PROJECT REPORT

Summer Training

PROJECT REPORT
ON

VINDHYANCHAL SUPER
THERMAL POWER STATION

Submitted by:

Parvej Akhter B.E.

(FINAL YEAR)
 Contents
1. Introduction of NTPC

2. Production of Electicity

3. Principal of Steam Power Plant

4. H.T.Switch gear

5. L.T.Switch gear

6. Generators and Transformers

7. D.C. System

8. Switch Yard

9. Coal Handling Plant

10. Coal Handling Plant Power Distribution

11. Demineral Plant(DM Plant)

12. Coal ,Water and Steam Cycle

13. Conclusion

INTRODUCTION OF NTPC
Established in 1975, NTPC the largest power company of the country has been consistently powering the
growth of India.

With an installed capacity of 30,144 MW, it contributes 28.6% of the nation's power generation with only
18.79% of India's total installed capacity. An ISO 9001:2000 certified company, it is world's sixth largest
thermal power generator and second most efficient in capacity utilization.

The corporation recorded a generation of 206.94 billion units (bus) in 2008-09, an increase of 3.03% over
2007-08, through 13 coal based and 7 gas based power plants spreads all over the country. Rated as one of
the "Best companies to work for in India it has developed in to a multi-location and multi fuel Company over
the past three decades.

Driven by its vision to lead, it has charted out an ambitious growth plan of becoming a 40,000 MW plus
company by 2012.

Following are the other important highlights of 2008-09:

1. Total Income of Rs.455, 000 million.

2. Net profit in excess of Rs.78, 274 million

3. A dividend payment of Rs.126, 865 million to the Govt. of India.

Received highest credit rating AAA by CRISIL and LAAA by ICRA for domestic bond and international rating for
Eurobond.
 NTPC contributes more than one-fourth of India's total
power generation with less than one-fifth capacity

TOTAL CAPACITY GENERATION

AS ON 31.03.2009 2008-09

28.60%

NTPC 27,850*MW NTPC 206.94*BUs All India

All India 147,965 MW 723.56 BUs
* excluding joint ventures

INTRODUCTION ABOUT PROJECT

Singrauli Super Thermal Power Plant is located at Shaktinagar in Sonebhadra district in Indian state of Uttar
Pradesh. The power plant is the first power plant of NTPC. It sources coal from Jayant and Bina mines and
water from Rihand Reservoir. The states benefitting from this power plant are Uttar Pradesh, Uttranchal,
Rajasthan, Punjab, Haryana, Jammu & Kashmir and Himachal Pradesh and the Union Territories of Delhi and
Chandigarh. An investment worth ^11,907 million (US$170 million) has already been cleared. It even gets
international assistance from IDA.

ON 31 December 2014, a 15 MW solar PV was commissioned at NTPC SIngrauli. An 8 MW small hydro CW

discharge plant has been constructed on discharge canal.

The NTPC has total installed capacity of 30, 144 Mega Watts and has the goal to reach the capacity of 40000
Mega Watts. Today it has project at the following places: -

1. Northern region station

1. Singrauli (5*2000+2*500) Mega Watts.

2. Rihand (2*500) Mega Watts.

3. Unchahar (5*210) Mega Watts.

4. Tanda (4*110) Mega Watts.

2. Southern region station

1. Ramagundem (3*200+3*500) Mega Watts.

Kayamkulam (2*155GT+1*120St) Mega Watts.
2.

3. Western region station

1. Korba (3*200+3*500) Mega Watts.

2. Vindhyanehal (6*210+2*500) Mega watts.
(4*106 GT+2*105 ST) Mega
3. Kawas Watts.

4. Eastern region station

1. Farakka (3*200+2*500) Mega Watts.

2. Kahalgaon (4*210) Mega Watts.

3. Takher (4*60+2*110) Mega Watts.

5. Nation capital region station

1. Dadri coal (4*210) Mega Watts.

2. Auta (3*88 GT+1*149 St) Mega Watts.

3. Auraiya (4*110 GT+2*106 ST) Mega Watts.

4. Faridabad (2*143 GT+1*144 ST) Mega Watts.

PRODUCTION OF ELECTRICITY

Capacity Coal based

The unit wise capacity and other details are as follows.

Stage Unit Number Installed Capacity (MW) Date of Commissioning

1st 1982 February

1 200
1st 1982 November
2 200
1st 3 1983 March
200
1st 4 1983 November
200
1st 5 1984 February
200
2nd 500 1986 December
6
2nd 7 500 1987 November

Total Seven
2000

The means and steps involved in the production of electricity in a coal-fired power station are described below.
The coal, brought to the station by train or other means, travels from the coal handling plant by conveyer
belt to the coal bunkers, from where it is fed to the pulverizing mills which grinds it as fine as face powder.
The finely powdered coal mixed with pre-heated air is then blown into the boiler by fan called Primary Air
Fan where it burns, more like a gas than as a solid in convectional domestic or industrial grate, with additional
amount of air called secondary air supplied by Forced Draft Fan. As the coal has been grounded so finely the
resultant ash is also a fine powder. Some of this ash binds together to form lumps which fall into the ash pits at
the bottom of the furnace. The water quenched ash from the bottom of the furnace is conveyed to pits for
subsequent disposal or sale. Most of ash, still in fine particles form is carried out of the boiler to the
precipitators as dust, where it is trapped by electrodes charged with high voltage electricity. The dust is then
conveyed by water to disposal
areas or to bunkers for sale while the cleaned flue gases pass on through ID Fan to be discharged up the
chimney.
Meanwhile the heat released from the coal has been absorbed by the many kilometres of tubing which line the
boiler walls. Inside the tubes is the boiler feed water which is transformed by the heat into the steam at high
pressure and temperature. The steam super-heated in further tubes (Super Heater) passes to the turbine
where it is discharged through the nozzles on the turbine blades. Just the energy of the wind turns the sail of
the wind-mill, so the energy of the steam, striking the blades, makes the turbine rotate.

Coupled to the end of the turbine is the rotor of the generator - a large cylindrical magnet, so that when the
turbine rotates the rotor turns with it. The rotor is housed inside the stator having heavy coils of copper bars in
which electricity is produced through the movement of the magnetic field created by the rotor. The electricity
passes from the stator winding to the step-up transformer which increases its voltage so that it can be
transmitted efficiently over the power lines of the grid.

The steam which has given up its heat energy is changed back into water in the condenser so that it is ready
for re-use. The condenser contains many kilometres of tubing through which the colder is constantly pumped.
The steam passing around the tubes looses the heat and is rapidly changed back to water. But the two lots of
water (i.e. boiler feed water & cooling water) must NEVER MIX. The cooling water is drawn from the river, but
the boiler feed water must be absolutely pure, far purer than the water we drink, if it is not to damage the
boiler tubes. Chemistry at the power station is largely the chemistry of water.

To condense the large quantities of steam, huge and continuous volume of cooling water is essential. In most
of the power stations the same water is to be used over and over again. So the heat which the water extracts
from the steam in the condenser is removed by pumping the water out to the cooling towers. The cooling
towers are simply concrete shells acting as huge chimneys creating a draught (natural/mechanically assisted by
fans) of air. The water is sprayed out at the top of towers and as it falls into the pond beneath it is cooled by the
upward draught of air. The cold water in the pond is then circulated by pumps to the condensers. Inevitably,
however, some of the water is drawn upwards as vapours by the draught and it is this which forms the familiar
white clouds which emerge from the towers seen sometimes.

Why bother to change steam from the turbine back into water if it has to be heated up again immediately?
The answer lies in the law of physics which states that the boiling point of water is related to pressure. The
lower the pressure, the lower the temperature at which water boils. The turbine designer want as low boiling
point of water as possible because he can only utilize the energy of the steam - when the steam changes back
into water he can get NO more work out of it. So a condenser is built, which by rapidly changing the steam back
into water creates a vacuum. This vacuum results in a much lower boiling point which, in turns, means he can
continue getting work out of the steam well below 100 degree Celsius at which it would normally change into
water.
Principle of the Steam Power Plant

The working principle of a steam plant is based upon the Rankine cycle.
Generally steam is taken as the working medium due to its ability to be stable and

that it's readily stable. The flow of steam in the plant can be very easily be

understood by the flow diagram of the plant. A graph plotted between the
temperature and the entropy would indicate the technical details of the working by

the rankine cycle. The entropy of a system can be understood as an index of

degradation of energy.

FUit' Gases

to Bus
4tr <BOIL<EQL ban
Steam Generator
Turbine

Circulating H C on denser
Pump

PLANT FLOW DIAGRAM

H.T.SWITCH GEAR

OPERATIONG VOLTAGE - 6.6KV

For low voltage circuits fuses may be used to isolate the faulty circuit. For voltage higher than 3.3 kV isolation
is achieved by circuit breaker.

Requirement of circuit breaker:

1. After occurrence of fault the switchgears must isolate the faulty circuit as quickly as possible i.e. keeping
the delay to minimum.
2. It should not operate when an over current flows under healthy condition.

Basic principal of operation of circuit breaker:

Circuit breaker consists of a fix contact and sliding contact into which moves a moving contact. The end of
moving contact it attached to a handle that can be manually operated or may operate automatically with
the help of mechanism that has a trip coil energized by secondary of CT. Under normal condition the
secondary of CT is not energized sufficiently to trip the coil but under false condition the coil is energized
fully to operate the trip coil and the circuit breaker is operated.

1. MOCB (Minimum oil circuit breaker)

2. SF6 (Sulphur hexafluoride circuit breaker)

Here oil and SF6 are used to quench the arc.

 L.T SWITCH GEAR

OPERATING VOLTAGE- 415VOLT

TYPES OF CIRCUIT BREAKER: - Air break circuit breaker

Air brake circuit breaker:

The arc interruption process of air- based circuit breaker is based on the natural deionization of gases by
cooling action. The arc is resilient and can be stretched, and has a resistance, which can be increased both by
length and confinement. Hence the arc resistance is increased by stretching the arc and as the resistance
increases to higher value, the short circuit current drops to zero and arc is extinguished.

Reducing the phase difference between the system voltage and the short circuit current assure that when the
are current is interrupt at its zero value, the recovery voltage has very low value at its not allowed to reach 2-3
times the value of the system peak voltage, a phenomenon that occurs in most cases, when arc current is
interrupted at low power factor.
 GENERATORS AND TRANSFORMERS

INTRODUCTION-

The auxiliaries in a plant can be divided into two categories-

1. URGENT AUXILIARIES- the urgent auxiliaries are those, which are associated with running of unit.
2. SERVICE AUXILIARIES- the service auxiliaries are those whose loss would not affect output.

EXCITATION SYSTEM-

STATIC EXCITATION SYSTEM-The generators in stage -1(u-1&u-2) have this excitation system. Static
excitation system has slip ring and carbon brush arrangement. It consists of step down transformer, converter
and AVR (automatic voltage regulator).

BRUSHLESS EXCITATION SYSTEM -The generators in stage -2(U-3, U-4& &U- 5) have this excitation
system. It has two exciters, one is main exciter and other is pilot exciter.

GENERATOR PROTECTION-

1. STATOR PROTECTION- The neutral of star connected winding is connected to primary of

neutral grounding transformer, so that earth fault current is limited by over voltage relay.

2. DIFFERENTIAL PROTECTION- In case of phase-to-phase fault generator is

protected by longitudinal differential relay.

3. ROTOR PROTECTION- Rotor winding may be damaged by earth faults or open circuits. The field is biased
by a dc voltage, which causes current to flow through the relay for an earth fault anywhere on the
field system.
4. OVER SPEED PROTECTION - Mechanically over speed device that is usually in the form of centrifugally
operated rings mounted on the rotor shaft, which fly out and close the stop valves if the speed of the
set increase more than 10%.

5. OVER VOLTAGE PROTECTION - It is provided with an over voltage relay. The relay is usually induction
pattern. The relay open the main circuit break and the field switch if the over voltage persists.

6. SEAL OIL SYSTEM - Hydrogen in the generator is under very high pressure.
There is a possibility of this hydrogen to come out of gaps, which is very hazardous. So, seal oil is
used to seal the gaps so that hydrogen doesn't come out.

7. LUBRICATION OIL SYSTEM - Turbine lubrication-oil system seeks to provide

proper lubrication of turbo generator bearings and operation of barring gear. Pumps are used to
circulate lubrication-oil inside the generator. The oil of the lubrication and the governing system
is cooled in the oil coolers. The cooling medium for these coolers is circulating water.

TRANSFORMER

TYPE PF TRANSFORMERS—

1. GENRATOR TRANSFORMER: -- This is a step up transformer. This supply gets its primary
supply from generator and its secondary supplies the switchyard from where it is transmitted to grid.
This transformer is oil cooled. The primary of this transformer is connected in star. The secondary is
connected in delta. These are four in number.
2. STATION TRANSFORMER: -- This transformer has almost the same rating as the generator transformer.
Its primary is connected in delta and secondary in star. It is a step down transformer. These are 4 in
number.
3. UNIT AUXILIARY TRANSFORMER: -- This is a step down transformer. The primary receives from
generator and secondary supplies a 6.6 KV bus. This is oil cooled. These are 8 in number.

4. NEUTRAL GROUNDED TRANSFORMER: -- This transformer is connected with

supply coming out of UAT in stage-2. This is used to ground the excess voltage if occurs in the
secondary of UAT in spite of rated voltage.

D.C SYSTEM

INTRODUCTION:

DC system is generally used for control and protection operation, as AC supply is not fully
dependable. To maintain constant supply in case of power failure we use DC supply.
DC system consists of a battery charger. These are the mode of energy storage.

CHARGING EQUIPMENTS:

The battery charging equipment comprises of trickle charger, quick charger, battery panel, main
distribution board and switch control and signaling board.

CHARGING EQUATION:

In battery PbO2 used as positive plate and Pb as negative plate.

1. DISCHARGING PROCESS

2. CHARGING PROCESS

BATTERY CHARGER:

Battery charger normally operates in two modes.

1. Float charging: It is constant voltage mode and works as a trickle charger.

2. Boost charging: It is constant current mode and works as a quick charger.

TRICKLE CHARGER:

This charger is fed from three-phase ac supply and gives a dc-stabilized output at rated full load current.
The variation of the dc output voltage is limited to +/- 1% for 0 to 100% load variation and simultaneously
ac voltage variation of +/- 10% of frequency variation of +/- 5% from 50 Hz.

The rectification is obtained through full bridge controlled silicon rectifier. Stack comprising of these SCR and
three diode with the surge suppression RC network connected across each SCR and diode.

SWITCH YARD

As we know that electrical energy can't be stored like cells, so what we generate should be consumed
instantaneously. But as the load is not constants therefore we generate electricity according to need i.e.
the generation depends upon load. The yard is the places from where the electricity is send outside. It has
both outdoor and indoor equipments.

SINGLE LINE DIAGRAM OF 220KV SWITCH YARD-

OUTDOOR EQUIPMENTS

1. BUS BAR

2. LIGHTENING ARRESTER

3. WAVE TRAP

4. BREAKER

5. CAPACITOR VOLTAGE TRANSFORMER

6. CORONA RING

7. EARTHING ROD

8. CURRENT TRANSFORMER

9. POTENTIAL TRANSFORMER

10. LIGHTENING MASK

11. LIGHTENING MOOSE

INDOOR EQUIPMENTS

1. RELAYS

2. CONTROL PANELS

CIRCUIT BREAKER:

The code for circuit breaker is 52. An electric power system needs some form of switchgear in order
to operate it safely & efficiently under both normal and abnormal conditions.

Circuit breaker is an arrangement by which we can break the circuit or flow of current. A circuit breaker in
station serves the same purpose as switch but it has many added and complex features. The basic
construction of any circuit breaker requires the separation of contact in an insulating fluid that servers two
functions:

1. It extinguishes the arc drawn between the contacts when circuit breaker opens.

2. It provides adequate insulation between the contacts and from each contact to earth.

The insulating fluids commonly used in circuit breakers are:

1. Compressed air

2. Oil which produces hydrogen for arc excitation.

3. Ultra high vacuum

4. Sulphur hexafluorides

The Specifications of the circuit breaker used are:

 MAKE CROMPTON GREAVES LTD.

TYPE AIR BLAST CIRCUITREAKER

RATED VOLTAGE 245 KV

RATED LIGHTING IMPULSE

WITHSTAND VOLTAGE 1050 KV

RATED SHORT CIRCUIT BREAKING CURRENT 25 -40KA

RATED FREQUENCY 50HZ

RATED NORMAL CURRENT 2000 A TO 4000 A

RATED CLOSING VOLTAGE 220 V DC

RATED OPENING VOLTAGE 220 V DC

LIGHTING ARRESTER:

It saves the transformer and reactor from over voltage and over currents. We have to use the lightning
arrester both in primary and secondary of transformer and in reactors.
A meter is provided which indicates the surface leakage and internal grading current of arrester.

1. Green - arrester is healthy

2. Red - arrester is defective.

In case of red we first de-energize the arrester and then do the operation.

AIR BREAK EARTHING SWITCH:

The code of earthling switch is 5, 6, 7.The work of this equipment comes into picture when we want to
shut down the supply for maintenance purpose. This help to neutralize the system from induced voltage
from extra high voltage. This induced power is up to 2KV in case of 400 KV lines.
 BUS BAR:

Bus bars generally are of high conductive aluminum conforming to IS-5082 or copper of adequate cross
section .Bus bar located in air -insulated enclosures & segregated from all other components .Bus bar is
preferably cover with polyurethane.

1. Current Transformer (CT):

A current transformer is a type of instrument transformer designed to provide a current in its

secondary winding proportional to the alternating current flowing in its primary

Current Transformer Diagram

Application:

1. They are commonly used in metering and protective relaying in the electrical power industry
where they facilitate the safe measurement of large currents, often in the presence of high
voltages.
2. The current transformer safely isolates measurement and control circuitry from the high
voltages typically present on the circuit being measured.
3. Current transformers are used extensively for measuring current and monitoring the operation
of the power grid. The CT is typically described by its current ratio from primary to
secondary. Often, multiple CTs are installed as a "stack" for various uses (for example,
protection devices and revenue metering may use separate CTs). Similarly potential
transformers are used for measuring voltage and monitoring the operation of the power
grid.
4. Capacitive Voltage Transformer (CVT):

A capacitor voltage transformer (CVT) is a transformer used in power systems to step-down extra high
voltage signals and provide low voltage signals either for measurement or to operate a protective relay. In its
most basic form the device consists of three parts: two capacitors across which the voltage signal is split, an
inductive element used to tune the device to the supply frequency and a transformer used to isolate and
further step-down the voltage for the instrumentation or protective relay as shown in figure below.

The device has at least four terminals, a high-voltage terminal for connection to the high voltage signal, a
ground terminal and at least one set of secondary terminals for connection to the instrumentation or
protective relay. CVTs are typically single-phase devices used for measuring voltages in excess of one hundred
kilovolts where the use of voltage transformers would be uneconomical. In practice the first capacitor, C1, is
often replaced by a stack of capacitors connected in series.This results in a large voltage drop across the stack
of capacitors that replaced the first capacitor and a comparatively small voltage drop across the second
capacitor C2, and hence the secondary terminals.
 COAL HANDLING PLANT

Introduction: -

NTPC Vindhyanagar gets its coal supply mainly from NCL, Singrauli. Now coal is also coming from Australia, as
coal produced in India is of low grade and ash content is more. The coal being filled in the wagons of the rail
reaches plant. The purpose of this plant is to convey the coal to the bunker in the size not larger than 20mm.It
handles and transports the coal to the bunker from the wagons by passing through various conveyors,
transfer points, crusher houses, etc.

Type of coal: -

BCCL costs Rs.4/kg

CCl cost Rs.6/kg

Type of unloading the coal: -

1. Manual Unloading: - Previously, manpower was used for unloading the wagons. But it
was very time consuming and more workers were required for the job to be done.

2. Box in (using wagon tippler for unloading): - For this method, Indian Railway
grants 10 hours for unloading the 58 wagons. In this method, Wagons are separated and tippled by using
wagon tippler. The Beetle Feeder is used to move the wagon on wagon tippler. The coal from the wagons
gets accumulated in The Track Hopper. At this time; the size of the coal is approximately 300mm.

3. BOBR: - Indian Railway grants only 2.5 hours for Unloading 58 BOBR wagons. This is an
advanced technology in which we use the compressor system.
 In Bottom Open Bottom Release (BOBR) technology the wagons are opened from side. Pressure is applied
by the compressor to open the bottom gates of the wagon so that the coal gets released over the track
hopper and wagon get unloaded quickly.

Various equipment used in CHP: -

1. WAGON TIPPLER: - The wagon tippler is a most important device in thermal power
project.
The Wagon tippler turns back the wagon at 135-degree angle and the structure of the wagon tippler is to
be very heavy. Upper side of the wagon is fixed with the many angles for supporting the wagon. When the
wagon is fixed on the Platform then whole platform is turned back and the coal fall down in the wagon
tippler hopper. The unloading time of the Rack is 6hours. Here the type of the rack is Box C / Box N type.

A- WTH, B-VF, C- BC, D- DS are the parts of the wagon tippler.

1. Wagon Tippler Hopper; - The Wagon tippler Hoper is a part of the wagon tippler where
the coal is stored from the wagon tippler. The size of the coal here is less than 300mm.

2. Vibrating Feeder; - The vibrating feeder is used for falling the coal on the conveyer
through Wagon tippler Hoper. Before Wagon tippler Hoper and Vibrating Feeder the gate is providing
to control the flow of the coal.

3. Beetle Charger; - The Beetle charger is a traveling device that is used to carry
the wagon on the wagon tippler platform.

4. Dust Suppuration; - Dust Suppuration is a useful device. When the wagon are
tippling then the dust is mixed in the air and that area becomes very dusty then Dust Suppuration
operates and water flows through its points and the dust settles down. It is an automatic device.
2. PADDLE FEEDER: - They have been installed on conveyors below the manual unloading track hopper.
There are 6 nos. of paddle feeders, 3 on each conveyer. 3 Paddle Feeders of each conveyer move to and
fro within a limiting range. The rotating part of the paddle feeder is called as plough wheel. Plough wheel
has 6 blades. By the rotation of the plough wheel, the coal of the track hopper gets accumulated between
the blades and is discharged on the conveyor below it. The main components of paddle feeder are:

1. Plough wheel-It is the rotating part consists of 6 blades. It is attached with the rotor of 3-phase
slip ring induction motor.

2. Reduction gear box- It is installed to control the speed of plough wheel.

3. End limit switch (left or right)-It provides the limiting motion of the paddle feeders.

4. Anti-collision switch- It provides the prevention from collision between two paddle feeders.

5. Interlock system-It is provided for safety purpose. By this, the conveyor belt moves first then paddle feeder
starts.

3. VIBRATING FEEDER: - They have been installed below the track hoppers of wagon tippler.
The coal is accumulated over the vibrating feeder so by giving vibrations to the vibrating feeder we
discharge the coal from track hopper to the conveyors. Their main purpose is to provide uniform feeding
on the conveyors. The vibrating feeders consist of a tray to which vibrator body is fixed on the rear end.

4. TRANSFER POINTS: - Transfer Point is provided with flap gate and Conveyer. In transfer
Point the coal is transferred from one conveyer to other conveyer.

1. Flap Gate: - The flap Gate is a two-way device. It consists of two gates. Both gates cannot operate together.
By help of the flap Gate, we change the way of coal that fall down on the conveyer.

2. Conveyers: - The Conveyer Belt is a moving device. It travels on its platforms. The shape of the
conveyer belt is to be flat but on the platforms it is to be in curve shape. The coal falls
 down the conveyer and goes to the primary Crusher House Platforms. The capacity of conveyer in
Stage - I is 800MT/ hr. & in Stage -II is 1200MT / hr.

Many protecting device provide to the Conveyer— a -Zero Speed

Switch, b -Pull Cord Switch, c - Belt Sway Switch

1. Zero Speed Switch: - The Zero Speed Switch prevents the Conveyer from over load run. When the
conveyer is over loaded, the speed of the conveyer is reduced and Zero Speed Switch is operated and
stops the conveyer. This device is provided at Head End of the Conveyer. The Zero Speed Switch is a
Centrifugal Switch.

2. Pull cord Switch: - This is a manual protecting device. When the Worker sees any mistake like big stone or
any dangerous fault, pulls this cord. The Pull Cord Switch is to be operated, and the Conveyer stops.

3. Belt Sway Switch: - The Belt Sway Switch also protects the conveyer. This device is provided on both side
of the conveyer. When the conveyer leaves its way the switch is operated and the conveyer stops.
This is also an automatic protecting device.

4. PRIMARY CRUSHER (ROTARY BREAKER): - In Primary Crusher House, the coal breaks in
Rotary Breaker. Here the coal comes from the Transfer point; breaks here and the stone fall down to a
separate place. Coal is converted from 300mm to 150mm size.
Part of the Primary Crusher House - a- Rotary Breaker b- Belt Feeder

1. ROTARY BREAKER; - The Rotary Breaker has a rotating mechanism. It is rotated on the
shaft. The coal come from the conveyer through the Flap Gate falls down into the rotary breaker. The
rotary breaker is to be rotated and coal moves up and down and collides and hence breaks. The
Rotary Breaker is H.T. 170KW 6.6KV Motor

2. BELT FEEDER; - The Belt Feeder is a small size of the conveyer. It is used for feeding the coal to the
conveyer through Flap Gate.

6. SECONDARY CRUSHER (RING GRANULATOR): - In Secondary crusher House first the

magnetic part separate from the coal and then feed to the Secondary Crusher. This Crusher breaks
 the coal in 20mm size and coal is sent to the Flap Gate and then feeded to the conveyer. The Secondary
crusher is hammer type. H.T. motor are used for breaking of the coal. Specifications are 700KW
6.6KVMotor.

7. CROSS BELT MAGNETIC SEPRATORS: - They will remove the ferrous particles, which passes along with
the coal. It consists of electromagnet around which a belt is moving. It is suspended from top,
perpendicular to the conveyor belt at certain height. Whenever any iron particle passes below the CBMS,
it is attracted by the magnet and stick to the cross belt below it. The CBMS capacity is of 50kg.

8. METAL DETECTOR: - The purpose of installation is to detect any metallic piece passing through the
conveyor. Whenever the pieces pass below the search coil of the metal detector, it gives the trip
command to the conveyor. Simultaneously, sand bag marker will fall on the conveyor belt so that the
metal can be searched easily and removed.

9. STACKER/RECLAIMER: - It is a very important device. The whole Structure of it is called

Super Structure. It stacks the excessive coal and reclaims the coal on its requirement. It is a twoway device.
It consists of following main parts.

1. Stacker; - The Stack is a position (1). When the rack comes, the excessive coal is send to the stacker
through the conveyer from Secondary Crusher house. The coals are stacked at the Secondary Crusher
Coal Heap. The coal falls down from the stacker through Boom Conveyer.

2. Reclaimer; - The Reclaimer is position (2). When the rack is not coming and there
is a shortage of coal, then reclaiming is to be started and the coal is lifted from the Secondary Crush
Coal Heap and feeded to the bunker.

3. Boom Conveyer; - The Boom conveyer is a Bi-directional conveyer. It moves clockwise &
anticlockwise direction. In stacking position, it is moving in clockwise direction and in the reclaiming
position its moving in anticlockwise direction. They are provided with Center Chute and End Chute on
the both end.
 4. Boom hoist; - The Boom hoist is a link of the Super Structure. The hoist is moved up and down. For
controlling the up & down position, limit switch is provided.

5. Slew drive; - The Slew Drive moves at 180-degree. When the coal is stored on both the side of the
track of travel, then the Slew Drive moves and lifts or fall the coal from Boom Conveyer. For control
the rotation of Slew Drive, the limit switch is provided.

6. Bucket wheel; - The Bucket Wheel is used when there is a requirement of the coal. It
is a rotary device. It is always rotated in anticlockwise. In the Reclaiming position, the Center Chute is
to be up and End Chute of the Boom Conveyer is fixed on the conveyer. The Bucket Wheel rotates;
when the Bucket of the wheel is full with coal and the wheel is rotated the coal fall down on the Boom
conveyer and the coal is send to the Super Structure.

7. Travel; - It is a slip ring induction motor driven system. The Super Structure
moves on it. The normal speed of the Travel is 10 meter / minute. It moves on its track from one end
to other end.

10. TRANSFER TOWER; - Here the coal is send to the Tipper. Transfer Tower is provided with
a coal sampler.

11. TIPPER; - The Tipper is a three-way device to feed the coal in Bunker. It is moveable
device. It is move on its track.
12. BUNKER: - Here the coal is collected from the tipper and stored. The capacity of the bunker for Stage-I is
4800MT & Stage-II is 8700MT
TERMS FULL FORM

CBMS Cross belt magnetic separator

ILMS Inline magnetic separator

PF Paddle feeder

TT Transfer tower

TP Transfer point

MD Metal detector

SM Suspended magnet

RB Rotary breaker

VGF Vibro grizzly feed

RPG Rack and pinion get

CR Crusher rotary

RH Reclaim hopper

VS Vibrating screen

BF Belt feeder

FG Flap gate

TC Telescopic chute

WT Wagon tippler

PH Pent house

PCH Primary crusher house

SCH Secondary crusher house

S/R Stacker/Reclaimer

CO Conveyor

CHP Coal handling plant

TH Track hopper

MCC Motor control center

LCS Local control switch

 PCS Pull card switch

BSS Belt swag switch

ZSS Zero speed switch

VF Vibrating feeder

VF. Vibrating fan

DEMINERAL (DM) PLANT

INTRODUCTION: --

Water is required in plant for many purposes like for formation of steam, for removal of ash, for safety during
fire, etc. But the water required for the formation of steam should be perfectly devoid of minerals because if
minerals are present in the steam and the steam strike the blades of the turbine, then due to being high in
pressure it produces scars or holes on the turbine blades.

PURIFICATION OF WATER: -

Water is purified in DM plant through a chain of processes as under: --

1. Carbon filter - Water taken from the river is first sent to the carbon filter for the
removal of carbon contents in the water.

2. Strong acid cation exchanger - After passing through the carbon filter, water is sent to the strong acid
cation exchanger, which is filled with the concentrated HCL. The acid produces anions, which get
combined with the cations present in the water.

3. Strong base anion exchanger - After that the water is sent to the strong base anion
exchanger, which is filled with the concentrated NaOH.The base produces cations, which get
combined with the anions present in the water.
4. Mixed bed exchanger - And then water is sent to the chamber of mixed bed exchanger where
the remaining ions are removed. This is the last stage of purification.

COAL, WATER & STEAM CYCLES

COAL CYCLE

C.H.P Plant-Bunker —R.C Feeder Pulverization mill Boiler section

1. R.C Feeder: It is an induction motor driven device, which determine the Quantity of coal
enter in the pulverize mill.

2. Pulverization mill: Pulverization means exposing a large surface area to the action of oxygen .Two Types

of mill are used in the plant.

1. Ball mail: A ball mill operates normally under suction. A large drum partly

filled with steel balls, is used in this mill .The drum is rotated slowly while coal is fed in to it .The ball

pulverize the coal by crushing. This type of mill is used in stage-1.

2. Contact mail: This mill uses impact principle. All the grinding elements and the

primary air fan are mounted on a single shaft. The flow of air carries coal to the primary stage
where it is reduced to a fine granular state by impact with a series of hammers. This type of mill is

used in stage-2.

WATER CYCLE
 D.M Plant-►Hot well C.E.P Pump -LOw Pressure Heater 1, 2, 3 Debater
Boiler Feed Pump_^High Pressure H^ate^ 5, 6 Feed Regulating station
Economizer Boiler Drum.

1. DERATER:

1. Feed strong tank of water

2. To produce sufficient pressure before feeding to B.F.D.

3. Filter the harmful chemicals.

2. FEED REGULATING STATIONS:

1. Control the quantity of water in to boiler drum.

3. ECONOMISER:

2. Flux gases coming out of the boilers carry lot of heat. An economizer extracts a part of this heat
from the flue gases and uses it for heating the feed water.

4. DRAFTS SYSTEM:

3. In forced draft system the fan is installed near the base of the boiler furnace. This fan forces air
through the furnace, economizer, air preheater and chimney .

4. In an induced draft system, the fan is installed near the base of Chimney.
 STEAM CYCLE

Boiler Drum-►Ring Header -Boiler Drum (Steam chamber) -Super Heater -HP
Turbine Repeater I.P Turbine L.P Turbine condenser

1. BOILER: Boiler drum consists two chambers water chamber, steam chamber. Before
Entering in super heater the steam is going in to boiler drum, where the boiler drum filtered the
moisture and stored in to water chamber.

2. SUPER HEATER: The function of super heater is to remove the last traces of moisture from the saturated
steam leaving the tube boiler. The temperature is approx.530 oC.

3. TURBINE: Steam turbine converts the heat energy in to mechanical energy and drives
the alternator. The velocity attained during expansions depends on initial and final heat content of
the steam. Turbine having number of stages in which the pressure drops takes place.
 Conclusion

On completion of my vocational training at Vindhyanchal Super Thermal

Power Project, Vindhyanagar I have come to know about how the very necessity of
our lives nowadays i.e., electricity is generated. What all processes are needed to
generate and run the plant on a 24x7 basis.
NTPC Vindhyanagar is one the plants in India to be under highest load factor
for the maximum duration of time and that to operating at highest plant efficiencies.
This plant is an example in terms of working efficiency and management of resources
to all other thermal plants in our country. The operating pf of the NTPC as compared
to the rest of country is the highest with 87.54% the highest since its inception.
The training gave me an opportunity to clear my concepts from practical point of
view with the availability of machinery of such large rating.
 Acknowledgements

Everything that happens in the world is an out come of interaction of various factor, some of which are
favourable while other not. Always for a desired result, the number of favourable factors is more. This work is
NO exception to this fact. I acknowledge that I've been fortunate enough to get the support, mentally and
physically in everything that I do.

I would give our special thanks to Mr. Akhilesh Singh(AGM, EMD) , for giving his very kind permission to
undergo the training program under the able guidance of NTPC engineers. . All these people were of immense
importance regarding the knowledge and supports for the well furnished equipments. I greatly acknowledge
the help and the mental strength provided by entire family for encouraging me and providing me knowledge &
guidance related with every deptt. of NTPC, Vindhyanagar.

At last I conclude by thanking all the employees of NTPC, Vindhynagar (both executives & workers) who helped
me in making our training a boon for me.

Parvej Akhter

B.E. Final Year, Electrical Engineering

Indira Gandhi Govt. Engg. College, Sagar, M.P.