Mahatma Gandhi Mission’s College of Engineering

and Technology Noida, U.P., India

Report on Practical Industrial Training

Carried out at

NTPC LIMITED DADRI

(National Thermal Power Corporation Limited
Dadri)

From 1st July, 2016 to 28th July, 2016

Academic Year 2016-2017

Submitted by: Submitted to:

Name: Kirshant Tomer Mechanical Engineering Department,
Class: BT-ME MGM’s COET, Noida
U.P. Roll No: 1609540012
2
 Mahatma Gandhi Mission’s
College of Engineering and Technology
Noida, U.P., India

Department of Mechanical Engineering

CERTIFICATE

This is to certify that of B. Tech. Mechanical Engineering, Class

BT-ME Roll No. 169540012 has completed his Industrial
Training during the academic year 2019-20 from 1st July, 2019
to 28th July, 2019 at National Thermal Power Corporation
Limited Dadri Vidyut Nagar -201008, Uttar Pradesh.

Training Coordinator Head of the

Department

i
CERTIFICATE

ii
 Acknowledgment

First I would like to thank Mr. A K Das (GM of company), Mr. Jitendra singh (Training
In-charge), Mr. Jitendra Sisodia (Operator), NTPC Dadri for giving me the opportunity
to do an internship within the organization. For me it was a unique experience to be in
this work shop. It also helped me to get back my interest in mechanical engineering and
to have new plans for my future career.

I am extremely grateful to all the technical staff of NTPC for their co-operation and
guidance that has helped me a lot during the course of training. I have learnt a lot
working under them and I will always be indebted of them for this value addition in
me.

I would like to thank all the people also that works in the organization.
Furthermore I want to thank all the engineers and students, with whom I did the
internship. We experienced great things together.

At last I would like to thank Mr. Karan Sir (Ex man), who told me all about the
organization and Quick services and also about the major-minor problem observed in
the Power Plant .

iii
 ABSTRACT

I was appointed to do 4 week training at this esteemed organization from 19th June to
19th July, 2019. I was assigned to visit AHP (Ash Handling Plant ) but I am also visit
in various division ,

• Boiler Maintenance Department (BMD I/II/III)

• Plant Auxiliary Maintenance (PAM)
• Turbine Maintenance Department (TAM)
• Coal Handling Department (CHD/NCHP)

These 4 weeks training was a very educational adventure for me. It was really amazing
to see the plant by yourself and learn how electricity, which is one of our daily
requirements of life, is produced.
This report has been made by my experience at NTPC. The material in this report has
been gathered from some textbook and trainers manuals and power journals provided
by training department. The specification and principles are as learned by me from the
employees of each division of NTPC.

iv
 TABLE OF CONTENT

CONTENT Page No.

Certificate I

Acknowledgment III

Abstract IV

Table of content V–V

Table of figure VI

List of tables VII

List of flow chart VII

CHAPTER 1 1-4

INTRODUCTION

1.1
1.1. Technological initiatives 3

1.2
1.2. Corporate social responsibility 3

1.3 Partnering government in various 4

initiatives

1.4
1.3. Environment management 4

1.5
1.4. Journey of ntpc 5

v
CHAPTER 2

BASIC STEPS OF ELECTRICITY GENERATION 6-9

2.1 Coal to electricity 6

2.1.1 Coal to steam 6

2.1.2 Steam to mechanical power 8

2.1.3 Mechanical power to electrical 9

power

CHAPTER 3 10-13
BASIC POWER PLANT CYCLE
3.1 Factor affecting thermal cycle efficiency 11

3.2 Rankine cycle 11

3.3 Rankine cycle with reheat 13

3.4 Regenerative Rankine cycle 13

CHAPTER 4 14-41

DIFFERENT DEPARTMENTS OF NTPC

4.1 Boiler maintenance department 14

4.2 Plant auxiliary maintenance 22

4.3 Ash handling plant 23

4.4 Turbine maintenance department 28

vi
 4.5 Maintenance planning department 33

4.6 Coal handling department 37

CONCLUSION 42

REFERENCES 43

vii
 TABLE OF FIGURE

NAME OF FIGURE Page No.

1.1 Growth graph of NTPC 2

2.1 Flow chart of basic steps 6

2.2 Diagram for coal based thermal plant 7

2.3 Side view of boiler 9

3.1 A simplified diagram of thermal power plant 10

3.2 S-T diagram 10

3.3 Rankine cycle 12

3.4 S-T diagram for steam 13

4.1 Boiler diagram 14

4.2 External View of an Industrial Boiler at NTPC, 18

DADRI

4.3 Tubes of a reheater 19

4.4 An economizer 20

4.5 An air preheater 21

4.6 A Pulverizer 21

viii
4.7 Ash Handling System at Dadri Thermal Power 23
Station

4.8 A water treatment plant 25

4.9 A demineralization tank 26

4.10 A service air compressor 28

4.11 A 95 MW generator 29

4.12 A typical water cooled condenser 31

4.13 An HP heater 33

4.14 Thermal distribution 36

4.15 The coal handling system 38

4.16 Coal handling division of NTPC 38

4.17 Coal storage area 40

4.18 Screening and separation unit of coal handling 41

ix
CHAPTER 1

INTRODUCTION

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. NTPC's core business is engineering,
construction and operation of power generating plants and providing consultancy to
power utilities in India and abroad. The total installed capacity of the company is 31134
MW (including JVs) with 15 coal based and 7 gas-based stations, located across the
country. In addition, under JVs, 3 stations are coal based & another station uses
naphtha/LNG as fuel. By 2017, the power generation portfolio is expected to have a
diversified fuel mix with coal-based capacity of around 53000 MW, 10000 MW
through gas, 9000 MW through Hydro generation, about 2000 MW from nuclear
sources and around 1000 MW from Renewable Energy Sources (RES). NTPC has
adopted a multi-pronged growth strategy which includes capacity addition through
green field projects, expansion of existing stations, joint ventures, subsidiaries and
takeover of stations.

Fig. 1.1 Growth Graph of NTPC

1
 NTPC has been operating its plants at high efficiency levels. Although the company
has 18.79% of the total national capacity it contributes 28.60% of total power
generation due to its focus on high efficiency. NTPC’s share at 31 Mar 2001 of the total
installed capacity of the country was 24.51% and it generated 29.68% of the power of
the country in 2008-09. Every fourth home in India is lit by NTPC. 170.88BU of
electricity was produced by its stations in the financial year 2005-2006. The Net Profit
after Tax on March 31, 2006 was INR 58,202 million. Net Profit after Tax for the
quarter ended June 30, 2006 was INR 15528 million, which is 18.65% more than for
the same quarter in the previous financial year. 2005). NTPC has set new benchmarks
for the power industry both in the area of power plant construction and operations. Its
providing power at the cheapest average tariff in the country. NTPC is committed to
the environment, generating power at minimal environmental cost and preserving the
ecology in the vicinity of the plants. NTPC has undertaken massive a forestation in the
vicinity of its plants. Plantations have increased forest area and reduced barren land.
The massive a forestation by NTPC in and around its Ramagundam Power station (2600
MW) have contributed reducing the temperature in the areas by about 3°c. NTPC has
also taken proactive steps for ash utilization.

1.5. TECHNOLOGICAL INITIATIVES

• Introduction of steam generators (boilers) of the size of 800 MW.

• Integrated Gasification Combined Cycle (IGCC) Technology.
• Launch of Energy Technology Centre -A new initiative for development of
technologies with focus on fundamental R&D.
• The company sets aside up to 0.5% of the profits for R&D.
• Roadmap developed for adopting ‘Clean Development.
• Mechanism’ to help get / earn ‘Certified Emission Reduction.

1.6. CORPORATE SOCIAL RESPONSIBILITY

• As a responsible corporate citizen NTPC has taken up number of CSR initiatives.
• NTPC Foundation formed to address Social issues at national level

2
 • NTPC has framed Corporate Social Responsibility Guidelines committing up to 0.5%
of net profit annually for Community Welfare.
• The welfare of project affected persons and the local population around NTPC projects
are taken care of through well drawn Rehabilitation and Resettlement policies.
• The company has also taken up distributed generation for remote rural areas.

1.7. PARTNERING GOVERNMENT IN VARIOUS INITIATIVES

• Consultant role to modernize and improvise several plants across the country.
• Disseminate technologies to other players in the sector.
• Consultant role “Partnership in Excellence” Programme for improvement of PLF of 15
Power Stations of SEBs.
• Rural Electrification work under Rajiv Gandhi Garmin Vidyutikaran.

1.8. ENVIRONMENT MANAGEMENT

• All stations of NTPC are ISO 14001 certified.
• Various groups to care of environmental issues.
• The Environment Management Group.
• Ash Utilization Division.
• Afforestation Group.
• Centre for Power Efficiency & Environment Protection.
• Group on Clean Development Mechanism.
• NTPC is the second largest owner of trees in the country after the Forest department.

1.9. JOURNEY OF NTPC

NTPC was set up in 1975 with 100% ownership by the

1975 Government of India. In the last 30 years, NTPC has grown into
the largest power utility in India.

3
 In 1997, Government of India granted NTPC status of
1997 “Navratna’ being one of the nine jewels of India, enhancing the
powers to the Board of Directors.

NTPC became a listed company with majority Government

2004 ownership of 89.5%. NTPC becomes third largest by Market

Capitalization of listed companies

The company rechristened as NTPC Limited in line with its

2005 changing business portfolio and transforms itself from a thermal

power utility to an integrated power utility.

National Thermal Power Corporation is the largest power

2008 generation company in India. Forbes Global 2000 for 2008
ranked it 411th in the world.

National Thermal Power Corporation is the largest power

2009 generation company in India. Forbes Global 2000 for 2008
ranked it 317th in the world.

NTPC has also set up a plan to achieve a target of 50,000 MW

2012 generation capacity.

NTPC has embarked on plans to become a 75,000 MW

2017 company by 2017.

4
 CHAPTER 2
BASIC STEPS OF ELECTRICITY GENERATION
The basic steps in the generation of electricity from coal involves following steps:
• Coal to steam
• Steam to mechanical power
• Mechanical power to electrical power

2.1. COAL TO ELECTRICITY

BASICS STEPS
The basic steps in the generation of coal to electricity are shown below

Fig. 2.1. Flow Chart Of Basic Steps

2.1.1. COAL TO STEAM

Coal from the coal wagons is unloaded in the coal handling plant. This Coal is
transported up to the raw coal bunkers with the help of belt conveyors. Coal is
transported to Bowl mills by Coal Feeders. The coal is pulverized in the Bowl Mill,
where it is ground to powder form. The mill consists of a round metallic table on which
coal particles fall. This table is rotated with the help of a motor. There are three large
steel rollers, which are spaced 120 apart. When there is no coal, these rollers do not
rotate but when the coal is fed to the table it packs up between roller and the table and
this forces the rollers to rotate. Coal is crushed by the crushing action between the
5
rollers and the rotating table. This crushed coal is taken away to the furnace through
coal pipes with the help of hot and cold air mixture from P.A. Fan. P.A. Fan takes
atmospheric air, a part of which is sent to Air-Preheaters for heating while a part goes
directly to the mill for temperature control. Atmospheric air from F.D. Fan is heated in
the air heaters and sent to the furnace as combustion air. Water from the boiler feed
pump passes through economizer and reaches the boiler drum. Water from the drum
passes through down comers and goes to the bottom ring header. Water from the bottom
ring header is divided to all the four sides of the furnace. Due to heat and density
difference, the water rises up in the water wall tubes. Water is partly converted to steam
as it rises up in the furnace. This steam and water mixture are again taken to the boiler
drum where the steam is separated from water.

Fig. 2.2. Diagram of Coal Based Thermal Power Plant

Water follows the same path while the steam is sent to superheaters for superheating.
The superheaters are located inside the furnace and the steam is superheated (540C)
6
and finally it goes to the turbine. Flue gases from the furnace are extracted by induced
draft fan, which maintains balance draft in the furnace (-5 to –10 mm of wcl) with
forced draft fan. These flue gases emit their heat energy to various super heaters in the
pent house and finally pass through air-preheaters and goes to electrostatic precipitators
where the ash particles are extracted. Electrostatic Precipitator consists of metal plates,
which are electrically charged. Ash particles are attracted on to these plates, so that they
do not pass through the chimney to pollute the atmosphere. Regular mechanical
hammer blows cause the accumulation of ash to fall to the bottom of the precipitator
where they are collected in a hopper for disposal.

2.1.2. STEAM TO MECHANICAL POWER

From the boiler, a steam pipe conveys steam to the turbine through a stop valve (which
can be used to shut-off the steam in case of emergency) and through control valves that
automatically regulate the supply of steam to the turbine. Stop valve and control valves
are located in a steam chest and a governor, driven from the main turbine shaft, operates
the control valves to regulate the amount of steam used. (This depends upon the speed
of the turbine and the amount of electricity required from the generator).
Steam from the control valves enters the high-pressure cylinder of the turbine, where it
passes through a ring of stationary blades fixed to the cylinder wall. These act as nozzles
and direct the steam into a second ring of moving blades mounted on a disc secured to
the turbine shaft. The second ring turns the shafts as a result of the force of steam. The
stationary and moving blades together constitute a ‘stage’ of turbine and in practice
many stages are necessary, so that the cylinder contains a number of rings of stationary
blades with rings of moving blades arranged between them. The steam passes through
each stage in turn until it reaches the end of the high-pressure cylinder and in its passage
some of its heat energy is changed into mechanical energy.
The steam leaving the high-pressure cylinder goes back to the boiler for reheating and
returns by a further pipe to the intermediate pressure cylinder. Here it passes through
another series of stationary and moving blades.

7
 Fig. 2.3. Side view of Boiler
Finally, the steam is taken to the low-pressure cylinders, each of which enters at the
centre flowing outwards in opposite directions through the rows of turbine blades
through an arrangement called the ‘double flow’- to the extremities of the cylinder. As
the steam gives up its heat energy to drive the turbine, its temperature and pressure fall
and it expands. Because of this expansion the blades are much larger and longer towards
the low pressure ends of the turbine.

2.1.3. MECHANICAL POWER TO ELECTRICAL POWER

As the blades of turbine rotate, the shaft of the generator, which is coupled to that of
the turbine, also rotates. It results in rotation of the coil of the generator, which causes
induced electricity to be produced.

8
CHAPTER 3
BASIC POWER PLANT CYCLE

Fig. 3.1. A simplified diagram of a thermal power plant

The thermal (steam) power plant uses a dual (vapour+ liquid) phase cycle. It is a close
cycle to enable the working fluid (water) to be used again and again. The cycle used is
Rankine Cycle modified to include superheating of steam, regenerative feed water
heating and reheating of steam.

Fig. 3.2. s-t Diagram

On large turbines, it becomes economical to increase the cycle efficiency by using
reheat, which is a way of partially overcoming temperature limitations. By returning
partially expanded steam, to a reheat, the average temperature at which the heat is
added, is increased and, by expanding this reheated steam to the remaining stages of
the turbine, the exhaust wetness is considerably less than it would otherwise be
conversely, if the maximum tolerable wetness is allowed, the initial pressure of the
steam can be appreciably increased.
9
 Bleed Steam Extraction: For regenerative system, nos. of non-regulated extractions are
taken from HP, IP turbine.
Regenerative heating of the boiler feed water is widely used in modern power plants;
the effect being to increase the average temperature at which heat is added to the cycle,
thus improving the cycle efficiency.

3.1. FACTORS AFFECTING THERMAL CYCLE EFFICIENCY

Thermal cycle efficiency is affected by following:
• Initial Steam Pressure.
• Initial Steam Temperature.
• Whether reheat is used or not, and if used reheat pressure and temperature.
• Condenser pressure.
• Regenerative feed water heating.

3.2. RANKINE CYCLE

The Rankine cycle is a thermodynamic cycle which converts heat into work. The heat
is supplied externally to a closed loop, which usually uses water as the working fluid.
This cycle generates about 80% of all electric power used throughout the world,
including virtually all solar thermal, biomass, coal and nuclear power plants. It is named
after William John Macquorn Rankine, a Scottish polymath..

Description

Fig. 3.3. Physical layout of the four main devices used in the Rankine cycle
A Rankine cycle describes a model of the operation of steam heat engines most
commonly found in power generation plants. Common heat sources for power plants
10
using the Rankine cycle are coal, natural gas, oil, and nuclear. The Rankine cycle is
sometimes referred to as a practical Carnot cycle as, when an efficient turbine is used,
the TS diagram will begin to resemble the Carnot cycle. The main difference is that a
pump is used to pressurize liquid instead of gas. This requires about 1/100th (1%) as
much energy as that compressing a gas in a compressor (as in the Carnot cycle).
The efficiency of a Rankine cycle is usually limited by the working fluid. Without the
pressure going super critical the temperature range the cycle can operate over is quite
small, turbine entry temperatures are typically 565°C (the creep limit of stainless steel)
and condenser temperatures are around 30°C. This gives a theoretical Carnot efficiency
of around 63% compared with an actual efficiency of 42% for a modern coal-fired
power station. This low turbine entry temperature (compared with a gas turbine) is why
the Rankine cycle is often used as a bottoming cycle in combined cycle gas turbine
power stations. The working fluid in a Rankine cycle follows a closed loop and is re-
used constantly. The water vapor and entrained droplets often seen billowing from
power stations is generated by the cooling systems (not from the closed loop Rankine
power cycle) and represents the waste heat that could not be converted to useful work.
Note that cooling towers operate using the latent heat of vaporization of the cooling
fluid. The white billowing clouds that form in cooling tower operation are the result of
water droplets which are entrained in the cooling tower airflow; it is not, as commonly
thought, steam. While many substances could be used in the Rankine cycle, water is
usually the fluid of choice due to its favourable properties, such as nontoxic and
unreactive chemistry, abundance, and low cost, as well as its thermodynamic
properties. One of the principal advantages it holds over other cycles is that during the
compression stage relatively little work is required to drive the pump, due to the
working fluid being in its liquid phase at this point. By condensing the fluid to liquid,
the work required by the pump will only consume approximately 1% to 3% of the
turbine power and so give a much higher efficiency for a real cycle.
The benefit of this is lost somewhat due to the lower heat addition temperature. Gas
turbines, for instance, have turbine entry temperatures approaching 1500°C.
Nonetheless, the efficiencies of steam cycles and gas turbines are fairly well matched.

11
3.3. Rankine cycle with reheat

In this variation, two turbines work in series. The first accepts vapor from the boiler at
high pressure. After the vapor has passed through the first turbine, it re-enters the boiler
and is reheated before passing through a second, lower pressure turbine. Among other
advantages, this prevents the vapor from condensing during its expansion which can
seriously damage the turbine blades, and improves the efficiency of the cycle.

Fig. 3.4. T-S Diagram for Steam

3.4. Regenerative Rankine cycle

The regenerative Rankine cycle is so named because after emerging from the condenser
(possibly as a subcooled liquid) the working fluid is heated by steam tapped from the
hot portion of the cycle. On the diagram shown, the fluid at 2 is mixed with the fluid at
4 (both at the same pressure) to end up with the saturated liquid at 7. The Regenerative
Rankine cycle (with minor variants) is commonly used in real power stations.
Another variation is where 'bleed steam' from between turbine stages is sent to
feedwater heaters to preheat the water on its way from the condenser to the boiler.

12
 CHAPTER 4

DIFFERENT DEPARTMENTS OF NTPC

• Boiler Maintenance Department (BMD I/II/III)

• Plant Auxiliary Maintenance (PAM)
• Turbine Maintenance Department (TAM)
• Coal Handling Department (CHD/NCHP)

4.1 BOILER MAINTENANCE DEPARTMENT

4.1.1 Boiler and Its Description

The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall.
Its walls are made of a web of high-pressure steel tubes about 2.3 inches (60 mm) in
diameter. Pulverized coal is air-blown into the furnace from fuel nozzles at the four
corners and it rapidly burns, forming a large fireball at the centre. The thermal radiation
of the fireball heats the water that circulates through the boiler tubes near the boiler
perimeter. The water circulation rate in the boiler is three to four times the throughput
and is typically driven by pumps. As the water in the boiler circulates it absorbs heat
and changes into steam at 700 °F (370 °C) and 3,200 psi (22.1MPa). It is separated
from the water inside a drum at the top of the furnace.

Fig. 4.1 Boiler Side of the Dadri Thermal Power Station

13
 The saturated steam is introduced into superheat pendant tubes that hang in the hottest
part of the combustion gases as they exit the furnace. Here the steam is superheated to
1,000 °F (540 °C) to prepare it for the turbine. The steam generating boiler has to
produce steam at the high purity, pressure and temperature required for the steam
turbine that drives the electrical generator.

The generator includes the economizer, the steam drum, the chemical dosing
equipment, and the furnace with its steam generating tubes and the superheater coils.
Necessary safety valves are located at suitable points to avoid excessive boiler pressure.
The air and flue gas path equipment include: forced draft (FD) fan, air preheater (APH),
boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or
baghouse) and the flue gas stack.

For units over about 210 MW capacity, redundancy of key components is provided by
installing duplicates of the FD fan, APH, fly ash collectors and ID fan with isolating
dampers. On some units of about 60 MW, two boilers per unit may instead be provided.

4.1.2. SPECIFICATIONS OF THE BOILER

1. Main Boiler (AT 100% LOAD):

i. Evaporation 700 tons/hr.
ii. Feed water temperature 247C
iii. Feed water leaving economizer 276C

2. Steam Temperature:
i. Drum 341C
ii. Super heater outlet 540C
iii. Reheat inlet 332C
iv. Reheat outlet 540C

3. Steam Pressure:
i. Drum design 158. 20 kg/cm2
ii. Drum operating 149.70 kg/cm2
iii. Super heater outlet 137.00 kg/cm2
iv. Reheat inlet 26.35 kg/cm2

14
 v. Reheat outlet 24.50 kg/cm2
4. Fuel Specifications
A) Coal
i. Fixed Carbon 38%
ii. Volatile Matter 26%
iii. Moisture 8.0%
iv. Ash 28%
v. Grindability 55HGI
vi. High Heat 4860 Kcal/Kg
vii. Coal size to Mill 20 mm
B) Oil
i. Low Heat value 10000 kcal/kg
ii. Sulphur 4.5% w/w
iii. Moisture 1% w/w
0
iv. Flash point 66 C.
0
v. Viscosity 1500 redwood at 37.8 C.
0
vi. Sp. Weight 0.98 at 38 C.

5. Heat Balance
i. Dry gas loss 4.63%
ii. Carbon loss 2%
iii. Radiation loss 0.26%
iv. Unaccounted loss 1.5%
v. H2 in air and H2O in fuel 4.9%

vi. Total loss 13.3%

vii. Efficiency 86.7%

15
 4.1.3. AUXILIARIES OF THE BOILER

FURNACE

• Furnace is primary part of boiler where the chemical energy of the fuel is converted to
thermal energy by combustion. Furnace is designed for efficient and complete
combustion. Major factors that assist for efficient combustion are amount of fuel inside
the furnace and turbulence, which causes rapid mixing between fuel and air. In modern
boilers, water furnaces are used.

BOILER DRUM

• Drum is of fusion-welded design with welded hemispherical dished ends. It is provided

with stubs for welding all the connecting tubes, i.e. down comers, risers, pipes, saturated
steam outlet. The function of steam drum internals is to separate the water from the
steam generated in the furnace walls and to reduce the dissolved solid contents of the
steam below the prescribed limit of 1 ppm and also take care of the sudden change of
steam demand for boiler.
• The secondary stage of two opposite banks of closely spaced thin corrugated sheets,
which direct the steam and force the remaining entertained water against the corrugated
plates. Since the velocity is relatively low this water does not get picked up again but
runs down the plates and off the second stage of the two steam outlets.
.

Fig. 4.2. External View of an Industrial Boiler at NTPC, DADRI

16
• The steam/vapour is passed through a series of steam and water separators and then
dryers inside the steam drum. The steam separators and dryers remove the water
droplets from the steam and the cycle through the water walls is repeated. This process
is known as natural circulation.
• Heat exchangers may be used where the geothermal steam is very corrosive or contains
excessive suspended solids. Nuclear plants also boil water to raise steam, either directly
passing the working steam through the reactor or else using an intermediate heat
exchanger.

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, absorbing the bulk
of radiant heat of the fuel burnt in the chamber. The front and rear walls are bent at the
lower ends to form a water-cooled slag hopper. The upper part of the chamber is
narrowed to achieve perfect mixing of combustion gases. The water wall tubes are
connected to headers at the top and bottom. The rear water wall tubes at the top are
grounded in four rows at a wider pitch forming g the grid tubes.

REHEATER

Reheater is used to raise the temperature of steam from which a part of energy has been
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 pipe safety equipment like safety valve, non-return valves, isolating
valves, high pressure feed pump, etc.: Reheater is composed of two sections namely the
front and the rear pendant section, which is located above the furnace arc between
water-cooled, screen wall tubes and rear wall tubes.

Fig. 4.3. Tubes of a reheater

17
 SUPERHEATER

Whatever type of boiler is used, steam will leave the water at its surface and pass into
the steam space. Steam formed above the water surface in a shell boiler is always
saturated and become superheated in the boiler shell, as it is constantly. If superheated
steam is required, the saturated steam must pass through a superheater. This is simply
a heat exchanger where additional heat is added to the steam. In water-tube boilers, the
superheater may be an additional pendant suspended in the furnace area where the hot
gases will provide the degree of superheat required. In other cases, for example in CHP
schemes where the gas turbine exhaust gases are relatively cool, a separately fired
superheater may be needed to provide the additional heat.

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 economizer was introduced mainly to recover the heat available in the flue gases
that leaves the boiler and provision of this addition heating surface increases the
efficiency of steam generators. In the modern boilers used for power generation feed
water heaters were used to increase the efficiency of turbine unit and feed water
temperature.

Fig. 4.4. An economizer

18
 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 and compactly
arranged within 12 sections. Sloped compartments of a radially divided cylindrical shell
called the rotor. The housing surrounding the rotor is provided with duct connecting
both the ends and is adequately scaled by radial and circumferential scaling.

Fig. 4.5. An air preheater

PULVERIZER

• A pulverizer is a mechanical device for the grinding of many types of materials. For
example, they are used to pulverize coal for combustion in the steam-generating
furnaces of the fossil fuel power plants.

Fig. 4.6. A Pulverizer

19
 4.2. PLANT AUXILIARY MAINTENANCE
4.2.1. WATER CIRCULATION SYSTEM

Theory of Circulation

Water must flow through the heat absorption surface of the boiler in order that it be
evaporated into steam. In drum type units (natural and controlled circulation), the water
is circulated from the drum through the generating circuits and then back to the drum
where the steam is separated and directed to the super heater. The water leaves the drum
through the down corners at a temperature slightly below the saturation temperature.
The flow through the furnace wall is at saturation temperature. Heat absorbed in water
wall is latent heat of vaporization creating a mixture of steam and water. The ratio of
the weight of the water to the weight of the steam in the mixture leaving the heat
absorption surface is called circulation ratio.

Types of Boiler Circulating System

i. Natural circulation system

ii. Controlled circulation system
iii. Combined circulation system

Natural Circulation System

Water delivered to steam generator from feed water is at a temperature well below the
saturation value corresponding to that pressure. Entering first the economizer, it is
heated to about 30-40C below saturation temperature. From economizer the water
enters the drum and thus joins the circulation system. Water entering the drum flows
through the down corner and enters ring heater at the bottom. In the water walls, a part
of the water is converted to steam and the mixture flows back to the drum. In the drum,
the steam is separated, and sent to superheater for superheating and then sent to the
high-pressure turbine. Remaining water mixes with the incoming water from the
economizer and the cycle is repeated. As the pressure increases, the difference in
density between water and steam reduces. Thus, the hydrostatic head available will not
be able to overcome the frictional resistance for a flow corresponding to the minimum

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requirement of cooling of water wall tubes. Therefore, natural circulation is limited to
the boiler with drum operating pressure around 175 kg/ cm2.

Controlled Circulation System

Beyond 80 kg/ cm2 of pressure, circulation is to be assisted with mechanical pumps to

overcome the frictional losses. To regulate the flow through various tubes, orifices
plates are used. This system is applicable in the high sub-critical regions (200 kg/ cm2).

4.3. ASH HANDLING PLANT

The widely used ash handling systems are:

• Mechanical Handling System

• Hydraulic System
• Pneumatic System
• Steam Jet System

Fig. 4.7. Ash Handling System at Dadri Thermal Power Station

The Hydraulic Ash handling system is used at the Dadri Thermal Power Station.

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4.3.1. Hydraulic Ash Handling System

The hydraulic system carried the ash with the flow of water with high velocity through
a channel and finally dumps into a sump. The hydraulic system is divided into a low
velocity and high velocity system. In the low velocity system, the ash from the boilers
falls into a stream of water flowing into the sump. The ash is carried along with the
water and they are separated at the sump. In the high velocity system, a jet of water is
sprayed to quench the hot ash. Two other jets force the ash into a trough in which they
are washed away by the water into the sump, where they are separated. The molten slag
formed in the pulverized fuel system can also be quenched and washed by using the
high velocity system. The advantages of this system are that its clean, large ash handling
capacity, considerable distance can be traversed, absence of working parts in contact
with ash.

Fly Ash Collection

Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric
bag filters (or sometimes both) located at the outlet of the furnace and before the
induced draft fan. The fly ash is periodically removed from the collection hoppers
below the precipitators or bag filters. Generally, the fly ash is pneumatically transported
to storage silos for subsequent transport by trucks or railroad cars.

Bottom Ash Collection and Disposal

At the bottom of every boiler, a hopper has been provided for collection of the bottom
ash from the bottom of the furnace. This hopper is always filled with water to quench
the ash and clinkers falling down from the furnace. Some arrangement is included to
crush the clinkers and for conveying the crushed clinkers and bottom ash to a storage
site.

4.3.2. WATER TREATMENT PLANT

As the types of boiler are not alike their working pressure and operating conditions vary
and so do the types and methods of water treatment. Water treatment plants used in
thermal power plants used in thermal power plants are designed to process the raw
water to water with a very low content of dissolved solids known as ‘demineralized
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 water’. No doubt, this plant has to be engineered very carefully keeping in view the
type of raw water to the thermal plant, its treatment costs and overall economics.

Fig. 4.8. A water treatment plant

The type of demineralization process chosen for a power station depends on three main
factors:

• The quality of the raw water.

• The degree of de-ionization i.e. treated water quality.
• Selectivity of resins.

Water treatment process is generally made up of two sections:

• Pretreatment section.
• Demineralization section

Pre-treatment Section

Pre-treatment plant removes the suspended solids such as clay, silt, organic and
inorganic matter, plants and another microscopic organism. The turbidity may be taken
as two types of suspended solid in water; firstly, the separable solids and secondly the
non-separable solids (colloids). The coarse components, such as sand, silt, etc: can be
removed from the water by simple sedimentation. Finer particles, however, will not
settle in any reasonable time and must be flocculated to produce the large particles.
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Demineralization

This filter water is now used for demineralizing purpose and is fed to cation exchanger
bed, but enroute being first dechlorinated, which is either done by passing through
activated carbon filter or injecting along the flow of water, an equivalent amount of
sodium sulphite through some stroke pumps. The residual chlorine, which is maintained
in clarification plant to remove organic matter from raw water, is now detrimental to
action resin and must be eliminated before its entry to this bed.

Fig. 4.9. A demineralization tank

A DM plant generally consists of cation, anion and mixed bed exchangers. The final
water from this process consists essentially of hydrogen ions and hydroxide ions which
is the chemical composition of pure water. The DM water, being very pure, becomes
highly corrosive once it absorbs oxygen from the atmosphere because of its very high
affinity for oxygen absorption. The capacity of the DM plant is dictated by the type and
quantity of salts in the raw water input. However, some storage is essential as the DM
plant may be down for maintenance. For this purpose, a storage tank is installed from
which DM water is continuously withdrawn for boiler make-up. The storage tank for
DM water is made from materials not affected by corrosive water, such as PVC. The

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piping and valves are generally of stainless steel. Sometimes, a steam blanketing
arrangement or stainless-steel doughnut float is provided on top of the water in the tank
to avoid contact with atmospheric air. DM water make-up is generally added at the
steam space of the surface condenser (i.e., the vacuum side). This arrangement not only
sprays the water but also DM water gets deaerated, with the dissolved gases being
removed by the ejector of the condenser itself.

Service Air Compressor

The station air compressor is generally a slow speed horizontal double acting double
stage type and is arranged for belt drive. The cylinder heads and barrel are enclosed in
a jacket, which extends around the valve also. The intercooler is provided between the
low- and high-pressure cylinder which cools the air between tag and collects the
moisture that condenses.

Fig. 4.10. A service air compressor

Air from L.P. cylinder enters at one end of the intercooler and goes to the opposite end
wherefrom it is discharged to the high-pressure cylinder; cooling water flows through
the nest of the tubes and cools the air. A safety valve is set at rated pressure.

25
 Two selector switches one with positions auto load/unload and another with positions
auto start/stop, non-stop have been provided on the control panel of the compressor. In
auto start-stop position, the compressor will start.

4.4. TURBINE MAINTENANCE DEPARTMENT

TURBINE CLASSIFICATION:

1. Impulse turbine:
In impulse turbine steam expands in fixed nozzles. The high velocity steam from
nozzles does work on moving blades, which causes the shaft to rotate. The essential
features of impulse turbine are that all pressure drops occur at nozzles and not on blades.
2. Reaction turbine:
In this type of turbine pressure is reduced at both fixed and moving blades. Both fixed
and moving blades act like nozzles. Work done by the impulse effect of steam due to
reverse the direction of high velocity steam. The expansion of steam takes place on
moving blades.

Fig. 4.11. A 95 MW Generator at NTPC, DADRI

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 SPECIFICATIONS OF THE TURBINE
• Type: Tandem compound 3-cylinder reheated type.
• Rated power: 210 MW.
• Number of stages: 12 in H.P., 11 in I.P. and 4*2 in L.P. cylinder.
• Rated steam pressure: 130 kg /sq. cm before entering the stop valve.
• Rated steam temperature: 535C after reheating at inlet.
• Steam flow: 670T / hr.
• H.P. turbine exhaust pressure: 27 kg /sq. cm., 327C
• Condenser back pressure: 0.09 kg /sq. cm.
• Type of governing: nozzle governing.
• Number of bearing; 5 excluding generator and exciter.
• Lubrication Oil: turbine oil 14 of IOC.
• Gland steam pressure: 1.03 to 1.05 kg /sq. cm (Abs)
• Critical speed: 1585, 1881, 2017.
• Ejector steam parameter: 4.5 kg /sq. cm.
• Condenser cooling water pressure: 1.0 to 1.1 kg /sq. cm.
• Condenser cooling water temperature: 27000 cu. M /hr.
• Number of extraction lines for regenerative heating of feed water; seven.

TURBINE COMPONENTS
• Casing.
• Rotor.
• Blades.
• Sealing system.
• Stop & control valves.
• Couplings and bearings.
• Barring gear.

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CONDENSER
There are two condensers entered to the two exhausters of the L.P. turbine. These are
surface-type condensers with two pass arrangement. Cooling water pumped into each
condenser by a vertical C.W. pump through the inlet pipe.
Water enters the inlet chamber of the front water box, passes horizontally through brass
tubes to the water tubes to the water box at the other end, takes a turn, passes through
the upper cluster of tubes and reaches the outlet chamber in the front water box. From
these, cooling water leaves the condenser through the outlet pipe and discharge into the
discharge duct.
Steam exhausted from the LP turbine washes the outside of the condenser tubes, losing
its latent heat to the cooling water and is connected with water in the steam side of the
condenser. This condensate collects in the hot well, welded to the bottom of the
condensers.

Fig. 4.12. A typical water cooled condenser

EJECTORS
There are two 100% capacity ejectors of the steam eject type. The purpose of the ejector
is to evacuate air and other non-compensating gases from the condensers and thus
maintain the vacuum in the condensers.
The ejector has three compartments. Steam is supplied generally at a pressure of 4.5 to
5 kg /cm2 to the three nozzles in the three compartments. Steam expands in the nozzle
28
 thus giving a high-velocity eject which creates a low-pressure zone in the throat of the
eject. Since the nozzle box of the ejector is connected to the air pipe from the condenser,
the air and pressure zone. The working steam which has expanded in volume comes
into contact with the cluster of tube bundles through which condensate is flowing and
gets condensed thus after aiding the formation of vacuum. The non-condensing gases
of air are further sucked with the next stage of the ejector by the second nozzle. The
process repeats itself in the third stage also and finally the steam-air mixture is
exhausted into the atmosphere through the outlet.

FEED WATER SYSTEM

The main equipment’s coming under this system are:
• Boiler feed Pump: Three per unit of 50% capacity each located in the ‘0’ meter level
in the T bay.
• High Pressure Heaters: Normally three in number and are situated in the TG bay.
• Drip Pumps: generally, two in number of 100% capacity each situated beneath the LP
heaters.
• Turbine Lubricating Oil System: This consists of the Main Oil Pump (MOP), Starting
Oil Pump (SOP), AC standby oil pumps and emergency DC Oil Pump and Jacking Oil
Pump (JOP). (one each per unit)
Boiler Feed Pump
This pump is horizontal and of barrel design driven by an Electric Motor through a
hydraulic coupling. All the bearings of pump and motor are forced lubricated by a
suitable oil lubricating system with adequate protection to trip the pump if the
lubrication oil pressure falls below a preset value.
The high-pressure boiler feed pump is a very expensive machine which calls for a very
careful operation and skilled maintenance. Operating staff must be able to find out the
causes of defect at the very beginning, which can be easily removed without
endangering the operator of the power plant and also without the expensive dismantling
of the high-pressure feed pump.

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Lubricating Pressure
All the bearings of boiler feed pump, pump motor and hydraulic coupling are force
lubricated. The feed pump consists of two radial sleeve bearings and one thrust bearing.
The thrust bearing is located at the free end of the pump.

High Pressure Heaters

These are regenerative feed waters heaters operating at high pressure and located by the
side of turbine. These are generally vertical type and turbine-based steam pipes are
connected to them.
HP heaters are connected in series on feed waterside and by such arrangement, the feed
water, after feed pump enters the HP heaters. The steam is supplied to these heaters to
form the bleed point of the turbine through motor operated valves. These heaters have
a group bypass protection on the feed waterside.
In the event of tube rupture in any of the HPH and the level of condensate rising to
dangerous level, the group protection devices divert automatically the feed water
directly to boiler, thus bypassing all the 3 H.P. heaters.

Fig. 4.13. An HP heater

Turbine Oil Lubricating System

This consists of main oil pump, starting oil pump, emergency oil pump and each per
unit.

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 4.5. MAINTENANCE PLANNING DEPARTMENT
4.5.1. PREDICTIVE MAINTENANCE

The art of predictive maintenance is to monitor the machine with the appropriate
technologies, frequently enough to detect the anticipated failure modes.

Also known as “Condition Based Maintenance” results in:

• Increased uptime
• Decreased unexpected breakdowns
• Reduced Maintenance Costs
• Maintenance is performed and it is planned
• Improved Plant Safety

Machines normally give off some signs before failing

• The sign may be change in sound level, vibration, pressure, temperature etc.
• Change in the performance
• Metal particles in the lubricant
• Change in motor current etc.

4.5.2. PROACTIVE MAINTENANCE

Also known by different names including “Precision Maintenance” and “Reliability

based Maintenance”. The motto here is “Fix it once & Fix it Right”

How an effective Predictive Maintenance Strategy Can Improve Plant Efficiency:

• Reduction in Lost Production

• Reduced Cost of Maintenance
• Less Likelihood of Secondary Damage
• Reduced Inventory
• Extending the Life of Plant Items
• Improved Product Quality

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 4.5.3. KNOWLEDGE BASED MAINTENANCE
• Shared information among all users
• Root cause analysis (proactive) - design problems out of machines, fix the problem not
the symptom

TECHNOLOGIES USED

• Vibration monitoring & analysis and balancing.

• Motor current signature analysis (mcsa).
• Thermography monitoring & analysis.
• Acoustic monitoring & analysis.
• Checking of ht/lt motors in electrical workshop

VIBRATION ANALYSIS AND UNBALANCE

• Amplitude proportional to the amount of unbalance

• Vibration high normally in radial direction (may be also in axial direction in case of
overhung and flexible rotors).
• 1* RPM vibration is greater than 80% (normally) of the overall reading.
• Horizontal and vertical 1* RPM amplitude should be nearly same, although it also
depends on system rigidity on the particular direction.
• Other frequency peaks may be less than 5% of the 1* RPM amplitude
• Phase shift of 90 deg. When sensor moves from horizontal to vertical.

MOTOR ROTOR BAR ANALYSIS

• On-line detection of broken rotor bars of Induction Motors.

• Detects Rotor bar faults at early stage using supportive software
• Avoids Motor Breakdown and hence forced reduction of unit load.

FACTORS LEADING TO ROTOR BAR CRACKS

• Most motor failures are preceded by long periods of wear.

• More starts & stops or rapidly fluctuating loads leads to Excess stresses
• Hardening of Joints of rotor bars and end ring
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 THERMOGRAPHY

• IRT camera has been very useful tools in predictive maintenance for detecting hot
spots in electrical & switchyard equipment.
• The thermal scanning survey in switchyard & other identified areas is done to monitor
the healthiness of electrical equipment.

Fig.
4.14. Machine image captured to know the Thermal distribution

ACCOUSTIC ANALYSIS

• What is acoustic emission?

Acoustic emission is a naturally occurring phenomenon wherein external mechanical
loading generates sources of elastic waves.
• What is acoustic analysis?
Acoustic analysis or noise analysis is a twostep process involving the acquisition and
interpretation of machinery acoustic data.
• Its purpose is:
To determine the condition of the machine and pin-point any specific mechanical or
operational defects i.e. Pressure or vacuum leaks (pneumatic, gas& steam) or arcing
and corona (electrical problems).

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 4.6. COAL HANDLING DEPARTMENT

As coal is the prime fuel for thermal power plant, adequate emphasis should be given
for its proper handling and storage. Also, it is equally important to have a sustained
flow of this fuel to maintain uninterrupted power generation. Coal is used as the fuel
because of the following advantages.
Advantages of coal as fuel:
• Abundantly available in India
• Low Cost
• Technology for power generation well developed.
• Easy to handle, transport, store and use.

4.6.1. COAL HANDLING SYSTEM

In the coal handling system of NTPC, three coal paths are normally available for direct
conveying of coal. These are:
• Path A: from track hopper to boiler bunker.
• Path B: from track hopper to stockyard.
• Path C: from stockyard to boiler bunkers.

Fig. 4.15. The Coal Handling System

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 The storage facilities at the stockyards have been provided only for crushed coal. The
coal handling system is designed to provide 100% standby for all equipment’s and
conveyors.

Fig. 4.16. Coal Handling Division of NTPC

COAL HANDLING EQUIPMENTS

i. Pulley
They are made of mild steel. Rubber lagging is provided to decrease the friction factor
in between the belt and pulley.
ii. Scrapper
Conveyors are provided with scrappers at the discharge pulley in order to clean the
carrying side of the belt built up material on idler rolls. Care should be taken to ensure
that the scrapper is held against the belt with the pressure sufficient to remove material
without causing damage to the belt due to excessive force exerted by the wiper. The
following categories of scrapper are common in use:
• Steel blade scrapper
• Rubber/fabric blade scrapper
• Nylon brush scrapper
• Compressed air blast scrapper.
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iii. Conveyor Belt
The conveyor belt consists of layers or piles of fabric duck, impregnated with rubber
and protected by a rubber cover on both sides and edges. The fabric duck supplies the
strength to withstand the tension created in carrying the load while the cover protects
the fabric carcass. Heat resistant belting is always recommended for handling
materials at a temperature over 66C.

Fig. 4.17. Coal Storage Area of the Dadri Thermal Power Station, New Delhi

iv. Vibrating Screen

The function of vibrating screen is to send the coal of having size less than 20 mm to
the crusher. The screen is operated by four v-belts connected to motor.
v. Vibrating Feeder
It is used to feed the coal on the underground conveyor belt from where coal goes to
bunker. Coal from the stockyard with the help of bulldozer is taken to the vibrating
feeder via reclaim hopper and underground conveyor belts. A tripper is provided in the
conveyor to stack the material at desired location on either side or along the conveyor
with the help of chute or chute fitted with the tripper itself. The tripper is provided with
wheels, which move on rails parallel to conveyor.
These trippers are of three types mainly:
• Motorized tripper

36
• Bell-Propelled Manually operated Tripper.
• Winch driven tripper

Fig. 4.18. Screening and Separation Unit of Coal Handling Division

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CONCLUSION

It was a great internship in NTPC full of knowledge. I really enjoyed the training
period. I have learnt about different Power Plants and the major minor problem
generally seen in the Plants and how to solve them.
Most of the time most of time our team survey in the plant and we see how the
coil or gas energy convert into mechanical energy and than how it convert into
electric energy.
I also seen that how an organization work under extreme pressure and how to
handle it like when there is more demand of electricity in the limited time it is
really a very big task, we also survey in the grit.
Overall it was a good experience and it increases my interest in the Public sectors.

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REFERENCES

➢ https://en.m.wikipedia.org/wiki/NTPC_Dadri
➢ https://www.google.com/url?sa=t&source=web&rct=j&url=https://www.ntpc.
co.in/power-generation/coal-based-power-
stations/dadri&ved=2ahUKEwihsfutxunjAhVNT30KHS7oCisQFjANegQIAx
AB&usg=AOvVaw3R4ZIMQvE4-h1nHMNjshlY

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