Galgotias College of Engineering and Technology

Department of Mechanical Engineering

INDUSTRIAL TRAINING REPORT ON

N.T.P.C. POWER STATION,DADRI

Submitted by SATYENDRA KUMAR SINGH Roll no 0809740081 (Session 2010-11) Under the guidance of SH.M.K SHARMA in partial fulfillment of Degree Requirements as per GBTU Syllabus for the award of

Bachelor of Technology (Mechanical Engineering) Batch of 2008-12

Gautam Budha Technical University, Lucknow

ACKNOWLEDGMENTS
I am very much thankful to N.T.P.C. POWER PLANT,DADRI for giving me such an excellent opportunity to be trained under experts of your company.I specially convey my thanks to SH.M.K SHARMA and other members of ring plant for their guidance during my training. Again I want to say thanks to H.O.D(mechanical engineering) and other professors for creating a learning environment and supporting the students to deliver their best performance.

SATYENDRA KUMAR SINGH

ABSTRACT

To meet the power demand of the country, it is required to set up new projects, time to time so that demand and generation gap may be narrowed but most important is to full utilization of existing capacity. This may be possible only by increasing the reliability, availability and maintainability of power generating units and by operating the units at its full capacity. This vocational training report is concerned with the overall operation of the plant, machines used in the plant, water treatment in the plant & thermodynamic cycles used in the NTPC, Dadri Power Plant

TABLE OF CONTENTS
LIST OF FIGURES
1. BRYATON CYCLE 1.1 SCHEMTIC FIGURE 1.2 P-V DIAGRAM 1.3 T-S DIAGRAM 2. RANKINE CYCLE 2.1 SCHEMTIC FIGURE 2.2 T-S DIAGRAM 3. INDUSTRIAL COOLING TOWERS. 4. AIR FLOW GENERATION METHOD COOLING TOWER 4.1 FORCED DRAFT COOLING TOWER 4.2 FORCED DRAFT COUNTER FLOW PAKAGE TYPE COOLING TOWER 5. CROSS FLOW DESIGN TYPE 6. COUNTER FLOW DESIGN TYPE 7. STEAM LOCOMOTIVE BOILER.

LIST OF SYMBOLS
1. P- Pressure 2. V-Volume 3. T-Temperature 4. S-Entropy 5. q in- heat supplied 6. q out-heat rejected

INDEX
1. TITLE PAGE 2. ACKNOWLEDGEMENT 3. CERTIFICATE 4. LIST OF FIGURES 5. LIST OF SYMBOLS 6. ABSTRACT 7. INTRODUCTION 8. OVERVIEW 9. STATION AT GLANCE 10. INTRODUCTION TO GAS POWER PLANT 10.1 Equipment. 10.2 Application. 11. COMBINED CYCLE 11.1 BRAYTON CYCLE 11.2 RANKINE CYCLE 12. FUELS 13. INDUSTRIAL COOLING TOWER 13.1 NATURAL DRAFT 13.2 MECHANICAL DRAFT 13.3 INDUCED DRAFT 13.4 FORCED DRAFT 14. CROSS FLOW 15. COUNTER FLOW 15.1 COMMAN IN BOTH DESIGNS 16. BOILER 16.1 POT OR HAYCOCK BOILER 16.2 FIRE TUBE BOILER 16.3 WATER TUBE BOILER 16.4 FLASH BOILER 17. CONTROLLING DRAUGHT 17.1 INDUCED DRAUGHT 17.2 FORCED DRAUGHT 17.3 BALANCED DRAUGHT 18. SAFETY 19. TYPES OF SAFETY 19.1 NORMATIVE SAFETY 19.2 SUBSTANTIVE SAFETY 19.3 PERCIEVED SAFETY 20. SAFETY MEASURES 21. 5S (METHODOLOGY) 21.1 SORTING (SEIRI) 21.2 STRAIGHTENING OR SETTING IN ORDER / STABILIZE (SEITON) 21.3 SWEEPING OR SHINING OR CLEANLINESS / SYSTEMATIC CLEANING (SEISO) 21.4 STANDARDIZING (SEIKETSU) 21.5 SUSTAINING THE DISCIPLINE OR SELF-DISCIPLINE (SHITSUKE) 5

7.INTRODUCTION
NTPC DADRI GAS POWER PLANT National Thermal Power corporation Limited National Capital Power Station -- Dadri P.O. Vidyut Nagar, District Gautam BudhNagar - 201 008 (UP).

NTPC was set up in the central sector in the 1975.Only PSU to achieve excellent rating in respect of MOU targets signed with Govt. of India each year. NTPC Dadri station has also bagged ISO14001 certification. Today NTPC contributes more than 3 / 5th of the total power generation in India.

Approved capacity: Gas Source: Alternate Fuel: Water Source: BeneficiaryStates

817MW HBJ Pipe line/ 3 MMSCMD (APM Gas) HSD Upper Ganga Canal

U.P.,Uttrakhand,Rajasthan,Delhi,Punjab,Haryana,HP,J&K,Chandigarh,Railways Approved Cost: Unit Sizes : Rs.960.35 crores (02.11.94) 4 GTX 130.19 MW + 2 STX 154.51 MW

Units Commissioned

GT-I- 130.19 MW May 1992 GT II- 130.19 MW June1992 GT III-130.19 MWAugust1992 GT IV-130.19 MW December1992 ST-I- 154.51 MW August 1996 ST-II- 154.51 MW April 1997

8.OVERVIEW
NTPC was set up in the central sector in the 1975 in response to widening demand & supply gap with the main objective of planning, promoting & organizing an integrated development to thermal power in India. Ever since its inception, NTPC has never looked back and the corporation is treading steps of success one after the other. The only PSU to have achieved excellent rating in respect of MOU targets signed with Govt. of India each year. NTPC is poised to become a 40,000 MW gint corporation by the end of XI plan i.e. 2012 AD. Lighting up one fourth of the nation,NTPC has an installed capacity of 19,291 MW from its commitment to provide quality power; all the operating stations ofNTPC located in the National and Korba station have also bagged ISO 14001 certification. Capital Region & western haveacquired ISO 9002 certification. The service groups like Engineering, Contracts, materials and operation Services have also bagged the ISO 9001 certification. NTPC Dari, Ramagundam, Vindhyachal.

9.STATION AT GLANCE
NTPC dadri is model project of NTPC. also it tit the best project of NTPC also known as NCPS ( National capital power station ).Situated 60 kames away from Delhi in the District of gautam budh Nagar, Uttar Pradesh. The station has an installed capacity of1669 MW of power 840 MW from Coal based units and 829MW Gas Based Station. The station is excelling in performance ever since itscommercial operation. consistentlyin receipts ofmeritorious projectivity awards, the coal based units of the station stood first in the country in terms of PLF for the financial year1999 2000 bygenerating an all time national high PLF of 96.12% with the mostmodernO & M Practices. NTPC Dadri iscommitted to generated clean and green Power. The Station alsohouses the first HVDC station of the country (GEP project) inassociation with centrefor power efficiency and Environmentprotection (CENEEP) NTPC& USAUID. The station hasbagged ISO 14001 & ISO 9002 certification during the financialyear 1999 2000, certified by Agency of International repute M/sDNV Netherlands M/s DNV Germany respectively.

10.INTRODUCTION TO GAS POWER PLANTS

The development of the sector in the country, sinceindependence has been predominantly through the StateElectricity Boards. In order to supplement the effects of the states in accelerating power development and topromote power development on a regional basis to enable the optimum utilisation of energy resources, the Government of India decided to take up a programme of establishment of large hydro and thermal power stations in the central sec torn a regional basis. With this in view, the Government set up the National Thermal Power Corporation Ltd., in November1975 with the objective of planning, construction, commissioning, operation and maintenance of Super Thermal and Gas Based Power projects in the country. The availability of gas in a large quantity in western offshore region has opened an opportunity to use the gas for power generation, which is uneconomical way and quicker method of augmenting power generating capacity by natural gas as fuel in combined cycle power plant in a power deficit country like ours.

NTPC to take up the construction of Kawas, Auraiya, Anta, Dadri and Gandhar Gas Power Project along the HBJ Gaspipe line. The power plant consists of gas turbine generating units waste heat recovery boilers, steam turbo generator, ancillary electrical and mechanical equipments. The power generated at this power station is fed over 220 KV AC transmission system associated with this project to distribute the power in the various Regions. In the Power Sector, gas turbine drive generators are used. Gas turbines range in size from less than 100 KW up to about140.000 KW. The gas turbine has found increasing application due to the following potential advantages over completive

10.1 Equipment. Small size and weight per horsepower Rapid loading capability

Self-contained packaged unit

Moderate first cost No cooling water required Easy maintenance High reliability Waste heat available for combined cycle

10.2 Application.

Low Gestation Period Low Pollution Hazards

The function of a gas turbine in a combined cycle power plant is to drive a generator which produce electricity and to provide input steam from the cycle

11.COMBINED CYCLE
It integrates two power conversion cycles namely. Brayton Cycle (Gas Turbines) and Rankine Cycle (Conventional steam power plant) with the principal objective of increasing overall plant efficiency.

11.1 BRAYTON CYCLE

Gas Turbine plant-operate on Brayton Cycle in which air is compressed this compressed air is heated in the combustor byburning fuel combustion produced is allowed to expand In the Turbine and the turbine is coupled with the generator without losses the theoretical cycle process is represented by 1 2 3 4. In the actual process losses do occur. Deviation from the theoretical process, results from the fact that compression and expansion are not performed isentropically but polytropically which is conditioned by heat dissipation (expansion) and heat supply (Compression) caused by various flow and fraction of loses. 9

Fig.1.1

Fig. 1.2

Fig. 1.3

11.2RANKINE CYCLE

The conversion of heat energy to mechanical energy with the aid of steam is carried out through this cycle. In its simplest form the cycle works as follows (fig.2).The initial state of the working fluid is water (point-3) which, at a certain temperature is compressed by a pump (process 3-4) and fed to the boiler. In the boiler the compressed water is heated at constant pressure (process 4-5-6-1). Modern steam power plants have steam temperature in the range of 5000C to 5500C at the inlet of the turbine.

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Fig. 2.1

T-S DIAGRAM(Fig. 2.2)

12.FUELS
Gas turbines are capable of burning a range of fuels including naptha, distillates, crude oils and natural gas. Selection of fuel (s) depends on several factors including fuel availability, fuel cost and cleanliness of fuel.

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13.INDUSTRIAL COOLING TOWERS

Fig.3 Industrial cooling towers can be used to remove heat from various sources such as machinery or heated process material. The primary use of large, industrial cooling towers is to remove the heat absorbed in the circulating cooling water systems used in power plants, petroleum refineries, petrochemical plants, natural processing plants, food processing plants, semiconductor plants, and for other industrial facilities such as in condensers of distillation columns, for cooling liquid in crystallization, etc. The circulation rate of cooling water in a typical 700 MW coal-fired power plant with a cooling tower amounts to about 71,600 cubic metres an hour (315,000 U.S. gallons per minute) and the circulating water requires a supply water make-up rate of perhaps 5 percent (i.e., 3,600 cubic metres an hour).

If that same plant had no cooling tower and used once-through cooling water, it would require about 100,000 cubic metres an hour and that amount of water would have to be continuously returned to the ocean, lake or river from which it was obtained and continuously re-supplied to the plant. Furthermore, discharging large amounts of hot water may raise the temperature of the receiving river or lake to an unacceptable level for the local ecosystem. Elevated water temperatures can kill fish and other aquatic organisms (see thermal pollution). A cooling tower serves to dissipate the heat into the atmosphere instead and wind and air diffusion spreads the heat over a much larger area than hot water can distribute heat in a body of water. Some coal-fired and nuclear power plants located in coastal areas do make use of 12

once-through ocean water. But even there, the offshore discharge water outlet requires very careful design to avoid environmental problems. Petroleum refineries also have very large cooling tower systems. A typical large refinery processing 40,000 metric tonnes of crude oil per day (300,000 barrels (48,000 m3) per day) circulates about 80,000 cubic metres of water per hour through its cooling tower system.

The world's tallest cooling tower is the 200 metre tall cooling tower of Niederaussem Power Station

AIR FLOW GENERATION METHOD

Fig. 4.1 A forced draft cooling tower

Fig. 4.2:Forced draft counter flow package type cooling towers

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With respect to drawing air through the tower, there are three types of cooling towers: 13.1 Natural draft, which utilizes buoyancy via a tall chimney. Warm, moist air naturally rises due to the density differential to the dry, cooler outside air. Warm moist is less dense than drier air at the same pressure. This moist air buoyancy produces a current of air through the tower.

13.2 Mechanical draft: which uses power driven fan motors to force or draw air through the tower.

13.3Induced draft: A mechanical draft tower with a fan at the discharge which pull air through tower. The fan induces hot moist air out the discharge. This produces low entering and high exiting air velocities, reducing the possibility of recirculation in which discharged air flows back into the air intake. This fan/fin arrangement is also known as draw-through.

13.4Forced draft: A mechanical draft tower with a blower type fan at the intake. The fan forces air into the tower, creating high entering and low exiting air velocities. The low exiting velocity is much more susceptible to recirculation. With the fan on the air intake, the fan is more susceptible to complications due to freezing conditions. Another disadvantage is that a forced draft design typically requires more motor horsepower than an equivalent induced draft design. The forced draft benefit is its ability to work with high static pressure. They can be installed in more confined spaces and even in some indoor situations. This fan/fill geometry is also known as blow-through.

Fan assisted natural draft. A hybrid type that appears like a natural draft though airflow is assisted by a fan. Hyperboloid cooling towers have become the design standard for all natural-draft cooling towers because of their structural strength and minimum usage of material. The hyperboloid shape also aids in accelerating the upward convective air flow, improving cooling efficiency. They are popularly associated with nuclear power plants. However, this association is 14

misleading, as the same kind of cooling towers are often used at large coal-fired power plants as well. Similarly, not all nuclear power plants have cooling towers, instead cooling their heat exchangers with lake, river or ocean water.

14. CROSS FLOW

Cross flow is a design in which the air flow is directed perpendicular to the water flow (see diagram below). Air flow enters one or more vertical faces of the cooling tower to meet the fill material. Water flows (perpendicular to the air) through the fill by gravity. The air continues through the fill and thus past the water flow into an open plenum area. A distribution or hot water basin consisting of a deep pan with holes or nozzles in the bottom is utilized in a cross flow tower. Gravity distributes the water through the nozzles uniformly across the fill material.

Fig 5.0 15

15. COUNTER FLOW In a counter flow design the air flow is directly opposite to the water flow. Air flow first enters an open area beneath the fill media and is then drawn up vertically. The water is sprayed through pressurized nozzles and flows downward through the fill, opposite to the air flow.

Fig 6.0 15.1 Common to both designs: The interaction of the air and water flow allows a partial equalization and evaporation of water. The air, now saturated with water vapour, is discharged from the cooling tower. A collection or cold water basin is used to contain the water after its interaction with the air flow. Both cross flow and counter flow designs can be used in natural draft and mechanical draft cooling towers 16

16. BOILER
Boilers can be classified into the following configurations: 16.1"Pot boiler" or "Haycock boiler": a primitive "kettle" where a fire heats a partially-filled water container from below. 18th century Haycock boilers generally produced and stored large volumes of very low-pressure steam, often hardly above that of the atmosphere. These could burn wood or most often, coal. Efficiency was very low.

16.2 Fire-tube boiler. Here, water partially fills a boiler barrel with a small volume left above to accommodate the steam (steam space). This is the type of boiler used in nearly all steam locomotives. The heat source is inside a furnace or firebox that has to be kept permanently surrounded by the water in order to maintain the temperature of the heating surface just below boiling point. The furnace can be situated at one end of a fire-tube which lengthens the path of the hot gases, thus augmenting the heating surface which can be further increased by making the gases reverse direction through a second parallel tube or a bundle of multiple tubes (two-pass or return flue boiler); alternatively the gases may be taken along the sides and then beneath the boiler through flues (3-pass boiler). In the case of a locomotive-type boiler, a boiler barrel extends from the firebox and the hot gases pass through a bundle of fire tubes inside the barrel which greatly increase the heating surface compared to a single tube and further improve heat transfer. Fire-tube boilers usually have a comparatively low rate of steam production, but high steam storage capacity. Fire-tube boilers mostly burn solid fuels, but are readily adaptable to those of the liquid or gas variety.

16.3 Water-tube boiler. In this type, the water tubes are arranged inside a furnace in a number of possible configurations: often the water tubes connect large drums, the lower ones containing water and the upper ones, steam and water; in other cases, such as a monotube boiler, water is circulated by a pump through a succession of coils. This type generally gives 17

high steam production rates, but less storage capacity than the above. Water tube boilers can be designed to exploit any heat source and are generally preferred in high pressure applications since the high pressure water/steam is contained within small diameter pipes which can withstand the pressure with a thinner wall.

16.4Flash boiler. A specialized type of water-tube boiler.

1950s design steam locomotive boiler, from a Victorian Railways J class

Fig 7.0 Fire-tube boiler with Water-tube firebox. Sometimes the two above types have been combined in the following manner: the firebox contains an assembly of water tubes, called thermic siphons. The gases then pass through a conventional fire tube boiler. Water-tube fireboxes were installed in many Hungarian locomotives, but have met with little success in other countries. Sectional boiler. In a cast iron sectional boiler, sometimes called a "pork chop boiler" the water is contained inside cast iron sections. These sections are assembled on site to create the finished boiler.

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17. CONTROLLING DRAUGHT

Most boilers now depend on mechanical draught equipment rather than natural draught. This is because natural draught is subject to outside air conditions and temperature of flue gases leaving the furnace, as well as the chimney height. All these factors make proper draught hard to attain and therefore make mechanical draught equipment much more economical.

There are three types of mechanical draught: 17.1 Induced draught: This is obtained one of three ways, the first being the "stack effect" of a heated chimney, in which the flue gas is less dense than the ambient air surrounding the boiler. The denser column of ambient air forces combustion air into and through the boiler. The second method is through use of a steam jet. The steam jet oriented in the direction of flue gas flow induces flue gasses into the stack and allows for a greater flue gas velocity increasing the overall draught in the furnace. This method was common on steam driven locomotives which could not have tall chimneys. The third method is by simply using an induced draught fan (ID fan) which removes flue gases from the furnace and forces the exhaust gas up the stack. Almost all induced draught furnaces operate with a slightly negative pressure.

17.2 Forced draught: Draught is obtained by forcing air into the furnace by means of a fan (FD fan) and ductwork. Air is often passed through an air heater; which, as the name suggests, heats the air going into the furnace in order to increase the overall efficiency of the boiler. Dampers are used to control the quantity of air admitted to the furnace. Forced draught furnaces usually have a positive pressure.

17.3 Balanced draught: Balanced draught is obtained through use of both induced and forced draught. This is more common with larger boilers where the flue gases have to travel a long distance through many boiler passes. The induced draught fan works in conjunction with the forced draught fan allowing the furnace pressure to be maintained slightly below atmospheric.

18. SAFETY
Safety is the state of being "safe" (from French sauf), the condition of being protected against physical, social, spiritual, financial, political, emotional, occupational, psychological, educational or other types or consequences of failure, damage, error, accidents, harm or any other event which could be considered non-desirable. Safety can also be defined to be the 19

control of recognized hazards to achieve an acceptable level of risk. This can take the form of being protected from the event or from exposure to something that causes health or economical losses. It can include protection of people or of possessions.

19. TYPES OF SAFETY

It is important to distinguish between products that meet standards, that are safe, and those that merely feel safe. The highway safety community uses these terms.

19.1 NORMATIVE SAFETY Normative safety is a term used to describe products or designs that meet applicable design standards and protection. 19.2 SUBSTANTIVE SAFETY Substantive or objective safety means that the real-world safety history is favorable, whether or not standards are met. 19.3 PERCEIVED SAFETY Perceived or subjective safety refers to the level of comfort of users. For example, traffic signals are perceived as safe, yet under some circumstances, they can increase traffic crashes at an intersection. Traffic roundabouts have a generally favorable safety record, yet often make drivers nervous.

20. SAFETY MEASURES

Safety measures are activities and precautions taken to improve safety, i.e. reduce risk related to human health. Common safety measures include: Root cause analysis to identify causes of a system failure and correct deficiencies. Visual examination for dangerous situations such as emergency exits blocked because they are being used as storage areas. Visual examination for flaws such as cracks, peeling, loose connections.

Chemical analysis X-ray analysis to see inside a sealed object such as a weld, a cement wall or an airplane outer skin.

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Destructive testing of samples Stress testing subjects a person or product to stresses in excess of those the person or product is designed to handle, to determining the "breaking point".

Safety margins/Safety factors. For instance, a product rated to never be required to handle more than 200 pounds might be designed to fail under at least 400 pounds, a safety factor of two. Higher numbers are used in more sensitive applications such as medical or transit safety. Implementation of standard protocols and procedures so that activities are conducted in a known way. Training of employees, vendors, product users Instruction manuals explaining how to use a product or perform an activity Instructional videos demonstrating proper use of products Examination of activities by specialists to minimize physical stress or increase productivity Government regulation so suppliers know what standards their product is expected to meet. Industry regulation so suppliers know what level of quality is expected. Industry regulation is often imposed to avoid potential government regulation. Self-imposed regulation of various types. Statements of Ethics by industry organizations or an individual company so its employees know what is expected of them. Drug testing of employees, etc. Physical examinations to determine whether a person has a physical condition that would create a problem. Periodic evaluations of employees, departments, etc. Geological surveys to determine whether land or water sources are polluted, how firm the ground is at a potential building site, etc.

21. 5S (METHODOLOGY)
5S is the name of a workplace organization methodology that uses a list of five Japanese words which are seiri, seiton, seiso, seiketsu and shitsuke. There are 5 primary phases of 5S: sorting, straightening, systematic cleaning, standardizing, and sustaining.

21.1 SORTING (SEIRI) 21

Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and so forth in the plant and work area. Keep only essential items and eliminate what is not required, prioritizing things per requirements and keeping them in easily-accessible places. Everything else is stored or discarded.

21.2 STRAIGHTENING OR SETTING IN ORDER / STABILIZE (SEITON) There should be a place for everything and everything should be in its place. The place for each item should be clearly labeled or demarcated. Items should be arranged in a manner that promotes efficient work flow, with equipment used most often being the most easily accessible. Workers should not have to bend repetitively to access materials. Each tool, part, supply, or piece of equipment should be kept close to where it will be used in other words, straightening the flow path. Seiton is one of the features that distinguishes 5S from "standardized cleanup". This phase can also be referred to as Simplifying.

21.3 SWEEPING OR SHINING OR CLEANLINESS / SYSTEMATIC CLEANING (SEISO) Clean the workspace and all equipment, and keep it clean, tidy and organized. At the end of each shift, clean the work area and be sure everything is restored to its place. This makes it easy to know what goes where and ensures that everything is where it belongs. Spills, leaks, and other messes also then become a visual signal for equipment or process steps that need attention. A key point is that maintaining cleanliness should be part of the daily work not an occasional activity initiated when things get too messy.

21.4 STANDARDIZING (SEIKETSU) Work practices should be consistent and standardized. All work stations for a particular job should be identical. All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station. Everyone should know exactly what his or her responsibilities are for adhering to the first 3 S's. 21.5 SUSTAINING THE DISCIPLINE OR SELF-DISCIPLINE (SHITSUKE) Maintain and review standards. Once the previous 4 S's have been established, they become the new way to operate. Maintain focus on this new way and do not allow a gradual decline back to the old ways. While thinking about the new way, also be thinking about yet better ways. When an issue arises such as a suggested improvement, a new way of working, a new tool or a new output requirement, review the first 4 S's and make changes as appropriate.

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REFERENCES

1. www.google.com. 2 .R.S.Khurmi text book. 3. NTPC brochure.

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