofoil—working part > Root > shrouds 17—june-2016 Today sir had meeting so he asked one worker to take us on site and tell us about the turbine. So we went there and asked a lot question to him though he didnt had very good knowledge but he explained satisfactorily. 18—june—2016 Today sir told us about condenser. He told that the condenser is surface— type condensers Water enters the inlet chamber of the front water box, passes horizontally through brass tubes to the water tubes to the water box at the other end, takes a turn, passes through the upper cluster of tubes and reaches the outlet chamber in the front water box. From these, cooling water leaves the condenser through the outlet pipe and discharge into the discharge duct. Steam exhausted from the LP turbine washes the outside of the condenser tubes, losing its latent heat to the cooling water and is connected with water in the steam side of the condenser. This condensate collects in the hot well, welded to the bottom of the condensers. Then we went to see how condenser looks like. 20—-june—2016 Today sir told what is cooling tower and explained how cooling tower works. He then told that air can be circulated in the cooling tower by natural draft and mechanical draft. Then we went to visit the cooling towers. 21—june-—2016 Today sir asked us to visit deaerator. We went there and asked question to the worker who was there. Then we again went to the sir cabin and he told us that deaerator is a device which is used to remove air (oxygen) entrapped in the water molecule. He told that oxygen containing water at higher temperature becomes corrosive and it may damage boiler and can lead to hazardous situation. So oxygen is removed from the water which is then send to the furnace in order to generate steam then he explained the working of the deaerator. 22-june—2016 Today was our last day at TMD. Sir asked whether we understood everything he told or not. Some of the students then asked their doubts. Today sir told us about the pumps used in powerplant. He told that the pump is horizontal and barrel design driven by electric motor through a hydraulic coupling. The function of the pump is that the water with the given operating temperature should flow continuously to the pump under a certain minimum pressure. Booster pump is also provided in the suction line which is driven by the main motor of the boiler feed pump. One of the major damage may occur to a boiler feed pump is from cavitation due to suction failure. Then we went to see pump. 23—-june—2016 Today, We reported asked to report at Coal Handling Plant(CHP).the official there told that they gets coal from jharia coal fields. Then he told us about the coal cycle. The coal is supplied to NTPC from field mines is loaded by rail car. Then it is unloaded by wagon tippler.he told that the bulky coal particle is broken by hammering then these broken particle are send to the crusher. These particles are crushed from 200mm _ to 20mm. He explained the mechanism of wagon tippler and asked one worker to show us unloading. I was amazed when I saw how the coal is unloaded. 24—june—2016 It was my second last day of internship. Today sir told us about various components of CHP like Conveyer belt which is used to transport coal. Scraper are used to clean the carrying side of belt built up material on idler rolls Idlers support the belt and enable it to travel freely without much frictional losses. Magnetic separator is an electromagnet placed above the conveyor to attract magnetic materials. Then we went to visit all the above components. 25—-june—2016 Today was my last day of internship at NTPC and we were asked to report G.D. Sharma Sir at EDC. We went there and sat in a room. On that day we had to submit the report and collect our certificate. Finally, Sir came they gave certificate and asked us to do entry in their notebook which they kept as a record. He wished us good luck for our future. While giving certificate sir asked how the experience was. Overall the internship was very good experience for me I learnt a lot and during my powerplant course I always had a thought how these component work in real and how they look. I thanked all the officials who helped me during my internship.

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