Table 1.

1 Installed capacity
NTPC OWNED NO. OF PLANTS CAPACITY(MW)
COAL 23 44,943
GAS/LIQUID FUEL 7 4,017
TOTAL 44 48,645
OWNED BY JVs
COAL AND GAS 10 8,461
TOTAL 54 57,106

1.3. Power Stations in India

Table 1.2. Gas-based

SR. NO. PROJECT STATE INST. CAPACITY(MW)
1. NTPC ANTA RAJASTAN 413
2. NTPC AURAIYA UP 652
3. NTPC KAWAS GUJARAT 645
4. NTPC DADRI UP 817
5. NTPC JHANOR GUJARAT 648
6. NTPC KAYAMKULAM KERALA 350
7. NTPC FARIDABAD HARYANA 430
TOTAL 3955

Table 1.2. Coal-based

S. NO. PROJECT STATE INST.
CAPACITY
1. SINGRAULI SUPER THERMAL UTTARPRADESH 2000
POWER STATION
2., NTPC KORBA 2,600
CHHATTISGARH

3. NTPC RAMAGUNDAM ANDHRA 2,600

PRADESH
4. FARAKKA SUPER THERMAL WEST BENGAL 2,100
POWER STATION
5. NTPC VINDHYACHAL MADHYA 4,760
PRADESH
6. RIHAND THERMAL POWER UTTAR PRADESH 3,000
STATION
7. KAHALGAON SUPER THERMAL BIHAR 2.340
POWER STATION
8. NTPC DADRI UTTAR PRADESH 1,820
9. NTPC TALCHER KANIHA ORISSA 3,000
10. FEROZE GANDHI UNCHAHAR UTTAR PRADESH 1,550
THERMAL POWER PLANT
11. TALCHER THERMAL POWER ORISSA 460
STATION
12. SIMHADRI SUPER THERMAL ANDHRA 2,000
POWER PLANT PRADESH

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2. NTPC Dadri Power Plant

2.1. Introduction

The NTPC Dadri Thermal Power Plant has an installed capacity of 2637 MW. The main plant
equipment was supplied by M/S. BHEL. The boiler of Stage-1 (4×210) MW units are of
Czechoslovakian design and that of 210 MW units are of Combustion engineering design. The
Turbo-alternators, supplied by M/S BHEL, are of Russian design and Control and
Instrumentation for Stage-1 (3×95) and Stage-2 units (2x490) MW units are mostly of Russian
design. The coal for the plant is sourced from Piparwar Mines, Jharkhand and the source of
water is Upper Ganga Canal.

Table 2.1. Power plant capacity

STAGE UNIT INT. CAPACITY DATE OF STATUS
NUMBER (MW) COMMISSIONING
First 1 210 October, 1991 Running
First 2 210 December, 1992 Running
First 3 210 March, 1993 Running
First 4 210 March, 1994 Running
Second 5 490 January, 2010 Running
Second 6 490 July, 2010 Running

Figure 2.1 Power Plant Layout

2.2 Basic Thermal Power Plant

In thermal generating plants, fuel is converted into thermal energy to heat water, making steam.
The steam turns an engine (turbine), creating mechanical energy to run a generator. Magnets
turn inside the generator, producing electric energy.

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 Figure 2.2 Components of a coal plant

Figure 2.3 Boiler maintenance department

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As the pressure increases, the difference in density between water and steam reduces. Thus, the
hydrostatic head available will not be able to overcome the frictional resistance for a flow
correspondingto the minimum requirement of cooling of water wall tubes. Therefore, natural
circulation is limited to the boiler with drum operating pressure around 175 kg/cm².

Figure 3.2 Natural circulation system

Controlled Circulation System

Beyond 80 kg/cm² of pressure, circulation is to be assisted with mechanical pumps to overcome
the frictional losses. To regulate the flow through various tubes, orifice plates are
used. This system is applicable in the high sub-critical regions (200 kg/cm²).

Combined Circulation System

Beyond the critical pressure, phase transformation is absent, and hence once through system is
adopted. However, it has been found that even at super critical pressure, it is advantageous to
recirculation the water through the furnace tubes and simplifies the start-up procedure. A typical
operating pressure for such a system is 260 kg/cm².

Figure 3.3 Combined circulation system

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Compressor House
An air compressor is anything that increases the amount of air that is contained within a
particular space. By packing in the air, the air pressure is increased. This creates a force that is
useful for a variety of purposes, such as industrial, manufacturing, commercial and personal
purposes. Another way to group air compressors is by the number of stages they have. A two-
stage air compressor usually is used for heavy-duty use and offers a higher level of
compression than smaller, single-stage air compressors. Two-stage air compressors can
store air for future use and are more energy efficient because they produce more air per unit of
horsepower than single-stage compressors. Also, less heat is generated in a two-
stage compressor, which means that wear on the unit is reduced. Portable
electric air compressors also are available for light-duty applications.

Figure 3.4 Compressor House

3.4. Water Treatment Plant

As the types of boiler are not alike their working pressure and operating conditions vary and
so do the types and methods of water treatment. Water treatment plants used in thermal power
plants are designed to process the raw water to water with very low in dissolved solids known
as "dematerialized water". No doubt, this plant has to be engineered very carefully keeping in
view the type of raw water to the thermal plant, its treatment costs and overall economics

Actually, the type of demineralization processchosen for a power station depends on three
main factors:
•The quality of the raw water.
•The degree of de-ionization i.e. treated water quality
•Selectivity of resins.
Water treatment process which is generally made up of two sections:
•Pre-treatment section
•Demineralization section

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4. Turbine Maintenance Department (TMD)

4.1. Steam Turbine Theory

Figure 4.1 Steam Turbine

Operating Principles

A steam turbines two main parts are the cylinder and the rotor. As the steam passes through the
fixed blades or nozzles it expands and its velocity increases. The high-velocity jet of steam
strikes the first set of moving blades. The kinetic energy of the steam changes into mechanical
energy, causing the shaft to rotate. The steam then enters the next set of fixed blades and
strikes the next row of moving blades. As the steam flows through the turbine, its pressure
and temperature decreases, while its volume increases. The decrease in pressure and
temperature occurs as the steam transmits energy to the shaft and performs work.
After passing through the last turbine
stage, the steam exhausts into the condenser or process steam system. The kinetic energy
of the steam changes into mechanical erringly through the impact (impulse) or reaction of
the steam against the blades.

4.2. Steam Cycle

The thermal (steam) power plant uses a dual (vapour+liquid) phase cycle. It is a closed cycle
to enable the working fluid (water) to be used again and again. The cycle used is "Rankine
Cycle" modified to include super heating of steam, regenerative feed water heating and
reheating of steam.
On large turbines, it becomes economic to increase the
cycle efficiency by using reheat, which is a way of partially
overcoming temperature limitations. By returning partially expanded steam to a reheat, the
average temperature at which heat is added is increased and by expanding this re-heated steam

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to the remaining stages of the turbine, the exhaust wetness is considerably less than it would
otherwise be conversely, if the maximum tolerable wetness is allowed, the initial pressure of
the steam can be appreciably increased.

Figure 4.2 Steam Cycle

4.3. Turbine Classification

Impulse Turbine
In Impulse Turbine steam expands in fixed nozzles. The high velocity steam from nozzles does
work on moving blades which causes the shaft to rotate. The essential features of impulse
turbine are that all pressure drops occur at nozzles and not on blades. A simple impulse turbine
is not very efficient because it does not fully use the velocity of the steam. Many impulse
turbines are velocity 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& moving blades. Both fixed
& moving blades act as nozzles. Work done by the impulse effect of steam due to reversals
of direction of high velocity steam. The expansion of steam takes place on moving blades. A
reaction turbine uses the "kickback" force of the steam as it leaves the moving blades and fixed
blades have the same shape and act like nozzles. Thus, steam expands, loses pressure and
increases in velocity as it passes through both sets of blades. All reaction turbines are pressure-
compounded turbines.

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