VOCATIONAL TRAINING

PROJECT TITLE: THE VOCATIONAL TRAINING

REPORT AT NATIONAL THERMAL POWER
CORPORATION LIMITED (NTPC LIMITED), DADRI.

DURATION: 10TH JUNE 2016 TO 7TH JULY 2016

PROJECT LOCATION: DADRI

DETAILS OF THE STUDENT

NAME: ARPITA RAWAT

COLLEGE: MADHAV INSTITUTEOF TECHNOLOGY
AND SCIENCE, GWALIOR
DEPARTMENT:MECHANICAL ENGINEERING
PROGRAMME:BE
CURRENT YEAR:4TH/7TH SEM
ENROLLMENT NO: 0901ME131023

SIGNATURE:
 STUDENT DECLARATION

This is to certify that the dissertation entitled “Vocational Training” at

NTPC DADRI has been prepared by Miss. Arpita Rawat in partial
fulfillment of requirements of B.E. Mechanical Engg. Program at
Madhav Institute of Technology and Science, Gwalior (M.P.).

I hereby declare that all the information and facts produced here are
based on my own findings and studies under the guidance of Head
& NTPC Team Members, NTPC DADRI during the period of 10 th
June 2016 to 7th July 2016.

The contents of report are a true expression of my efforts on the said

topic.

Any resemblance to earlier project or research is purely co-incidental.

Student Name: DATE:07-07-2016 :

ARPITA RAWAT SIGNATURE:

 ACKNOWLEDGEMENTS

I am truly thankful to all faculties/guides who imparted the

lectures on various subjects/ topics and took me to the plant in
a guided study visit along detailed explaining about the plant
and machinery.

My thanks and appreciations also go to my colleague in

developing the project and also the people who have willingly
helped me out with their abilities.

ARPITA RAWAT
INTRODUCTION TO NATIONAL THERMAL POWER
CORPORATE LIMITED (NTPC LIMITED)

India’s largest power company, NTPC was set up in 1975 to accelerate power development in
India. NTPC is emerging as a diversified power major with presence in the entire value chain of
the power generation business. Apart from power generation, which is the mainstay of the
company, NTPC has already ventured into consultancy, power trading, ash utilization and coal
mining. NTPC ranked 317th in the ‘2009, Forbes Global 2000’ ranking of the World’s biggest
companies.
The total installed capacity of the company is 30, 144 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 naptha/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.

NTPC Limited is the largest thermal power generating company of India. A 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. It
also provides consultancy in the area of power plant constructions and power generation to
companies in India and abroad. As on date the installed capacity of NTPC is 27,904 MW
through its 15 coal based (22,895 MW), 7 gas based (3,955 MW) and 4 Joint Venture Projects
(1,054 MW). NTPC acquired 50% equity of the SAIL Power Supply Corporation Ltd.
(SPSCL). This JV company operates the captive power plants of Durgapur (120 MW),
Rourkela (120 MW) and Bhilai (74 MW). NTPC also has 28.33% stake in Ratnagiri Gas &
Power Private Limited (RGPPL) a joint venture company between NTPC, GAIL, Indian
Financial Institutions and Maharashtra SEB Holding Co. Ltd.

NTPC’s share on 31 Mar 2007 in the total installed capacity of the country was 20.18% and
it contributed 28.50% of the total power generation of the country during 2006-07.
 EVOLUTION 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.

In 1997, Government of India granted NTPC status of “Navratna”

1997
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

2005 The company rechristened as NTPC Limited in line with its changing
business portfolio and transform itself from a thermal power utility to
an integrated power utility.
NTPC is the largest power utility in India, accounting for about 20% of India’s installed
capacity.

National Capital Power Station Dadri

The National Capital Power Station [NCPS] has the distinction of being the country's only three
in one project ; consisting of Stage-I 840 MW; Stage-II 490MW ( and 490 MW under
construction) of coal based units , 829 MW gas based modules , and a 1,500 MW H.V.D.C.
converter station {under the operational control of P.G.C.I.L. since October '93}. The stage-II
(490MW*2) coal based units are scheduled in 2010 to meet the common wealth games power
requirement. The commercial operation of Stage-II Unit-V 490 MW has been declared on
31.01.2010. Also work for Stage-II UNIT-VI 490MW is under full swings. Besides the station
has the largest switchyard in the country with a power handling capacity of 4,500 MW
The station's capacity allocation is mainly concentrated in northern region of India . Spread over
2,465 acres , the station is situated on the Dadri -Dhaulana road [10 kms. off Dadri G.T. road ,
and 12 kms. off the National Highway # 24] . The route from New Delhi to NCPS is 60 kms.
long and is about 25 kms. from Ghaziabad
The station has the unique distinction of having Asia's first 100 percent dry ash extraction with
transit ash storage silos and final storage place converted to an green ash mound . An Ash
Technology park has also been set up to demonstrate the uses of ash which has become the point
of attraction for the visitors.

POWER PRODUCTION AT NTPC DADRI

 RANKINE CYCLE- THE BASIC POWER PLANT CYCLE

The Rankine cycle is a model that is used to predict the performance of steam turbine systems.
The Rankine cycle is an idealized thermodynamic cycle of a heat engine that converts heat into
mechanical work. The heat is supplied externally to a closed loop, which usually uses water as
the working fluid.

The Rankine cycle closely describes the process by which steam-operated heat
engines commonly found in thermal power generation plants generate power. The rankine cycle
is sometimes referred as practical Carnot Cycle because, when an efficient turbine is used, the
TS diagram begins to resemble the Carnot cycle. The main difference is that heat rejection and
heat addition are isobaric in rankine cycle and isothemal in theoretical Carnot Cycle.

There are four processes in the Rankine cycle. These states are identified by numbers (in brown)
in the above T-s diagram.
 Process 1-2: The working fluid is pumped from low to high pressure. As the fluid is a liquid
at this stage, the pump requires little input energy.
 Process 2-3: The high pressure liquid enters a boiler where it is heated at constant pressure
by an external heat source to become a dry saturated vapour. The input energy required can
be easily calculated graphically, using an enthalpy-entropy chart (aka h-s chart or Mollier
diagram), or numerically, using steam tables.
 Process 3-4: The dry saturated vapour expands through a turbine, generating power. This
decreases the temperature and pressure of the vapour, and some condensation may occur.
The output in this process can be easily calculated using the chart or tables noted above.
 Process 4-1: The wet vapour then enters a condenser where it is condensed at a constant
pressure to become a saturated liquid.
COMPONENTS OF COAL BASED POWER PLANT
A thermal power station is a power plant in which heat energy is converted to electric power.
In most of the places in the world the turbine is steam-driven. Water is heated, turns into steam
and spins a steam turbine which drives an electrical generator. After it passes through the
turbine, the steam is condensed in a condenser and recycled to where it was heated; this is known
as a Rankine cycle. The greatest variation in the design of thermal power stations is due to the
different heat sources, fossil fuel dominates here, although nuclear heat energy and solar heat
energy are also used. Some prefer to use the term energy center because such facilities convert
forms of heat energy into electrical energy.
Typical diagram of a coal-fired thermal power station
1. Cooling tower 10. Steam Control valve 19. Superheater
11.High 20. Forced draught
2.Cooling water pump
pressure steam turbine (draft) fan
3. Transmission
12. Deaerator 21. Reheater
line (3-phase)
4.Step-
22. Combustion air
up transformer (3- 13. Feed water heater
intake
phase)
5. Electrical
14. Coal conveyor 23. Economiser
generator (3-phase)
6. Low pressure steam
15. Coal hopper 24. Air preheater
turbine
7. Condensate pump 16. Coal pulverizer 25. Precipitator
26. Induced draught
8. Surface condenser 17. Boiler steam drum
(draft) fan
9. Intermediate
18. Bottom ash hopper 27. Flue-gas stack
pressure steam turbine

1. COOLING TOWER: A cooling tower is a heat rejection device that rejects waste
heat to the atmosphere through the cooling of a water stream to a lower temperature.
Cooling towers may either use the evaporation of water to remove process heat and cool
the working fluid to near the wet-bulb air temperature or, in the case of closed circuit dry
cooling towers, rely solely on air to cool the working fluid to near the dry-bulb air
temperature. Cooling towers vary in size from small roof-top units to very
large hyperboloid structures that can be up to 200 metres (660 ft) tall and 100 metres
(330 ft) in diameter, or rectangular structures that can be over 40 metres (130 ft) tall and
80 metres (260 ft) long. The hyperboloid cooling towers are often associated with nuclear
power plants, although they are also used in some coal-fired plants and to some extent in
some large chemical and other industrial plants.

2. THREE PHASE TRANSMISSION LINE: Three phase electric power is a common

method of electric power transmission. three-phase electric power systems have at least
three conductors carrying alternating current voltages that are offset in time by one-third
of the period.

3. ELECTRIC GENERATOR: In electricity generation, a generator is a device that

converts mechanical energy to electrical energy for use in an external circuit. A generator
forces electrical current to flow through an external circuit. The sources of mechanical
energy include steam turbines, gas turbines, water turbines, internal combustion
engines and even hand cranks.
4. STEAM TURBINE: A steam turbine is a device that extracts thermal energy from
pressurized steam and uses it to do mechanical work on a rotating output shaft. Because
the turbine generates rotary motion, it is particularly suited to be used to drive
an electrical generator – about 80% of all electricity generation in the United States
(1996) is by use of steam turbines. The steam turbine is a form of heat engine that derives
much of its improvement in thermodynamic efficiency from the use of multiple stages in
the expansion of the steam, which results in a closer approach to the ideal reversible
expansion process.
5. BOILER FEED PUMP: A boiler feed pump is a specific type of pump used to pump
feedwater into a steam boiler. The water may be freshly supplied or returning condensate
produced as a result of the condensation of the steam produce by the boiler. These pumps
are normally high pressure units that take suction from a condensate return system and
can be of centrifugal type or positive displacement type.
6. STEAM CONDENSOR: The condenser condenses the steam form the exhaust of the
turbine into liquid to allow it to be pumped. if the condenser can be made cooler, the
pressure of exhaust steam is reduced and efficiency of cycle increases. A surface
condenser is a commonly used term for a water-cooled shell and tube heat
exchanger installed on the exhaust steam from a steam turbine in thermal power stations.
These condensers are heat exchangers which convert steam from its gaseous to its liquid
state at a pressure below atmospheric pressure. Where cooling water is in short supply, an
air-cooled condenser is often used. An air-cooled condenser is however, significantly
more expensive and cannot achieve as low a steam turbine exhaust pressure (and
temperature) as a water-cooled surface condenser.
7. CONTROL VALVES: A control valve is a valve used to control fluid flow by varying
the size of the flow passage as directed by a signal from a controller. The opening or
closing of automatic control valves is usually done by electrical, hydraulic or pneumatic
actuators. Normally with a modulating valve, which can be set to any position between
fully open and fully closed, valve positioners are used to ensure the valve attains the
desired degree of opening.
8. DE-AERATOR: A deaerator is a device that is widely used for the removal of oxygen
and other dissolved gases from the feed water to steam-generating boilers. In particular,
dissolved oxygen in boiler feedwaters will cause serious corrosion damage in steam
systems by attaching to the walls of metal piping and other metallic equipment and
forming oxides (rust). Dissolved carbon dioxide combines with water to form carbonic
acid that causes further corrosion. Most deaerators are designed to remove oxygen down
to levels of 7 ppb by weight (0.005 cm³/L) or less as well as essentially eliminating
carbon dioxide.
9. FEED WATER HEATER: A feedwater heater is a power plant component used to pre-
heat water delivered to a steam generating boiler. Preheating the feedwater reduces the
irreversibilities involved in steam generation and therefore improves the thermodynamic
efficiency of the system. This reduces plant operating costs and also helps to avoid
thermal shock to the boiler metal when the feedwater is introduced back into the steam
cycle.
10. COAL CONVEYOR BELT: A conveyor system is a common piece of mechanical
handling equipment that moves materials from one location to another. A belt conveyor
 system consists of two or more pulleys (sometimes referred to as drums), with an endless
loop of carrying medium—the conveyor belt—that rotates about them. One or both of the
pulleys are powered, moving the belt and the material on the belt forward. The
powered pulley is called the drive pulley while the unpowered pulley is called the idler
pulley. There are two main industrial classes of belt conveyors; Those in general material
handling such as those moving boxes along inside a factory and bulk material
handling such as those used to transport large volumes of resources and agricultural
materials, such as grain, salt, coal, ore, sand, overburden and more.
11. PULVERISER: A pulverizer or grinder is a mechanical device for the grinding of many
different types of materials. For example, a pulverizer mill is used to pulverize
coal for combustion in the steam-generating furnaces of fossil fuel power plants.
12. BOILER DRUM: A steam drum is a standard feature of a water-tube boiler.It is a
reservoir of water/steam at the top end of the water tubes. The drum stores the steam
generated in the water tubes and acts as a phase-separator for the steam/water mixture.
The difference in densities between hot and cold water helps in the accumulation of the
"hotter"-water/and saturated-steam into the steam-drum.
13. SUPERHEATER: A superheater is a device used to convert saturated steam or wet
steam into superheated steam or dry steam. Superheaters are used in steam engines or in
processes, such as steam reforming. There are three types of superheaters: radiant,
convection, and separately fired. A superheater can vary in size from a few tens of feet to
several hundred feet (a few metres to some hundred metres).
14. ECONOMISER: Economisers are mechanical devices intended to reduce energy
consumption, or to perform useful function such as preheating a fluid. The term
economizer is used for other purposes as well. Boiler, power plant,
heating, Refrigeration, ventilating, and air conditioning (HVAC). In simple terms, an
economizer is a heat exchanger.
15. ELECTROSTATIC PRECIPITATION- An electrostatic precipitator (ESP) is a
filtration device that removes fine particles, like dust and smoke, from a flowing gas
using the force of an induced electrostatic charge minimally impeding the flow of gases
through the unit. In contrast to wet scrubbers which apply energy directly to the flowing
fluid medium, an ESP applies energy only to the particulate matter being collected and
therefore is very efficient in its consumption of energy (in the form of electricity).

ASH AND ITS HANDLING

INTRODUCTION TO ASH HANDLING SYSTEM

Ash handling refers to the method of collection, conveying, interim storage and load out of
various types of ash residue left over from solid fuel combustion processes.
The most common types of ash include bottom ash, bed ash, fly ash and ash clinkers resulting
from the combustion of coal, wood and other solid fuels.
Ash handling systems may employ pneumatic ash conveying or mechanical ash conveyors.
A typical pneumatic ash handling system will employ vacuum pneumatic ash collection and ash
conveying from several ash pick up stations-with delivery to an ash storage silo for interim
holding prior to load out and transport. Pressurized pneumatic ash conveying may also be
employed.
Coarse ash material such as bottom ash is most often crushed in clinker grinders (crushers) prior
to being transported in the ash conveyor system.
Very finely sized fly ash often accounts for the major portion of the material conveyed in an ash
handling system. It is collected from bag house type dust collectors, electrostatic precipitators
and other apparatus in the flue gas processing stream.
Ash mixers (conditioners) and dry dustless telescopic devices are used to prepare ash for transfer
from the ash storage silo to transport vehicles.

ELECTROSTATIC PRECIPITATORS: MAIN SOURCE OF ASH

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

TYPES OF ASH HANDLING SYSTEMS

Bottom ash system
In this system, the ash slag discharged from the furnace is collected in water impounded scraper
installed below bottom ash hopper. The ash collected is transported to clinkers by chain
conveyors. The clinker grinders churn ash which is then mixed with water to form slurry.
Fly ash handling system (both wet and dry)
Fly ash is considered to be collected in ESP hoppers. Fly ash from ESP hoppers extracted by
vacuum pumps up to intermediate surge hopper cum bag filter for further dry conveying to fly
ash silo. Under each surge hopper ash vessels shall be connected with oil free screw compressor
from intermediate surge hopper to silo.

Coarse ash handling system

Ash generated I economizer hoppers shall be evacuated continuously through flushing boxes.
Continuous generated economizer slurry shall be fed by gravity into respective bottom ash
hopper pipes.

Bottom ash handling System

The bottom ash quantity is around 20% of the total Ash generation and there are mainly two
types of bottom ash disposal systems.
 Dry Type Bottom Ash Disposal
 Wet Ash Slurry Disposal
Dry Type Bottom Ash Disposal: First of all we will discuss about the Dry type bottom ash
disposal system.
 Submerged Scrapper Conveyor: Submerged Scraper Conveyor is used for cooling and
transmitting the hot bottom ash. The scraper conveyor used to send the bottom ash to the
bottom ash silo. The Bottom ash hoppers are partially filled with water in order to avoid
the direct impact of the Clinkers due to free fall. Whatever the ash, falling on the SSC
conveyor is getting scrapped by the scrappers to the clinker grinder.

 Clinker Grinder: A clinker grinder is provided at the outlet of SCC to control the
bottom ash size as in the bottom ash there will be some big clinkers and to make the ash
of even size we use a clinker grinder.The output of the bottom ash after the clinker
grinder is around 25mm to 50mm,it is adjustable.

 Drag Conveyor: It transmits the crusher output to the bottom ash silo. It is same as that
of scrapper conveyor. Just for conveying purpose for the bottom ash.
  Bottom ash silo: Each boiler is equipped with a bottom ash silo. It is used for storing the
bottom ash for a period of time and then it is dumped in the trucks for disposal

Fly Ash Handling System

In Fly Ash Handling System, the major objective is to collect and transport the fly ash from the
ash hoppers of the ESP to the Fly ash silo or to the Ash Slurry making tank. Generally the power
plants prefer Dry Fly ash Disposal instead of making Ash Slurry from the Fly ash and the reason
is that the fly ash collected from the ESP Bottom Hopper is very fine and suitable for Cement
making, if we are making slurry of it then it will not be suitable for Cement making and
economically also it is very good if you are selling the Ash to the Cement Plants. So these are the
reasons why most of the plants are going for Fly ash Disposal instead of Slurry Disposal (Ash
Water).
Slurry Type Fly Ash Disposal System: This is one of the simplest system for ash disposal from
ESP hopper to the slurry pond. High Pressure water and fly ash is mixed below the ESP hopper
and below in the diagram you can see that tapping for mixing of water is provided.
 ESP Hopper: Hopper is a large conical type container used for dust or ash collection.
After the field charging in ESP we go for hammering of collecting plates and the fly ash
deposited on the collecting plates gets stored in the hopper. To ensure free flow of ash
into the ash vessels from the hopper, the lower portions of the hoppers are provided with
electric heaters. Because if the temperature of the ash falls below the ash fusion
temperature then the ash will form big clusters and may choke the entire conveying
system.

 Dome valve: It is situated between the ESP hopper and Ash vessel; it is a special type of
valve which is highly leak proof. It consists of a dome type structure with a rubber seal
which is continuously getting supply from the compressed air.

 Air Vent Line: To remove the trapped air from the vessel, we use vent line and due to
this line air from the vessel is transported to Hopper and ash come down. It basically does
two things, first of all by removing the air from the vessel, it is removing the back-
pressure from the Vessel and simultaneously it is pressurizing the ash hopper.
  Compressor: A compressed air station is set up in the plant. The compressed air station
provides air for the pneumatic conveying system and purging of fabric filters as we
already explained in ESP. After compressing the air, we have to remove all the moisture
content from the air. To remove the moisture from air we use Adsorbent Air Drier (AAD)
and Refrigeration Air Drier (RAD).The pressure of the compressor is depended on the
system design.

 Ash Vessels: Ash vessels are present just below the ESP hoppers with the Dome Valve
assembly. They are supposed to contain the fly ash for a certain amount of time which
will be carried to the fly ash silos. Their ash holding capacity is depended on the
conveying capacity of the ash line to the Ash Silos.

 Fly Ash Silos: store the fly ash generated by the Boiler in the maximum continuous
operating conditions (BMCR).The bottom of each fly ash silo is equipped with two ash
discharging chutes. One ash discharging chute is used for discharging the
comprehensively used dry fly ash and the other one is connected with a wet mixer,
discharging the wet fly ash. The wet ash mixer is just a back-up for the dry ash disposal
system. Each fly ash silo is equipped with the bag filters and bag filter cleaning facilities
with exhaust fans.
1. Air extraction fan: It is used to create a negative pressure inside the vessel of the silo
and the air goes out through the bag filters.
2. Extractor: It is used to evacuate the Air from the Bulkers (Closed Vessel Truck), which
is connected to the ash disposal chute and the discharge is connected to ash vessel.
3. Diverting and dump valve: If one ash silo will not work we divert the line into another
silo with the help of diverting valve and to dump the ash into ash silo dump valve is used.
Wet Fly Ash Disposal System: Up to the hopper part it is same as that of Dry Fly Ash handling
system. After the hopper instead of going into the vessel, the ash gets mixed with a high Pressure
water and this mixture goes to a slurry tank for further pumping. The slurry formed is further
pumped through a series of pumps or a single GEVO pump for dumping in the Ash yard. For
mixing of fly ash with water, a tapping is provided for High Pressure water below the hopper.

FLY ASH REUSE

Dadri ash have been successfully used in the following applications .

 LAND FILLS
 ROAD EMBANKMENTS
 ROAD CONSTRUCTION
 PORTLAND POZZOLONA CEMENT
 BUILDING PRODUCTS
 CONCRETE
Use of ash in above applications have resulted in saving in terms of money , conservation of
natural resources viz mother earth, lime stone, coal, sand, energy, land and water apart from
reduction in CO2 emission and thus environment.

CHALLENGES OF ASH HANDLING

 Indian coal presents high ash content generally which tends to be inconsistent.
 Design of the system has to adequately cover anticipated variations and be capable of
handling the worst situation.
 System has to be environmentally friendly.
 System has to be reliable with least maintenance costs.
 System has to be energy sufficient.