Summer Training Presentation

AT NTPC, BADARPUR BY Jitender Chandra Shekhar Ankit Srinivasan

NTPC- THE POWER GIANT

It is the largest power generating company in INDIA. Established in NOV 1975. Has installed capacity of 29,394 MW. It has 15 Coal based, 7 Gas based and 4 Power Stations in joint ventures. It plans to be a 75000 MW company by 2017. It has diversified into hydro power, coal mining, power equipment manufacturing, power trading and distribution.

POWER GENERATION AT NTPC

Coal is used as fuel to produce steam. The steam produced is used to spin a turbine.

This

turbine drives an electrical generator.

Capacity 210 MW 95 MW No. of generators 2 3 Total Capacity 420 MW 285 MW

Sr. no. 1. 2.

POWER GENERATION AT NTPC

i.
ii. iii.

There are three main units of the power plant. Steam generator or boiler Steam turbine Electric generator Thermal power plant works on the principle that depend upon the above three units.

Diagram of Coal based thermal power plant

Coal is conveyed in a pulverized fuel mill. This coal is mixed with preheated air. The hot air- fuel mixture is forced at high pressure into the boiler where it ignites. The water flows along the tube lined walls of the boiler. This water is then turned into steam due to the ignited mixture. The steam is superheated where its temperature and pressure rapidly increases.

Diagram of Coal based thermal power plant

This steam is then piped to the high pressure turbine. The three phase turbine process starts. The steam exhausted is returned to boiler reheater, it is then passed through intermediate and then the low pressure turbine. Now the exiting steam is brought in contact with cold water pumped in from cooling towers inside the condenser.

COAL HANDLING PLANT

WAGON TIPPLER CRUSHER MAGNETIC FILTER

RC BUNKER

RC FEEDER

MILL

FURNACE

WHAT IS C.H.P

A coal handling plant is a facility that washes coal of soil and rock. Removes the impurities after passing the coal from different stages. It is the major part of thermal power plant. Coal before entering the furnace follows different stages such as coal handling, sampling, usability, crushing, screening, metal separation.

MAJOR COMPONENTS OF C.H.P

WAGON TIPPLER

Wagons from the coal yard come to the tipplers and are emptied here The process is performed by slip-ring motor of rating 55KW,415V,1480RPM. This motor turns the wagon by 135 degrees and the coal falls directly on the conveyer belt.

CONVEYER

There are 14 conveyers in the plant. They are 1m wide, 3cm thick and made of chemically treated vulcanized rubber and move with speed of 250-300 m/min. Motors employed for conveyers has a capacity of 150hp. Have a capacity of carrying a coal at the rate of 400 tons per hour. Few are double belt so that if a belt develops any problem then the process is not stalled. It also has a switch after every 25-30m to stop the belt in case of emergency. The max angular elevation of the conveyer is designed such that its about 20 degrees. ZERO SPEED SWITCH- It is a safety device for motors i.e. if the belt is not moving and the motor is on then the switch checks the speed of the belt and switches off the motor when speed is zero.

COAL HANDLING

Coal collected is then passed through the conveyer belt to the larger field. The coal needs to be stored in these larger fields. The field consists of coal, rocks, minerals, contaminations etc. Coal handling is the larger part of bulk material handling and is a complex and vital part of the CHP.

SAMPLING OF COAL

It is one of the important part of the process. A routine sample is taken at a set frequency. A coal sampling consists of samplers, crushers, motors and feeders. During wash ability a liberation process takes place in which physical breakage is required to separate material of different densities.

SCREENING AND SEPARATION

Screens are used to group process particles into ranges by size. Dewatering screen is done which removes water from the product. It can be static or mechanically vibrated. Screen decks can be made from materials high tensile strength, stainless steel or polyethylene.

MAGNETIC SEPARATION

It is used to separate any metal pieces from the coal. This process takes place before the coal is being sent through the conveyer belt for crushing. The capacity of this device is around 50kg.

COAL CRUSHER

To ensure that the coal is of uniform size it is passed through the crusher. The crusher is of ring type. Has a motor rating of 400HP, 606KV. It is designed to crush the pieces to 20mm size.

PULVERIZER

Pulverization takes place in two stationary rollers and a power driven boul. Its main functions are Drying of coal Grinding Separation of particles of the desired size Coal is thus pulverized to increase its surface exposure thus permitting rapid combustion.

PRIMARY AIR CYCLE

P A FAN

COLD AIR DUCT

APH

SEAL AIR FAN

HOT AIR DUCT

PULVERISER

FLUE GAS CYCLE

FURNACE PLATEN SH REHEATER FINAL SH

LOW TEMP SH

CHIMNEY

ID FAN

APH

ECONOMIZER

STEAM CYCLE
BOILER DRUM PLATENT S.H. FINAL S.H. H.P. TURBINE

CRH CONDENSER

HRH

L.P. TURBINE

I.P. TURBINE

CONDENSATE CYCLE
HOT WELL CONDENSATE

PUMPS
L.P HEATER 2 L.P HEATER 3 L.P. HEATER 4 DEAERATOR BOILER FEED PUMP

FEED WATER CYCLE

BOILER FEED PUMP H.P. HEATER 5 H.P. HEATER 6 H.P. HEATER 7

DOWN COMERS

BOILER DRUM

ECONOMIZER

FEED REGULATION STN

WATER WALLS

UPRISERS

ASH HANDLING TECHNIQUE

A natural result from the burning of fossil fuels, particularly coal, is the emission of flyash. Ash is mineral matter present in the fuel. For a pulverized coal unit, 60-80% of ash leaves with the flue gas. Two emission control devices for flyash are the fabric filters and electrostatic precipitators. Electrostatic precipitators have a collection efficiency of 99%, but do not work well for flyash with a high electrical resistivity (as commonly results from combustion of low-sulfur coal). In addition, the designer must avoid allowing unburned gas to enter the electrostatic precipitator since the gas could be ignited.

COAL ASH CAN BE USED IN:

Construction of embankments and fills Construction of road in sub-base Manufacture of cement Manufacture of bricks/blocks Filling as flowable fill material Agriculture as soil amendment/source of essential plant nutrients

GENERATORS AT NTPC

Both generators are of 2 pole 3000rpm 50hz Rating of 95 MW Generator Manufacture by Bharat heavy electrical Limited (BHEL) Capacity - 117500 KVA Voltage - 10500V Speed - 3000 rpm Power factor - 0.85 (lagging) Stator current - 6475 A Frequency - 50 Hz Stator wdg connection - 3 phase star connection

Rating of 210 MW Generator Capacity - 247000 KVA Voltage (stator) - 15750 V Current (stator) - 9050 A Voltage (rotor) - 310 V Current (rotor) - 2600 V Speed - 3000 rpm Power factor - 0.85(lagging) Frequency - 50 Hz Stator wdg connection - 3 phase star connection

TRANSFORMERS AT NTPC
There are three types of transformers which are present at NTPC namely : 1. Generating transformer : Stepsup the voltage of 10.5kV & 15.75kV to a higher voltage of 220 kV. This is then transmitted to switchyard. 2. Unit auxiliary transformer : Steps-down this voltage of 15.75kV and 10.5kV to a comparatively lower voltage of 6.6 KV which is required to run the auxiliaries of the Main Plant such as I.D.Fan, P.A. Fan, F.D. Fan and other auxiliary motors. Each unit has its own separate G.T. & U.A.T.

3. Station transformer : There is one more Transformer known as station transformer used only for initializing the start-up of the station (Main Plant).It is very beneficial during emergency situations such as tripping of Units, shut-down etc.It gets the supply in its primary from 220 kV switchyard, steps-down it to 6.6kV which is used for starting various equipments & devices used in the Main Power Plant.

Rating of generating transformer : Type of cooling:O.F.W.F. No-load Voltage (KV):H.V. 400/3 L.V. 21 Line current(Amps.):H.V. 866.0 L.V. 9523.8 Temperature rise(C):Oil 50 Windings 60 Phase: 3 Frequency (Hz): 50 Core & winding(Kg.): 123050 Weight of Oil(Kg.): 27500 Total weight (Kg.): 179500 Oil quantity(l.): 29540 Transport weight(Kg.): 138000 Untanking weight(Kg.): 12000 Connection symbol: H.V : Y L.V : D

Ratings of U.A.T : Rating (KVA): 12000/16000 Cooling Method ONAN/ONAF % of cooling: 75 /100 KV (At no load):H.V. 15.75 L.V. 6.9 Amperes: H.V. 439.8/586.53 L.V. 1004.1/1338.8 Phases: H.V. & L.V. Three Temp.rise (C):Tap oil 40 Winding 50 Total Mass(Kg.): 37700 Untanking Mass(Kg.): 19200 Mass of Oil(Kg.): 7100 Volume of Oil(l.): 8250 Transport Mass with Oil(Kg.): 30000 Frequency(Hz): 50 Connection of windings: H.V : D & L.V : Y

Ratings of station transformer : Rating(KVA): 19000/25000/31500 Amperes : H.V. 83.1/109.3/137.8

KV at no-load : H.V. 132 L.V. 6.9 Phases: H.V. & L.V. 3 Temp. rise(C): Oil 40 Winding 55 Frequency(Hz): 50 Total Mass(Kg.): 63000 Untanking Mass(Kg.): 29000 Mass of Oil(Kg.): 17000 Volume of Oil(l.): 19600 Transport Mass with Oil(Kg.): 47000 Cooling Methods: ONAN/ONAF/OFAF
60 /80 /100 Vector group: H.V : Y & L.V : Y

L.V. 1589.8/2091.8/2635.7

SWITCHYARD DIAGRAM