VOCATIONAL TRAINING REPORT

“KORBA SUPERTHERMAL POWER PLANT”

(Period From 27 June to 23 July)
on

Guided By Submitted By

Mr. M.K. Roy Sir PAKJAT HUSSAIN

B.TECH 2ND YEAR

MECHANICAL ENGG.
GOVT.ENGG.COLLEGE
BILASPUR KONI C.G.

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 ACKNOWLEDGMENT

I take this opportunity to express my profound gratitude and

deep regards to Mr. PRADEEP RANJAN BHATTACHARJEE
(DGM, EDC) for his exemplary guidance, monitoring and
constant encouragement throughout the course of this thesis.

I also take this opportunity to express a deep sense of

gratitude to, Mr. M K Roy for his cordial support, valuable
information and guidance, which helped me in completing
this training properly.

I am obliged to employees of NTPC Korba, for the valuable

information provided by them in their respective fields. I am
grateful for their cooperation during the period of my
vocational training.

I am thankful to entire NTPC management for successful

completion of my vocational training.

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CONTENT Page no.
1. About NTPC 04
2. Safety 05
3. Coal Source 07
4. Coal Handling plant(CHP) 07
5. Track Hopper 07
6. Conveyor belt 08
7. Crusher 08
8. Bunker 08
9. Main Plant 08
10. Feeder 08
11. Pulverizer 08
12. Furnace 09
13. Air and Flue Gases Cycle 10
14. Boiler 10
15. Superheater 11
16. Types of fan 11
17. Turbine 13
18. Reheater 13
19. Condenser 14
20. Condensate And Feed Water Cycle 15
21. Steam Water Cycle 15
22. Circulate Water Scheme 16
23. Generator 18
24. Switchyard 18
25. Ash handling 19-20
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 ABOUT NTPC KORBA

NTPC Korba Super Thermal Power Project is a cynosure of power

generation in India. It is a priceless gem of mineral rich state of
Chhattisgarh. Power station located at Jamnipali Village of Korba
District. It is a coal fed station and water is sourced from Hasdeo
barrage.

Total installed capacity of Korba Super Thermal Power Project is

2600MW (stage I 3x200 + stage II 3x500 + stage III 1x500). It get
coal supply from Gevra mines of SECL, Korba. The coal is
transported via dedicated MGR system of total length 34.80 km.

Mission of NTPC
PROVIDE RELIABLE POWER AND RELATED SOLUTIONS IN AN
ECONOMICAL, EFFICIENT AND ENVIRONMENT FRIENDLY
MANNER, DRIVEN BY INNOVATION AND AGILITY.

Vision of NTPC
TO BE THE WORLD’S LEADING POWER COMPANY, ENERGIZING
INDIA’S GROWTH.

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SAFETY
By taking certain basic safety steps, you can substantially minimize
the odds of employees being harmed due to avoidable on-the-job
accidents. What's most important is that you adhere to all official
safety regulations and laws. The following power plant safety tips
can also help you protect your workers.

● Safety Equipment
● Risk Assessment
● Safety Training
● Emergency Evacuation Drills
● Working with Tools
● Operating Heavy Machinery
● Maintaining Cleanliness
● Keeping a Clear Head

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COAL SOURCE

● In NTPC korba coal source from Gevra mines and Kusmunda block
through trains & by road. And this coal size is approx 200mm

● Korba is also well with national highwys like NH200 etc

● It is also connected to Champa, the nearest railway junction on the

Howrah-Nagpur-Mumbai line.

COAL HANDLING PLANT

Coal is an important component, requiring a lot of coal throughout the
day, it is necessary for a continuous flow of coal, to bring the coal to the
plant, the rapists' railways, roads or pipeline are also used.
If the plant is near the sea, coal can be delivered directly to the
plant from the ship with the help of conveyer belt or coal flow through
the river, but coal from the river is not possible in India.

TRACK HOPPERS

● UNDERGROUND HOPPER AT POWER STN END

FOR UNLOADING

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 ● TRACK HOPPER 1&2 FOR ST-1(200MW) AND ST-2 (500MW)
RESPECTIVELY
● TRACK HOPPER –1 : 3000 TON
● TRACK HOPPER –2 : 3200 TON

CONVEYOR BELT
● TRANSPORTS COAL FROM ONE PLACE TO OTHER
● CAPACITY: 2000 TON/HR
● MATERIAL:COMPOUND OF NYLON/POLYESTER ETC
WITH RUBBER COATING.
● 100% STANDBY

CHRUSHER
Crusher crushes coal from 100mm size to 20mm size. There are four
crushers installed in each station-1 and station-2. Two of the crushers
run at a time.

BUNKERS
● BUNKERS (EACH 390 TON CAP) IN A 200 MW UNIT
● 9 BUNKERS (EACH 900 TON CAP) IN A 500 MW UNIT

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 ● TRIPPER CONVEYORS FOR TRANSFERING COAL FROM
CONVEYOR TO BUNKER.

FEEDER

● TRANSFERS COAL FROM BUNKERS TO

MILL/PULVERIZER
● VARIABLE SPEED ● DC OR AC MOTOR
DRIVEN

PULVERIZER
PULVERIZES COAL FROM 20 MM SIZE TO 200 MESH
SIZE i.e> 70% SHOULD PASS THRU 200 MESH(200
HOLES/SQ.INCH)~ 75 MICRON

BOWL ROTATED BY MOTOR AND 3 ROLLERS AT 120

DEG APART (BOWL MILL)

PULVERIZED COAL IS TAKEN TO BOILER BY HOT+COLD PRIMARY

AIR.

Process :-
At Gevra mines, coal is loaded on trains (marry-go-round, total track
length: 34.80km) using silo located at mines end, and unloaded at track
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hopper located at the plant end. After unloading at the track hopper
the coal goes to crusher which reduces the size of the coal from
<100mm to 20mm.Coal is feed through tripper conveyer into the
bunker for regular generation of electricity and then flows from the
outlet into the feeder that transport it to the pulverizer which reduces
the size of the coal to 75 microns (100 mesh). Hot air is passed to
pulverizer to absorb moisture and blow the powdered coal to furnace.
And excess coal stored at the stackyard to use during lean period.

AIR AND FLUE GASES CYCLE:-

Primary Air :- Primary fan takes air from atmosphere then divide it
into two parts , it send one part to the air preheater and use other part
to adjust temperature . Hot air coming from air preheater goes to mil,
from mill it carries coal powder to the furnace and also removes the
moisture content from the coal.

Secondary Air:-Forced Draft fan also takes air from atmosphere and
then send it to the air preheater. Hot air coming out is then sent to the
furnace to carry out combustion.

At first induced fan is started which help to create negative pressure

inside the furnace. Then forced draft fan is started which supplies
secondary air to the furnace to carry out combustion. Then oil (LDO) is
supplied through oil guns and spark is ignited. After this the primary air
supplies coal from mill to the furnace. After burning completes flues
gases starts flowing. At first it flows to super heaters were it heats the
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main steam then it flows to the reheater were it heats the steam
coming from HP turbine. Then it flows to economizer where feed water
is heated then it flows to air preheater to heat primary and secondary
gases. After that it flows to electrostatic precipitator in which the ash
particles are filtered from gas and then it passed to chimney.

BOILER
The function of boiler is to generate steam at desired pressure and
temperature by transferring heat produced by burning of fuel in a
furnace to change water into steam.

There are many classifications of steam boilers according to the contents

in the tube, position of furnace, number of tubes, method of circulation
of water, use, heat sources etc. However in NTPC, water tube boiler is
used for steam generation.

SUPERHEATER
Fossil fuel power plants often have a superheater section in the steam
generating furnace. The steam passes through drying equipment inside
the steam drum on to the superheater, a set of tubes in the furnace. Here
the steam picks up more energy from hot flue gases outside the tubing
and its temperature is now superheated above the saturation
temperature. The superheated steam is then piped through the main
steam lines to the valves before the high pressure turbine
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 TYPE OF FAN
1.FORCED DRAFT FAN
• They are installed at inlet to the air preheater. Forced Draft Fans (FD)
supply the air necessary for fuel combustion by pushing the air
through combustion air supply system and into the furnace.
• Forced Draft fan produces pressure up to 510 mmwc at volume flow
rates 20 to100 m3/s and operates against temperature 25 to 50°C for
200 MW plant.
• These fans are typically the most efficient fans in the power

plant because they have the cleanest operating environment

2. PRIAMERY AIR FAN

• Supply high pressure primary air through APH needed to dry &
transport coal directly from the pulveriser to the furnace. PA fan
operate at temperature up to 70 °C and produces pressure up to
1187mmwc at 75 m3/s volume flow rate for
200MW plant
• Power requirement of PA fan is higher.

3.INDUSED DRAFT FAN

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 ● Located in between the ESP and foot of the stack. Sucks the
combustion gases out of the furnace and discharge them into the
stack.
● Handles large volume hot dust/ash laden flue gases which are
Exhaust from furnace. High power requirement than FD fan,it
require 1100 KW motor for 200MW plant.
● Induced-draft fans produces volume flow rate up to 225 m3/s
at inlet temperatures between 130 and 150°C and pressure ●
ranges from 356 mmwc for 200MW plant.

Process:-
Water-tube boiler consists of a furnace enclosed by the water
tubes. The crushed fuel from the crushers is fed into the boiler furnace.
The hot air from the Forced Draft (FD) fan is mixed with the
crushed fuel causing combustion of fuel. Combustion of fuel generates
a lot of radiation heat which is transferred to water in the tubes. Flue
gases generated during combustion travel at high velocity across the
convection bank of tubes thereby heating water through convection
heat transfer. Hot water is sent to a boiler drum at high pressure
through the feed-water pump. The boiler tubes which are in contact
with low temperature acts as down comers to circulate the water while
the tubes which are in contact with high temperature acts as risers to
carry steam. This leads to an effective circulation of water thereby
preventing the tubes from getting overheated.
The steam leaving the boiler is at saturated temperature and
pressure but there are a lot of heat losses during its transportation to
the turbines. So to increase the quality of steam, steam superheater
is used to increase its temperature and dryness fraction without
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increasing its pressure as well as to accommodate for the
transportation temperature losses.

TURBINE
● A thermal power station is a power plant in which heat energy is
converted to electric power.
● In most of the world the turbine issteam-driven. 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 and recycled to where it was heated; this is known as a
Ranking cycle.
● The greatest variation in the design of thermal power stations is
due to the different heat sources, fossil fuel dominates here,
although nuclear heat energy and solar heat energy are also used.

REHEATER
Power plant furnaces may have a reheater section containing tubes
heated by hot flue gases outside the tubes. Exhaust steam from the
heigh pressure turbine is passed through these heated tubes to collect
more energy before driving the intermediate and then low pressure
turbines.

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 CONDENSER
The main work of turbine is to condense the exhaust steam form the
turbine to reuse in the cycle. And to maximize turbine efficiency by
creating vacuuThe warm water from the condenser is cooled by cooling
towers or ponds and it provides a source of good and pure feed water
to the boiler. This reduces, considerably, the water softening plant
capacity. Air and non-condensate gases are also removed from the
steam when it passes through the condenser.

CONDENSATE AND FEED WATER

CYCLE:-

The condensate is pumped from hotwell using CEP (condensate

extraction pump) and send it to the GSC (gland steam condenser) were
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its temp is increased. Then it flows to CPU (condensate polishing unit)
were different parameters of steam were checked . After that it flows
to the several low pressure heaters were its temperature is further
increased. Then it flows to deaerator were inert gases were removed
from it .Then TDBFP (turbine driven boiler feed pump) pumps it and
send it to the high pressure heaters (HPH5, HPH6) and through FRS it
flows to economizer where it gets heated up with the help of flue gases.

STEAM CYCLE:-

As combustion takes place steam starts generating in the tubes. It then

flows to boiler drum. The drum stores the steam and acts as a separator
for the steam/water mixture. Then it flows through several super
heaters to get superheated steam. First it flows to LTSH (low temp
super heater) then DPNL ( divisional panel super heater) then Platen
super heater then it flows to final super heater . After that it flows to
the HP Turbine were it rotates the turbine then it comes out as CRH
steam (cold reheat steam) and flows to reheater through CRH line. After
reheating it comes out as HRH steam (hot reheat steam) and flows
through HRH line to IP Turbine. After rotating it, steam flows to the LP
Turbine from it , steam flows to the condenser were it get condensed
into water and stored in hot well.

CIRCULATING WATER SCHEME

• Reservior:- NTPC Korba takeswater from the Hasdev River.

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 • Canal:- It is an artifical channel used to carry water to the
field from reservoir.
• Intake channel:-It is RCC open trench from where raw water
is taken through canal.
• Trash rack:-To avoid entering wood, tree, branches, animal,
plastic, floating object.
• TWS(Travelling water screen):-It is a water filteration
device,it catches small piece of coal,graturbine thenc.
• CW pump(Circulating water pumps):-It is used to pump
cooling water to the condenser.
• Hot Pond:-It is a reservoir like structure which is used to
store the hot raw water coming from tubes of condenser.
• CT Pumps(Cooling tower pumps):- It pumps the hot water
at the top of the cooling tower.
Cooling tower:-It is a specialized heat exchanger in which air and water
are brought into direct contact with each other in order to reduce the
water’s temperature. There are following types of cooling tower:

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Process:-
In CW Scheme raw water taken from the reservoir which
carried to the plant through canal. Before entering to plant the raw
water passes through the trash rack which removes the unwanted
floating objects like trees, branches, animal, plastic, etc and then it
passes through the TWS which filter the small objects like small pieces
of coal, gravels, etc. After filtration this water goes through the tubes of
condenser by the help of CW pumps which reduces the temperature of
hot steam coming from the LP turbine and this steam became
condensate (DM water) and stored in hot well. After this the cooling
water becomes hot and gets collected in the hot pond. This hot water
through CT pumps goes to cooling tower which is collected at the top of
tower and allowed to trickle down through these baffles by gravity.
Meanwhile, cold air is drawn from the bottom of tower and forced up in
opposite direction to trickling droplets of water. Thus heat transfer
takes place between warm water and cool atmospheric air. After this
water is released in the reservoir or in the canal for recirculation.

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GENERATOR
The turbine generator consists of a series of steam turbine
interconnected to each other and a generator on a common shaft.
The generator consists of a stationary stater and a spinning rotor.
Electric generators work on the principle of Electromagnetic
induction Generators use an electromagnet; a magnet produced by
electricity. A basic electromagnetic generator has a series of insulated
coils of wire that form a stationary cylinder called a stator and
surrounding an electromagnetic shaft called a rotor.
Turning the rotor makes an electric current flow in each section of
the wire coil, which becomes a separate electric conductor. The
currents in the individual sections combine to form one large current.
This current is the electricity that moves from generators through
power lines to consumers.

SWITCH YARD
Switch-yard is a switching station which is the main link between the
generating plant and the transmission system. It can be considered
as the heart of the power plant, the generated power will only be
worthy if it can be transmitted and received by the consumers.
Switch-yard is a junction which carries the generated power to the
destination, it plays a major part in the security of the system, it can
control the reactive power devices which plays a major role in
power quality

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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, bed ash, fly ash
and ash clinkers resulting from the combustion of coal, wood and
● other solid fuels.

● 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 thrash
conveyor system.

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● Very finely sized fly ash often accounts for the major portion of the
material conveyed in an ash handling system.
● It is collected from bughouse type dust collectors, electrostatic
precipitators and other apparatus in the flue gas processingstream.
Ash mixers (conditioners) and dry dustless telescopic devices are
used to prepare ash for transfer from the ash storage silo to
transport vehicles.

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THANK YOU !

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