THERMAL POWER PLANT

SUBMITTED BY:
NISHI KATIYAR
EE-FINAL YEAR
ROLL NO. 1505220029
INDEX
ACKNOWLEDGEMENT
1. INTRODUCTION
1.1 ABOUT NTPC
1.2
ACKNOWLWDGEMENT
The internship opportunity I had with [NTPC] was a great chance for
learning and professional development. Therefore, I consider myself as a
very lucky individual as I was provided with an opportunity to be a part
of it. I am also grateful for having a chance to meet so many wonderful
people and professionals who led me though this internship period.
Bearing in mind previous I am using this opportunity to express my
deepest gratitude and special thanks to the MD of [NTPC] who in spite of
being extraordinarily busy with her/his duties, took time out to hear, guide
and keep me on the correct path and allowing me to carry out my project
at their esteemed organization and extending during the training.
 A.INTRODUCTION
1. About NTPC

NTPC Limited (also known as National Thermal Power Corporation Limited) is an Indian
Central Public Sector Undertaking (CPSU) under the Ministry of Power, Government of India,
engaged in the business of generation of electricity and allied activities. It is a company
incorporated under the Companies Act 1956 and a "Government Company" within the meaning
of the act. The headquarters of the company is situated at New Delhi. NTPC's core business is
generation and sale of electricity to state-owned power distribution companies and State Electricity
Boards in India. The company also undertakes consultancy and turnkey project contracts that
involve engineering, project management, construction management and operation and
management of power plants. The company has also ventured into oil and gas exploration and coal
mining activities. It is the largest power company in India with an electric power generating
capacity of 43,803 MW. Although the company has approx. 18% of the total national capacity it
contributes to over 27% of total power generation due to its focus on operating its power plants at
higher efficiency levels (approx. 83% against the national PLF rate of 78%).
It was founded by Government of India in 1975, which now holds 70% of its equity shares on
13 May 2015.
In May 2010, NTPC was conferred Maharatna status by the Union Government of India. It is
ranked 424th in in the Forbes Global 2000 for 2014
The company has set a target to have an installed power generating capacity of 1,28,000 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.
Vision
“To be the world’s largest and best power producer, powering India’s growth”

Mission
“Develop and provide reliable power, related products and services at competitive prices,
integrating multiple energy sources with innovative and eco-friendly technologies and
contribute to society”.
 2. Installed Capacity
TABLE 1.1 – Installed Capacity of NTPC
Projects No. of Projects Commissioned
Capacity
(MW)
NTPC OWNED
COAL 14 22,395
GAS/LIQ. FUEL 07 3,955
TOTAL 21 26,350
OWNED BY JVCs
Coal 3 314
Gas/LIQ. FUEL 1 740
GRAND TOTAL 25 27,404

TABLE 1.2 -COAL BASED PLANTS

Coal based State Commissioned
Capacity
(MW)
1. Singrauli Uttar Pradesh 2,000
2. Korba Chhattisgarh 2,100
3. Ramagundam Andhra Pradesh 2,600
4. Farakka West Bengal 1,600
5. Vindhyachal Madhya Pradesh 3,260
6. Rihand Uttar Pradesh 2,000
7. Kahalgaon Bihar 1,340
8. NTCPP Uttar Pradesh 840
9. TalcherKaniha Orissa 3,000
10. Unchahar Uttar Pradesh 1,050
11. Talcher Thermal Orissa 460
12. Simhadri Andhra Pradesh 1,000
13. Tanda Uttar Pradesh 440
14. Badarpur Delhi 705
Total (Coal) 22,395
 Commissioned
Gas based State Capacity
(MW)
1 Anta Rajasthan 413

2 Auraiya Uttar Pradesh 652

3 Kawas Gujarat 645

4 Dadri Uttar Pradesh 817

5 Jhanor-Gandhar Gujarat 648

Rajiv Gandhi
CCPP
6 Kerala 350
Kayamkulam
7 Faridabad Haryana 430
Total (Gas) 3,955
GAS BASED PLANTS

3. Working Principle
A coal based powerplant basically works on Rankine Cycle. Steam is produced in boiler is
exported in prime mover and is condensed in condenser to be fed into the boiler again. In practice
of good number of modifications are affected so as to have heat economy and to increase the
thermal efficiency of plant.

Many of the impracticalities associated with the Carnot cycle can be eliminated by superheating
the steam in the boiler and condensing it completely in the condenser. The cycle that results is the
Rankine cycle, which is the ideal cycle for vapor power plants. The ideal Rankine cycle does not
involve any internal irreversibility's .

1–2 BFP work

2–3 Heating of water to convert it finally to superheated steam in boiler
3–4 Expansion in HP turbine
4–5 Reheating
5–6 Expansion in IP and LP turbine
6–1 Cooling in Condenser
Fig 1.3 – Rankine Cycle (with reheat)

4. About NTPC Dadri

National Capital Power Station (NCPS) Or NTPC Dadri, is the power project to meet the power
demand of National Capital Region (India). It has a huge coal-fired thermal power plant and a gas-
fired plant and has a small township located in Uttar Pradesh, India for its employees.
NTPC Dadri is a unique power plant of NTPC group which has both coal based thermal plant
and gas based thermal plant of 1820 MW and 817 MW respectively and 5 MW solar plant
totaling 2642 MW
Installed Capacity
Coal based
The coal-based station mainly meets power requirements of the National Capital Region [NCR]
and the northern grid . With the World Bank funding component, the capital cost of the units is
Rs.16.69 billion. There are four 210 MW coal based units and two 490MW coal based units. The
units have a coal-fired boiler and a steam turbine each. The boiler design is also suitable for 100%
operations with heavy furnace oil firing. For this, three storage tanks, each of capacity 15,000 kL,
enough for 10 days continuous oil firing requirements have been provided for the boilers.
 TABLE 1.6 – NTPC Dadri Coal Based
Unit Installed Date of
Stage
Number Capacity (MW) Commissioning
1 210 1991 October

2 210 1992 December

1st
3 210 1993 March

4 210 1994 March

5 490 2010 January

2nd
6 490 2010 July
Total Six 1820

NTPC Dadri Gas Based

Unit Installed Date of
Stage GT / ST
Number Capacity (MW) Commissioning

1 130.19 1992 March GT

2 130.19 1992 May GT

3 130.19 1992 June GT

1st
4 130.19 1992 November GT

5 154.51 1993 February ST

6 154.51 1993 March ST

Total Six 829.78
Grand Total capacity is 2637 MW.

1.8.2 Location
It is located in Gautam Budh Nagar district of Uttar Pradesh about 25 km from Ghaziabad and
about 9 km fromDadri. It is nearly 48 km from New Delhi towards Hapur. The township has an
area of about 500 acres over all. NTPC Dadri is a branch of National Thermal Power Corporation,
which is a public sector now. It is about 20km from Ghaziabad via Badalpur, Mahawar,
Bamabawar, and Akilpur Jagir.

1.8.3 Coal Source

The coal is transported from the Piparwar block of mines of the North Karanpura Coalfields of
Jharkhand , over a distance of about 1,200 kms. , by the Indian Railways bottom discharge , and
Box 'N' type of wagons . The coal requirement for the six units is about 25000M.T. each day. The
station has its' own 14 kms. Long rail track from the Dadri Railway Statio , to the site, and a 6 km
in-plant track, on electric traction.
1.8.4 Water Source
Upper Ganga Canal Dehra Headworks, During closure of UGC through network of tube wells.
The consumption of cooling water is 50 cusecs (1415.85 litres/sec).

B. COAL CYCLE

1. Coal Supplied at NTPC Dadri

Coal is supplied to NTPC, Dadri by Piparwar coal mines. The type of coal is Bituminous and
Semi Bituminous with following specifications:-
Moisture- less than 8%
Volatile matter-17% to 19%
Ash- 35% - 40%
Calorific Value- 4500 to 5300 Kcal/kg
Coal is received in railway box rakes containing 50-60 wagons in each rake.
Capacity of each box wagon is about 55 ton.
The BOX-N type wagons are placed on 2 wagon tippler (one for Stage-I and other for
Stage-II)
The BOBR type wagons are emptied on track hoppers

2. Different Components of Coal Cycle

Wagon Tippler
Track Hopper
Paddle Feeder
Conveyer Belts
Crusher House
Stacker cum Reclaimer
Coal Yard
Coal Bunker
Coal Feeder
Coal Mills
Furnace
Fig 2.1 – Coal Cycle

Wagon Tippler
Wagon from coal yard come to the tippler and emptied here. There are 2 wagon tipplers. The
tippler is tilted to about 135° so that coal from the wagon is emptied into the hopper. Elliptics
paddle feeders are used to move the coal from hoppers to conveyer belts.
In this it takes 52 sec to raise a wagon, 10 sec to empty the wagon completely & then again 52 sec
to bring the tippler down. A semicircular huge WT gear is used to run the tippler. Protocol cameras
have been installed for safety to ensure that no moving creature or object is near the wagon which
is on the tippler.
Track Hopper
Coal in BOBR (Box Open Bottom Release) was unloaded on the track hoppers. The track hoppers
are shown as follows.
The Coal is stored in the hoppers from where it is passed on to the conveyer belts by paddle feeders,
towards the crusher house.

Fig 2.2 – Wagon Tippler Fig 2.3 – Track Hoppers

2.2.3 Paddle Feeder

These are movable elliptical feeders with paddle like structures so as to move the coal from the
bottom of the track hoppers to the conveyer belts. There are 4 paddle feeders which can move
along the bottom of the track hopper at different positions.

2.2.4 Conveyer Belts

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 and the material on the belt
forward.
Conveyer belts are used in the CHP to transfer coal from one place to other as required in a
convenient & safe way. All the belts are numbered accordingly so that their function can be easily
demarcated. These belts are made of rubber & move with a speed of 250-300 m/min.

2.2.5 Safety Switches in Conveyers

There are certain switches which are used for safe operation of th conveyers used throughout the
plant.
Belt Sway Switch
These are the switches which are operated when there is sway in the conveyer belt, i.e. the
belt move in a particular direction outside its fixed path. These are located on both the sides
of the belt. In case there is a sway in the belt, the switch gets activated and stop the conveyer
so as to avoid accidents
Pull Cord Switch
These are the switches which are installed at every 10m gap in a conveyer belt to ensure
the safety of motors running the conveyer belts. If at any time some accident happens or
the conveyer belt is needed to be stopped immediately, then the cord is pulled which
activates the switch and stops the conveyer.
ero Speed Switch
It is used as a safety device for the motor i.e. when the belt is not moving but the pulley is
rotating. This switch checks the speed of the belt & switches off the motor when speed of
the belt is zero.
2.2.6 Crusher House
After the coal is unloaded in the wagon tipplers and track hopper (size of coal=-250mm), it is
conveyed to the crusher house for reducing the size of the coal upto -20mm which is the optimum
size for transfer via conveyers.

Table 2.1 – Crusher House

No. and Make of Crusher 8, Pennsylvenia, USA
Type and Size Ring Granulators, TKKGN-48093
Main Crusher Capacity 875 tonnes/hr
Motor Rating 800hp (597KW)
Power Supply 6.6kv, 3Φ, 50Hz
RPM 743

Fig 2.4 – Coal Sizes

2.2.7 Stacker cum Reclaimer

It is used for stacking (storage) of the excess coal in the coal yards. When there is a requirement
of the stored coal, reclaiming process starts and the coal is sent to the coal bunkers through
conveyer belts.
There are 3 Stacker Reclaimers at NTPC Dadri with stacking capacity of 1400tph and reclaiming
capacity of 1400tph with boom conveyer speed of 3m/s
Fig 2.5 – Stacker cum Reclaimer

2.2.8 Coal Yard

Whenever the coal bunkers are filled and there is excess crushed coal in the plant, it is stored in
the coal yard.
Capacity - 45 days coal of stagel requirement, 500000m3 of coal approx.
No. of coal piles in stockyard – 6
Length/Height of each pile - 470/10m
Water is continuously sprayed on the coal piles so as to settle the coal dust. The water also cools
the coal so as to prevent the escape of the volatile material from the coal
The coal yards of both the stages are interconnected by conveyers so as to supply coal to the one
who is in deficiency of coal at a particular time
2.2.9 Coal Bunker
After the coal is crushed in the crusher house, it is either sent to the coal yards or directly to the
coal bunkers. These are very large coal storage containers which are placed above the coal mills
(where the coal is ground finely).
These are cylindrical in shape with conical cum hyperbolic hopper at bottom and made up of 8mm
M.S. plate
Stage I – 6 Coal Bunkers per unit
Stage II – 9 Coal Bunkers per Unit

Fig 2.6 – Coal Bunkers (in Yellow)

2.2.10 Coal Feeder

It is situated just below the coal bunkers. It is used to send calculated amount of coal from
the coal bunkers to the coal mills as per the requirement of the furnace. The quantity of
coal fed is controlled by controlling the speed of the conveyer inside it. Maximum and
minimum capacity of the feeder is 60MT/hr and 6MT/hr respectively
2.2.11 Coal Mill
The coal mills are situated just below the raw coal feeders. It’s main function
is to pulverize the coal from -25mm size to 200mesh size. In NTPC Dadri
there is a bowl type coal mill in which there is a bowl and three rollers at 120°
to each other. The bowl rotates at 50rpm and the rollers rotate about their own
axis. The rollers are pressed against the bowl using springs so as to facilitate
the grinding of coal.
The coal comes in the coal mill from the top from the coal feeder through a
single pipe. After the coal is pulverized it is carried by the primary air (which
enters the mill from bottom towards the top) to the furnace through 4 pipes.
These four pipes carry the coal to the 4 corners of the furnace.
able 2.2 – Coal Mill
Make BHEL
No. per boiler 6
Type XRP 883
Capacity 49 T/hr
Coal size-inlet 25 mm
- outlet 70% through 200 mesh
Grinding roll material Ni -Hard Gr II
 Fig 2.7 – Coal Mills (Pulveriser) Fig 2.8 – Rollers of Coal Mill

2.2.12 FURNACE
Furnace is primary part of the boiler where the chemical energy available in the fuel is converted
into thermal energy by combustion. Furnace is designed for efficient and complete combustion.
Major factors that assist for efficient combustion are the temperature inside the furnace and
turbulence, which causes rapid mixing of fuel and air. In modern boilers, water-cooled furnaces
are used. The boiler fuel firing system is tangentially firing system in which the fuel is introduced
from wind nozzle located in the four corners inside the boiler. The crushed coal from the coal
crusher is transferred into the unit coalbunkers where the coal is stored for feeding into pulverizing
mill through rotary feeder. The rotary feeders feed the coal to pulverize mill at a definite rate. Then
coal burners are employed to fire the pulverized coal along with primary air into furnace. These
burners are placed in the corners of the furnace
nd they send horizontal streams of air and fuel tangent to an imaginary circle in the centre of the
furnace.

Table 2.3 – Furnace specifications

Type Fusion welded walls
Bottom Dry
Furnace projected area 3275 m2
Fuel heat input 519.3 MK Cal/hr
Residence time for fuel particles in furnace 3.14 sec
Effective volume used to calculate the residence time 4200 m3
Draft Balanced
Furnace width 13.868 m
Furnace depth 10.592 m
Furnace height (Ring header to furnace roof) 43.136 m
(viii) Furnace volume 5570 m3

WATER CYCLE
Fig 3.1 – Water Cycle

3.1 De-Mineralized Water/Steam Cycle

Condensate Cycle
Feed Water Cycle
Steam Cycle

3.2 Condensate Cycle

Different Components of Condensate Cycle
Hot Well
Condensate Extraction Pump
Low Pressure Heater
Deaerater
Feed Storage Tank

1 Hot Well
After the steam is condensed in the condenser, it gets collected in the hotwell so that the water can
be recirculated in the system.

3.2.2 Condensate Extraction Pump

This pump is used to extract the condensed water from the hotwell to the deaerater through the
low pressure heaters
Table 3.1 – Condensate Extraction Pump specifications
Manufactuer BHEL
No. of pumps & capacity 2x100%
Type NESJ14OD (2shaft), vertical
 centrifugal connister type
No. of stages 5
Discharge capacity 655 m3/hr
Diff. head 190 mlc
Input power to pump 422 kw
Temperature of medium 46.30c
RPM 1485
Efficiency of pump 79.5%

3.2.3 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 boiler metal when the feed water is
introduced back into the steam cycle. In a steam power plant, 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.
The water here is heated by the steam which is extracted from the different stages of the turbine
These are of two types
Low Pressure Heater
These are called as low pressure heaters as they extract steam from the stages of low
pressure turbine
LPH1-Stage 7 of LPT
LPH2-Stage 5 of LPT
LPH3-Stage 3 of LPT
High Pressure Heater
These are called as low pressure heaters as they extract steam from the exit of the High
Pressure Turbine

Fig 3.2 – Low Pressure Heater Fig 3.3 – High Pressure Heater
3.2.4 Deaerater
A Deaerator is a device for air removal and used to remove dissolved gases (mainly O2 and CO2)
from boiler feed water to make it noncorrosive. 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 is a type of open feed water heater in which feedwater comes in direct contact with the
steam extracted from CRH line and IPT exhaust. These are of three types

Spray type Deaerator

Tray type Deaerator
Spray Cum Tray type Deaerator
In NTPC Dadri, a spray cum tray type Deaerator is used. In this feedwater is first sprayed and then
made to cascade down a series of trays and bled steam flows upwards. Due to this water gets heated
and scrubbed to release the dissolved gases.
. If operated properly, the deaerator will guarantee that oxygen in the deaerated water will not
exceed 7 ppb by weight (0.005 cm3/L)
3.2.5 Feed Storage Tank
After the water is deaerated it is stored in the feed storage tank just below the deaerater. Feed
Storage tank acts as the inlet for the Boiler Feed Pump. So it is kept about 25m above the BFP so
as to maintain a net positive suction head for the BFP so as to avoid cavitation.

Fig 3.4 – Deaerator (upper cylinder) and Feed Storage Tank (lower cylinder)

3.3 Feed Water Cycle

Different Components of Feed Water Cycle
Boiler Feed Pump
High Pressure Heater
Feed Regulating Station
Economiser
Boiler Drum
Boiler

3.3.1 Boiler Feed 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 positive displacement type.
Construction and operation: Feed water pumps range in size up to many horsepower and the
electric motor is usually separated from the pump body by some form of mechanical coupling.
Large industrial condensate pumps may also serve as the feed water pump. In either case, to force
the water into the boiler, the pump must generate sufficient pressure to overcome the steam
pressure developed by the boiler. This is usually accomplished through the use of a centrifugal
pump. Feed water pumps usually run intermittently and are controlled by a float switch or other
similar level-sensing device energizing the pump when it detects a lowered liquid level in the
boiler. Some pumps contain a two-stage switch. As liquid lowers to the trigger point of the first
stage, the pump is activated. If the liquid continues to drop, (perhaps because the pump has failed,
its supply has been cut off or exhausted, or its
charge is blocked) the second stage will be triggered. This stage may switch off the boiler
equipment (preventing the boiler from running dry and overheating), trigger an alarm, or both

Table 3.2 – Boiler Feed Booster Pump specifications

BOILER FEED BOOSTER PUMP
Pump type FA 1B 56
Liquid pumped Boiler feed water
Suction temperature 160.70c
Differential head 100m
Flow rate 450 m3 / hr
Efficiency 79 %
Speed 1485 rpm
Power 141 kw
NPSH, required 4.03 m.

Table 3.3 – Boiler Feed Pump specifications

BOILER FEED
PUMP
No and Capaciy 3 x 50%
Make BHEL, Hyderabad
Pump type FK 6 D 30
No. of stages 6
Liquid pumped Boiler feed water
Differential head 2123m
Design flow rate 450 m3 / hr
Minimum recirculation flow 110 m3 / hr
Efficiency 81%
Speed 5150 rpm.
Power 2911 kw
 NPSH required 24.0 mlc

Fig 3.5 – Boiler Feed Pump

3.3.2 Feed Regulating Station

It is the station which is used to regulate the amount of feed water into the economiser. Here there
are two lines
30% Line for the starting load
100% Line for the full load

3.3.3 Economiser
Economiser is a mechanical device intended to reduce energy consumption, or to perform another
useful function like preheating a fluid. 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). 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 .
Table 3.4 – Economiser Specifications
Type Plain, drainable, non-steaming
Tube Material SA210 GrA1
OD of Tube, mm 44.5
Actual Thickness of Tubes, mm 4.5
Length of Tubes, mm 32100
Tube pitch, mm
a) Parallel to gas path 130
b) Across gas path 96
Water side effective heating area, m2 3580
Gas side effective heating area, m2 5617
Gas flow path area, m2 62.8
Design Pressure of tubes, kg/cm2 161.0
4 Boiler Drum
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 in drum. The
separated steam is drawn out from the top section 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
through downcomers to the ring header from where the water sent to the boiler
Table 3.5 – Boiler Drum specifications
Construction Fusion welded
Material specification SA-299
Design pressure, kg/cm2 abs. 176.4
Max. operating pressure, kg/cm2 abs. 167.2
Design temperature, 0C 354.0
Overall length of drum mm 12200
O.D. of Drum, mm 2083
Internal dia. of Drum, mm 1778
No. of distribution headers 6
Normal water level in drum 250 mm below drum centreline.

Fig 3.6 – Boiler Drum

5 Boiler
Boiler is an enclosed vessel in which water is heated and circulated until the water is turned in to
steam at the required pressure. Coal is burned inside the combustion chamber of boiler. The
products of combustion are nothing but gases. These gases which are at high temperature come in
contact with different heat exchangers and vaporize the water inside them to steam. This steam is
further heated in a super heater as higher the steam pressure and temperature the greater efficiency
the powerplant will have in converting the heat in steam in to mechanical work. This steam at high
pressure and temperature is used directly as a heating medium, or as the working fluid in a prime
mover (turbine) to convert thermal energy to mechanical work, which in turn is converted to
electrical energy.

Boilers are classified mainly into two categories as following:

Fire Tube Boiler
In this type the products of combustion pass through the tubes which are surrounded by
water. These are economical for low pressure only.
Water Tube Boiler
In this type of boiler water flows inside the tubes and hot gases flow outside the tubes.
These tubes are interconnected to common water channels and to steam outlet.
At NTPC Dadri there is a water tube boiler in both stage I and stage II

Table 3.6 – Boiler Specifications

Manufacturer BHEL (C.E. design)
Type Natural circulation, balanced draft, smooth tube
double pass, single drum, single reheat direct
pulverised coal/oil fired,dry bottom type.
Capacity 700t/hr.
Boiler Efficiency 87.28%
FW. inlet temp 246 C
Type of firing Tilting tangential
Temp and Pressure at outlet of-
Superheater 154.0 kg/cm2; 5400c
Reheater 38.8 kg/cm; 5400c
Water volume
Generating surface (Water walls) 116 m3
Economiser 47 m3
Superheater (Drum to SHO heater) 77 m3
Drum (full) 34 m3
Reheater 50 m3
Total water volume of boiler 324 m3

4 Steam Cycle
Different Components of Steam Cycle
Boiler Drum
Superheater
Low Temperature Superheater
 Platen Superheater
Final Superheater
Reheater
Turbine
High Pressure Turbine
Intermediate Pressure Turbine
Low Pressure Turbine
Steam Lines
Condenser
3.4.1 Superheater
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 power plant, and are
widely adopted. Here the temperature of the steam is raised above the saturated temperature of the
steam so that even after isentropic expansion in the turbine the wetness of steam remains in the
desired region
In NTPC Dadri, the boiler has in total 14 superheater headers located at various positions in the
boiler. Superheaters are of three types
Low Temperature Superheater
Platen Superheater
Final Superheater
Table 3.7 – Superheater specifications
LTSH Pendant Platen Final
Horizontal S.H. S.H.
Type Convection Radiant Convection
Direction of flow Counter Parallel Parallel
Effective heating surface 3700 1097 1543
area, m2
Gas flow path area, m2 73 138.9 72
Total no. of tubes 480 203 238
O.D., mm 44.5 47.63 44.5
Effective length, mm 26466 8900 8360
Gross length, m 34700 10100 9760
No. of elev/section 4 7 2
Tube pitch
(a) Parallel of gas flow,mm 96 57 95/96
(b) Across gas flow, mm 114.3 457.2 114.3

2 Reheater
Reheater is a heater which is used to raise the temperature of steam which has fallen after the
expansion in High Pressure Turbine. This is done so as to increase the efficiency of the power
plant and to maintain the dryness fraction of the steam within the desired limit.
Table 3.8 – Reheater Specifications
Type Spaced, single stage
Max. operating pressure,kg/cm2 42.08
 Design pressure, kg/cm2 50.00
Total circumferential heating suface, m2 2858
Gas flow path area, m2 118
Space between two banks in direction of gas flow, 900
mm
Mean effective length per one tube, mm 20.000
Gross length per tube, mm 22,000
Total no. of tubes 354
Acutal tube thickness O.D., mm 47.63/54.00
Tube material SA 210 Gr A1, SA 213T11, T 22
Tube pitch
(a) Parallel to gas flow, mm 101.6
(b) Across gas flow, mm 228.6
Method of joining long tubes Butt welded

3.4.3 Steam Lines

Main Steam Line
It is the pipeline which carries the superheated steam from the final superheater to the
HPT
Cold Reheat Line
It is the pipeline which carries the outlet steam of the HPT to the reheaters in the boiler
where the temp of the steam is again brought back to 540°C at the same pressure
Hot Reheat Line
It is the pipeline which carries the reheated steam from the reheaters to the IPT

3.4.4 Condenser
These condensers are heat exchangers which convert exhaust steam from its gaseous to its liquid
state at a pressure below atmospheric pressure. This is done because handling of the steam is more
difficult and requires more power as compared to that for condensed water.
The condenser used is a shell and tube type condenser in which steam is in the shell while cooling
water is in the tubes. After condensing the steam, the cooling water gets heated up and is sent to
the cooling towers to cool it and use it again Specifications of the condenser used in NTPC Dadri
is as follows
able 3.9 – Condenser Specifications
Type Surface type, double pass with divided
water box construction.
Design c.w. flow 22,500 m3/hr
Design cold wate temp. 320c
Design back pressure 76 mm of Hg (abs)
No. of tubes 15330 nos.
Tube O.D. x thickness, 25.4 x 0.7 thick
Tube material Stainless steel welded
ASTM A 249 TP 304
 Surface area 13727 M2
C.W. velocity 1.83 m/s
Pressure drop C.W. side 4.18 mwc
C.W. temp rise 10.80c

Fig 3.7 - Condenser

Cooling Water Cycle

Different Components of Cooling Water Cycle
Raw Water Reservoir
 Water Softening Plant
De-mineralized Water Plant
Forebay
Circulating Water Pump House
Condenser
Cooling Tower
Intake Channel

3.5.1 Raw Water Reservoir

Water is brought to the plant through small canal which is further connected to the Upper Ganga
Canal. This water is stored temporarily in a water reservoir before sending it to the water treatment
plant. This water is called raw water and is sent to WTP through Raw Water pump house

3.5.2 De-Mineralizing Plant

The principle problem in high pressure boiler is to control corrosion and steam quality. Internal
corrosion costs power station crores of rupees in repair without strict control impurities in steam
also form deposit over turbine blades and nozzles. The impurities present in water are as follows
:-

Un-dissolved and suspended solid materials.

Dissolved slats and minerals.
Dissolved gases
Other minerals ( oil, acid etc.)
Turbidity & Sediment.
Silica.
Micro Biological.
Sodium & Potassium Salt.
Dissolved Sales Minerals.
O2 gas.
CO2 gas.
he water treatment plant is divided in to two parts:
Water Softening Plant
Water Softening Plant deals with removing larger solid impurities by sedimentation and by
coagulation and flocculation, and de-infection of water through aeration. Here, Alum and
Chlorine dosing is done so as to remove the hardness present in the water. After this the
water is sent to de-mineralizing plant and also serves as the drinking water for the NTPC
township
The De-Mineralization plant. (DM plant)
In this plant all the dissolved minerals are removed from the water. The water from water
softening plant is passed through SAC (strong acid cation) which contains acidic resins and
remove dissolved cations such as Mg, Ca, Na etc. It is then passed through degasser tower
to force out the dissolved carbon dioxide gas and carbonate ions. Then the water is passed
through the SBA chamber which contains strong basic resins which remove chlorine and
sulphate ions. From SBA the water is passed through MB (mixed bed) chamber which
 removes both cationic and anionic impurities , if any, and the water is then sent to DM
storage tank, from where it is transported for various uses.

3.5.3 Forebay
After the water is cooled in the cooling tower, it goes to the CW Pump house through forebay. It
connects water from all the four cooling towers in a single channel which finally becomes the
intake of CW Pump house.
3.5.4 Cooling Water Pump House
It circulates the cooling water coming out of the cooling tower to the condenser.
It consists of 8 vertical francis, single stage pumps which take inlet from the forebay

3.5.5 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. In thermal
power plant, it is used to cool the circulation water which comes out of the condenser. The towers
vary in size from small roof-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. There are two types of cooling towers
Natural Draught Cooling Tower
Forced Draught Cooling Tower
In NTPC Dadri, both natural and forced draught cooling towers are used
Natural Draft is used in Coal Based Unit while Forced Draft is used in Gas based units
able 3.10 – Cooling Tower Specifications
Type Natural draft type
No. 4, 1 for each unit
Construction type Reinforce concrete, hyperbolic, double curvature
shell with a big beam at the base supported on
rocker columns
Total height 117 m
Base diameter 78.9 m
Throat diameter 46.7 m
Top diameter 49.77 m
Flow 25,000 m3/hr
Range of cooling 110c
Recooled water temp. 320c
Ambient wet bulb temp. 270c
Design relative humidity 50%
Approach. 50c
Fig 3.8 – Natural Draft Cooling Towers Fig 3.9 – Cooling Tower from inside

TURBINE AND GENERATOR

4.1 Turbine
A turbine, is a rotary mechanical device that extracts energy from a fluid flow and converts it
into useful work. A turbine is a turbomachine with at least one moving part called a rotor
assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades so that
they move and impart rotational energy to the rotor. 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 the rotating 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.
Here in Thermal Power Plant Superheated Steam is used as the fluid to run the turbine
4.1.1 High pressure Turbine
Steam coming from Boiler directly feeds into HPT at a temperature of 540°C and at a pressure of
156 kg/cm2. This turbine is a single flow 25 stage reaction turbine. After expansion the
temperature goes down to 352°C and pressure as 40.4 kg/cm2. The outlet of the HPT is taken back
to the reheaters in the boiler through CRH lines where the steam is again heated to 540°C at same
constant pressure.
Fig 4.1 – High Pressure Turbine

.1.2 Intermediate Pressure turbine

Intermediate Pressure Turbine (IPT) is a 20 x 2 stages, double flow reaction turbine. After coming
out of the reheaters, the steam is brought to the IPT through HRH lines at 540°C temperature and
36 kg/cm2 pressure. The steam is sent in the middle of the IPT from where it expands in both the
directions.

Fig 4.2 – Intermediate Pressure Turbine

4.1.3 Low Pressure Turbine

Low Pressure Turbine (LPT) is a 8 x 2 stages, double flow reaction turbine. After expansion in the
IPT, steam is fed directly in the LPT. Here also the steam is fed in the middle of the tubine and it
expands in both the directions.
Fig 4.3– Low Pressure Turbine

able 4.1 – Turbine Specifications

Make BHEL, KRAFTWERK UNION DESIGN
Type Tandem compound, regenerative, reheat, condensing, three
cylinder having single flow HP turbine, double flow IP & LP
turbine.
No of stages HP 25 no.
IP 20 x 2 no.
LP 8 x 2 no.
Type of HP/IP/LP turbine HPT-Reaction, barrel single flow type
LPT-Reaction, double flow axially split type
LPT-Reaction, double flow three shell design
Nominal rating 210 MW
Peak loading 229 MW
Max./Min. speed 3090/2850 rpm (47.5 to 51.5 HZ)
Permissible for a maximum of 2 hours operation during the
life of the LP blading speed below 47.5 HZ & speed above
51.5HZ.
Weight of turbine 475 tonne (approx.)

HPT IPT LPT

Height of first stage moving blade 43 66 755
Mean dia. of first stage moving blade 643 756 1473.5
Height of last stage moving blade 95 100 668.8
Mean dia. of last stage moving blade 695 1041 2144.8
Overall length 16.975m
Overall width (with cross around 10.5 (approx.)
pipes)
Total exhaust area (LP Turbine) 2 x 5 m2
The generator works on the principle of electromagnetic induction. There are two components
stator and rotor. The rotor is the moving part and the stator is the stationary part. The rotor, which
has a field winding, is given a excitation through a set of 3000rpm to give the required frequency
of HZ. The rotor is cooled by Hydrogen gas, which has high heat carrying capacity of low density.
If oxygen and hydrogen get mixed then they will form very high explosive and to prevent their
combining in any way there is seal oil system. The stator cooling is done by de-mineralized (DM)
water through hollow conductors. Water is fed by one end by Teflon tube. A boiler and a turbine
are coupled to electric generators. Steam from the boiler is fed to the turbine through the
connecting pipe. Steam drives the turbine rotor. The turbine rotor drives the generator rotor which
turns the electromagnet within the coil of wire conductors.
Hydrogen gas is used to cool down the rotor.
Lube oil is used to cool the bearings.
DM water is used to cool the stator.
Seal oil is used to prevent hydrogen leakage
Seal oil coolers are present to cool the seal oil
Hydrogen dryer are used which removes the moisture from hydrogen gas and then is
supplied to the generator.
Clarified water in cooling tower is used to cool down the hydrogen gas.

Fig 4.4 – Generator (Red) and Turbine (Green)

ble 4.2 – Stage I (210MW) Generator specifications
Make BHEL
Type THW - 201-2 Two pole, cylindrical, steam turbine
driven
Cooling Stator winding Directly water cooled
Stator core and Rotor Directly hydrogen cooled
MW rating 210
Rated terminal voltage 16.5 kv
Rated terminal current 8,645 A
 Rated power factor 0.85 lag
Rated speed/frequency 3000 rpm/50 HZ
Efficiency at MC Condition 98.55%
Phase connection Double star

The 210 MW generates 16.5 KV three phase electricity. The voltage is stepped up to 220 KV with
the help of station transformer and is connected to the switch yard. This electricity is further
stepped up to 400KV and then supplied to the grid
Some of the electricity is stepped down to 6.6KV with the help of Unit Auxiliary Transformer to
drive the different auxiliaries in the plant.

4.4 Transformer
It is a static machine which increases or decreases the AC voltage without changing the frequency
of the supply. It is a device that:
Transfer electric power from one circuit to another.
It accomplishes this by electromagnetic induction.
In this the two electric circuits are in mutual inductive influence of each other.
It works on Faraday’s Law of Electromagnetic Induction (self or mutual induction depending on
the type of transformer).
There are two types of transformers
Station Transformer
It is the transformer which steps up the 16.5KV electricity generated by the generator to
220KV
Unit Auxiliary Transformer
It is the transformer which steps down some of the electricity to 6.6KV so as to run the
auxiliaries in the plant

Fig 4.5 – Station Transformer

4.5 Switch Yard

As we know that electrical energy can‟t be stored like cells, so what we generate should be
consumed instantaneously. But as the load is not constants therefore we generate electricity
according to need i.e. the generation depends upon load. The switchyard is the place from where
the electricity is send outside to the grid. Its main function is to convert the electricity in the
required form and connect to the grid to supply this electricity.

Fig 4.6 – Switch Yard

.5.1 Circuit Breaker

Circuit breaker is an arrangement by which we can break the circuit or flow of current. A circuit
breaker in station serves the same purpose as switch but it has many added and complex features.
The basic construction of any circuit breaker requires the separation of contact in an insulating
fluid that servers two functions:
extinguishes the arc drawn between the contacts when circuit breaker opens.
It provides adequate insulation between the contacts and from each contact to earth.

AIR AND FLUE GAS CYCLE

5.1 Air Cycle
Different Components of Air Cycle
Fans
Primary Air Fan
Forced Draft Fan
Induced Draft Fan
Seal Air Fan
Scanner Air Fan
Air Preheter
 Cold Air Duct
Hot Air Duct
Wind Box

Fig 5.1 – Flue Gas Cycle

.2 Fans

5.2.1 Primary Air Fan (PA Fan)

It is the fan which is used to carry pulverized coal from the coal mills to the furnace. The PA Fan
takes suction from the FD fan outlet from where the air is sent to the air preheaters. From APH,
the heated air is sent to the coal mills. Heating of primary air is done so as to remove the moisture
content from the coal so as to facilitate the combustion process.

Table 5.1 – PA Fan specifications

Manufacturer BHEL
No. per boiler Two
Type NDZV 19 HERKALES Axial double suction
radial discharge simply supported
Medium handled Clean air from FD fan discharge
Location Ground mounted on concrete floor
Top delivery with 45 inclined suction
Orientation chamber.
 Capacity 77.4 cu.m/sec.
Total head developed 931 mmwc
Temp. of medium 53 c
Speed 1480 rpm

5.2.2 Forced Draft Fan (FD Fan)

It is the external fan provided to give sufficient air for combustion. The forced draught fan takes
air from the atmosphere and, warms it in the air preheater for better combustion and injects it via
the air nozzles on the furnace wall. This air is called secondary air.

Table 5.2 – FD Fan specifications

Manufacturer BHEL
No. per boiler Two
Type AP1-19/11
Medium handled Clean air
Location Ground mounted on concrete floor
Orientation Horizontal axis
Capacity 144.7 cu.m/sec
Total head developed 334 mmwc.
Temp. of medium 500c
Speed 1480 rpm

Fig 5.2 – Forced Draft Fan (bottom left) and Primary Air Fan (bottom right)

5.2.3 Induced Draft Fan (ID 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 ash particles
carried by the outlet gases are removed by ESP to avoid atmospheric pollution.
 Table 5.3 – ID Fan specifications
Manufacturer BHEL
No. per boiler Two
Type NDZV 31 SIDOR Axial double
suction radial discharge
Medium handled Flue gas
Location Ground mounted
Orientation Bottom delivery with 450
inclined suction
Capcity 222 cu.m/sec
Total head developed 418 mmwc
Temp. of medium 1450c
Speed 740 rpm

Fig 5.3 – Induced Draft Fan

5.3 Flue Gas Cycle

Different Components of Flue Gas Cycle
Furnace
Superheater
Reheater
Economiser
Air Preheater
Electrostatic Precipitator
Induced Draft Fan
Chimney
5.3.1 Air Preheater
Air preheater 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.
There are two types of Air Preheaters
1. Recuperative Air Preheater
2. Regenerative Air Preheater
In NTPC Dadri, a regenerative air preheater is used. Every unit consists of two air preheaters. It is
of two types
Bisector Air Preheater
Trisector Preheater
Here, a trisector type preheater is used. In this the whole circular area is divided into three sectors
of 180° (for flue gas), 120° (for secondary air) and 60° (for primary air)

Fig 5.4 – Air Preheater

5.3.2 Electrostatic 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. Here ESP is used to separate ash
particles from the flue gases. A DC current of 75 KV is passed through the electrodes which ionizes
the ash particles. These particles then get deposited on the collecting electrodes. 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

Table 5.4 – Electrostatic Precipitator specifications

Manufacturer BHEL
Type FAA-6x45-69135-2
Gas flow rate 312.7 cu.m / sec
Temperature 1360c
No. ofgas paths per boiler Four
No. of fields in series in each gas pass Six
Treatment time 32.18 seconds

Guarantee of collection efficiency for design 99.9%

conditions
Power consumption 505 kw
No. of rows of collecting electrodes per field 24
No. of collecting electrode plates per field 144
total no, of collecting plates per boiler 3456
Nominal height of collecting plate 13.5 m
Nominal length of collecting plate 750 mm
Specific collecting area (with one field out of 214.48 sq.m/cu.m/sec
service)
Type of emmiting electrodes Spiral with hooks
Size of emmiting electrodes Dia 2.7 mm
No. of emmiting electrodes in the frame forming 54 fields
one row
No. of emitting electrodes in each field 1242
Total no. of emitting electrodes per boiler 29808
Total length of emitting electrode per field 6967.62 m.
Fig 5.5 – Electrostatic Precipitator

5.3.3 Chimney
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 or oil is burnt in the furnace. Flue gas is usually composed of carbon dioxide
(CO2) and water vapour as well as nitrogen and excess oxygen remaining from the
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 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.
Table 5.5 – Chimney Specifications
No. of fuel 4 NO.
Wind shield material Reinforced concerete
flue material Steel
Chimney height 220 m
Chimney base diameter 32.975
Chimney raft diameter 43.120 m
Flue diameter 4.5 m
Fig 5.6 – Chimney

.4 Ash Handling Plant

Ash handling refers to the method of collection, conveying, interim storage and load out of various
types of ash residue left over from solid fuel combustion processes. The most common types of
ash include bottom ash, fly ash and ash clinkers resulting from the combustion of coal. Ash
handling systems may employ pneumatic ash conveying or mechanical ash conveyors. A typical
pneumatic ash handling system will employ vacuum pneumatic ash collection and ash conveying
from several ash pick up stations with delivery to an ash storage silo for interim holding prior to
load out and transport. Pressurized pneumatic ash conveying may also be employed. Coarse ash
material such as bottom ash is most often crushed in clinker grinders (crushers) prior to being
transported in the ash conveyor system. Very finely sized fly ash often accounts for the major
portion of the material conveyed in an ash handling system. It is collected from baghouse type dust
collectors, electrostatic precipitators and other apparatus in the flue gas processing stream. There
are two types of ash in a Power Plant:
Bottom Ash.
It refers to part of the non-combustible residues of combustion. In an industrial context, it
usually refers to coal combustion and comprises traces of combustibles embedded in
forming clinkers and sticking to hot side walls of a coal-burning furnace during its
operation. The portion of the ash that escapes up the chimney or stack is, however, referred
to as fly ash. The clinkers fall by themselves into the water or sometimes by poking
manually, and get cooled.
Fly Ash
It is one of the residues generated in combustion, and comprises the fine particles that rise
with the flue gases. In an industrial context, fly ash usually refers to ash produced during
combustion of coal. Fly ash is generally captured by electrostatic precipitators or other
particle filtration equipments before the flue gases reach the chimneys of coal-fired power
plants.

There are basically 2 types of ash handling processes undertaken by AHP:

Dry ash system
Ash slurry system

Dry Ash System

Dry ash is required in cement factories as it can be directly added to cement. Hence the dry ash
collected in the ESP hopper is directly disposed to silos using pressure pumps. The dry ash from
these silos is transported to the required destination.
Ash Slurry System
Ash from boiler is transported to ash dump areas by means of sluicing type hydraulic system which
consists of two types of systems:
Bottom ash system
In this system, the ash slag discharged from the furnace is collected in water impounded scraper
installed below bottom ash hopper. The ash collected is transported to clinkers by chain
conveyors. The clinker grinders churn ash which is then mixed with water to form slurry.

Ash water system

In this system, the ash collected in ESP hopper is passed to flushing system. Here low pressure
water is applied through nozzle directing tangentially to the section of pipe to create turbulence
and proper mixing of ash with water to form slurry. Slurry formed in above processes is
transported to ash slurry sump. Here extra water is added to slurry if required and then is
pumped to the dump area

Fig 5.7 – Hydrobins

Fig 5.8 – Dry Ash Silos

ONCLUSION
The industrial training has proved to be quiet fruitful. It provided an opportunity for encounter
with such huge machines. The architecture of the power plant the way various units are link and
the way working of whole plant is controlled make the student realize that engineering is not just
learning the structure description and working of various machines, but the greater part is of
planning proper management.

The practical experience that I have gathered during the overview training of thermal power plant
having a large capacity of 2637 MW in 45 days will be very useful and a stepping stone in building
bright professional career in future life. It gave me large spectrum to utilize the theoretical
knowledge and to put it into practice. The trouble shooting activities in operation and decision
making in case of crisis made me more confident to work in the industrial atmosphere. Moreover,
this overview training has also given a self-realization & hands-on experience in developing the
personality, interpersonal relationship with the professional executives, staffs and to develop the
leadership ability in industry dealing with workers of all categories. I would like to thank
everybody who has been a part of this project, without whom this project would never be
completed with such ease.