Industrial Training

Report

National Thermal Power Corporation (TANDA)

Abdur Rahman
18BEE048
7th Semester
ACKNOWLEDGEMENT
I HEREBY TAKE THIS OPPORTUNITY TO THANK NTPC LTD. TANDA FOR
GIVING ME THIS OPPORTUNITY TO CONDUCT MY TRAINING IN NTPC LTD.,
TANDA. I AM GRATEFUL FOR ALLOWING ME TO CONDUCT MY TRAINING
IN THE CONTROL & INSTRUMENTATION DEPARTMENT.I AM HEARTLY
INDEBTED FOR PROVIDING ME WITH DETAILED IN DEPTH KNOWLEDGE
AND VERY USEFUL INFORMATION ABOUT THE PROCESSES AND SYSTEMS
USED IN THE PLANT.THE SUPPORT WAS INSTRUMENTAL IN MY TRAINING
BEING FRUITFULL. I AM ALSO VERY TANKFUL TO ALL THE OFFICERS AND
STAFF OF NTPC LTD., TANDA FOR EXTENDING A HELPING HAND
WHENEVER I NEEDED IT.

WITH REGARDS,

Abdur Rahman

18BEE048

(VOCATIONAL TRAINEE)
INTRODUCTION
NTPC is the largest power generation company in India, with
comprehensive in-house capabilities in building and operating power projects. It
is producing 67907.5MW. Its family consists of 24 coal based power plant and 7
gas based power plant. It is also setting up 2 hydro based power. In this firm
government has 89.5% stake and 10.5% with public. More than one-fourth of
India’s generation with one-fifth capacity. The next largest power utility owns
7.9% of market share in terms of capacity and 8.12% of share in terms of units
generated. NTPC’s vision is to become world class integrated power major,
powering India’s growth, with increasing global presence. It also develops and
provides reliable power, related products and services at competitive prices,
integrating multiple energy sources with innovative and eco-friendly
technologies and contributes to society. NTPC stations are regular recipients of
CEA’s meritorious performance awards. This firm is also well concern about the
environmental factors. It uses world’s largest ESP’s and also gives emphasis on
environmental monitoring along with efforts to increase energy efficiency.

BRIEF HISTORY OF THE POWER PLANT (TANDA)

This prestigious power plant was inaugurated by late Prime Minister “Smt.
Indira Gandhi” in 30th December 1981. It is located 22km away from the distt. Of
Akbarpur (Ambedkar Nagar) and 60km (Approx) from Faizabad in the state of
Uttar Pradesh. The capacity of the Power Plant is 1760MW consisting of the four
units each of 110MW capacity and two units of 660MW capacity. This Power
plant originally was owned by U.P. State Electricity board but the level of
performance that is P.L.F.(Power load factor) deteriorated which was taken over
by NTPC at the date of 15 th January on the year 2000 and It’s now successfully
run by the co-operation work of engineers, workers, helpers and the other
people who indirectly help the growth of this power plant and is now running an
average of 100+% (PLF). In the starting period of acquisition the PLF was these
units were supplied, erected and commissioned by M/s BHEL. The Power house
was located on the bank of river Saryu and West of the existing Mehripur
pumping station of the Tanda canal system. Necessary land, water and transport
facilities are available.

Land facility :
1. Land for Power Station including storage yard, Marshalling yard, Switching
yard 120 hectares

2. Land for ash disposal 160 hectares

3. Land for colony 100 hectares

Water facility :
1. Water for once thru cooling 726.5 cusecs

2. Water for cooling tower 45.0 cusecs

PRODUCTION AND TRANSMISSION

The 4*110MW power electricity is produced at the station using four
different units. Each unit generates 110MW power. The arrangement of each
unit is same. Since it is a thermal power plant, coal is used as the main source of
energy. This coal is mainly supplied from the Dhanbad (Bihar) and other places.
Generated electricity supplied to following station

1. Sultanpur 1 3. Gorakhpur

2. sultanpur 2 4. Basti

Since this power plant had been undertaken by NTPC in 2000 its
performance in terms of power factor load(PLF) is improved in a great manner
and can be observed from the given graph.

CONCEPT OF PRODUCING ELECTRICITY

NTPC, Tanda is a thermal power station comprises of 4 units each having
an installed capacity of producing 110MW. In this power plant electricity is
produced by using a non-renewable source of energy i.e. coal. Coal is converted
into pulverized form to enhance easy burning. The heat generated is used to
convert water to steam which is further used to move the turbine to produce
electricity. NTPC, Tanda is capable of producing a total of 440 MW of electricity.
The main area of concern in any power plant is continuous operation along with
an effort to increase its efficiency of producing electricity.

FAMILIARIZATION OF THE POWER PLANT

Basic operations of a power plant

Coal to electricity

Generating steam from coal

Conversion of thermal energy to mechanical energy

Generation and load dispatch of electric power.

COAL TO ELECTRICITY
NTPC, Tanda is a thermal power station which produces electricity by using
a non-renewable source of energy i.e. coal. Coal is converted into pulverised
form to enhance easy burning. The heat generated is used to convert water to
steam which is further used to move the turbine to produce electricity. NTPC,
Tanda is capable of producing a total of 440 MW of electricity.

BASIC POWER PLANT CYCLE

The thermal power plant uses a dual (vapour+liquid) phase cycle . It is a
closed cycle to enable the working fluid (water) to be used again and again . The
cycle used is ranking cycle modified to include super heating of steam
regenerative feed water heating and reheating of steam .
 Figure shows this cycle and is self explanatory. On large turbines , it
becomes economical to increase the cycle efficiency by using reheat which is
away of partially overcoming temperature limitations . By returning partially
expand steam to a reheat the avg. temperature at which heat is added increase
by expanding this reheated steam to the remaining stage of the turbine .

Factors affecting Power Plant Cycle efficiency :

Initial steam pressure

Initial steam temperature

Condenser pressure
Feed water heating

Regenerative feed water heating

COAL TO STEAM
Coal from the coal wagons is unloaded in the coal handling plant . This coal
is transported upto the raw coal bunkers with the help of belt conveyors . coal rs
transported to mills by coal feeder . The coal is pulverized into powder form .

This crushed coal is taken away to the furnace through coal pipes with the
help of hot and cold air mixture from P.A. fans. P.A. fans taken atmospheric air
,a part of which is sent to atmosphere for heating while a part goes directly to
the mill for temperature control . Atmospheric air F.D. fan is heated in the air
heaters and sent to the furnace as combustion air.

Water from the boiler fed pump passes through economiser and reaches
the boiler drum . Water from the drum passes through down comers and goes
to bottom ring header . Water from the bottom ring header is divided to all the
four sides of the furnace . Due to heat and the density difference the water
rises up in the water wll tubes “ Water is partly converted to steam as it rises up
in the furnace . This steam and water mixture is again taken to boiler drum
where the steam is seprated from water . Water follows the same path while
the steam is sent to superheater for superheating . The superheaters are
located inside the furnace and thesteam is superheated (540”C) and finally it
goes to turbine

STEAM TO MECHANICAL POWER

From the boiler saturated superheated steam enters the high pressure
turbine where it passes through its various stages. The steam leaving the high
pressure turbine goes back to the boiler for reheating and returns by a further
pipe to the intermediate pressure turbine. Here it passes through another series
of blades.

Finally the steam is taken to the low pressure turbines, each of which it
enters at the centre flowing outwards in opposite directions through the rows of
turbine blades. As the steam gives up its heat energy to drive the turbine, its
temperature and pressure fall and it expands. Because of this expansion the
blades are much larger and longer towards low pressure ends of turbine.

When as much energy as possible is extracted from the steam it is

exhausted directly to the condenser and further condensate cycle and feed
water cycle take place. It is passed through further boiler for reconversion into
steam .

MECHANICAL POWER TO ELECTRICAL POWER

LP turbine end is connected to generator . Generator converts mechanical
energy to electrical energy.

Turbine shaft usually rotates at 3,000 rpm . This speed determined by the
frequency of the electrical system used in this country and is the speed at which
a 2-pole generator must be driven to generate alternating current frequency of
50 cycle per second .

BASIC CYCLES OF POWER PLANT

For proper functioning of a power plant ,its working operation has been
divided into following main operation cycles.

Steam cycle
 Feed water cycle

Condensate water cycle

Primary air cycle

Flue gas cycle

Secondary air cycle

STEAM CYCLE
This cycle basically deals with the flow of steam at different pressure and
temperature to different turbines namely HP,IP and LP turbines which is
connected to the generator. It can be explained from the figure shown below
 Steam coming out from super heater at 540degree C and 139kg per square
cm. Three cylinders of 2 set of main stop and governing valve arrangement on
either side of HP casing and each set consist of one stop valve and 2 governing
valve assembling series. The steam from the boiler is admitted the reheater
where it heated at original temp. The reheated steam is taken to IP casing
through combined stop and interceptor valve arrangement at either of IP casing.
The exhaust from the IP casing has taken directly the LP casing. The steam
expanded in the LP turbine to a very low blade pressure which is maintained by
the condenser below atmospheric pressure about 3% of makeup water is
required to condensate the losses of cooling water due to evaporation in cooling
tower. Finally steam exhausted by LP turbine is condensed in the surface type
condenser type cooling water following through a large no. of tubes. The HP, IP
&LP turbine coupled in series and mechanical power generated from steam
transmitted to generator.

FEED WATER CYCLE

This cycle deals with the flow of water to boiler feed pump from feed
storage tank , which is later fed to the boiler drum passing through high pressure
heater and economizer
This system plays an important role in the supply of feed water to the boiler at
requisite pressure and steam/water ratio. This system starts from boiler feed
pump to feed regulating station via HP heaters.

Boiler feed pump:

This pump is horizontal and barrel design driven by an electric motor
through a hydraulic coupling. all the bearings of the pump and motor are forced
lubricated by oil lubricating system. The feed pump consists of pump barrel into
which is mounted the inside starter, together with rotor. Water cooling and oil
lubricating are provided with their accessories. The brackets of the radial bearing
of the suction side and the radial and thrust bearing of the discharged side are
fixed to low pressure cover.
High pressure heater:
These are regenerative feed water heater operating at high pressure and
located by the side of turbine. It is connected in series on feed water side and by
such arrangement the feed water after feed pump enters the hp heater. T he
steam supply to these heater from the bleed point of the turbine through motor
operated valves
CONDENSATE WATER CYCLE
It deals with the water flowing through the condenser which plays an
important role in increasing the efficiency of the plant. It consists of a feedback
path from main ejector to hot well.

The steam after condensing in the condenser known as condensate, is extracted

out of the condenser hot well by condensate pump and taken to the de-aerator
through ejectors, gland steam cooler and series of LP heaters Condensate pump.
The function of these pumps is to pump out the condensate to the dearator
taken to the de-aerator through ejectors, gland steam cooler and series of LP
heaters. This pump is rated generally for 160 cubic meter/hour at a pressure of
13.2 kg/cm square.

LP Heater:
There are four LP heater in which 4 extraction are used. These heaters are
equipped with necessary safety valves in the steam space level indicator. The
condensate flows in the u tube in 4 passes and extraction steam washes the
outside tubes.
Dearator:
 The inner corrosion can be prevented by removing dissolved gases from
the feed water. It can be achieved by embodying into the boiler feed system a
Dearating unit whose function is to remove the dissolved gases. It works on two
principles:: Henry law and solubility law.

PRIMARY AIR CYCLE

In this cycle, air is used to carry pulverized coal from mill to the burning
zone of boiler.

FLUE GAS CYCLE

In this cycle, gas containing waste materials are removed from the system
using various techniques like electrostatic precipitator, ID fans etc. The flue gas,
before being removed is used to heat the primary and secondary air.

SECONDARY AIR CYCLE

In this cycle, fuel is mixed with air (known as secondary air) for proper
burning of coal.

BOILER TERMINOLOGY
FOLLOWING ACCESSORIES
1. ECONOMISER 7. DIV PANEL

2. BOILER DRUM 8. PLATEN SH

3. DOWN COMERS 9. REHEATER

4. CCW PUMPS 10. BURNER

5. BOTTOM RING HEADER 11. APHs

6. WATER WALLS

ECONOMISER
 Boiler Economizer are feed-water heaters in which the heat from waste
gases is recovered to raise the temperature of feed-water supplied to the boiler.
It preheats the feed water by utilizing the residual heat of the flue gas.It reduces
the exhaust gas temperature and saves the fuel.

BOILER DRUM
It is an enclosed Pressure Vessel
Heat generated by Combustion of Fuel is transferred to water to become
steam
It serves two main function.
It separates heat from the mixture of water and steam.
It consists of all equipments used for purification of the steam after being
separated from water.

BOILER DRUM LEVEL CONTROL

Drum up to level at boiler start-up and maintain the level at constant speed
load.

Decrease in this level will uncover boiler tubes and get overheated and damaged.

Increase in this level will make separation Important for both plant protection
and equipment safety.

Maintain between steam and moisture difficult with in drum.

Controlled circulation is required to maintain the difference in the density

between water and steam with increase in pressure.

DOWN COMERS
It carries water from boiler drum to the ring header. They are installed from
outside the furnace to keep density difference for natural circulation of water &
steam.

Heating and Evaporating the feed water supplied to the boiler from the
economizer.

WATER WALLS
These are membrane walls, no. of tubes are joined.
Vertical tubes connected at the top and bottom of the Headers.
Receives water from the boiler drum by down –comers.