INTRODUCTION With increasing for developing large power resources, regional concept of power planning was implemented th during

4 plan and Govt. of India decided to setup large pit head Thermal Power Station as a strategy to augment the power generation in a big way. National Thermal Power Corporation Ltd (NTPC) was incorporated on 7 November, 1975 in the central sector as a Thermal Power Generating with the objecting of planning, monitoring & organising for an integrated development of thermal power in the country. Farakka Super Thermal Power Project, the fourth of a series of pit head Super Thermal Power Projects was setup by NTPC. SALIENT FEATURES 1. Foundation Stone: Laid by former Prime Minister Late Smt. I ndira Gandhi 2. Location: Place- Farakka District- Murshidabad Nearest Railway Station- New Farakka Jn. State- West Bengal Distance from Kolkata- 300km (approx) Airport- Netaji Subhas International Airport 3. Capacity: A. Stage 1- 3x200MW B. Stage 2- 2x500MW C. Stage 3- 1x500MW (under construction) 4. Power Distribution: A. West Bengal- 33.12% B. Bihar- 30.19% C. Orissa- 20.69% D. DVC- 14.44% E. Sikkim- 01.56% 5. Resources: A. Coal: Source- Lalmatia coal mine, Rajmahal area, Godda Dist, Jharkhand (Dedicated to FSTPS) Transport- 85km long Merry-Go-Round (MGR) system Requirement- 28,000 MT/Day B. Water: Source- Farakka Feeder Canal of river Ganges
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Requirement- 3000 Cusecs 6. Area: A. Plant- 2129 Acres B. Ash ponds- 1826 Acres C. Townships- 375 Acres Total- 4330 Acres 7. Approved costs: A. Stage 1- Rs730.93 Cr B. Stage 2- Rs2453.00 Cr CHRONOLOGY OF EVENTS 1. Govt. approval of stage 1 - May 1979 2. Foundation stone lying - 29 December 1981
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3. Govt. approval of stage 2 - September 1984 4. Synchronisation of unit 1 - 1 January 1986 5. Synchronisation of unit 2 - 24 December 1986 6. Synchronisation of unit 3 - 6 August 1987 7. Synchronisation of unit 4 - 25 September 1992 8. Synchronisation of unit 5 - 16 February 1994 FUNDAMENTALS A Thermal Power Plant is a plant where electrical energy is obtained from chemical energy. BASIC POWER PLANT CYCLE The thermal (steam) power plant uses a dual (vapour+liquid) phase cycle. It is a closed cycle to enable the working fluid (water) to be used again and again. The cycle used is ranking cycle modified to include superheating of stream, regenerative feed water heating and reheating of steam. FACTOR AFFECTING THERMAL CYCLE EFFICIENCY Thermal cycle efficiency is affected by following: A. Initial steam pressure. B. Initial steam temperature. C. Reheating. D. Condenser pressure. E. Regenerative feed water heating. COAL TO STEAM
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By coal handling plant, coal is prepared to appropriate size. Then coal is taken away to the furnace through coal pipe with the help of hot and cold air mixture through P.A. Fan. Through air pre-heater and F.D. Fan, air is heated and sent to the furnace as combustion air. Water; from boiler feed pump is passed through economiser, boiler drum, down comers, bottom ring header and wall tubes. Then water is partly converted to steam. By super heating the temp of steam is raised (540C), and sent to turbine. Flue gasses from furnace which emits their heat energy to super heaters extracted by I.D. Fans. Finally passes through air pre heater and goes to electrostatic precipitator (ESP) to extract ash to control pollution. STEAM TO MECHANICAL POWER A steam pipe conveys steam to the turbine through control valves, which regulate the supply of steam to the turbine. Then steam enters the high pressure cylinder of the turbine and passes through a ring of stationary blades, guiding the steam into a second ring of moving blades mounted to turbine shaft. It is called stage . Steam passes through no of stages until it reaches the end of high pressure cylinder to change heat energy to mechanical energy. When maximum possible energy has been extracted from the steam, it is exhausted to the condenser. It consists of about 20,000 tubes of 25mm in diameter. Ambient cold water is circulated through the pipes to convert steam to water, to reduce the pressure. The condensed water then reused in boiler and the cooling water is also reused. MECHANICAL ENERGY TO ELECTRICITY The turbine shaft is coupled with the generator shaft. As the generator rotates, a magnetic flux interaction takes place. As a result, the desired electricity is obtained. ENERGY CONVERSION PROCESS Sl. No. 1 2 3 Energy converted from Chemical (coal) Heat (steam) Mechanical (kinetic) Energy converted to Heat (steam) Mechanical (kinetic) Electrical Converted at Boiler Turbine Generator

TRANSMISSION The generated electricity is then feed to transmission line through generator transformer, isolator, circuit breaker and another isolator. From circuit breaker, the current is taken to busbar and through another circuit breaker it is fed to the GRID. COAL TRANSPORTATION AND HANDLING As coal, is the primary fuel for a thermal power plant, adequate emphasis needs to be given for its proper handling and storage. Also it is equally important to have a sustained flow of this fuel to maintained uninterrupted power generation. Each NTPC project of 2,000MW project requires 30,000 tons coal per day. Here in FSTPS, a captive transport system, called Merry-Go-Round (MGR) rail transportation is involved. It has the following advantages:

A. High loading enables loading of train quickly thus achieving high turnover of wagons and reduction of rolling stock requirement. B. Top open railway wagons are loaded with maximum possible load consistently and accurately. Simple loading arrangements to a point avoid the need for a big marshalling yard with cumbersome system.

SOURCE OF COAL FOR FSTPS: Lalmatia Coal Mine (Undertaken by Eastern Coalfield Ltd.). Rajmahal Area. Godda District. Jharkhand. The mine is dedicated to FSTPS. The coal comes to FSTPS through the following steps: A. Loading Silo: it is a arrangement by which coal is loaded to wagon. Hydraulically operated horizontal snap gates are used to load coal from silo to wagon. A size of 200mm coal is supplied from mine. B. Merry-Go-Round (MGR): Between Lalmatia and FSTPS, the MGR is situated. The MGR is as follows: a. Distance : 81.865km b. At 20.30km : Kumarpur station c. At 33.00km : Berhait station d. At 52.55km : Pathra station e. At 81.865km : Loading point f. Total length of MGR : 164km In FSTPS, coal is processed and taken for combustion through Coal Handling Plant (CHP), which consists of: A. Track hopper: It is the underground part of coal unloading unit, just under the rail. It transmits the coal to conveyor belt. Specification: a. Manufacturer : M/S MAMC b. Length : 200 m c. Capacity : 3,500 MT B. Idler: Idlers consist of rolls made of seamless steel tube enclosed at each end and fitted with stationary shaft. It helps the conveyer belt to move freely. C. Pulleys: Pulleys are made of MS. Rubber lagging is provided to increase the friction factor between the belt and the pulley. D. Conveyor Belt: It contains of layers impregnated with rubber and protected by a rubber cover on both sides and edges. It is used to carry coal from one unit to another. Heat resistance is 66C. E. Drive unit: This comprises of motor coupled to reduction gear box with the help of flexible couplings on the high speed shaft of the gear box. It drives the belt. F. Skirt board: This are used to guide the materials centrally on the belt while loading until it has settled down on the belt. G. Crusher: The role of crusher is to crush the coal from 200mm to 20mm size received from the vibrating screen. This is accomplished by means of granulators. Coal enters the top of the crusher and is crushed between rotating granulators and fluid cage path. It can crush around 600 tons per hour. H. Vibrating screen: It send the coal of size less than 20mm to belt feeder through the bypass chute.

I. J. K. L.

Stacker-cum-re claimer: This is used for stacking and reclaiming the coal from and to stockyard. It handles the excess amount of prepared coal. Plough Feeder: The plough feeder is normally installed under hoppers. It guides to feed the material properly to the belt by rotor blades. Vibrating Feeder: It is used for throwing the coal on the underground conveyor belt from where coal goes to bunker. Tripper: The tripper is provided in the conveyor to stack the material at desired locations with the help of chute fitted with the tripper itsel f.

WATER TREATMENT PLANT The objective of water treatment is to produce a boiler feed water so that there shall be a. b. c. No scale formation causing resistance to passage of heat and burning tube. No corrosion and No priming or foaming problems.

The process of demineralisation is described below. Raw water: Raw water is the crude ambient water collected to the plant.

The crude water is then made clarified water by applying Alum, Lime & Chlorine.

Clarified water: Clarified water is free of undissolved particles a nd also partially organic particles free.

Then clarified water is pass through gravity sand filter (GSF) to eliminate the residual undissolved particles, it is called filter water.

Filter water: Filter water is purified drinkable water.

Then filter water is taken to DM plant.

Demineralised water (DM water): When filter water is passed through various types of ionic resins, DM water is obtained which is totally free from all type of undissolved (clay, sand etc), dissolved (chemicals, salts etc), organic (microbes) particles.

In the DM plant, the following reactions takes place:

Cation Resin: R H + Na p R Na + H 2SO4 Anion Resin: R OH + H 2SO4p R SO 4 + H 2O Recharging the exhausted form of resin i.e. regeneration employing 5% of acid/alkali as below:

Cation Resin: R Na + HCPp R H + NaCl Anion Resin: R SO4 + NaOH p R OH + Na 2SO4 The entire DM process can be shown as: Filter water p ACF p WAC p SAC p ADU p WBA p SBA p MB p DM Water [ACF Activated Carbon Filter; WAC Weak Acid Cation; SAC Strong Acid Cation; ADU WBA Weak Base Anion; SBA Strong Base Anion; MB Mixed Bed] Air Degasser Unit;

Utilisation of water:

Raw water is used for cleaning and fire extinguishing. Clarified water is used for cooling. Filter water is used as drinking water. DM water is supplied to the Boiler to produce steam which is feed to the Turbine. STEAM GENERATION Steam plays a vital role in thermal power plant, is to rotate the turbine. The steam is generated after the combustion of oil and coal in boiler system. The main components of boiler system are: Furnace: A boiler furnace is a space adjacent to a boiler in which fuel is burned and form which the combustions products pass into the boiler proper. Here the reaction is isolated and confined as it remains a controlled force. Boiler Drum: The function of it is to separate the water from the generated steam in the furnace walls. The drum is located on the upper front of the boiler. Economiser: The purpose of economiser is to preheat the boiler feed water before it is introduce into the boiler drum by recovering heat from the flue gases leaving the boiler. It is located in the boiler rear gas pass below the rear horizontal super heater. Super Heater: Three super heaters located above economiser assembly in the rear pass, it is to super heat the 2 steam. The obtained steam from super heater is of 540C and 157 Kg/cm and go to H.P. Unit. Re heater: It is to reheat the steam coming from high pressure turbine to a temperature of 540C. re heater is located at furnace arc and hater hanger. Burner: There are twenty four pulverised coal burners for corner fired C.E. type boilers and twelve oil burners provided each in between two pulverised fuel burner. Oil burners are fed with heavy fuel oil till boiler load reaches to about 25%. Igniters: There twelve side eddy plate oil/H.E.A igniters per boiler. The atomising air for igniters is taken from 2 plant air compressors at 7 Kg/cm (gauge). Coal bunker: These are in-process storage silos for storing crushed coal from CHP. This is made of welded steel plates. Generally, six such bunkers are involved. Coal feeder: Mills are provided with drag link chain/rotary/gravimetric feeder to transport raw coal from bunker to the inlet chute, leading meal at a desired rate. Mill: There are six mills (25% capacity each), for every 200 MW unit, located adjacent to the furnace at 0 m level. These pulverise coal to actual size. P.A. Fan: The primary air fans (50% x 2) are to handle atmospheric air up to a temperature of 50C. These are located at 0 m level near the boiler. Air pre-heater: Air pre-heater transfer heat from flue gases to cold primary and/or secondary air by means of rotating heating surface element. A steam coil air pre-heater is involved in it, situated in a secondary pass of the furnace at 16 m level. A 200 MW unit has such to setups. F.D. Fan: The forced draught fans (50% X 2) are to handling secondary air of the boiler. These are located at 0 m level near the P.A. Fan. Wind Box: These are the distributing media for supplying secondary air to the furnace, located on the left and right sides of the furnace while facing the chimney.

nit an: These fans, two per boiler, used to supply air for cooling igniters and combustion of igniters air fuel mixture.

l ct ostatic Precipitator: ES are generally two plate type located between boiler and chimney. The ES is arranged for horizontal gas flow and constructed with welded steel casings. . . Fan: There are two induced draught fans, per boiler between the ES and the chimney, to suc flue gas from furnace.

Chi ney: These are tall RCC structures with single/multiple flues (one flue per unit) the height varies depending on location. Seal Air Fan: These are used to supply seal air to the mills to prevent ingross to cold dust into gear box lubrication oil. There are two fans per boiler for 200 MW units. Soot Blo ers: The soot blowers are used for efficient on-load cleaning of furnace, super heaters, re-heaters and regenerative oil heaters. POWER GENERATION TURBINE As it is a thermal power plant steam turbine is used to generate electricity. Ad antage: The steam is expanded down to a lower bac pressure and makesa generator heat drop. As a constant load is applied to the turbine, a constant torque is developed at the coupling and the generator. Operating Principle: In a multistage Turbine, steam at a high pressure and high temperature enters in first row of fixed blades or nozzles through air valves. As the steam passes through the fixed blades it expands and its velocity increases. The high velocity jet of steam strikes the first set of moving blades. The kinetic energy of the steam changes into mechanical energy, causing the shaft to rotate. The steam then enters the next set of fixed blades and strikes the next row of moving blades. In a thermal power plant, the turbine system comprises of three categories: A. High Pressure Turbine (HPT) B. Intermediate Pressure Turbine (IPT) C. Low Pressure Turbine (LPT) Co ponents: A. Turbine Casing:

Steam flow through a turbine

HP Casing, nozzle boxes and steam chests are made of creep resisting Chromium-Molybdenum-vanadium (Cr-Mo-V) steel casing. IP Casing is made of two parts. The front part is made of creep resisting Cr-Mo-V steel casing and the exhaust part is of fabricated structure. The two parts are connected by a vertic l joint. From the IP Turbine a steam is carried through cross-over pipes to the double flow LP cylinder. LP Casing consists of three parts as, one middle part and tow exhaust parts. The three parts are fabricated from weld able mild steel. The exhaustcasings are bolted to the middle casing by a vertical flange. B. Rotor: HP Rotor is machined from single Cr-Mo-v steel forging with integral discs. The rotor forging is thermally stabilised to prevent abnormal deflection. The blades are attached to their respe ctive wheels by T root fastening.

Scann

an: These are to supp y re u s te air for scanner cooling, wo per boiler. t

   

IP Rotor has seven discs integrally forged with rotor while last four discs are shrunk fit. The shaft is made of high creep resisting Cr-Mo V steel forging while the shrunk fit discs are machined from high strength nickel steel forging. LP Rotor consists of shrunk fit discs a shaft is a forging of CrMo-V steel while the discs are of high strength nickel steel forging. Blades are secured to the respective discs by riveted fork root fastening. C. Blades: Blades are fitted in stationary part are called guide blades and those fitted in the rotor are called moving or working blades.
y a. b. c.

Cl ifi ti :Cylindrical Blade (Fig-A) Taper Cylindrical Blade Twisted and Varying Profile Blade (Fig -B)

Part :-

A. Aerofil: It is the working part of the blade and one of the types described above. B. Root: It is the portion of the blade which is held with the disc, drum or casing. a. T-roots:- used for small blades. b. Fir Tree or Serrated roots:- used for large blades. c. Fork and Pin root:- used for longer blades shrunk on disc type rotor. C. Shrouds: It can be either riveted by tannon to main blade or can be integrally machined with the blade. D. Sealing Glands: To eliminated the possibility of steam leakage to atmosphere from the inlet and exhaust ends of the cylinder, Labyrinth glands of the radial clearance type are provided which provide a trouble free frictionless sealing. Steam is supplied to the sealing chamber at1.03 to 1.05 Kg/sq. m abs and at temperature 130 C to 150 C from the header. E. Emergency Stop Val es and Control Val es: Emergency stop valves (ESV) are provided in the main steam line and Interceptor valves (IV) are provided in the hot reheat line. Control valves (CV) are actuated by the governing system through servomotors to regulate steam supply as required by the load. F. Bearings: The Journal bearings are manufactured in two halves and consist bearing body faced with anti -friction tin based babbiting to decrease co-efficient of friction. The Thrust bearing is mitchel type and combined with a Journal bearing, housed in spherically machined steel shell. The bearing between HP and IP rotors are thrust type bearing and the rest are journal type bearing. G. Barring Gear:

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"

  

Blade Profile

It is mounted on the rear bearing cover to mesh with spur gear on LP rotor rear coupling. It is to rotate the turbo-generator rotor slowly and continuously during start-up and shut-down periods when change in rotor temperature occur. GENERATOR Operating Principle: The AC generator is based upon the principle of electromagnetic induction and consists of a stationary part, stator and a rotating part, rotor. Stator has the armature winding. Rotor has field winding where DC voltage is applied through slip rings. When the rotor rotates, a magnetic flux interaction occurs and a induced e.m.f. is generated in the stator which can be expressed as: E = 4.44 /O FN volts O = Strength of magnetic field (wb) F = Frequency (c.p.s. or Hz) = Pn/120 N = Number of turns in a coil of stator winding P = Number of poles n = Revolution per second of rotor Components: A. Rotor: The rotor is cast steel ingot and it is further forged and machined. Very often a hole is bored through the centre of the rotor axially from one end to the other for inspection. Then slots are machined on the rotor for winding and ventilation. It is an electromagnet and to give it necessary magnetic strength, the winding should carry a fairly high current. Rotor Winding: Silver bearing copper is used for winding with mica as the insulation between the conductor. A mechanically strong insulators such as micanite is used for lining the slots. Later designs of windings for large rotors incorporate combination of hollow conductors with slots or holes arranged to provide for circulation of the cooling gas through the actual conductors. The two ends of windings are connected to slip rings, usually made of forged steel, and mounted on insulated sleeves. Rotor Balancing: The completed rotor should be tested for mechanical balanced means a check is made to see if it is run upto normal speed without vibration. If a vibration occurs, adjustable balance weights around the circumference at each end are to be applied. B. Stator: It is the outer stationary part of the generator with certain windings. After magnetic flux interaction the induced e.m.f. generated in it and collected from it. Stator Frame: This comprises an inner frame and outer frame. The outer frame is a rigid fabricated structure of welded steel plates, within this shell is a fixed cage of girder built circular and axial ribs. The ribs divide the yoke in the compartments through which hydrogen flows into radial ducts in the stator core and circulate through the gas coolers. The inner cage is fixed into the yoke by springs to dampen the double frequency in 2 pole generator. The fabricated inner cage is inserted in the outer frame after the stator core winding completed.

Stator Core: The stator core is built up from a large number of punching or sections of thin steel plates. The use of cold rolled grain-oriented steel can contribute to reduction in the weight of the stator core. Stator Windings: Stator winding are made up from copper strips wound with insulated tape which is impregnated with varnish, dried under vacuum and hot pressed to form a solid insulation bar. These are then placed in stator slots and held in with wedges to form the complete winding which is connected together at each end of the core forming the end turns. The water is fed to the windings through plastic tubes. OFF-SITE FACILITIES FUEL OIL SYSTEM In thermal power plants with coal fired Boiler, the fuel oil plays a vital role in initial firing of the boilers and running it upto 25-30% of its rated load capacity. The fuel oil is also used as a stabilizing fuel in the pulverized fuel fired boilers till the coal flame stabilizes in the furnace and for proper coal burning while the load is reduced in the boiler for shut down. Heavy Oil Handling System: Heavy oil is received at the site in railway tankers of 20 tonne capacity each. An unloading header by the side of receiving railway tankers has been laid in the underground trench and is provided with number of receiving points so that a number of wagons can be unloaded at a time. The unloading header is of approximately 200 meters in length and 450 mm in dia. Railway tankers are supposed to be equipped with steam heating coils for oil heating. Oil transfer pumps for steam jacketed type, are provided for transferring oil from collecting headers to storage tanks. Oil from discharge end of pumps can be stored in any tanks through plug valves. The main storage tanks are interconnected to suction sides of unloading pumps. To keep the viscosity of oil in main storage tank low, it is essential to keep the oil warm 50 -70 C, a steam floor heating coil is laid at the bottom of the tank. Heavy fuel oil from service tank is led to the fuel oil pumps located in the pump house at a pump able temperature of 40-60 C. Light Oil Transfer and Pumping System: Light oil is used as the fuel for the igniters. Light oil is also required for warming up oil gun to start up the boiler. Due to low viscosity, atomization is done by air. Road tankers discharge oil into a common receiving header through flexible hose pipes. Then oil is pumped into the light oil storage tanks by light oil pumps. Then oil is pumped to burners by light oil pressure pumps. Light oil pumping unit is located in the pump house near the day tank and it draws light oil from day tank and delivers through common piping to the boilers. ASH HANDLING PLANT The ash produced in the boiler is transported to ash dump area by means of sluicing type hydraulic ash handling system. it consists of bottom ash system, fly ash system, ash water system and ash slurry system. Bottom ash system: In the system the ash slag discharge from the furnace bottom is collected in two water impounded scraper installed below ash hoppers. The ash continuously transported by means of scraper chain conveyor on the clinker grinders. From here ash fall into the ash sluice trench provided below the bottom ash hopper.

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Main type of hoppers: a. Water Filter Hoppers consists of a tank made of steel plate. Bottom ash from the boiler falls into water filled tank and quenched large pieces of ash break up due to thermal shock, and ash collected will be fairly small size. b. Quencher Cooled Ash Hopper located near the top of the hoppers provides fine spray of water. This ensures that the ash is cooled sufficiently to prevent after combustion and simitering within the hopper. It also cools the hoppers. Fly Ash System: The flushing apparatus are provided under E.P. hoppers (40 nos.), economizer hopper (4 nos.), air preheater hoppers (4 nos.) and stack hoppers (2 nos.). This is collected in this hoppers drop continuously to flushing apparatus. Ash Water System: High pressure water required for B.A. hopper quenching nozzles, B.A. hoppers window spraying, clinker grinder sealing scraper bars, economiser hoppers etc. Low pressure water required for bottom ash hopper seal through make up, scrapper conveyor make up, flushing apparatus etc. Ash Slurry System: Bottom ash and fly ash slurry of the system is sluiced upto ash slurry pump along the channel with the aid of high pressure water jets located at the suitable intervals along the channels. Slurry pump suction line consisting of reducing elbow with the drain valve, reducer and butterfly valve and portion of slurry pump delivery line consisting of butterfly valve, pipe and fittings to be provided. CIRCULATING WATER SYSTEM Water is required in the thermal power station for various purposes. Filtered water is used for bearing cooling, drinking and other general uses and ordinary water is used for condenser cooling and ash disposal system. Water Requirements of a Thermal Power Station: a. Water is required for cooling the steam in condensers, 1.5-2.0 cusecs / MW. b. Water is used for sluicing out ash. c. Water is also used for cooling of various components. Source of Water: Here water is consumed from the feeder canal of river Ganges. Intake of Structure: It is situated at a point where the main channel of the river huge the intake structure bank. It should not endanger the foundations. The floor level of intake structure should be higher than the maximum flood level of the river. Silting at the entrance should be avoided. The intake structure can be either an open channel or RCC ducts/pipes upto the power house. The total system should not increase the temperature of the system and endanger the marine life. HYDROGEN GENERATION PLANT Hydrogen gas is used for generator cooling.

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Hydrogen is prepared by electrolysis of pure D.M. water. To make the D.M. water conductor, NaOH / KOH is added to it. When direct current is passed through the electrolyte, hydrogen is given off at negative electrode and oxygen is evolved at the positive electrode. Description of Arrangement:A.C. power at 400-440 V, 3 phase is converted to D.C. power by rectifier which is controlled by a regulator. Gas production is proportional to the passed D.C. current. Cooling water is supplied to the water seal to prevent back flow from the gas holder when the plant is not operated. Hydrogen gas flows from the gas washing tank to a low pressure wet seal gas holder and then to a compressor. Oxygen gas produced in the process is let off to atmosphere. Gas Holder: The gas holder should be leak proof and float at a pressure of 4.5 water column. Valves are provided at the lowest points on the lines entering and leaving the gas holder to drain any condensate. CO2 should be eliminated from the cells of the gas holder.

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