Vocational Training Report

On

Synopsis on Thermal Power Station

At

NTPC Vindhyachal

In partial fulfilment of the

requirements For the award of the
degree BACHELOR OF
ENGINEERING IN
Mechanical Engineering
By
TANMAY KHARE
(Roll. No. – 0201ME161080)

Under the
Guidance Of
Mr. RAVINDRA PATEL

Department Of Mechanical Engineering

JABALPUR ENGINEERING COLLEGE
JABALPUR (M.P.), India
MAY-JUNE 2019
 Vocational Training
Report ON

Synopsis on Thermal Power Station

NTPC Vindhyachal
Under Guidance of:
Mr. RAVINDRA PATEL
AGM- Turbine Maintenance
Department
NTPC Vindhyachal

PREPARED BY-

TANMAY KHARE
JEC Jabalpur

Training MAY-JUNE
2019
 ACKNOWLEDGEMENT

With profound respect and gratitude, I take opportunity to convey

my thanks to Mr. Anand Kumar Mourya Sir for permitting me
to complete my training in NTPC Ltd. and to be the part of this
esteemed organization.

I extend my heartfelt thanks to O.P. Khare Sir for providing me the

proper guidance during my training period in Vindhayachal
Stage I.

I’m extremely grateful to all- the operation and guidance that has
helped me a lot during the course of training. I have learnt a lot under
them and I will always be indebted to them for this value addition
in me.

My special thanks to Mr. Ravindra Patel Sir (AGM - TMD , NTPC

Vindhyachal) who helped me at every stage of training and making
this project possible.

At last I would like to convey my thanks to all the members of

the Turbine Maintenance Dept. and I am are forever indebted
to the omnipotent and to my parents for their cheerful
encouragement, unfailing patience and consistent support.

TANMAY KHARE
VOCATIONAL TRAINEE
16TH May to 15th June
 INTRODUCTION: NTPC Ltd.
• NTPC Limited (formerly National Thermal Power Corporation) is the
largest Indian state-owned electric utilities company based in New Delhi, India.
• It is listed in Forbes Global 2000 for 2012 ranked at 337th in the world.
• SERVICE – Electricity generation and distribution natural gas
exploration, production, transportation and distribution
• PRODUCT - electrical power, natural gas

• REVENUE- 690.36 billion (US$13 billion) (2011–12)

• NET INCOME - 98.14 billion (US$1.8 billion)(2011–12)
• EMPLOYEE-26,000 (2012)
• It is an Indian public sector company listed on the Bombay Stock
Exchange in which at present the Government of India holds 84.5% (after
divestment of the stake by Indian government on 19 October 2009) of its
equity.
• With an electric power generating capacity of 41,184 MW, NTPC has
embarked on plans to become a 128,000 MW company by 2032.
On 21 May 2010, NTPC was conferred Maharatna status by the Union
Government of India.
• NTPC's core business is engineering, construction and operation of
power generating plants and providing consultancy to power utilities
in India and abroad.
• The total installed capacity of the company is 36,514 MW (including Joint
Ventures) with 16 coal-based and 7 gas-based stations, located
across the country. In addition under JVs (joint ventures), six stations are
coal-based, and 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 27,535 MW, 3,955 MW through gas,
1,328 MW through hydro generation, about 1,400 MW from nuclear sources
and around 1,000 MW from Renewable Energy Sources (RES).
• NTPC’s share at 31 Mar 2001 of the total installed capacity of the country
was 24.51% and it generated 29.68% of the power of the country in 2008–
09. Every fourth home in India is lit by NTPC.
• By approval of the Central Government under section 21 of the Companies
Act, 1956, the name of the Company "National Thermal Power Corporation
Limited" has been changed to "NTPC Limited" with effect from 28 October
2005. The primary reason for this is the company's foray into hydro and
nuclear based power generation along with backward integration by coal
mining.
LOCATION:

Vindhyachal station of NTPC is located at Vindhyanagar in Singrauli District of MP

state. The station is situated on the bank of Govind Vallabh Pant Sagar popularly known
as Rihand reservoir. Distance of station from Varanasi in UP and Sidhi in MP is about
240 Kms. and 100 Kms. Respectively.

CAPACITY (4260 MW):

STAGE NUMBER CAPACITY(MW) COMMISSIONED

STAGE I 6 X 210 = 1260 MW 10th June’87
’88,’89,’89,
(UNIT II,III,IV,V&VI)
STAGE II 2 X 500 = 1000 MW 1999 & 2000
(UNIT VII & VIII)
STAGE III 2 X 500 = 1000 MW 27th July’06
(UNIT IX &X)
STAGE IV 2 X 500 = 1000 MW 2013& 2014
STAGE V 500 MW (under construction)

• Stage-I & Stage-II were totally declared commercial in Feb’92 and Oct’2000 respectively.
• Stage-III– Unit-9 Synchronized on 27th Jul 2006 and became commercial
from 1st Dec 2006. Unit-10 was synchronized on 8th Mar 2007 and unit
became commercial from 15th Jul 2007.
• Stage-IV-Unit- 11& 12 were totally declared commercial in Mar’13 and
Mar’14 respectively

LAND:

Total land acquired 6178 acres.

WATER:

Water for NTPC Vindhyachal is drawn from NTPC Singrauli station discharge channel
which in turn takes it from Rihand reservoir. A total commitment of 190 cusecs of Make
- up water is already available which covers requirement for Stage-I, II & III. Closed
loop cooling water system using Cooling Towers has been adopted at Vindhyachal
Station.

COAL:

The coal linkage for this station is from the Nigahi Coal Mines of NCL. From there, the
coal is transported by Merry Go Round (MGR) transportation system (22 Kms length
with double track) owned and operated by NTPC. The requirement of coal per year for
use in stage- I, II and stage-III is around 17.1 million MT.
STAGE WISE COMMISSIONING

• STAGE I - Oct. 1987-Feb.1991 (7th Plan)

• STAGE II - Mar. 1999-Feb. 2000 (9th Plan)
• STAGE III –Jul. 2006 -Mar.2007 (10th Plan)
• STAGE IV-Mar. 2013-Mar.2014(11th Plan)

ASSOCIATED TRANSMISSION SYSTEM:

Power generated by NTPC-Vindhyachal flows to the Western Region Grid. The power
is shared between various states of Western Region. Transmission lines connected to
Vindhyachal Station are as follows –
• 400 KV –4 lines to Jabalpur
• HVDC –Link between Western –Northern Region
• 400 KV –Link line to Korba
• 400 KV –4 Lines to Satna –Bina
• 132 KV –2 Lines to Waidhan

ALLOCATION OF POWER:

The percentage sharing of power from 2260 MW (Stage-I & II) of Vindhyachal
between the beneficiary states is as below –

• Madhya Pradesh 29.5 %

• Maharashtra 36.1 %
• Chhattisgarh 3.4 %
• Gujrat 23.6 %
• Goa, Daman & Diu, Dadra, Nagar Haweli 7.4 %

The allocation of power from 1000 MW of stage-III is as below

• Madhya Pradesh 23.1 %

• Maharastra 31.9 %
• Gujrat 23.9 %
• Chhattisgarh 4.2 %
• Goa, Daman & Diu, Dadra, Nagar Haweli 1.9 %
• Unallocated 15.0 %

PERFORMANCE HIGHLIGHTS:

Some of the major performance highlights are as below –

• Station qualified for meritorious productivity award of Govt. of India several times.
• Vindhyachal stood 4th in the Country in 1998-99 with a PLF of 90 %
• Vindhyachal stood 5th in the Country in 1999-2000 with a PLF of 88%
• Vindhyachal stood 12th in the country in 2002-03 with a PLF of 85 %
• Vindhyachal stood 18th in the country in 2003-04 with a PLF of 82 %
 • Vindhyachal stood 5th in the country in 2005-06 with a PLF of 92 %
• Vindhyachal stood 8th in the country in 2006-07 with a PLF of 92 %
• Uninterrupted running of Vindhyachal Unit #3 (210 MW) for 559
days is a new national record.

TREE PLANTATION:

Due emphasis has been given on Tree Plantation at NTPC-Vindhyachal. So far more than
17.38 lakh trees have been planted in and around the station. The work of tree
plantation is being taken as one of the targets every year and is being monitored
regularly.

ASH UTILIZATION:

2006-2007 21, 04632 MT 56.00%

SAFETY & OTHER AWARDS TO STATION:

• 1987 –National Safety Council Award

• 1998 –British Safety Council Award
• 1999 –British Safety Council Award
• 1999 –National Safety Award
• 2000 –National Safety Award
• 2003 –Golden Globe Award for Environment (By NTPC)
• 2004 –Green-tech Safety award
• 2005 − CII EXIM Business Excellence Award
• 2006 –Green-tech Silver Award for Environment
• 2007- National award for economics of quality (dl shah commendation
award) by Hon’able President of India on 9th Feb’07
• 2008- National award for economics of quality (dl shah award) on 16th Feb’ 08
• 2008- National award for economics of quality (dl shah commendation
award) on 16th Feb’ 08

POWER PLANT BASICS

1. LOCATING A THERMAL POWER PLANT

(1) SITE REQUIREMENT

Adequate Land–Lease from forest

department. For Each 1000MW = 90 to 200

Acres of land.

(2) GEOLOGY
Soil Requirement
Which can bear Heavy structures.

(3) WATER REQUIREMENT For

Boiler 3 to 4 Tons/hr./MW.

For cooling once through -20000m3/hr./100MW.

(4) COAL REQUIREMENT: NIGAHI MINE S- CLOSE TO 60000 TONS/DAY.

(5) TRANSPORT

(6) DISPOSAL OF ASH- 30% ASH

(7) TRANSMISION OF POWER

(8) PROXIMITY TO AIR FIELD

(9) FISHERIES AND MARINE LIFE. 10C

(10) PERSONNEL REQUIREMENT

2. PLANT LOADING FACTOR (PLF)

It is defined as the ratio of total generation of the power plant to its installed capacity.
Since its inception, NTPC has always maintained high values of PLF close to 85% - 95%
which has increased the overall power production capability of the plant.

3. POWER PURCHASE AGREEMENT (PPA)

Before setting up of a power plant, MoU’s are interested in purchasing the power from the
plant. A fixed amount is allotted and the concerned state has to pay the cost accordingly even
if the demand is less.
 BASIC LAYOUT OF A COAL FIRED PLANT

The basic building block of a coal fired plant is steam, which is generated from properly
treated and De-Mineralized water (DM water), supplied by CW (Circulating Water) pump
house. The coal is finely powered to increase its surface area for efficient firing and this
process is called pulverization and it is carried out in Coal Handling Plant (CHP) located
near MGR (Merry Go Round) system of NTPC. The Pulverized coal is then sent to bunkers
via conveyor belts and is then sent to the furnace via a typical air draft system discussed at
later stage.

The firing of coal inside furnace maintains it to a very high temperature and this heat
energy is converted into pressure energy in the form of super heated steam extracted
from the DM water flowing inside the water walls located in the boiler which is in turn
embedded into the furnace.

This super heated steam does the actual work on turbine blades which reduces its
temperature and pressure and converts the pressure (&heat) energy into kinetic energy
of moving blades. The exhaust steam is re circulated via condenser which would be
discussed later. Now the rotational kinetic energy of turbine is converted into electrical
energy using Turbo Generator (TG) and sent to the distribution sector (Switchyard) via
Generator Transformer (GT). The power flow and all the necessary protection regarding
load dispatch is commissioned in Switchyard.
 COMPLETE DESCRIPTION OF POWER PLANT

COAL TRANSPORTATION & HANDLING

Coal is a heterogeneous solid fuel and Composed of two types of

material Coal = Combustible + Non- combustible
(Maceral) (Mineral)
1. Maceral is the coaly matter produces heat on coal combustion C
(coal) + O2 (Air) = CO2 +Heat (exothermic reaction)
Heat→ Steam raising → Mechanical energy →Ele
2. Second part mineral is undesirable one and on combustion forms ash.
Ash = thermally transformed minerals (Oxides)

WHY COAL QUALITY?

•Coal Quality affects the performance of a power station starting from Milling system to
ESP

•Coal quality has a significant bearing on design of steam generator and on types & size
of auxiliaries.

•Knowledge of coal quality is Essential for its Efficient utilization

•Correct Assessment of Coal quality is Essential for Correct Performance Assessment.

Grade Useful Heat Value Corresponding Gross Calorific

(UHV) (Kcal/Kg) Ash% + Moisture Value GCV (Kcal/
% at (60% RH & Kg) (at 5%
40O C) moisture level)
A Exceeding 6200 Not exceeding 19.5 Exceeding 6454
B Exceeding 5600 but 19.6 to 23.8 Exceeding 6049 but
not exceeding 6200 not exceeding 6454
C Exceeding 4940 but 23.9 to 28.6 Exceeding 5597 but
not exceeding 5600 not exceeding.
6049
D Exceeding 4200 but 28.7 to 34.0 Exceeding 5089 but
not exceeding 4940 not Exceeding 5597
E Exceeding 3360 but 34.1 to 40.0 Exceeding 4324 but
not exceeding 4200 not exceeding 5089
F Exceeding 2400 but 40.1 to 47.0 Exceeding 3865 but
not exceeding 3360 not exceeding.
4324
G Exceeding 1300 but 47.1 to 55.0 Exceeding 3113
not exceeding 2400

MGR

MGR is merry-go-round system of NTPC for captive transportation of coal from the mine
end to the power plant. MGR of NTPC-VINDHYACHAL has its own locomotives and
wagons. Various rakes are deployed for transportation of around 30,000 MT/day of coal.
One rake consists of one locomotive and up to 33 wagons. Due to configuration of tracks at
track hoppers end and for safety reason more than 33 wagons are never deployed in a rake.
Signalling is also provided for safety of the rake movement. Operational activities of MGR,
which are required for bringing coal from mine end to track hopper of NTPC- Vindhyachal
are identified and planned in accordance.
For unloading of coal from the locomotive, two methods are deployed-

• Manual via track hopper

• Wagon Tippler

Track hoppers are conical arrangements for inlet of coal inside the conveyor belt
arrangement system via paddle feeders which directs the flow of coal to conveyors. Track
Hopper, normally of 200-250m length. Manual labor required for coal scavenging.
 In wagon tippler arrangement the wagons are jacked at once and turned down into
the track hopper. No manual labor required.

COAL HANDLING PLANT

The coal is received at track hopper of CHP through the merry go round system used for
coal transportation. Coal flows through paddle feeders, belt conveyors, vibro feeder /
vibrating screen to the crusher where it undergoes size reduction (-20 mm size). The
crushed coal is transported through different conveyors and trippers to the respective
unit bunkers. The coal crushed in excess of the requirement is stacked at stockyard of
CHP through stacker / reclaimers.
Whenever required by system, the coal is reclaimed and fed to unit bunkers through
stacker / reclaimers. Cage bar / cage screen are checked regularly to ensure that crusher
output is always maintained as per the requirement stated above. In case bigger size coal
is found, that crusher is offloaded and inspected for rectification.

BUNKERING:

Uncrushed coal from track hopper is fed to crusher, where it under goes a size reduction,
and then it is fed to the bunkers through various conveyors and trippers. The sizes of coal
feeding to the bunkers are being checked manually by physical inspection.

STACKING:

The coal which comes from mine through the MGR system is crushed and the crushed coal
from crusher is diverted to the stacker-cum-reclaimers through concerned conveyors if
 all unit bunkers level is normal. The coal is stacked in 05 nos. available yards in a planned
manner by proper dozing and water spraying process.

RECLAIMING:

Coal is reclaimed from stack yard with the help of stacker-cum-reclaimer and fed to the
bunkers as per requirement of the process or whenever

The conveyor belt motors are continuously monitored for over/under loading conditions via
SCADA interface panel from CHP control room. Magnetic separators and various types of
protection limit switches are present inside the conveyor belt region for monitoring. Transfer
points (TP) are used for connecting various conveyor regions and Penthouse contains
magnetic separators and metal detectors in the raw coal. The
Coal is then crushed in CRUSHER HOUSE and sent to Bunkers via other set of conveyor bel
 WORKING OF STEAM POWER PLANT

Coal is burnt in a boiler, which converts water into steam.

The steam is expanded in a turbine used to drive alternator.
The steam expanded is condensed in a condenser to be feed into the boiler again.

SCHEMATIC ARRANGEMENT OF COAL STEAM POWER PLANT

Steam generating equipment includes:

1. BOILER
A boiler is closed vessel in which water is converted into steam by utilizing the
heat of coal combustion. Steam boilers are broadly classified into following two
types:

• Water tube boilers

In a water tube boiler, water flows through the tubes and the hot gases of
combustion flow over these tubes. Water-tube boilers are used for high-
pressure boilers

• Fire tube boiler

In a fire tube boiler, the hot products of combustion pass through the tubes
surrounded by water. The heated water then rises into the steam drum. Here,
saturated steam is drawn off the top of the drum. The steam will reenter the
furnace in through a superheater in order to become superheated. Superheated
steam is used in driving turbines. Since water droplets can severely damage
turbine blades, steam is superheated to 730°F (390°C) or higher in order to
ensure that there is no water entrained in the steam.
2. SUPER HEATER
• A device which removes last traces of moisture.
• It helps in reduction in requirement of steam quantity.
• Steam being dry reduces the mechanical resistance of turbine.
• No corrosion at the turbine blades

3. ECONOMISER AND AIR HEATER

• They are such devices which recover the heat from the flue gases on their
way to chimney and raise the temperature of feed water.
• Economizer raises boiler efficiency.
• Air Pre-heaters recover the heat from the flue gases leaving the economizer
and heat the incoming air required for combustion

4. CONDENSER
• Which condenses the steam at the exhaust of turbine
• It creates a very low pressure at the exhaust of turbine, this helps in
converting heat energy of steam into mechanical energy in the prime
mover.
• The condensed steam can be used as feed water to the boiler.
• It creates a very low pressure at the exhaust of turbine, this helps in
converting heat energy of steam into mechanical energy in the prime
mover.
• The condensed steam can be used as feed water to the boiler.

5. PRIME MOVER (TURBINE)

• A steam turbine is a mechanical device that extracts thermal energy from
pressurized steam, and converts it into mechanical energy.
• About 86% of all electric generation in the world is by use of steam
turbines.
• It has almost completely replaced the reciprocating piston steam engine.

6. COOLING TOWER
• Remove heat from the water discharged from the condenser so that the
water can be discharged to the river or re circulated and reused.
• Air can be circulated in the cooling towers through natural draft and
mechanical draft.
 ARRANGEMENT OF STEA M POWER PLANT

Induced Draft Forced Draft

 ELECTROSTATIC PRECIPITATOR

Indian coal contains about 30% of ash. The hourly consumption of coal of a 200 MW unit
is about 110 tons. With this, the hourly production of ash will be 33 tons. If such large
amount of ash is discharge in atmosphere, it will create heavy air pollution thereby
 resulting health hazards. Hence it is necessary to precipitate dust and ash of the flue
gases.
Precipitation of ash has another advantage too. It protects the wear and erosion of ID fan.
To achieve the above objectives, Electrostatic Precipitator (ESP) is used. As they are
efficient in precipitating particle form submicron to large size they are preferred to
mechanical precipitation.

CONSTRUCTION:

An ESP has series of collecting and emitting electrons in a chamber collecting electrodes
are steel plates while emitting electrodes are thin wire of 2.5mm diameter and helical
form. Entire ESP is a hanging structure hence the electrodes are hung on shock bars in an
alternative manner.
It has a series of rapping hammer mounted on a single shaft device by a motor with the
help of a gear box at a speed of 1.2 rpm. At the inlet of the chamber there are distributor
screens that distribute the gas uniformly throughout the chamber.
There are transformer and rectifiers located at the roof of chamber. Hopper and flushing
system form the base of chamber.

WORKING

Flue gases enter the chamber through distributor screen and get uniformly distributed.
High voltage of about 40 to 70 KV form the transformer is fed to rectifier. Here ac is
converted to dc. The negative polarity of this dc is applied across the emitting electrode
while the positive polarity is applied across the collecting electrodes. This high voltage
produces corona effect negative (–ve) ions from emitting electrode move to collecting
electrode. During their motion, they collide with ash particles and transfer their charge.
On gaining this charge, ash particles too move to collecting electrode and stock to them.
Similar is the case with positive (+ve) ions that moves in opposite direction.
The rapping hammers hit the shock bars periodically and dislodge the collected dust
from it. This dust fall into hopper and passes to flushing system. Here it is mixed with
water to form slurry which is passed to AHP.Efficiency of ESP is approximately 99.8%.

1. Side view of electrostatic precipitator

 BASIC CYCLES OF A POWER PLANT

The power plant now can be subdivided into a number of closed process cycles which
are as follows-
1. Coal cycle
2. Primary and Secondary Air draft cycle
3. Super Heated Main Steam Cycle
4. Circulating Water and Condensate cycle
5. Flue Gas Cycle.

COAL CYCLE

Now the basic inputs and requirements for proper burning of coal are
1. Pulverization of coal for increased surface area and easy flow into furnace.
2. Proper Ignition temperature and moisture free.
3. Air for complete combustion. Thus the required for burning of coal and conversion
of water into steam is covered under the above mentioned cycles.

Raw Coal from Coal

Storage
Crusher
In
Bunker.

TO FA AND FD
DRAUGHT SYSTEM

Raw Coal Mill Motors

Feeders
 Bunkers are cylindrical storage tanks of crushed coal from CHP. The coal level is always
maintained within limits and is handled by conveyors whose rate can be controlled from
the CHP control room. For a 210MW stage at BTPS there are 10 bunkers and each bunker
is connected to RC feeder which is special type of motor arrangement for feeding properly
crushed coal into mill motors. The idea here is to reject any type of metallic or impurity or
unwanted substances from coal. A RC feeder consists of three rollers with a conveyor belt
in it, the amount once released from this feeder definitely goes into the furnace and the
amount is controlled via the speed of conveyor belt and two opening gates, one motorized
and one manual. There are 10 set of Mill Motors. Each mill motor contains a bowl and
roller arrangement for crushing of coal and this crushed coal is carried away to the
furnace via mix PA discussed at later stage.

RC FEEDER SPECIFICATIONS

Type SECO - 36'' Gravimetric (with Mechanic

Weighing)
Capacity Minimum - 11350 Kg/hr.
Maximum - 87820 Kg/hr.
Supplier SECO. U.S.A.
Density of material to be handled 720 to 1280 Kg/m3
Drive Motor (KW) 5.6
Clean out motor (KW) 0.22
Power supply 415V, 3-phase, 50 Hz
Gear reduction 130.5,1 at 1375 rpm
Special features Free standing control cabinet Tropical
service, Eddy current clutch control,
water sprays Motion monitor, Purge air
valve.

MOTOR USED IN BOWL MILL

Manufacturer M/s Siemens West Germany/BHEL Bhopal.

Motor Type SQ – Motor
Standard continuous rating at 400C 560 KW
Derated rating for specified normal 525 KW
Rated voltage 6600 Volts
Minimum permissible starting voltage 90% rated
Rated speed 590 RPM

AIR DRAFT CYCLE

The Primary Air, Secondary Air & Flue gas System:

The PA needed to carry away the pulverized coal from the Pulverizes to furnace is
supplied by two numbers PA Fans. A portion of PA passes through APH where it picks
up the heat from flue gas and becomes hot PA.
 FD SAP WIND B

PA Cold PAPH
FANS PA MIL

The SA which ensures the complete combustion of the fuel in the furnace is supplied by two
numbers Force Draught (FD) fans. The whole SA passes through APH & picks up heat from
flue gases & goes to wind box. From wind box it goes to furnace via SADC comprising of
FAD located at coal mill elevation which opens proportional to feeder speed. Auxiliary air
dampers which maintains furnace to wind box DP. Oil air dampers, which are open at the
oil elevation, are in-service proportional to the oil pressure. In case there is no oil firing,
these dampers behaves like Auxiliary air dampers.

In order to avoid the furnace getting subjected to the positive pressures, the flue gases
which results from the combustion of the coal are drawn out of the furnace via APH (Air
Pre Heaters) using two numbers ID fans, which discharges the flue gas to Chimney which
is further discussed in flue gas cycle.

The temperature of the air provided by PA Fan is controlled via cold PA extracted from
the PA line before APH, the cold PA is then mixed with Hot PA from PAPH and passed via
bowl mill motors creating primary air draft system.
Seal Air Fan:

These are used for supplying seal air to the mills to prevent ingress of coal dust into
gearbox lubrication oil. There are two fans per boiler.

Soot Blowers:

The soot blowers are used for efficient on-load cleaning of furnace, super heaters,
Reheaters and regenerative air heaters. There are three types of soot blowers provided in
the plant in requisite numbers. They are:
1. Long retractable soot blowers
2. Wall blower
3. Air heater blower
Superheated steam is tapped from the super heater for the purpose of soot blowing.

STEAM CYCLE
BOILER

Boiler can simply defined as the device where any liquid is boiled or Boiler may be defined
as a device that is used to transfer heat energy being produced by burning of fuel to liquid,
generally water, contended in it to cause its vaporization. Boiler, in simple
terms, can be called“Steam Generator”. The following are fact efficient combustion usually
referred as “The three T’s”.
a) Time –It will take a definite time to heat the fuel to its ignition temperature
and having ignited, it will also take time to burn.
b) Temperature –A fuel will not burn until it reaches its ignition temperature.
c) Turbulence –Turbulence is introduced to achieve a rapid relative motion
between the air and fuel particles

Block Diagram of Steam Cycle

COMPONENTS OF A BOILER

1. ECONOMISER
2. BOILER DRUM
3. DOWN COMERS
4. WATER WALL
5. PRIMERY SUPER HEATER
6. PLATEN SUPER HEATER
7. FINAL SUPER HEATER
8. RE-HEATER
9. BURNER
10. OIL GUNS
11. IGNITORS
12. BUCK STAYS

ECONOMISER
1.
FORMED IN TWO STAGES - ECO I & II AND ECO III
2.
FORMS PART OF FEED WATER CIRCUIT
3.
PRE HEAT BOILER FEED WATER
4.
RECOVERY OF HEAT FROM FLUE GAS
5.
LOCATED IN BOTTOM OF REAR PASS
6.
NO STEAM FORMATION

BOILER DRUM
1.
TO SEPARATE WATER FROM STEAM
2.
TO REMOVE DISSOLVED SOLIDS
3.
TO PROTECT WATER WALLS FROM STARVATION
4.
ACTS AS TEMPORARY PRESSURE RESERVOIR DURING TRANSIENT LOADS

WATER WALL
1. FORMS FURNACE ENCLOSURE
2. GENERATION OF STEAM
3. PROVIDES SEALING TO FURNACE
SUPER HEATER

RAISE STEAM TO HIGHER TEMPERATURE ARRANGED IN 3 STAGES

LTSH LOCATED ABOVE ECONOMISER

RADIANT PENDENT TYPE (DIV PANEL) ABOVE FURNACE
CONVECTIVE FINAL SUPER HEATER ABOVE FURNACE IN CONVECTIVE PATH

RE HEATER

RE HEAT THE STEAM FROM HP TURBINE TO 540 DEG

•
COMPOSED OF THREE SECTIONS
•
RADIANT WALL REHEATER ARRANGED IN FRONT & SIDE WATER WALLS
•
REAR PENDANT SECTION ARRANGED ABOVE GOOSE NECK
•
FRONT SECTION ARRANGED BETWEEN UPPER HEATER PLATEN & REAR WATER
WALL HANGER TUBES
The Main steam & Re-Heated steam System :

The heat produced by the combustion of the coal is used to generate the steam. The steam
is further heated in the super heaters & forms Main Steam. This main steam is delivered
to the Turbine through main steam (MS) lines in a controlled manner by means of Main
Steam Stop Valves & Control valves that are regulated by the TG Governing System. In
turbine the steam expands & converts Heat energy in to Mechanical energy.

In between the HP turbine & IP turbine the steam is again carried to the Boiler, where it is
reheated & delivered to the IP turbine in a controlled manner by means of RH steam stop
valves & control valves that are regulated by the TG Governing system
After the turbine, the steam goes to the condenser where it is condensed under deep
vacuum using CW. The condensate is collected in the Hot well

CIRCULATING WATER CYCLE

Condensate, Feed Water & Boiler Water system

The condensate from the hot well is extracted by CEP & is pumped, via LP Heaters where
it gets heated up, to the Deaerator. The condensate now becomes feed water & gets stored
in the Feed Storage Tank just below Deaerator. The BFP takes Suction from this Feed
Storage tank & pumps this feed water through HP heaters, feed control station &
economizer to the Boiler Drum, where it becomes Boiler Water. This boiler water goes to
the boiler water walls where it absorbs heat, transforms in to steam & return back to the
Boiler drum. In stage I boiler this circulation of boiler water is natural, whereas in stage III
boiler it is assisted by CW pumps.
CW System

CW system consists of CW pump house having CW pumps for supplying CW to the

condenser of stage III units through common CW duct & also for supplying raw water to
Auxiliary pond for miscellaneous use. Auxiliary Water pump house, which draws water
from Auxiliary pond & supplies for various purposes such as fire water system, raw water
supply for clarification plant etc. Clarification plant, where the raw water is clarified & is
fed to the clarified water tank. Clarified water pump house, where the clarified water is
pumped to supply it to generator gas coolers & other BCW system.

STEAM TURBINE

GENERAL:

At Vindhyachal Station 500 MW capacity turbines are of Kraft Werk Union (KWU -
Germany) design and supplied by BHEL. The turbine is condensing, tandem compounded,
horizontal, reheat type, single shaft machine. It has got separate high pressure, intermediate
and low pressure parts. The HP part is a cylinder and IP & LP parts are double flow cylinders.
The turbine rotor is rigidly coupled with each other and with generator rotor.

HP turbine has throttle control. The stream is admitted through two combined stop and
control valves. The steam from reheaters is admitted to IP turbine through two combined
stop and control valves. Two crossover pipes connect IP and LP cylinder.

The entire turbine is provided with reaction blading. The moving blades of HPT, LPT and
front rows of LPT have inverted T roots and shrouded. The last stages of LPT are twisted;
drop forged moving blades with fir tree roots. They also have guide blades for proper
functioning. The TG unit is mounted on six bearings HPT rotor is mounted on two bearings,
a double wedged journal bearing at the front and combined thrust bearing adjacent to front
IP rotor coupling.

In the 500 MW KWU turbines, single oil is used for lubrication of bearings, control oil for
governing and hydraulic turbine turning gear. During start-ups, auxiliary oil pump (2
Nos.) supplies the control oil. Once the speed of the turbine crosses 90% of the rated
speed, the main oil pump takes over. Under emergency, a DC oil pump can supply
lubrication oil. Before the turbine is turned or barred, the Jacking Oil Pump (2 Nos.)
supplies high pressure oil to jack up the turbine generator shaft to prevent boundary
lubrication in bearing.

The turbine is equipped with a hydraulic turning gear assembly comprising two rows of
moving blades mounted on the coupling between IP and LP rotors. The oil under pressure
supplied by the AOP strikes against the hydraulic turbine blades rotates the shaft at 110rpm
(220 rpm under full vacuum condition).

Turbine shaft glands are sealed with auxiliary steam supplied by an electro-hydraulically
controlled seal steam pressure control valve. A pressure of 0.01 Kg / square-cm (g) is
maintained in the seals.

Above a load of 80 MW the turbine becomes self-sealing. The leak off steam from HPT/IPT
glands is used for sealing LPT glands.

TURBINE PROTECTION SYSTEM

Turbine protection system performs to cover the following functions:-

1. Protection of turbine from inadmissible operating conditions.
2. In case of plant failure, protection against subsequent damages.
3. It restricts occurring failures to minimum.

Standard turbine protection system comprises the

following:-hydraulic turbine protection.

The main elements of the Turbine Protection system are as follows:

1. Emergency Governors.
2. Emergency Governor Pilot Valves.
3. Emergency stop valve (ESV) Servomotors.
4. Interceptor valve (I V) Servomotors.
5. Turbine shutdown switch.
6. Electro-hydraulic transducer.
7. Initial steam pressure unloading gear.

H.P. - L.P. BY- PASS SYSTEM

The HP By-pass system in coordination with LP By-pass enables boiler operation and
loading independent of the turbine. For matching the live steam and metal temperature
for a quick start-up, by-pass stations have been provided, which dumps the steam to the
condenser through pressure reducing station and de superheaters, during the period the
steam parameters at the boiler are being raised. This allows quick rising of parameters to
a level acceptable to the turbine for rolling during start-up. It helps in quick start of
turbine and low noise level, also economizes the consumption of DM water. The HP By-
pass system consists of two parallel branches that divert steam from the Main Steam line
to Cold Reheaters line. The steam pressure on the valve upstream side can be maintained
at the desired level. The steam is de-superheated in order to keep the steam temperature
in cold reheat line within limits, below 345 degree Celsius. The steam downstream of the
HP by-pass station is maintained by 2 nos. pf spray water temperature control valves
BPE-1 and BPE-2 with valve mounted electro-hydraulic actuators.
With the use of turbine by-pass station it is possible to build up the matching steam
parameters at the boiler outlet during any regime of starting, independent of the steam
flow through turbine. The steam generated by boiler, and not utilized by the turbine
during start-up or shutdown, is conserved within the power cycle and thus losses of
steam into the atmosphere are cut down to the barest minimum. By-pass system enables
to shorten the start-up time.

CONDENSATE EXTRACTION PUMP (CEP)

The condensate extraction pump (CEP) is a centrifugal type vertical pump, consisting of
pump body, can, distributor housing and the driven lantern. The pump body is arranged
vertically in the can and is attached to the distributor with the rising main. The rotor is
guided in bearings lubricated by the fluid pumped, is suspended from the support
bearing, which is located in the bearing pedestal in the driven lantern. The shaft exit in the
driver lantern is sealed off by one packed stuffing box. The steam after condensing in the
condensing in the condenser known as condensate is extracted out of the condenser hot
well by condensate pump and taken to the Deaerator through ejectors, gland steam cooler
and series of LP heaters. The function of these pumps is to pump out the condensate to
the Deaerator through injector, gland steam cooler, and LP heaters. These pumps have
four stages and since the suction is at a negative pressure, special arrangements have
been made for providing sealing.

BOILER FEED PUMP (BFP)

These pumps almost consume 2% of total power generation of the power plant. Basically
these pumps are meant to supply continuous water to the boiler drum.
There are two- types of BFP’s
1. Turbine Driven (TDBFP)
2. Motor Driven (MDBFP)
Initially the plant is started with MD-BFP, and then after attaining proper steam pressure TD-BFP’s
are used to decrease power consumpti
Each BFP is provided with a Booster pump in its suction line which is driven by the main
motor of the boiler feed pump. One of the major damages which may occur to a BFP is
from Cavitation or vapour bounding at the pump suction due to suction failure.
Cavitations will occur when the suction pressure of the pump at the pump suction is equal
or very near to the vapour pressure of the liquid to be pumped at the particular feed water
temperature. By the use of the booster pump in the main pump suction line, always there
will be positive suction pressure which will remove the possibility of Cavitations.
Therefore all 3 feed pumps are provided with the main shaft driven booster pump in its
suction line for obtaining a definite positive suction pressure.
 Water Treatment Plant and Storage

Since there is continuous withdrawal of steam and continuous return of

condensate to the boiler, losses due to blow down and leakages have to be made up to
maintain a desired water level in the boiler steam drum. For this, continuous make-up
water is added to the boiler water system. Impurities in the raw water input to the plant
generally consist of calcium and magnesium salts which impart hardness to the water.
Hardness in the make-up water to the boiler will form deposits on the tube water surfaces
which will lead to overheating and failure of the tubes.

Thus, the salts have to be removed from the water, and that is done by a water de-
mineralizing treatment plant (DM). A DM plant generally consists of cation, anion, and
mixed bed exchangers. Any ions in the final water from this process consist essentially of
hydrogen ions and hydroxide ions, which recombine to form pure water. Very pure DM
water becomes highly corrosive once it absorbs oxygen from the atmosphere because of its
very high affinity for oxygen.

The capacity of the DM plant is dictated by the type and quantity of salts in the raw water
input. However, some storage is essential as the DM plant may be down for maintenance.
For this purpose, a storage tank is installed from which DM water is continuously
withdrawn for boiler make-up. The storage tank for DM water is made from materials not
affected by corrosive water. The piping and valves are generally of stainless.

CONCLUSION

Industrial training being an integral part of engineering curriculum provides not

only easier understanding but also helps acquaint an individual with technologies. It
exposes an individual to practical aspect of all things which differ considerably from
theoretical models. During my training, I gained a lot of practical knowledge which
otherwise could have been exclusive to me. The practical exposure required here will pay
rich dividends to me when I will set my foot as an Engineer.

The training at NTPC Vindhyachal was altogether an exotic experience, since work,
culture and mutual cooperation was excellent here. Moreover fruitful result of adherence
to quality control awareness of safety and employees were fare which is much evident
here.
 BIBLIOGRAPHY

WIKIPEDIA
PRESENTATIONS FROM EDC DEPARTMENT,BTPS
PRESENTATION FROM SENIORS AND EMPLOYEES OF VSTPP
NTPC VSTPP WEBSITE
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