A Report on Vocational Training in NTPC-Singrauli Shaktinagar, Sonebhadara (U.P.

Guided By:Mr. Brajesh Kumar Dy. Supdt. (C&I)

Presented By:Sarvesh Yadav B.Tech. (EEE)

S.S.T.P.S.

Roll- 0805621057

Acknowledgement
I am very grateful and thankful to all those who were a part of this project and helped me towards its smooth and efficient completion. I feel especially thankful to Mr.Brijesh kumar and many others for their helpful contribution and knowledge without which my project would not be a reality. I am also thankful to my friends to encourage me & who helped me to learn such valuable things.

SARVESH YADAV B.Tech. 4th Year (ELECTRICAL &ELECTRONIC ENGINEERING) N.I.E.C.(LUCKNOW)

CONTENT
About Singrauli Super Thermal Power Station Introduction Types of Power Generating Plants Journey From coal to Electricity BOILER AND ITS AUXILIARIES GENERATOR AND ITS AUXILIERIES SWITCHYARD

About Singrauli Super Thermal Power Station

Set up in 1975 NTPC, the MAHANAVARATNA Power Company of the country, and rank 6th, largest thermal power generating utility in the world. Every 4th Bulb of India is lit by NTPC

SSTPS is the flageship station of NTPC. Its total generating capacity is

2000MW. It is located at a distance of 200KM south from varanasi on the bank of Gobind Ballabh Pant Sagar in Shaktinagar at Sonebhadra District in Uttar Pradesh.

In Singrauli there are two(02) stage of power generating units.In St-I there are fives(05) units of 200 Mw ,while in St-II two (02) units of 500 Mw.

Introduction
Development of a country like India depends much upon its industrial development which, in turn, depends upon the development of infrastructures required to carry out industrial activity. Power ( Electricity) is one of the most important requirement in infrastructure. Power sector, therefore, has to play a very important role in development.

Types of Power Generating Plants 1.Thermal:Turbine is rotated by steam in this type of power plant. Fuel used coal or gas. 2. Hydro:Turbine is rotated with the help of water jet. 3. Nuclear:Turbine is rotated by steam . Fuel used radio-active elements. 4. Renewable:Used non-conventional energy sources.

Why Coal Based Thermal Power Plants Are WidelyUsed In India? Advantages of Coal Fuel Abundantly available in India Low cost Technology for Power Generation well developed. Easy to handle, transport, store and use

Shortcomings of Coal Low Calorific Value Large quantity to be Handled Produces pollutants, ash Disposal of ash is Problematic Reserves depleting fast Indias Coal Reserves are estimated to be 206 billion tonnes. Present consumption is about 450 million tonnes.

Cost of coal for producing 1 unit of electricity (Cost of coal Rs 1000/MT)is Rs 0.75. Cost of Gas for producing 1 unit of electricity (Cost of Gas Rs 6/SMC)is Rs 1.20.

Journey From coal to Electricity

Coal Mines Coal CHP

Silo
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W a te r
B o ile r D r u m Down
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BOILER AND ITS AUXILIARIES

MECHANICAL STEAM GENERATOR: The steam generator for this plant has a primary steam flow of 700t/hr. at 139kg/square cm. & 535 degree C at superheated outlet. It has 11000 MT of weight. The boiler is tangentially fired, balanced draught, natural circulation, radiant single reheat, dry bottom, open door type & direct fired with Indian bituminous pulverized coal. The steam generator has single drum equipped with steam purifying unit such as cyclone. To limit the carry-over of dissolved solids to the stipulated requirement the drum supplies the water to the water walls adequately through the down comers so as to permit the unrestricted circulation. 1: FURNACE: The main boiler has following accessories:

Steam generator has a single furnace with negative draught, with fusion welded panels having width of 13.868 m and depth of 10.529 m. Furnace is made of water walls of 60.5 dia. and 6mm thickness of carbon steel. The rear wall has a goose neck formation. Additional heating area is provided by 4 platen water walls suspended on front at the top of the combustion chamber. Furnace is fired with the help of 24 tilting type tangentially fired burners located in each corner of furnace at 6 different elevations interposed between coal burners. There are 3 oil burners in each corners of furnace to ignite the crushed coal incoming from coal burners.
2: ECONOMIZERS:

The economizer is continuos unfinned loop type & water flows in upward direction & gas is in the downward direction. This is a good proposition as it is used to recover the heat of exit flue gases economically by using plane economizer tubes. Modern size of economizers is relatively small as compared to earlier economizers. Since in modern plant feed water heaters are used to increase the feed water temperature and efficiency of turbine unit

3) BOILER DRUM:

The boiler drum serves two functions: 1) To separate steam from the mixture of water and steam discharged into it.

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2) To house all the equipments used for purification of steam after being separated from water. This equipment is commonly known as drum internals. Boiler drum is made of C steel plates. The quantity of water contained in the boiler below the water level is relatively small as compared to the total steam outlet as result, regardless the drum size, the worthy point to be noted is that the drum size is not primarily determined by the water storage. It is determined by the space required to accommodate the steam separating and purifying equipments. The steam space provided should be significant to prevent priming and foaming. Drum diameter and length should be sufficient to provide accessibility for installation, inspection & servicing of the drum internals. The drum length depends on furnace width or steam separating devices. For this purpose the drum length is kept at least 900 mm more than the furnace width. The technical data about drum for 200 MW and 500 MW units is given respectively as follows: Weight: 127 & 237 MT (metric tones). Length: 17 & 22 mt. Made of: 1676 & 2130 mm OD, 133 & 152.4 mm thickness steel plates. Location at: 53.340 & 72 mt. from ground level. The function of drum internals is to separate water and steam from the mixture generated in water walls. The drum internals reduces the dissolved solids of the steam to below the acceptable limit of 1 ppm.
4: WATAR WALLS AND DOWN COMERS:

Water walls and down comers serve as the only means of heating & evaporating the feed water supplied to the boiler from the economizer. Water walls consist of tangential vertical tubes & are connected at the top & bottom to the headers. These tubes receive water from the boiler drum by means of down comers connected between water walls lower header and drum. In a boiler approx. 50% of heat released by the combustion of fuel in the furnace is absorbed by the water walls. Heat so absorbed by the water walls is used in evaporation of water supplied by the boiler drum. The mixture of steam & water is discharged from the top of the water walls tubes into the upper wall header & then passes through the riser tubes to the steam drum where the steam is separated from water & the accompanying water together with in coming feed water is returned to the water walls through the down comers.
5: SUPER HEATERS:

Super heating is done in 3 phases by radiation & convection mode of heat transfer. The super heaters are continuous tube type with the horizontal

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primary section located above the economizer & pendant platen secondary section at furnace exit i.e. the convective SH is suspended in the second pass, the radiant SH is in the radiant zone & final SH is between first and second pass. The side panels of first pass & roof of the first & second pass both also from the super heating surface. A spray type attemporator is also envisaged to control the super heater outlet temperature for varying load. Classification of super heaters: The super heaters are classified on the basis of: 1: Position and shape: 1) Pendant type SH. 2) Horizontal type SH. 3) Platen type SH. 2: Method of heat receiving: 1) Radiant type SH. 2) Convection type SH. 3) Combined SH. Super heaters are meant to raise the temperature of the saturated steam absorbing the heat from flue gas & thus increase the cycle efficiency economically. 1) 2) 3) 4) 5) There are 4 sections of SH: Roof section-located above the furnace with radiation mode heat transfer. Steam cooled-made of 51mm OD tubes forms all 3(side, front, rear) walls & roof of vertical gas pass. Platen-directly above the furnace consisting of 29 assemblies of 51 mm OD tube by radiation h/t. Pendant located behind screen tube & is connected between super heater vertical spaced inlet & outlet header. Convection horizontal-located in rear vertical gas pass above the economizer. It is called LTSH (Low Temperature Super Heater).

Saturated steam from drum = LTSH (via roof section SH and steam cooled walls) = Platen SH (through inter stage de-super heater) = pendant convection type SH =Turbine (via 2 MS lines of 323.9*42 square mm connected to 2 ends of SH).

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6: REHEATER:

Reheater is used for further increasing the cycle thermal efficiency by raising the temperature of already expanded steam up to 540 degree C again. It is placed in the hotter zone so that minimum surface requirement is kept. Reheating is done by pendant type of coils of the RH suspended vertically inside the furnace between platen & exit of super heater. Reheater temperature is 535 degree C at 582 tones/hr. at 24.5 cm2 pressure. Burner tilt is used for controlling Reheater temperature. This is a part of boiler which receives steam back from the turbine after it has given up some of its energy in the high pressure section of the turbine. The Reheater raises the temperature of this steam, usually to its original value, for further expansion in the turbine. The purpose of this reheating is to add energy to the partially used steam.
7: BURNERS:

In stage 1, there are 24 total pulverized coal burners for corner fired C.E. type boiler & 12 oil burners provided each in between 2 coal burners. The pulverized coal burners are arranged in such a way that 6 mills supply the coals to the burners at 4 corners of the furnace. All the nozzles of the burners are interred linked & can be tilted as a single unit from 30 to -30 degree. The oil burners are fed with heavy fuel oil till boiler load reaches to about 25%.
8: IGNITERS:

Igniters are used for lighting the main oil gun. In stage 1, there are 2 igniters air fans which supplies air for combustion of igniters oil. Mainly 2 types of igniters are used: 1) Eddy plate igniters. 2) High energy arc type igniters. There are 12 side HEA type igniters for boiler. The atomizing air for igniters is taken from plate air compressor at 7 kg/square cm (gauge). The burners are located at 3 elevations. Each elevation has 4 oil burners & igniters. These elevations are normally known as AB elevation, CD elevation & EF elevation. In our plant HEA igniters have been used. It can directly ignite the heavy fuel oil. The main part of these igniters:
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1) An Exciter unit: this stores the energy and releases it at a high voltage & for short duration. 2) A spark rod which is designed to convert the electrical energy into an intensive spark. 3) A pneumatically operated retracts mechanism which is used to position the spark in the firing position & to retract it in non firing position.
9: AIR PRE HEATERS:

For stage 1, there are 2 no. of trisector, regenerative type air pre heaters forming 2 parallel passes and heating the primary air and secondary air with flue gases. It has 900 square m surfaced of heating are a pre air heaters. Theses are electrically rotated at 14 rpm. 4 no. of swiveling type soot blowers with steam as media are used to remove the soot from APH. 2no. of steam coil APH are also used with medium as secondary air at FD fan discharge with heating surface area 770 square m per air heater. There are 2 sets of each of FD, ID & PA fans. Air pre heating is done by the rotation of rotor with 14 rpm. When the coils of pre heater comes in contact with hot flue gases from furnace they absorbs the energy of flue gases with the rotation of coils this energy is transferred to the second pass air heading towards the furnace again for combustion.
10: DE-SUPER HEATER:

These are direct spray type de super heaters. Two DSHs are located between rear horizontal outlet header & platen inlet header & CRH towards RH inlet header. These are used to reduce the steam temperature when necessary & to maintain the temperature at designed value. It is done by injecting water spray into the path of the steam through a nozzle at the entering end of the DSH. Spray water source is from boiler feed water system, in order to prevent chemical deposition in the super heater & RH & carry over of the solids to the turbine.
11: FANS:

There are many types of fan used in the power plant; some of them are given as follows for stage 2:
1: PA FAN:

Primary Air fan is used to suck the air from atmosphere to deliver it to the coal mills to fly the pulverized coal from coal mills to the furnace. There are two passes provided through PA fan, hot & cold air pass with the help of their mixture we control the humidity in coal. The PA fan having radial design with over hung impeller, coupled with motor & having inlet vane control.
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PRINCIPLE: It is based on the energy transformation principle due to centrifugal forces. Some amount of the velocity energy is converted into pressure energy in the spiral casing.

2: FD FAN:

Forced draught fan is used to supply the air for combustion in the furnace. This air is called secondary air which is being supplied with the help of 2 no. of axial reaction FD fans with variable pitch control coupled with motor.
3: ID FAN:

Before stack, one no. of impulse type ID fan with inlet vane control coupled with motor is provided for each stream. Fans have been designed for 60% MCR flow conditions of the boiler keeping in view the specified coal characteristics. PRINCIPLE: This fan works according to impulse energy principle. The major part of the energy transformed to the gas is velocity energy after the impeller. The velocity energy is converted into pressure energy by diffuser. Flow is controlled by changing the direction of gas entering to the impeller blades by providing adjustable guide vanes.
12: AUXILIARY BOILER:

To provide steam at 16 kg/square cm & at 215 degree C to various auxiliaries at initial stages of the operation of the main plant & for heating the heavy fuel oil of 10500 kcal/kg HCV a package type aux. boiler of 55 tones/hr. capacity has been installed. It is front fixed, natural circulation, bi drum boiler with bottom support.

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GENERATOR AND ITS AUXILIERIES

The generator is of 3 phase, 2 pole, cylindrical rotor, and 3000 rpm. For stage 1, The rated o/p is 235.3 MVA at 0.85 pf. The terminal voltage is 15.75 Kv at 50 Hertz frequency at .5 SCR & 8625 Ampere current. Stator winding is designed for connection in double star with 3 phase and 6 neutral terminals brought out on the slip rings side. The terminal brushings are of porcelain & housed in the lower part of stator terminal box made of non magnetic steel plates. The stator body is totally enclosed gas tight, explosion proof fabricated structure. The shaft and the body are forged in the one piece of Cr-Mo-V steel. The rotor is balanced to a high accuracy & subjected to 20% over speeding for 2 minutes as per standards. The field windings consist of formed coils made up of hard drawn silver bearing copper with bonded insulation. Gap pick up system is employed for direct hydrogen cooling of rotor winding.
HYDROGEN COOLING SYSTEM:

The rotor winding is cooled by hydrogen flowing through the radial ventilating ducts. It is designed for hydrogen pressure up to 3 kg/square cm gauge. Hydrogen is cooled by gas cooler mounted on the stator body. Hydrogen cooling water is cooled by suitable water to water heat exchanger external to machine. Since hydrogen is of lower density than air & superior thermal properties. The stator temperature limit is 105 degree C.
WATER COOLING SYSTEM:

The stator is cooled by the circulating D.M. water through hollow conductors. The system is designed to maintain a constant rate of cooling water flow to the stator windings at a nominal water inlet temperature of 40 deg. C. The cooling water is again cooled by water which is also demineralised to avoid contamination with any impure water in case of cooler tube leakage. The cooling water is in turn cooled by clarified water taken from clarified water header.

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SEAL OIL SYSTEM:

Shaft seal operating with a flow of oil under pressure are used to prevent the escape of hydrogen along with generator shaft. A pressure regulating valve maintains a constant differential pressure of seal oil over hydrogen pressure in the generator. Vacuum treated oil from the seal oil supply unit is fed to the center of the seal ring assembly from where it flows between rings and shaft in the both direction, and a film thus established in the constricted area prevents the leakage of hydrogen. A SOP is provided for maintaining pressure.
EXCITATION:

To have increased transient stability & capability of generator in leading p.f. zone a fully static thyristorized excitation system is provided. Power required for excitation system is tapped off from generator bus duct, steeped down, rectified in thyristor bridges & fed to the generator slip rings. During start up the system shall be fed from the station AC power suitably rectified by a separate rectifier.
BUS BARS:

Generator main bus bars consist of natural air cooled, continuous enclosure type isolated phase bus. There is no connection between generator and main transformer. Al alloy is for conductor material.
GENERATOR T/F:

For each unit of 200 MW, one 250 MVA, 15.75 KV/400 KV, 3 phase, out door type t/f has been installed in the t/f yard. It is connected to the generator through isolated phase duct. LV winding is delta connected & HV winding is star connected. The percentage impedance is about 14%. The GT is oil cooled. Rating is 250 MVA, quantity is 5, type is of two windings, VR (voltage ratio) is 15.75 KV/400 KV and temperature rise is 40 deg. C by oil and 60 deg. C by windings.

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RELAY : Protective relays are devices that detect abnormal conditions in electrical circuits by constantly measuring the electrical quantities. The basic quantities, which may change during faulty conditions, are voltage, current, frequency, phase angle etc. It disconnects the faulty parts as quickly as possible. It disconnects the faulty part from the healthy part, causing least disturbance to the healthy system. It sounds an alarm, so that the operator may take some corrective action. COST OF ELECTRICITY : The direct cost of electric energy produced by a thermal power station is the result of cost of fuel, capital cost for the plant, operator, labor, maintenance, and factors such as ash handling and disposal. Indirect, social or environmental costs such as the economic value of environmental impacts, or environmental and health effects of the complete fuel cycle and plant decommissioning, are not usually assigned to generation costs for thermal stations in utility practice, but may form part of an environmental impact assessment. In now a day A.B.T(Availability Based Tariff) concept is used by grid for pay the cost of generated electricity by power house .In this system power house has to declare its availability of Mega Units generation for next 24 hours and if power house get fail then penalty is forced on it and in some special circumstance if power demand increase and power house helps to over-come this problem then for this extra amount is pay on increased rate . This whole concept is based to balance the difference between demand and supply because power is unique commodity and it cannot be seen ,store and packed . SWITCHYARD It is a switching station which has the following credits : Main link between generating plant and Transmission system, which has a large influence on the security of the supply. StepUp and/or Step-down the voltage levels depending upon the Network Node.

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Switching ON/OFF Reactive Power Control devices, which has Quality of power. SWITCHYARD EQUIPMENTS Following equipments are used in switchyard : Lightening arrestor Current transformer Voltage transformer Power transformers / I.C.T. Bus bar and clamp fittings Support structure Isolators Circuit Breaker Wave traps Earthling switch FUNCTION OF VARIOUS EQUIPMENTS USED : Transformers :

effect on

- Transforms the voltage levels from higher to lower level or vice versa, keeping the power constant. Circuit breakers : - Automatically breaks the electrical circuits under loaded condition. Isolators OPERATES UNDER NO LOAD CONDITION INTERLOCKED WITH BREAKERS AND EARTHSWITCHES SHOULD WITHSTAND EXTREME WIND PRESSURES MOTOR DRIVEN AND HAND DRIVEN LOCAL AS WELL AS REMOTE OPERATION POSSIBLE ISOLATES SECTIONS FOR MAINTENANCE USED TO SELECT BUS BARS CT SWITCHING FOR BUS BAR PROTECTION
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Instrument transformers : - For stepping-down the electrical parameter (Voltage or Current) to a lower and safe value for Metering and Protection logics.

Earth switch : - Used to connect the charged body to ground to discharge the trapped charge to have a safe maintenance zone. Lightning arrestors : The distance of L.A. from Generator Transformer should be as minimum as possible to avoid passing of traveling surges to Generator Transformer. However, it should not be too close to cause damage to transformer bushing in case of shattering of LAs. Further possibility of using shatter proof L.As needs to be checked in the market. It is observed that the counter / leakage current monitors of most of the L.As are not operating properly only due to breakage of glass or rusting of enclosures or entry of dust / water in the enclosures. It is necessary to provide rugged enclosures with IP67 degree of protection. Further the leakage current measured at works should be indicated on the name plate. In case the leakage current increases more than two times the factory recorded current, the L.A. should be replaced Overhead earth wire : - Protects the overhead transmission line from Lightning strokes. Bus bar : - Conductors to which a number of circuits are connected. Wave Traps/Line traps :

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- Wave trap is used for Protection of the transmission line and communication between the Substations. Reactive Power control devices : - Controls the reactive power imbalance in the grid by switching ON/OFF the Shunt Reactors, Shunt Capacitors etc.

Current Limiting Reactors : - Limits the Short circuit currents in case of faulty conditions. CURRENT TRANSFORMERS Current transformers are used to step-down the high magnitude of current to a safe value for Measuring and Protection logics Current transformers are used for the instrumentation, protection or metering of power systems.

VOLTAGE TRANSFORMERS : Voltage transformers are to step-down the high magnitude of voltage to a safe value for Measuring and Protection logics. Voltage transformers serve a number of functions in a power system. They are required for the operation of many types of instrumentation and relay protective Factors effecting the selection of Switching Scheme System Security Operational Flexibility Simplicity of Protection arrangements Ability to limit the Short Circuit levels Maintenance Ease of extension
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Total land area Cost

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