NTPC LTD.

SIMHADRI SUPER THERMAL POWER STATION, VISAKHAPATNAM, ANDHRA PRADESH

Submitted By Kolli Niharika 4/4 B.E Mechanical 309107020020

NTPC - AN OVERVIEW NTPC's core business is engineering, construction and

operation of power generating plants and providing consultancy to power utilities in India and abroad.

The total installed capacity of the company is 31134 MW with 15 coal based and 7 gas based stations, located across the country. In addition under JVs, 3 stations are coal based & another station uses naphtha/LNG as fuel.

SALIENT FEATURES OF NTPC SIMHADRI

First coastal based coal fired thermal power project of NTPC Biggest sea water intake well in India Use of sea water for condenser cooling and ash disposal Asias tallest natural cooling towers, 6th in the world Use of fly ash bricks in the construction of all buildings Coal based project of NTPC whose entire power is allocated to home state.

Use of monitors as Man Machine Interface for operating the plant Use of Process Analysis, Diagnosis and Optimization for the first time in NTPC

Use of monitors as Man Machine Interface for operating the plant. Use of Process Analysis, Diagnosis and Optimization for the first time in NTPC

Boiler mapping by Acoustic Pyrometers

Use of distributed digital control and Management Information system. Use of INERGEN as fire protection system for the first time in NTPC.

Commissioning of 1st unit in Record 39 months

Use of Process Analysis, Diagnosis and Optimization for the first time in NTPC

OPERATION OF A STEAM POWER PLANT

Introduction Steam Generator or Boiler Steam Turbine Electric Generator

Introduction of power plant Power Station is an industrial facility for the generation of
electric power. At the centre of nearly all power stations is a generator, a rotating machine that converts Mechanical energy into Electrical energy by creating relative motion between a magnetic field and a conductor. In thermal power stations, mechanical power is produced by a heat engine, which transforms Thermal energy into rotational energy. Thermal Energy obtained from combustion of fuel.

STEAM GENERATOR (BOILER)

A Boiler is a closed vessel in which water is heated. The vaporized fluid exits the boiler for use in production of electric power. The type of firing inside the Boiler is Tilting Tangential type.

The type of furnace used is single radiant, dry bottom, controlled circulation and the wall is water steam cooled.
The residence time for fuel particles is 3 seconds.

 The boiler used here is water tube boiler. In this type, the water tubes are arranged inside the furnace in a number of possible configurations Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the centre. The thermal radiation of the fireball heats the water that circulates through the boiler tubes near the boiler perimeter.
The water circulation rate in the boiler is three to four times the output and is typically driven by pumps.

As the water in the boiler circulates it absorbs heat and changes into steam. It is separated from the water inside a drum at the top of the furnace

BOILER AUXILIARIES
Efficiency of the system is of most concern. Thus it is very important to maintain a system as efficient as possible. Boiler auxiliaries help in improving boiler efficiency. The following are important boiler auxiliaries. ECONOMISER: Its purpose is to preheat the feed water before entering the boiler drum by utilizing the heat from the flue gases leaving the furnace. The type of economizer being used is plain tube, nonsteaming. The design temperature is 334 deg

SUPERHEATER:

Its purpose is to increase the temperature of the steam to the superheated region. There are three different super heaters being used based on different temperatures. They are termed as 1.Ltsh (stage 1) 2.Divisional Panel(stage 2) 3. Platen(stage 3).
The mode of heat transfer in the stage 1 is mostly convective and during other two stages is mostly radiant. The temperature obtained in stage 1 is 493 deg, during stage 2 is 513 deg and during stage 3 is 592 deg.

REHEATER:
Its purpose is heat addition and to increase the temperature of the steam leaving the high pressure turbine to 540 degrees. The type of reheater being used here is radiant front platen and convective rear pendant.

The design pressure is 52.4 kg per sq cm. the number of elements used are of number 888.
SOOT BLOWER: It blows off the ash deposited in the water wall tubes. It uses steam for blowing purpose.

Air Preheater: It pre-heats the air entering the furnace by recovering heat from flue gases in order to ease the combustion process. Draft Fans: They handle the supply of air and the pressure of furnace. Oil Guns: They are used to spray oil to raise the temperature of furnace to ignition temperature of fuel. Wind Box: It distributes the excess air uniformly through out furnace. BOILER MOUNTINGS: These are used for the safe operation of boiler. Some examples are water level indicating drum, furnace temperature probe, pressure gauge indicating steam pressure.

COAL HANDLING PLANT

 In a coal based thermal power plant, the initial process in the power generation is Coal Handling. The huge amount of coal is usually supplied through railways. A railway sliding line is taken into the power station and the coal is delivered in the storage yard. The coal is unloaded from the point of delivery by means of wagon tippler. It is rack and pinion type. The coal is taken from the unloading site to crusher house by belt conveyors. The transfer points are used to transfer coal to the next belt.

 The belt further elevates the coal to the transfer point and it reaches the crusher through belt.
In the crusher a high-speed 3-phase induction motor is used to crush the coal to a size of 50 mm so as to be suitable for milling system. Coal rises from crusher house and reaches the dead storage by passing through transfer point. The coal required to the boiler is sent to the Bunker and then it is passed to the feeder from which it enters the mill. The P.A fan helps in the proper movement of coal into the boiler.

ASH HANDLING PLANT (AHP) The ash produced on the combustion of coal is collected by ESP. This ash is now required to be disposed off. This problem of ash disposal is solved by Ash Handling Plant (AHP). There are basically 2 types of ash handling processes:

Dry ash system :

Dry ash is required in cement factories as it can be directly added to cement. Hence the dry ash collected in the ESP hopper is directly disposed to silos using pressure pumps. The dry ash from these silos is transported to the required destination.

Bottom ash system

In this system, the ash slag discharged from the furnace is collected in water impounded scraper installed below bottom ash hopper. The ash collected is transported to clinkers by chain conveyors. The clinker grinders churn ash which is then mixed with water to form slurry.
ELECTROSTATIC PRECIPITATOR

An electrostatic precipitator (ESP), or electrostatic air cleaner is a particulate collection device that removes particles from a flowing gas (such as air) using the force of an induced electrostatic charge.

 Electrostatic precipitators are highly efficient filtration devices that

minimally impede the flow of gases through the device, and can easily remove fine particulate matter such as dust and smoke from the air stream.

TURBINE A steam turbine is a device that extracts thermal energy from

pressurized steam and uses it to do mechanical work on a rotating output shaft.
Because the turbine generates rotary motion, it is particularly suited to be used to drive an electric generator. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible process.

 There are three types of turbines being used in SIMHADRI namely HP, IP, LP Turbine.

Out of which HP(High Pressure) turbine is of single flow, IP(Intermediate turbine) and LP (Low pressure turbine) are of double flow type. Specifications of main turbine : TYPE : Three cylinder Reheat Condensing Turbine
STAGES : HPT 17 Reaction Stages IPT 12*2 Reaction stages LPT 6*2 Reaction Stages Direction of rotation is Anticlockwise when viewed from front pedestal to the generator

 Rated Load is 500 MW Rated Speed is 50 C/sec Turbine overall length is 19.94 m Turbine overall width is 15.1 m
TURBINE LOAD SHARING CAPACITY HP Turbine 26% IP Turbine 34% LP Turbine 40% Differential Expansions HPT IPT Overall expansion of IP+LP Rotor

-5 TO +3.5mm -1 TO +5.5 mm -3 TO 30 mm

Condenser
The surface condenser is a shell and tube heat exchanger in which cooling water is circulated through the tubes.

CONDENSOR SPECIFICATIONS

Type Total Surface Area Of Heat Transfer Number Of Cooling Tubes Length Of Each Tube Design C.W Temp CW flow quantity Number of CW Passes Condensate Back Pressure

Double Pass, Single Shell 356031 sq meters 22688 14.73 m 33 deg Celsius 54300 cubic meter/hr 2 0.1045 ata

NATURAL DRAFT COOLING TOWERS

A Natural Draft cooling tower Utilizes buoyancy via a tall chimney.

Warm, moist air naturally rises due to the density differential compared to the dry, cooler outside air. Warm moist air is less dense than drier air at the same pressure.

This moist air buoyancy produces an upwards current of air through the tower.

GENERATOR

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