CHAPTER 1

INTRODUCTION
1.1 About NTPC
NTPC Limited (also known as National Thermal Power Corporation Limited) is
an Indian Central Public Sector Undertaking (CPSU) under the Ministry of Power, Government
of India, engaged in the business of generation of electricity and allied activities. It is a
company incorporated under the Companies Act 1956 and a "Government Company" within
the meaning of the act. The headquarters of the company is situated at New Delhi. NTPC's
core business is generation and sale of electricity to state-owned power distribution
companies and State Electricity Boards in India. The company also undertakes consultancy
and turnkey project contracts that involve engineering, project management, construction
management and operation and management of power plants. The company has also
ventured into oil and gas exploration and coal mining activities. It is the largest power
company in India with an electric power generating capacity of 43,803 MW . Although the
company has approx. 18% of the total national capacity it contributes to over 27% of total
power generation due to its focus on operating its power plants at higher efficiency levels
(approx. 83% against the national PLF rate of 78%).
It was founded by Government of India in 1975, which now holds 70% of its equity shares on
13 May 2015.
In May 2010, NTPC was conferred Maharatna status by the Union Government of India. It is
ranked 424th in in the Forbes Global 2000 for 2014
The company has set a target to have an installed power generating capacity of 1,28,000 MW
by the year 2032. The capacity will have a diversified fuel mix comprising 56% coal, 16% Gas,
11% Nuclear and 17% Renewable Energy Sources(RES) including hydro. By 2032, non-fossil
fuel based generation capacity shall make up nearly 28% of NTPCs portfolio.

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Fig 1.1 - PLF vs Year graph

1.2 Strategies of NTPC

Fig 1.2 Strategies of NTPC

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1.3 Vision
To be the worlds largest and best power producer, powering Indias growth

1.4 Mission
Develop and provide reliable power, related products and services at competitive prices,
integrating multiple energy sources with innovative and eco-friendly technologies and
contribute to society

1.5 Core Values

B
E
C
O
M
M
I
T
T
E
D

Business Ethics
Environmentally & Economically Sustainable
Customer Focus
Organizational & Professional Pride
Mutual Respect & Trust
Motivating Self & others
Innovation & Speed
Total Quality for Excellence
Transparent & Respected Organization
Enterprising
Devoted

1.7 Installed Capacity

TABLE 1.1 Installed Capacity of NTPC
Projects
No. of Projects

NTPC OWNED
COAL
GAS/LIQ. FUEL
TOTAL
OWNED BY JVCs
Coal
Gas/LIQ. FUEL
GRAND TOTAL

Commissioned
Capacity
(MW)

14
07
21

22,395
3,955
26,350

3
1
25

314
740
27,404

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TABLE 1.2 Coal Based Plants

Coal based

State

1.

Singrauli

Uttar Pradesh

2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Korba
Ramagundam
Farakka
Vindhyachal
Rihand
Kahalgaon
NTCPP
TalcherKaniha
Unchahar
Talcher Thermal
Simhadri
Tanda

Chhattisgarh
Andhra Pradesh
West Bengal
Madhya Pradesh
Uttar Pradesh
Bihar
Uttar Pradesh
Orissa
Uttar Pradesh
Orissa
Andhra Pradesh
Uttar Pradesh

2,100
2,600
1,600
3,260
2,000
1,340
840
3,000
1,050
460
1,000
440

Delhi

705
22,395

14. Badarpur
Total (Coal)

Commissioned
Capacity
(MW)
2,000

TABLE 1.3 Gas Based Plants

Gas based

State

Commissioned
Capacity
(MW)

Anta

Rajasthan

413

Auraiya

Uttar Pradesh

652

Kawas

Gujarat

645

Dadri

Uttar Pradesh

817

Jhanor-Gandhar

Gujarat

648

Rajiv Gandhi CCPP

Kayamkulam

Kerala

350

Faridabad

Haryana

430

Total (Gas)

3,955

Page | 4

TABLE 1.4 Projects Under Implementation

Coal / Hydro

State

Fuel

Additional Capacity Under

Implementation (MW)

1.

Kahalgaon Stage II (Phase I)

(Phase II)

Bihar

Coal

500
500

2.

Sipat (Stage I) (Stage II)

Chhattisgarh

Coal

1980
1000

3.

Barh

Bihar

Coal

1980

4.

Bhilai (Exp. Power Project-JV

with SAIL)

Chhattisgarh

Coal

500

5.

Korba (Stage III)

Chhattisgarh

Coal

500

6.

Farakka (Stage III)

West Bengal

Coal

500

7.

NCTPP (Stage II)

Uttar Pradesh

Coal

980

8.

Simhadri (Stage II)

Andhra Pradesh

Coal

1000

9.

Koldam (HEPP)

Himachal
Pradesh

Hydro

800

10. Loharinag Pala (HEPP)

Uttarakhand

Hydro

600

11. TapovanVishnugad (HEPP)

Uttarakhand

Hydro

520

Total (Coal + Hydro)

11,360

TABLE 1.5 Power Plants with Joint Ventures

Coal
Based

State

Fuel

Commissioned
Capacity
(MW)

Durgapur West Bengal

Coal

120

Rourkela Orissa

Coal

120

Bhilai

Chhattisgarh

Coal

74

RGPPL

Maharastra

Naptha/LNG 740

Total(JV)

1054

Grand Total (Coal + Gas + JV)

27,404

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1.7 Working Principle

A coal based powerplant basically works on Rankine Cycle. Steam is produced in boiler is
exported in prime mover and is condensed in condenser to be fed into the boiler again. In
practice of good number of modifications are affected so as to have heat economy and to
increase the thermal efficiency of plant.
Many of the impracticalities associated with the Carnot cycle can be eliminated by
superheating the steam in the boiler and condensing it completely in the condenser. The
cycle that results is the Rankine cycle, which is the ideal cycle for vapor power plants. The
ideal Rankine cycle does not involve any internal irreversibility's .
12
23
34
45
56
61

BFP work
Heating of water to convert it finally to superheated steam in boiler
Expansion in HP turbine
Reheating
Expansion in IP and LP turbine
Cooling in Condenser

Fig 1.3 Rankine Cycle (with reheat)

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1.8 About NTPC Dadri

National Capital Power Station (NCPS) Or NTPC Dadri, is the power project to meet the
power demand of National Capital Region (India). It has a huge coal-fired thermal power plant
and a gas-fired plant and has a small township located in Uttar Pradesh, India for its
employees.
NTPC Dadri is a unique power plant of NTPC group which has both coal based thermal plant
and gas based thermal plant of 1820 MW and 817 MW respectively and 5 MW solar plant
totaling 2642 MW

1.8.1 Installed Capacity

Coal based
The coal-based station mainly meets power requirements of the National Capital Region
[NCR] , and the northern grid . With the World Bank funding component , the capital cost of
the units is Rs. 16.69 billion . There are four 210 MW coal based units and two 490MW coal
based units. The units have a coal-fired boiler and a steam turbine each . The boiler design is
also suitable for 100% operations with heavy furnace oil firing . For this , three storage tanks ,
each of capacity 15,000 kL , enough for 10 days continuous oil firing requirements have been
provided for the boilers .
TABLE 1.6 NTPC Dadri Coal Based
Stage

1st

2nd
Total

Unit
Number

Installed
Capacity (MW)

Date of
Commissioning

210

1991 October

210

1992 December

210

1993 March

210

1994 March

490

2010 January

490

2010 July

Six

1820

Page | 7

TABLE 1.7 NTPC Dadri Gas Based

Stage

Unit
Number

1st

Total

Installed
Capacity (MW)

Date of
Commissioning

GT / ST

130.19

1992 March

GT

130.19

1992 May

GT

130.19

1992 June

GT

130.19

1992 November

GT

154.51

1993 February

ST

154.51

1993 March

ST

Six

829.78

Grand Total capacity is 2637 MW.

1.8.2 Location
It is located in Gautam Budh Nagar district of Uttar Pradesh about 25 km from Ghaziabad and
about 9 km fromDadri. It is nearly 48 km from New Delhi towards Hapur. The township has an
area of about 500 acres over all. NTPC Dadri is a branch of National Thermal Power
Corporation, which is a public sector now. It is about 20km from Ghaziabad via Badalpur,
Mahawar, Bamabawar, and Akilpur Jagir.

1.8.3 Coal Source

The coal is transported from the Piparwar block of mines of the North Karanpura Coalfields of
Jharkhand , over a distance of about 1,200 kms. , by the Indian Railways bottom discharge ,
and Box 'N' type of wagons . The coal requirement for the six units is about 25000M.T. each
day. The station has its' own 14 kms. Long rail track from the Dadri Railway Statio , to the site,
and a 6 km in-plant track, on electric traction.

1.8.4 Water Source

Upper Ganga Canal Dehra Headworks, During closure of UGC through network of tube wells.
The consumption of cooling water is 50 cusecs (1415.85 litres/sec).

Page | 8

CHAPTER 2

COAL CYCLE
2.1 Coal Supplied at NTPC Dadri
Coal is supplied to NTPC, Dadri by Piparwar coal mines. The type of coal is Bituminous and
Semi Bituminous with following specifications: Moisture- less than 8%
Volatile matter-17% to 19%
Ash- 35% - 40%
Calorific Value- 4500 to 5300 Kcal/kg
Coal is received in railway box rakes containing 50-60 wagons in each rake.
Capacity of each box wagon is about 55 ton.
The BOX-N type wagons are placed on 2 wagon tippler (one for Stage-I and other for
Stage-II)
The BOBR type wagons are emptied on track hoppers

2.2 Different Components of Coal Cycle

Wagon Tippler
Track Hopper
Paddle Feeder
Conveyer Belts
Crusher House
Stacker cum Reclaimer
Coal Yard
Coal Bunker
Coal Feeder
Coal Mills
Furnace

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Fig 2.1 Coal Cycle

2.2.1 Wagon Tippler

Wagon from coal yard come to the tippler and emptied here. There are 2 wagon tipplers. The
tippler is tilted to about 135 so that coal from the wagon is emptied into the hopper. Elliptics
paddle feeders are used to move the coal from hoppers to conveyer belts.
In this it takes 52 sec to raise a wagon, 10 sec to empty the wagon completely & then again 52
sec to bring the tippler down. A semicircular huge WT gear is used to run the tippler. Protocol
cameras have been installed for safety to ensure that no moving creature or object is near the
wagon which is on the tippler.

2.2.2 Track Hopper

Coal in BOBR (Box Open Bottom Release) was unloaded on the track hoppers. The track
hoppers are shown as follows.
The Coal is stored in the hoppers from where it is passed on to the conveyer belts by paddle
feeders, towards the crusher house.

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Fig 2.2 Wagon Tippler

Fig 2.3 Track Hoppers

2.2.3 Paddle Feeder

These are movable elliptical feeders with paddle like structures so as to move the coal from
the bottom of the track hoppers to the conveyer belts. There are 4 paddle feeders which can
move along the bottom of the track hopper at different positions.

2.2.4 Conveyer Belts

A belt conveyor consists of two pulleys, with a continuous loop of material- the conveyor Belt
that rotates about them. The pulleys are powered, moving the belt and the material on the
belt forward.
Conveyer belts are used in the CHP to transfer coal from one place to other as required in a
convenient & safe way. All the belts are numbered accordingly so that their function can be
easily demarcated. These belts are made of rubber & move with a speed of 250-300 m/min.

2.2.5 Safety Switches in Conveyers

There are certain switches which are used for safe operation of th conveyers used throughout
the plant.
Belt Sway Switch
These are the switches which are operated when there is sway in the conveyer belt, i.e.
the belt move in a particular direction outside its fixed path. These are located on both
the sides of the belt. In case there is a sway in the belt, the switch gets activated and
stop the conveyer so as to avoid accidents
Pull Cord Switch
These are the switches which are installed at every 10m gap in a conveyer belt to
ensure the safety of motors running the conveyer belts. If at any time some accident
happens or the conveyer belt is needed to be stopped immediately, then the cord is
pulled which activates the switch and stops the conveyer.
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 Zero Speed Switch

It is used as a safety device for the motor i.e. when the belt is not moving but the pulley
is rotating. This switch checks the speed of the belt & switches off the motor when
speed of the belt is zero.

2.2.6 Crusher House

After the coal is unloaded in the wagon tipplers and track hopper (size of coal=-250mm), it is
conveyed to the crusher house for reducing the size of the coal upto -20mm which is the
optimum size for transfer via conveyers.
Table 2.1 Crusher House
No. and Make of Crusher
Type and Size
Main Crusher Capacity
Motor Rating
Power Supply
RPM

8, Pennsylvenia, USA
Ring Granulators, TKKGN-48093
875 tonnes/hr
800hp (597KW)
6.6kv, 3, 50Hz
743

Fig 2.4 Coal Sizes

2.2.7 Stacker cum Reclaimer

It is used for stacking (storage) of the excess coal in the coal yards. When there is a
requirement of the stored coal, reclaiming process starts and the coal is sent to the coal
bunkers through conveyer belts.
There are 3 Stacker Reclaimers at NTPC Dadri with stacking capacity of 1400tph and
reclaiming capacity of 1400tph with boom conveyer speed of 3m/s

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Fig 2.5 Stacker cum Reclaimer

2.2.8 Coal Yard

Whenever the coal bunkers are filled and there is excess crushed coal in the plant, it is stored
in the coal yard.
Capacity - 45 days coal of stagel requirement, 500000m3 of coal approx.
No. of coal piles in stockyard 6
Length/Height of each pile - 470/10m
Water is continuously sprayed on the coal piles so as to settle the coal dust. The water also
cools the coal so as to prevent the escape of the volatile material from the coal
The coal yards of both the stages are interconnected by conveyers so as to supply coal to the
one who is in deficiency of coal at a particular time

2.2.9 Coal Bunker

After the coal is crushed in the crusher house, it is either sent to the coal yards or directly to
the coal bunkers. These are very large coal storage containers which are placed above the
coal mills (where the coal is ground finely).
These are cylindrical in shape with conical cum hyperbolic hopper at bottom and made up of
8mm M.S. plate
Stage I 6 Coal Bunkers per unit
Stage II 9 Coal Bunkers per Unit

Page | 13

Fig 2.6 Coal Bunkers (in Yellow)

2.2.10 Coal Feeder

It is situated just below the coal bunkers. It is used to send calculated amount of coal from the
coal bunkers to the coal mills as per the requirement of the furnace. The quantity of coal fed
is controlled by controlling the speed of the conveyer inside it. Maximum and minimum
capacity of the feeder is 60MT/hr and 6MT/hr respectively

2.2.11 Coal Mill

The coal mills are situated just below the raw coal feeders. Its main function is to
pulverize the coal from -25mm size to 200mesh size. In NTPC Dadri there is a bowl
type coal mill in which there is a bowl and three rollers at 120 to each other. The
bowl rotates at 50rpm and the rollers rotate about their own axis. The rollers are
pressed against the bowl using springs so as to facilitate the grinding of coal.
The coal comes in the coal mill from the top from the coal feeder through a single
pipe. After the coal is pulverized it is carried by the primary air (which enters the
mill from bottom towards the top) to the furnace through 4 pipes. These four
pipes carry the coal to the 4 corners of the furnace.

Page | 14

Table 2.2 Coal Mill

Make
No. per boiler
Type
Capacity
Coal size-inlet
- outlet
Grinding roll material

Fig 2.7 Coal Mills (Pulveriser)

BHEL
6
XRP 883
49 T/hr
25 mm
70% through 200 mesh
Ni -Hard Gr II

Fig 2.8 Rollers of Coal Mill

2.2.12 FURNACE
Furnace is primary part of the boiler where the chemical energy available in the fuel is
converted into thermal energy by combustion. Furnace is designed for efficient and complete
combustion. Major factors that assist for efficient combustion are the temperature inside the
furnace and turbulence, which causes rapid mixing of fuel and air. In modern boilers, watercooled furnaces are used. The boiler fuel firing system is tangentially firing system in which
the fuel is introduced from wind nozzle located in the four corners inside the boiler. The
crushed coal from the coal crusher is transferred into the unit coalbunkers where the coal is
stored for feeding into pulverizing mill through rotary feeder. The rotary feeders feed the coal
to pulverize mill at a definite rate. Then coal burners are employed to fire the pulverized coal
along with primary air into furnace. These burners are placed in the corners of the furnace
Page | 15

and they send horizontal streams of air and fuel tangent to an imaginary circle in the centre of
the furnace.
Table 2.3 Furnace specifications
Type
Bottom
Furnace projected area
Fuel heat input
Residence time for fuel particles in furnace
Effective volume used to calculate the residence time
Draft
Furnace width
Furnace depth
Furnace height (Ring header to furnace roof)
(viii) Furnace volume

Fusion welded walls

Dry
3275 m2
519.3 MK Cal/hr
3.14 sec
4200 m3
Balanced
13.868 m
10.592 m
43.136 m
5570 m3

Page | 16

CHAPTER 3

WATER CYCLE

Fig 3.1 Water Cycle

3.1 De-Mineralized Water/Steam Cycle

Condensate Cycle
Feed Water Cycle
Steam Cycle

3.2 Condensate Cycle

Different Components of Condensate Cycle
Hot Well
Condensate Extraction Pump
Low Pressure Heater
Deaerater
Feed Storage Tank
Page | 17

3.2.1 Hot Well

After the steam is condensed in the condenser, it gets collected in the hotwell so that the
water can be recirculated in the system.

3.2.2 Condensate Extraction Pump

This pump is used to extract the condensed water from the hotwell to the deaerater through
the low pressure heaters
Table 3.1 Condensate Extraction Pump specifications
Manufactuer
BHEL
No. of pumps & capacity
2x100%
Type
NESJ14OD (2shaft), vertical
centrifugal connister type
No. of stages
5
Discharge capacity
655 m3/hr
Diff. head
190 mlc
Input power to pump
422 kw
Temperature of medium
46.30c
RPM
1485
Efficiency of pump
79.5%

3.2.3 Feed Water Heater

A Feed water heater is a power plant component used to pre-heat water delivered to a steam
generating boiler. Preheating the feed water reduces the irreversibility involved in steam
generation and therefore improves the thermodynamic efficiency of the system. This reduces
plant operating costs and also helps to avoid thermal shock to the boiler metal when the feed
water is introduced back into the steam cycle. In a steam power plant, feed water heaters
allow the feed water to be brought up to the saturation temperature very gradually. This
minimizes the inevitable irreversibility associated with heat transfer to the working fluid.
The water here is heated by the steam which is extracted from the different stages of the
turbine
These are of two types
Low Pressure Heater
These are called as low pressure heaters as they extract steam from the stages of low
pressure turbine
LPH1-Stage 7 of LPT
LPH2-Stage 5 of LPT
LPH3-Stage 3 of LPT
High Pressure Heater
These are called as low pressure heaters as they extract steam from the exit of the High
Pressure Turbine
Page | 18

Fig 3.2 Low Pressure Heater

Fig 3.3 High Pressure Heater

3.2.4 Deaerater
A Deaerator is a device for air removal and used to remove dissolved gases (mainly O2 and
CO2) from boiler feed water to make it noncorrosive. A Steam generating boiler requires that
the circulating steam, condensate, and feed water should be devoid of dissolved gases,
particularly corrosive ones and dissolved or suspended solids. The gases will give rise to
corrosion of the metal. The solids will deposit on the heating surfaces giving rise to localized
heating and tube ruptures due to overheating. Under some conditions it may give rise to
stress corrosion cracking
Deaerator is a type of open feed water heater in which feedwater comes in direct contact
with the steam extracted from CRH line and IPT exhaust.
These are of three types
Spray type Deaerator
Tray type Deaerator
Spray Cum Tray type Deaerator
In NTPC Dadri, a spray cum tray type Deaerator is used. In this feedwater is first sprayed and
then made to cascade down a series of trays and bled steam flows upwards. Due to this water
gets heated and scrubbed to release the dissolved gases.
. If operated properly, the deaerator will guarantee that oxygen in the deaerated water will
not exceed 7 ppb by weight (0.005 cm3/L)

3.2.5 Feed Storage Tank

After the water is deaerated it is stored in the feed storage tank just below the deaerater.
Feed Storage tank acts as the inlet for the Boiler Feed Pump. So it is kept about 25m above
the BFP so as to maintain a net positive suction head for the BFP so as to avoid cavitation.

Page | 19

Fig 3.4 Deaerator (upper cylinder) and Feed Storage Tank (lower cylinder)

3.3 Feed Water Cycle

Different Components of Feed Water Cycle
Boiler Feed Pump
High Pressure Heater
Feed Regulating Station
Economiser
Boiler Drum
Boiler

3.3.1 Boiler Feed Pump

A Boiler feed water pump is a specific type of pump used to pump water into a steam boiler.
The water may be freshly supplied or returning condensation of the steam produced by the
boiler. These pumps are normally high pressure units that use suction from a condensate
return system and can be of the centrifugal pump type or positive displacement type.
Construction and operation: Feed water pumps range in size up to many horsepower and the
electric motor is usually separated from the pump body by some form of mechanical
coupling. Large industrial condensate pumps may also serve as the feed water pump. In either
case, to force the water into the boiler, the pump must generate sufficient pressure to
overcome the steam pressure developed by the boiler. This is usually accomplished through
the use of a centrifugal pump. Feed water pumps usually run intermittently and are
controlled by a float switch or other similar level-sensing device energizing the pump when it
detects a lowered liquid level in the boiler. Some pumps contain a two-stage switch. As liquid
lowers to the trigger point of the first stage, the pump is activated. If the liquid continues to
drop, (perhaps because the pump has failed, its supply has been cut off or exhausted, or its
Page | 20

discharge is blocked) the second stage will be triggered. This stage may switch off the boiler
equipment (preventing the boiler from running dry and overheating), trigger an alarm, or
both
Table 3.2 Boiler Feed Booster Pump specifications
BOILER FEED BOOSTER PUMP
Pump type
FA 1B 56
Liquid pumped
Suction temperature
Differential head
Flow rate
Efficiency
Speed
Power
NPSH, required

Boiler feed water

160.70c
100m
450 m3 / hr
79 %
1485 rpm
141 kw
4.03 m.

Table 3.3 Boiler Feed Pump specifications

BOILER FEED PUMP
No and Capaciy
3 x 50%
Make
Pump type
No. of stages
Liquid pumped
Differential head
Design flow rate
Minimum recirculation flow
Efficiency
Speed
Power
NPSH required

BHEL, Hyderabad
FK 6 D 30
6
Boiler feed water
2123m
450 m3 / hr
110 m3 / hr
81%
5150 rpm.
2911 kw
24.0 mlc

Page | 21

Fig 3.5 Boiler Feed Pump

3.3.2 Feed Regulating Station

It is the station which is used to regulate the amount of feed water into the economiser. Here
there are two lines
30% Line for the starting load
100% Line for the full load

3.3.3 Economiser
Economiser is a mechanical device intended to reduce energy consumption, or to perform
another useful function like preheating a fluid. They are devices fitted to a boiler which save
energy by using the exhaust gases from the boiler to preheat the cold water used to fill it (the
feed water). A common application of economizer in steam power plants is to capture the
waste heat from boiler stack gases (flue gas) and transfer thus it to the boiler feed water thus
lowering the needed energy input , in turn reducing the firing rates to accomplish the rated
boiler output .
Table 3.4 Economiser Specifications
Type
Tube Material
OD of Tube, mm
Actual Thickness of Tubes, mm
Length of Tubes, mm
Tube pitch, mm
a) Parallel to gas path
b) Across gas path
Water side effective heating area, m2
Gas side effective heating area, m2
Gas flow path area, m2
Design Pressure of tubes, kg/cm2

Plain, drainable, non-steaming

SA210 GrA1
44.5
4.5
32100
130
96
3580
5617
62.8
161.0
Page | 22

3.3.4 Boiler Drum

Steam Drums are a regular feature of water tube boilers. It is reservoir of water/steam at the
top end of the water tubes in the water-tube boiler. They store the steam generated in the
water tubes and act as a phase separator for the steam/water mixture. The difference in
densities between hot and cold water helps in the accumulation of the hotter water and
saturated steam in drum. The separated steam is drawn out from the top section of the drum.
The steam will re-enter the furnace in through a super heater, while the saturated water at
the bottom of steam drum flows down through downcomers to the ring header from where
the water sent to the boiler
Table 3.5 Boiler Drum specifications
Construction

Fusion welded

Material specification
Design pressure, kg/cm2 abs.
Max. operating pressure, kg/cm2 abs.
Design temperature, 0C
Overall length of drum mm
O.D. of Drum, mm
Internal dia. of Drum, mm
No. of distribution headers
Normal water level in drum

SA-299
176.4
167.2
354.0
12200
2083
1778
6
250 mm below drum centreline.

Fig 3.6 Boiler Drum

Page | 23

3.3.5 Boiler
Boiler is an enclosed vessel in which water is heated and circulated until the water is turned in
to steam at the required pressure. Coal is burned inside the combustion chamber of boiler.
The products of combustion are nothing but gases. These gases which are at high
temperature come in contact with different heat exchangers and vaporize the water inside
them to steam. This steam is further heated in a super heater as higher the steam pressure
and temperature the greater efficiency the powerplant will have in converting the heat in
steam in to mechanical work. This steam at high pressure and temperature is used directly as
a heating medium, or as the working fluid in a prime mover (turbine) to convert thermal
energy to mechanical work, which in turn is converted to electrical energy.
Boilers are classified mainly into two categories as following:
Fire Tube Boiler
In this type the products of combustion pass through the tubes which are surrounded
by water. These are economical for low pressure only.
Water Tube Boiler
In this type of boiler water flows inside the tubes and hot gases flow outside the tubes.
These tubes are interconnected to common water channels and to steam outlet.
At NTPC Dadri there is a water tube boiler in both stage I and stage II
Table 3.6 Boiler Specifications
Manufacturer
Type

Capacity
Boiler Efficiency
FW. inlet temp
Type of firing
Temp and Pressure at outlet of Superheater
Reheater
Water volume
Generating surface (Water walls)
Economiser
Superheater (Drum to SHO heater)
Drum (full)
Reheater
Total water volume of boiler

BHEL (C.E. design)

Natural circulation, balanced draft, smooth tube
double pass, single drum, single reheat direct
pulverised coal/oil fired,dry bottom type.
700t/hr.
87.28%
246 C
Tilting tangential
154.0 kg/cm2; 5400c
38.8 kg/cm; 5400c
116 m3
47 m3
77 m3
34 m3
50 m3
324 m3

Page | 24

3.4 Steam Cycle

Different Components of Steam Cycle
Boiler Drum
Superheater
Low Temperature Superheater
Platen Superheater
Final Superheater
Reheater
Turbine
High Pressure Turbine
Intermediate Pressure Turbine
Low Pressure Turbine
Steam Lines
Condenser

3.4.1 Superheater
A Super heater is a device in a steam engine that heats the steam generated by the boiler
again increasing its thermal energy. Super heaters increase the efficiency of the power plant,
and are widely adopted. Here the temperature of the steam is raised above the saturated
temperature of the steam so that even after isentropic expansion in the turbine the wetness
of steam remains in the desired region
In NTPC Dadri, the boiler has in total 14 superheater headers located at various positions in
the boiler. Superheaters are of three types
Low Temperature Superheater
Platen Superheater
Final Superheater
Table 3.7 Superheater specifications

Type
Direction of flow
Effective heating surface
area, m2
Gas flow path area, m2
Total no. of tubes
O.D., mm
Effective length, mm
Gross length, m
No. of elev/section
Tube pitch
(a) Parallel of gas flow,mm
(b) Across gas flow, mm

LTSH Pendant
Horizontal
Convection
Counter
3700

Platen
S.H.
Radiant
Parallel
1097

Final
S.H.
Convection
Parallel
1543

73
480
44.5
26466
34700
4

138.9
203
47.63
8900
10100
7

72
238
44.5
8360
9760
2

96
114.3

57
457.2

95/96
114.3
Page | 25

3.4.2 Reheater
Reheater is a heater which is used to raise the temperature of steam which has fallen after
the expansion in High Pressure Turbine. This is done so as to increase the efficiency of the
power plant and to maintain the dryness fraction of the steam within the desired limit.
Table 3.8 Reheater Specifications
Type
Max. operating pressure,kg/cm2
Design pressure, kg/cm2
Total circumferential heating suface, m2
Gas flow path area, m2
Space between two banks in direction of gas flow,
mm
Mean effective length per one tube, mm
Gross length per tube, mm
Total no. of tubes
Acutal tube thickness O.D., mm
Tube material
Tube pitch
(a) Parallel to gas flow, mm
(b) Across gas flow, mm
Method of joining long tubes

Spaced, single stage

42.08
50.00
2858
118
900
20.000
22,000
354
47.63/54.00
SA 210 Gr A1, SA 213T11, T 22
101.6
228.6
Butt welded

3.4.3 Steam Lines

Main Steam Line
It is the pipeline which carries the superheated steam from the final superheater to the
HPT
Cold Reheat Line
It is the pipeline which carries the outlet steam of the HPT to the reheaters in the boiler
where the temp of the steam is again brought back to 540C at the same pressure
Hot Reheat Line
It is the pipeline which carries the reheated steam from the reheaters to the IPT

3.4.4 Condenser
These condensers are heat exchangers which convert exhaust steam from its gaseous to its
liquid state at a pressure below atmospheric pressure. This is done because handling of the
steam is more difficult and requires more power as compared to that for condensed water.
The condenser used is a shell and tube type condenser in which steam is in the shell while
cooling water is in the tubes. After condensing the steam, the cooling water gets heated up
and is sent to the cooling towers to cool it and use it again
Specifications of the condenser used in NTPC Dadri is as follows
Page | 26

Table 3.9 Condenser Specifications

Type
Surface type, double pass with divided
water box construction.
Design c.w. flow
22,500 m3/hr
Design cold wate temp.
320c
Design back pressure
76 mm of Hg (abs)
No. of tubes
15330 nos.
Tube O.D. x thickness,
25.4 x 0.7 thick
Tube material
Stainless steel welded
ASTM A 249 TP 304
Surface area
13727 M2
C.W. velocity
1.83 m/s
Pressure drop C.W. side
4.18 mwc
C.W. temp rise
10.80c

Fig 3.7 - Condenser

Page | 27

3.5 Cooling Water Cycle

Different Components of Cooling Water Cycle
Raw Water Reservoir
Water Softening Plant
De-mineralized Water Plant
Forebay
Circulating Water Pump House
Condenser
Cooling Tower
Intake Channel

3.5.1 Raw Water Reservoir

Water is brought to the plant through small canal which is further connected to the Upper
Ganga Canal. This water is stored temporarily in a water reservoir before sending it to the
water treatment plant. This water is called raw water and is sent to WTP through Raw Water
pump house

3.5.2 De-Mineralizing Plant

The principle problem in high pressure boiler is to control corrosion and steam quality.
Internal corrosion costs power station crores of rupees in repair without strict control
impurities in steam also form deposit over turbine blades and nozzles.
The impurities present in water are as follows :

Un-dissolved and suspended solid materials.

Dissolved slats and minerals.
Dissolved gases
Other minerals ( oil, acid etc.)
Turbidity & Sediment.
Silica.
Micro Biological.
Sodium & Potassium Salt.
Dissolved Sales Minerals.
O2 gas.
CO2 gas.

Page | 28

The water treatment plant is divided in to two parts:

Water Softening Plant
Water Softening Plant deals with removing larger solid impurities by sedimentation and
by coagulation and flocculation, and de-infection of water through aeration. Here,
Alum and Chlorine dosing is done so as to remove the hardness present in the water.
After this the water is sent to de-mineralizing plant and also serves as the drinking
water for the NTPC township
The De-Mineralization plant. (DM plant)
In this plant all the dissolved minerals are removed from the water. The water from
water softening plant is passed through SAC (strong acid cation) which contains acidic
resins and remove dissolved cations such as Mg, Ca, Na etc. It is then passed through
degasser tower to force out the dissolved carbon dioxide gas and carbonate ions. Then
the water is passed through the SBA chamber which contains strong basic resins which
remove chlorine and sulphate ions. From SBA the water is passed through MB (mixed
bed) chamber which removes both cationic and anionic impurities , if any, and the
water is then sent to DM storage tank, from where it is transported for various uses.

3.5.3 Forebay
After the water is cooled in the cooling tower, it goes to the CW Pump house through
forebay. It connects water from all the four cooling towers in a single channel which finally
becomes the intake of CW Pump house.

3.5.4 Cooling Water Pump House

It circulates the cooling water coming out of the cooling tower to the condenser.
It consists of 8 vertical francis, single stage pumps which take inlet from the forebay

3.5.5 Cooling Tower

Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove process heat
and cool the working fluid to near the wet-bulb air temperature or in the case of closed circuit
dry cooling towers rely solely on air to cool the working fluid to near the dry-bulb air
temperature. In thermal power plant, it is used to cool the circulation water which comes out
of the condenser. The towers vary in size from small roof-top units to very large hyperboloid
structures that can be up to 200 meters tall and 100 meters in diameter, or rectangular
structures that can be over 40 meters tall and 80 meters long.
There are two types of cooling towers
Natural Draught Cooling Tower
Forced Draught Cooling Tower
In NTPC Dadri, both natural and forced draught cooling towers are used
Natural Draft is used in Coal Based Unit while Forced Draft is used in Gas based units
Page | 29

Table 3.10 Cooling Tower Specifications

Type
Natural draft type
No.
4, 1 for each unit
Construction type
Reinforce concrete, hyperbolic, double curvature
shell with a big beam at the base supported on
rocker columns
Total height
117 m
Base diameter
78.9 m
Throat diameter
46.7 m
Top diameter
49.77 m
Flow
25,000 m3/hr
Range of cooling
110c
Recooled water temp.
320c
Ambient wet bulb temp.
270c
Design relative humidity
50%
Approach.
5 0c

Fig 3.8 Natural Draft Cooling Towers

Fig 3.9 Cooling Tower from inside

Page | 30

CHAPTER 4

TURBINE AND GENERATOR

4.1 Turbine
A turbine, is a rotary mechanical device that extracts energy from a fluid flow and converts it
into useful work. A turbine is a turbomachine with at least one moving part called a rotor
assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades so
that they move and impart rotational energy to the rotor. The turbine normally consists of
several stages with each stages consisting of a stationary blade (or nozzle) and a rotating
blade. Stationary blades convert the potential energy of the steam into kinetic energy 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. The turbine shaft is connected to a generator, which produces the electrical
energy.
Here in Thermal Power Plant Superheated Steam is used as the fluid to run the turbine

4.1.1 High pressure Turbine

Steam coming from Boiler directly feeds into HPT at a temperature of 540C and at a pressure
of 156 kg/cm2. This turbine is a single flow 25 stage reaction turbine. After expansion the
temperature goes down to 352C and pressure as 40.4 kg/cm2. The outlet of the HPT is taken
back to the reheaters in the boiler through CRH lines where the steam is again heated to
540C at same constant pressure.

Fig 4.1 High Pressure Turbine

Page | 31

4.1.2 Intermediate Pressure turbine

Intermediate Pressure Turbine (IPT) is a 20 x 2 stages, double flow reaction turbine. After
coming out of the reheaters, the steam is brought to the IPT through HRH lines at 540C
temperature and 36 kg/cm2 pressure. The steam is sent in the middle of the IPT from where it
expands in both the directions.

Fig 4.2 Intermediate Pressure Turbine

4.1.3 Low Pressure Turbine

Low Pressure Turbine (LPT) is a 8 x 2 stages, double flow reaction turbine. After expansion in
the IPT, steam is fed directly in the LPT. Here also the steam is fed in the middle of the tubine
and it expands in both the directions.

Fig 4.3 Low Pressure Turbine

Page | 32

Table 4.1 Turbine Specifications

Make
Type

No of stages

Type of HP/IP/LP turbine

Nominal rating
Peak loading
Max./Min. speed

Weight of turbine

BHEL, KRAFTWERK UNION DESIGN

Tandem compound, regenerative, reheat, condensing, three
cylinder having single flow HP turbine, double flow IP & LP
turbine.
HP 25 no.
IP 20 x 2 no.
LP 8 x 2 no.
HPT-Reaction, barrel single flow type
LPT-Reaction, double flow axially split type
LPT-Reaction, double flow three shell design
210 MW
229 MW
3090/2850 rpm (47.5 to 51.5 HZ)
Permissible for a maximum of 2 hours operation during the
life of the LP blading speed below 47.5 HZ & speed above
51.5HZ.
475 tonne (approx.)

Height of first stage moving blade

Mean dia. of first stage moving blade
Height of last stage moving blade
Mean dia. of last stage moving blade
Overall length
Overall width (with cross around
pipes)
Total exhaust area (LP Turbine)

HPT
43
643
95
695
16.975m
10.5 (approx.)

IPT
66
756
100
1041

LPT
755
1473.5
668.8
2144.8

2 x 5 m2

4.2 Electricity Cycle

Different Components of Air Cycle
Generator
Exciter
Transformer
Unit Transformer
Unit Auxiliary Transformer
Switch Yard
Interconnecting Transformer
Outgoing Feeder

Page | 33

4.3 Generator
The generator works on the principle of electromagnetic induction. There are two
components stator and rotor. The rotor is the moving part and the stator is the stationary
part. The rotor, which has a field winding, is given a excitation through a set of 3000rpm to
give the required frequency of HZ. The rotor is cooled by Hydrogen gas, which has high heat
carrying capacity of low density. If oxygen and hydrogen get mixed then they will form very
high explosive and to prevent their combining in any way there is seal oil system. The stator
cooling is done by de-mineralized (DM) water through hollow conductors. Water is fed by one
end by Teflon tube. A boiler and a turbine are coupled to electric generators. Steam from the
boiler is fed to the turbine through the connecting pipe. Steam drives the turbine rotor. The
turbine rotor drives the generator rotor which turns the electromagnet within the coil of wire
conductors.
Hydrogen gas is used to cool down the rotor.
Lube oil is used to cool the bearings.
DM water is used to cool the stator.
Seal oil is used to prevent hydrogen leakage
Seal oil coolers are present to cool the seal oil
Hydrogen dryer are used which removes the moisture from hydrogen gas and then is
supplied to the generator.
Clarified water in cooling tower is used to cool down the hydrogen gas.

Fig 4.4 Generator (Red) and Turbine (Green)

Rating of Generators used

Stage I 210MW
Satge II 490MW
Page | 34

Table 4.2 Stage I (210MW) Generator specifications

Make
BHEL
Type
THW - 201-2 Two pole, cylindrical, steam turbine
driven
Cooling Stator winding
Directly water cooled
Stator core and Rotor
Directly hydrogen cooled
MW rating
210
Rated terminal voltage
16.5 kv
Rated terminal current
8,645 A
Rated power factor
0.85 lag
Rated speed/frequency
3000 rpm/50 HZ
Efficiency at MC Condition
98.55%
Phase connection
Double star

The 210 MW generates 16.5 KV three phase electricity. The voltage is stepped up to 220 KV
with the help of station transformer and is connected to the switch yard. This electricity is
further stepped up to 400KV and then supplied to the grid
Some of the electricity is stepped down to 6.6KV with the help of Unit Auxiliary Transformer
to drive the different auxiliaries in the plant.

4.4 Transformer
It is a static machine which increases or decreases the AC voltage without changing the
frequency of the supply. It is a device that:
Transfer electric power from one circuit to another.
It accomplishes this by electromagnetic induction.
In this the two electric circuits are in mutual inductive influence of each other.
It works on Faradays Law of Electromagnetic Induction (self or mutual induction depending
on the type of transformer).
There are two types of transformers
Station Transformer
It is the transformer which steps up the 16.5KV electricity generated by the generator
to 220KV
Unit Auxiliary Transformer
It is the transformer which steps down some of the electricity to 6.6KV so as to run the
auxiliaries in the plant

Page | 35

Fig 4.5 Station Transformer

4.5 Switch Yard

As we know that electrical energy cant be stored like cells, so what we generate should be
consumed instantaneously. But as the load is not constants therefore we generate electricity
according to need i.e. the generation depends upon load. The switchyard is the place from
where the electricity is send outside to the grid. Its main function is to convert the electricity
in the required form and connect to the grid to supply this electricity.

Fig 4.6 Switch Yard

Page | 36

4.5.1 Circuit Breaker

Circuit breaker is an arrangement by which we can break the circuit or flow of current. A
circuit breaker in station serves the same purpose as switch but it has many added and
complex features. The basic construction of any circuit breaker requires the separation of
contact in an insulating fluid that servers two functions:
extinguishes the arc drawn between the contacts when circuit breaker opens.
It provides adequate insulation between the contacts and from each contact to earth.

Page | 37

CHAPTER 5

AIR AND FLUE GAS CYCLE

5.1 Air Cycle
Different Components of Air Cycle
Fans
Primary Air Fan
Forced Draft Fan
Induced Draft Fan
Seal Air Fan
Scanner Air Fan
Air Preheter
Cold Air Duct
Hot Air Duct
Wind Box

Fig 5.1 Flue Gas Cycle

Page | 38

5.2 Fans
5.2.1 Primary Air Fan (PA Fan)
It is the fan which is used to carry pulverized coal from the coal mills to the furnace. The PA
Fan takes suction from the FD fan outlet from where the air is sent to the air preheaters.
From APH, the heated air is sent to the coal mills. Heating of primary air is done so as to
remove the moisture content from the coal so as to facilitate the combustion process.
Table 5.1 PA Fan specifications
Manufacturer
BHEL
No. per boiler
Type
Medium handled
Location
Orientation
Capacity
Total head developed
Temp. of medium
Speed

Two
NDZV 19 HERKALES Axial double suction
radial discharge simply supported
Clean air from FD fan discharge
Ground mounted on concrete floor
Top delivery with 450 inclined suction
chamber.
77.4 cu.m/sec.
931 mmwc
530c
1480 rpm

5.2.2 Forced Draft Fan (FD Fan)

It is the external fan provided to give sufficient air for combustion. The forced draught fan
takes air from the atmosphere and, warms it in the air preheater for better combustion and
injects it via the air nozzles on the furnace wall. This air is called secondary air.
Table 5.2 FD Fan specifications
Manufacturer
No. per boiler
Type
Medium handled
Location
Orientation
Capacity
Total head developed
Temp. of medium
Speed

BHEL
Two
AP1-19/11
Clean air
Ground mounted on concrete floor
Horizontal axis
144.7 cu.m/sec
334 mmwc.
500c
1480 rpm

Page | 39

Fig 5.2 Forced Draft Fan (bottom left) and Primary Air Fan (bottom right)

5.2.3 Induced Draft Fan (ID Fan)

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
ash particles carried by the outlet gases are removed by ESP to avoid atmospheric pollution.
Table 5.3 ID Fan specifications
Manufacturer
BHEL
No. per boiler
Two
Type
NDZV 31 SIDOR Axial double
suction radial discharge
Medium handled
Flue gas
Location
Ground mounted
Orientation
Bottom delivery with 450
inclined suction
Capcity
222 cu.m/sec
Total head developed
418 mmwc
Temp. of medium
1450c
Speed
740 rpm

Page | 40

Fig 5.3 Induced Draft Fan

5.3 Flue Gas Cycle

Different Components of Flue Gas Cycle
Furnace
Superheater
Reheater
Economiser
Air Preheater
Electrostatic Precipitator
Induced Draft Fan
Chimney

5.3.1 Air Preheater

Air preheater is a general term to describe any device designed to heat air before another
process (for example, combustion in a boiler). The purpose of the air preheater is to recover
the heat from the boiler flue gas which increases the thermal efficiency of the boiler by
reducing the useful heat lost in the flue gas. As a consequence, the flue gases are also sent to
the flue gas stack (or chimney) at a lower temperature allowing simplified design of the
ducting and the flue gas stack.
There are two types of Air Preheaters
1. Recuperative Air Preheater
2. Regenerative Air Preheater
Page | 41

In NTPC Dadri, a regenerative air preheater is used. Every unit consists of two air preheaters.
It is of two types
Bisector Air Preheater
Trisector Preheater
Here, a trisector type preheater is used. In this the whole circular area is divided into three
sectors of 180 (for flue gas), 120 (for secondary air) and 60 (for primary air)

Fig 5.4 Air Preheater

5.3.2 Electrostatic Precipitator

An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate 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, and can easily remove
fine particulate matter such as dust and smoke from the air steam. Here ESP is used to
separate ash particles from the flue gases. A DC current of 75 KV is passed through the
electrodes which ionizes the ash particles. These particles then get deposited on the
collecting electrodes. Automatic rapping systems and hopper evacuation systems remove the
collected particulate matter while on line allowing ESPs to stay in operation for years at a
time
Table 5.4 Electrostatic Precipitator specifications
Manufacturer
Type
Gas flow rate
Temperature
No. ofgas paths per boiler
No. of fields in series in each gas pass
Treatment time

BHEL
FAA-6x45-69135-2
312.7 cu.m / sec
1360c
Four
Six
32.18 seconds
Page | 42

Veloctiy of gas at electrode zone on total area

0.839 m/sec

Guarantee of collection efficiency for design

conditions
Power consumption
No. of rows of collecting electrodes per field
No. of collecting electrode plates per field
total no, of collecting plates per boiler
Nominal height of collecting plate
Nominal length of collecting plate
Specific collecting area (with one field out of
service)
Type of emmiting electrodes
Size of emmiting electrodes
No. of emmiting electrodes in the frame forming
one row
No. of emitting electrodes in each field
Total no. of emitting electrodes per boiler
Total length of emitting electrode per field

99.9%
505 kw
24
144
3456
13.5 m
750 mm
214.48 sq.m/cu.m/sec
Spiral with hooks
Dia 2.7 mm
54 fields
1242
29808
6967.62 m.

Fig 5.5 Electrostatic Precipitator

5.3.3 Chimney
A Flue gas stack is a type of chimney, a vertical pipe, channel or similar structure through
which combustion product gases called flue gases are exhausted to the outside air. Flue gases
are produced when coal or oil is burnt in the furnace. Flue gas is usually composed of carbon
dioxide (CO2) and water vapour as well as nitrogen and excess oxygen remaining from the
Page | 43

intake combustion air. It also contains a small percentage of pollutants such as particulates
matter, carbon mono oxide, nitrogen oxides and sulphur oxides. The flue gas stacks are often
quite tall so as to disperse the exhaust pollutants over a greater area and thereby reduce the
concentration of the pollutants to the levels required by government's environmental policies
and regulations.
Table 5.5 Chimney Specifications
No. of fuel
Wind shield material
flue material
Chimney height
Chimney base diameter
Chimney raft diameter
Flue diameter

4 NO.
Reinforced concerete
Steel
220 m
32.975
43.120 m
4.5 m

Fig 5.6 Chimney

Page | 44

5.4 Ash Handling Plant

Ash handling refers to the method of collection, conveying, interim storage and load out of
various types of ash residue left over from solid fuel combustion processes. The most
common types of ash include bottom ash, fly ash and ash clinkers resulting from the
combustion of coal. Ash handling systems may employ pneumatic ash conveying or
mechanical ash conveyors. A typical pneumatic ash handling system will employ vacuum
pneumatic ash collection and ash conveying from several ash pick up stations with delivery to
an ash storage silo for interim holding prior to load out and transport. Pressurized pneumatic
ash conveying may also be employed. Coarse ash material such as bottom ash is most often
crushed in clinker grinders (crushers) prior to being transported in the ash conveyor system.
Very finely sized fly ash often accounts for the major portion of the material conveyed in an
ash handling system. It is collected from baghouse type dust collectors, electrostatic
precipitators and other apparatus in the flue gas processing stream.
There are two types of ash in a Power Plant:
Bottom Ash.
It refers to part of the non-combustible residues of combustion. In an industrial
context, it usually refers to coal combustion and comprises traces of combustibles
embedded in forming clinkers and sticking to hot side walls of a coal-burning furnace
during its operation. The portion of the ash that escapes up the chimney or stack is,
however, referred to as fly ash. The clinkers fall by themselves into the water or
sometimes by poking manually, and get cooled.
Fly Ash
It is one of the residues generated in combustion, and comprises the fine particles that
rise with the flue gases. In an industrial context, fly ash usually refers to ash produced
during combustion of coal. Fly ash is generally captured by electrostatic precipitators or
other particle filtration equipments before the flue gases reach the chimneys of coalfired power plants.
There are basically 2 types of ash handling processes undertaken by AHP:
Dry ash system
Ash slurry system
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.
Ash Slurry System
Ash from boiler is transported to ash dump areas by means of sluicing type hydraulic system
which consists of two types of systems:
Page | 45

 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.
Ash water system
In this system, the ash collected in ESP hopper is passed to flushing system. Here low
pressure water is applied through nozzle directing tangentially to the section of pipe to
create turbulence and proper mixing of ash with water to form slurry. Slurry formed in
above processes is transported to ash slurry sump. Here extra water is added to slurry if
required and then is pumped to the dump area

Fig 5.7 Hydrobins

Fig 5.8 Dry Ash Silos

Page | 46

CONCLUSION
The industrial training has proved to be quiet fruitful. It provided an opportunity for
encounter with such huge machines. The architecture of the power plant the way various
units are link and the way working of whole plant is controlled make the student realize that
engineering is not just learning the structure description and working of various machines,
but the greater part is of planning proper management.
The practical experience that I have gathered during the overview training of thermal power
plant having a large capacity of 2637 MW in 45 days will be very useful and a stepping stone
in building bright professional career in future life. It gave me large spectrum to utilize the
theoretical knowledge and to put it into practice. The trouble shooting activities in operation
and decision making in case of crisis made me more confident to work in the industrial
atmosphere. Moreover, this overview training has also given a self-realization & hands-on
experience in developing the personality, interpersonal relationship with the professional
executives, staffs and to develop the leadership ability in industry dealing with workers of all
categories. I would like to thank everybody who has been a part of this project, without
whom this project would never be completed with such ease.

Page | 47

REFERENCES
Thermal Power Plant (Wikipedia)
NTPC Dadri Technical Diary
Power Plant Engineering by P.K. Nag
TMH Publications
Thermodynamics by P.K. Nag
TMH Publications
www.ntpc.co.in

Page | 48