INDEX

 PREFACE

 ACKNOWLEDGEMENT

 ABOUT NTPC

 POWER PLANT CYCLE

 POWER STATIONS IN INDIA

 NTPC BADARPUR

 AN OVERVIEW ON POWER PRODUCTION

 BOILER MAINTENANACE DEPARTMENT (BMD)

 PLANT AUXILLARY MAINTENANCE (PAM)

 TUBINE MAINTENEANCE DEPARTMENT (TMD)

 MAINTENANCE & PLANING DIVISION (MPD)

 PREFACE

This report contains the principle of power generation, machines and its
working. Different departments of the power plant such as boiler maintenance
department, plant auxiliary department, turbine maintenance department and
maintenance and planning department. Different part such as boiler,
superheater, reheater, different types of pumps, condenser, compressor, and
their way of there maintenance.

In this report the working, its working condition, rating etc. are described for
the machine. The mechanism and specifications are also included in it.
 ACKNOWLEDGEMENT

I am very grateful to Mr. Manmohan Singh(Sr. Manager) for giving me a

chance to get training at NTPC, BADARPUR. It is very encouraging to see and
learn about the working process of the plant.

I would like to thank officers and employees who help me to understand the
process and its working principles. The employees here are very caring and co-
operative, help me in sorting my problems and doubts.

ANIMESH JAIN
 CER

This is to certify that

MECHANICAL EN
 NTPC
NTPC is the largest thermal power generating company of India. A public
sector company incorporated in the year 1975 for power development in the
country as a wholly owned company of the government of India. At present
government of India holds 89.5% of the total equality shares of company and
the balance 10.5% is held by FIIs, Domestic banks, public and others. With in a
span of 30 years, NTPC has emerged as a truly NATIONAL POWER
COMPANY with power generation facilities is all the major regions of the
country. NTPC is one of the NAVARATNA comprises of the public sector. It
is the 6th largest thermal power company in the world. It supplies one-fourth of
the power produced to the country. It is now taking up the project using non-
conventional source of energy also.

Environment Policy & Environment Management System

Driven by its commitment for sustainable growth of power, NTPC has evolved
a well defined environment management policy and sound environment
practices for minimizing environmental impact arising out of setting up of
power plants and preserving the natural ecology.

National Environment Policy:

At the national level, the Ministry of Environment and Forests had prepared a
draft Environment Policy (NEP) and the Ministry of Power along with NTPC
actively participated in the deliberations of the draft NEP. The NEP 2006 has
since been approved by the Union Cabinet in May 2006. NTPC Environment

Policy:

As early as in November 1995, NTPC brought out a comprehensive document

entitled "NTPC Environment Policy and Environment Management System".
Amongst the guiding principles adopted in the document are company's
proactive approach to environment, optimum utilization of equipment, adoption
of latest technologies and continual environment improvement. The policy also
envisages efficient utilization of resources, thereby minimizing waste,
maximizing ash utilization and providing green belt all around the plant for
maintaining ecological balanceNTPC has actively gone for adoption of best
organization has purs international practices on environment, occupational
health and

Environment Management, Occupational Health and

Safety Systems:
ued the Environmental Management System (EMS) ISO 14001 and the
Occupational Health and Safety Assessment System OHSAS 18001 at its
different establishments. As a result of pursuing these practices, all NTPC
power stations have been certified for ISO 14001 & OHSAS 18001 by reputed
national and international Certifying Agencies.

Pollution Control systems:

While deciding the appropriate technology for its projects, NTPC integrates
many environmental provisions into the plant design. In order to ensure that
NTPC comply with all the stipulated environment norms, various state-of-the-
art pollution control systems / devices as discussed below have been installed to
control air and water pollution.

Electrostatic Precipitators:
The ash left behind after combustion of coal is arrested in high efficiency
Electrostatic Precipitators (ESP’s) and particulate emission is controlled well
within the stipulated norms. The ash collected in the ESP’s is disposed to Ash
Ponds in slurry form.

Flue Gas Stacks:

Tall Flue Gas Stacks have been provided for wide dispersion of the gaseous
emissions (SOX, NOX etc) into the atmosphere.

Low-NOXBurners:
In gas based NTPC power stations, NOx emissions are controlled by provision
of Low-NOx Burners (dry or wet type) and in coal fired stations, by adopting
best combustion practices.

Neutralisation Pits:
Neutralisation pits have been provided in the Water Treatment Plant (WTP) for
pH correction of the effluents before discharge into Effluent Treatment Plant
(ETP) for further treatment and use.

Coal Settling Pits / Oil Settling Pits:

In these Pits, coal dust and oil are removed from the effluents emanating from
the Coal Handling Plant (CHP), coal yard and Fuel Oil Handling areas before
discharge into ETP.

DE & DS Systems:
Dust Extraction (DE) and Dust Suppression (DS) systems have been installed
in all coal fired power stations in NTPC to contain and extract the fugitive dust
released in the Coal Handling Plant (CHP).

Cooling Towers:

Cooling Towers have been provided for cooling the hot Condenser cooling
water in closed cycle Condenser Cooling Water (CCW) Systems. This helps in
reduction in thermal pollution and conservation of fresh water.

Ash Dykes & Ash Disposal systems:

Ash ponds have been provided at all coal based stations except Dadri where
Dry Ash Disposal System has been provided. Ash Ponds have been divided into
lagoons and provided with garlanding arrangements for change over of the ash
slurry feed points for even filling of the pond and for effective settlement of the
ash particles. Ash in slurry form is discharged into the lagoons where ash
particles get settled from the slurry and clear effluent water is discharged from
the ash pond. The discharged effluents conform to standards specified by CPCB
and the same is regularly monitored. At its Dadri Power Station, NTPC has set
up a unique system for dry ash collection and disposal facility with Ash Mound
formation. This has been envisaged for the first time in Asia which has resulted
in progressive development of green belt besides far less requirement of land
and less water requirement as compared to the wet ash disposal system.

Ash Water Recycling System:

Further, in a number of NTPC stations, as a proactive measure, Ash Water

Recycling System (AWRS) has been provided. In the AWRS, the effluent from
ash pond is circulated back to the station for further ash sluicing to the ash
pond. This helps in savings of fresh water requirements for transportation of
ash from the plant. The ash water recycling system has already been installed
and is in operation at Ramagundam, Simhadri, Rihand, Talcher Kaniha, Talcher
Thermal, Kahalgaon, Korba and Vindhyachal. The scheme has helped stations
to save huge quantity of fresh water required as make-up water for disposal of

Dry Ash Extraction System (DAES):

Dry ash has much higher utilization potential in ash-based products (such as
bricks, aerated autoclaved concrete blocks, concrete, Portland pozzolana
cement, etc.). DAES has been installed at Unchahar, Dadri, Simhadri,
Ramagundam, Singrauli, Kahalgaon, Farakka, Talcher Thermal, Korba,
Vindhyachal, Talcher Kaniha and BTPS.

Liquid Waste Treatment Plants & Management System:

The objective of industrial liquid effluent treatment plant (ETP) is to discharge
lesser and cleaner effluent from the power plants to meet environmental
regulations. After primary treatment at the source of their generation, the
effluents are sent to the ETP for further treatment. The composite liquid
effluent treatment plant has been designed to treat all liquid effluents which
originate within the power station e.g. Water Treatment Plant (WTP),
Condensate Polishing Unit (CPU) effluent, Coal Handling Plant (CHP)
effluent, floor washings, service water drains etc. The scheme involves
collection of various effluents and their appropriate treatment centrally and re-
circulation of the treated effluent for various plant uses. NTPC has
implemented such systems in a number of its power stations such as
Ramagundam, Simhadri, Kayamkulam, Singrauli, Rihand, Vindhyachal, Korba,
Jhanor Gandhar, Faridabad, Farakka, Kahalgaon and Talcher Kaniha. These
plants have helped to control quality and quantity of the effluents discharged
from the stations.

Sewage Treatment Plants & Facilities:

Sewage Treatment Plants (STPs) sewage treatment facilities have been
provided at all NTPC stations to take care of Sewage Effluent from Plant and
township areas. In a number of NTPC projects modern type STPs with
Clarifloculators, Mechanical Agitators, sludge drying beds, Gas Collection
Chambers etc have been provided to improve the effluent quality. The effluent
quality is monitored regularly and treated effluent conforming to the prescribed
limit is discharged from the station. At several stations, treated effluents of
STPs are being used for horticulture purpose.

Environmental Institutional Set-up:

Realizing the importance of protection of the environment with speedy

development of the power sector, the company has constituted different groups
at project, regional and Corporate Centre level to carry out specific
environment related functions. The Environment Management Group, Ash
Utilisation Group and Centre for Power Efficiency & Environment Protection
(CENPEEP) function from the Corporate Centre and initiate measures to
mitigate the impact of power project implementation on the environment and
preserve ecology in the vicinity of the projects. Environment Management and
Ash Utilisation Groups established at each station, look after various
environmental issues of the individual station.

Environment Reviews:

To maintain constant vigil on environmental compliance, Environmental

Reviews are carried out at all operating stations and remedial measures have
been taken wherever necessary. As a feedback and follow-up of these
Environmental Reviews, a number of retrofit and up-gradation measures have
been undertaken at different stations. Such periodic Environmental Reviews
and extensive monitoring of the facilities carried out at all stations have helped
in compliance with the environmental norms and timely renewal of the Air and
Water Consents.

Waste Up gradation & retrofitting of Pollution Control Systems:

Management

Various types of wastes such as Municipal or domestic wastes, hazardous

wastes, Bio-Medical wastes get generated in power plant areas, plant hospital
and the townships of projects. The wastes generated are a number of solid and
hazardous wastes like used oils & waste oils, grease, lead acid batteries, other
lead bearing wastes (such as garkets etc.), oil & clarifier sludge, used resin,
used photo-chemicals, asbestos packing, e-waste, metal scrap, C&I wastes,
electricial scrap, empty cylinders (refillable), paper, rubber products, canteen
(bio-degradable) wastes, buidling material wastes, silica gel, glass wool, fused
lamps & tubes, fire resistant fluids etc. These wastes fall either under hazardous
wastes category or non-hazardous wastes category as per classification given in
Government of India’s notification on Hazardous Wastes (Management and
Handling) Rules 1989 (as amended on 06.01.2000 & 20.05.2003). Handling
and management of these wastes in NTPC stations have been discussed below.

Advanced / Eco-friendly Technologies

NTPC has gained expertise in operation and management of 200 MW and 500
MW Units installed at different Stations all over the country and is looking
ahead for higher capacity Unit sizes with super critical steam parameters for
higher efficiencies and for associated environmental gains. At Sipat, higher
capacity Units of size of 660 MW and advanced Steam Generators employing
super critical steam parameters have already been implemented as a green field
project. Higher efficiency Combined Cycle Gas Power Plants are already under
operation at all gas-based power projects in NTPC. Advanced clean coal
technologies such as Integrated Gasification Combined Cycle (IGCC) have
higher efficiencies of the order of 45% as compared to about 38% for
conventional plants. NTPC has initiated a techno-economic study under
USDOE / USAID for setting up a commercial scale demonstration power plant
by using IGCC technology. These plants can use low-grade coals and have
higher efficiency as compared to conventional plants. With the massive
expansion of power generation, there is also growing awareness among all
concerned to keep the pollution under control and preserve the health and
quality of the natural environment in the vicinity of the power stations. NTPC is
committed to provide affordable and sustainable power in increasingly larger
quantity. NTPC is conscious of its role in the national endeavour of mitigating
energy poverty, heralding economic prosperity and thereby contributing
towards India’s emergence as a major global economy.
Lay out of Employee’s Overall Power Generation

Unit 1997-98 2006-07 % of increase

Installed Capacity MW 16,847 26,350 56.40
Generation MUs 97,609 1,88,674 93.29
No. of employees No. 23,585 24,375 3.34
Generation/employee MUs 4.14 7.74 86.95
The table below shows the detailed operational performance of coal based
stations over the years.
OPERATIONAL PERFORMANCE OF COAL BASED NTPC
STATIONS
97- 98- 99- 00- 01-
Unit 02-03 03-04 04-05 05-06 06-07
98 99 00 01 02
Generation BU 106.2109.5118.7130.1133.2140.86149.16 159.11 170.88 188.67
PLF % 75.2076.6080.3981.8 81.1 83.6 84.4 87.51 87.54 89.43
Availability
% 85.0389.3690.0688.5481.8 88.7 88.8 91.20 89.91 90.09
Factor
The energy conservation parameters like specific oil consumption and auxiliary
power consumption have also shown considerable improvement over the years.
 POWER PLANT CYCLE
The thermal power plants are based on Rankine cycle (modern). This ideal
cycle is more suitable as a creation for actual steam cycle than Carnot cycle.
 POWER STATIONS IN INDIA

COAL POWER PLANTS

Sno. Place State Installed capacity
01 Singrauli Uttar Pradesh 2000MW

02 Karba Madhya Pradesh 2100MW

03 Ramaquandam Andhra Pradesh 2100MW

04 Farakka West Bengal 1600MW

06 Vindhyachal Madhya Pradesh 2260MW

07 Rihand Uttar Pradesh 1000MW

08 Kahalgaon Bihar 840MW

09 Dadri Uttar Pradesh 840MW

10 Talchar kaniha Orissa 3000MW

11 Unchahar Uttar Pradesh 840MW

12 Sinhadri Andhra Pradesh 1000MW

13 Tanda Uttar Pradesh 440MW

GAS AND LIQUID FUEL PLANT
Sno. Place State Installed capacity
01 Anta Rajasthan 413MW

02 Auraiya Uttar Pradesh 653MW

03 Kawas Gujarat 645MW

04 Jhanar Gandhar Gujarat 648MW

05 Dadri Uttar Pradesh 817MW

06 Kayankulam Kerala 400MW

07 Faridabad Haryana 400MW

POWER STATION MANAGED BY NTPC

Sno. Place State Installed capacity
01 Badarpur New Delhi 705MW

02 Balco Power Madhya Pradesh 270MW

 NTPC BADARPUR
I was assigned to do training in operation division from 18th June 2007 to 23rd
June 2007
ELECTRICITY FROM COAL Coal from the coal wagons is unloaded with
the help of wagon tipplers in the C.H.P. this coal is taken to the raw coal
bunkers with the help of conveyor belts. Coal is then transported to bowl mills
by coal feeders where it is pulverized and ground in the powered form. This
crushed coal is taken away to the furnace through coal pipes with the help of
hot and cold mixture P.A fan. This fan takes atmospheric air, a part of which is
sent to pre heaters while a part goes to the mill for temperature control.
Atmospheric air from F.D fan in the air heaters and sent to the furnace as
combustion air. Water from boiler feed pump passes through economizer and
reaches the boiler drum . Water from the drum passes through the 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 density difference the
water rises up in the water wall tubes. This steam and water mixture is again
taken to the boiler drum where the steam is sent to super heaters for super
heating. The super heaters are located inside the furnace and the steam is super
heated (540 degree Celsius) and finally it goes to the turbine. Fuel gases from
the furnace are extracted from the induced draft fan, which maintains balance
draft in the furnace with F.D fan. These fuel gases heat energy to the various
super heaters and finally through air pre heaters and goes to electrostatic
precipitators where the ash particles are extracted. This ash is mixed with the
water to from slurry is pumped to ash period. The steam from boiler is
conveyed to turbine through the steam pipes and through stop valve and control
valve that automatically regulate the supply of steam to the turbine. Stop valves
and controls valves are located in steam chest and governor driven from main
turbine shaft operates the control valves the amount used. Steam from
controlled valves enter high pressure cylinder of turbines, where it passes
through the ring of blades fixed to the cylinder wall. These act as nozzles and
direct the steam into a second ring of moving blades mounted on the disc
MAIN GENERATOR DATA
Maximum continuous KVA rating 24700KVA
Maximum continuous KW 210000KW
Rated terminal voltage 15750V
Rated Stator current 9050 A
Rated Power Factor 0.85 lag
Excitation current at MCR Condition 2600 A
Slip-ring Voltage at MCR Condition 310 V
Rated Speed 3000 rpm
Rated Frequency 50 Hz
Short circuit ratio 0.49
Efficiency at MCR Condition 98.4%
Direction of rotation viewed Anti Clockwise
Phase Connection Double Star
9( 6 neutral and 3
Number of terminals brought out
phase)

MAIN TURBINE DATA

Rated output of Turbine 210 MW
Rated speed of turbine 3000 rpm
Rated pressure of steam before emergency 130 kg/cm^2
Stop valve rated live steam temperature 535 degree Celsius
Rated steam temperature after reheat at inlet to
535 degree Celsius
receptor valve
Steam flow at valve wide open condition 670 tons/hour
Rated quantity of circulating water through
27000 cm/hour
condenser
1. For cooling water temperature (degree
24,27,30,33
Celsius)
1.Reheated steam pressure at inlet of 23,99,24,21,24,49,24.8
interceptor valve in kg/cm^2 ABS 2
2.Steam flow required for 210 MW in ton/hour68,645,652,662
3.Rated pressure at exhaust of LP turbine in 19.9,55.5,65.4,67
Installed Capacity 720 MW

Location New Delhi

Coal Source Jharia Coal Fields

Water Source Agra Canal

Beneficiary States Delhi

Unit Sizes 3X95 MW

2X210 MW

Units Commissioned Unit I- 95 MW - July 1973

Unit II- 95 MW August 1974
Unit III- 95 MW March 1975
Unit IV - 210 MW December 1978
Unit V - 210 MW - December 1981

Transfer of BTPS to NTPC Ownership of BTPS was transferred to NTPC with

effect from 01.06.2006 through GOI’s Gazette Notification.
 AN OVERVIEW ON POWER
PRODUCTION
Today electricity is a need of everyone’s life. Without it one cannot even think
about work. We use the electrical utensils pretty easily but don’t think about the
way and procedure of production of power. It is a difficult process to produce
electricity but an interesting and important from engineering point of view. The
procedure of production is described in short below.

The main divisions of any thermal power plant are boiler division, turbine and
plant auxiliary division. Starting with boiler division, raw coal is crushed and
transferred to the raw coal bunker (R C Bunker), which is at a height of 30m-
40m above the ground level, with the help of conveyors. This crushed coal is
feed into raw coal feeder (R C Feeder) which feeds the required amount of
coal to the pulverize mill i.e. ball mill (for 100MW) or bowl mill (for
210MW). These mills pulverize the coal and are ready for the input in the
furnace.

Fans like force draft fans (F D Fan), induced draft fans (I D Fan) and
primary air fans (P A Fan) are used for air flow, which is also a transporting
medium. P A Fan sucks the atmospheric air and sends it to air preheater for
heating. It is then comes to pulverized mill form where it carries the coal
particles to the furnace for its combustion. This air which is delivered by P A
Fan is also called primary air. F D Fan delivers the required air for
combustion. It is also called secondary air which is hot enough for the
combustion.

The burned coal which converted into ash dropped in scraper conveyor due to
gravity. This ash is cooled with the help of water and dumped in the water
where it forms slurry. The rest of the ash is carried to electrostatic precipitator
(ESP) with the help of air. This flow of air is due to I D Fan which drafts the
air form furnace to the chimney. In ESP ash sticks to the electrodes due to
electric field produced by the electrodes. The ash collected in the plates is put
down by roller hammers. This ash is mixed with water to make slurry and
dumped along with the slurry produced at scraper conveyor. The ash removed
by the ESP is about 99% and the rest is passed to atmosphere via chimney.

Now starting the water cycle from boiler drum, there is hot water is collected
in the boiler drum. This water is supplied to the tubes placed in furnace, where
water converted to and move above in the furnace in superheater. Here steam
get superheated to a temperature of 535°C at a high pressure and then injected
to turbine. The low pressure steam at the outlet it send to condenser where it
condenses with the help of cold water running in small (in diameter) tubes. This
water is supplied by cooling water pump (C W Pump). This condensate is
pumped to deareator placed 18m above the ground wit the help of condensate
pump. This may be called as a temporary storage tank. From here the water is
pumped to the boiler for regeneration of steam by boiler feed pumps (BFP)
placed at ground level. The condensate goes through economizer and reheater
to the boiler drum.

The cooling water n water for other purpose is provided by the high pressure
pump (H P Pump); low pressure pumps (L P Pump) etc. Water is pumped
from Agra canal which is filtered properly to make it suitable for the usage.
GENERAL LAYOUT OF A POWER PLANT
 BOILER

MAINTENANC
E

DEPARTMENT

(BMD)
 BMD I, II & III
BOILERS
A part of power plant, which is concerned with heat generation from burning of
fuel and with transfer of heat to the water to convert it into superheated steam.
Boilers are broadly classified as:-
 Fire tube type Boiler
 Water tube type Boiler

If hot combustion gases are confined inside the tubes, and the tubes are
surrounded with water, the boiler is called Fire tube boiler.
If water is inside the tubes and hot gases outside the tube makes it a Water
tube boiler.

BOILER DRUM
The boiler drum contains both steam and water, the former being trapped from
the top of the drum where the highest concentration of dry steam exists.
Modern boiler drums are usually provided with effective arrangement for
separation of water from steam, so that the outlet of steam is as dry as possible,
the quantity of dryness being over 99.5%.

METHODS OF COAL FIRING

There are two general ways of firing unpulverized coal in combustion furnace,
viz. hand firing and stoker or mechanical firing.
Hand firing is simple but can be used only in small installation as the
uniformity of combustion is difficult to control with this type of firing. It is also
tiring and need close supervision.
Stoker firing permits feeding and burning of large quantity of fuel with great
uniformity, and easier control of combustion. It achieves greater efficiency
through less manual effort.

BURNER
Burners are used to focus the flame so as to burn the coal. There are 24 burners
placed among 4 corners from 18-26m height.

OIL GUN
It is used to indicate and sustain the flame which is necessary for burning coal.
Oil gun is used to provide oil to the burners and is placed between two burners.

SOOT BLOWER
Soot blowers are placed at the surface of furnace so as to blow the soot or
deposits along the water tubes. The soot reduces the efficiency of the transfer of
heat to the water from the heat produced by the burning of coal. Soot blowers
are placed on all sides of furnace at different elevations. They produce a jet of
air which blows away the soot.
SUPERHEATER
Superheaters are used to superheating steam to the desired temperature. These
are made of coils of tubes forming parallel tube circuits connected between
headers. The superheater tubes are made of high temperature strength special
alloy steels such as chromium-molybdenum.
Superheater system consists of four basic stages or sections, namely a platan
superheater, a pendent superheater, a rear horizontal superheater and the steam
cooled wall and roof superheaters.

REHEATER
The function of reheater is to reheat the steam coming out from high pressure
turbine to a temperature of 540°C. Reheater composed of two sections: the
front pendant section and rear pendant section. The rear pendant section is
located above the furnace arc and the rear water wall and front pendant section
is located between water hanger tubes and the superheater platen section.

ECONOMIZER
The purpose of the economizer is to preheat the boiler feed water before it is
introduced into the steam drum, and to recover some of the heat from the flue
gases leaving the boiler.

AIR PREHEATER
Since the heat of the exit gases cannot be fully extracted through the
economizers, air preheaters are employed o recover some of the heat escaping
in these gases. If the gases can be cooled by 19°C to 22°C due to preheating of
air, the plant efficiency is increased by about 1%.
SCRAPER CONVEYOR
Scraper conveyor is machine placed directly below the furnace or combustion
chamber. Its work is to clear the ash formed by the combustion of coal. As the
ash particles may combine together to form a big clinker, these clinkers are
break down with the help of clinker grinder. Clinker grinder is cylindrical in
shape with spikes on the curved surface.

Ash which is collected in scraper conveyor is mixed with water to bring its
temperature down and then dump in the water, flowing at a very high velocity.
This mixture of ash and water, which is called slurry, then dumping it at waste
land with the help of pumps, where it is used for making bids, bricks etc.

ELECTROSTATIC PRECEPITATOR
This dust collector employs an electrostatic field between two sets of electrodes
other and between which the flue gases are made to pass. The dust particles are
joined as the gases passes through the electric field, and are attracted by the
collecting electrode which is grounded. Then the roller hammers, which are
operated with the help of motors, strike the electrode simultaneously to bring
the ash down to the hoppers. Ash collected in hoppers is then mixed with water
and mixed with the slurry coming through scrapper conveyor. The efficiency of
ESP is 90% in dust collection.

CHIMNEY
Chimney is a tall tower through which the hot flue gases and remaining ash
escapes in air. Normally the height of chimney is about 150 meters.
RAW COAL BUNKER (RC BUNKER)
RC Bunker is a place where raw coal is placed (and collected) with the help of
conveyor belts. From here the coal is feed into the combustion chamber.
Another advantage is that pulverizing operation can be done at a constant rate
so that the fuel is kept in the bunkers.

RAW COAL FEEDER (RC FEEDER)

The raw crushed coal is delivered from the bunker to the feeders, which in turn
feed the coal at the controlled rate to the bowl mill each feeder supplying an
individual bowl mill.
Hot air is admitted into the feeder through a slot in the lower part of the feed
roll core. The air aids in drying of coal and keeps it from clogging between the
feed roller blades. The speed of feeder is varied depending on the feed rate
required.

Some specifications of RC Feeder:

No. of feeders per boiler 6
Capacity Maximum 38 T/hr
Rated speed 955 RPM
Speed ratio 1:6 (2.64:16 RPM)
Motor rated power 2.2KW

BOWL MILL
In bowl mill the smooth rollers move in a rotating bowl and acts as a grinding
tool. These three rollers are placed at 120° apart with a separation of 1mm from
the surface of the bowl. To save the interior of the bowl from the wearing
action a hardened metal ring is fitted on the inside periphery. Adjustment of
rollers with respect to the grinding ring ensures proper size of product.
Bowl mill is basically used for 210MW unit. Some of its specifications are as
follows:
No. of Bowl mills per boiler 6
Type Medium speed Bowl Mill pressurized type
No. of grinding rollers per mill 3
Rated RPM 990
Rated output 320KW

BALL MILL
A ball mill is a type of grinder used to grind materials into extremely fine
powder for use in paints, pyrotechnics, and ceramics.

Ball mill

A ball mill, a type of grinder, is a cylindrical device used in grinding (or

mixing) materials like ores, chemicals, ceramic raw materials and paints. Ball
mills rotate around a horizontal axis, partially filled with the material to be
ground plus the grinding medium. Different materials are used as media,
including ceramic balls, flint pebbles and stainless steel balls. An internal
cascading effect reduces the material to a fine powder. Industrial ball mills can
operate continuously, fed at one end and discharged at the other end. Large to
medium-sized ball mills are mechanically rotated on their axis, but small ones
normally consist of a cylindrical capped container that sits on two drive shafts
(pulleys and belts are used to transmit rotary motion). A rock tumbler functions
on the same principle. Ball mills are also used in pyrotechnics and the
manufacture of black powder, but cannot be used in the preparation of some
pyrotechnic mixtures such as flash powder because of their sensitivity to
impact. High-quality ball mills are potentially expensive and can grind mixture
particles to as small as 0.0001 mm, enormously increasing surface area and
reaction rates. Ball Mills works on principle of critical speed.

INDUCED DRAFT FAN (I D FANS)

I D fans is used to extract flue gases from the combustion chamber. Each fan is
capable of delivering 936,000 m3/hour flue gas from the furnace for subsequent
evacuation through the chimney. Each 210MW boiler is provided with two I D
fans.

Some specifications of I D Fans:

No. of fans per Boiler Two
Fan capacity 936000 m3/hr
Speed 990 RPM
Rating 1100KW
Voltage 6.6KV 3-phase star connected
Rated current 116.5A
Temperature at full load 90°C
Bearing Sleeve bearing
Made by BHEL Bhopal, India

FORCE DRAFT FAN (F D FANS)

F.D.fan supplies air for combustion process by taking directly atmospheric air.
The secondary air after preheating in the air heaters mixes with the primary air
and coal dust in the manner to shape the flame and promote rapid mixing for
proper combustion.
Some specifications of F D Fans:
No. of fans per Boiler Two
Fan capacity 406800 m3/hr
Speed 1400 RPM
Rating 800KW
Voltage 6.6KV 3-phase star connected
Rated current 84.5A
Temperature at full load 90°C
Bearing Ball bearing, Roller Bearing
Made by BHEL Bhopal, India

PRIMARY AIR FANS (P A FANS)

This fan handles the clean atmospheric air which then preheated in preheater.
The hot primary air which comes out of the preheater scavenges the bowl mill
and carries the coal particle to the burners.
A part of the primary cold air is used to sealing the R C Feeder, coal dust lines
at the discharge end of bowl mill seal air ring header of mill.
A part of primary cold air is used for regulating temperature of the hot air
entering the bowl mill.

Some specifications of PA Fans:

No. of fans per Boiler Two
Fan capacity 254880 m3/hr
Speed 1485 RPM
Rating 1250KW
Voltage 6.6KV 3-phase star connected
Rated current 112.2A
Temperature at full load 90°C
Bearing Ball bearing, Roller Bearing
Made by BHEL Bhopal, India
 PLANT

AUXILARY

MAINTENANC
E

(PAM)
WATER IN POWER PLANT
Water plays a very important role in power plant. Water is basically used for
two purposes viz. cooling and for making steam. Therefore, a power plant
should have a water source for this purpose.

The major problem for water is not quantity but quality. Water used for steam
cycle should be treated well before sending it to boiler for steam cycle. The
requirement of water for steam cycle is 3-4 tones/hr/MW and makeup quantity
is 2-3% of the same. For condensation purpose the amount of water required is
approximately 20000m3/hr/100MW. A small proportion is required for cooling
of generator and other machinery. This amount can be fulfilled by canal or even
by tube well.

As the quantity of water doesn’t matter, it is the quality of water that matters.
The water should undergo various water treatments such as hardness testing,
caustic embritillment, ion exchange method, and deoxidization etc.

In NTPC Badarpur, water is supplied through Agra canal which came from
Yamuna River. This water is filtered first to make it free from dirt, and then it is
pumped via different pumps to there respective destination where it is used in
its required form. The waste water is again feed to the river via different path.
COMPRESSOR HOUSE
In power plant, compressors are used to provide the required compressed gas
which is used for opening and closing of valves which are out of reach of
worker or where manual operation is difficult. It is also used for cooling of
various air cooling machines.

There are mainly four types of compressor which are functioning in compressor
house they are:
1. Reciprocating Compressor
2. Electric Screw Air Compressor
3. Blaster Compressor
4. Mechnofore Compressor

Reciprocating Compressor

Reciprocating compressor is actually double acting reciprocating compressor. It

consists of a cylinder, a piston which compresses the air in both direction of its
motion.

Some of its specifications are as follows:

Bore -LP Cylinder 380mm

-HP Cylinder 245mm
Stroke 125mm
Compressor speed 980RPM
Piston displacement 27.54m3/min
Free Air Delivery (FAD) at 8Kg/cm3 g 18 m3/min
Motor KW 120KW
Net weight of compressor 2900Kg (approx)
Lubricating oil 25L
Compressor Lubricating oil pressure 2.5 to 4Kg/cm2 g
Cooling water flow rate 180L/min
Electric Screw Air Compressor

A screw compressor consists of two rotors, one male and other female. These
rotors have symmetric profile lobes encircling the rotor in the form of thread.
The male rotors have 4-lobes while female have 6.

Some specifications of screw compressor:

Types of compressor→ SES520 SES770 SES1000 SES1500

Free Air Delivery (FAD) 520cfm 770cfm 1000cfm 1500cfm
(in m3/min) 14.7 21.8 28.3 42.5

Working pressure 100psig 100psig 100psig 100psig

7Kg/cm g 7Kg/cm2g
2
7Kg/cm2g 7Kg/cm2g

Motor power (HP/KW) 125/93 180/132 250/187 350/258

Speed of motor (RPM) 3000 3000 3000 3000

*1m3/min=35.37 cfm **1KW=1.344 HP

ASH CONTROL PUMP HOUSE
The basic function of ash control pump house is as its name suggests is to dump
the slurry i.e. mixture of water and ash to a place far away from the residential
place, so that it cannot harm any living organism.

For this purpose pumps are working. They suck the slurry and discharge it
through the pipelines.

In NTPC Badarpur, there four pumps serving this purpose. They suck the slurry
and discharge it through the pipelines to a place 8Km south east near Yamuna
River. There this slurry dries up and they are used for making bids, bricks etc.

CONTROL STUCTURE PUMP HOUSE

This pump house is very necessary for the plant. It supplies the water needed by
the power plant. It provides water for cooling purpose, cleaning purpose and of
course for the boiler. Water for boiler doesn’t directly feed to boiler; it is first
send for water treatment to purify and dematerialization.

It consists of four different types of pump such as HP Pump, LP Pump, CRW

Pump, and FS Pump. All of these pumps are used for different purposes like LP
Pumps are used for boiler water; HP Pumps are used for cleaning water purpose
etc.

In NTPC Badarpur water is taken from Agra canal which is first filtered
properly and then it supplies water for required usage. Here 6HP Pumps, 3 LP
Pumps, 3 CRW Pumps and 2 FS Pumps are installed. The cooling water is
supplied to the plant through underground water tunnel which is about 20m
deep. Hence it is a very important part of the power plant.
 TURBINE

MAINTENANC
E

DEPARTMENT

(TMD)
BOILER FEED PUMP (BFP)
During normal running of the unit, the feed pump has to handle hot water
received from feed water storage tank of deaerator through its booster pump
enhancing the positive suction pressure and has to deliver the hot water under
high pressure to boiler drum, through high pressure heaters and economizers for
steam generation. Te feed pump may be treated as the heart of unit and,
therefore, full attention is paid during its startup, shutting down and normal
running.

In 210MW units the boiler feed pumps are coupled to motor by hydraulic
coupling. The hydraulic coupling serves the purpose of controlling the speed of
feed pump for maintaining a definite delivery head and delivered quantity of
the pump as per requirement of the boiler.

CONDENSATE PUMP
Condensate pump takes suction from condenser and delivers condensate water
to deaerator through main ejector, gland steam coolers and L.P Heaters.
Condensate water discharged by the condensate pump is also utilized for the
following purposes:
1. Sealing of valve with gland seals.
2. For PRDS and DSS temperature control of main steam lines and hot
reheats lines respectively.
3. For filling siphons of ejectors and 15m siphon drain expander.
4. For cooling down the steam dumped in steam throw off device built in
both condensers.
COOLING WATER PUMP (CW PUMP)
CW Pumps are required for the cooling purpose i.e. for cooling the hot, low
pressure steam. These pumps are single suction single discharge type which
discharge water at a pressure of 0.4Kg/cm2. The pump rotates at 450 RPM and
has a length of 14m.

CW Pump pumps cooling water which flows through the tubes of small
diameter in the condenser. Here steam is all around the tubes looses energy and
condenses. The point is to be note is that steam condenses but still it is at a
temperature of 160°C because it is not cooled, so that its pressure should
increase.

The make up water is provide by the DM Tank i.e. De Mineralized water Tank
where extra water is stored. When extra make up water is supplied then the
extra water is automatically transferred to the Unit Drain Tank (UDT). From
here UDT Pump pumps the water for make up.

There is another pump in this category called sub pump. It is used basically for
cleaning purpose. It is used to pump waste water split on the ground and
collected in a pit. Sub pump pumps this water out of the pit.

MAIN TURBINE
The steam turbine is a condensing tandem compound, three cylinders (HP, IP,
and LP) horizontal, disc, and diaphragm type with nozzle governing and
regenerative feed water heating. The LP turbine is a double flow type which
incorporates a multi-exhaust in each flow.

The complete turbine assembly is mounted on pedestals and sole plates, which
are designed to ensure that the components are free to expand, whistle correct
alignment is maintained under all conditions.
The three rotors are supported on five bearings HP and IP rotor have common
bearing which is a combined journal and radial thrust bearing.

Some specifications of turbine:

Rated output of turbine 210MW

Rated speed 3000RPM
Rated live steam temperature 535°C
Rated pressure of steam before emergency stop valve 130Kg/cm2 abs
Rated pressure at the exhaust of LP turbine 45.2mm of HgC
Rated quantity of circulating water to condenser 27000m3/hr
MAINTENANC
E

AND
PLANNING

DIVISION
 (MPD)
MAINTENANCE SECTION
Maintenance and planning department works on whole power plant. It has
responsibility of maintenance of the machinery, planning the repair work etc. It
records the previous analysis of different machine.

A team regularly checks the running condition of the machine so that the unit
work properly and there is no case of shut own of unit. The testing of machines
is done by different methods such as vibration analysis (by an instrument called
CSI), thermography, oil sampling, noise analysis and motor current etc.

Vibration analysis: With the help of an instrument called CSI the vibration in
bearing in horizontal, vertical and axial direction is find out. These readings are
put in a database and compare with standard and pervious readings. On the
bases of comparison, it is decided that a machine needs repair or not, if yes then
in which part of the machine.

Thermography: In this method the hot and cold regions are identified. This data
is analyzed and then work is done accordingly.

Noise analysis: This instrument is used to measure the noise level of the
machine and readings are note down. Higher noise level means that there is
some problem in the machine in specific part where noise level is high.
Oil analysis: Incase of oil analysis the sample of lubrication oil coming out of
the machine is tested. According to the report it is clear that is there a contact
between bearing and shaft exists or not.

Motor current: Using method the maintenance of electrical appliances is done.

There are standard readings of every part of every machine which are feed in
the testing device. Therefore only by checking the machine the device tells the
condition and status of part and it become easier to localize the failure in
machine. It also increases the life, running time and condition of machine.

PLANNING SECTION
Along with maintenance, this department also does the planning work. Some
times it is required to shut down the unit so before shutting down the unit the
time required is calculated and according to the time limit the work done per
day is planned so that the repair work should take minimum time and the unit
start working soon.

DESIGN SECTION
This department also does the design work with the help of software like
AutoCAD. This is a very effective step to improve the working of the machine.
These designs are available on the LAN and can be used or seen by any officer
easily at any time.