CONTENT

1. Acknowledgement 2. Declaration 3. Brief Introduction to project 4. NTPC- Introduction 5. Working(Coal To Electricity) 6. Thermal Power Plant 7. Main Components of plant 8. Uses of Coal Ash 9. Advantages of Ash Mound 10.Features of Ash Mound 11.Measurement of Parameters 12.Control Valves 13.Conclusion 14.References

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ACKNOWLEDGEMENT

I take this opportunity to thank Mr. Kailash Chandra (Supritendent C&I) for his valuable guidance and support during complete internship period. I sincerely thank to complete NTPC staff for extending all the help and cooperation during the visit in plant.

ADITI JAIN (8503897) (ECE- A7)

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DECLARATION
I Aditi Jain hereby state that this final evaluation report has been submitted to Jaypee Institute of Information Technology in partial fulfillment of the requirements of Summer Internship Program in B. Tech program of class 2008. The empirical information of this report is based on my experience in student internship program. Any part of this project has not been reported or copied from any report of the university and others.

ADITI JAIN (8503897) (ECE- A7)

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BRIEF INTRODUCTION TO THE PROJECT

Our Project has following objectives:-

1. To know the working of DADRI thermal plant (Stage I and Stage II). 2. To know the specifications of main components in plant. 3. To understand the control unit of plant which is based on DDCMIS (discrete digital control monitoring and information system), under the department of computerized data acquisition system (DAS). 4. To know the methods of measurements in control units.

NTPC:- A Brief Introduction NTPC is one of the India's leading power generating

corporations. Established on 7th November 1975. NTPC is the 6th largest in terms of thermal generation

and second most efficient in terms of capacity utilization amongst top 10 utilities in the world. NTPC contributes one-fourth of India's total power generation with less than one-fifth capacity. Its current capacity is 24249 MW. It has 13 coal based, 7 gas based and 3 joint venture projects. The National Capital Power Station [NCPS], DADRI, has the distinction of being the country's only three in one project ; consisting of 840 MW of coal based units , 829 MW gas based modules , and a 1,500 MW H.V.D.C. converter station {under the operational

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control of P.G.C.I.L. since October '93}. Besides the station has the largest switchyard in the country with a power handling capacity of 4,500 MW. NTPC WORKING (COAL TO ELECTRICITY)

STEP1: COAL TO STEAM:

Coal from the coal wagons is unloaded in the Coal Handling Plant. This coal is transported to the coal bunkers with the help of conveyors belts. Coal is then transported to the bowl mills by coal feeders. This coal is pulverized in the bowl mill where it is grounded to a powder form.

The crushed coal is taken away to the furnace through coal pipes with the help of hot and cold air mixture from PA fan (primary air fan).

Atmospheric airs, from FD fan (force draft fan) is heated in the air heaters and send to furnace as combustion air.

Water from the boiler feed pump passes through economizer and reaches the boiler drum.

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Due to heat and density difference the water rises up in the water wall tubes. Water is partly converted into steam as it rises up in the furnace. This steam and water mixture is again taken to the boiler drum where the steam is separated from water. Water follows the same path while the steam is send to super heater for super heating.

Flue gases from the furnace are extracted by induced draft fan.

STEP2: STEAM TO MECHANICAL POWER:

A steam pipe from the boiler conveys steam to turbine through a stop valve and control valve.

Steam from the control valves enter the high pressure cylinder of the turbine (HPT) where it passes through a ring of stationary blades fixed to the cylinder wall.

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 (IPT).

Finally the steam is taken to the low pressure cylinders (LPT) as the steam gives up its heat energy to drive the turbine its temperature and pressure fall and it expands.

The turbine shaft usually rotates at 3000 revolution per minute (rpm) this speed is determined by the frequency of the electrical system used in this country and is the speed at which a two pole generator must be driven to generate alternating current at a frequency of 50 cycles per seconds.

When maximum energy has been extracted from the steam it is exhausted directly to the condenser.

From the condenser the condensate is pumped through low pressure heaters by the extraction pump, after which its pressure is raised to boiler pressure by boiler feed

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pump. It is passing through further feed heather to the economizer and the boiler for re-conversion to steam.

STEP3: MECHANICAL TO ELECTRICAL POWER:

The turbine is coupled to 2-pole generator, which produce the electrical power (210 MW-typical) at a frequency of 50Hz and voltage 16.5kv (typical).

STEP4: TRANSMISSION AND DISTRIBUTION:

Electricity is usually produced in the stator winding of large generators at about 16.5 to 25kv and is fed to terminal connection to one side of generator transformer that steps up the voltage to 132kv, 220kv or 400kv.

From here conductors carry it to a series of three switches comprising an isolator, a circuit breaker and another isolator.

Thermal Power Plant

Stage I of Thermal plant has 4 units each of capacity 210 MW while StageII has 2 units of 490 MW each.

The two basic neccesities are Coal and Water. Supply of coal is from North Karanpura Bihar (1150km from plant). Water is taken from Dehra feeder, Upper Ganga Canal.

The Water used in plant is in Demineralised Form for which separate DM plant is established.

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Main Components of Plant

1) Boiler 2) Turbine 3) Generator

The C&I department handles the Boiler and Turbine .

Figure 2. Plant Layout

Real Time Data : Steam : 683 t/h

F. Water : 668 t/h

Coal : 185.4 t/h

Oil : .00 t/h

Air : 781 t/h

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BOILER

The stage I of plant has 4 units. Each unit has its own Boiler, Turbine Generator, fans etc. arrangement. Each unit has two ID Fans, two FD Fans, two PA Fans, 6 Coal mills (4- full load + 2- stand by), 6 Coal Feeders (4- full load + 2- stand by), 4 oil guns etc.

The height of boiler is 56m.

Figure 3. Arrangement of main Boiler

Boiler Drum: The Function of steam drum is to separate the water from the steam generated in the furnace wall and to reduce the dissolved solid contents of he steam to below the prescribed limit of 1 ppm. The drum is located on the upper front of boiler. Industrial Training Report on NTPC, Dadri Page 10

Economiser: the purpose of economiser is to preheat the boiler feed water before it is introduced into the steam drum by recovering heat from the flue gases leaving the boiler. The economiser is located in the boiler rear gas pass below the rear horizontal superheater. The economiser is continuous unfinned loop type and water flows in upward direction and gas in the downward direction.

Super Heater: There are three stages of superheater besides the side walls and extended sidewalls. The first stage consists of horizontal superheater of convection mixed flow type with upper and lower banks located above economiser assembly in the rear pass. The upper bank terminates into hanger tubes, which are connected to outlet header of the first stage superheater. The second stage superheater consists of pendant platen which is of radiant parallel flow type. The third stage superheater pendant spaced is of convection parallel flow type.

The outlet temperature and pressure of the steam coming out from superheater is 540 C and 157 Kg/Cm2 respectively for H.P. units.

Reheater : The function of reheater is to reheat the steam coming out from high pressure turbine to a temperature of 540 C. The reheater is composed of two sections. The front pendant section and rear pendant section.

Burners: there are total 24 pulverised coal burners for corner fired C.E. type boilers and 12 oil burners provided each in between two pulverized fuel burner.

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The pulverized coal burners are arranged in such a way that six mills supply the coal the burners at 4 corners, of the furnace. All the nozzles of the burners are inter linked and can be tilted as a single unit from 30 to -30.

The oil burners are fed with heavy fuel oil till boiler load reaches to about 25%.

Igniters: There are 12 side eddy plate oil/H.E.A. igniters per boiler. The atomizing air for ignitor is taken from plant air compressors at 7 Kg/cm2.

Boiler has 4 corners. The powdered coal is blowed from the four corners into the chamber.

Water circulation system

Water must flow through the heat absorption surface of the boiler in order that it be evaporated into steam. In drum type units ( natural and controlled circulation) the water is circulated from the drum through the generating circuits and back to the drum where steam is separated and directed to the superheater. The water leaves the drum through the downcomers at a temperature slightly below saturation temperature. The flow through the furnace wall is at saturation temperature. Heat absorbed in water wall is latent heat of vaporization creating a mixture of steam and water. The ratio of the weight of water to the weight of steam in the mixture leaving the heat absorption surfaces is called Circulation Ratio.

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Various auxiliary equipments are shown in the figure 4.

Figure 4. Arrangement of boiler auxiliaries.

Mills: Pulverised fuel firing is a method whereby the crushed coal, generally reduces to a fineness such that 70-80% passes through a 200 mesh sieve, is carried forward by air through pipes directly to burners or storage bins from where it is passed to burners. When discharged into combustion chamber, the mixture of air and coal ignites and burns in suspension.

Burner arrangement: There are twenty four pulverized coal burners arranged on the corners at a height of 18 to 25 meters and twelve oil burners provided each in between two pulverized fuel burners. The pulverized coal burners are arranged in such a way that six mills supply the coal to burners at 4 corners, of the furnace, all the nozzle of the burners are inter linked and can be tilted as a single unit from +30 deg. to -30 deg.

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The oil burners are fed with heavy fuel oil till boiler load reaches to about 25%. There are four wind boxes fixed at 4 corners of the furnace. There are 13 nozzle in each wind box 6 for coal and 7 for air.

Turbines

The 210 MW turbine installed in our power stations is predominantly of condensing tandom compound, three cylinder, horizontal, disc and disphragm, reheat type with nozzle governingand regenerative system of feed water heating and is coupled directly with A.C. Generator.

Figure5: Turbine and its auxiliaries

The superheated steam from boiler is led towards H.P.T (High Pressure Turbine) which is rotates it and cools down. This steam is reheated and passed to I.P.T (Intermediate Pressure Turbine) Industrial Training Report on NTPC, Dadri Page 14

from where the left out steam goes to L.P.T (Low Pressure Turbine). The steam left from LPT goes to condenser from where it is sent to LP Heater and then to Deaerator from where it is again sent to Boiler.

FUELS: The Fuels required in the power plant are Coal and Oil. Oil used is of two types : LDO (Light Diesel Oil) and HFO (High Fuel Oil). Normally, HFO is fired first in the furnace due to its High viscosity it is not suitable in winters. So LDO is fired first in winters however LDO is costlier than HFO.

USES OF COAL ASH: DADRI ash has been successfully used in the following applications: LAND FILLS ROAD EMBANKMENTS ROAD CONSTRUCTION PORTLAND POZZOLONA CEMENT BUILDING PRODUCTS CONCRETE

Use of Dadri ash in above applications have resulted in saving in terms of m o n e y , c o n s e r v a t i o n o f n a t u r a l r e s o u r c e s v i z m o t h e r e a r t h , l i m e s t o n e , coal, sand, energy, land and water apart from reduction in CO2 emission and thus environment.

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PRESENT SENARIO IN INDIA : 65% of the total installed power generation is coalbased. 230 - 250 million MT coal is being used every year. High ash contents vrying from 30 to 50%. 95 million MT ash generated every year. Ash generation likely to reach 170 million MT by 2010. Presently 65000 Acres of Land occupied by AshPonds.

The NCPS Dadri project has the unique distinction of having Asia's first 100 percent dry ash extraction with transit ash storage silos and final storage place converted to an green ash mound

Ash can be collected in following categories:

DRY FLY ASH:Dry ash is collected from different rows of electrostatic precipitators. It is available in two different grades of fineness in silos for use as resource material by different users. BOTTOM ASH:Bottom ash collected from bottom of boiler and transported to hydro bins and then ash mound for use in Road Embankment. CONDITIONED FLY ASH: Conditioned fly ash is also available in Ash mound for use in Landfills and Ash Building prod

NTPC -A trend setter in the country has set up 100 % dry ash extraction cum disposal in the form of Ash Mound at NTPC Dadri.

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Ash mound has come out as the most viable alternative for ash disposal in an economic friendly way by minimum use of land and water.

ADVANTAGES OF ASH MOUND : Less requirement of land only 1/3rd land requirement compared to wet disposal system. 375 acres of land is required as compared to 1000acres for installed capacity of 840 MW at Dadri. Only 1/50th water required in comparison to wetsystem Eliminates leaching effect. Separate storage of fly ash (PFA) and furnace bottomash(FBA). Facilitates large scale utilization at later stage. The green ash mound can be used as a useful piece of land.

FEATURES OF ASH MOUND: Ash mound covers area of 375 acres. Ultimate height 55 meters. Side slope 1:4 with haulage road at 15 m interval. Top most flat area 140 acres. Capacity of ash storage 53 million cum. Sufficient for running 840 MW for 40 years. Side slopes covered with green grass and plantation of trees . Beautiful green spot in the vicinity of power house.

Some differences in specification of Stage II compared to Stage I : Industrial Training Report on NTPC, Dadri Page 17

Instead of 6 mills, we have 9 mills in stage II ( 6- full load, 3- stand by). Five Oil Elevations in stage II compared to four in Stage I. In Stage II pressure is 190 KSC while in Stage I it is 170 KSC. Excitation system in Stage II is AVR (Automatic Voltage Regulator) system. There are 10 scanners in stage II. Control system is MAX DNA which works on commands only. In stage I all 3 BFPs (Boiler Feed Pump) are motor driven while in stage II two are Turbine driven (TDBFP) and one is motor driven.

Before TDBFP, Booster pump are used to increase suction pressure. In stage I, reheated steam has temp. 540 deg C while in stage II it is 568 deg C. In stage II circulation is done by CCP (Controlled Circulation Pump).

MEASUREMENT of PARAMETERS:

1) Temperature: Temperature can be measured by a diverse array of sensors. All of them infer temperature by sensing some change in a physical characteristic. The most popular types are: thermocouples, resistive temperature detectors (RTD's) Thermocouples Thermocouples consist of two electrical conductors made of different metals that are joined at one end. Changes in temperature at the measurement junction induce a change in electromotive force (emf) between the other ends. Refer to the International Temperature Scale of 1990 (ITS90) for standardized tables of temperature vs thermocouple emf valves. ISA and ASTM have designated letters for particular types of thermocouples. There are two groups, the base metal Industrial Training Report on NTPC, Dadri Page 18

thermocouples J, K, T, E and N and the precious metal thermocouples R, S and B. Each type has a characteristic emf vs temperature curve and application range. The EMF curve is very dependant on the composition of each conductor. Type J and K are the most widley used in industrial applications. Type J (iron vs copper-nickel(Constantan)) is versatile in that it can be used in both oxidizing and reducing atmospheres up to 1,400F. Iron rusts at low temperatures where condensation can form. Type K (nickel-chromium(Chromel) vs nickelaluminum( Alumel)) can be used up to 2,300F in an oxidizing or inert atmosphere. Type K thermocouples exhibit a number of instabilities and inaccuracies, particularly at higher temperatures, changing their emf/temperature characteristics. In reducing atmospheres (lack of oxygen) at temperatures of 1,500 to 1,750F the positive thermoelement forms a greenish chromic oxide, commonly known as "green rot". This causes a decrease in the electromotive force of the thermocouple. Type K is also subject to aging when exposed to 800 to 1,200F for a few hours. Temperature cycling above 1,400F and then below 700F causes a random error due to changes in the composition (inter-granular structure) of the conductors.

Resistive Temperature Detectors (RTD's)

RTD's contain a sensing element whose resistance changes with temperature. The sensors are usually packaged so they can be placed into a position in the process where it can reach the same temperature. Platinum wire or film RTD's are the most common type in use today. Platinum RTD's are used to measure temperatures from -450 F to 1200 F.

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The signal transmission system can have a negative effect on the accuracy and reliability of the temperature signal. This is true for thermocouples and RTDs. Thermocouple signals must be transmitted via thermocouple extension wire made from the same material as the thermocouple elements. Use of wire materials other than the thermocouple materials will result in errors where the ambient temperature changes. Voltage drops could also develop which would cause additional errors.

RTD extension wire can cause an error because the resistance of the wire is added to the sensor resistance. 3 and 4 wire RTDs have compensating leads that can be used to eliminate the wire resistance.

2) Pressure : Pressure Sensors:

Figure 6: Different pressure sensors Industrial Training Report on NTPC, Dadri Page 20

3) Flow : Some typical head meters are described briefly in the following:

a) Orifice: An orifice plate is a restriction with an opening smaller than the pipe diameter which is inserted in the pipe; the typical orifice plate has a concentric, sharp edged opening, as shown in Figure 1. Because of the smaller area the fluid velocity increases, causing a corresponding decrease in pressure. The flow rate can be calculated from the measured pressure drop across the orifice plate, P 1-P3. The orifice plate is the most commonly used flow sensor, but it creates a rather large nonrecoverable pressure due to the turbulence around the plate, leading to high energy consumption (Foust, 1981).

b) Venturi Tube: The venturi tube shown in Figure 2 is similar to an orifice meter, but it is designed to nearly eliminate boundary layer separation, and thus form drag. The change in cross-sectional area in the venturi tube causes a pressure change between the convergent section and the throat, and the flow rate can be determined from this pressure drop. Although more expensive that an orifice plate; the venturi tube introduces substantially lower non-recoverable pressure drops (Foust, 1981).

Figure 7. Venturi flow meter Industrial Training Report on NTPC, Dadri Page 21

c) Flow Nozzle: A flow nozzle consists of a restriction with an elliptical contour approach section that terminates in a cylindrical throat section. Pressure drop between the locations one pipe diameter upstream and one-half pipe diameter downstream is measured. Flow nozzles provide an intermediate pressure drop between orifice plates and venturi tubes; also, they are applicable to some slurry systems. d) Elbow meter: A differential pressure exists when a flowing fluid changes direction due to a pipe turn or elbow, as shown in Figure 3 below. The pressure difference results from the centrifugal force. Since pipe elbows exist in plants, the cost for these meters is very low. However, the accuracy is very poor; there are only applied when reproducibility is sufficient and other flow measurements would be very costly.

Figure 8. Elbow flow meter.

CONTROL VALVES

A valve is a device that regulates the flow of substances (either gases, fluidized solids, slurries or liquids) by opening, closing , or partially obstructing various passageways. Industrial Training Report on NTPC, Dadri Page 22

There are three types of valves that are used in power industries besides the handle valves. They are: Pneumatic Valves they are air or gas controlled which is compressed to turn or move them. Hydraulic valves they utilize oil in place of Air as oil has better compression. Motorized valves these valves are controlled by electric motor.

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CONCLUSION
As I have been undergoing training, I was able to know the practical application of theory what I used to study from books. With trainings help understood that studies helps us to know things but practical helps to apply theories for betterment of Human kind. I would like to give special thanks to the NTPC DADRI staff for their cordial support for making the training a success.

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REFERENCES

1) www.ntpc.co.in 2) http://www.wxboiler.com/english/cpjs_1.htm 3) Power Plant Familiarization by Power Management Institute, Noida 4) http://www.temperatures.com`

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