Industrial Internship

Review MEE3099
Presented By:
Dhruv Kandwal 15BME1004
 At the engineering office complex of NTPC Noida, I was allowed to
see and learn as to how a feasibility report of a thermal power plant
is prepared by using a sample case of GADARWARA POWER
PLANT.
I was introduced to following things:
 What are the various aspects/factors which are considered while
site selection
ABSTRACT:  How is the plant layout designed
 What are the components of the layout
 Which equipment are used in a thermal plant
 What are the waste products and how are they utilised/recycled.
I was allowed to see the thermal power plant as a part of my
internship.
  Power development is one of the key infrastructure elements for
the economic growth of the country. Central Electricity Authority
(CEA) was identified as the nodal agency for centralised planning
of generation and transmission system.
 National Thermal Power Corporation Limited was set up in
November 1975 with the objective of planning, promoting and
Something organising integrated development of thermal power in the
about NTPC country. Since then NTPC has been a key player in the power
sector of the country. The power generation from NTPC plants
stands to about more than one fourth of the total power
generation of the country.
 The power plant is located near villages Gangai & Umaraiya in
Narsinghpur District of Madhya Pradesh, surveying of the site and
the areas around the plant is carried out and the final selection of
the site is done based on the following factors:
 Availability of suitable & adequate land.
FEASIBILITY  Availability of sufficient coal and easy transportation.

STUDIES  Availability of a power source.

 Availability of reliable water source.
 Availability of infrastructural facilities.
 Environmental aspects.
Physical map
of power plant
site
Decided  About 1844 acres of land was allocated for the entire plant.

factors for the  Water requirement is met by the water from the river Narmada
flowing at a distance of 30 and also its tributary river Shakkar.
selection of  Coal requirement is met by the supply from Mand-Raigarh
the site coalfields allocated to NTPC.
 The general plant layout for the power plant is prepared by the
authorities and after studying the layout, it can be found that the
layout was influenced by following factors.
 availability of land & shape
 nearby rivers in the vicinity
PLANT LAYOUT  ground features & terrain
 corridor for outgoing transmission lines
 road/rail approaches, prevailing wind direction
 the water drawl and associated pipe corridor
Thermal plant
layout
  Firstly coal from the coal mines is transported to the thermal plant
via railway, this coal is stored in the coal yard built within the
thermal plant facility.
 Coal from the yard is transported to the crusher house where the
MATERIAL coal is crushed to smaller pieces allowing for easier and
homogeneous burning of coal (The inter plant transportation of
FLOW coal is carried out by conveyor belts)
 After crushing the coal is sent to a boiler, where the coal is burned
to produce heat which is in turn used to produce steam, which is
then used to produce electricity through turbines.
  Two types of ash are produced upon the burning of the coal, fly
ash which are the lighter ash particles and stay suspended in the
heated air. Ash which are heavier bigger particles, settle down at
the bottom of the boiler and this ash is intermittently removed by
mixing it with water.
Material Flow  Finally the waste heat is later let out through a cooling tower, the
cooling tower used in this thermal plant is forced convection
cooling tower in which axial fans are placed at the top to aid heat
rejection.
Flow Diagram
  Survey of land covering the plant site is an important process
since it allows to analyse the topography and hence decide
upon the type of foundation and design parameters.
CIVIL WORKS  Topographical studies were carried out to discover Boreholes,
drainage lanes (nallahs), the type of soil, ground water level,
tabulate all the data and hence see how the structures effected by
these factors(directly or indirectly) were designed and positioned.
 Total Boreholes 17(11 outside the plant boundary)

Drainage Lanes 4(1 passing through main plant area)

Topographical Ground Water Level 15.0 m – 20.0 m

Survey
Based on the available soil data, boreholes and other
topographical features – Foundation system was proposed
along with net allowable bearing pressure.
 COAL HANDLING SYSTEM

 Crusher House
 Transfer Points
 Conveyor Tunnel
Civil Works  Conveyor Galleries

Components ASH HANDLING SYSTEM & RE-CIRCULATION SYSTEM

 Bottom Ash Slurry Pump House

 Ash Water Pump House
 Transport Air Compressor House
Coal Handling
System
Schematic
Ash Handling
System
Schematic
 I was introduced to various mechanical components that were used
in the thermal plant through the feasibility report such as:
MECHANICAL  Steam Generator & Auxiliaries
WORKS once through, water tube, direct pulverized coal fired, top
supported, balanced draft furnace, single reheat, radiant, dry
bottom type generator
Boiler
Employed in
the plant
Coal
Transportation  The systems were selected/designed to meet the power
production need of 2X800 MW units, resulting in the need of
& Handling about 21190 tonnes based on gross calorific value of 4200
Kcal/kg, 100% plant load factor and 2317.44 Kcal/kWh unit heat
System rate.
Coal  Coal Transportation System: Indian Railway rakes are being used
for transporting the coal from the coal mines to the power plant.
Transportation  Coal Handling System: this system has double stream (one
& Handling working and one stand by) belt conveyors along with facilities for
receiving, unloading, crushing and conveying the crushed coal to
System boiler bunkers.
  The bottom ash from the boilers is collected and disposed in wet
form through an intermittent operating jet pumps coupled with
a water impounded hopper. The intermittent operating cycle is
designed to meet the ash removal rate generated by the amount
of coal burning per unit time.

Ash Handling  Fly ash collected from the electrostatic precipitator is collected
and conveyed(through pneumatic system) in dry form to storage
System silos located near the plant where it may be used to create a by-
product gypsum or FAB (fly ash bricks), or in case of non-
utilization it is mixed with water to form slurry and disposed in
ash disposal area.

 An ash water re-circulation system has been employed to re-

circulate the ash water from the ash pond located outside of the
plant to transport water after decantation back to the plant to be
re-used.
Control & C&I Systems are employed in the control rooms at the operating
floors along with programmers’ room. These systems are employed
Instrumentation to achieve safe and efficient functioning & monitoring of the
machines employed in the plant, further relieve the operator from
System redundant tasks/ continuous duties.
  Boiler, turbine and generator along with their auxiliaries are
monitored from the common control room.
 Various components such as transmitters, sensors etc. are used
for measurement of pressure, temperature, level, flow etc.
 Microprocessor based vibration monitoring systems are
Control & installed for vibration monitoring of major equipment.
Instrumentati  Environmental monitoring instruments for measuring the
emission of SOx, NOx, O2, CO2, CO and particulate matter.
on System  Distributed Digital Control Monitoring & Information System
(DDCMIS) is employed for safe, reliable and efficient operation of
Steam Generator, Water System, Coal Handling System, Ash
Handling System.
 NTPC being a leader in India in power generation has a green
outlook to it to promote other to follow environment friendly
practises and so ensures all possible environmentally practises are
efficiently employed in all its facilities.
 Air Pollution Control Measures
Environmental High efficiency electrostatic precipitators (ESPs) are installed to
Aspects limit the particulate emission
Further Flue Gas Desulphurisation (FGD) systems are being
discussed to be employed in the pre-planned spaces
‘Alkaline Scrubbing can be employed as a method for FGD’
 Water re-circulation with integrated treatment plants are employed
in the facility to allow efficient usage of water resources and also
Water reduce the amount of fresh water used on a daily basis by the
Pollution facility.
Majority of power plants deal with fly ash produces by providing
Control it as a raw material to brick manufacturing companies at very low
Measures costs.
 NTPC being the face of power generation in India leads in such
practises, these practises I was allowed to see at the Gadarwara
thermal power plant where:
 There are 8 cement manufacturing plants in the vicinity of the
plant, and are the users of fly ash.
Water  NTPC has set up a number of small capacity fly ash brick
manufacturing plants.
Pollution
 NTPC has started encouraging entrepreneurs to set up ash based
Control building products by providing incentives, processing systems at
cheaper prices, teaching drives etc.
Measures
 In order to explore the possibilities of use of ash in
agricultural/wasteland development, studies/ demonstration
projects are regularly carried out at various NTPC stations.
 Rail loading facilities are provided by NTPC so as to allow easy
transportation of fly ash to the user industries.
 Through this internship I was able to:
 Learn and see what are all the steps and planning that goes into
setting up a power plant from scratch.
 Conducting topography study, soil testing.
Conclusion  Learning about the various processes involved in power
generation, seeing the various apparatus involved its set up, its
selection and how do they work.
 How dealing with the waste produced is as important as rest of
the things which contribute to proper functioning of a thermal
power plant.