Documente Academic
Documente Profesional
Documente Cultură
Report Of
By:
Vimal Kumar
M.E. (7th Sem.)
1209040207
DEPARTMENT OF MACHENICAL
ENGINEERING
Acknowledgements
This project involved the collection and analysis of information
from a wide variety of sources and the efforts of many people
beyond me. Thus it would not have been possible to achieve
the results reported in this document without their help,
support and encouragement.
I will like to express my gratitude to the following people for
their help in the work leading to this report:
Contents
Introduction
Description
Boiler Auxiliaries
Technical Data On Pulverizing Plant
Description Of Equipments
Hydrogen Plant
Cooling Tower
Water Treatment Plant
Compressor House
Ash Handling Plant
Core Values:
B- Business ethics
C-Customer focus
O-Organizational & professional pride
M-Mutual respect & trust
I-Innovation & speed
T-Total quality for excellence
NTPC Limited is the largest thermal power generating company
of India, Public Sector Company. It was incorporated in the year
1975 to accelerate power development in the country as a
wholly owned company of the Government of India. At present,
Government of India holds 89.5% of the total equity shares of
the company and the balance 10.5% is held by FIIs, Domestic
Banks, Public and others. Within a span of 31 years, NTPC has
emerged as a truly national power company, with power
generating facilities in all the major regions of the country.
Evolution Of NTPC
1975: NTPC was set up in 1975 with 100% ownership by the
Government of India. In the last 30 years, NTPC has grown into
the largest power utility in India.
1997: In 1997, Government of India granted NTPC status of
Navratna being one of the nine jewels of India, enhancing the
powers to the Board of Directors.
2004: NTPC became a listed company with majority
Government ownership of 89.5%.
NTPC becomes third largest by Market Capitalization of listed
companies
2005: The Company rechristened as NTPC Limited in line with
its changing business portfolio and transforms itself from a
thermal power utility to an integrated power utility.
NTPC is the largest power utility in India, accounting for about
20% of Indias installed capacity.
Step up transformer
Electrical generator
Low pressure steam
Boiler feed water pump
Surface condenser
Intermediate pressure steam turbine
Steam control valve
High pressure steam turbine
Deaerator feed water heater
Coal conveyer
Coal hopper
Coal pulverizer
Boiler steam drum
Boiler ash hopper
Super heater
Force draught (draft) fan
Reheater
Combustion air intake
Economizer
Air preheater
Precipitator
Induced draught (draft) fan
Fuel gas stack
Cooling towers:
Cooling towers are evaporative coolers used for cooling
water. Cooling tower use evaporation of water to reject heat
from processes such as cooling the circulating water used in
oil refineries, chemical plants, power plants, etc. The tower
vary in size from small roof top units to very large
hyperboloid structures that can be up to 200 meters tall and
100 meters in diameter, or rectangular structure that can be
over 40 meters tall and 80 meters long. Smaller towers are
normally factory built while larger ones are constructed on
site. The primary use of large, industrial cooling tower
Electrical generator:
An electrical generator is a device that coverts mechanical
energy to electrical energy, using electromagnetic induction
whereas electrical energy is converted to mechanical energy
with the help of electric motor. The source of mechanical
energy may be a reciprocating turbine steam engine.
Turbines are made in variety of sizes ranging from small 1
hp(0.75 kW) used as mechanical drives for pumps,
compressors and other shaft driven equipment to 2,000,000
hp(1,500,000 kW) turbines used to generate electricity.
Deaerator:
A Deaerator is a device for air removal and used to remove
dissolved gases from boiler feed water to make it noncorrosive. A deaerator typically includes a vertical domed
deaeration section as the deaeration feed water tank. A
steam generating boiler requires that the circulating steam,
condensate and feed water should be devoid of dissolved
gases, particularly corrosive ones and dissolved or
suspended solids. The gases will give rise to corrosion of the
metal. The solids will deposit on heating surfaces giving rise
to localized heating and tube ruptures due to overheating.
Deaerator level and pressure must be controlled by adjusting
control valves-the level by regulating condensate flow and
pressure by regulating steam flow. Most deaerators
guarantee that if operated properly, oxygen in deaerated
water will not exceed 7ppb by weight.
around them. The pulleys are powered, moving the belt and
the material on the belt forward. Conveyer belts are
extensively used to transport industrial and agricultural
material, such as grain, coal, ores, etc.
Pulverizer:
A pulverizer is a device for grinding coal for combustion in a
furnace in a fossil fuel power plant.
Super Heater:
A Super heater is a device in a steam engine that heats the
steam generated by the boiler again increasing its thermal
energy and decreasing the likelihood that it will condense
inside the engine. Super heaters increase the efficiency of
the steam engine, and were widely adopted. Steam which
has been superheated is logically known as superheated
steam; non-superheated steam is called saturated steam or
wet steam; Super heaters were applied to steam locomotives
Economizers:
Economizer, or in the UK economizer, are mechanical
devices intended to reduce energy consumption, or to
perform another useful function like preheating a fluid. The
term economizer is used for other purposes as well. Boiler,
power plant and heating ventilating and air conditioning. In
boilers, economizer are heat exchange devices that heat
fluids , usually water, up to but not normally beyond the
boiling point of the fluid. Economizers are so named because
they can make use of the enthalpy and improving the boilers
efficiency. They are a device fitted to a boiler which saves
energy by using the exhaust gases from the boiler to preheat
the cold water used the fill it (the feed water). Modern day
boilers, such as those in cold fired power stations, are still
fitted with economizer which is decedents of Greens original
design. In this context they are turbines before it is pumped
to the boilers. A common application of economizer is steam
power plants is to capture the waste hit from boiler stack
gases (flue gas) and transfer thus it to the boiler feed water
thus lowering the needed energy input, in turn reducing the
firing rates to accomplish the rated boiler output. Economizer
lower stack temperatures which may cause condensation of
acidic combustion gases and serious equipment corrosion
damage if care is not taken in their design and material
selection.
Air Preheater:
Air preheater is a general term to describe any device
designed to heat air before another process (for example,
combustion in a boiler). The purpose of the air preheater is
to recover the heat from the boiler flue gas which increases
the thermal efficiency of the boiler by reducing the useful
heat lost in the fuel gas. As a consequence, the flue gases
are also sent to the flue gas stack (or chimney) at a lower
temperature allowing simplified design of the ducting and
the flue gas stack. It also allows control over the temperature
of gases leaving the stack.
Precipitator:
An Electrostatic precipitator (ESP) or electrostatic air cleaner
is a particulate device that removes particles from a flowing
gas (such As air) using the force of an induced electrostatic
charge. Electrostatic precipitators are highly efficient
filtration devices, and can easily remove fine particulate
matter such as dust and smoke from the air steam. ESPs
continue to be excellent devices for control of many
industrial particulate emissions, including smoke from
electricity-generating utilities (coal and oil fired), salt cake
collection from black liquor boilers in pump mills, and
catalyst collection from fluidized bed catalytic crackers from
several hundred thousand ACFM in the largest coal-fired
boiler application. The original parallel plate-Weighted wire
design (described above) has evolved as more efficient ( and
robust) discharge electrode designs were developed, today
focusing on rigid discharge electrodes to which many
sharpened spikes are attached , maximizing corona
production. Transformer rectifier systems apply voltages of
50-100 Kilovolts at relatively high current densities. Modern
controls minimize sparking and prevent arcing, avoiding
damage to the components. Automatic rapping systems and
hopper evacuation systems remove the collected particulate
matter while on line allowing ESPs to stay in operation for
years at a time.
At NTPC (Badarpur) the man two paths are the flue gas or air
cycle and steam or condensate paths.
Capital Overhaul
NTPC has been in news due to extensive load sheds in
many areas in Delhi and the main cause behind these load
sheds was the capital overhaul of one of 210 MW units.
Unit IV was under an extensive check, which has caused
shut down of the plant and the plant, was dismantled
completely to change the old parts and cleaning up the
whole unit. But capital overhaul has no meaning because
such a deep checking of the plant happens once in five to
seven years.
Coal to Steam
Its other raw materials are air and water. The coal brought
to the station by trains or by other means, travels
handling plant by conveyer belts, travels from pulverizing
mills, which grind it as fine as the face powder of size upto
20 microns. The finely produced coal mixed with
preheated air is then blown into the boiler by a fan called
primary air fan where it burns more like a gas than as a
solid, in the conventional domestic or industrial grate, with
additional amount of air, called secondary air supply, by
forced draft fan.
As coal is ground so finally the resultant ash is also a fine
powder. Some of it binds together to form pumps, which
falls into ash pits at the bottom of the furnace. The waterquenched ash from the bottom is conveyed to pits for
subsequent disposal or sale. Most of ash, still in fine
Boiler Maintenance
Department
(BMD)
From
Atmosphere
P.A Fans
Air Pre-Heaters
Hot P.A Fans
Cold P.A Fans
Seal Air Fans
Pulverized Bowl
Mill
Furnace
Description
The second stage of Badarpur Thermal Power Station consists
of two units of 210MW each. The boilers are manufactured and
supplied by B.H.E.L. It is of semi outdoor type single drum,
natural circulation, two- pass vertical membrane water wall
construction, reheat dry bottom , tangentially fired furnace
using pulverized fuel and having a maximum continuous rating
of 700 T/ hr. at working pressure of 137 kg/cm2 and final steam
temperature of 540*c .
The boiler is equipped with six
Raymond Bowl mills, two PA fans, forced Draught (FD) fans, two
Induced Draught (ID) fans, two regenerative type air-heaters,
dust collecting plants and other accessories. This boiler is direct
fired having six elevations of coal and three elevations of oil.
The first pass of boiler is combustion chamber enclosed with
water walls of fusion welded construction on all four sides. In
addition, there are four water walls platens to increase the
radiant heating surface. Besides this the platen pendant super
heater, reheater section are also suspended in furnace i.e.,
combustion chamber.
The second pass is surrounded by steam cooled walls on all
four sides as well as roof of boilers. Feed water is supplied to
the steam drum through the economizer links. The steam and
water mixture from the water wall plantens are collected in
boiler drum where the steam is separated and led to various
super heater stages. The boiler drum houses turbo separators
and driers.
Each turbo separator consists of primary and secondary stages.
The primary stage of two concrete cans spinner blades impart a
centrifugal motion to the mixture of steam and water thereby
Specifications:
Main boiler
At 100% load
Evaporation
:
Feed water temp.
Feed water economizer
700 T/hr.
:
247 0C
:
276 0C
Steam temperature
Drum
Super heater outlet :
Re-heater inlet
:
Re-heater outlet
:
540
332
:
341 0C
0
C
0
C
540 0C
Steam pressure
Drum design
:
Drum operating
Super heater outlet :
Reheater inlet
:
Reheater outlet
158.2 kg/cm2
:
149.7 kg/cm2
137.0 kg/cm2
26.35 kg/cm2
:
24.50 kg/cm2
Fuel
Coal
Fixed carbon
Volatile matter
Moisture
Grindability
Furnace
Width
Depth
Height
Volume
:
:
:
38%
26%
8%
:
50% hard groove
:
:
:
:
13.868 m
10.562 m
42.797 m
5210 m3
Boiler Auxiliaries
Furnace:
It is the primary part of the boiler where the chemical
energy of fuel is converted to thermal energy by
combustion.
Major factors that assist for efficient combustion are time
of residence (fuel) inside the furnace and turbulence which
causes rapid mixing between fuel and air.
The furnace of the boiler may be P.E. fired dry bottom
furnace, slag type furnace, oil fired furnace. Normally
about 65% of furnace volume is enough for an oil fired
boiler as compared to the corresponding P.F fired boiler.
Boiler Drum:
Drum is of fusion welded design with hemi-spherical
dished ends. It is provided with manholes and cover. The
drum is provided with stubs for welding all the connecting
tubes i.e. down comers, risers, pipes, saturated steam
outlet. The function of steam drum internal is to separate
Drum Internal:
The boiler drum internal consists of the following equipments
arranged inside the drum of MW unit Cyclone steam separator: In this system, steam water
mixture is admitted tangentially. The water forms a layer
against the cylinder walls and the steam of less density
moves to the core of the cylinder and the water goes to the
drum.
Phosphate dozing line: All small pipe with no. of small holes
along its
Length is used to distribute the chemical into drum. The
phosphate is fed by a small high pressure pump in the
compartment to remove silver impurities.
Feed water distribution: The salt compartment is fed with
water from clean compartment through special holes in the
dividing partitions.
Drier: These are used as a second stage separation to
remove almost all water from the steam passing through the
super heater. The drier consists of closely packed strips of
steal with steam passing through strips making one or more
sharp changes of direction and throwing the heavier water
particles in to contact with the strip. The water runs the drier
and is returned to boiler water. The velocity of steam through
the drier must not be high else there will be chance of water
entering and hence the drier would get overloaded.
Girth baffler: It guides steam-water mixture from the riser to
the separator. At the same time it keeps the bulk of water in
the drum free from disturbance by steam bubbles.
Dry box: At the top of the drum is a compartment used to
collect the dry steam from drier and distribute it to super
heater off take tubes. Sometimes they are also known as
super saturated tubes because they carry dry saturated
steam.
Attemperator: It is also known as desuperheater. This
provides direct heat exchange with feed water which by
passing through the economizer is sprayed in to steam flow.
Water walls: Water flows to the water walls from the boiler
drum by natural circulation. The front and the two side water
walls constitute the main evaporation surface.
Reheater:
Reheater is used to raise the temperature of steam from
which a part of energy has seen extracted in high pressure
turbine. This is another method of increasing the cycle
efficiency. Reheating requires additional equipment i.e.,
heating surface connecting boiler and turbine piping safety
equipment like safety valve non-return valve, isolating valve,
high pressure feed pump etc.
Specifications:
Rear convection super heater:
Upper bank
Lower bank
:
:
15 m
05 m
Terminal tube
Heating surface
:
:
26.5m
556 m2
:
:
:
76.3 T
29
9445 m2
:
:
:
69 T
119
1036 m2
:
:
35 m
:
42 m
26 m
850 m2
De-super heater:
De-super heater are provided in the super heater connecting
links and the cool reheater lines to permit reduction of steam
temperature and is necessary to maintain the temp. at
design values within the limits of nozzles capacity.
Temperature reduction is accomplished by injecting spray
water in to the path of the steam through the nozzle.
Maintenance of de-super heater is not needed, even then
they should be inspected in 2-2.5 yrs. Spray nozzles and
lines are the wearing parts of the super heater. Excessive
noise observed in de-super heater in service means wear in
nozzles or lines.
Specifications:
Super heater of de-super heater:
Design pressure
Design temp.
Type
:
:
:
154.50 kg/cm2
430 0C
Spray Type
:
:
:
33.50 kg/cm2
345 0C
Spray Type
Economizer:
The function of an economizer in a steam generating unit is
to absorb heat from the flue gases and add as a sensible
heat to the feed water before the water enters the
evaporation circuit of the boiler.
Earlier economizers were introduced mainly to recover the
heat available in flue gases that leaves the boiler and
provision of this addition heating surface increase the
efficiency of steam generation by increasing the temp. of
feed water to the boiler and hence also named as feed water
heater.
Air preheater:
Air preheater absorbs waste heat from the flue gases and
transfers this heat to incoming cold air, by means of
continuously rotating heat transfer element of specially
formed metal plates. Thousands of these high efficiency
elements are spaced compactly arranged within 12 section
shaped compartments of a radially divided cylindrical shell,
called the rotor. Special sealing arrangements are provided in
the air preheater to prevent leakage between the air and gas
sides.
The air preheater heating surface elements are provided with
two types of cleaning arrangements, soot blower to clean
normal deposits, and washing arrangements to clean the
elements when soot blowing alone cannot keep them clean.
Specifications:
No. of air preheater
Heating surface area
Rotor drive motor
:
Speed reduction ratio :
:
:
2 per unit
1900 each
15 hp
110:1
Pulverizing plant:
Fuel data:
Type
Calorific value
Moisture content
Volatile matter
Ash content
Inlet size of coal to mill
Drying medium
Temp. of flue gases
Bituminous
:
:
4727 kcal/kg
7.5%
:
:
43%
32%
:
:
:
20mm
hot flue gases
480 0C
:
:
:
:
Drum mill:
Drum mill consists of:
motor
totally
:
:
:
:
22500 kg
20000 kg
10000 kg
52500 kg
During operation only balls with diameter 60mm are added and
will be approx. 500 kg/week.
Specifications for mill balls:
Ball diameter :
Weight per ball :
Tolerance in mm
40mm
0.26 kg
:
+3
50mm
0.15 kg
+ 3
60mm
0.89 kg
+ 3
Hydrogen Plant
Hydrogen Gas is used for generation cooling so supply of
pure hydrogen in power station is essential for generation
filling and maintenance of hydrogen gas pressure inside the
generator casing.
Description:
Hydrogen is prepared by electrolysis of pure De-mineralized
water in an electrolytic cell. When DC is passed through
water, it decomposes the water into two elements 1volume
oxygen and 2volume hydrogen. Pure distill water is bad
conductor of electricity but if acid or salt is added it becomes
a good conductor. To make economical use of electrolysis of
water a solution called electrolyte has to be used which is
passed through the electrolyte Hydrogen is given out of
Capacity of :
KG Khosla Machine Compressor is 14.2mcu/min.
KIRLOSKAR Compressor 18mcu/min
PLANT AIR Compressor 30mcu/min.
Cooling Tower
Water is required in the Thermal Power Station for various
purposes. Filtered water is used for bearing cooling, drinking
Degasifier
Anion Exchanger
Mixed Bed
Activated Carbon Filter: To neutralize chlorine in water,
The water is passed through activated carbon filter. It
consists of as capsule shaped tower, which is about 5m high
and contains a bed of activated coal. The chlorine gets
collected in the bed in HCl form. After sometime the carbon
bed gets exhausted. For regeneration the inlet and outlet
valves are closed and the back washing of the bed is done by
passing water at high pressure in opposite direction and the
HCl is washed awayin drain. The regeneration is necessary
after 16hours.
Cation Exchanger: In the Cation Exchanger the cations
present in water such as Ca2+, Mg2+, Al3+, Na+, and K+
are removed. In cation battery there is sand like resin, which
is in granular form but sands is lighter than the resin
material. The composition of the resin is never disclosed by
Supplier Company basically it is polystyrene sulphorate. The
resin is in RH for. Positive ion reacts with resin free water is
removed and hydrogen is replaced. Capacity of resins
850Tonnes in the power station Maximum quantity of water
50T/H. thus regeneration is necessary after every 16hours.
For regeneration inlet and outlet values of water is closed
and 5%HCl solution is added to the cation exchanger and
regeneration is allowed for 55min. on addition HCl, CaCl2
etc. are formed and are reached by back washing by feeding
High Pressure from bottom.
Degasifier: In this whatever Carbon dioxide is dissolved in
water removed. In the degasifier the partial pressure of
carbon dioxide is decreased to zero and thus carbon dioxide
gas escapes in the atmosphere. Thus, the dagasifer works on
the principle of Henrys law of partial pressure.
Anion Exchanger: The anion resins are basically are amines
technically the anion resin used in the anion exchanger is
named as DAN IP. After sometimes the anion battery gets
exhausted and has tobe regenerated. Life of this battery is
Back Washing
Regeneration of Anion Battery
Regeneration of Cation Battery
Again Rinse the battery
Again final rinsing of particle like HCl and NaOH
Fixed Mixing is done by passing compressed air into the
bed.
Compressor House:
Two types of air is generally used in the power plant are:
The plant air or station air
Instrumental air.
The Plant Air may be somewhat impure and contains
moisture oil particles etc. it is used for general purposes in
plant there are:
Sand blasting of turbine blades
Filter cleaning of main oil tank
Fly Ash:
It is the waste product or residue obtained after burning of
coal. The following are the methods that are employed at
BTPS to control the manage fly ash.
Fly ash is made to mix with water to form slurry which is
then put alone with stack pipe of ash, which are
covered by plantation.
Electrostatic precipitator has been installed which help
a lot in reducing the pollution.
Coal is washed before burning to reduce amount of ash
produced.
Turbine Maintenance
Department
(TMD)
From Boiler
Drums
L.T.S.H
Palten S.H
Final S.H
Main Steam
Line
H.P.Turbine
C.R.H Line
I.P.Turbine
L.P.Turbine
To Condensate
Turbine
Turbine Cycle:
Fresh steam from the boiler is supplied to the turbine through
the emergence stop valve from the stop valve steam is
supplied to four control valves situated on high pressure
cylinder at front bearing end. After expansion through 20
stages of H.P. cylinders , steam flows to the central part of L.P.
cylinder through two cross over pipes of 900-mm dia. each from
the central part of L.P. cylinder the exhaust steam enters the
condenser or welded direct to exhaust part of turbine.
Turbine is provided with regenerative system of feed water
heating. Heated steam is extract3ed from 7 non-regulated
bleed points of the turbine from L.P. condensate of 6kg/cm
2
absolute pressure.
Steam at 1.01 to 1.03 Kg/cm2 is supplied to gland steam seals
of the turbine from the deaerator trough a collector where the
pressure of the steam is regulated . From the end chambers of
seals the air steam mixture is sucked out with the help of
special steam ejector.
From the condenser, the condensate is pumped to deaerator
with the help 3*50% capacity condensate pumps through
2*100% capacity ejector and four L.P. heaters condensate while
passing through the main ejector condense the air steam
mixture sucked out from condenser. A portion of the main
condensate is passed through gland steam cooler to condense
the steam from air steam mixture sucked out from the gland
seal of turbine.
Turbine Auxillaries:
Vacuum System
Condensor: 2 per 200MW unit at exhaust of L.P.
turbine.
Ejector: One starting and two main ejectors connected
to a condenser located near turbine.
CW Pump: 2 per unit.
Condensate System
Condensate Pumps: 3 per unit each located near the
condenser hot well.
Low Pressure Heaters: Normally 4 in no. with no. 1
located at the upper part of the condenser and no. 2,
3and 4 around 4m level.
Deaerator: One per unit located around 18m level.
Feed Water System
Boiler Feed Pump: 3 per unit each located in 0m level
in TG bay.
High Pressure Heater: normally 3 in no.
Drip Pump: 2 in no. , each situated beneath L.P.
heater.
Turbine Lub. Oil System
Range: Up to 2000 KW
Application: Pump Drive, Blower
Drive
Sugar Cane Mill & Fibrizor Drives
FD & ID Fan Drives Compressors,
Exhausters Power Generation
Condenser:
There are two surface type condensers which are both air
and water tight, with an equalizing pipe between them . The
condenser steam inlet, the expansion being taken up by the
spring on which condensers are seated. Each condenser has
separate inlet and outlet of cooling water to facilitate
cleaning of the cooling tubes with 50-60% load on turbojet. it
is also provided with an inlet for dematerialized make up
water . In the upper part of each condenser, two sections of
L.P. heater no.1 are installed. These two sections connected
in parallel and steam is supplied from the same bleed point.
Specifications:
Cooling surface
:
Pressure
Consumption of cooling water
No. of water flows for each condenser
4000m2(each)
:
0.098kg/cm2
:
800m3/hr.
:
2
No. of tubes
Tube material
7700
:
Brass
Starting Ejector:
It is provided for creation of vacuum in condenser. The
ejector is supplied with steam from the deaerator at the rate
of 1100kg/hr.
Main Ejector:
These ejectors are capable of removing 60kgs of dry air per
hr. The ejector is provided with necessary pressure and
vacuum gauges for measurement of steam pressure and
thermometers for measurement of temp. at the inlet and
outlet of the condensate and of air-steam mixture.
Regenerative Equipment:
L.P. Heater No.1:
Heater no.1 is installed inside the condenser. It is horizontal
type consisting of two sections, one is connected in parallel
and steam is supplied from the same bleed. The heaters
have u-shaped brass tubes rolled with brass tube plates.
Specifications:
Heating surface
Bleed steam pressure
Tube design pressure
No. of tubes
No. of paths
:
:
:
:
:
200m2
0.408kg/cm2
15kg/cm2
524
4
:
:
180m2
5kg/cm2
1550C
5kg/cm2
7600C
:
:
:
NO.6
NO.7
275
275
11
300
21
350
225
225
180
272
23
180
272
Drain Coolers:
Drain cooler is of horizontal welded construction designed for
cooling the drain of L.P. heater no. 3. part of main
condensate passes through and takes off the heat from the
drain of L.P. heater no. 3 . the tubes are of brass rolled in
steam tube plates .
Thermometers for measuring temp. of condensate at inlet
and outlet of drain are provided.