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AKNOWLEDGMENT
With profound respect and gratitude ,I take the opportunity to convey my thanks to complete the training here .I am extremely grateful to all the technical staff of BTPS/NTPC for their cooperation and guidance that has helped me a lot during the course of training .I have learnt a lot working under them and I will always be indebted of them for this value addition in me .I would like to thanks the all the faculty members of Mechanical And Automation Engineering Department for their effort of constant cooperation which have been a signification factor in the accomplishment of my industrial training
CERTIFICATE
This is to certify that GAURAV BHARDWAJ ,Student of final year B. tech Mechanical And Automation Engineering, Amity School Of Engineering And technology, has been successfully completed his Industrial Training at NATIONAL THERMAL POWER CORPORATION, NEW DELHI from 20th May to 29th June 2013. He has competed the whole training as per the training report submitted by him
TRAINING INCHARGE
NTPC, Badarpur, NEW DELHI
TRAINING AT NTPC
I was appointed to do 3 week training at this esteemed organization from 18th may to 6th June; 2013.I was assigned to visit various of the plant, which were:
Boiler Maintenance Department (BMD I/II/III) Primary Auxiliary Maintenance (PAM) Turbine Maintenance Department (TMD) Coal Handling Department (CHD)
These 6 weeks training was a very educational venture for me .It was really amazing to see the plant by yourself and learn how electricity , which is one of our daily requirement of life ,is produced. This report has been made by my experienced at NTPC .The material in this report has been gathered from my textbook ,senior student reports and trainers manuals and power journals provided by training department .The specification and principles are as learned by me from the employees of each division of NTPC
INDEX
ABOUT NTPC ABOUT BTPS ABOUT STEP OF ELECTRICITY GENERATION RANKINE CYCLE BOILER MAINTENANCE DIVISION PRIMARY AUXILIARY DEPARTMENT TURBINE MAINTENACE DIVISION COAL HANDLING DEPARTMENT
ABOUT NTPC
NTPC Limited is the largest thermal power generation company of india ,public sector company.It was incorporated in the year 1975 to accelerate power development in the country as a wholly owned company of the government of india holds 70% of the total equity shares of the company and the balance 30% is held by FIIs,domestic banks, public and others.Within a space of 38 years,NTPC has emerged as a truly national power company,with power generation facilities in all the major regions of the country. NTPCs core business is engineering,construction and operation of power generation plants and providing consultancy to power utility in india and abroad. The total installed capacity of the company is 41184 MW(including JVs) with 16 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 to have a diversified fuel mix with coal based capacity of around 53000MW, 1000MW through gas, 9000MW through hydro generation ,about 2000MW from nuclear sources and around 1000MW from Renewable Energy Sources.NTPC has adopted a multi-pronged growth strategy which includes capacity addition through Greenfield projects,expansion of existing station ,joint ventures, Subsidiaries and takeover of stations
TOTAL CAPACITY IN MW
41184 NTPC REST OF INDIA 159816
Technological Initiatives Introduction of steam generatio(boilers)of size of 800 MW. Integrated gasification combined cycle(IGCC)technology. Launch of Energy Technology Centre-A new initiative for development of technologies with focus on fundamental R&D. The company sets aside up to 0.5% of the profits for R&D. Roadmap developed for adopting Clean Development. Mechanism to help get Certified Emission Reduction. Corporate Social Responsibility As a responsible corporate citizen NTPC has taken up number of CSR initiatives. NTPC Foundation forms to address Social issues at national level NTPC has framed corporate Social Responsibility guidelines committing us to 0.5% of net profit annually for community welfare.
The welfare of project affected persons and the local population around NTPC projects are taken care of through well drawn Rehabilitation and Resettlement policies. The company has also taken up distributed generation for remote rural area centre for Power Efficiency &Environment protection. Group on clean Development Mechanism. NTPC is the second largest owner of trees in the country after the forest department JOURNEY OF NTPC NTPC was set up in 1975 with 100% ownership by the government of india .In the last 30 years ,NTPC has grown into the largest power utility in indai. In 1975,Government of india granted NTPC status of navratnabeing one of the nine jewels of india ,enhancing the powers to the board of directors. In 1997 NTPC became a listed company with majority government ownership of 89.5% In 2004 NTPC becomes third largest by market capitalization of listed companies The company rechristened as NTPC Limited in line with its changing business portfolio and transforms itself from a thermal power utility to an integrated power utility In 2005 NTPC is the largest power generation company in india . Forbes Global 2000 for 2008 ranked it 411th in the world. In 2008 NTPC is the largest power generation company in India.Forbes Global 2000 for 2008 ranked 317th in the world. NTPC has also set up a plan to achieve a target of 50,000 MW generation capacity. NTPC has embarked on plans to become a75,000 MW company by 2017 Partnering government in various initiatives Consultant role to modernize and improvise several plants across the country. Disseminate technologies to other players in the sector.
Consultant role partnership in excellence programme for improvement of PLF of 15 Power Stations of SEBs. Rural Electrification work under Rajiv Gandhi Garmin vidyutikaran. Environment Management All stations of NTPC are ISO 14001 certified Various group to care environmental issues,
ABOUT BTPS
Badarpur thermal power station started working in 1973 with a single 95MW unit. There were 2 more units (95 MW each) installed in next 2 consecutive years ,now it has total five units with total capacity of 720 MW .ownership of BTPS was transferred to NTPC with effect from 01.06.2006 through GOIs gazette notification given below are the details of unit with the year they are installed Address: Telephone: Fax: Installed Capacity Derated Capacity Location Coal Source Water source Beneficiary states Unit sizes Unit commissioned Badarpur,New Delhi-110044 (STD-011)-26949523 26949532 720 MW 705 MW New Delhi Jharia Coal Fields Agra Canal Delhi 3*95 MW 2*210 MW I-95 MW july 1973 II-95 MW-August 1974 III-95 MW March 1975
IV-210 MW December 1978 V-210 MW-December 1981 Transfer of BTPS to NTPC ownership of BTPS was transferred to NTPC With effect from 01.06.2006 through GOIs Gazette Notification
Coal
Superheated steam
Turbine torque
A C in STATOR
CHEMICAL ENERGY
THERMAL ENERGY
KINETIC ENERGY
ELECTRICAL ENERGY
Coal to steam
Coal from the coal wagons is unloaded in the coal handling plant. This coal is transported up to thr raw coal bunkers with the help of belt conveyors. Coal is transported to bowl mills by coal feeders. The coal is pulverized in the bowl mill, where it is ground to powder form .the mill consists of a round metallic table on which coal particles fall. This table is rotated with the help of a motor there are three large steel rollers,which are spaced 120 apart.when there is no coal these rollers do not rotate but when the coal is fed to the table it packs up between roller and the table and the forces the rollers to rotate .coal is crushed by the crushing action between the rollers and the rotating table. This crushed coal is taken away to the furnace through coal pipes with the help of hot and could air mixture from P.A. fan. P.A. Fan takes atm air ,a part of which is sent to Air-preheaters for heating while a part goes directly to the mill for temperature control Atmospheric air from F.D. fan is heated in the air heaters and sent to the furnace as combustion air. Water from the boiler feed pump passes through economizer and reaches the boiler drum. Water from thr drum passes through down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat and density difference , the water rises up in the water wall tube .water is partly converted to steam as it rises up in the furnace. This steam and water mixture is taken to thee boiler where the steam is separated from water
1.cooling tower 2.cooling water pump 3.transmission line 4.unit transformer 5.Electric generator 6.Low pressure turbine 7.condensate extraction pum 8.condensor 9.Intermediate pressure turbine
10.steam governor valve 11.High pressure turbine 12.Deaerator 13.feed heater 14.coal conveyor 15.coal hopper 16.Pulverised fuel mill 17.boiler drum 18.Ash hopper
19.superheater 20.Forced draught fan 21.Reeheater 22.Air intake 23.economiser 24.Air preheater 25.precipitator 26.Induced draught fan 27.chimeny stack
Water follows the same path while the steam is sent to superheaters for superheating .the superheaters are located inside the furnace and the steam is superheated (540C)and finally it goes to the turbine, Flue gases from the furnace are extracted by induced draft fan ,which maintains balance draft in the furnace(-5 to -10mm of wcl)with forced draft fan .these flue gases emit their heat energy to various super heaters in the pent house and finally pass through air-preheaters and goes to electrostatic precipitators where the ash particles are extracted .Electrostatic precipitator consists of metal plates, which are electrically charged. Ash particles are attracted on to these plates ,so that they do not pass through the chimney to pollute the atmosphere.
Regular mechanical hammer blows cause the accumulation of ash to the bottom of the precipitator where they are collected in a hopper for disposal.
On a large turbine ,it becomes economical to increase the cycle efficiency by using reheat, which is a way of partially overcoming temperature limitations. By returning partially expanded steam, to a reheat, the average temperature at which the heat is added ,is increased and ,by expanding this reheated steam to the remaining stages of the turbine, the exhaust wetness is considerably less than it would otherwise be conversely ,if the maximum tolerable wetness is allowed, the initial pressure of the steam can be appreciably increased. Bleed steam extraction:For regeneration system , nos. of non-regulated extractions is taken from HP, IP turbine Regenerative heating of the boiler feed water is widely used in modern power plants ;the effect being to increase temp. at which heat is added to the cycle , thus improving the cycle efficiency.
RANKINE CYCLE
The Rankine cycle is a thermodynamic cycle which converts heat into work. The heat is supplied externally to a closed loop, which usually uses water as the working fluid .this cycle generates about 80% of all electric power used throughout the world , including virtually all solar thermal ,biomass ,coal and nuclear power plants. It is named after William John Macquorn Rankine, a Scottish polymath.. Wetness is considerably less than it would otherwise be conversely, if the maximum tolerable wetness is allowed ,the initial pressure of the steam can be appreciably increased.
Bleed steam Extraction: For regenerative system, nos. of non-regulated extraction is taken from HP,LP turbine. Regenerative heating of the boiler feed water is widely used in modern power plants; the effect being to increase the average temperature at which heat is added to the cycle ,thus improving the cycle efficiency.
There are four processes in the rankine cycle,each changing the state of the working fluid . these states are identified by number in the diagram to the right
Process 1-2: The working fluid is pumped from low to high pressure , as the
fluid is aliquid at this stage the pump requires little input energy. Process 2-3: the high pressure liquid enters a boiler where it is heated at constant pressure by an external heat source to become a dry saturated vapour. Process 3-4: the dry saturated vapor expands through a turbine, generating power . this decreases the temperature and pressure of the vapor , and some condensation may occur. Process 4-1: The wet vapor then enters a condenser where it is condensed at a constant pressure and temperature to become a saturated liquid. The pressure and temperature of the condenser is fixed by the temperature of the cooling coils as the fluid is undergoing a phase change.
In this variation, two turbines work in series. The first accepts vapor from the boiler at high pressure. After the vapor has passed the first turbine, it reenters the boiler and is reheated before passing through a second , lower pressureturbine. Among other advantages, this prevents the vapor condensing improves the efficiency of the cycle
Regeneration
Preheats steam entering boiler using a feedwater heater, improving efficiency Also deaerates the fluid and reduces large volume flow rates at turbine exit. BOILER MAINTENANCE DEPARTMENT
Boiler and its description
The boiler is rectangular furnace about 50 ft on a side and 130 ft tall.Its walls are made of a web of high pressure steel tubes about 2.3 inches in diameter.pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the centre. The thermal radiation of the fireball heats the water that circulation rate in the boiler is three to four times the throughout and is typically driven by pumps .The water in the boiler circulates it absorbs heat and changes into steam at 370 C and 3,200 psi.
Specification of boiler
1. Steam temperature i. Drum 341 C ii. Super heater outlet 540 C iii. Reheat inlet 332C iv. Reheat outlet 540C 2. Steam pressure
i. ii. iii. iv. v. Drum design 158.20 kg/cm2 Drum operating 149.70kg/cm2 Super heater outlet 137.00kg/cm2 Reheat inlet 26.35 kg/cm2 Reheat outlet 24.50 kg/cm2
3.
iv.Ash 28% v.Grindability 55HGI vi. High heat 4860 kcal/kg vii.Coal size to mill 20mm (b)oil i. low heat value 10000 kcal/kg ii.Sulphur 4.5% w/w iii. moisture 1% w/w iv flash point 660 C v.Viscosity 1500 redwood at 37.80 C vi.Sp.weight 0.98 at 380C
2. BOILER DRUM
Drum is of fusion-welded design with welded hemispherical ends. It is provided with stubs for welding all the connecting tubes, i.e. downcomers, risers, pipes, saturated steam outlet. The function of steam drum internals is to separate the water from the steam generated in the furnace walls and to reduce the dissolved solid contents of the steam below the prescribed limit of 1ppm and also take care of the sudden change of stam demand for boiler.
4. SUPERHEATER
Whatever type of boiler is used, steam will leave the water at its surface and pass into the steam space. Steam formed above the water surface in a shell boiler is always saturated and become superheated in the boiler shell, as it is constantly. If superheated steam is required, the saturated steam must pass through a superheater. This is simply a heat exchange where additional heat is added to the steam
5. ECONOMIZER
The function of an economizer in a steam generation unit is to absorb heat from the flue gases and add as a sensible heat to the feed water before the water enters the evaporation circuit of the boiler.
6. AIR PREHEATER
Air preheater absorbs waste heat from the flue gases and transfer this heat to incoming cold air ,by means of continuously rotating heat transfer element of specially formed metal plates. Thousands of these efficiency elements are spaced and compactly arranged within 12 sections. Sloped compartments of a rotor is provided with duct connecting both the ends and is adequately by radial and circumferential scaling APH is the last heat exchanger in the boiler flue gas circuit. To achieve maximum boiler efficiency maximum possible useful heat must be removed from the gas before it leaves the APH. However certain minimum temperature has to be maintained in the flue gas to prevent cold end corrosion
PULVERIZER
A Pulverizer is a mechanical device for the grinding of many types of materials for example, they are used to pulverize coal for combustion in the steam- generation furnaces of the fossil fuel power plants
A ball mill is a pulverizer that consists of a horizontal cylinder, up to three diameter in length ,containing a change of tumbling or cascading steel balls, pebbles or steel rods. A tube mill is a revolving cylinder of up to five diameters in length used for finer pulverization of ore, rock and other such materials; the materials mixed with water is fed into the chamber from end, and passes out the other end .
ID Fans
The fan housing is sealed by means of two-part labyrinth seals. Bearings are lubricated with oil.
Classification
IMPULSE TURBINE REACTION TURBINE
Based on Compounding:
Pressure compounded Velocity compounded
IMPULSE TURBINE
An impulse turbine uses the impact force of the steam jet on the blades to turn the shaft. Steam expands as it passes through the nozzles, where its pressure drops and its velocity increases. As the steam flows through the moving blades, its pressure remains the same, but its velocity decreases. The steam does not expand as it flows through the moving blades.
REACTION TURBINE
In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles. This type of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor