P RAC TI CAL TRA INING R EPOR T

A TRAINING REPORT

Submitted By

JITENDRA KUMAR

In partial fulfillment for the award of the degree

Of

BATHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

At

JODHPUR INSTITUTE OF ENGINEERING AND TECH.

NH-65 , NEW PALI ROAD , MOGRA , JODHPUR (RAJ)

RAJASTHAN TECHNICAL UNIVERSITY KOTA

2016-17
 BONAFIDE CERTIFICATE

This is to certify that Mr. JITENDRA KUMAR of Mechanical

Engineering Department , Jodhpur Institute Of Engineering And
Technology having roll no. 15EJIME202 has compl eted his industrial
training during the academic year 201 6-17 as partial fulfillment of
Bathelor Of Technology in Mechanical Engineering affiliated from
Rajasthan Technical University , Kota.

SIGNATURE SIGNATURE

PROF. M R BAID ER. DARA SINGH MEENA

HOD – ME DEPARTMENT MANAGER MN

JIET – JODHPUR NTPC , ANTA(BARAN)

SIGNATURE

VIVEK SINGH SHEKHAWAT

TRAINING COORDINATOR

JIET – JODHPUR

Internal Examiner

External Examinar
 TABLE OF CONTENTS

1. Acknowledgement

2. Introduction

2.1 Introduction to practical training

2.2 Company overview

2.2.1 Company Profile

2.2.2 Mission and Vision Statement

2.2.3 Quality Aspects

2.2.4 Organization Chart

2.2.5 Types of Services/Produ cts Given/Produces

3. The Project/Training

3.1 Project/Training Prof ile

3.1.1 Objective

3.1.2 Project/Training Scope

3.2 Methodology

3.2.1 Learning Through Objective

3.2.2 Problem Solving Method

3.2.3 Analysis of Data on The Basis Of Acquired Knowledge

3.3 Conclusion

3.3.1 Problems and Issues in Current Situation/System

3.3.2 Suggestions and Recommendations for New Proposel/System

3.4 Attachments/Project Documentation

3.4.1 Tables

3.4.2 Daigrams

3.4.3 Charts
 3.4.4 List of Symbols,Abbreviations and Nomenculture

3.4.5 User‟s Manuals

4. Refrences and Appendices

 1

Acknowledgement

I wish to express my sincere thanks and gratitude to Mr. DARA SINGH

MEENA sir , Manager MN at NTPC Anta ( Baran ) for suggesting me the
topic and providing me the guidance , motivation and constructive criticism
throughout the course of project.

I also express my sincere thanks and gratitude to Mr. PANKAJ VASHISTHA

sir , HR (MANAGER) at NTPC Anta (Baran) for their valuable guidance and
timely suggestionsduring the entire dur ation of my project work.

I also thanks all faculty for thier help regarding theortical studies and for
their valuable time.

JITENDRA KUMAR

JIET-JODHPUR

ROLL NO- 15EJIME202

 2

Introduction

2.1 Intoduction to Practical Training :-

Summer internship is the main

platform for engineering students . This helps to improve thier practical
knowledge as well as theortical.

Summer internship is done after completing 3 r d year ( 6 t h sem ) . Duratiaon

for summer training is 60 days , during this period student achieves a lot of
practical knowledge.

This course ( summer training ) provides experience of effetive

communication , team work and prof essional perspective . This course builds
proactive attitude among students and increase their confidence to be an
excellent coach. Also during training students learn the meaning of regularity
and respect.

During this period student have to complete a sum mer training file , this file
contains all material which are covered in lecture and practical.

Importance of File:-

This file is main part of training as this contains all

material during internship.

This file helps student for any interview , interviewer check this file and take
interview on the basis of this file so for any job purpose this file is important.
Also this file helps student to keep in mind all material during training .

Certificate provided after completing th is file and interview were taken by

faculty .
2.2 Company Overview :-

NTPC is india‟s largest energy

conglomerate with roots planted wayback in 1975 to accelerate power
development in india. Since then it h as established itself as the dominant
power major with presence in the entire value chain of of the power
generation business. From fossil fuels it has forayed into generating electricity
via hydro, nuclear and renewable energy sources. This foray will pla y major
role in lowering its carbon footprintby reducing green house gas emissions. To
strengthen its core business, the corporation has diversified into the fields of
consultancy, power trading, training of power professionals, rural
electrification, ash utilisation and coal mining as well.

NTPC is commited to generating power reponsibly and sustainably. NTPC

occupies thepremier position in the indian energy sector in terms of size and
efficiency. It accounts for 25%of the india‟ s total generation during the
finacial year 2015-16. With an increasing presence in the power value chain,
NTPC is well on its way to becoming an “Integrated Power Major” powering
india‟s growth story.

NTPC became a maharatna company in May 2010, one of the only four
companies to be awarded this status. NTPC was ranked 400 t h in the „2016,
Forbes Global 2000‟ ranking of the World‟s biggest companies.

Every fourth home in India is lit by NTPC

 The total installed capacity of the company is 51,635 MW including JVS.
 This capacity contains 7 gas based stations, 1 hydro based stations and 1
wind based stations
 The company has 17.73% of the total national capacity.
Current Scenerio in India :-

 Power Installed Capacity : 329.20 GW

 Energy Generation (p.a) : 1116.84 TWh
 Supply Demand Gap : -1.6% Peak
 Per Capita Power Consumption : 1074 kWh.
Installed Capacity :-
 NTPC ANTA :-

NTPC Anta is the 1 s t Gas Power Plant of India.

NTPC Anta is a natural gas fired power station located in Baran distric in the
Indian state of Rajasthan.

The gas for it is sourced from GAIL HBJ Pipeline South Basin Gas field, and
its source of water is the Chambal River.

Capacity

Stage Unit no. Installed DO GT/ST

cap.(MW) commission
1st 1 88.7 April 1989 GT
1st 2 88.7 May 1989 GT
1st 3 88.7 July 1989 GT
1st 4 153.2 July 1990 ST
Total Four 419.3 MW
2.3 vision And Mision :-

VISION :-

“TO BE THE WORLD‟S LEADING POWER COMPANY,

ENERGIZING INDIA‟S GROWTH”

MISION :-

“PROVIDE RELIABLE POWER AND RELATED SOLUTIONS IN

AN ECONOMICAL, EFFICIENT AND ENVIRONMENT FRIENDLY
MANNER, DRIVEN BY INNOVATION AND AGILITY”
CORE VALUES :-

ICOMIT

INTEGRITY

CUSTMER FOCUS

ORGANISATIONAL PRIDE

MUTUAL RESPECT & TRUST

INNOVATION & LEARNING

TOTAL QUALITY AND SAFETY

QUALITY ASPECT :-

NTPC continues to place great emphasis on quality , wi th

the view to secure long term reliability and availability of its productive
assets and the investment. This is ensured by committing adequate number of
qualified and trained human resources for quality related activities,
maintaining field laboratries at the construction sites and pursuing t i m e
tested systems & processes, resulting in world class standards of performance
of the plant. The dynamic feedback system ensure that the gaps (if any) are
filled through resetting the methods and standards rusultin g in continuous
improvement.

NTPC‟s robust performance on all parameters is a testimony to the soundness

of the quality system deployed.

PERFORMANCE:-

In terms of operation , NTPC has always been considerably

above the national average.

The table and chart shows the detailed operational performance of COAL and
GAS based stations over the years .
Year Gross generation (BU) PLF( % ) ( coal stations)
(coal & gas)
2016-17 250 78.60
2015-16 241.98 78.61
2014-15 241.139 80.23
2013-14 233.269 81.50
2012-13 232.00 83.08
2011-12 222.07 85.00
2010-11 220.54 88.29
2009-10 218.84 90.81
2008-09 206.94 91.14
2007-08 200.86 92.24
2006-07 188.67 89.43
2005-06 170.88

RELIABILITY & DURABILITY:-

As we know reliability can be difined as the

probability that a product, system or service will perform its intended
function adequately for a specified period of time.

NTPC is committed to generating power respnsibility and sustainability.

Besides fossil fuels the company has diversified into producing energy through
cleaner and green sources such as hydro and solar energy. NTPC occupies the
premier position in the indian energy sector in terms and efficiency. It
accounts for 25%of India‟s total generation during the finacial year 2015 -16
with an increasing presence in the power value chain, NTPC is well on its way
to becoming an “Integrated Po wer Major”. Powering India‟s growth story .
SERVICEABILITY:-

Serviceability of NTPC is very very fine because there

may be a big problem when any of parts goes failure.

In NTPC if there is a problem or failure in any componets t hen power shut up

automatic and then can be serviced with in a short time duration. There are
many cameras to keep eye on every procedure, every man and every
department. So there are rare chance of failure.

FEATURES:-

NTPC have many features. Some of them are as folllow

 Power installed capacity 329.20 GW.

 India‟s first company which producing power by coal, gas, wind, hydro,
solar, nuclear and geothermal etc.
 Company has the 19% of the total national capacity and every fourth
home in india is lit by NTPC.
 At present NTPC has a total of 19,917 MW capacity under construction.
 NTPC has 16 coal based and 7 gas based power plants .

ORGANISATIONAL CHART:-

How a business accomplishes and coordinates

work activities is determined by the companies interrelationships. These
relationships reflects business leader‟s decision regarding chain of command,
work specialization, authority and span of control. Such interrelationships
are reflected by the companies organisational structure, which is documented
with an organisation chart. NTPC‟s org chart is as follow -

NTPC‟s board of directors guides the overall philosophy and

direction of the organisation and has a united vision.

“TO BE THE WORLD‟S LEADING POWER COMPANY,

ENERGIZING INDIA‟S GROWTH.”

MR. GURDEEP
SINGH
(CMD)

MR. KULAMANI MR. K.K SHARMA MR. A.K. GUPTA

MR. S. ROY MR. A.K. JHA MR. S.C. PANDEY
BISWAL ( DIRE.- (DIREC.-
(DIRECTOR-HR) (DIRECTOR -TECH) (DIR-PROJECTS)
( DIRE-FINANCE) OPERATION) COMMERCIAL)

MR. PRADEEP MR. ANIRUDH

KUMAR KUMAR
(JS- F&A) (JS - HERMAL)

TYPES OF SERVICES/PRODUCTS GIVEN/PRODUCES :-

Main service of NTPC is

generating power and supply it according to demand. Power produced by
many sources as wind, solar, gas etc. At NTPC Anta power produced by GAS
and Coal.
Except these services, NTPC has ventured successfully into related fields
capitalising on their rich legacy and formidable track record.

From consultancy for the power sector to setting up its own R&D facility
NETRA and Power Management Institute -the state of the art training
institute for power professionals.

The midas touch of NTPC extends to these thriving initiatives as well.

 CONSULTANCY
 POWER MANAGEMENT INSTITUTE

CONSULTANCY:-

The consultancy wing of NTPC undertakes consultancy

and turnkey project contracts for domestic and international clients in
different phases of the power plants. NTPC has emerged as the acknowledged
leader in engineering, construction, O&M, RLA/R&M and management of
power projects hence is preferred for consultancy assignments. It is
accredited with ISO 9001:2008 certification and was established in 1989.

NTPC offers consultancy services related to infrastructure sector business

such as:

 Fossil fuel based thermal power plants.

 Combined cycle power plants.
 Cogeneration plants.
 Water supply and treatment.
 Environment engineering and management.

An entire gamut of services is offered in the areas mentioned above. These

are:

 Owner‟s engineering services.

 Lender‟s engineering services.
 Environment Engineering and management.
 Contract and procurement service.
 Project management.
  Quality assurance and inspection services.
 Material management.
 Construction management, erection and commissioning.
 Financial system and modelling.
 Operation and maintenance (O&M).
 Human Resources Development (HRD) & Training.
 Research & Development.
 Information technology.
 Management consultancy.
 Commercial consultancy.

POWER MANAGEMENT INSTITUTE:-

NTPC runs a state of the art Power Management Institute (PMI) , at Noida.
PMI has over the years trained a large no of professionals from NTPC, State
Electricity Board and other power utilities in the country. Also, PMI delivers
programmes to power sector companies in the Gulf counties at their locations
and participants from South Asia, Gulf and African countries come to PMI
for attending programmes.
With a wide range of the expertise and the experience acquired over the years,
PMI offers the programmes in the following category:

 Enhancing general management competence and sk ills.

 Enhancing technical expertise.
 Upgrading functional skills.
 Managing information technology.
 Induction level training programmes.
 Employee development programmes.
 3

THE PROJECT

3.1 PROJECT PROFILE

3.1.1 OBJECTIVE:-

Study of Waste Heat Recovery Boiler

3.1.2 Scope of WHRB:-

WHRB is a waste heat recovery unit that is

used to recover heat rejected from turbines in many companies like power
plants, cement plants and steel plants etc.

In power plants there are many turbines and generators to produce energy
with the help of incoming fuels (gas, c oal, solar, wind etc). Incoming fuel
firstly heated in the primary boiler and then send to turbine where from hot
fuel comes out with a decreased temperature about 505 -510, this temperature
is too high in compare to environment , so there is a WHRU used to recover
this temperature and used to preheat the incoming fuel and increase the
efficiency of power plant. Some recovery units are boiler, regenerator,
economizer etc.

3.2 METHODOLOGY

3.2.1 LEARNING THROUGH OBJECT: -

In this session we will learn about

the working principle, operation, advantage/disadvantage and application of
WHRB.
WORKING PRINCIPLE OF WHRB:-

The working principle of WHRB is same as the simple boiler, in simple boiler
the water flows around the tubes and inside the tubes hot gases flues, water
absorbs heat from hot gases and changes into steam, this steam utilize to
generate power or electricity.

In power plants there are rotating gas turbines to start generator and through
generator electricity produced. I n the rotating turbine hot steam comes from
the combustion chamber at the temperature of 1000 ° C (P=60-65 bar) and
leave at a temperature of 500°-505° C, this temperature is very high and
dangerous for environment or exhaust component so this gas further used to
produce electricity or drive some components as prime mover by heating in
WHRB. So WHRB is a most useful component to reheat the exhaust gases and
change them into steam and improve the efficiency of the power plant. The
WHRB used in NTPC anta is vertical non -fired.

CONSTRUCTION OF WHRB:-

WHRB consists of the following c o m p o n e n t s -

 High and Low pressure Pumps

 Condensate Pre Heater
 High and Low pressure Economiser
 High and Low pressure Boiler Drum
 High and Low pressure Circulating Pumps
 High and Low pressure Evaporators
 High and Low pressure Super Heaters
 Vertical non fired Boiler
 Water and Steam Pipes

HIGH AND LOW PRESSURE PUMPS:-

These pumps are used to feed the

water at low and high pressure to the low and high pressure boiler drums
respectively. Max pressure is about 64 bar and min 6 bar.
CONDENSATE PRE HEATER:-

The condensate pre heater is located

outside the boiler in the system to drawn the heat indirectly from the flue
gases via economiser. Performance of the condensate pre heater is less
sensitive to the boiler.

HIGH AND LOW PRESSURE ECONOMISER :-

The economiser is a mechanical

device intended to reduce energy consumption, or to perform useful function
such as pre heating a fluid up to boiling point of the fluid. Economisers so
named because they can make use of the enthalpy in fluid streams that are
hot, but not hot enough to be used in a boiler, thereby recovering more useful
enthalpy and improving the boiler‟s efficiency.

In power plants modern day boilers are fitted with economiser which are
referred to as feed water heaters and heat the condensate from turbines
before it is pumped to the boiler.

Economiser are commonly used as part of a heat recovery steam generator in

a combined cycle power plants in a HSRG, water passes through an
economiser, then a boiler and then a super heater .
HIGH AND LOW PRESSURE BOILER DRUM :-

A steam drum or boiler

drum is standard feature of a water tube boiler. It is a reservoir of
water/steam at the top end of the water tubes. The drum stores the steam
generated in the water tubes and acts as phase separator for the steam/water
mixture. The difference in densities between hot and cold water helps in the
accumulation of the hotter water and saturated steam into the steam drum.

Hot steam accumulates over the cold water in the drum and goes to the super
heater for further heating.
HIGH AND LOW PRESSURE CIRCULATING PUM P:-

Circulating
pumps are centrifugal pumps designed to generate a forced circulation in a
closed system. These are also known as feed water pumps. These are mostly
used to pump feed water to the boiler (WHRB), these are connected to the HP
boiler drum and LP boiler drum with HP and LP evaporator respectively.
 HORIZONTAL PUMP

VERTICAL PUMP

HIGH AND LOW PRESSURE EVAPORATOR :-

An evaporator is a device which is

used to change the liquid form of any chemical substance into gasses/vapour
form. In simple manner liquid changed into vapour form to protect turbine
fans to be damaged in power plants. The solution containing the desired
product is fed into the evaporator and passes across a heat source. The
applied heat converts the water solution into vapour. The vapour removed
from the rest of the solution and is condens ed while the non concentrated
solution is either fed into a second evaporator or is removed. Evaporator
consists of plates which are made of copper or aluminium.
HIGH AND LOW PRESSURE SUPER HEATERS :-

A super heater is a device used

to convert saturated steam into superheated steam or dry steam. These are
used in steam turbines for electric generation, steam engines, and in processes
such as steam reforming. In NTPC anta high and low pressure super heater
are used for high and low pressure saturated steam respectively. Mainly there
are three type of super heaters radiant, convection and separately. During
this process all the moister content removed from the saturated steam .
VERTICAL NON FIRED BOILER :-

This is the most important part of the

WHRB, it is a vertical stack in and around which all the components of the
WHRB are arranged. It‟s upper ends acts as the chimney from whic h the flue
gasses exits at a temperature of 110 ° C & lower end acts as entry point for the
flue gasses to WHRB at a temperature of 550° C.

WATER AND STEAM PIPES:-

These are the pipes used to make connection

between the different components of the WHRB and used to transfer water as
well as steam in WHRB from one point to the other point.

WORKING OF WHRB:-

Flue gasses after passing through the 3 Gas Turbines

reaches the WHRB at a its lower end at a temperature of about 505 ° C. The
WHRB consists of 2 steam turbines HP&LP for which 2 different processes
takes place, these are as follows:
For HP Steam Turbine:-

 The HP feed water pump starts to pump demineralised water which is

obtained from the Right main Canal of Chambal River .
 For ease of operation this water is pre heated to a particular
temperature range by passing it through condensate pre heater.
 This pre heated water is now send to the HP economiser1 to heat the
water to a particular temperature range. As to further increase the
temperature of the water, this water again send to an another
economiser called as HP economiser2 (the importance of heating the
water is by heating the water before sending it to the boiler there is a lot
of energy saved which could be used to heat the water at a high
temperature range in the boiler).
  Now this heated water is send to the HP drum boiler in whic h it will be
again heated at a particular temperature range . In this boiler drum the
water achieves a sufficient temperature range that it could convert into
the steam of about 64 bar pressure.
 Some amount of water is taken from the HP drum boiler in which is send
to the LP evaporator which converts this water into the steam by using
the heat of the flue gasses coming from the 3 gas turbine.
 This steam is again send to the HP drum boiler to convert into the steam
obtained from the water into the drum.
 This steam contains a particular amount of moister in it and known as
wet steam which is not suitable to use in the steam turbine, so this wet
steam is send to the HP super heater 1&2 where this wet steam converted
into dry or super heated steam having temperat ure about 485° C.
 At this temperature this dry steam is send to the HP steam turbine from
which electrical energy generated.

For LP Steam Turbine:-

 The LP feed water pump starts to pump demineralised water which is

taken from Right main Canal of Chambal River.
 For ease of operation this water is pre heated to a particular
temperature range by passing it through condensate pre heater.
 This pre heated water is now send to the LP economiser to heat the water
to a particular temperature range.
 Now this heated water is send to the LP drum boiler in which it will be
again heated to a particular temperature range.
 This water is taken from the LP drum boiler which is send to the HP
evaporator which converts this water into the steam by using the heat of
the hot flue gasses coming from 3 Gas Turbine.
 Now this steam is again send to the LP drum boiler in which the water
from LP feed pump is heating .
  In this boiler drum the water achieves a sufficient temperature range
that it could convert into the steam (along with the steam from HP
evaporator) of about 6 bar pressure.
 This steam contains a particular amount of moister in it and known as
wet steam which is not suitable to use in the steam turbine, so this steam
send is send to the LP super heater where this wet steam is converted
into LP dry steam of temperature range of about 225 ° C.
 At this temperature this steam is send to the LP steam turbine from
which electrical energy is generated.

After all the above operation the maximum amount of heat energy of the flue
gasses coming from the 3 gas turbines is used due to which the temperature of
the flue gasses reduced at the end of the operation when it reaches at the exit
of WHRB at the top section of the boiler.

The exits temperature of the flue gasses is about 110 ° C, at this temperature
range the flue gasses are send to the atmosphere.