Industrial Training Report on

“THERMAL POWER PLANT”

Submitted by

SHASHANK JHA

Enrolment no: 06514803615

At
Maharaja Agrasen Institute of Technology
Sec-22, Rohini
New Delhi
TRAINING CERTIFICATE
 ACKNOWLEDGEMENT

I have taken efforts in this project. However, it would not have been
possible without the kind support and help of many individuals. I would
like to extend my sincere thanks to all of them.

I am highly indebted to Mr. Abhishek Khatri, my project manager, for

his guidance and constant supervision as well as for providing necessary
information regarding the project & also for his support in completing the
project.

I would also like to express my gratitude towards Mr. Rajan Mishra and
Mr. Satyabhan Kumar for their kind co-operation and encouragement
which helped me in completion of this project.
 CONTENTS

COVER PAGE

TRAINING CERTIFICATE

ACKNOWLEDGEMENT

ABOUT THE COMPANY

INTRODUCTION TO GAS
PLANTS AND CYCLES

COMBINED-CYCLE POWER
PLANT

GAS TURBINE AND STEAM

TURBINE

COOLING TOWERS AND

THEIR TYPES
 ABOUT THE COMPANY

(I) Overview of NTPC :

NTPC was set up in the central sector in the 1975 in response to widening
demand & supply gap with the main objective of planning, promoting &
organizing an integrated development to thermal power in India. Ever
since its inception, NTPC has never looked back and the corporation is
treading steps of success one after the other. The only PSU to have
achieved excellent rating in respect of MOU targets signed with Govt. of
India each year. NTPC is poised to become a 40,000 MW gint corporation
by the end of XI plan i.e. 2012 AD.

Lighting up one fourth of the nation, NTPC has an installed capacity of

19,291 MW from its commitment to provide quality power; all the
operating stations of NTPC located in the National Capital Region &
western have acquired ISO 9002 certification. The service groups like
Engineering, Contracts, materials and operation Services have also
bagged the ISO 9001 certification. NTPC Dadri, Ramagundam,
Vindhyachal and Korba station have also bagged ISO 14001 certification.

Today NTPC contributes more than 3 / 5th of the total power generation
in India.
(II) Station At A Glance :

NTPC, Dadri is a model project of NTPC. It is also the best project of

NTPC till now known as NCPS (National capital power station). It is
situated 60 km away from Delhi in the District of Gautam Budh Nagar,
Uttar Pradesh.

The station has an installed capacity of 1669 MW of power – 840 MW

from Coal based units and 829 MW Gas Based Station. The station is
excelling in performance ever since its commercial operation.
Consistently in receipts of meritorious project awards, the coal based units
of the station stood first in the country in terms of PLF for the financial
year 1999 – 2000 by generating an all-time high national PLF of 96.12 %
with the most modern O & M Practices. NTPC–Dadri is committed to
generate clean and green Power.

The station also houses the first HVDC station of the country (GEP
project) in association with the center for Power efficiency and
Environment protection (CENEEP) – NTPC & USAUID.
 1. Introduction To Gas Power Plants

Introduction

The development of the sector in the country, since independence has been
predominantly through the State Electricity Boards. In order to supplement
the effects of the states in accelerating power development and to promote
power development on a regional basis to enable the optimum utilization
of energy resources, the Government of India decided to take up a
programme of establishment of large hydro and thermal power stations in
the central sector on a regional basis. With this in view, the Government
set up the National Thermal Power Corporation Ltd., in November 1975
with the objective of planning, construction, commissioning, operation
and maintenance of Super Thermal and Gas Based Power projects in the
country.

The availability of gas in a large quantity in western offshore region has

opened an opportunity to use the gas for power generation, which is an
economical way and quicker method of augmenting power generating
capacity by natural gas as fuel in combined cycle power plant in a power
deficit country like ours. With this intention in mind the Government asked
NTPC to take up the construction of Kawas, Auraiya, Anta, Dadri and
Gandhar Gas Power Project along the HBJ Gas pipe line.

The power plant consists of gas turbine generating unit waste heat
recovery boilers, steam turbo generator, ancillary electrical and
mechanical equipment. The power generated at this power station is fed
over 220 KV AC transmission system associated with this project to
distribute the power in the various Regions.
In the Power Sector, gas turbine drive generators are used.

Gas turbines range in size from less than 100 KW up to about 140.000
KW. The gas turbine has found increasing application due to the following
potential advantages over completive equipment.

• Small size and weight per horsepower

• Rapid loading capability
• Self-contained packaged unit
• Moderate first cost
• No cooling water required
• Easy maintenance
• High reliability
• Waste heat available for combined cycle application.
• Low Gestation Period
• Low Pollution Hazards
 2. COMBINED CYCLE
Combined Cycle power plant integrates two power conversion cycles
namely. Brayton Cycle (Gas Turbines) and Rankin Cycle (Conventional
steam power plant) with the principal objective of increasing overall plant
efficiency.

2.1 Brayton Cycle

This cycle was named after George Brayton who describes the working
of a constant-pressure heat engine. The original Brayton engines used a
piston compressor and piston expander, but more modern gas turbine
engines and air breathing jet engines also follow the Brayton cycle.
 2.2 Rankine Cycle
The Rankine cycle is a vapor power cycle that forms the
thermodynamic basis for most steam power plants. These plants may
use coal, oil, gas, or nuclear power as fuel for a high temperature
source, but the basic thermodynamic operation remains fairly constant.

The gas of choice for most Rankine cycles is steam. The system operates
on the premise that the easiest way to make high pressure steam is to start
with high-pressure water and then heat that water at constant pressure.
2.3 Combining two Cycles to Improve Efficiency

We have seen in the above two cycles that gas turbine exhaust is at a
temperature of 500–550 0C and in Rankine Cycle heat is required to
generate steam at the temperature of 500-550 0C. So, why not use the gas-
turbine exhaust to generate steam in the Rankine cycle and save the fuel
required to heat the water? Combined Cycle does just the same.

The efficiency of Gas Turbine cycle alone is 30% and the efficiency of
Rankine Cycle is 35%. The overall efficiency of combined cycle comes to
48%.
2.4 Advantages of Combined Cycle Plants

Apart from the higher overall efficiency, the combined cycle power plants
have following advantages:

Low installation Cost:

Power from a combined cycle power plant is approximately 70% of a

conventional coal based power plant of same capacity.

Low Gestation Period:

Power from a combined cycle power plant can be obtained in two phases,
i.e. two third power, obtainable from gas turbines, is available within 16-
18 months and the balance in next 1 month. This is much lower than the
gestation period for conventional thermal power plants, which is around
48-60 months.

Better Reliability:

Combined cycle power plants are considered to be highly reliable with the
reliability factor of 85-90% as compared to 60-65% for conventional coal
Fired Power Plants.
2.5 How Does A Combined-Cycle Power
Plant Work?

Power Generation:

Air Inlet:

 The amount of air needed for combustion is 800,000 cubic feet per
minute. This air is drawn though the large air inlet section where it
is cleaned, cooled and controlled, in order to reduce noise.

Turbine-Generators:

 The air then enters the gas turbine where it is compressed, mixed
with natural gas and ignited, which causes it to expand. The
pressure created from the expansion spins the turbine blades, which
are attached to a shaft and a generator, creating electricity.

 Each gas turbine produces 185 megawatts (MW) of electricity.

 The blades are attached to a rotor, which spins the generator, and
makes electricity. Think of a generator as a huge spinning magnet
inside a coil of wire. As the magnet spins, electricity is created in
the wire loops.
 3.GAS TURBINE and STEAM
TURBINE

3.1 Gas Turbine Starting System :

The function of the starting system is to crank the gas turbine up to the
required speed until it becomes self-sustaining.

One method of starting large gas turbine is by using a motor driven

hydraulic starting system. Alternatively, the GTG can be started by using
a frequency converter to rotate the generator which drives the turbine for
starting.

A typical hydraulic starting system for each gas turbine consist of the
following:

• Starting motor, electric AC induction motor

• Hydraulic torque converter

• Auxiliary Gear

• Couplings
3.2 Working of starting motor

The electric starting motor drives the hydraulic torque generator through a
coupling. The hydraulic torque converter consists of an impeller, which
forces the fluid against hydraulic starting motor. The hydraulic torque
converter is coupled to the accessory gear, which is connected to the gas
turbine shaft. The torque converter receives hydraulic fluid from hydraulic
and lube oil reservoir during operation.

When gas turbine reaches self-sustaining speed the starting device is

disconnected and shut down. To break the inertia of the starting motor and
reduce the starting current a pony motor is provided. Gas turbines of GE
and WH designs are provided with starting motor system for cranking
purpose.

The static frequency converter serves the same function of starting,

accelerating running at preset speed by starting the generator as a
synchronous motor by feeding variable frequency current drawn from the
connected grid.
3.3 Introduction to Steam Turbine

 The steam turbine is a Siemens Westinghouse KN Turbine

Generator, capable of producing up to 240 MW. It is located on top
of the condenser, across from the cooling tower.

 Steam enters the turbine with temperatures as high as 1000 degrees

Fahrenheit and pressure as strong as 2,200 pounds per square inch.
The pressure of the steam is used to spin turbine blades that are
attached to a rotor and a generator, producing additional electricity,
about 100 megawatts per HRSG unit.

 After the steam is spent in the turbine process, the residual steam
leaves the turbine at low pressure and low heat, about 100 degrees.
This exhaust steam passes into a condenser, to be turned back into
water.

 By using this “combined-cycle” process, two gas turbines and one

steam turbine, we can produce a total of about 600 megawatts of
electricity.
3.4 Heat Recovery Steam Generator (HRSG)

 The hot exhaust gas exits the turbine at about 1100 degrees
Fahrenheit and then passes through the Nooter Erickson, Heat
Recovery Steam Generator (HRSG).

 In the HRSG, there are 18 layers of 100-foot tall tube bundles, filled
with high purity water. The hot exhaust gas coming from the
turbines passes through these tube bundles, which act like a radiator,
boiling the water inside the tubes, and turning that water into steam.
The gas then exits the power plant through the exhaust stack at a
much cooler 180 degrees, after having given up most of its heat to
the steam process.

 About 1 million pounds of steam per hour is generated in this way

and sent over to the steam turbine through overhead piping.
 4. COOLING TOWERS

The cooling tower rejects waste heat from the steam cycle to the
atmosphere. The use of cooling towers has become increasingly
widespread as the availability of large water sources required for once-
through systems has decreased and as environmental restrictions on
thermal discharges associated with once-through systems has increased.

Cooling towers can be characterized in several ways. The most common

ways are by type of draft (mechanical or natural) or by the relationship
between the air and water flows (crossflow or counter flow).
4.1 MECHANICAL DRAFT COOLING TOWER:

A mechanical draft cooling tower uses large fans to produce airflow

through the tower fill. Water is distributed over the tower fill, and heat
transfer takes place by evaporation and convection as a result of water to
air interface. There are two types of mechanical draft towers, forced draft
and induced draft.

 Forced draft cooling towers have the fans mounted at the base of the
tower. Air is forced in at the bottom and discharged through the top
of the tower.
 The induced draft tower has the fans located downstream of the
tower fill section so that the air is pulled through the fill section.
4.2 NATURAL DRAFT COOLING TOWER:

The natural draft cooling tower produces airflow through utilization of the
stack, or chimney, effect. The density difference between the warm (less
dense) air inside the stack and the relatively cool (denser) ambient air
outside produces the required airflow.
4.3 CROSSFLOW:

The crossflow cooling tower has a fill configuration through which the air
flows horizontally, across the downward fall of water. The air enters the
tower through louvers, passes through the fill and drift eliminators, enters
the central air plenum, and is drawn up through the fan stack(s). Hot water
is delivered to open hot water basins above the fill areas. The hot water is
distributed to the fill by gravity through orifices in the floor of the hot
water basin.
4.4 COUNTERFLOW:

The counter flow tower has a fill configuration through which air flows
vertically upward, counter to the falling water. The air enters the tower
through the openings in the lower portion of the tower, turns 90 degrees,
and passes upward through the fill section, where heat and mass transfer
between the air and the water take place. The air then passes through the
drift eliminators above the fill, enters the tower plenum space, and passes
out through the fan stack.
4.5 DIFFERENCES B/W FORCED DRAFT &
INDUCED DRAFT COOLING TOWER:

 Forced Draft Cooling Towers

 Forced draft cooling towers have the fans mounted at the base of the
tower.
 Its airflow characteristic is a high inlet air velocity and a low exit air
velocity.
 The location of the tower fans in the entering airstream also makes
them subject to potential icing problems.
 Recirculation is common in these types of cooling towers.

 Induced Draft Cooling Towers

 The induced draft tower has the fans located downstream of the
tower fill section.
 The airflow characteristic of this induced draft arrangement is a
lower inlet air velocity and a higher exit air velocity.
 Icing of the mechanical equipment is also reduced because the fans
are located in the warm airstream.
 High exit velocity reduces the tendency for recirculation.