ABSTRACT

According to the rules of Rajasthan Technical University, I have undergone my 30 days Practical Inplant Training at NTPC, Anta which is incorporated in the syllabus for 4 year B.Tech. Course. The training report hereby submitted outlines the course of work during my training in an oriented manner over a period of 30 days for Electronic Instrumentation and Control branch. The whole capacity of plant is 419.33 MW with 4 generating units. The report consists of generation of electricity in its 4 units & constructional features of main parts of plant. Adequate diagrams and layouts have been provided for a more descriptive outlook and clarity of understanding. In all, I have tried my best to present this report in a very precise and profitable manner. Engineering students gain theoretical knowledge only through books, which in not sufficient for absolute mastery in our field. Thus, I made a sincere attempt to bring about the details which I experienced during my training at NATIONAL THERMAL POWER CORPORATION (ANTA) from 15 JUNE TO 14 JULY 2011 through this report. I have tried my best to reproduce the facts & findings of the training site.

CHAPTER -1 INTRODUCTION

1. BRIEF NTPC-AN INTEGRATED POWER MAJOR

A journey towards excellence established in 7 Nov. 1975, NTPC limited, a premier sector enterprise, is Indias largest power utility with an installed capacity of 27,904MW through 26 power station including station operated under joint exploration, power distribution trading and also plans to enter into nuclear power development. NTPC plans to become a 50,000MW Company by 2012 and 75,000MW plus company by 2017. The company contributed 29.25% share of the total installed capacity of the nation including capacity and generation of joint venture companies

.
Figure 1.1

1.1 COMBINED CYCLE TECHNOLOGY:The year was 1985, government of India decided to effectively use the sweetened natural gas, which was to be made available by GAIL through cross-country HBJ gas pipe line NTPC was entrusted with a responsibility to set up gas based power project in Gujarat, Rajasthan and Utter Pradesh, NTPC submitted the feasibility reports for 3 gas based projects at Anta(Rajasthan), Auraiya (U.P) and Kawas (Gujarat). The feasibility report of anta was approved by government of India in October, 1986. The land was simultaneously acquired,bhoomipoojan of the land to start the work performed on 16.01.1987 by the then CMD shri M.L. shishoo, and the charging of construction power was inaugurated.

1.2 MILE STONE:Govt. approval of feasibility report Bhoomipoojan Award of main plant turnkey contract Synchronization of GT-1 Synchronization of GT-2 Synchronization of GT-3 Synchronization of ST Location Total land Fuel Water source Net plant output 20.10.86 16.01.87 24.08.87 20.01.89 04.03.89 04.05.89 09.03.90

: anta in Baran district of Rajasthan : 390.75 acres. : natural gas naphtha : KOTA RIGHT MAIN CANAL : 419.33 MW

1.3 SALIENT FEATURES OF ANTA

1. GAS TURBIN :89, TYPE 13D-2, ABB MAKE, 5TH STAGE REACTION TURBINE 2. GT COMPRESSR : 18TH ST; AGE AXU\IAL FLOW, REACTION BLADING 3. COMBUSTION CHAMBER :SINGLE SILO TYPE, DUAL FUEL FIREBURNER 4. AIR INTAKE FILTER :SELF CLEANIN, SYNTHETIC PAPER, TOTAL 945 FILTERS IN THREE TIRES 5. BYPASS STACK 6. WASTE HEAT RECOVERY :VERTICAL 25M. HIGH :DUAL PRESSURE, DOUBLEDRUM, UNFIRED, FORCED CIRCULLATION BOILER HP LP 7. STEAM TURBINE PRESSURE 62.70 BAR 5.5 BAR FLOW 163 T/HR 39.1 T/HR TEMP 485 207

:153.20MW, TANDEM COMPOUNDED , DOUBLEEXHAUTST, CONDENSING

TYPE, SINGLE FLOW HORIZONTAL 25 STAGE HP TURBINES. 8. CONDENSOR :DOUBLE PASS SURFACE CONDENSOR WITH STAINLESS STEEL TUBES, COOLING 13988M3.

9. GENERATOR OUTPUT GTG.135MVA STG. 191MVA 10. BLACK START FACILITY

:3 PHASE, TWO POLE, IR COOLED VOLTAGE 10.5KV 15.75KV SPEED 3000RPM 3000RPM

: 2.4MW DIESEL GENERATOR SET, V6.6KV

11. COOLING SYSTEM FOR

:3*50% COOLING WATER PP AND CONDENSER 2*50%COOLING TOWER PP, CAPACITY 15000M3 EACH, 11 NOS ARIFLOCCUATORS, CAP. 110M3/HR

12. PT. PLANT

:2 NOS AIRSLOCCULATORES, CAP.110M3/HR :TWO STEAM OF 35M3/HR EACH :419.33MW :NATURAL GAS (MAIN FUEL), THROUGH HBJPIPE LINE, NAPTHA, (ALTERNATER) FUEL BY ROAD TANKER

13. DM. WATER PLANT 14. NET PLANT OUT 15. FUEL

16. WATER SOURCE 17. RESERVIOUR 18. TOTAL LAND 19. PLANT OUTPUT

:KOTA RIGHT MAIN CANAL :10 MILLION M3, FOR 1 MONTH :390.75 ACRES :419.3 3MW

CHAPTER -2 GERNAL DESCRIPTION OF COMBINED CYCLE

The 419.33MW anta combined cycle power plant consist of three gas turbines generator sets of 89.20MW each and one steam turbine generator set of 153.20 MW. The gas turbines are equipped with a dual fuel burner for gaseous fuel (natural) and liquid fuel (naphtha). The station can be operated in the open cycle mode via their exhaust gas bypass stacks or as modules together with their waste heat recovery boilers and STG in the combined cycle mode. The WHRBS is designed as dual pressure boilers with high pressure (HP) and low pressure (LP) sections and condensate preheating at the tail end. The condensate pumped from the condenser hot well is degasified in the deairator at constant pressure and stored in the feed water tank. From feed water tank, the boiler feed water is extracted by mean of separate boiler feed water pumps for the HP and LP system serving the 3 WHRBS in common HP and LP main steam lines the turbojet is composed of single flow HP turbine and one double flow LP turbine. The generator is directly coupled to the shaft of LP cylinder. The exhaust steam of the STG is condensed in a surface condenser cooled by fresh water of the right main Kota canal in the once through cycle. During the shutdown of canal, the condenser is cooled via a wet cooling tower in the closed cycle alternatively. For start-up and shutdown as well as trip of STG one common HP and LP steam bypass station for all 3 modules are provided leading the steam directly into the condenser.
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1. PRINCIPAL OF COMBINED CYCLE:The function of a gas turbine in a combined cycle power plant is to drive a generator, which produces electricity, and to provide input heat for the steam cycle. Power for driving the compressor is also drive from gas turbine. Combined cycle power plant integrated two power conversion cycles namely, Brayton cycle (gas turbine) and rankine cycle (conventional steam power plant) with the principle objective of increasing overall plant efficiency.

Figure 2.1

Figure 2.2

2. BRAYTON CYCLE
The Brayton cycle, named after the American engineer George Brayton (that built a two-stroke reciprocating engine in 1876 and advanced combustion chambers at constant pressure ), is a good model for this operation of a gas-turbine engine
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(first successfully tested by F.Whittle in 1937, and first applied by the Heinkel Aircraft Company in 1939) ,nowadays used by practically all aircraft except smallest ones, by many fast boats and increasingly been used for stationary power generation, particularly when both power and heat are of interest. In the ideal air-standard Brayton cycle, the working fluid is just air, which is assumed to Follow four processes is entropic compression, constant-pressure heat input from the hot source, isentropic expansion, and constant pressure heat rejection to the environment. Contrary to reciprocating engines, the gas turbine is a rotating device working at a nominal steady state (it can hardly work at partial loads) spark ignition is used to start up, since air compressor output temperature is not high enough to inflame the fuel. THEIDEAL BRAYTON CYCLE IN THE T-S AND P-V DIAGRAM, AND THE REGENERATIVE BRAYTON CYCLE

Figure 2.3

3. RANKINE CYCLE:
The conversion heat energy to mechanical (or electrical) energy with the energy of steam is carried out by this cycle. In its simplest form the cycle works as follows. The initial state of working fluid is water which, at the certain temperature is compressed by a pump and feed to the boiler. In the boiler the compressed water is heated at a constant pressure. Modern steam power plants have steam temperature in the range of 500-5500C at the inlet of turbine.

Figure 2.4

4. ADVANTAGE OF COMBINED CYCLE PLANTS:

In addition to higher energy efficiencies, the advantages of combine-cycle units over more conventional power generation sources include the following advantages:1. Lower construction and maintenance costs 2. Low gestation period 3. Better reliability

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CHAPTER -3 GAS TURBINE

GENERAL DESCRIPTIONA gas turbine plant in its most simple form consist of the following main part 1. Air intake system 2. Compressor 3. Combustion chamber 4. Turbine 5. Generator

1. AIR INTAKE SYSTEM:The air flow radial inward through the filter elements then upward to clean air duct. The air inlet connection has horizontal air inlet and situated axially in front of the compressor. three are three horizontal floors in t filter house each floor carry 315 filters. (Total filters are made of synthetic and cellulose fibers, using resign impregnated).

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2. COMPRESSOR:It is 18 stages with additional inlet guide blade, axial flow, reaction compressor. The blade of the 18 rotor and 19 fixed rows are made of high tensile ferric chrome steel. The compressor casing is horizontally split at axis, and is made of spherical graphite cast iron. This material possesses high tensile strength and good expansion quality. upper and lower halves of the compressor casing are provided with robust flanges and are held together by expansion studs with socket head. The compressor casing has three circular ducts at 4th, 7th, 10th row of fixed blades. These ducts are closed to the outside by four bleed halves. Bleed halves are kept open unto 2700rpm,so that certain amount of compressor air can be blow off. These bleed valves reduces the external power input required running compressor during start up.

3. COMBUSTION CHAMBER:In combustion chamber, the air compressed and supplied by compressor is brought to the required process temp. by combustion of liquid/gas fuel. The single combustion chamber is fitted with only one duel fired burner and mounted vertically on the compressor/turbine assembly. The combustion chamber is all welded steel plate fabricated. The main parts are jacket with cover, lower upper combustion chamber bodies, finned segment body, burner and inner casing.

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Combustion chamber jacket, which houses the components, is made of heat resistant, low alloy ferrite steel. Finned segment body encloses the hottest zon e of the combustion chamber. The air from the compressor enter the combustion chamber from below and flow upward through the annular space between combustion chamber jacket and inner section of the lower combustion chamber body. Approximately 30% air flow enter the combustion chamber through eight mixing nozzles provided at the lower body as secondary and approximately 30% air flow enter the combustion chamber through upper body via fined segment row (there are 5row, the remaining 40%flow as primary air for combustion, into the swirl insert and enter the combustion space with turbulence. After the fuel has ignited these gases are thoroughly mixed with secondary air form mixing nozzles and brought to the permissible turbine inlet temp. The inner casing guides the hot gases coming from combustion chamber to the turbine halding.it is thin welled construction made of heat resistant chromenickel austenitic alloy.

4. TURBINE:Turbine is five stage reaction turbines. Due to high temp.of incoming gases, the first and second row of rotor and fixed blading are air cooled with air from compressor discharge. The cooling air is fed to the first and second row of fixed blades through holes drilled in the blade carrier and to the first & second row of rotor blades through hole drilled in shaft. Cooling air passes along several holes

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made in blades and finally blowing out through numbers of slits in the trailing/leading edge of the blade. This method of cooling ensures that blades are thoroughly cooled, thereby avoiding cracks induced by thermal stresses. These cooled blades are fixed rotor blades of other rows are made of cast in nickel based alloy. The fourth and fifth row of rotor blades fifth row of fixed blades are drop forged. turbine outer casing is split into two halves like compressor casing are bolted together at radial flange with expansion bolts, turbine casing is made of heat resisting ferrite steel in order to with stand thermal stresses. The blade carrier for turbine fixed blades is made of ferrite steel alloy casting and axially like turbine/compressor.

Figure 3.1

4.1 FEATURES OF ABB 13D2 TYPE GAS TURBINE1. A single shaft of welded construction. 2. Axial compressor of 18 stages with bleed valves after 3rd,6th ,9th stages for protection against surging and also reduced power required for startup.
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3. A single combustion chamber with a single burner. The combustion chamber is mounted vertically on the turbine outer casing. The large size of the combustion chamber provides easy access to inspection of its internals as well as approach to the turbine inner casing and first stage blades of turbine. 4. The burner is of dual fuel design and either gas, naphtha (or any liquid fuel) or both can be fixed. 5. Five stage axial turbine with axial exhaust for easy connection to a waste heat boiler. First two stages of turbine blades are coated. 6. First five stages of compressor blades are coated to protect against corrosion due to humidity. 7. First 2 stages of turbine blades are coated against high temperature corrosion.

4.2 OTHER CHARACTERISTICS OF GAS TURBINE1. The gas flow ducts must offer minimum hydraulic resistance. 2. The axial flow at exit from last stage of a gas turbine constitutes 150-200 mm/s and the kinetic energy of the gases attain 10%of the total useful energy. To minimize losses an exhaust diffuser is provided. 3. If the ratio of mid diameter of stage to blade height is less than or equal to 12 to 14 twisted blades are decided. 4. There is no extraction like in steam turbines hence the flow path is simpler.

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5. Liquid fuel usually contains impurities like VA, NA, S, etc. These substances destroy corrosion protective film on heat resistant steels. 6. Along with use of high temp and heat resistant metals, various design techniques are employed to reduce temperature levels and remove heat from the hottest elements in gas turbines. As much as 15% of compressor discharge air is used for cooling of blades, rotors and blade carrier etc. 7. First rows of blades are made hollow or have longitudinal bore holes for cooling. Non solid and often have a thinned portion at the tip to minimize risk of damage on contact with the turbine casing. 8. Gas turbine rotors are usually disc type with intense cooling arrangement. 9. Turbine blade carrier is horizontal split and is of strong and stiff designs in order minimize radial blade clearances. Hence casing is made of symmetrical cross section and with uniform wall thickness in order that temperature deformations due to frequent and sharp changes in turbine operation could not distort the cylindrical shape from inside. To lower casing wall temperature heat shields and cooling is provided. 10. there is no governing stage in gas turbine.Partial admission is not permissible and load control is only control through of TIT.

4.3 GAS TURBINE PLANT OPERATION:The compressor sucks in air from the atmosphere through the filters called air intake filters. The compresses air at approx. 9 to 11 bar passes into the
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combustion chamber where it is used as primary air for combustion and secondary air for cooling of very hot parts. The gas turbine generates the necessary power to drive the axial-flow compressor and the generator. The turbine and compressor are in common casing. Start-up of the GT is drives with the help of starting equipment which runs the generator as a motor with speed increasing from 0 to 600 rpm. At this speed a pilot is ignited in the combustion chamber, fuel (gas/naphtha) enters and combustion takes place. The speed increases further both with the help of generator motoring and the combustion of fuel up to about 2000 rpm. At this speed starting equipment is switched off and only the generator is made ready for synchronization with the grid. After synchronizations, the turbine load increases up to the base load with more and more fuel entering the combustion chamber. The hot gases after combustion enter the gas turbine at about 1000 (at

base load). The higher pressure and temperature gas pass through the turbine rotating it and generator, this produces the electrical power. The exhaust gas coming out of the GT is at about 500 . This can be utilized to produce steam in WHRB.

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Figure 3.2

4.4 ADVANTAGES OF GAS TURBINE OVER STEAM TURBINE

1.Gas turbine is more compact. There is no boiler or condenser. Auxiliaries are very few. 2. They can be started and loaded very quickly(within 20 minutes form cold start to full load) 3. Gas turbines are simpler in maintenance and designs. 4. Gas turbine plants involve less metal and material. 5. They are lower in cost for installation capacity. 6. Gas turbines dont require enormous quantities of cooling water as in steam turbines.
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4.5 DISADVANTAGE
1. Gas turbines have lower specific power. 2. They have lower efficiency. 3. Gas turbines have shorter service life. 4. They are very sensitive to fuel quality.

5.GENERATOR
Generator is three phases, two pole air cooled machine. The generator and turbine are placed on common and plane concrete foundation, with same centre line level for turbine and generator rotor. The mechanical energy generated by turbine is converted to electrical energy by the generator and appear in the stator winding in the form of current and voltage. That balances the torque of the gas turbine. It leads the magnetic flux, and carries the field winding, the generator id self excited. The power required for the excitation is % taken from the generator term finals and fed to the field winding through the excitation transformer and the thruster- controlled rectifier units.

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5.1 GAS TURBINE GENERATOR (Mka):1. Generator Type 2. No. of phases 3. No. of poles 4. Stator winding 5. Insulation class 6. Nominal apparent power 7. Nominal voltage 8. Nominal current 9. Reactance A. Direct axis synchronous reactance ad B. Direct axis transient reactance xd C. Direct axis sub transient reactance D. Negative sequence reactance x2 E. Zero sequence reactance x0 F. Short circuit ratio kc 10. Full load efficiency 11. Stator winding resistance at 200c 12. Rotor winding resistance at 200c 13. Stator winding capacitance ph. to core 14. Weight, generator assembled 15. Rotor weight : : : : : : : : : : : : 191% 14.4% 10.2% 12.8% 5.8% 0.58% 98.38% 0.000607 ohm 0.2177 ohm 0.52 micro F 162 MT 31 MT : : : : : : : : wy18 L-095ll 3 2 star f 135MVA 10.5kv 7423a

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CHAPTER -4 FUEL SYSTEM

1. GAS:Gas comes from GPRS bars at around 18 bars; manual isolation valve is to be opened by operator. Motorized stop relief valve is depressurized. When valve opens, the relief port is closed. In the gas control block there is an emergency stop valve(ESV). This opens with the help of power oil pressure against spring force. Whenever, turbine trip the oil is drained (depressurized) and spray force closes the valve cutting off gas supply to combustion chamber.

2. NAPHTHA:Naphtha comes from naphtha solution via the forwarding pumps at around 15bar. Manual isolation valve outside GT hall is to be opened by the operator manual isolation valves before main fuel pump and also to be opened. Motorized valve will be opened by GT program and when FG liquid fuel is selected. NAPHTHA then passes through duplex filter to the main fuel oil pump, which raises the press to approx. 80 bar. There is release valve which opens when firing speed is reached (600 rpm)

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There is an emergency stop valve similar toone in the gas scheme. Finally there is the control valve directly coupled with the NAPHTHA nozzle. A minimum opening of the nozzle is already pre-set. once stable flames formed, the nozzle opening increases with the control valve opening.

3. LUBRICATING OIL/POWER:The turbo generator set has four bearing which are continuously supplied with lubricating oil form MOT which is located between the compressor and generator. There are two bearings on either side of generator and one bearing at turbine end bearing at compressor end. AN auxiliary lube pump (AC motor drive) supplies lube oil during the start up and during rotor turning operation in case of AC supply failure DC lube oil pump will start automatically. there are two high pressure AC motor driven jacking oil pumps there function is lift the turbine/generator slightly, during start up, so that starting force is reduced. A vent fan mounted on the MOT keeps it under vacuum and removes the fumes/vapours to atmosphere. Barring gear pump-AC motor driven pump rotates the shaft in term intently during rotor-turning operation to prevent sagging of rotor .in case of an auxiliary power oil pump (AC pump) driven provides hydraulic oil for operation of hydraulically operated valves. A motor driven circulation pump keeps oil in circulation through power oil system when the GT is under shut-down,to avoid ingress of air.
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During normal operation all the above pumps remain off. the lube and power oil are provided by a shaft driven main oil pumps located inside the Gear box on the top of the MOT. Lube oil is cooled in coolers outside GT hall. These are air cooled radiator type coolers. Lube oil passes through tubes and air passes over these tubes induced by 3 fans. After cooler, the oil is passed through duplex type filters and goes to bearings.

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CHAPTER -5 BOILER

The boiler installed in national thermal power corporation is manufactured by Austrya. The boiler is used to generate high pressure, super heater steam which is ultimately used to drive the turbine coupled to the generator hence producing electrical power. Boiler unit comprise to following units:1. Boiler 2. Super heater 3. Economizer The steam generator is of radiant reheat, natural, circulation, single drum, dry bottom an semi out door type unit, designed for firing gas as principle fule. The super heater steam has mainly three sections. The low temperature super heater, the radiant temperature super heater (arranged at the out section of furnace) and the final super heater (arranged after re-heater). Two super heater, de-heater are provided in between the list section and platen super heater for controlling super heater steam temperature over wide load range. The complete back pass of the boiler (up to economizer) has been covered with steam cooled super heater wall section the complete re-heater has been arranged as one section and located in the horizontal pass of the boiler in between the radiant platen super heater and final super heater. Two re-heater de-super heater are provided in the cooled re-heated inlet, hot re-heater outlet, economizer inlet heaters are provided with required guides to take care of forces and moments from external, piping connections. The complete part system is suspended from the boiler structure steel roof section and arranged for expansion downward.
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1. SYSTEM DESCRIPTION OF WHRB:Wagner-biro supplied boilers for anta combined cycle power plant known as waste heat recovery boilers (WHRB),which are of non fired ,dual pressure, forced circulation type. The boiler has two different water/steam cycles known as high pressure system and low pressure system. Each system has its own boiler drum and circulating pumps, and are feed by HP&LP feed water pumps from a common feed water tank. The pressure and temperature the HP&LP steam from the three boilers from four common headers HP live steam line, HP bypass line, LP live steam line, LP bypass line, the bypass line dump steam in condenser through the HP and LP bypass system. The HP steam drives the HP steam turbine through stop valves and control valves . The LP steam after passing through stop valves and control valves mixes with the HP turbine exhaust and drives the gas turbine. This dual system of operating utilizes the waste heavy from the gas turbine with maximum efficiency. From LP turbine steam enters the condenser where it get condensed to water with the help of cooling water. Condenser is shell and tube, water flow through the tubes and steam flow outside. The condensate get collected in hot well, from hot well it enters the feed water tank through condensate extraction pump (3*50%) via the help of (2*50%) vacuum pump. Each of WHRB is feed with waste heat flue gas from the respective gas turbine (GT). The gas turbines are fired either with gas or naphtha. The flu gas temperature at boiler inlet is about 500c depending on GT load and outside

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temperature conditions. The flue gas temperature at boiler outlet is about 110c140c to avoid cold end corrosion. During WHRB operation the flue gas is led through a horizontal duct with integrated silencer to diverter flap of the WHRB. There two positions of diverter flap, one open to the boiler and another is open to bypass stack. The energy from waste heat flue gas is transferred to water/steam by means of heating surface of super heaters, evaporators, economizers and condensate preheater. The heating surface of each boiler is about 96000sq.m. The heating surfaces in staggered arrangement are manufactured as finned tubes arranged horizontally and installed in vertical duct supported by tube plates. The steam water system consist of a high (HP) and low (LP) pressure system and in addition there is a condenser preheated in order to obtain a higher efficiency.

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Figure 5.1

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Figure 5.2

2. COMPONENTS OF WHRB
2.1 LP-BOILER PART:2.1.1 ECONOMIZER:The LP feed water, which flows from the (3*50%) LP feed water pumps through the common feed water line to the 3 WHRBs in parallel, enters a WHRB at economizer gate valve. The gate valve is equipped with a parallel bypass valve, which is used for first filling of WHRB and pressure equalization. In economizer the feed water is heated up by the flue gas. After the economizer the feed water enters the LP boiler drum through feed regulating
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station (FRS), where the feed water control valve ensures the correct supply of feed water to the boiler. Another part of feed water after economizer is branched to the feed water tank, where it used for de-airating purposes.

2.1.2 LP-BOILER DRUM-EVAPORATOR:The feed water in LP boiler drum is pumped through evaporator by means of (2*100%) LP circulation pumps. In evaporator the water is partially by the flue gas passing at the outside of the evaporator tubes. The steam and water mixture again enters the drum, where steam is separated and this steam flows to the LP super heaters and water is circulated again. Low level and high level protections are provided for the protection of one vent valve is mounted on the drum which opens automatically during start and closes when the pressure in drum rises above 1bar.2 nos. of safety valve with silencers are also mounted against the over pressure protection. The circulation pumps ensure the correct water flow through the evaporator for which the differential pressure between discharge and suction side of pump is supervised by means of pressure differential switch. When the pressure drops the stand by pump will starts immediately.

2.1.3 LP- SUPER HEATER:The steam leaving at the top of the LP drum flows through the flue gas heated Super Heater, where it reaches the end temperature of about 206c.

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The outlet header is equipped with motorised drain valve which is automatically operated during start-up and this valve closes automatically after pressurization. At outlet pipe a safety valve protects the super heater against over pressure.

2.2 HP-BOILER PART:The principal design of the HP-boiler part is the same as for the LP-part.The basic difference is of operating pressure.

2.2.1 ECONOMIZER:The HP fed water, which flows from the (3*50%) HP feed water pumps through the common feed water line to the HP part of 3 WHRB in parallel, enters a WHRB at the gate valve of economizer. This gate valve is equipped with a parallel bypass valve as in LP-economizer. The HP economizer coils are in two parts, one part is just below the LP economizer and the other is below the LP super heater and both the coils are connected in series. After the economizer the feed water enters the HP boiler drum through high pressure feed regulating station (FRS) , where the feed water control valve ensures the correct supply of feed water to the boiler.. The HP/LP economizers are provided with safety valves against the protection of over pressure.

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2.2.2 HP- BOILER DRUM, EVAPORATOR:The feed water in the HP- boiler drum is pumped through the evaporator by means of 2x100% HP circulation pumps in the evaporator water is partially steamed as in LP part, this partially steamed water enters in HP drum where steam is separated, and water is circulated again. These steam is super heated in HP super heater. The HP circulation pumps ensure the correct water flow through evaporator for which differential pressure switches are provided. One vent valve and two nos. of safety valves with silencers are also mounted on the HP drum just like the LP drum.

2.2.3 HP-SUPER HEATER:The HP super heater consists of two parts with a spray attemperator between them. This configuration allows the temp. controlof the super-heatedsteam. the spray water which is cooling medium is branched from the feed water line at the HP economizer inlet via a control valve to the attemperator if the temp. of superheater increases beyond the predetermined temp. Then spray water control valves opens automatically and keeps down the super heater tank at about 4980c. The outlet is equipped with mortised drain valves. A safety valve is also given against the over protection.

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2.3 CONDENSATE PREHEATER:The main condensate is pumped by 3x50% condensate extraction pumps (CEP) to the feed water tank. Before entering the feed water tank the condensate is passed through the condensate preheaters which are situated at the tail end of the WHRB and heated by the flue gas to achieve the highest cycle efficiency. By means of the 3-way control valve the preheaters can be partially or totally bypassed. At certain load conditions and also depending on ambient temperatures, it is necessary to increase the condensate temperature before entering the preheater. This is to avoid drop of the flue gas temperature below the sulphuric dew point, which would cause corrosion at the preheaters. For this purpose 2x100% condensate circulation pumps are installed. These pumps take automatic start when the condensate temperature falls below a certain limit.

2.4 BLOW DOWN TANK:One blow down tank is provided for each WHRB to collect drains e.g. CBD, IBD and drum over flow water from HP and LP system of WHRB. The water level in this tank is maintained through an over flow pipe, which leads the water to hot drain collecting system. The steam flows via a silencer to the atmosphere.

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CHAPTER -6 STEAM TURBINE

GENERAL DESCRIPTION:The steam turbine consists of two turbine sections, a single flow high pressure turbine and double flow low pressure turbine arranged in same center line. The shaft turning gear is engaged and disengaged automatically when turbine is started and shutdown. HP live steam is taken from the boiler HP system through the main steam pipe to the combined main stop and control valves. From there it flow through four opening in the outer casing into the interior of the HP turbine and enters the reaction blading through exhaust connection at the top of the HP casing. The cross over the pipe between HP and LP turbines brings the steam to the reaction blading in the LP turbine, where it expends down to condense pressure. The LP steam is taken from LP boiler system through the LP steam main line to the combined stop and control valves. From there LP steam enters the cross over piping, where it mixes with the HP exhaust before entering the reaction blading of the LP turbine. In LP turbine expansion take place and finally steam get condensed in the condenser. The turbo generator set has four bearing which are continuously supplied with lubricating oil from MOT like gas turbine. There are two bearings on either side of generator and one bearing at HP turbine end one bearing in between HP.
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CHAPTER -7 POWER PLANT CHEMISTRY

Figure 7.1

1. SHORT TERM PLANNING:

Under short term planning work elements are established as follows:  Work receipt and control, i.e. work order system  Planning and scheduling  Preventive maintenance work programs

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 Integration of PM schedule with corrective maintenance to minimize downtime  Condition monitoring  Plant and work history recording  Work management analysis and management reporting

2. CONDITION MONITORING:The condition monitoring mainly covers the vibration measurement of rotating equipments, to analyse any abnormality or high vibration, to measure the sound level and analysis of lubricating oil.

3. LONG TERM PLANNING:The major functions of the long term planning are as follows:  Compilation of the station five year rolling plan  To prepare and ensure all necessary arrangements for the following years overhaul work programs.  Produce, distribute and monitor major overhaul and control

programmed  Custody of all licenses of equipment covered under Indian boiler regulation act, Indian electricity act, Indian explosive act and other safety rules and to take action for renewal of these licenses.

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4. STATUARY REQUIREMENT:The long term planning engineer is also responsible for the safe custody of all licenses and takes advance action for the renewal of such licenses. At anta the following licenses are being taken as the statuary equipment: a) Factory licenses b) Licenses for storing naphtha fuel c) Licenses for storing diesel d) Licenses for HP boiler drum(3nos) e) Licenses for LP boiler drum(3nos)

5. PERMIT TO WORK SYSTEM (PTW SYSTEM):Permit to work is a written permission to carry out the work on any equipment/ system. This system is required because the electrical and mechanical items of plant and apparatus are interconnected to from electromechanical systems and contain inherent dangers. Hence, while working on any equipment/ system, it is to be ensured that it is safe to work on. The permit to work system followed at anta is computerized one. The permit to work is always issued by the operation department and taken by the respective maintenance department. Each permit to work has unique PTW number so that identification is easy. The procedure which is followed is issue any permit to work is follows:

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a. Whenever any work is to be done on any apparatus/ equipment in the plant area respective maintenance person applies for a permit to work. Permit to work is must for any work to be done in the plant area which may affect the normal operation of the plant. b. After receiving the permit to work request, operation engineer carry out the isolations as required. The isolation which is required is jointly finalized by operation and maintenance engineers. Maintenance engineer specifies his equipment keeping in mind the safely and operation engineer take care of the process requirement. c. A danger tag is attached to the electrical supply or at the control station mentioning the PTW number and name of the equipment etc. After carrying out the isolation. d. When it is ensured that the equipment/ system are isolation and safe to work on, permit to work is issued after signature of the operation and maintenance engineer. After issuance of permit to work, the required work is being carried out by the maintenance department. Every permit to work has duty. Time and date and permit to work should be returned by in case the work could not be completed till that time may be extended by operation engineer on the request of maintenance engineer the procedure for cancellation of permit to work is follows: a. After completion of work and clearance from the permit to work holder (maintenance engineer) certifying that all men and material removed and equipment is ready to be put in service, the isolations done are removed by the operation engineer.

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b. The trial run of the equipment is taken jointly, wherever required. After satisfactory trial run, the permit to work may be closed. c. The details of the work done are entered in the computer and permit to work is closed by operation engineer.

6. POWER EVACUATION:There are total 220 kava transmission lines for evacuation of power generated at anta. There are two lines for Bhilwara, two lines for Jaipur and one line for Kota. One lines for Rawatbhata power plant

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CHAPTER -8 WATER TREATMENT PLANT

The principle problem in high pressure boiler is to control corrosion and steam quality. Internal corrosion costs crores of rupees in repair. Without strict control, impurities in steam also form deposit over turbine blades and nozzles. impurities present in water are as follows: Un-dissolved and suspended solid materials.  Dissolved slats and minerals.  Dissolved gases.  Other minerals (oil, acid etc.).  Turbidity & Sediment.  Silica.  Micro Biological.  Sodium & Potassium Salt.  Dissolved Sales Minerals.  O2gas.  CO2 gas. Thus to make water pure for feeding in B.F.P. and to have protection against corrosion and other above mentioned problems de-mineralisation is needed. The procedure is explained asThe

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1. D.M. PLANT
In this plant process, impure water is fed. This plant consists of two streams, each stream passes through activated carbon filter, weak acid, cation exchanger and mixed bed exchanger. The impure water is fed to DM plant through 250 dia. header from it is taken to softening plant. Two filtered water booster pumps are provided on filtered water line for meeting the pressure requirement in DM Plant. Sodium Sulphate solution of required strength is dosed into different filtered water streams by means of dosing pump to neutralize chlorine prior to activated carbon filter. Water passes through an activated carbon filter to remove residual chlorine from water. Water then goes to weak base anion exchanger unit & enters de-gasified unit where free CO2 is scrubbed out of water by upward counter flow of low pressure air flow. This de-gasified water is pumped to strong base exchanger (anion exchanger).

Figure 8.1

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2. C.W. PLANT
Circulating water pump house has pumps for condensing the steam for condenser. After condensing the water is discharged back into the river. Each of the 5 pumps for 1st and 2nd unit has capacity of 8275 M3/Hr, and develop pressure about 1.94 kg. /Cm2. 3 seal water pumps are used for sealing circulating water pump shaft at pr. 4.5 kg./cm2. One pump is taken standby at a time. From main line water passes through filter bed to filter the water. Clarified water is pumped to 42 m elevation where water is stored in tank and used for cooling the oil coolers and returns back to river.

3. B.C.W. PUMP HOUSE

Filtered water after demineralization is used for Bearing Cooling from BCW pump house. Water enters at 30-32oC and leave exchanger at 38oC. The raw water used in ash handling plant and remaining quantity is stored in BCW Pump House. From here the water is pumped to CW pumps. BCW here stand for water used for cooling oil used for cooling the bearing. In CW pump house water is discharged from nozzle and impinged for travelling water screens for cleaning it.

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CHAPTER -9 MAINTENANCE MANAGEMENT

The maintenance management system consist mainly the following areas  Preventive maintenance/ lubrication schedule.  Break-down maintenance.  Capital overhauls/ scheduled inspections.  Condition monitoring.  Spare parts management.  Statuary requirements.  Short term planning engineer.  Long term planning engineer.  Spare parts management and spare parts development. The short term planning covers the preventive maintenance, lubrication schedule, break-down maintenance and condition monitoring. The long term planning covers the capital overhauls, scheduled inspections and statutory requirements. The spare parts management and spare part development is the third area looked separately by one engineer. The anta gas power project being completely imported plant supplied by M/S ABB, Germany on the turn-key basis, the spare part indigenization has been given due importance.

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ANGPP has four discipline of the maintenance section as follows:  Mechanical maintenance section  Electrical maintenance section  C&I maintenance section  Civil maintenance section Each of section is headed either by manager or senior manager (E5/E6) and the area engineers are as follows: Mechanical maintenance section Electrical maintenance section C&I maintenance sections Civil maintenance section 5nos. 4nos. 6nos. 2nos.

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CHAPTER -10 CONCLUSION

Electricity has a prominent role to play in life. It is a vital to all segments of the economy. It is a precursor to the progress and prosperity of the nation. Government of India has a target of per capita availability of electricity to be increased to over 1000 units and minimum lifeline consumption of 1unit/house hold/day as a merit good by year 2012. In electricity the more you supply the greater is demand as supply of power causes economic development and increased standard living which enhances the demand. The digital economy enterprises data warehouses, call centres, software technology parks and other computer control mission critical businesses are the fastest growing segments of power consumers. These enterprises require nearly 100% up time to guarantee integrity of their products and services. The power sector has made rapid strides in absolute term on. III the spheres viz. generation, transmission network and energy mix. Despite these achievements the power sector has been plagued by serious shortages of electricity, as it has not been able to keep pace with rapid growth in demand. However the power sector has reached a point, from where it is possible to consolidate the growth made till now and sustain and enhance that growth to keep pace with economic development.

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SCHEDULE OF THE INDUSTRIAL TRAINING

DURATION- 30 days(15 June 14 July)
DATE 15 June 17 June 18 June 20 June 21 June 24 June 25 June 27 June 29 June 01 July 04 July 05 July 08 July 09 July 12 July 14 July TOPIC Joining Formalities General Introduction of NTPC & Power Scenario in India Economics of Power Generation Power Generation Process Safety Aspects in Power Plant Steam Turbine Auxiliaries-Intro. (CW/CT) Production of DM/ Clarified/ Softening of water and its quality control Plant Visit Evacuation of Power from Anta- Intro to 220 KV Switchyard Process Control STG/GT & Instrumentation-

Electrical apparatus in Power Station and their Protection Plant Visit HR Structure & System Finance & accounting System Information Technology & communication Systems/ SAT System Distribution of certificates

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