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INDUSTRIAL TRAINING REPORT ON NTPC, BADARPUR

Submitted By:- RUPAK KUMAR Mechanical(3rd year)

Department of Mechanical Engineering G.L BAJAJ Institute of Technology & MANAGEMENT, Greater Noida.

ACKNOWLEDGEMENT
I express my sincere thanks to the engineers and electrical maintenance persons for the guidance and support that they provided during my training period of May-June 2012. I would like to thank Mr.G.D SHARMA sir for giving me opportunity to take training in esteem organization of NTPC Badarpur. I would like to specially convey my heartily thanks to Mr. P.K Prabhakar of BMD, Mr. Gaurav Goel at the PAM section, and Mr.S.K Garg at the TMD section and many other employees of NTPC for devoting their time to give me on-site presentations.

Rupak kumar ME-1001940048

G.L BAJAJ INSTITUTE OF TECHNOLOGY & MANAGEMENT GREATER NOIDA

TO WHOM IT MAY CONCERN


I hereby certify that Rupak Kumar Roll.1019240048 of G.L BAJAJ INSTITUTE OF TECHNOLOGY & MANAGEMENT GREATER NOIDA has undergone 27 days industrial training from 28th may to 23rd June 2012 at our organization to fulfill the requirements for the award of degree of B.Tech in Mechanincal. He works on Power Plant Overview project during the training under the supervision of Mr. G. D. Sharma. During his tenure with us we found him sincere and hard working. We wish him a great success in the future.

Signature of the Student

CONTENTS

History of power development in India Thermal power development in India Thermal power station and its CLASSIFICATION COAL TO ELECTRICITY NTPC Performance POWER STATIONS in INDIA BTPS Introduction

Steam Generator or Boiler Boiler Furnace and Steam Drum Fuel Preparation System Fuel Firing System and Igniter System Steam Turbine Coal Handling Plant Generator Transformer

History of power development in India:


India is one of the youngest and yet the largest domestic republic in the world, having an area of 1.27 million square miles with a population of around 1000 millions there are 5.76 lakhs villages in India and cover a population of about 70% of total population .The history of power development in India dates back to 1897 when 200 kW hydro station was first commissioned at Darjeeling. In

early years, most of the electricity supplies were privately owned and it catered to the needs of towns and cities. The majority of the earlier power stations comprised of diesel generating sets. The first steam station was commissioned in Calcutta in 1899 with a total installed capacity of 1000 kW. During the first two decades of the twentieth century, steam power stations at Kanpur, Madras and Calcutta of 2170 kW, 9000 kW, 15000 kW capacities respectively, were commissioned. Similarly, hydro-plants of 4500 kW at Sivasamud in Karnataka in 1902, 3000 kW at Mohara in J&K in 1907, 500 kW at Shimla in Himachal Pradesh in 1911 1550 kW at Gokak falls in 1914 and 40000 kW at Tata hydro(Mumbai) in 1915 were installed. By the end of 1940, the total installed capacity rose to 1208 MW. The installed capacities in utilities by march 1951 was 1710 MW comprising hydro 560 MW, thermal 1000 MW and diesel 150 MW. The installed capacity in self-generating non-utilities was 590 MW. Efforts for organizing the power supply in industry in a rational manner began only after independence. Planned power development in a systematic manner began in 1951 with the launching of the first 5 year plan. During the first plan (1951-56), the installed generating capacity increased by 1100 MW bringing the total capacity to 3400 MW at the end of the plan . During the five years period covered by the plan, the generation increased from 7514 KWh to 11872 million KWh. In the second plan period the investment made in the power sector was three times the investment made in the preceding plan. The total generation rose to 20123 million KWh during this period. The first 220 kV line was commissioned in during this period. Third five year plan was characterized by two important developments. The first was the recognition of the importance of rural electrification as a key to infrastructure for economic development. The second was the development of the importance of the interconnecting power stations so that the available generating capacities could be pooled and used for the best advantage. This logically led to the demarcation of the country, for system operation purposes into five regions, namely, northern region (U.P, Haryana, Punjab, Rajasthan, Himachal Pradesh , and JK); western region(M.P, Gujarat, Maharashtra, Goa, Daman and Diu); southern region (A.P, Karnataka, T.N, Pondicherry and Kerala); eastern region(Bihar, Orissa, West Bengal) and North Eastern region(Assam, Meghalaya, Tripura, Arunachal Pradesh, Nagaland, Manipur and Mizoram) and establishment of Regional Electricity Board in each of these five regions. The growth of power generation during various five year plans has been 10.5 %( first plan), 4.9 %( second plan), 14.3 %( third plan) and 6.9 %( fourth plan). This shows that the power industry in the country has been facing serious problems at the end of fourth plan due to shortfall in achievement of targets. This was due to lack of proper maintenance of plants leading to sub-optimum utilization of installed capacity, organizational weakness and scarcity of funds. Since the beginning of fifth five year plan, a concentrated effort has been made to reorganize the scenario for more effective performance. One of the major developments in this sector is the thermal power generation which is still our main feeding source for the power we need. Thermal power generation can be achieved in various following ways:

Coal Diesel Gas Nuclear Though other sources of power development are available, power production by using coal as fuel is most common in India. It is cheapest and most reliable form of energy till date due to the vast reserve of coal fields available in India as well as in other countries from where it can be easily imported.

Thermal power development in India:


The known resources of coal in India is assumed to be 81,000 million tones which are fairly localized in four states West Bengal, Bihar, M.P and Andhra Pradesh. Most of the resources are inferior quality (non cooking type). The limited resource for higher grade cooking coal to the mines of Bihar and West Bengal are conserved for metallurgical industries. The present day annual production of coal is 90 million tones (as per data available in 1978) of which thermal stations consume about 30 million tones which is low grade coal with high ash content (as high as 40%). Presently, India imports coal from Australia which stands at $489 million in 1993-94. According to new guidelines prescribed by ministry of environment, all coal based power plants with an installed capacity of 500 MW or more will be granted environmental clearance only when the plants have a linkage with mines which supply washed coal.

Thermal power station and its CLASSIFICATION:

In thermal power stations, mechanical power is produced by a heat engine, which transforms thermal energy, often from combustion of a fuel, into rotational energy. Most thermal power stations produce steam, and these are sometimes called steam power stations. About 86% of all electric power is generated by use of steam turbines. Not all thermal energy can be transformed to mechanical

power, according to the second law of thermodynamics. Therefore, there is always heat lost to the environment. If this loss is employed as useful heat, for industrial processes or district heating, the power plant is referred to as a cogeneration power plant or CHP (combined heat-and-power) plant. In countries where district heating is common, there are dedicated heat plants called heat-only boiler stations. An important class of power stations in the Middle East uses byproduct heat for desalination of water.

Classification:

CHP plant in Warsaw, Poland

Geothermal power station in the Philippines

Coal Power Station in Tampa FL Thermal power plants are classified by the type of fuel and the type of prime mover installed.

By fuel

Nuclear power plants use a nuclear reactor's heat to operate a steam turbine generator. Fossil fuelled power plants may also use a steam turbine generator or in the case of natural gas fired plants may use a combustion turbine. Geothermal power plants use steam extracted from hot underground rocks. Renewable energy plants may be fuelled by waste from sugar cane, municipal solid waste, landfill methane, or other forms of biomass. In integrated steel mills, blast furnace exhaust gas is a low-cost, although low-energy-density, fuel. Waste heat from industrial processes is occasionally concentrated enough to use for power generation, usually in a steam boiler and turbine.

By prime mover

Steam turbine plants use the dynamic pressure generated by expanding steam to turn the blades of a turbine. Gas turbine plants use the dynamic pressure from flowing gases to directly operate the turbine. Natural-gas fuelled turbine plants can start rapidly and so are used to supply "peak" energy during periods of high demand, though at higher cost than base-loaded plants.

Combined cycle plants have both a gas turbine fired by natural gas, and a steam boiler and steam turbine which use the exhaust gas from the gas turbine to produce electricity. This greatly increases the overall efficiency of the plant, and most new baseload power plants are combined cycle plants fired by natural gas. Internal combustion Reciprocating engines are used to provide power for isolated communities and are frequently used for small cogeneration plants. Hospitals, office buildings, industrial plants, and other critical facilities also use them to provide backup power in case of a power outage. These are usually fuelled by diesel oil, heavy oil, natural gas and landfill gas. Microturbines, Stirling engine and internal combustion reciprocating engines are low cost solutions for using opportunity fuels, such as landfill gas, digester gas from water treatment plants and waste gas from oil production.

Cooling towers

Coal power plant in China with a hyperbolic cooling tower Because of the fundamental limits to thermodynamic efficiency of any heat engine, all thermal power plants produce waste heat as a byproduct of the useful electrical energy produced. Natural draft wet cooling towers at nuclear power plants and at some large thermal power plants are large hyperbolic chimney-like structures (as seen in the image at the left) that release the waste heat to the ambient atmosphere by the evaporation of water (lower left image).

A Marley mechanical induced-draft cooling tower However, the mechanical induced-draft or forced-draft wet cooling towers (as seen in the image to the right) in many large thermal power plants, petroleum refineries, petrochemical plants, geothermal, biomass and waste to energy plants use fans to provide air movement upward through down coming water and are not hyperbolic chimney-like structures. The induced or forced-draft cooling towers are rectangular, box-like structures filled with a material that enhances the contacting of the up flowing air and the down flowing water. In desert areas a dry cooling tower or radiator may be necessary, since the cost of make-up water for evaporative cooling would be prohibitive. These have lower efficiency and higher energy consumption in fans than a wet, evaporative cooling tower. Where economically and environmentally possible, electric companies prefer to use cooling water from the ocean, or a lake or river, or a cooling pond, instead of a cooling tower. This type of cooling can save the cost of a cooling tower and may have lower energy costs for pumping cooling water through the plant's heat exchangers. However, the waste heat can cause the temperature of the water to rise detectably. Power plants using natural bodies of water for cooling must be designed to prevent intake of organisms into the cooling cycle. A further environmental impact would be organisms that adapt to the warmer plant water and may be injured if the plant shuts down in cold weather.

Evaporation of water" at Ratcliffe Power Plant, UK

Other sources of energy


Other power stations use the energy from wave or tidal motion, wind, sunlight or the energy of falling water, hydroelectricity. These types of energy sources are called renewable energy.

Hydroelectricity
Hydroelectricity impounds a reservoir of water and releases it through one or more water turbines to generate electricity.

Pumped storage
A pumped storage hydroelectric power plant is a net consumer of energy but decreases the price of electricity. Water is pumped to a high reservoir during the night when the demand, and price, for electricity is low. During hours of peak demand, when the price of

electricity is high, the stored water is released to produce electric power. Some pumped storage plants are actually not net consumers of electricity because they release some of the water from the lower reservoir downstream, either continuously or in bursts.

Solar

A control room of a modern power station A solar photovoltaic power plant converts sunlight into electrical energy, which may need conversion to alternating current for transmission to users. This type of plant does not use rotating machines for energy conversion. Solar thermal electric plants are another type of solar power plant. They direct sunlight using either parabolic troughs or heliostats. Parabolic troughs direct sunlight onto a pipe containing a heat transfer fluid, such as oil, which is then used to boil water, which turns the generator. The central tower type of power plant uses hundreds or thousands of mirrors, depending on size, to direct sunlight onto a receiver on top of a tower. Again, the heat is used to produce steam to turn turbines. There is yet another type of solar thermal electric plant. The sunlight strikes the bottom of the pond, warming the lowest layer which is prevented from rising by a salt gradient. A Rankine cycle engine exploits the temperature difference in the power station layers to produce electricity. Not many solar thermal electric plants have been built. Most of them can be found in the Mojave Desert, although Sandia National Laboratory, Israel and Spain have also built a few plants.

Wind
Wind turbines can be used to generate electricity in areas with strong, steady winds. Many different designs have been used in the past, but almost all modern turbines being produced today use the Dutch six-bladed, upwind design. Grid-connected wind turbines now being built are much larger than the units installed during the 1970s, and so produce power more cheaply and reliably than earlier

models. With larger turbines (on the order of one megawatt), the blades move more slowly than older, smaller, units, which makes them less visually distracting and safer for airborne animals. However, the old turbines can still be seen at some wind farms, particularly at Altamont Pass.

COAL TO ELECTRICITY
Coal from the coal wagons is unloaded in the coal handling plant. This coal is up to the raw coalbunkers with the help of belt conveyers. Coal is transported to the bowl mills by coal feeders. The coal is pulverized in the bowl mill where it is ground to a powder form. The mill consists of a round metallic table on which coal particles fall. This table is rotated with the help of a motor. These are three large rollers, which are spaced 120 degree apart. When there is no coal, these rollers do not rotate but when coal is fed to the table it packs up between roller and the table and this forces the roller to rotate. Coal is crushed by the crushing action between rollers and the rotating table. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold air mixture from P.A. fan. This fan takes atmospheric air, a part of which is sent to air pre-heaters for heating while a part goes directly to the mill for temperature control. Atmospheric air from F.D. fan is heated in the air heaters and sent to the furnace as combustion air. Water from boiler feed pump passes through economizer and reaches the boiler drum. Water from the drum passes through down comers and goes to bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat and density difference the water rises up in the water wall tubes. Water is partly converted to steam as it rises up in the furnace. This steam and water mixture is again taken to the boilers drum where the steam is separated from the water. Water follows the same path while the steam is sent to super heaters for superheating. The super heaters are located inside the furnace and the steam is superheated (540 deg C) finally it goes to turbine. A flue gas from the furnace is extracted from the induced draft fan, which maintains balance draft in the furnace with forced draft fans. These flue gases emits their heat energy to various super heaters in the pant house and finally passes through air pre-heaters and goes to electrostatic precipitator where the ash particles are extracted. Electrostatic precipitator consists of metal plates which are electrically charged. Ash particles are attracted on to these plates, so that they do not pass through the chimney, to pollute the

atmosphere. A regular mechanical hammer causes the accumulation of ash to fall to the bottom of the precipitator where they are collected in a hopper for disposal. This ash is mixed with water to form slurry and is pumped to ash pond. The steam from the boiler is conveyed to the turbine through the steam pipes and through stop valve and control valve that automatically regulate the supply of steam to the turbine. Stop valves and control valves are located in a steam chest and governor driven from the main turbine shaft operates the control valves to regulate the amount used. Steam from the control valves enters the high-pressure cylinder of the turbine, where it passes through the ring of blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on the disc secured to the turbine shaft. The second ring turns the shaft as a result of the force of the steam. The stationary and moving blades together constitute a stage of a turbine and in practice many stages are necessary, so that the cylinder contains a number of rings of stationary blades with rings of moving blades arranged between them. The steam passes though each stage in turn until it reaches the end of the high-pressure cylinder and in its passage some of its heat energy is changed in to mechanical energy. The steam leaving the high-pressure cylinder goes back to the boiler for reheating and returns by a further pipe to the intermediate pressure cylinder. Here it passes through another series of stationary and moving blades. Finally the steam is taken to the low pressure cylinders, each of which it enters at the center flowing outwards in the opposite directions through the rows of turbines blades an arrangement known as double flow-to extremities of the cylinder as the steam gives up its heat energy to drive the turbine its temperature and pressure falls and it expands, because of this expansion the blades are much larger and longer towards the low pressure ends of the turbine. The turbine shaft usually rotates at 3000rpm.this speed is determined by the frequency of the electrical system used in this country and is the speed at which a 2 pole generator must be driven to generate alternating current at a frequency of 50 cycles /sec. When as much as energy as possible has been extracted from the steam it is exhausted directly to the condenser. This runs the length of the low pressure part of the turbine and may be beneath on either side of it the condenser consist of a large vessel containing some 20000 tubes each about 25mm in diameter cold water from the river, estuary, sea or cooling tower is circulated through these tubes and as the steam from the turbine passes round them it is rapidly condensed into water condensate. Because water has a much smaller comparative volume than steam, a vacuum is created in the condenser. This allows the steam to reduce down to pressure below that of the normal atmosphere and more energy can be utilized. From the condenser, the condensate is pumped through low-pressure heaters by the extraction pumps after which its pressure is raised to boiler pressure by the boiler feed pump. It is passed through further feed heaters to the economizer and the boiler for the reconversion into steam.

A power station generating 2000000 KW of electricity requires about 227500 cubic meter of water an hour for cooling purpose. Here cooling towers are used, about 1/100 part of the cooling water evaporates and a certain amount is returned to its source to carry away any impurities that collects most of it is however recirculated.

RANKINE CYCLE:
The thermodynamic cycle on which the steam (or thermal) power plant is operated is modified ranking cycle. A simple ranking cycle consists of four processes: reversible constant pressure heat addition; reversible adiabatic expansion; reversible constant pressure heat rejection; reversible adiabatic compression.

REGENERATIVE CYCLE:
The sample plant cycle illustrated with symbols, lines, and process units in this diagram is more complex than any previous examples. Note the two independent closed heaters at points (b) and (d). The other units in this cycle have their conventional roles in the generation of power from a working fluid. On the lower half of the diagram is the temperature-entropy (TS) diagram resulting from examination of the ideal process. The stages of regeneration actually shift the water among different saturation lines, permitting an increase in temperature and therefore increases in both the maximum power output and thermal efficiency of the design without unduly altering entropy. Instead of boiling water at the low pressure pL or even at intermediate pressures pj or pi, the phase change occurs at the highest possible pressure, pH , available for the design. Since turbines operate most effectively and most efficiently when a large pressure drop is established, a plant employing regeneration of this type will be able to produce more power per unit of original energy resource and mass of water. Regeneration basically means "generation again" or "repeat generation." As the heavy black line on the process flow diagram on the left shows, water is partially condensed between points (d) and (a), but then prior to arrival at the boiler for another heating stage, the working fluid enters the turbine again in order to extract all possible useful energy from the water and vapor. A thermal power plant works on a modified ranking cycle that is a combination of reheat and regenerative. So there is also a low and high pressure turbine for reheat purposes and heaters (L.P. and H.P.) for regenerative purposes.

Some of the vital parts of the power plant are as follows: Boilers Electrostatic precipitators(ESP) Conveyors Draught systems Economizers Super heaters Desuperheaters Cooling towers Pumps Turbines Furnace Pulverizing plant

Basic concepts
In a fossil fuel power plant the chemical energy stored in fossil fuels such as coal, fuel oil, natural gas or oil shale is converted successively into thermal energy, mechanical energy and, finally, electrical energy for continuous use and distribution across a wide geographic area. Almost all large fossil fuel power plants are steam-electric power plants, except for gas turbines and utility-sized reciprocating engines that may run on natural gas or diesel. The burning of fossil fuel is summarized in the following chemical reaction:

and the simple word equation for this chemical reaction is: All fossil fuels generate carbon dioxide, when combusted. Chemical side reactions also take place, generating, among others, sulfur dioxide (predominantly in coal) and oxides of nitrogen. Each fossil fuel power plant is a highly complex, custom-designed system. Present construction costs, as of 2004, run to US$1,300 per kilowatt, or $650 million for a 500 MWe unit. Multiple generating units may be built at a single site for more efficient use of land, natural resources and labor.

NTPC Performance
The operating performance of NTPC has been considerably above the national average. The availability factor for coal stations has increased from 78.21% in 1985-86 to 88.54% in 2000-01, which compares favorably with international standards. The PLF has increased from 70% in 1992-93 to 81.8% during the year 2000-01. However, for regions other than Eastern Region which has power evacuation constraints due to low system demand, a PLF of 88.6% was achieved during this year. Over eight years, employee productivity has increased almost threefold as measured by the ratio of turnover to number of employees.

It may be seen from the table below that while the installed capacity has increased by 49.36% in the last eight years, the employee strength went up by only 10.2%. This includes employees of Orissa State Electricity Board who had to be absorbed in NTPC consequent upon the take over of 460 MW Talcher Power Station from the Orissa Government on 3-6-1995 and 440 MW Tanda Thermal Power Project from U. P. Government on 15-01-2000.

Description Installed capacity Generation No. of employees Generation/employee Turnover/employee

Unit MW MUs No. MUs Rs.(Lakhs)

92-93 13,054 66,113 21,797 3.03 20.74

2000-01 19,497 1,30,154 24,012 5.42 80.04

% of increase 49.36 96.87 10.2 83.1 385.9

Description Installed capacity Generation No. of employees Generation/employee Turnover/employee

Unit MW MUs No. MUs Rs. Lakh

92-93 13,054 66,113 21,797 3.03 20.74

2000-01 19,497 1,30,154 24,012 5.42 80.04

% of increase 49.36 96.87 10.2 83.1 385.9

For the year 2000-01, NTPC's Dadri Coal & Singrauli Station recorded a PLF of 93.6% which was the highest in the country.

NTPC:
1. Stands for National Thermal Power Station. 2. 6th leading company in India. 3. Core business includes- engineering, construction & operation of power plants. 4. Also provides Consultancy service in India & abroad. 5. Owns 14 coal based plants, 7 fuel based plants. 6. Total installed capacity(all over INDIA) 24,600 MegaWatts.

The development of power in the country was achieved through State Electricity Boards (SEBS) during the first three decades after independence. The outlay for power during viii-plan was Rs.34270 crores against Rs.393 crores during the first plan period. The outlay for power remained 19-20% during all plan periods out of total outlay. With significance achievements since independence, power shortage has persisted because the demand has always been outstripping the supply. This was because, financial resources were not available to the extent required to create the necessary power supply capacity. Due to shortage of power in different regions and imbalance power generation, and non availability of inter-regional grids, it was decided to install generation capacity in central sector. Two central companies, the National Thermal Power Corporation (NTPC est. in 1975 Nov.) and the National Hydroelectric Corporation (NHPC) were setup in 1975 and NEEPC (North Eastern Electric Power Corporation) to serve north eastern region thus was considered a major stride in the establishment of an integrated grid at the national level through inter-connection of national grids. A third central generation company, the Nuclear Power Corporation (NPC) has been formed to develop nuclear power potential.

The NTPC is executing a number of super thermal power projects and associated transmission systems at an approved investment of Rs.13568 crores. During vi-plan, NTPC alone accounted for 20.2%of total thermal capacity additions in the country and 15.5% of total generating capacity addition. During vii-plan it has contributed nearly 40% of the total thermal capacity additions and would be nearly 24% of the total thermal capacity in the country. It is expected that NTPC would have an installed capacity of about 29500 MW at the present cost of Rs.40, 000 crores by the end of the century. The first super-thermal power station of 2000MW capacity was installed in Singrauli in U.P by NTPC. The power generated is fed to U.P, Punjab, Haryana, Rajasthan, H.P and Delhi through the northern grid. NTPC ushers the era of 500 MW units in the country commissioning the first 500 MW units at Singrauli in Dec. 1986 and another 5oo MW unit in Korba super thermal station in M.P in May 1987. The NTPCs projects spread over the different parts of the country include Singrauli(U.P) with installed capacity of 2000MW, fully operational , the Korba in western region, the largest power station in the country of 2100 MW capacity, the Ramagundam(A.P) of 1600 MW capacity in the southern region, and Farakka(West Bengal) of 600 MW capacity in the eastern region. The Vindhyachal project in M.P, has achieved a capacity of 630 MW. Two units of 500 MW each in the Richard project in U.P have been commissioned. The Kahalgaon project in Bihar comprises four units of 210 MW each, which is to be setup with Russian assistance. The four units of 210 MW each has been setup at Dadri in U.P. in addition to this NTPC is also managing the Badarpur power plant of 720 MW capacity on behalf of the Govt. of India since 1st April 1978. Govt. of India has drawn a program to setup six more super thermal power stations in central sector. These will be taken up at Waiden in M.P of 3000 MW, Pench of 840 MW in M.P, Kahalgaon of 2800 MW, in Bihar, Manguru of 3000 MW in A.P & Singrauli-II of 3000 MW in U.P Coming to the gas projects, three gas turbines of Anta project each 88 MW capacities have been commissioned. At Auraiya in U.P, two gas turbines of 112 MW each capacity have been synchronized and another project at Talchar of 1000 MW is coming up at Orissa. The gas turbine power plants at Kawas, Anta and Auraiya will be converted into combined cycle plants in future. By the end of 1988, the NTPC has a capacity of 8418 MW. NTPC has contributed substantially towards capacity addition program in the country. During VII-plan NTPC has added 7718 MW till March 1989 against anticipated target of 7152 MW. Total capacity installed by NTPC by 1990 would be 9352 MW which will be 21.8% total thermal capacity installed in the country. During VIII-plan, NTPC has a program of capacity addition of around 11150 MW which contributes 39.7% of total thermal capacity addition program in the country. The new projects during VIII-plan include North Karanpura (1000 MW), Chandrapur (2 *500 MW), Manuguru (2*5oo MW), Dadri gas (817 MW), Faridabad (800 MW), Kayamkulam (420 MW), Yamunagar (840 MW) and Mangalore (320 MW). A long range plan till the end of the century, capacity addition of 28000 MW is proposed at the cost of Rs.30000 crores. NTPC has also pioneered the introduction of new technologies in generation and transmission fields in the country like merry-go-

round rail transportation system, data acquisition system, & micro processor based distributed control system, satellite communication and computerization. The NTPC energized the following 400 kV transmission lines during 1984-85. 1. Bihar-Koradi -273 km 2. Muradnagar-Panipat-86 km 3. Hyderabad-Nagarjun Sagar- 150 km The transmission system associated with Rihand super thermal power station (3000 MW) includes construction of 910 km of high voltage direct current (HVDC) line. The HVDC technology in transmission is being introduced in the country for the first time by NTPC. To combat the acute power shortage in the south, the NTPC has planned to shift focus to the southern states, where the mismatch between demand and supply is quite alarming. The bulwork of NTPC in the south would be 2100 MW Ramagundam super thermal power station (226 km) from Hyderabad which is to be upgraded to 2600 MW making it the countrys largest single thermal power station. The other southern projects of the NTPC are only in the conceptual stage now. The states where the projects are planned are Andhra Pradesh, Tamil Nadu and Karnataka. Kayamkulam power project of 1300 MW in Kerela, gas based station using naphtha in the beginning and switch over to natural gas later, 500 MW station in Karnataka, the expansion of Tuticorin thermal power station and power station at Cuddalore in Tamil Nadu are in the future plan of NTPC. The NTPC has planned to add over 5000 MW in IX-plan period where these projects will involve an investment of Rs.16000 crores at todays price The NTPC has installed 16085 MW generating capacity during last two decades and navigated from construction to operation stage. The corporation operates presently 11-coal based and five-gas based combined cycle plants including Bharat Aluminium Captive Power Project and Badarpur in Delhi. The power projects of NTPC generated 79093 million units which is 23% of the total generation of the country during 1994-95. The corporation netted profit in the same year was rs.1112 crores. For the next 8 years (1995-2003), NTPC has chalked out an ambitious capacity additional program of 10,000 MW by installing several coal and gas based power plants. This will take the total installed capacity of NTPC to more than 25000 MW (20%, 25% of total national capacity). The future development program includes the second stage Vindhyachal thermal power station in M.P where first stage where 1260 MW already under operation. The work on expansion of the Unchaher stage two of 420 MW plant in U.P has also been under taken with the completion of second stage Unchaher capacity will go up to 840 MW. Rihand expansion in U.P will add a capacity if another 1000 MW. Expansions of the Talcher super thermal project in Orissa will add another 2000 MW. Also, the expansion of the Kawas,

Anta, and Auraiya gas projects located in Gujarat, Rajasthan and U.P are in the pipeline. Work on the Kayamkulam project of 400 MW capacity in Kerela is expected to start soon. The cabinet committee on economic affairs has cleared this project with estimated cost of Rs.1310 crores (aug. 1995). The first gas turbine has been made ready by the middle of 1998. The whole project will be supplied to Kerela in view of heavy power shortage in the state. The 400 MW gas project at Faridabad is yet to be cleared by the public investment bureau (PIB). The A.P government has allocated two projects to NTPC, 1000 MW thermal project at Simhadri near Vizag and a 650 MW naphtha based Hyderabad Metro power project near Hyderabad. Recognizing and anticipating the emerging scenario in the power sector with particular reference to private sector participation, NTPC is seeking alliance with companies having complimentary strength. After successful joint venture with a private company for setting up 208 MW unit in A.P, a MoU has also been concluded with Bombay suburban electricity services to take up construction, erection and project management activities in power sector as joint ventures. For an environment friendly growth, NTPC has developed a comprehensive action plan. Keeping in view, the environmental regulation and need to utilize the ash effectively, an ash utilization division has been formed. During the year 1994-95, about 1.8 MT of ash has been utilized for various productive purposes. Agreements have already been signed with a couple of parties for making bricks and other various products from fly ash. NTPC is also executing transmission lines and substation packages in Nepal and Dubai. Recently an order has been secured from the Tanzanian govt. for the preparation of feasibility and project reports for a power station. The story of NTPC is the story of three powerful and successful decades of excellence in power generation. In a short span of two decades, NTPC has installed 16085 MW, contributing 23% of the total power generating capacity of the country, lighting one-fifth of the nation. Another outstanding feature is. Plant load factor during 1994-95 was 0.766. it employs 22500 people with a net profit of Rs.1125 crores in 1994-95.

NTPCs role in development of gas based power station:


The NTPC has already executed or in the stage of executing 4 gas based combined cycle projects. Out of four, Anta, Auriya have achieved their phased operational capacity. The other two at Kawas and Dadri are at different stages of completion. Seventh plan period witnessed the introduction of gas based power generation. First gas based unit was commissioned in 1989. NTPC has established itself as a pioneer in setting up and operating combined cycle gas based plants. This is going to be beneficial to the nation as substantial power generation is anticipated through gas based plants. With the recent indication of increasing availability

of natural gas in the country, gas based power plants offer growth opportunities. NTPC has taken up to install gas based plants at Gandhar (650 MW), Faridabad (800 MW), Dadri (1200 MW), Anta (430 MW), Godavari (800 MW) and Tripura (500 MW). The commissioning of NTPCs gas based units not only marked heralding of the era of gas based combined cycle plant but also created history in terms of shortening the generation period. The recent discoveries of gas reserves in the country have come at a very opportune time and would help to bridge the gap between energy supply and demand over the shorter time horizon. It is unfortunate that the country has gas reserves of 1200 billion cubic meters. But the govt. is yet to firm up its policy on use of natural gas for power generation on long term basis. But in view of the advantages of gas based generation, it is anticipated that power generation based on gas would continue to increase in the next decade and beyond.

Mission
1) Make available reliable and quality power in increasingly large quantities at appropriate tariffs, and ensure timely realization of revenues. 2) Speedily plan and implement power projects, with contemporary technologies. 3) Implement strategic diversifications in the areas of R&M, Hydro, LNG and non-conventional and eco-friendly fuels and explore new areas like transmission, information technology etc. 4) Promote consultancy and make prudent acquisitions.

5) Continuously develop competent human resources to match world standards Be a responsible corporate citizen with thrust on environment protection, rehabilitation and ash utilization

Objectives
In pursuance of the vision & mission, the following would be the Corporate Objectives of NTPC: 1) To add generating capacity within prescribed time and cost; 2) To expand consultancy operations and to participate in ventures abroad; 3) To diversify in Hydro and Non-Conventional Energy Sources Power Generation; 4) To diversify into power related businesses to ensure integrated development of energy sector in India.

Performance Leadership To achieve continuous performance improvement in the areas of project implementation, plant operation and maintenance, generation efficiency etc. and to acquire and sustain internationally comparable standards in these areas with good business ethics and values Human Resources Development

1) To develop a learning Organization having knowledge-based competitive edge. 2) To create a culture of team building, empowerment and accountability to convert knowledge into productive action with speed, creativity and flexibility.

Financial Soundness 1) To maintain and improve the financial soundness of NTPC by managing the financial resources in accordance with the best commercial utility practices. 2) To develop appropriate commercial polices which ensure remunerative tariffs and minimum receivables. Technology Leadership To acquire, assimilate and adopt reliable, efficient and cost-effective technologies and to disseminate knowledge to other constituents of the power sector in the country.

CORE VALUES (Commitments)


Customer focus Organizational pride Mutual respect and trust Initiative and speed Total quality

NTPC Limited

Type Founded

Public 1975

Headquarters Delhi, India Mr. T. Sankaralingam, Key people Chairman & Managing Director Industry Power Generation Products Electricity INR 261 billion (2006) or Revenue USD 5.91 billion INR 5.8 billion (2006) or Net income USD 131 million Employees 23867 (2006)

POWER STATIONS in INDIA:

BTPS

1. Stands for Badarpur Thermal Power Station. 2. Total installed capacity 705 MW in 5 units - 3 units: 95 MW each - 2 units: 205 MW each 3. Main Operating Divisions consists of -Electrical Maintenance Division -Operations -Control & Instrumentation

Unit Unit-I Unit-II

Capacity 95 MW 95 MW

Year 1973-74 1974-75

Unit-III Unit-IV Unit-V

95 MW 210 MW 210 MW

1974-75 1978-79 1981-82

The Management of the Centrally owned Badarpur Thermal Power Station was handed over to NTPC on April 15, 1978.

Introduction
The operating performance of NTPC has been considerably above the national average. The availability factor for coal stations has increased from 85.03 % in 1997-98 to 90.09 % in 2006- 07, which compares favourably with international standards. The PLF has increased from 75.2% in 1997-98 to 89.4% during the year 2006-07 which is the highest since the inception of NTPC.

Operation Room of Power Plant

In a Badarpur Thermal Power Station, steam is produced and used to spin a turbine that operates a generator. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed in a condenser; this is known as a Rankine cycle. Shown here is a diagram of a conventional thermal power plant, which uses coal, oil, or natural gas as fuel to boil water to produce the steam. The electricity generated at the plant is sent to consumers through high-voltage power lines. The Badarpur Thermal Power Plant has Steam Turbine-Driven Generators which has a collective capacity of 705MW. The fuel being used is Coal which is supplied from the Jharia Coal Field in Jharkhand. Water supply is given from the Agra Canal.

There are basically three main units of a thermal power plant 1. Steam Generator or Boiler 2. Steam Turbine 3. Electric Generator We have discussed about the processes of electrical generation further. A complete detailed description of the three units is given further. Typical Diagram of a Coal based Thermal Power Plant

Coal is conveyed (14) from an external stack and ground to a very fine powder by large metal spheres in the pulverised fuel mill (16). There it is mixed with preheated air (24) driven by the forced draught fan (20). The hot air-fuel mixture is forced at high pressure into the boiler where it rapidly ignites. Water of a high purity flows vertically up the tube-lined walls of the boiler, where it turns into steam, and is passed to the boiler drum, where steam is separated from any remaining water. The steam passes through a manifold in the roof of the drum into the pendant superheater (19) where its temperature and pressure increase rapidly to around 200 bar and 540C, sufficient to make the tube walls glow a dull red. The steam is piped to the high pressure turbine (11), the first of a three-stage turbine process. A steam governor valve (10) allows for both manual control of the turbine and automatic set-point following. The steam is exhausted from the high pressure turbine, and reduced in both pressure and temperature, is returned to the boiler reheater (21). The reheated steam is then passed to the intermediate pressure turbine (9), and from there passed directly to the low pressure turbine set (6). The exiting steam, now a little above its boiling point, is brought into thermal contact with cold water (pumped in from the cooling tower) in the condensor (8), where it condenses rapidly back into water, creating near vacuum-like conditions inside the condensor chest. The condensed water is then passed by a feed pump (7) through a deaerator (12), and pre-warmed, first in a feed heater (13) powered by steam drawn from the high pressure set, and then in the economiser (23), before being returned to the boiler drum. The cooling water from the condensor is sprayed inside a cooling tower (1), creating a highly visible plume of water vapor, before being pumped back to the condensor (8) in cooling water cycle. The three turbine sets are sometimes coupled on the same shaft as the three-phase electrical generator (5) which generates an intermediate level voltage (typically 20-25 kV). This is stepped up by the unit transformer (4) to a voltage more suitable for transmission (typically 250-500 kV) and is sent out onto the three-phase transmission system (3).Exhaust gas from the boiler is drawn by the induced draft fan (26) through an electrostatic precipitator (25) and is then vented through the chimney stack (27)

Steam Generator or Boiler


The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60 mm) in diameter. 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 center. 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 throughput and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700 F (370 C) and 3,200 psi (22.1 MPa). It is separated from the water inside a drum at the top of the furnace. The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to 1,000 F (540 C) to prepare it for the turbine. The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. The generator includes the economizer, the steam drum, the chemical dosing equipment, and the furnace with its steam generating tubes and the superheater coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include: forced draft (FD) fan, air preheater (APH), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or baghouse) and the flue gas stack.
Schematic diagram of a coal-fired power plant steam generator

For units over about 210 MW capacity, redundancy of key components is provided by installing duplicates of the FD fan, APH, fly ash collectors and ID fan with isolating dampers. On some units of about 60 MW, two boilers per unit may instead be provided.

Boiler Furnace and Steam Drum


Once water inside the boiler or steam generator, the process of adding the latent heat of vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical reaction of burning some type of fuel.

The water enters the boiler through a section in the convection pass called the economizer. From the economizer it passes to the steam drum. Once the water enters the steam drum it goes down the down comers to the lower inlet water wall headers. From the inlet headers the water rises through the water walls and is eventually turned into steam due to the heat being generated by the burners located on the front and rear water walls (typically). As the water is turned into steam/vapor in the water walls, the steam/vapor once again enters the steam drum.

External View of an Industrial Boiler at Badarpur Thermal Power Station, New Delhi The steam/vapor is passed through a series of steam and water separators and then dryers inside the steam drum. The steam separators and dryers remove the water droplets from the steam and the cycle through the water walls is repeated. This process is known as natural circulation. The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot blowers, water lancing and observation ports (in the furnace walls) for observation of the furnace interior. Furnace explosions due to any accumulation of combustible gases after a trip- out are avoided by flushing out such gases from the combustion zone before igniting the coal. The steam drum (as well as the superheater coils and headers) have air vents and drains needed for initial startup. The steam drum has an internal device that removes moisture from the wet steam entering the drum from the steam generating tubes. The dry steam then flows into the superheater coils.

Geothermal plants need no boiler since they use naturally occurring steam sources. Heat exchangers may be used where the geothermal steam is very corrosive or contains excessive suspended solids. Nuclear plants also boil water to raise steam, either directly passing the working steam through the reactor or else using an intermediate heat exchanger.

Fuel Preparation System


In coal-fired power stations, the raw feed coal from the coal storage area is first crushed into small pieces and then conveyed to the coal feed hoppers at the boilers. The coal is next pulverized into a very fine powder. The pulverizers may be ball mills, rotating drum grinders, or other types of grinders. Some power stations burn fuel oil rather than coal. The oil must kept warm (above its pour point) in the fuel oil storage tanks to prevent the oil from congealing and becoming unpumpable. The oil is usually heated to about 100C before being pumped through the furnace fuel oil spray nozzles.

Boiler Side of the Badarpur Thermal Power Station, New Delhi Boilers in some power stations use processed natural gas as their main fuel. Other power stations may use processed natural gas as auxiliary fuel in the event that their main fuel supply (coal or oil) is interrupted. In such cases, separate gas burners are provided on the boiler furnaces.

Fuel Firing System and Igniter System


From the pulverized coal bin, coal is blown by hot air through the furnace coal burners at an angle which imparts a swirling motion to the powdered coal to enhance mixing of the coal powder with the incoming preheated combustion air and thus to enhance the combustion.

To provide sufficient combustion temperature in the furnace before igniting the powdered coal, the furnace temperature is raised by first burning some light fuel oil or processed natural gas (by using auxiliary burners and igniters provide for that purpose).

Air Path
External fans are provided to give sufficient air for combustion. The forced draft fan takes air from the atmosphere and, first warming it in the air preheater for better combustion, injects it via the air nozzles on the furnace wall. The induced draft fan assists the FD fan by drawing out combustible gases from the furnace, maintaining a slightly negative pressure in the furnace to avoid backfiring through any opening. At the furnace outlet, and before the furnace gases are handled by the ID fan, fine dust carried by the outlet gases is removed to avoid atmospheric pollution. This is an environmental limitation prescribed by law, and additionally minimizes erosion of the ID fan.

Auxiliary Systems
Fly Ash Collection 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. Bottom Ash Collection and Disposal At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from the bottom of the furnace. 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.

Boiler Make-up Water Treatment Plant and Storage Since there is continuous withdrawal of steam and continuous return of condensate to the boiler, losses due to blow-down and leakages have to be made up for so as to maintain the desired water level in the boiler steam drum. For this, continuous make-up water

is added to the boiler water system. The impurities in the raw water input to the plant generally consist of calcium and magnesium salts which impart hardness to the water. Hardness in the make-up water to the boiler will form deposits on the tube water surfaces which will lead to overheating and failure of the tubes. Thus, the salts have to be removed from the water and that is done by a water demineralising treatment plant (DM).

Ash Handling System at Badarpur Thermal Power Station, New Delhi A DM plant generally consists of cation, anion and mixed bed exchangers. The final water from this process consists essentially of hydrogen ions and hydroxide ions which is the chemical composition of pure water. The DM water, being very pure, becomes highly corrosive once it absorbs oxygen from the atmosphere because of its very high affinity for oxygen absorption.

The capacity of the DM plant is dictated by the type and quantity of salts in the raw water input. However, some storage is essential as the DM plant may be down for maintenance. For this purpose, a storage tank is installed from which DM water is continuously withdrawn for boiler make-up. The storage tank for DM water is made from materials not affected by corrosive water, such as PVC. The piping and valves are generally of stainless steel. Sometimes, a steam blanketing arrangement or stainless steel doughnut float is provided on top of the water in the tank to avoid contact with atmospheric air. DM water make-up is generally added at the steam space of the surface condenser (i.e., the vacuum side). This arrangement not only sprays the water but also DM water gets deaerated, with the dissolved gases being removed by the ejector of the condenser itself.

Steam Turbine
Steam turbines are used in all of our major coal fired power stations to drive the generators or alternators, which produce electricity. The turbines themselves are driven by steam generated in 'Boilers' or 'Steam Generators' as they are sometimes called. Energy in the steam after it leaves the boiler is converted into rotational energy as it passes through the turbine. The turbine normally consists of several stages with each stage consisting of a stationary blade (or nozzle) and a rotating blade. Stationary blades convert the potential energy of the steam (temperature and pressure) into kinetic energy (velocity) and direct the flow onto the rotating blades. The rotating blades convert the kinetic energy into forces, caused by pressure drop, which results in the rotation of the turbine shaft. The turbine shaft is connected to a generator, which produces the electrical energy. The rotational speed is 3000 rpm for Indian System (50 Hz) systems and 3600 for American (60 Hz) systems.

In a typical larger power stations, the steam turbines are split into three separate stages, the first being the High Pressure (HP), the second the Intermediate Pressure (IP) and the third the Low Pressure (LP) stage, where high, intermediate and low describe the pressure of the steam. After the steam has passed through the HP stage, it is returned to the boiler to be re-heated to its original temperature although the pressure remains greatly reduced. The reheated steam then passes through the IP stage and finally to the LP stage of the turbine.

A distinction is made between "impulse" and "reaction" turbine designs based on the relative pressure drop across the stage. There are two measures for pressure drop, the pressure ratio and the percent reaction. Pressure ratio is the pressure at the stage exit divided by the pressure at the stage entrance. Reaction is the percentage isentropic enthalpy drop across the rotating blade or bucket compared to the total stage enthalpy drop. Some manufacturers utilise percent pressure drop across stage to define reaction. Steam turbines can be configured in many different ways. Several IP or LP stages can be incorporated into the one steam turbine. A single shaft or several shafts coupled together may be used. Either way, the principles are the same for all steam turbines. The configuration is decided by the use to which the steam turbine is put, co-generation or pure electricity production. For co- generation, the steam pressure is highest when used as process steam and at a lower pressure when used for the secondary function of electricity production.

Nozzles and Blades


Steam enthalpy is converted into rotational energy as it passes through a turbine stage. A turbine stage consists of a stationary blade (or nozzle) and a rotating blade (or bucket). Stationary blades convert the potential energy of the steam (temperature and pressure) into

kinetic energy (velocity) and direct the flow onto the rotating blades. The rotating blades convert the kinetic energy into impulse and reaction forces caused by pressure drop, which results in the rotation of the turbine shaft or rotor. Steam turbines are machines which must be designed, manufactured and maintained to high tolerances so that the design power output and availability is obtained. They are subject to a number of damage mechanisms, with two of the most important being: Erosion due to Moisture: - The presence of water droplets in the last stages of a turbine causes erosion to the blades. This has led to the imposition of an allowable limit of about 12% wetness in the exhaust steam; Solid Particle Erosion: - The entrainment of erosive materials from the boiler in the steam causes wear to the turbine blades.

Cogeneration Cycles
In cogeneration cycles, steam is typically generated at a higher temperature and pressure than required for a particular industrial process. The steam is expanded through a turbine to produce electricity and the resulting extractions at the discharge are at the temperature and pressure required by the process. Turbines can be condensing or non-condensing design typically with large mass flows and comparably low output. Traditionally, pressures were 6.21 MPa and below with temperatures 441 C or lower, although the trend towards higher levels of each continues. There are now a considerable number of co-generation steam turbines with initial steam pressures in the 8.63 to 10 MPa range and steam temperatures of 482 to 510 C.

Bearings and Lubrication


Two types of bearings are used to support and locate the rotors of steam turbines: Journal bearings are used to support the weight of the turbine rotors. A journal bearing consists of two half-cylinders that enclose the shaft and are internally lined with Babbitt, a metal alloy usually consisting of tin, copper and antimony; and Thrust bearings axially locate the turbine rotors. A thrust bearing is made up of a series of Babbitt lined pads that run against a locating disk attached to the turbine rotor. High-pressure oil is injected into the bearings to provide lubrication. The oil is carefully filtered to remove solid particles. Specially designed centrifuges remove any water from the oil.

Shaft Seals

The shaft seal on a turbine rotor consist of a series of ridges and groves around the rotor and its housing which present a long, tortuous path for any steam leaking through the seal. The seal therefore does not prevent the steam from leaking, merely reduces the leakage to a minimum. The leaking steam is collected and returned to a low-pressure part of the steam circuit.

Turning Gear
Large steam turbines are equipped with "turning gear" to slowly rotate the turbines after they have been shut down and while they are cooling. This evens out the temperature distribution around the turbines and prevents bowing of the rotors.

Vibration
The balancing of the large rotating steam turbines is a critical component in ensuring the reliable operation of the plant. Most large steam turbines have sensors installed to measure the movement of the shafts in their bearings. This condition monitoring can identify many potential problems and allows the repair of the turbine to be planned before the problems become serious

Condenser
The surface condenser is a shell and tube heat exchanger in which cooling water is circulated through the tubes. The exhaust steam from the low pressure turbine enters the shell where it is cooled and converted to condensate (water) by flowing over the tubes as shown in the adjacent diagram. Such condensers use steam ejectors or rotary motor-driven exhausters for continuous removal of air and gases from the steam side to maintain vacuum.

A Typical Water Cooled Condenser

For best efficiency, the temperature in the condenser must be kept as low as practical in order to achieve the lowest possible pressure in the condensing steam. Since the condenser temperature can almost always be kept significantly below 100oC where the vapor pressure of water is much less than atmospheric pressure, the condenser generally works under vacuum. Thus leaks of noncondensible air into the closed loop must be prevented. Plants operating in hot climates may have to reduce output if their source of condenser cooling water becomes warmer; unfortunately this usually coincides with periods of high electrical demand for air conditioning. The condenser generally uses either circulating cooling water from a cooling tower to reject waste heat to the atmosphere, or oncethrough water from a river, lake or ocean.

Feedwater Heater
A Rankine cycle with a two-stage steam turbine and a single feedwater heater. In the case of a conventional steam-electric power plant utilizing a drum boiler, the surface condenser removes the latent heat of vaporization from the steam as it changes states from vapour to liquid. The heat content (btu) in the steam is referred to as Enthalpy. The condensate pump then pumps the condensate water through a feedwater heater. The feedwater heating equipment then raises the temperature of the water by utilizing extraction steam from various stages of the turbine.

A Rankine cycle with a two-stage steam turbine and a single feedwater heater

Preheating the feedwater reduces the irreversibilities involved in steam generation and therefore improves the thermodynamic efficiency of the system.[9] This reduces plant operating costs and also helps to avoid thermal shock to the boiler metal when the feedwater is introduced back into the steam cycle.

Deaerator
A steam generating boiler requires that the boiler feed water should be devoid of air and other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the metal. Generally, power stations use a deaerator to provide for the removal of air and other dissolved gases from the boiler feedwater. A deaerator typically includes a vertical, domed deaeration section mounted on top of a horizontal cylindrical vessel which serves as the deaerated boiler feedwater storage tank.

Boiler Feed Water Deaerator (with vertical, domed aeration section and horizontal water storage section) There are many different designs for a deaerator and the designs will vary from one manufacturer to another. The adjacent diagram depicts a typical conventional trayed deaerator. If operated properly, most deaerator manufacturers will guarantee that oxygen in the deaerated water will not exceed 7 ppb by weight (0.005 cm/L).

Auxiliary Systems
Oil System An auxiliary oil system pump is used to supply oil at the start-up of the steam turbine generator. It supplies the hydraulic oil system required for steam turbine's main inlet steam stop valve, the governing control valves, the bearing and seal oil systems, the relevant hydraulic relays and other mechanisms. At a preset speed of the turbine during start-ups, a pump driven by the turbine main shaft takes over the functions of the auxiliary system. Generator Heat Dissipation The electricity generator requires cooling to dissipate the heat that it generates. While small units may be cooled by air drawn through filters at the inlet, larger units generally require special cooling arrangements. Hydrogen gas cooling, in an oil-sealed casing, is used because it has the highest known heat transfer coefficient of any gas and for its low viscosity which reduces windage losses. This system requires special handling during start-up, with air in the chamber first displaced by carbon dioxide before filling with hydrogen. This ensures that the highly flammable hydrogen does not mix with oxygen in the air. The hydrogen pressure inside the casing is maintained slightly higher than atmospheric pressure to avoid outside air ingress. The hydrogen must be sealed against outward leakage where the shaft emerges from the casing. Mechanical seals around the shaft are installed with a very small annular gap to avoid rubbing between the shaft and the seals. Seal oil is used to prevent the hydrogen gas leakage to atmosphere. The generator also uses water cooling. Since the generator coils are at a potential of about 15.75 kV and water is conductive, an insulating barrier such as Teflon is used to interconnect the water line and the generator high voltage windings. Demineralized water of low conductivity is used. Generator High Voltage System

The generator voltage ranges from 10.5 kV in smaller units to 15.75 kV in larger units. The generator high voltage leads are normally large aluminum channels because of their high current as compared to the cables used in smaller machines. They are enclosed in wellgrounded aluminum bus ducts and are supported on suitable insulators. The generator high voltage channels are connected to step-up transformers for connecting to a high voltage electrical substation (of the order of 220 kV) for further transmission by the local power grid. The necessary protection and metering devices are included for the high voltage leads. Thus, the steam turbine generator and the transformer form one unit. In smaller units, generating at 10.5 kV, a breaker is provided to connect it to a common 10.5 kV bus system.

Coal Handling Plant


Coal is delivered by highway truck, rail, barge or collier ship. Some plants are even built near coal mines and coal is delivered by conveyors. A large coal train called a "unit train" may be a kilometers (over a mile) long, containing 60 cars with 100 tons of coal in each one, for a total load of 6,000 tons. A large plant under full load requires at least one coal delivery this size every day. Plants may get as many as three to five trains a day, especially in "peak season", during the summer months when power consumption is high. A large thermal power plant such as the Badarpur Thermal Power Station, New Delhi stores several million tons of coal for use when there is no wagon supply.

Modern unloaders use rotary dump devices, which eliminate problems with coal freezing in bottom dump cars. The unloader includes a train positioner arm that pulls the entire train to position each car over a coal hopper. The dumper clamps an individual car against a platform that swivels the car upside down to dump the coal. Swiveling couplers enable the entire operation to occur while the cars are still coupled together. Unloading a unit train takes about three hours. Shorter trains may use railcars with an "air-dump", which relies on air pressure from the engine plus a "hot shoe" on each car. This "hot shoe" when it comes into contact with a "hot rail" at the unloading trestle, shoots an electric charge through the air dump apparatus and causes the doors on the bottom of the car to open, dumping the coal through the opening in the trestle. Unloading one of these trains takes anywhere from an hour to an hour and a half. Older unloaders may still use manually operated bottom-dump rail cars and a "shaker" attached to dump the coal. Generating stations adjacent to a mine may receive coal by conveyor belt or massive dieselelectric-drive trucks.

Layout of Coal Handling Plant at Badarpur Thermal Power Station, New Delhi

Coal is prepared for use by crushing the rough coal to pieces less than 2 inches (50 mm) in size. The coal is then transported from the storage yard to in-plant storage silos by rubberized conveyor belts at rates up to 4,000 tons/hour. In plants that burn pulverized coal, silos feed coal pulverizers (coal mill) that take the larger 2 inch pieces grind them into the consistency of face powder, classify them, and mixes them with primary combustion air which transports the coal to the furnace and

preheats the coal to drive off excess moisture content. In plants that do not burn pulverized coal, the larger 2 inch pieces may be directly fed into the silos which then feed the cyclone burners, a specific kind of combustor that can efficiently burn larger pieces of fuel.

Run-Of-Mine (ROM) Coal


The coal delivered from the mine that reports to the Coal Handling Plant is called Run-of-mine, or ROM, coal. This is the raw material for the CHP, and consists of coal, rocks, middlings, minerals and contamination. Contamination is usually introduced by the mining process and may include machine parts, used consumables and parts of ground engaging tools. ROM coal can have a large variability of moisture and maximum particle size.

Coal Handling
Coal needs to be stored at various stages of the preparation process, and conveyed around the CHP facilities. Coal handling is part of the larger field of bulk material handling, and is a complex and vital part of the CHP.

Stockpiles
Stockpiles provide surge capacity to various parts of the CHP. ROM coal is delivered with large variations in production rate of tonnes per hour (tph). A ROM stockpile is used to allow the washplant to be fed coal at lower, constant rate.

Coal Handling Division of Badarpur Thermal Power Station, New Delhi

A simple stockpile is formed by machinery dumping coal into a pile, either from dump trucks, pushed into heaps with bulldozers or from conveyor booms. More controlled stockpiles are formed using stackers to form piles along the length of a conveyor, and reclaimers to retrieve the coal when required for product loading, etc. Taller and wider stockpiles reduce the land area required to store a set tonnage of coal. Larger coal stockpiles have a reduced rate of heat lost, leading to a higher risk of spontaneous combustion.

Stacking
Travelling, lugging boom stackers that straddle a feed conveyor are commonly used to create coal stockpiles. Stackers are nominally rated in tph (tonnes per hour) for capacity and normally travel on a rail between stockpiles in the stockyard. A stacker can usually move in at least two directions typically: horizontally along the rail and vertically by luffing its boom. Luffing of the boom minimises dust by reducing the height that the coal needs to fall to the top of the stockpile. The boom is luffed upwards as the stockpile height grows.

Wagon Tripler at Badarpur Thermal Power Station, New Delhi

Some stackers are able to rotate by slewing the boom. This allows a single stacker to form two stockpiles, one on either side of the conveyor.

Stackers are used to stack into different patterns, such as cone stacking and chevron stacking. Stacking in a single cone tends to cause size segregation, with coarser material moving out towards the base. Raw cone ply stacking is when additional cones are added next to the first cone. Chevron stacking is when the stacker travels along the length of the stockpile adding layer upon layer of material. Stackers and Reclaimers were originally manually controlled manned machines with no remote control. Modern machines are typically semi-automatic or fully automated, with parameters remotely set.

Reclaiming
Tunnel conveyors can be fed by a continuous slot hopper or bunker beneath the stockpile to reclaim material. Front-end loaders and bulldozers can be used to push the coal into feeders. Sometimes front-end loaders are the only means of reclaiming coal from the stockpile. This has a low up-front capital cost, but much higher operating costs, measured in dollars per tonne handled.

Coal Storage Area of the Badarpur Thermal Power Station, New Delhi

Coal Sampling

Sampling of coal is an important part of the process control in the CHP. A grab sample is a one- off sample of the coal at a point in the process stream, and tends not to be very representative. A routine sample is taken at a set frequency, either over a period of time or per shipment.

Screening
Screens are used to group process particles into ranges by size. These size ranges are also called grades. Dewatering screens are used to remove water from the product. Screens can be static, or mechanically vibrated. Screen decks can be made from different materials such as high tensile steel, stainless steel, or polyethelene.

Screening and Separation Unit of Coal Handling Division of a Thermal Power Plant.

Magnetic Separation
Magnetic separators shall be used in coal conveying systems to separate tramp iron (including steel) from the coal. Basically, two types are available. One type incorporates permanent or electromagnets into the head pulley of a belt conveyor. The tramp iron clings to the belt as it goes around the pulley drum and falls off into a collection hopper or trough after the point at which coal is charged from the belt. The other type consists of permanent or electromagnets incorporated into a belt conveyor that is suspended above a belt conveyor carrying coal. The tramp iron is pulled from the moving coal to the face of the separating conveyor, which in turn holds and carries the tramp iron to a collection hopper or trough. Magnetic separators shall be used just ahead of the coal crusher, if any, and/or just prior to coal discharge to the in-plant bunker or silo fill system.

Coal Crusher
Before the coal is sent to the plant it has to be ensured that the coal is of uniform size, and so it is passed through coal crushers. Also power plants using pulverized coal specify a maximum coal size that can be fed into the pulverizer and so the coal has to be crushed to the specified size using the coal crusher. Rotary crushers are very commonly used for this purpose as they can provide a continuous flow of coal to the pulverizer.

Pulverizer
Most commonly used pulverizer is the Boul Mill. The arrangement consists of 2 stationary rollers and a power driven baul in which pulverization takes place as the coal passes through the sides of the rollers and the baul. A primary air induced draught fan draws a stream of heated air through the mill carrying the pulverized coal into a stationary classifier at the top of the pulverizer. The classifier separates the pulverized coal from the unpulverized coal.

An external view of a Coal Pulverizer

Advantages of Pulverized Coal Pulverized coal is used for large capacity plants. It is easier to adapt to fluctuating load as there are no limitations on the combustion capacity. Coal with higher ash percentage cannot be used without pulverizing because of the problem of large amount ash deposition after combustion.

Increased thermal efficiency is obtained through pulverization. The use of secondary air in the combustion chamber along with the powered coal helps in creating turbulence and therefore uniform mixing of the coal and the air during combustion. Greater surface area of coal per unit mass of coal allows faster combustion as more coal is exposed to heat and combustion The combustion process is almost free from clinker and slag formation. The boiler can be easily started from cold condition in case of emergency. Practically no ash handling problem. The furnace volume required is less as the turbulence caused aids in complete combustion of the coal with minimum travel of the particles.

The pulverized coal is passed from the pulverizer to the boiler by means of the primary air that is used not only to dry the coal but also to heat is as it goes into the boiler. The secondary air is used to provide the necessary air required for complete combustion. The primary air may vary anywhere from 10% to the entire air depending on the design of the boiler. The coal is sent into the boiler through burners. A very important and widely used type of burner arrangement is the Tangential Firing arrangement. Tangential Burners:

The tangential burners are arranged such that they discharge the fuel air mixture tangentially to an imaginary circle in the center of the furnace. The swirling action produces sufficient turbulence in the furnace to complete the combustion in a short period of time and avoid the necessity of producing high turbulence at the burner itself. High heat release rates are possible with this method of firing. The burners are placed at the four corners of the furnace. At the Badarpur Thermal Power Station five sets of such burners are placed one above the other to form six firing zones. These burners are constructed with tips that can be angled through a small vertical arc. By adjusting the angle of the burners the position of the fire ball can be adjusted so as to raise or lower the position of the turbulent combustion region. When the burners are tilted downward the furnace gets filled completely with the flame and the furnace exit gas temperature gets reduced. When the burners are tiled upward the furnace exit gas temperature increases. A difference of 100 degrees can be achieved by tilting the burners.

Ash Handling
The ever increasing capacities of boiler units together with their ability to use low grade high ash content coal have been responsible for the development of modern day ash handling systems. The widely used ash handling systems are 1. Mechanical Handling System 2. Hydraulic System 3. Pneumatic System 4. Steam Jet System The Hydraulic Ash handling system is used at the Badarpur Thermal Power Station.

Hydraulic Ash Handling System


The hydraulic system carried the ash with the flow of water with high velocity through a channel and finally dumps into a sump. The hydraulic system is divided into a low velocity and high velocity system. In the low velocity system the ash from the boilers falls into a stream of water flowing into the sump. The ash is carried along with the water and they are separated at the sump. In the high velocity system a jet of water is sprayed to quench the hot ash. Two other jets force the ash into a trough in which they are washed away by the water into the sump, where they are separated. The molten slag formed in the pulverized fuel system can also be quenched and washed by using the high velocity system. The advantages of this system are that its clean, large ash handling capacity, considerable distance can be traversed, absence of working parts in contact with ash.

Transformers

Transformer is a static (or stationary) piece of apparatus by means of which electric power in one circuit is transformed to electric power of the same frequency in another circuit. It can raise or lower the voltage in a circuit but with a corresponding decrease or increase in current. This topic deals with the basic theory, constructional features and types of major transformers found in a power station.

Principle
In its simplest form, it consists of two inductive coils, which are electrically separated by magnetically linked through a path of low reluctance. The two coils possess high mutual inductance. If one coil is connected to a source of alternating voltage, an alternating flux is set up in the laminated core and it produces mutually induced e.m.f. If the second coil circuit is closed, a current flows in it and so electrical energy is transferred from the first coil to the second coil. The first coil, in which electric energy is fed from the a.c supply mains, is called primary winding, while the second coil is known as secondary winding. The necessity of the transformer arises when voltages are required to be changed. For example, the generated voltage of the alternators will be around 15 KV. It is not economical to have transmission and distribution systems at this voltage as, for the same power transmitted, the current will be more when compare to high voltage transmission i.e., as the transmission voltage increases, for the same power transmitted, the current through the conductor is reduced and thereby copper losses are reduced. As the current through the conductor is reduced the conductor diameter can be reduced resulting in saving on the cost of conductor material and on the weight of the support structures. Thus for stepping up of voltage from the generating voltage to transmission voltage we need a step up transformer. There are situations where the voltages will require stepping down also.

E.M.F. Equation of a Transformer

Let, N1 = No. of turns on primary N2 = No. of turns on secondary M = maximum flux in core F = frequency The EMF induce in primary--E1 and EMF induced in secondary--E2 In an ideal transformer ''V1= E1" & "V2= E2 Therefore, (E2/E1)=(V2/V1)=(N2/N1)= k 'k' is called the transformation ratio. Again for an ideal transformer input VA = output VA. Therefore (V1*I1) / (V2 *I2)=(1/K) Hence currents are in the inverse ratio of the transformation ratio. The efficiency of the transformer is very high as there are no moving parts and so there are no mechanical losses. The only losses in a transformer are (a) Iron losses due to eddy current and hysterisis in the magnetic core and (b) copper losses in the primary and secondary windings.

Transformers- Construction
The simple elements of a transformer consist of two coils and a laminated steel core. The two coils are insulated from each other and the from the steel core. Other parts are a) Suitable container for the assembled core and windings b) suitable medium for insulating the core and its windings from its container and (c) suitable bushings for insulating and bringing out the terminals of the windings from the tank.

In all types of transformers, the core is constructed of sheet steel lamination to provide continuous magnetic path with a minimum of air gap. The steel used should have high permeability and a low hysterisis loss at the usual operating flux densities. The eddy currents loss is minimized by laminating the core with the laminations being insulating from each other by a high coat of core plate varnish or by an oxide layer on the surface. The thickness of laminations vary from 0.30 mm to 0.5mm The transformers are of two general types; distinguished from each other by the manner in which the primary and secondary coils are placed around the laminated steel core. They are: a) shell type b) core type. Steel surrounding the coils is shell form type of construction coils surrounding the steel is core form type of construction.

Generator

Generator Fundamentals
The transformation of mechanical energy into electrical energy is carried out by the Generator. This Chapter seeks to provide basic understanding about the working principles and development of Generator.

Working Principle
The A.C. Generator or alternator is based upon the principle of electromagnetic induction and consists generally of a stationary part called stator and a rotating part called rotor. The stator housed the armature windings. The rotor houses the field windings. D.C. voltage is applied to the field windings through slip rings. When the rotor is rotated, the lines of magnetic flux (viz magnetic field) cut through the stator windings. This induces an electromagnetic force (e.m.f.) in the stator windings. The magnitude of this e.m.f. is given by the following expression. E = 4.44 /O FN volts 0 = Strength of magnetic field in Webers. F = Frequency in cycles per second or Hertz. N = Number of turns in a coil of stator winding F = Frequency = Pn/120 Where P = Number of poles n = revolutions per second of rotor. From the expression it is clear that for the same frequency, number of poles increases with decrease in speed and vice versa. Therefore, low speed hydro turbine drives generators have 14 to 20 poles where as high speed steam turbine driven generators have generally 2 poles. Pole rotors are used in low speed generators, because the cost advantage as well as easier construction.

Generator Components

This topic deals with the two main components of the Generator viz. Rotor, its winding & balancing and stator, its frame, core & windings.

Rotor
The electrical rotor is the most difficult part of the generator to design. It revolves in most modern generators at a speed of 3,000 revolutions per minute. The problem of guaranteeing the dynamic strength and operating stability of such a rotor is complicated by the fact that a massive non-uniform shaft subjected to a multiplicity of differential stresses must operate in oil lubricated sleeve bearings supported by a structure mounted on foundations all of which possess complex dynamic be behavior peculiar to themselves. It is also an electromagnet and to give it the necessary magnetic strength the windings must carry a fairly high current. The passage of the current through the windings generate heat but the temperature must not be allowed to become so high, otherwise difficulties will be experienced with insulation. To keep the temperature down, the cross section of the conductor could not be increased but this would introduce another problems. In order to make room for the large conductors, body and this would cause mechanical weakness.

Rotor winding
Silver bearing copper is used for the winding with mica as the insulation between conductors. A mechanically strong insulators such as micanite is used for lining the slots. Later designs of windings for large rotor incorporate combination of hollow conductors with slots or holes arranged to provide for circulation of the cooling gas through the actual conductors. When rotating at high speed. Centrifugal force tries to lift the windings out of the slots and they are contained by wedges. The end rings are secured to a turned recess in the rotor body, by shrinking or screwing and supported at the other end by fittings carried by the rotor body. The two ends of windings are connected to slip rings, usually made of forged steel, and mounted on insulated sleeves.

Stator

The stator is the heaviest load to be transported. The major part of this load is the stator core. This comprises an inner frame and outer frame. The outer frame is a rigid fabricated structure of welded steel plates, within this shell is a fixed cage of girder built circular and axial ribs. The ribs divide the yoke in the compartments through which hydrogen flows into radial ducts in the stator core and circulate through the gas coolers housed in the frame. The inner cage is usually fixed in to the yoke by an arrangement of springs to dampen the double frequency vibrations inherent in 2 pole generators. The end shields of hydrogen cooled generators must be strong enough to carry shaft seals. In large generators the frame is constructed as two separate parts. The fabricated inner cage is inserted in the outer frame after the stator core has been constructed and the winding completed.

Stator Windings
Each stator conductor must be capable of carrying the rated current without overheating. The insulation must be sufficient to prevent leakage currents flowing between the phases to earth. Windings for the stator are made up from copper strips wound with insulated tape which is impregnated with varnish, dried under vacuum and hot pressed to form a solid insulation bar. These bars are then place in the stator slots and held in with wedges to form the complete winding which is connected together at each end of the core forming the end turns. These end turns are rigidly braced and packed with blocks of insulation material to withstand the heavy forces which might result from a short circuit or other fault conditions. The generator terminals are usually arranged below the stator. On recent generators (210 MW) the windings are made up from copper tubes instead of strips through which water is circulated for cooling purposes. The water is fed to the windings through plastic tubes.

Excitation System
The electric power generators require direct current excitation magnets for its field system. The excitation field system must be reliable, stable in operation and must respond quickly to excitation current requirements. This topic deals in details about such a system.

It is sometimes considered that exciter response in terms of the generator no-load excitation voltage may introduce errors when dealing with response under load conditions. Exact values can be obtained only by testing and results of tests done indicate that exciter response under loaded generator conditions is not markedly different from the value under no-load conditions.

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