ARAVALI POWER CORPORATION

PRIVATE LIMITED
INDIRA GANDHI SUPER THERMAL POWER PROJECT
JHAJJAR , HARYANA
A TRAINING REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF
THE DEGREE OF

BACHELOR OF TECHNOLOGY
(Mechanical & Automation Engineering)

SUBMITTED TO
AMITY UNIVERSITY, RAJASTHAN
SUBMITTED BY
Vijay Kumar
A20405413119
28-05-16 to 27-06-16

AMITY SCHOOL OF ENGINEERING & TECHNOLOGY

AMITY UNIVERSITY, RAJASTHAN

ARAVALI POWER CORPORATION

PRIVATE LIMITED
INDIRA GANDHI SUPER THERMAL POWER PROJECT
JHAJJAR , HARYANA
A TRAINING REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF
THE DEGREE OF

BACHELOR OF TECHNOLOGY
(Mechanical & Automation Engineering)

SUBMITTED TO
AMITY UNIVERSITY, RAJASTHAN
SUBMITTED BY
Vijay Kumar
A20405413119
28-05-16 to 27-06-16

AMITY SCHOOL OF ENGINEERING & TECHNOLOGY

AMITY UNIVERSITY, RAJASTHAN

ACKNOWLEDGEMENT
I would like to place on record my deep sense of gratitude to Er. Sarfaraj Ali, HR manager
and Ranbir Singh for vocational training for his support during the start of my training.
I express my sincere gratitude to Anil Sir, Water Treatment Manager for his stimulating
guidance, and continuous encouragement .
I also wish to extend my thanks to Er. B.L Thakur ,O.P Sharma, Rahul Sharma, Rinku Sir and
other workers for guiding and providing the knowledge related to machinery and processes.
I am extremely thankful to Dr. DD Shukla, Director, ASET, for encouragement and I am also
thankful to the faculty members of Mechanical & Automation Engineering department for
providing the opportunity to get the knowledge .

Signature of Student
Vijay Kumar (9896254423)

CERTIFICATE
I hereby certify that I have completed the Four weeks Training in partial fulfillment of the
requirements for the award of Bachelor of Technology in Mechanical & Automation
Engineering. I did my training at Indira Gandhi Super Thermal Power Station from 2805-16 to 27-06-16.

The matter presented in this Report has not been submitted by me for the award of any other
Degree elsewhere.

Signature of Student
Vijay Kumar (9896254423)

Signatures
Examined by:

SAMPLE SHEET

CERTIFICATE

This is to certify that Mr.___________________________ has

partially completed / completed / not completed the Training in our
Organization / Industry during the period 01-05-16 to 15-06-16. His
overall performance during the period was Excellent / Very Good /
Good / Average / Poor.

Signature & Seal of Training Manager

Note: This certificate must be typed on the company letter head.

Student must add Xerox of the certificate provided by the company

TABLE OF CONTENTS
Page No.

Acknowledgement
CHAPTER 1
ABOUT COMPANY

IGSTPP

PLANT LAYOUT

CHAPTER 2
STEAM GENERATOR

BOILER

BOILER ASSESORIES

11

STEAM CIRCULATION

17

CHAPTER 3
FUEL OIL SYSTEM

22

MILL

24

TYPE OF FUEL FIRING

27

ELECTROSTATIC PRECIPITATOR

29

FLUE GAS AND AIR PATH

32

CHAPTER 4
TURBINE

33

HP TURBINE

36

IP TURBINE

37

LP TURBINE

38

TURBOGENERATOR

38

CHAPTER 5

COOLING TOWER

40

DM WATER

42

COAL HANDLING

43

CHAPTER 1
ABOUT COMPANY
Indias largest power company, NTPC was set up in 1975 to accelerate
power development in India. NTPC is emerging as a diversified power
major with presence in the entire value chain of the power generation
business. Apart from power generation, which is the mainstay of the
company, NTPC has already ventured into consultancy, power trading, ash
utilization and coal mining. NTPC ranked 317th in the 2009, Forbes Global
2000 ranking of the Worlds biggest companies.

The total installed capacity of the company is 31,704 MW (including JVs)

with 15 coal based and 7 gas based stations, located across the country. In
addition under JVs, 3 stations are coal based & another station uses
naphtha/LNG as fuel. By 2017, the power generation portfolio is expected
1

to have a diversified fuel mix with coal based capacity of around 53000
MW, 10000 MW through gas, 9000 MW through Hydro generation, about
2000 MW from nuclear sources and around 1000 MW from Renewable
Energy Sources (RES). NTPC has adopted a multi-pronged growth strategy
which includes capacity addition through green field projects, expansion of
existing stations, joint ventures, subsidiaries and takeover of stations.
NTPC has been operating its plants at high efficiency levels. Although the
company has 18.10% of the total national capacity it contributes 28.60%
of total power generation due to its focus on high efficiency. In October
2004, NTPC launched its Initial Public Offering (IPO) consisting of 5.25% as
fresh issue and 5.25% as offer for sale by Government of India. NTPC thus
became a listed company in November 2004 with the government holding
89.5% of the equity share capital. The rest is held by Institutional Investors
and the Public. The issue was a resounding success. NTPC is among the
largest five companies in India in terms of market capitalization.

NTPC Ltd. has been named a Platts Top 250 Global Energy Company for
the year 2009. NTPC Ltd. was awarded the No.1 Independent Power
Producer (IPP) in Asia and No. 10 in overall performance among the energy

companies in Asia, by Platts, a division of the reputed Mc Graw-Hill

companies. NTPC has also been ranked as the No.2 Independent Power
Producer globally and No. 73 on overall global performance among energy
companies.

VISION
A world class integrated power major, powering India's growth with increasing
global presence.

MISSION

Develop and provide reliable power related products and services at competitive prices,
integrating multiple energy resources with innovative & Eco-friendly technologies and
contribution to the society. View of a well flourished power plant Core Values.
Business Ethics
Customer Focus
Organizational & Professional Pride
Mutual Respect & Trust
Innovation & Speed
Total Quality for Excellence

ABOUT IGSTPP:

Capacity

Stage I: 1500MW(3X500MW) Commissioned

Stage II: 1320 MW (2 x 660MW)- Future provision

Status

Mega Power Project

Equity Sharing

NTPC (50%), HPGCL (25%), IPGCL (25%)

Location

Site Jharli is 35 km from Jhajjar district of Haryana and 100 km (approx.) from Delhi.

Beneficiary

Haryana, Delhi, Himachal Pradesh, Jammu & Kashmir, Punjab, Rajasthan, Uttar Pradesh, Uttarakhand, Andhra
Pradesh, Kerala and Telangana.

Coal Linkage

As on date, coal linkage made from Mahanadi Coalfield Ltd.,Eastern Coalfield Ltd. & Northern Coalfield Ltd.

Water Source

Make up water from Jawahar Lal Nehru (JLN) feeder canal.

Power

Through two associated 400 KV Double Circuit transmission system to Daulatabad (Haryana) and Mundka

Evacuation

(Delhi).

A.
Special Feature

Drum type sub critical boiler Pressure 178 Kg/Sq cm and steam Temp 540 deg (MS) & 568 deg (RH).

B.

KWU turbine with Single reheats, having 17 stages in HP, 12X2 stages in IP and 6X2 stages in LP.

C.

Closed cycle cooling system with Natural Draft Cooling tower.

D.

Water being stored intwo reservoirs built on 350 Acresland and provided with HDPE lining. Each has
storage capacity of 35 Lac Cum.

E.

100% Dry Ash collection from ESP hoppers and disposal by High concentration Slurry Disposal
system (HCSD) and dry ash system.

F.

Ash water recirculation system is installed to re-use the ash slurry disposal over flow water

G.

RO Plant for recycling the waste water of station to ensure zero effluent discharge.

H.

The height of chimney is 275 meters.

STEAM GENERATOR
500 MW
Boiler also known as steam generator is used to convert water into steam
using the heat given by the fuel.
The plant uses super-critical steam generation, with water instantly being
converted into steam without passing through the boiling phase. The
boiler used has following unique features:Start up and low load system-separator and collecting vessel in place
of drum.
New materials for high temperature and pressure applications.
Larger size components for large unit sizes.
Furnace walls small tube diameters (spiral and vertical walls).

BOILER VERTICAL VIEW

BOILER SIDE VIEW

Technical Details of Boiler

Parameters

Stage-1

Main boiler type

Coal fired, Balanced draft , Corner

fired

Steam Temp./Pressure at SH
outlet

568
256Kg/cm2

Steam flow at SH outlet

2100T/Hr

Steam Temp./Pressure at RH

596

outlet

59.5Kg/cm2

Steam flow at RH outlet

1691T/Hr

No. of fans

2 Nos of ID, PA and FD fans

No. of mills

DETAILS OF MATERIALS IN 500 MW STEAM GENERATORS

Material

Composition

Temp Range

Used in

SA 210 C

C = 0.35%,Si =
1.06%,

289.7 0 C To 340.4
C

Economizer

304.9 0 C To 457.1 C

LTRH

P=0.048%,S=
0.058
SA209T12

SA
T23

Low alloy Steel, Low

Carbon 0.5% Mo

213 2.25%Cr, 1%Mo,

1.5%W

492 0 C To 540 C

LTRH, RH FINAL
SH FINAL, SH PLATEN

SA
T91

T22

213 9%Cr, 1%Mo,

0.25%Mn

2.25%Cr, 1%Mo

492 0 C To 540 C

RH FINAL, SH FINAL,
FC SPACER TUBES

340 0 C To 411.2 C

VERTICAL FURNACE
REAR WALL, SCREEN
FURNACE REAR
WALL,HGR, SPIRAL
WALL,FURNACE REAR
ARCH,

The boiler is having salient design features some of them are as following:Two pass.
9

Spiral and vertical wall water tubes

Single Reheat
Tangential corner Firing
Bowl Mills
Bisector Air Pre heater
Balanced draft system
Radiant dry system

Principle of Operation: This plant works on the rankine cycle. The water is
heated above its critical point so that it changes into steam without
boiling. Critical is a thermodynamic expression describing the state of a
substance beyond which there is no clear distinction between the liquid
and gaseous phase.

ADVANTAGES OF SUPERCRITICALTECHNOLOGY
The principal advantages of supercritical steam cycle are:
Reduced fuel costs due to improved thermal efficiency
Reduced CO2 emissions by about 15% compared with typical existing
sub critical plant
Well-proven technology with excellent availability, comparable with that
of existing sub critical plant
Very good part-load efficiencies, typically half the drop in efficiency
experienced by sub critical plant.

Supercritical Steam generation by once through

principle only
No latent heat on supercritical pressure.
Continuous transformation from a compressed liquid (temp <
374.16oC) to a gaseous state (temp > 374.16oC).
Therefore, supercritical boilers have to be once thru type.

10

Mass flow rate thru all heat transfer circuits from Eco. inlet to SH
outlet is kept same unlike drum type boilers except at low loads.
The fundamental difference lies in heat absorbing surface or
evaporation portion of the unit.

BOILER MAIN PARTS

Economizer: - The function of an economizer in a boiler is to absorb heat

from flue gases and used to heat feed water before the water enters into
evaporative circuit of boiler. This leads into the greater efficiency of the
boiler and also the temperature of flue gases decreases. The location of
the economizer is ahead of pre heater and following the super heaters and
reheaters.Water flow is from bottom to top so that steam if any formed
during the heat transfer can move along with water and prevent locking of
steam and hence over heating and failure of economizer tube.

Ring Header: - The function of ring header is to pass the water to spiral

water tubes by collecting from the economizer.

11

Separator: - The main work of the separator is to separate the wet steam
from dry steam. The wet steam is send to storage tank and the dry steam
to super heaters.

1. Storage Tank: - This is used to store the wet steam coming from

separator. The steam is then send to economizer for recirculation.

12

Super heater
Super Heater Arranged In 3 Stages:

Low Temperature Superheater (LTSH)

Radiant Pendent Type
Convective Final Super Heater
Super heater heats the high-pressure steam
temperature to a higher specified temperature.

from

its

Super heaters are often divided into more than one stage.
The enthalpy rise of steam in a given section should not exceed
o 250 420 kJ/kg for High pressure (> 17 MPa)
o < 280 kJ/kg for medium pressure(7 Mpa 17 MPa)
o < 170 kJ/kg for low pressure (< 7 MPa)

Platen Superheater
13

saturation

Platen Superheater: Flat panels of tubes located in the upper part of

the furnace, where the gas temperature is high.
The tubes of the platen SH receive very high radiation as well as a
heavy dust burden.
Mechanism of HT : High Radiation & Low convection
Thermal Structure:
No. of platens
No. of tubes in a platen
Dia of a tube
Length of a tube

Convective Superheater (Pendant)

Convective super heaters are vertical type (Pendant) or horizontal

types.
The Pendant SH is always arranged in the horizontal crossover duct.
Pendant SH tubes are widely spaced due to high temperature and ash
is soft.
Transverse pitch : S1/d > 4.5
Longitudinal pitch: S2/d > 3.5.
The outside tube diameter : 32 51mm
Tube thickness : 3 7mm

14

Desuperheater

The preferred location of desuperheater, especially for temperature

above 450C is between sections of superheater. The steam is first
passed through a primary superheater where it is raised to
intermediate temperature. It is then passed through the desuperheater
and its temperature reduction is controlled so that, after continuing
through the secondary or final stage of the superheater, the required
constant conditions are maintained at the outlet.

Low Temperature Reheater (LTRH)

Steam from the exhaust of the first stage turbine goes back to the boiler
for reheating and is returned to the second stage. Reheater coils in the
15

flue gas path does the reheating of the returned steam. The reheat steam
is at a much lower pressure than the super heated steam but the final
reheater temperature is greater than superheated steam temperature.
Reheating to high temperatures improves the output and efficiency of the
Power Plant. Final Reheater temperature is 596C for this boiler. Reheat
steam pressure is 59.5 Kg/cm2.

The pressure drop inside re-heater tubes has an important adverse

effect on the efficiency of turbine.
Pressure drop through the re-heater should be kept as low as possible.
The tube diameter : inlet 63.5*4 outlet 76.2*5.5

Reheate
r

Air Preheater
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 chimney at a lower temperature, allowing simplified
design of the ducting and the flue gas chimney. It also allows control over
the temperature of gases leaving the chimney (to meet emissions
16

regulations).The rotating-plate regenerative air preheaters consists of a

central rotating-plate element installed within a casing that is divided into
two (bi-sector type) .The seals allow the element to rotate through all the
sectors, but keep gas leakage between sectors to a minimum while
providing separate gas air and flue gas paths through each sector. The flue
gases are at a higher temperature after passing through the economizer.
The hot flue gases transfer their heat energy to the primary and secondary
air i.e. the temperature of flue gases decreases where as the temperature
of Primary Air and Secondary Air increases. 2 Air Preheater are used in this
boiler one to heat PA and the other to SA. The temperature of flue gas
decreases where as the temperature of PA increases.

Airpreheat
er

STEAM CIRCULATION SYSTEM

17

The feed water coming from boiler feed pump is first supplied at
economizer inlet header in which the feedwater is heated using the flue
gases remaining heat. The temperature of water increases from 291C to
305C. After that this heated water goes into economizer outlet header
from where it goes to the ring header or furnace lower header. The water
then flows through the spiral and vertical water tubes and heated up into
wet steam. Thereafter it goes into the separator. The wet steam is sent to
economizer through the storage tank for recirculation. The dry steam then
circulates through back pass sidewall tubes and back pass upper side wall
header. Then it circulates through the super heater platen assemblies and
super heater for super heating of steam above its critical temperature. The
super heated steam of temperature 540Cthe goes to high pressure
turbine for expansion. The steam after expansion again comes into boiler
for reheating. The steam is reheated into reheater assemblies up to
temperature of 568Cand then it is send to expand in intermediate and
low pressure turbines. After that the steam condenses into condenser and

18

then again fed to boiler using boiler feed pump and feed water regulatory
system.

Flow diagram of steam from Economizer to RH finish

ECONOMIZER INLET HEADER

PANELETTES

S.H. DIVISION

FURNACE VERTICAL WATERWALL

ASSEMBLIES

ECONOMIZER

TUBES

SEPARATORS

STORAGE

TANK

BACKPASS LOWER RING

HEADER
RECIRCULATION PUMP

BOILER

BACKPASS SIDEWALL TUBES

SIDEWALL

BACKPASS UPPER
HEADE

S.H. FINISHING ASSEMBLIES

ASSEMBLIES

S.H. PLATEN

S.H. FINISHING OUTLET PIPE

TEMP. INLET

R.H. LOW.
HEADER &

PIPE

19

R.H. LOW. TEMP. PENDANT

R.H. LOW. TEMP.

HORIZONTAL
ASSEMBLIES

ASSEMBLIES

R.H. FINISHING
OUTLET

R.H. FINISHING

ASSEMBLY

HEADER & PIPE

STEAM FLOW DIAGRAM

20

50

593

247
HPT

D
D

2.08

0.98
1

172.
1

LPH3

IP
T

565

LPH2

102.
2

L
P
T
B

0.37
7

LPH1

CONDENSER

GSC

CE
P

Drain
cooler

Steam line
PRESSURE
Feedwater line

Drip line
steam/water

21

TEMPERATURE

F
D

BOILER

H
A
C

75.9
1

53.2
0

23.93

DE
ARA
TO
R

480.4

382.
4

HPH8

334.
0

(I)

HPH7

HPH6

(I)

(I)

LPH
4

L
75.9
1

53.2
0

23.93

480.4
382.
4

HPH8
(II)

334.
0

HPH7

HPH6
(II)

( II)

TDBF
P

PRESSURE
TEMPERATURE

22

FUEL OIL SYSTEM

Purpose: (a) to establish initial boiler light up. (b) To support the furnace
flame during low load operation.
Fuel oil system consists of
Fuel oil Pumps
Oil heaters
Filters
Steam tracing lines
Objective is to get filtered oil at correct pressure and temperature.

Oil Burners
The types of oil used in the oil burners are:
a) Light Diesel Oil

23

b) Heavy fuel oil

c) Low sulpher heavy stock (LSHS).
Heavy oil guns are used for stabilizing flame at low load carrying. Warm up oil
guns are used for cold boiler warm up during cold start up and igniter are used
for start up and oil flame stabilizing.

Coal Mill & Feeder

The Major components are:Coal Preparation Equipments
Feeders
Mills
Coal Firing Equipments
Burners

24

MILLS
The coal is pulverized using bowl mills so that it can be used in the boiler
furnace. Total 9 mills are used in this boiler, 4 on one side and 5 on the
other side of the boiler .these mills are arranged upto 9 elevation .the coal
coming through the conveyer belt goes into bowl mill where it is
pulverized upto 200 mesh. Then it is blown up using the hot primary air
supplied from PA Fan. Then this coal is fed into the boiler from four corners
with the help of four outlet pipes from the bowl mill. The air required for
burning of coal is provided by wind box on which the hot secondary air is
supplied from the Air Preheater.

Location of Coal Nozzle:

Coal
nozzle

Height

25.766M

27.267M

28.768M

30.269M

31.770M

33.271M

34.772M

36.273M

37.773M

TOP OF WIND BOX EL 39.678M

For startup and temperature maintaince oil burners are used in the boiler. 20 oil
guns are placed upto five elevations resulting in four oil guns at each elevation.

25

Location of Oil Gun:

Oil gun

Elevation

26.517M

28.018M

31.020M

34.022M

37.024M

PULVERISER DATA

Type of mill:

Bowl Mill

Size of mill:

HP 1103

No. of mills provided per boiler:

9 (Nine)

Mill motor rating/Speed (Kw/rpm ):

696 / 1000

PF fineness required (% thru mesh):70 % thru 200 mesh &98 % thru

50 mesh
Mill outlet temperature range:

Deg C 66 to 90

Features of Bowl Mills

Grinding chamber
Classifier mounted above it
Pulverization takes place in rotating bowl
Rolls rotating free on journal do the crushing
Heavy springs provide the pressure between the coal and the rolls
Rolls do not touch the grinding rings

26

Tramp iron and foreign material discharged.

Role of Mills
Produces Pulverized coal 80% of which passes through 200 mesh

Air mixed with Pulverized coal (PF) is carried to the coal nozzle in the
wind box assembly.
PF from coal nozzle is directed towards the centre of boiler burning
zone
Pre-heated secondary air enters boiler and surrounds the PF and help
in combustion

Bowl mill

27

Methods of Fuel Firing

Vertical Firing: A number of rectangular fan shaped nozzles are set

across the width of the furnace in an arch. Pulverized fuel mixture ignites
under the arch and is directed vertically downwards to the bottom of the
furnace where the gases are made to turn upwards to pass through the
combustion chamber this gives a long path to the flame and is particularly
suitable for coals of low volatile content.

Horizontal Firing: Horizontal firing with the turbulent type of burner

is set up usually in the front (front wall fired) or rear walls of the furnace.
Burner consists of an inner cone for primary air and fuel which is given a
rotary motion as it passes through the burner.

Impact Firing: This is the arrangement with the type of burner used
with slag tap furnaces where the ash is kept in a molten state on the
furnace floor and tapped off as and when necessary.

Corner or tangential Firing: Burners are set at each corner of the

furnace and are directed to strike the outside of an imaginary circle in the
centre of the furnace.

28

Tangential firing

DRAFT SYSTEM

Most boilers now depend on mechanical draft equipment rather than natural
draft. This is because natural draft is subject to outside air conditions and
temperature of flue gases leaving the furnace, as well as the chimney height. All
these factors make proper draft hard to attain and therefore make mechanical
draft equipment much more economical.
There are three types of mechanical draft:
Induced draft: This is obtained one of three ways, the first being the "stack
effect" of a heated chimney, in which the flue gas is less dense than the
ambient air surrounding the boiler. The denser column of ambient air forces
combustion air into and through the boiler. The second method is through

29

use of a steam jet. The steam jet oriented in the direction of flue gas flow
induces flue gasses into the stack and allows for a greater flue gas velocity
increasing the overall draft in the furnace. This method was common on
steam driven locomotives which could not have tall chimneys. The third
method is by simply using an induced draft fan (ID fan) which removes flue
gases from the furnace and forces the exhaust gas up the stack. Almost all
induced draft furnaces operate with a slightly negative pressure.
Forced draft: Draft is obtained by forcing air into the furnace by means of a
fan (FD fan) and ductwork. Air is often passed through an air heater; which,
as the name suggests, heats the air going into the furnace in order to
increase the overall efficiency of the boiler. Dampers are used to control the
quantity of air admitted to the furnace. Forced draft furnaces usually have a
positive pressure.
Balanced draft: Balanced draft is obtained through use of both induced
and forced draft. This is more common with larger boilers where the flue
gases have to travel a long distance through many boiler passes. The
induced draft fan works in conjunction with the forced draft fan allowing the
furnace pressure to be maintained slightly below atmospheric.
In this boiler balanced draft system is used both ID Fan and FD Fan are used in
this boiler for this type of system.

Induced Draft Fan. The hot flue gases from the furnace are drawn out by the
Induced draft fan. The gases pass through the various heating surfaces of the
boiler, the Electrostatic Precipitator and discharges to the atmosphere at the top
of the stack. Induced Draft Fan provides the energy for this flow of flue gases. The
Induced

Draft

Fan

is

normally

located

adjacent

to

the

Stack.

Forced Draft Fan supplies most of the Combustion air. This fan takes air from the
atmosphere and blows it into the furnace through air ducts. The Air Heater heats
the air before it enters the Furnace.

30

ASH HANDLING SYSTEM :

ELECTROSTATIC PRECIPITATOR

The ash content in the Indian coal is of the order of 30 to 40%. When coal is fired
in boiler, ashes are liberated and about 90% of coal is carried out by flue gases. If
these gases are allowed in atmosphere it will create an air pollution and hence
health hazards. Hence it is necessary to precipitate the dust from flue gas and in
this process electrostatic precipitator finds a place in boiler.

The additional advantage obtained because of ESP is that the wear of I.D. Fan
blades is reduced due to precipitation of dust. The ESP is efficient in precipitation
of particles from submicron to large sizes of particles and hence they are
preferred to mechanical precipitators. These dust-laden gases pass through an
electrostatic precipitator that collects most of the dust. Cleaned gas then passes
out of the precipitator and through a stack to the atmosphere. Precipitators
typically collect 99.9% or more of the dust from the gas stream. Precipitators
function by electro statically charging the dust particles in the gas stream. The
charged particles are then attracted to and deposited on plates or other
collection devices. When enough dust has accumulated, the collectors are shaken

31

to dislodge the dust, causing it to fall with the force of gravity to hoppers below.
The dust is then removed by a conveyor system for disposal or recycling.
Discharge electrodes emit charging current and provide voltage that generates
an electrical field between the discharge electrodes and the collecting plates. The
electrical field forces dust particles in the gas stream to migrate toward the
collecting plates. The particles then precipitate onto the collecting plates.
Collecting plates are designed to receive and retain the precipitated particles
until they are intentionally removed into the hopper. Collecting plates are also
part of the electrical power circuit of the precipitator. These collecting plate
functions are incorporated into the precipitator design. Plate baffles shield the
precipitated particles from the gas flow while smooth surfaces provide for high
operating voltage. Collecting plates are suspended from the precipitator casing
and form the gas passages within the precipitator.

32

FLUE GAS AND AIR PATH

Ash is the inert matter in coal and is the residue after combustion. This has to be collected and
disposed off without letting it out into the atmosphere. A part of the ash, around 15 % collects
as Bottom ash at the bottom of the furnace. The other part collects as Fly ash in the
Electrostatic Precipitators. The flue gas is then passed to I.D. Fan and then from there to the
chimney for discharging it in the atmosphere.
33

34

TURBINE
A turbine is a rotary engine that extracts energy from a fluid flow and
converts it into useful work. A working fluid contains potential energy
(pressure head) and kinetic energy (velocity head). The fluid may be
compressible or incompressible. Several physical principles are employed
by turbines to collect this energy. The turbine is of two types:

Impulse turbines -These turbines change the direction of flow of a high

velocity fluid or gas jet. The resulting impulse spins the turbine and leaves
the fluid flow with diminished kinetic energy. There is no pressure change
of the fluid or gas in the turbine rotor blades (the moving blades), as in the
case of a steam or gas turbine; the entire pressure drop takes place in the
stationary blades (the nozzles). Before reaching the turbine, the fluid's

35

pressure head is changed to velocity head by accelerating the fluid with a

nozzle. Newton's second law describes the transfer of energy for impulse
turbines.

Reaction turbines -These turbines develop torque by reacting to the gas

or fluid's pressure or mass. The pressure of the gas or fluid changes as it
passes through the turbine rotor blades. The casing contains and directs
the working fluid and, for water turbines, maintains the suction imparted
by the draft tube. Newton's third law describes the transfer of energy for
reaction turbines.

But both turbines have some shortcomings the impulse turbine cannot be
used due to following reasons:-

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As the steam flows through the nozzle its pressure falls from inlet
pressure to the exit pressure (atmospheric pressure, or more usually,
the condenser vacuum). Due to this higher ratio of expansion of
steam in the nozzle the steam leaves the nozzle with a very high
velocity. The steam leaving the moving blades is a large portion of the
maximum velocity of the steam when leaving the nozzle.
The enthalpy drop is in the nozzle hence the rotor velocity is very high
such a high velocity cannot be used for electricity production.

Hence the turbine used in this plant is both impulse and reaction type. The
turbine used in STAGE-1 is having four turbine casings. One high pressure
casing, one intermediate pressure casing and two low pressure casings.

Design and operation data

Turbine Designation: K 660-247 {K = Condensing, 660MW & 247=

Continuous rating pressure}
Manufacturer:
Type of blading:
Number of turbine cylinders
o HPC:
o IPC:

LMZ
impulse and reaction
1
1
37

LPC:

Type of arrangement:
Tandem
Directly coupled to generator
Type of governing:
Nozzle governing
CRITICAL Speeds:
820, 1360, 1753, 1812, 2386, 3950, 4180 RPM

HP Turbine

The super heated steam coming from the boiler expands into the high
pressure turbine in total 17 stages. The steam expansion occurs in single
flow and the in series i.e. the steam expands firstly in 9 stages then in 8
stages. The extraction of steam is done after 13th stage and at exhaust for
heating the feed water through HPH7 and HPH8.

o Temp of steam at inlet:

540C

o Temp of steam at outlet:

296.76C

o Pressure of steam at inlet:

247 Ksc

o Pressure of steam at outlet:

47.62 Ksc

o Number of regenerative stages: 2

o Number of impulse stages:

o Number of reaction stages:

16

o First regenerative stage:

13th stage extraction to HPH8.

o Second regenerative stage:

from HPT exhaust to HPH7.

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IP Turbine
The super heated steam after expansion in HPT is send to boiler for
reheating. The reheated steam then expands in intermediate pressure
turbine in 22(11*2) stages. The expansion occurs in double flow.

o Temp of steam at inlet:

568C

o Temp of steam at outlet:

212C

o Pressure of steam at inlet:

42.85Ksc

o Pressure of steam at outlet:

3.10Ksc

o Number of regenerative stages: 4

o Number of impulse stages:

11*2

o Number of reaction stages:

None

o First regenerative stage:

3rd stage extraction to HPH6.

o Second regenerative stage:

6th stage to dearator.

o Third regenerative stage:

8th stage extraction to LPH4.

o Fourth regenerative stage:

From IPT exhaust to LPH3.

LP Turbine

The reheated steam after expanding in IPT goes into two LPTs for further
expansion. The low pressure turbine is double flow and each LP turbine
consist 10(5*2) stages.

o Temp of steam at inlet:

212.59C
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o Temp of steam at outlet:

49.05C

o Pressure of steam at inlet:

3.10 Ksc

o Pressure of steam at outlet:

0.104 Ksc

o Number of regenerative stages: 2

o Number of impulse stages:

(5*2)*2

o Number of reaction stages:

o First regenerative stage:

None
3rd stage extraction to LPH2.

o Second regenerative stage:

4th stage extraction to LPH1

GENERATOR

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The A.C. generator is based upon on the principle of electromagnetic

induction and consist of a stationary part called stator and a rotating part
called rotor. The rotor carries a magnetic field which rotates as the rotor
turns within the stator. This causes electrical current to be generated in
copper windings. The use of gaseous hydrogen as a coolant is based on its
properties, namely low density, high specific heat, and highest thermal
conductivity at 0.168 W/(mK) of all gases; it is 7-10 times better coolant
than air. Hydrogen gas is circulated in a closed loop within the generator to
remove heat from its active parts; then it is cooled by gas-to-water heat
exchangers that are part of the stator frame. A hydrogen-cooled generator
can be significantly smaller, and therefore less expensive, than an aircooled one. For stator cooling water can be used in the stator. The energy
flows from the generator to a transformer where the voltage is increased
before sending the power out to the customer. Helium with a thermalconductivity of 0.142 W/(mK) was considered as coolant as well, however
its high cost hinders its adoption despite its non-flammability. Hydrogen
has very low viscosity, a favorable property for reducing drag losses in the
rotor; these losses can be significant, as the rotors have large diameter
41

and high rotational speed. Every reduction in the purity of the hydrogen
coolant increases windage losses in the turbine; as air is 14 times denser
than hydrogen, each 1% of air corresponds to about 14% increase of
density of the coolant and the associated increase of viscosity and drag. A
purity drop from 97 to 95% in a large generator can increase windage
losses by 32%; this equals to 685 kW for a 907 MW generator. The
windage losses also increase heat losses of the generator and the
associated cooling problems. The flammability limits (4-93) % of hydrogen
in air at normal temperature, wider at high temperatures, its auto ignition
temperature at 571C, its very low minimum ignition energy, and its
tendency to form explosive mixtures with air, require provisions to be
made for maintaining the hydrogen content within the generator above
the upper or below the flammability limit at all times, and other hydrogen
safety measures. When filled with hydrogen, overpressure has to be
maintained as inlet of air into the generator could cause a dangerous
explosion in confined space.

o Stator is water cooled

o Rotor is hydrogen cooled
o Voltage rating 24 KV
o Current rating 32.352 K amp.
o Rated/ max. Output 776.5 MVA/ 660 MW
o Max. Continuous Output 808.4 MVA/ 687.1 MW
o Terminal voltage 24 KV
o Terminal current 18680 Amperes

COOLING TOWERS
The steam extracted from the low pressure turbine must be cooled down
before it can be used again in the boiler. The volume of the steam coming
42

from the turbine is very large so a lot work needs to be done if this has to
be pumped again in the boiler. The cooling of steam is done by using the
water coming through the C.W. pump. The water flows through the tubes
in the condenser and get heated up cooling the circulating steam.
The cooling tower is consists of large fans at the top an the hot water is
sprayed under it , it is break down into small droplets using the fins that
are made of PVC. Every unit has two towers and each tower has 12 fans.

o The temperature reduction in each tower 10.2 degrees

o Capacity of each tower = 40000 cusec
o Number of outlet pipe from condenser = 4

The cold water is supplied from cooling tower through a circulating water
channel. The six motors used in C.W. pump house provide the required
head to water to come through the condenser at cooling tower. The water

43

is supplied by four pipes at the condenser outlet and it is assembled into

and at cooling tower only one pipe of discharge 3750 cubic cm remains.

The C.W. Pump house has pumps .These pumps are used to provide the
head to the cold water to circulate through the condenser and pass
through the cooling tower.

D.M.WATER SYSTEM
Demineralization or Deionization is the process of removing mineral salts
from water by using the ion exchange process. With most natural water
44

sources it is possible to use Demineralization and produce water of a

higher quality than conventional distillation.

COAL HANDLING PLANT

45

The overall layout of the CHP is mentioned below:1. Wagon tripper unloads the coal from the railway wagons into the
storage space for the coal.
2. There are two types of railway wagons which are used to supply coal
in the power plants. One type of wagon opens from the bottom to
unload the coal and the other type of the wagon has to be inverted
sideways by the wagon tripper.
3. The wagon tripper which is used at NTPC Barh has the capacity of 24
tips per hour.
4. Dust extraction and dust compression is performed before the initial
point of the conveyor.
5. Dust extraction means to remove the coal dust from the coal to be
sent to the conveyor.
6. Dust suppression means to deposit the dust bye suppressing it
before the coal is fed into the conveyor.
7. Any extra coal, if comes, is led into the stacker from which the coal
is used in case of shortage.
8. Then the coal is loaded on the conveyor.
9. The conveyor has the following specifications:Length - 450 meters
Width 50 meters

46

Height 30 meters
Inclination 14 degrees
10.

The optimum inclination is 14 degrees since if the angle of

inclination is kept more than 14 degree the backflow of the coal

comes into existence.
11.

Conveyor moves with 3.2 meter per second.

12.

Pedal feeder is placed at the point of unloading of the coal

from the wagons.

13.

Pedal feeder has the capacity of 2400 metric tones per hour.

14.

Pedal feeder is a fan like structure with scoops which loads the

coal from the coal house onto the conveyor.

15.

Then the coal is fed into the crusher house where the coal is

crushed to a size of the order of 20 mm.

16.

Then the coal is supplied to the bunker where the unloading of

the coal takes place.

17.

There are bunkers on two sides for each boiler; five on one

side and four on the other side.

18.

There are mills in each bunker and these mills serve the

purpose of pulverization of the coal to a size of the order of microns

or it can be said to be of the size of the talcum powder.
19.

In the conveyor belt, there are various TP (transfer point)

wherever the direction of the conveyor has to be changed.

20.

Conveyor moves in both the directions, i.e. forward as well as

backward.
21.

VGF (Vibrating grizzly feeder) is used for the filtering of the

47

coal of a particular size.

22.

CSU (Coal Sampling Unit) is used to check the quality of the

coal which has come from the railway wagons. Coal is of two grades
A grade and B grade.
23.

ILMPS (Inline Magnet Particle Separator) - It is magnetized by

the electric current and it is used to extract the magnetic particles

from the coal mixture.

48