INDUSTRIAL TRAINING REPORT

AT

National Thermal Power Corporation

SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE AWARD

OF THE DEGREE OF

BACHELOR OF TECHNOLOGY
(Electrical Engineering)

SUBMITTED BY
 
Alka Bharti
Electrical Engineering
Roll No. 1616008
Univ. Roll No. 1606824

Department of Electrical Engineering

Guru Nanak Dev Engineering College
Ludhiana, 141006
 INDUSTRIAL TRAINING REPORT
AT

National Thermal Power Corporation

SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE AWARD

OF THE DEGREE OF

BACHELOR OF TECHNOLOGY
(Electrical Engineering)

SUBMITTED BY
 
Alka Bharti
Electrical Engineering
Roll No. 1616008
Univ. Roll No. 1606824

Department of Electrical Engineering

Guru Nanak Dev Engineering College
Ludhiana, 141006

GURU NANAK DEV ENGINEERING COLLEGE, LUDHIANA

TO WHOM IT MAY CONCERN

I hereby certify that “Alka Bharti” Roll No. 1616008, Univ. Roll No. 1606824 of Guru

Nanak Dev Engineering College Ludhaina, has undergone six weak industrial training from 16

June 2018 to 15 July 2018 at our organization to fulfill the requirements for the award of

degree of B.Tech. (Branch). He works on web designing and development on php project

during the training under the supervision of Abhishek Anand. During his tenure with us we

found him sincere and hard working. Wishing him a great success in the future.

Signature of the Student

Signature of the SUPERVISOR

i

 ACKNOWLEDGEMENT

I would like to extend my heartfelt gratitude to all those who have contributed towards the

successful completion of my project and converge my thanks to Director of power plant

Institute Dr. Ravinder Singh. I would be failing in my duty, if I do not express my gratitude to

training head Shri. Deepak Kr Sharma for his helpfulness generously extended support and by

sparing his valuable time to guide and suggest me towards the completion of my project also

thanks to Mr. V.K Gupta head of electrical department in power plant who guide me to

understand the most important things of power plant.

I attribute heartiest thanks to all the engineers of electrical department of especially to Er.

Romil Kumar Sir who helped me out in every step of my training schedule and I would even

like to thank Mr. Ankit Goyal, Mr. Pankaj ,Panda for their guidance.

I do owe a great sense of gratitude to all my friends and all those who stood with me and for

their continuous support and co-operation during the project.

Thank you

Alka Bharti

ii

 LIST OF FIGURES

Fig. No. Figure Description Page No.

Figure 1.1 Growth of NTPC Installed Capacity & Generation Chart 2

Figure 1.2 Power Contribution chart of NTPC in INDIA 3

Figure 1.3 Strategies Chart of NTPC7 3

Figure 2.1: Block Diagram Of NTPC Power Plant 9

Figure 2.2 Thevarious parts of the coal thermal power plants 10

Figure 2.3 Operation of a Rankine cycle 20

Figure 2.4 T-S diagram of a typical Rankine cycle 21

Figure 3.1 Reheater 27

Figure 3.2 Economizer 28

Figure 3.3 Air pre-heater 29

Figure 3.4 Pulverizer 30

Figure 3.5 Ash handling system 32

Figure 3.6 Water treatment plant 33

Figure 3.7 Demineralization 37

Figure 3.8 Operating principle of steam turbine 36

Figure 3.9 Steam cycle diagram 38

Figure 3.10 Turbine & Turbine cycle 40

Figure 3.11 A Typical water cooled condenser 43

Figure 3.12 A Deaerator 44

iii
Figure 3.13 Coal cycle diagram 46

Figure 3.14 Coal handling system 46

Figure 3.15 Coal handling division at NTPC 47

Figure 3.16 A Idler 48

Figure 3.17 Coal Storage Area of the NTPC 49

iv

 TABLE OF CONTENTS

Contents Page No.

Supervisor’s Certificate i

Acknowledgement ii

List of Figures iii

Table of Contents v

CHAPTER 1: INTRODUCTION 1

1.1 Company overview 1

1.2 Training overview 4

CHAPTER 2: Product/Process details 8

2.1 Operation of a power plant 8

2.2 Basic steps of electricity generation 8

2.3 Rankine cycle 19

CHAPTER 3: Details of training 23

3.1 Department/Section Detail 23

3.1.1 Boiler Maintenance Department 23

3.1.2 Plant Auxiliary Maintenance 30

3.1.3 Turbine Maintenance Department 35

3.2 Coal Handling Department 45

References 50
 CHAPTER 1: INTRODUCTION

1.1 Company Overview

NTPC is the largest thermal power generating company of India. 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 341st in the 2010, Forbes Global 2000‟ ranking of the World’s biggest

companies. NTPC became MaharatnaCompany in May, 2010, one of the only four companies

to be awarded this status.

The total installed capacity of the company is 39,174 MW (including JVs) with 18 coal based

and 7 gas based stations, located across the country. In addition under JVs, 7 stations are coal

based & another station uses LNG as fuel. The company has set a target to have an installed

power generating capacity of 128000 MW by the year 2032. The capacity will have a

diversified fuel mix comprising 56% coal, 16% Gas, 11% Nuclear and 17% Renewable Energy

Sources(RES) including hydro. By 2032, non-fossil fuel based generation capacity shall make

up nearly 28% of NTPC”s portfolio.

NTPC has been operating its plants at high efficiency levels. Although the company has

17.75% of the total national capacity, it contributes 27.40% of total power generation due to its

focus on high efficiency.

Page 1
"

"

Figure 1.1 Growth of NTPC Installed Capacity & Generation Chart

In October 2004, NTPC launched its Initial Public Offering (IPO) consisting of 5.25% as fresh

issue and 5.25% as offer for sale by Government of India. NTPC thus became a listed company

in November 2004 with the Government holding 89.5% of the equity share capital. In February

Page 2
2010, the Shareholding of Government of India was reduced from 89.5% to 84.5% through

Further Public Offer. The rest is held by Institutional Investors and the Public.

NTPC contributes more than one-fourth of India’s total power generation with less than one-

fifth capacity

ALL India
Rest of India NTPC NTPC

" "

NTPC 308308* MW NTPC 220.54* BUs

ALL India 1,73,626 MW ALL India 805.5* Bus

Figure 1.2 Power Contributions chart of NTPC in INDIA

"

Figure 1.3 Strategies Chart of NTPC

Page 3
 JOURNY OF NTPC

"

Table 1.1 Chart Journey of NTPC

1.2 Training Overview

ABOUT NTPC

Barh Super Thermal Power Station or NTPC Barh is located in Barh in the Indian state of

Bihar. NTPC Barh is located barely four kilometres east of the Barh sub-division on National
Page 4
Highway-31 in Patna district. The project has been named a mega power project, and is owned

by Indian energy company National Thermal Power Corporation.

The 1,980MW (3x660 MW) Barh Stage-1 is being built by Russian firm Technopromexport

(TPE), and 1,320MW (2x660 MW) Barh Stage-2 extension is being built by BHEL.

Bihar's share is 1183 MW from NTPC Barh(26% from stage 1 and 50% from stage 2).

The main power plant and the township is spread over an area of 1,186 acres.The legal

possession of 1,186 acres of land has been acquired for setting up the main power plant and its

township which includes 12 villages.

The then PM, Atal Bihari Vajpayee, had laid the foundation stone of the main plant of stage-1

of NTPC Barh on March 6, 1999. The formal inauguration of its site office and laying of the

foundation stone of the training centre at the plant site was done in September 2003. Former

Union power minister Sushil Kumar Shinde had inaugurated the main plant house of stage-2 of

NTPC Barh on May 29, 2006

Project Cost

The plant is to produce 3,300MW of power at a cost of over Rs 26,000 crore. The total

approved cost of stage-1 (660MWx3) has Rs 8,692.97 crore. The total approved cost of stage-2

(unit 1) plant is Rs 7,688.12 crore.

Capacity

Unit-1 of stage-2 commissioned in November 2013. Sikkim and West Bengal were allocated

some share of power from NTPC Barh units.

Inland Waterways Authority of India received bids in 2013 September for coal movement on

1620 km National Waterway 1 (India) from Haldia to NTPC's Barh which is about 1000 km

away.

Page 5
Stage Unit EPC Contractor Date of Capacity Status

number commissioning in (MW)

1st 1 Tecchnopromexport 660 Delayed as

Techniproexport is

saying it has entered a

loss-making contract

and is asking for $570

million before it can

fulfil its obligation to

which NTPC

objected.
2 Technopromexport 660 Delayed
3 Technopromexport 660 Delayed

Page 6
2nd 4 Bharat Heavy 2013 November Commissioned in

Electricals 660 2013 November but

commercial

production yet to start

as there are technical

issue of multiple tube

leakage which is yet

to be resolved as of

April 2014. This is the

first 660 MW unit

supplied by BHEL.

Commercial operation

starts in Nov 2014

after resolving faults.

5 Bharat Heavy 2015 March 660 Running

Electricals
Total 5 3300

Page 7
 CHAPTER 2

PRODUCT/PROCESS DETAILS

2.1 Operation of a power plant

Basic Principle:-

As per FARADAY’S Law-“Whenever the amount of magnetic flux linked with a circuit

changes, an EMF is produced in the circuit. Generator works on the principle of producing

electricity. To change the flux in the generator turbine is moved in a great speed with steam.”

To produce steam, water is heated in the boilers by burning the coal. In Barh Thermal

PowerStation, steam is produced and used to spin a turbine that operates a generator. 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; this is known as a Rankin

cycle.

The electricity generated at the plant is sent to consumers through high-voltage power lines The

Barh Thermal Power Plant has Steam Turbine-Driven Generators which has a collective

capacity of 660MW. The fuel being used is Coal which is supplied from the Jharia Coal Field in

Jharkhand. Water supply is given from the Ganga.

2.2 Basic steps of electricity generation

The basic steps in the generation of electricity from coal involves following steps:

1. Coal to steam

2. Steam to mechanical power

3. Mechanical power to electrical power

Page 8
"

Figure 2.1: Block Diagram Of NTPC Power Plant

Page 9
The various parts of the coal thermal power plants are

"

Figure 2.2 thevarious parts of the coal thermal power plants

1. Cooling Tower: Cooling towers are heat removal devices used to transfer process waste heat

to the atmosphere. 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. Common applications include cooling the circulating water used in oil refineries,

chemical plants, power stations and building cooling. The towers vary in size from small roof-

Page 10
top units to very large hyperboloid structures that can be up to 200 meters tall and 100 meters

in diameter, or rectangular structures that can be over 40 meters tall and 80 meters long.

Smaller towers are normally factory-built, while larger ones are constructed on site. The

absorbed heat is rejected to the atmosphere by the evaporation of some of the cooling water in

mechanical forced-draft or inducedDraft towers or in natural draft hyperbolic shaped cooling

towers as seen at most nuclear power plants.

2. Cooling Water Pump:it pumps the water from the cooling tower which goes to the

condenser.

3. Three phase transmission line:Three phase electric power is a common method of electric

power transmission. It is a type of poly phase system mainly used to power motors and many

other devices. A three phase system uses less conductive material to transmit electric power

than equivalent single phase, two phase, or direct current system at the same voltage. In a three

phase system, three circuits reach their instantaneous peak values at different times. Taking

current in one conductor as the reference, the currents in the other two are delayed in time by

one-third and two-third of one cycle.This delay between “phases” has the effect of giving

constant power transfer over each cycle of the current and also makes it possible to produce a

rotating magnetic field in an electric motor. At the power station, an electric generator converts

mechanical power into a set of electric currents, one from eachelectromagnetic coil or winding

of the generator. The current are sinusoidal functions of time, all at the same frequency but

offset in time to give different phases. In a three phase system the phases are spaced equally,

giving a phase separation of one-third of one cycle. Generators output at a voltage that ranges

from hundreds of volts to 30,000 volts.

4. Unit transformer (3-phase):At the power station transformers step-up this voltage to one

more suitable for transmission. After numerous further conversions in the transmission and

Page 11
distribution network the power is finally transformed to the standard mains voltage (i.e. the

“household” voltage). The power may already have been split into single phase at this point or

it may still be three phase. Where the step-down is 3 phase, the output of this transformer is

usually star connected with the standard mains voltage being the phase-neutral voltage. Another

system commonly seen in North America is to have a delta connected secondary with a centre

tap on one of the windings supplying the ground and neutral. This allows for 240 V three phase

as well as three different single phase voltages( 120 V between two of the phases and neutral ,

208 V between the third phase ( or wild leg) and neutral and 240 V between any two phase) to

be available from the same supply.

5. Electrical generator:An Electrical generator is a device that converts kinetic energy to

electrical energy, generally using electromagnetic induction. The task of converting the

electrical energy into mechanical energy is accomplished by using a motor. The source of

mechanical energy may be water falling through the turbine or steam turning a turbine (as is the

case with thermal power plants). There are several classifications for modern steam turbines.

Steam turbines are used in our entire major coal fired power stations to drive the generators or

alternators, which produce electricity. The turbines themselves are driven by steam generated in

"boilers “or "steam generators" as they are sometimes called. Electrical power stations use large

steam turbines driving electric generators to produce most (about 86%) of the world’s

electricity. These centralized stations are of two types: fossil fuel power plants and nuclear

power plants. The turbines used for electric power generation are most often directly coupled to

their-generators.As the generators must rotate at constant synchronous speeds according to the

frequency of the electric power system, the most common speeds are 3000 r/min for 50 Hz

systems, and 3600 r/min for 60 Hz systems. Most large nuclear sets rotate at half those speeds,

and have a 4-polegenerator rather than the more common 2-pole one.

Page 12
6. Low Pressure Turbine: Energy in the steam after it leaves the boiler is converted into

rotational energy as it passes through the turbine. The turbine normally consists of several

stages with each stages consisting of a stationary blade (or nozzle) and a rotating blade.

Stationary blades convert the potential energy of the steam into kinetic energy and direct the

flow onto therotating blades. The rotating blades convert the kinetic energy into impulse and

reaction forces, caused by pressure drop, which results in the rotation of the turbine shaft. The

turbine shaft is connected to a generator, which produces the electrical energy. Low Pressure

Turbine (LPT) consists of 4x2 stages. After passing through Intermediate Pressure Turbine

steam is passed through LPT which is made up of two parts- LPC REAR & LPC FRONT. As

water gets cooler here it gathers into a HOTWELL placed in lower parts of turbine.

7. Condensation Extraction Pump:A Boiler feed water pump is a specific type of pump used

to pump water into a steam boiler. The water may be freshly supplied or returning condensation

of the steam produced by the boiler. These pumps are normally high pressure units that use

suction from a condensate return system and can be of the centrifugal pump type or

positivedisplacement type.

8. Condenser:The steam coming out from the Low Pressure Turbine (a little above its boiling

pump) is brought into thermal contact with cold water (pumped in from the cooling tower) in

the condenser, where it condenses rapidly back into water, creating near Vacuum-like

conditions inside the condenser chest.

9. Intermediate Pressure Turbine:Intermediate Pressure Turbine (IPT) consists of 11 stages.

When the steam has been passed through HPT it enters into IPT. IPT has two ends named as

FRONT & REAR. Steam enters through front end and leaves from Rear end.

10. Steam Governor Valve:Steam locomotives and the steam engines used on ships and

stationary applications such as power plants also required feed water pumps. In this situation,

Page 13
though, the pump was often powered using a small steam engine that ran using the steam

produced by the boiler a means had to be provided, of course, to put the initial charge of water

into the boiler (before steam power was available to operate the steam-powered feed water

pump).The pump was often a positive displacement pump that had steam valves and cylinders

at one end and feed water cylinders at the other end; no crankshaft was required. In thermal

plants, the primary purpose of surface condenser is to condense the exhaust steam from a steam

turbine to obtain maximum efficiency and also to convert the turbine exhaust steam into pure

water so that it may be reused in the steam generator or boiler as boiler feed water. By

condensing the exhaust steam of a turbine at a pressure below atmospheric pressure, the steam

pressure drop between the inlet and exhaust of the turbine is increased, which increases the

amount heat available for conversion to mechanical power. Most of the heat liberated due to

condensation of the exhaust steam is carried away by the cooling medium (water or air) used by

the surface condenser. Control valves are valves used within industrial plants and elsewhere to

control operating conditions such as temperature, pressure, flow and liquid level by fully or

partially opening or closing in response to signals received from controllers that compares a

“set point” to a“process variable” whose value is provided by sensors that monitor changes in

such conditions. The opening or closing of control valves is done by means of electrical,

hydraulic or pneumatic systems.

11. High Pressure Turbine:Steam coming from Boiler directly feeds into HPT at a

temperature of 540°C and at a pressure of 136 kg/cm². Here it passes through 12 different

stages due to which its temperature goes down to 329°C and pressure as 27 kg/cm².This line is

also called as CRH – COLD REHEAT LINE. It is now passed to a REHEATER where its

temperature rises to 540°C and called as HRH-HOT REHEATED LINE.

Page 14
12. Deaerator:A Deaerator is a device for air removal and used to remove dissolved gases (an

alternate would be the use of water treatment chemicals) from boiler feed water to make it

noncorrosive. A deaerator typically includes a vertical domed deaeration section as the

deaeration boiler feed water tank. A Steam generating boiler requires that the circulating steam,

condensate, and feed water should be devoid of dissolved gases, particularly corrosive ones and

dissolved or suspended solids. The gases will give rise to corrosion of the metal. The solids will

deposit on the heating surfaces giving rise to localized heating and tube ruptures due to

overheating. Under some conditions it may give rise to stress corrosion cracking. Deaerator

level and pressure must be controlled by adjusting control valves the level by regulating

condensate flow and the pressure by regulating steam flow. If operated properly, most deaerator

vendors will guarantee that oxygen in the deaerated water will not exceed 7 ppb by weight

(0.005 cm3/L)

13. Feed water heater:A Feed water heater is a power plant component used to pre-heat water

delivered to a steam generating boiler. Preheating the feed water reduces the irreversibility

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

boilermetal when the feed water is introduced back into the steam cycle. In a steam power

(usually modeled as a modified Rankin cycle), feed water heaters allow the feed water to be

brought up to the saturation temperature very gradually. This minimizes the inevitable

irreversibility associated with heat transfer to the working fluid (water).

14. Coal conveyor:Coal conveyors are belts which are used to transfer coal from its storage

place to Coal Hopper. A belt conveyor consists of two pulleys, with a continuous loop of

material- the conveyor Belt – that rotates about them. The pulleys are powered, moving the belt

Page 15
and the material on the belt forward. Conveyor belts are extensively used to transport industrial

and agricultural material, such as grain, coal, ores etc.

15. Coal Hopper:Coal Hoppers are the places which are used to feed coal to Fuel Mill. It also

has the arrangement of entering Hot Air at 200°C inside it which solves our two purposes:- 1. If

our Coal has moisture content then it dries it so that a proper combustion takes place. 2. It

raises the temperature of coal so that its temperature is more near to its Ignite Temperature so

that combustion is easy.

16. Pulverized Fuel Mill:A pulveriser is a device for grinding coal for combustion in a furnace

in a fossil fuel power plant.

17. Boiler drums:Steam Drums are a regular feature of water tube boilers. It is reservoir of

water/steam at the top end of the water tubes in the water-tube boiler. They store the steam

generated in the water tubes and act 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 steam drum. Made from high-grade steel (probablystainless)

and its working involve temperature of 390°C and pressure well above 350psi (2.4MPa). The

separated steam is drawn out from the top section of the drum. Saturated steam is drawn off the

top of the drum. The steam will re-enter the furnace in through a super heater, while the

saturated water at the bottom of steam drum flows down to the mud-drum /feed water drum by

down comer tubes accessories include a safety valve, water level indicator and fuse plug.

18. Ash Hopper:A steam drum is used in the company of a mud-drum/feed water drum which

is located at a lower level. So that it acts as a sump for the sludge or sediments which have a

tendency to accumulate at the bottom.

19. Super Heater:A Super heater is a device in a steam engine that heats the steam generated

by the boiler again increasing its thermal energy. Super heaters increase the efficiency of the

Page 16
steam engine, and were widely adopted. Steam which has been superheated is logically known

as superheated steam; non- superheated steam is called saturated steam or wet steam. Super

heaters were applied to steam locomotives in quantity from the early 20th century, to most

steam vehicles, and also stationary steam engines including power stations.

20. Force Draught Fan:External fans are provided to give sufficient air for combustion. The

forced draught fan takes air from the atmosphere and, warms it in the air preheated for better

combustion, injects it via the air nozzles on the furnace wall.

21. Reheater:Reheater is a heater which is used to raise the temperature of steam which has

fallen from the intermediate pressure turbine

22. Air Intake:Air is taken from the environment by an air intake tower which is fed to the

fuel.

23. Economizers:Economizer, or in the UK economizer, are mechanical devices intended to

reduce energy consumption, or to perform another useful function like preheating a fluid. The

term economizer is used for other purposes as well-Boiler, power plant, heating, ventilating and

air-conditioning. In boilers, economizer are heat exchange devices that heat fluids , usually

water, up to but not normally beyond the boiling point of the fluid. Economizers are so named

because they can make use of the enthalpy and improving the boilers efficiency. They are

devices fitted to a boiler which save energy by using the exhaust gases from the boiler to

preheat the cold water used to fill it (the feed water). Modern day boilers, such as those in cold

fired power stations, are still fitted with economizer which is decedents of Green’s original

design. In this context there are turbines before it is pumped to the boilers. A common

application of economizer in steam power plants is to capture the waste heat from boiler stack

gases (flue gas) and transfer thus it to the boiler feed water thus lowering the needed energy

input , in turn reducing the firing rates to accomplish the rated boiler output . Economizer lower

Page 17
stack temperatures which may cause condensation of acidic combustion gases and serious

equipment corrosion damage if care is not taken in their design and material selection.

24. Air Preheater :Air preheated is a general term to describe any device designed to heat air

before another process (for example, combustion in a boiler). The purpose of the air preheater

is to recover the heat from the boiler flue gas which increases the thermal efficiency of the

boiler by reducing the useful heat lost in the flue gas. As a consequence, the flue gases are also

sent to the flue gas stack (or chimney) at a lower temperature allowing simplified design of the

ducting and the flue gas stack. It also allows control over the temperature of gases leaving the

stack.

25. Precipitator:An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate

device that removes particles from a flowing gas (such as air) using the force of an induced

electrostatic charge. Electrostatic precipitators are highly efficient filtration devices, and can

easily remove fine particulate matter such as dust and smoke from the air steam. ESPs continue

to be excellent devices for control of many industrial particulate emissions, including smoke

from electricity-generating utilities (coal and oil fired), salt cake collection from black liquor

boilers in pump mills, and catalyst collection from fluidized bed catalytic crackers from several

hundred thousand ACFM in the largest coal-fired boiler applications. The original parallel

plate-Weighted wire design (described above) has evolved as more efficient (and robust)

discharge electrode designs, today focus is on rigid discharge electrodes to which many

sharpened spikes are attached , maximizing corona production. Transformer –rectifier systems

apply voltages of 50-100 Kilovolts at relatively high current densities. Modern controls

minimize sparking and prevent arcing, avoiding damage to the components. Automatic rapping

systems and hopper evacuation systems remove the collected particulate matter while on line

allowing ESPs to stay in operation for years at a time.

Page 18
26. Induced Draught Fan:The induced draft fan assists the FD fan by drawing out

combustible gases from the furnace, maintaining a slightly negative pressure in the furnace to

avoid backfiring through any opening. At the furnace outlet and before the furnace gases are

handled by the ID fan, fine dust carried by the outlet gases is removed to avoid atmospheric

pollution. This is an environmental limitation prescribed by law, which additionally minimizes

erosion of the ID fan.

27. Flue gas stacks: A Flue gas stack is a type of chimney, a vertical pipe, channel or similar

structure through which combustion product gases called flue gases are exhausted to the

outside air. Flue gases are produced when coal, oil, natural gas, wood or any other large

combustiondevice. Flue gas is usually composed of carbon dioxide (CO2) and water vapour as

well as nitrogen and excess oxygen remaining from the intake combustion air. It also contains a

small percentage of pollutants such as particulates matter, carbon mono oxide, nitrogen oxides

and sulphur oxides. The flue gas stacks are often quite tall, up to 400 meters (1300 feet) or

more, so as to disperse the exhaust pollutants over a greater area and thereby reduce the

concentration of the pollutants to the levels required by government's environmental policies

and regulations. The flue gases are exhausted from stoves, ovens, fireplaces or other small

sources within residential abodes, restaurants, hotels through other stacks which are referred to

as chimneys.

2.3 RANKINECYCLE:-

The Rankine cycle is a thermodynamics cycle which converts heat into work. The heat is

supplied externally to a closed loop, which usually uses water as the working fluid. This cycle

generates about 80% of all electricity power used throughout the world, including virtually all

solar thermal, biomass, coal and nuclear power plants. It is named after William John

MacqueenRankine, a Scottish polymath.

Page 19
 DESCRIPTION:A Rankine cycle describes a model of the operation of a steam heat

"

Figure 2.3Operation of Rankine cycle

that a pump is used to pressurize liquid instead of gas. This requires about 1/100th (1%)as

much energy Engines most commonly found in power generation plants. Common heat sources

for power plants using the Rankine cycle are coal, natural gas ,oil, and nuclear.

The Rankine cycle is sometimes referred to as a practical Carnot cycle as, when an efficient

turbine is used, the T-S diagram will begin to resemble the Carnot cycle. The main difference is

as that compressing a gas in a compressor (as in the Carnot cycle).

The efficiency of a Rankine cycle is usually limited by the working fluid. Without the pressure

going super critical the temperature range the cycle can operate over is quite small, turbine

entry temperature are around 30°C. This gives a theoretical Carnot efficiency of around63%

compared with an actual efficiency of 42% for a modern coal-fired power station. This low

turbine entry temperature (compared with a gas turbine) is why the Rankine cycle is often used

as a bottoming cycle in combined cycle gas turbine power stations. The working fluid in a

Rankine cycle follows a closed loop and is re-used constantly. The water vapour and entrained

droplets often seen billowing from power stations is generated by the cooling systems (not

from the closed loop Rankine power cycle) and represents the waste heat that could not be

Page 20
converted to useful work. Note that cooling towers operate using the latent heat of vaporization

of the cooling fluid. The white billowing clouds that form in cooling tower operation are the

result of water droplets which are entrained in the cooling tower air flow; it is not, as

commonly thought, steam. While many substances could be used in the Rankine cycle, water is

usually the fluid of choice due to its favourable properties, such as nontoxic and uncreative

chemistry, abundance, and low cost, as well as its thermodynamic properties. One of the

principal advantages it holds over other cycles is that during the compression stage relatively

little work is required to drive the pump, due to the working fluid being in its liquid phase at

this point. By condensing the fluid to liquid, the work required by the pump will only consume

approximately 1% to 3% of the turbine power and so give a much higher efficiency for a real

cycle.

The benefit of this is lost somewhat due to the lower heat addition temperature. Gas turbines,

for instance, have turbine entry temperatures approaching 1500°C.Nonetheless, the efficiencies

of steam cycles and gas turbines are fairly well matched.

"

Figure 2.4T-S diagram of a typical Rankine cycle

T-S diagram of a typical Rankine cycle operating between pressures of 0.06bar and

50bar .There are four processes in the Rankine cycle, each changing the state of the working

fluid. These states are identified by number in the diagram to the right.

Page 21
1. 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.

2. 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.

3. 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.

4. Process 4-1: The wet vapour then enters a condenser where it is condensed at a constant

pressure and temperature to become saturated liquid. The pressure and temperature of the

condenser is fixed by the temperature of the cooling coils as the fluid is undergoing a phase

change.

In an ideal Rankine cycle the pump and turbine would be isentropic, i.e. the pump and turbine

would generate no entropy and hence maximize the net work output. Process 1-2 and 3-4 would

be represented by vertical lines on the T-S diagram and more closely resemble that of the

Carnot cycle.

The Rankine cycle shown here prevents the vapour ending up in the super heated region after

the expansion in the turbine, which reduces the energy removed by the condensers.


Page 22
 CHAPTER 3

DETAILS OF TRAINING

3.1 Department/Section Detail

3.1.1Boiler Maintenance Department (BMD)

Boiler and Its Description:

The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls

are made of a web of high pressure steel tubes about 2.3inches (60 mm) in diameter. Pulverized

coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns,

foaming a large fireball at the centre. The thermal radiation of the fireball heats the water that

circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the

boiler is three to four times the throughput and is typically driven by pumps. As the water in the

boiler circulates it absorbs heat and changes into steam at700 °F (370 °C) and 3200psi

(22.1MPa). It is separated from the water inside a drum at the top of furnace.

The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of

the combustion gases as they exit the furnace. Here the steam is superheated to 1,000 °F

(540°C)to prepare it for the turbine. The steam generating boiler has to produce steam at the

high purity, pressure and temperature required for the steam turbine that drives the electrical

generator. The generator includes the economizer, the steam drum, the chemical dosing

equipment, and the furnace with its steam generating tubes and the superheated coils.

Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air

and flue gas path equipment include: forced draft (FD) fan, air preheated (APH), boiler furnace,

induced draft (ID) fan, fly ash collectors (electrostatic precipitator or bag house) and the flue

gas stack. For units over about 210MW capacity, redundancy of key components is provided by

Page 23
installing duplicates of the FD fan, APH, fly ash collectors and ID fan with isolating dampers.

On some units of about 60MW, two boilers per unit may instead be provided.

AUXILARYIES OF BOILER:

I. FURNACE

Furnace is primary part of boiler where the chemical energy of the fuel is converted to thermal

energy by combustion. Furnace is designed for efficient and complete combustion. Major

factors that assist for efficient combustion are amount of fuel inside the furnace and turbulence,

which causes rapid mixing between fuel and air. In modern boilers, water furnaces are used.

II. BOILER DRUM

"

Figure 2.5 Boiler Drum

Page 24
Drum is of fusion-welded design with welded hemispherical dished ends. It is provided with

stubs for welding all the connecting tubes, i.e. down comer, risers, pipes, saturated steam outlet.

The function of steam drum internals is to separate the water from the steam generated in the

furnace walls and to reduce the dissolved solid contents of the steam below the prescribed limit

of 1ppm and also take care of the sudden change of steam demand for boiler.

• The secondary stage of two opposite banks of closely spaced thin corrugated sheets, which

direct the steam and force the remaining entertained water against the corrugated plates.

Since the velocity is relatively low this water does not get picked up again but runs down the

plates and off the second stage of the two steam outlets.

• From the secondary separators the steam flows upwards to the series of screen dryers,

extending in layers across the length of the drum. These screens perform the final stage of the

separation.

• Once water inside the boiler or steam generator, the process of adding the latent heat of

vaporization or enthalpy is underway. The boiler transfers energy to the water by the

chemical reaction of burning some type of fuel.

• The water enters the boiler through a section in the convection pass called the economizer.

From the economizer it passes to the steam drum. Once the water enters the steam drum it

goes down the down comers to the lower inlet water wall headers. From the inlet headers the

water rises through the water walls and is eventually turned into steam due to the heat being

generated by the burners located on the front and rear water walls (typically). As the water is

turned into steam/vapour in the water walls, the steam/vapour once again enters the steam

drum.

• The steam/vapour is passed through a series of steam and water separators and then dryers

inside the steam drum. The steam separators and dryers remove the water droplets from the

Page 25
 steam and the cycle through the water walls is repeated. This process is known as natural

circulation.

• The boiler furnace auxiliary equipment includes coal feed nozzles and igniter’s guns, so out

blowers, water lancing and observation ports (in the furnace walls) for observation of the

furnace interior. Furnace explosions due to any accumulation of combustible gases after a trip

out are avoided by flushing out such gases from the combustion zone before igniting the coal.

• The steam drum (as well as the super heater coils and headers) have air vents and drains

needed for initial start-up. The steam drum has an internal device that removes moisture from

the wet steam entering the drum from the steam generating tubes. The dry steam then flows

into the super heater coils. Geothermal plants need no boilers incest they use naturally

occurring steam sources.

• Heat exchangers may be used where the geothermal steam is very corrosive or contains

excessive suspended solids. Nuclear plants also boil water to raise steam, either directly

passing the working steam through the reactor or else using an intermediate heat exchanger.

III. WATER WALLS:

Water flows to the water walls from the boiler drum by natural circulation. The front and the

two side water walls constitute the main evaporation surface, absorbing the bulk of radiant heat

of the fuel burnt in the chamber. The front and rear walls are bent at the lower ends to form a

water-cooled slag hopper. The upper part of the chamber is narrowed to achieve perfect mixing

of combustion gases. The water wall tubes are connected to headers at the top and bottom. The

rear water wall tubes at the top are grounded in four rows at wider pitch forming the grid tubes.

IV.REHEATER:

Reheater is used to raise the temperature of steam from which a part of energy has been

extracted in high-pressure turbine. This is another method of increasing the cycle

Page 26
efficiency.Reheating requires additional equipment i.e. heating surface connecting boiler and

turbine pipe safety equipment like safety valve, non return valves, isolating valves, high

pressure feed pump, etc; Reheater is composed of two sections namely the front and the rear

pendant section, which is located above the furnace arc between water-cooled, screen

wall tubes and rear wall tubes.

"

Figure 3.1 Reheater

V. SUPERHEATER:

Whatever type of boiler is used, steam will leave the water at its surface and passing to the

steam space. Steam formed above the water surface in a shell boiler is always saturated and

become superheated in the boiler shell, as it is constantly. If superheated steam is required,the

saturated steam must pass through a super heater. This is simply a heat exchanger where

additional heat is added to the steam.

In water-tube boilers, the super heater may be an additional pendant suspended in the furnace

area where the hot gases will provide the degree of superheat required. In other cases, for

example in CHP schemes where the gas turbine exhaust gases are relatively cool, a separately

fired super heater may be needed to provide the additional heat.

Page 27
VI. ECONOMIZER:

The function of an economizer in a steam-generating unit is to absorb heat from the flue gases

and add as a sensible heat to the feed water before the water enters the evaporation circuit

of the boiler.

Earlier economizer were introduced mainly to recover the heatavailableinthe flue gases that

leaves the boiler and provision of this addition heating surface increases the efficiency of steam

"

Figure 3.2 Economizer

generators. In the modern boilers used for power generation feed water heaters were used to

increase the efficiency of turbine unit and feed water temperature.

Use of economizer or air heater or both is decided by the total economy that will result in

flexibility in operation, maintenance and selection of firing system and other related equipment.

Modern medium and high capacity boilers are used both as economizers and air heaters. In low

capacity, air heaters may alone be selected.

Page 28
Stop valves and non-return valves may be incorporated to keep circulation in economizer into

steam drum when there is fire in the furnace but not feed flow. Tube elements composing the

unit are built up into banks and these are connected to inlet and outlet heaters.

VII.AIR PREHEATER:

Air preheater absorbs waste heat from the flue gases and transfers this heat to incoming cold

air, by means of continuously rotating heat transfer element of specially formed metal plates.

Thousands of these high efficiency elements are spaced and compactlyarranged within 12

sections. Sloped compartments of radially divided cylindrical shell called the rotor. The

housing surrounding the rotor is provided with duct connecting both the ends and is adequately

scaled by radial and circumferential scaling.

Special sealing arrangements are provided in the air preheater to prevent the leakage between

the air and gas sides. Adjustable plates are also used to help the sealing arrangements and

prevent the leakage as expansion occurs. The air preheater heating surface elements are

provided with two types of cleaning devices, soot blowers to normal devices and washing

devices to clean the element when soot blowing alone cannot keep the element clean.

"

Figure 3.3 Air preheater

Page 29
VIII.PULVERIZER:A pulverizer is a mechanical device for the grinding of many types of

materials. For example, they are used to pulverize coal for combustion in the steam-generating

furnaces of the fossil fuel power plants.

"

Figure 3.4Pulverizer

3.1.2 PLANT AUXILIARY MAINTENANCE

I. WATER CIRCULATION SYSTEM

Theory of Circulation:

Water must flow through the heat absorption surface of the boiler in order that it is evaporated

into steam. In drum type units (natural and controlled circulation), the water is circulated from

the drum through the generating circuits and then back to the drum where the steam is

separated and directed to the super heater. The water leaves the drum through the down corners

at a temperature slightly below the saturation temperature. The flow through the furnace wall is

at saturation temperature. Heat absorbed in water wall is latent heat of vaporization creating a

mixture of steam and water. The weight of the water to the weight of the steam in the mixture

leaving the heat absorption surface is called circulation ratio.

Types of Boiler Circulating System:

Page 30
Natural circulation system

Controlled circulation system

Combined circulation system

I. Natural Circulation System:

Water delivered to steam generator from feed water is at a temperature well below the

saturation value corresponding to that pressure. Entering first the economizer, it is heated to

about 30-40C below saturation temperature. From economizer the water enters the drum and

thus joins the circulation system. Water entering the drum flows through the down corner and

enters ring heater at the bottom. In the water walls, a part of the water is converted to steam and

the mixture flows back to the drum. In the drum, the steam is separated, and sent to superheat

for superheating and then sent to the high-pressure turbine. Remaining water mixes with the

incoming water from the economizer and the cycle is repeated.

As the pressure increases, the difference in density between water and steam reduces. Thus the

hydrostatic head available will not be able to overcome the frictional resistance for a flow

corresponding to the minimum requirement of cooling of water wall tubes. Therefore natural

circulation is limited to the boiler with drum operating pressure around 175 kg/cm².

II. Controlled Circulation System:

Beyond 80 kg/cm² of pressure, circulation is to be assisted with mechanical pumps to overcome

the frictional losses. To regulate the flow through various tubes, or if ice plates are used. This

system is applicable in the high sub-critical regions (200 kg/cm²).

II. ASH HANDLING PLANT

The widely used ash handling systems are:

i. Mechanical Handling System

ii. Hydraulic System

Page 31
iii. Pneumatic System

iv. Steam Jet System

"

Figure 3.5Ash handling system

Hydraulic Ash handling system is used at the Barh super Thermal Power

Station.

The hydraulic system carried the ash with the flow of water with high velocity through a

channel and finally dumps into a sump. The hydraulic system is divided into a low velocity and

high velocity system. In the low velocity system the ash from the boilers falls into a stream of

water flowing into the sump. The ash is carried along with the water and they areseparated at

the sump. In the high velocity system a jet of water is sprayed to quench the hotash. Two other

jets force the ash into a trough in which they are washed away by the water into the sump,

where they are separated. The molten slag formed in the pulverized fuel system can also be

quenched and washed by using the high velocity system. The advantage of this system are that

its clean, large ash handling capacity, considerable distance can be traversed, absence of

working parts in contact with ash.

Page 32
Fly Ash Collection:

Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag

filters (or sometimes both) located at the outlet of the furnace and before the induced draftfan.

The fly ash is periodically removed from the collection hoppers below the precipitators or bag

filters. Generally, the fly ash is pneumatically transported to storage silos for subsequent

transport by trucks or railroad cars.

Bottom Ash Collection and Disposal:

At the bottom of every boiler, a hopper has been provided for collection of the bottom ashfrom

the bottom of the furnace. This hopper is always filled with water to quench the ash andclinkers

falling down from the furnace. Some arrangement is included to crush the clinkers and for

conveying the crushed clinkers and bottom ash to a storage site.

III. WATER TEATEMENT PLANT:

As the types of boiler are not alike their working pressure and operating conditions vary andso

do the types and methods of water treatment. Water treatment plants used in thermal power

plants used in thermal power plants are designed to process the raw water to water with a very

low content of dissolved solids known as µdematerialized water. No doubt, this plant has to be

engineered very carefully keeping in view the type of raw water to the thermal plant, its

treatment costs and overall economics.

"

Figure 3.6Water treatment plant

Page 33
The type of demineralization process chosen for a power station depends on three main factors:

I. The quality of the raw water.

II. The degree of de-ionization i.e. treated water quality.

III. Selectivity of resins.

Water treatment process is generally made up of two sections:

• Pretreatment section

• Demineralization section

PRETREATEMENT SECTION:

Pretreatment plant removes the suspended solids such as clay, silt, organic and inorganic

matter, plants and other microscopic organism. The turbidity may be taken as two types

of suspended solid in water; firstly, the separable solids and secondly the non-separable solids

(colloids). The coarse components, such as sand, silt, etc; can be removed from the water by

simple sedimentation. Finer particles, however, will not settle in any reasonable time and must

be flocculated to produce the large particles, which are settle able. Long term abilityto remain

suspended in water is basically a function of both size and specific gravity.

DEMINERALIZATION:

This filter water is now used for dematerializing purpose and is fed to cation exchanger

bed, but enroots being first dechlorinated, which is either done by passing through activated

carbon filter or injecting along the flow of water, an equivalent amount of sodium sulphite

through some stroke pumps. The residual chlorine, which is maintained in clarification plant to

remove organic matter from raw water, is now detrimental to action resin and must be

eliminated before its entry to this bed.

Page 34
 "

Figure 3.7 Demineralization

3.1.3 TURBINE MAINTENANCE DEPARTMENT:

TURBINE CLASSIFICATION:

1.Impulse Turbine:

In impulse turbine steam expands in fixed nozzles. The high velocity steam from nozzles does

work on moving blades, which causes the shaft to rotate. The essential features of impulse

turbine are that allpressure drops occur at nozzles and not on blades.

2. Reactionturbine:

In this type of turbine pressure is reduced at both fixed and moving blades. Both fixed and

moving blades act like nozzles.Work done by the impulse effect of steam due to reverse the

direction of high velocity steam. The expansion of steam takes place on moving blades.

Page 35
"

Figure 3.8 A95 MW GENERATOR AT NTPC, BARH

MAIN TURBINE:

The 210MW turbine is a cylinder tandem compounded type machine comprising of H.P, I.P and

L.P cylinders. The H.P. turbine comprises of 12 stages the I.P turbine has 11 stages and the L.P

has four stages of double flow. The H.P and I.P. turbine rotor are rigidly compounded and the

I.P. and L.P rotor by lens type semi flexible coupling. All the 3 rotorsare aligned on five

bearings of which the bearing number is combined with thrust bearing.The main superheated

steam branches off into two streams from the boiler and passes through the emergency stop

valve and control valve before entering the governing wheel chamber of the H.P. Turbine.After

expanding in the 12 stages in the H.P. turbine then steam is returned in the boiler for

reheating.The reheated steam from boiler enters I.P. turbine via the interceptor valves and

control valves and after expanding enters theL.P stage via 2 numbers of cross over pipes. In the

L.P. stage the steam expands in axially opposed direction to counteract the thrust and enters the
Page 36
condenser placed directly below the L.P. turbine. The cooling water flowing through the

condenser tubes condenses the steam and the condensate the collected in the hot well of the

condenser. The condensate collected the pumped by means of 3x50% duty condensate pumps

through L.P heaters to deaerator from where the boiler feed pump delivers the water to the

boiler through H.P. heaters thus forming a closed cycle.

STEAM TURBINE:

A steam turbine is a mechanical device that extracts thermal energy from pressurized steamand

converts it into useful mechanical work.From a mechanical point of view, the turbine is ideal,

because the propelling force is applied directly to the rotating element of the machine and has

not as in the reciprocating engine to be transmitted through a system of connecting links, which

are necessary to transform a reciprocating motion into rotary motion. Hence since the steam

turbine possesses for its moving parts rotating elements only if the manufacture is good and the

machine is correctly designed, it ought to be free from out of balance forces.If the load on a

turbine is kept constant the torque developed at the coupling is also constant. A generator at a

steady load offers a constant torque. Therefore, a turbine is suitable for driving a generator,

particularly as they are both high-speed machines.A further advantage of the turbine is the

absence of internal lubrication. This means that the exhaust steam is not contaminated with oil

vapour and can be condensed and fed back to the boilers without passing through the filters. It

also means that turbine is considerable saving in lubricating oil when compared with

reciprocating steam engine of equal power. A final advantage of the steam turbine and a very

important one is the fact that a turbine can develop many time the power compared to a

reciprocating engine whether steam or oil.

Page 37
STEAM CYCLE:

The thermal(steam) power plant uses a dual(vapor + liquid) phase steam, regenerative feed

water heating and re heating of steam cycle. It is a closed cycle to enable the working fluid

(water) to be used again and again. The cycle used is ‘Rankine cycle’ modified to include

superheating of

"

Figure 3.9 Steam cycle diagram

MAIN TURBINE:

The 210MW turbine is a tandem compounded type machine comprising of H.P and I.P

cylinders. The H.P turbines comprise of 12 stages, I.P turbine has 11 stages and the L.P turbine

has 4 stages of double flow.

The H.P and I.P turbine rotors are rigidly compounded and the L.P. motor by the lens type semi

flexible coupling. All the three rotors are aligned on five bearings of which the bearing no. 2 is

combined with the thrust bearing.

The main superheated steam branches off into two streams from the boiler and passes through

the emergency stop valve and control valve before entering the governing wheel chamber of

Page 38
the H.Pturbine. After expanding in the 12 stages in the H.P turbine the steam is returned

in boiler for reheating.

The reheated steam for the boiler enters the I.P turbine via the interceptor valves and control

valves and after expanding enters the L.P turbine stage via 2 nos of cross-over pipes. In the L.P.

stage the steam expands in axially opposite directionto counter act the trust and enters the

condensers placed below the L.P turbine. The cooling water flowing throughout the

condenser tubes condenses the steam and the condensate collected in the hot well of the

condenser.The condensate collected is pumped by means of 3*50% duty condensate pumps

through L.P heaters to deaerator from where the boiler feed pump delivers the water to boiler

through H.P heaters thus forming a close cycle.

"

Page 39
"

Figure 3.10 Turbine & Turbine Cycle

The selection of extraction points and cold reheat pressure has been done with a view to

achieve a high efficiency. These are two extractors from H.P turbine, four from I.P turbine and

one from L.P turbine. Steam at1.10 and 1.03 g/sq.cm .As is supplied for the gland scaling.

Steam for this purpose is obtained from deaerator through a collection where pressure of steam

is regulated. From the condenser, condensate is pumped with the help of 3*50% capacity

condensate pumps to deaerator through the low-pressure regenerative equipments.Feed water is

pumped from deaerator to the boiler through the H.P. heaters by means of 3*50% capacity feed

pumps connected before the H.P. heaters.

TURBINE COMPONENTS:

Casing.

Rotor

Blades
Page 40
 Sealing System

Stop & control valves

Coupling & Bearing

Barring Gear

TURBINE CASINGS:

HP Turbine Casing:

• Outer casing: a barrel-type without axial or radial flange.

• Barrel-type casing suitable for quick startup and loading.

• The inner casing- cylindrically, axially split.

• The inner casing is attached in the horizontal and vertical planes in the barrel casingso that it

can freely expand radially in all the directions and axially from a fixed point(HP- inlet side)

I.P Turbine Casing:

The casing of the IP turbine is split horizontally and is of double-shell construction.

Both are axially split and a double flow inner casing is supported in the outer casingand carries

the guide blades.

ROTORS:

HP Rotor:

• The HP rotor is machined from single Cr-Mo-V steel forging with integral discs.

• In all the moving wheels, balancing holes are machined to reduce the pressuredifference

across them, which results in reduction of axial thrust.

• First stage has integral shrouds while other rows have surroundings, riveted to the blades are

periphery.

Page 41
I.P Rotor:

The IP rotor has seven discs integrally forged with rotor while last four discs areshunk fit.

BLADES:

• Most costly element of the turbine.

• Blades fixed in stationary part are called guide blades/ nozzles and those fitted inmoving part

are called rotating/working blades.

• Blades have three main part:

• Aerofoil: working part.

• Root.

• Shrouds.

• Shroud is used to prevent steam leakage and guide steam to next set of moving blades.

VACUUM SYSTEM:

This comprises of:

Condenser: 2 for 200MW unit at the exhaust of L.P turbine.

Ejectors: One starting and two main ejectors connected to the condenser located near the

turbine.

C.W Pumps: Normally two per unit of 50% capacity.

CONDENSER:

There are two condensers entered to the two exhausters of the L.P.

turbine.These are surface-type condensers with two pass arrangement. Cooling water pumped

into each condenser by a vertical C.W. pump through the inlet pipe.

Page 42
 "

Figure 3.11 A Typical Water Cooled Condenser

Water enters the inlet chamber of the front water box, passes horizontally through brass tubes to

the water tubes to the water box at the other end,takes a turn, passes through the upper cluster

of tubes and reaches the outlet chamber in the front water box. From these, cooling

water leaves the condenser through the outlet pipe and discharge into the discharge duct.Steam

exhausted from the LP turbine washes the outside of the condenser tubes, losing its latent heat

to the cooling water and is connected with water in the steam side of the condenser. This

condensate collects in the hot well, welded to the bottom of the condensers.

EJECTORS:

There are two 100% capacity ejectors of the steam eject type. The purpose of the ejector is to

evacuate air and other non-condensation gases from the condensers and thus maintain the

vacuum in the condensers. The ejector has three compartments. Steam is supplied generally at a

pressure of 4.5 to 5 kg/cm² to the three nozzles in the three compartments. Steam expands in

the nozzle thus givinga high-velocity eject which creates a low-pressure zone in the throat of

the eject. Since the nozzle box of the ejector is connected to the air pipe from the condenser, the

Page 43
air and pressure zone. The working steam which has expanded in volume comes into contact

with the cluster of tube bundles through which condensate is flowing and gets condensed thus

after aiding the formation of vacuum. The non-condensing gases of air are further sucked with

the next stageof the ejector by the second nozzle. The process repeats itself in the third stage

also andfinally the steam-air mixture is exhausted into the atmosphere through the outlet

Deaerator:

The presence of certain gases, principally oxygen, carbon dioxide and ammonia, dissolved in

water is generally considered harmful because of their corrosive attack on metals, particularly

at elevated temperatures. One of the most important factors in the prevention of internal

corrosionin modern boilers and associated plant therefore, is that the boiler feed water

should be free as far as possible from all dissolved gases especially oxygen. This is achieved by

embodying into the boiler feed system a deaerating unit, whose function is to remove

"

Figure 3.12a Deaerator

Page 44
PRINCIPAL OF DEAERATION:

It is based on following two laws.

• Henry’s Law

• Solubility

The Deaerator comprises of two chambers:

• Deaerating column

• Feed storage tank

Boiler Feed Pump:

This pump is horizontal and of barrel design driven by an Electric motor through a hydraulic

coupling. All the bearings of pump and motor are forced lubricated by a suitable oil lubricating

system with adequate protection to trip the pump if the lubrication oil pressure falls below a

preset value.

3.2.2 COAL HANDLING DEPARTMENT:

As coal is the prime fuel for thermal power plant, adequate emphasis should be given

for its proper handling and storage. Also it is equally important to have a sustained flow of this

fuel to maintain uninterrupted power generation. Coal is used as the fuel because of the

followingadvantages.

Advantages of coal as fuel:

I. Abundantly available in India

II. Low Cost

III. Technology for power generation well developed.

IV. Easy to handle,transport, store and use.

Page 45
COAL CYCLE:

"

Figure 3.13 Coal cycle Diagram

COAL HANDLING SYSTEM:

In the coal handling system of NTPC,three coal paths are normally available for the diret

conveying of coal. These are:

• Path A: From track hopper to boiler bunker.

• Path B: From track hopper to stock yard.

• Path C: From stock yard to boiler bunkers.

"

Figure 3.14 Coal handling system

Page 46
The storage facilities at the stockyards have been provided only for crushed coal. The

coal handling system is designed to provide 100% standby for all equipments and

conveyors.The 200 mm coal as received at the track hopper is fed to the crusher house for

crushing.Crusher of 50% capacity is provided and these are preferred to two crushers of 100%

capacity because of increased reliability and possible higher availability. A series of parallel

conveyors are designed thereafter to carry crushed coal directly to the boiler bunkers or to

divert it to the stockyard.

"

Figure3.15Coal handling division at NTPC,Barh

COAL HANDLING EQUIPMENTS

PULLEY :

They are made of mild steel. Rubber lagging is provided to decrease the friction factor in

between the belt and pulley.

SCRAPPER:

Conveyors are provided with scrappers at the discharge pulley in order to clean the carrying

side of the belt built up material on idler rolls. Care should be taken to ensure that scrapper is

held against the belt with the pressure sufficient to remove material without causing damage to

Page 47
the belt due to excessive force exerted by the wiper. The following categories of scrapper are

common in use :

I. Steel blade scrapper

II. Rubber/fabric blade scrapper

III. Nylon brush scrapper

IV. Compressed air blast scrapper.

IDLERS:

These essentially consist of rolls made out of seamless steel tube enclosed fully at each end and

fitted with stationary shaft,anti-friction bearing and seals. They support the belt and enable it to

travel freely without much frictional losses and also keep the belt properly trained.

"

Figure3.16 an Idler

CONVEYOR BELT:

The conveyor belt consists of layers or piles of fabric duck, impregnated with rubber and

protected by a rubber cover on both sides and edges. The fabric duck supplies the strength to

with stand the tension created in carrying the load while the cover protects the fabric arecas.

Heat resistant belting is always recommended for handling materials at a temperature over 66˚

Page 48
 "

Figure 3.17 Coal Storage Area of the barh superThermal Power Station,

VIBRATING SCREEN:The function of vibrating screen is to send the coal of having size

less than 20 mm to the crusher. The screen is operated by four v-belts connected to motor.

CRUSHER:The role of crusher is to crush the coal from 200 mm to 20 mm size of coal

received from the vibrating screen. This is accomplished by means of granulators of ring type.

There are about 37 crushing elevations; each elevation has 4 granulators-2 of plain type and 2

of toothtype, arranged alternately.The granulators are made of manganese steel because of their

work hardening property. The coal enters the top of the crusher and is crushed between rotating

granulators and fluid case path. The crushed coal through a chute falls on belt feeder. Normally

these crushers have a capacity round 600tonnes/hr.

MAGNETIC SEPAROTERS: This is an electromagnet placed above the conveyor to

attract magnetic materials. Over this magnet

There is one conveyor to transfer these materials to chute provided for dumping at ground

level.Because of this, continuous removal is possible. It can remove any ferrous impurity from

10gms to 50kg. 


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 References

1. Optical fibres, cables and system ITU-T Manual 2009

2. Centre for Railway Information Systems, INDIAN RAILWAYS, DELHI

3. On ―LOCAL AREA NETWORKǁ

4. Fundamentals of Photonics Bahaa E. A. Saleh, Malvin Carl Teich

5. Signalling and Telecommunication in Indian Railways Report No. PA 26 of 200809 


(Railways)

6. Fiber Optic Telecommunication Nick Massa Springfield Technical Community College 


Springfield, Massachusetts

7. Fiber-Optic Technology, cornings

8. E I M S - Interactive Voice Response System, Redox Technologies

9. Chapter 11, Introduction to DSL Technology, Taylor & Francis Group, LLC

10. Introduction to the Synchronous Digital Hierarchy (SDH), Calyptech

11. Wikipedia

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