NLC INDIA LIMITED–NEYVELI

INTERNSHIP REPORT ON
OPERATION OF BOILER AND TURBINE OF 500MW THERMAL POWER PLANT
IN NEYVELI NEW THERMAL POWER STATION(NNTPS)

SUBMITTED BY
ABINASH A - 2051003

Under the Guidance of Mr. A. JAYAPRAKASH DCE/MECH

GOVERNMENT COLLEGE OF ENGINEERING, SALEM-636 011.

B.E MECHANICAL ENGINEERING

(An autonomous institution affiliated to anna university, Chennai)
SALEM-636 011, Tamil Nadu.

1
 (“NAVRATNA” – A GOVERNMENT OF INDIA ENTERPRISE’’)

NEYVELI, TAMIL NADU

BONAFIDE CERTIFICATE

Certified that the Internship Training titled “OPERATION OF BOILER AND

TURBINE OF 500MW” in NNTPS is the Bonafide work of,

ABINASH A - 2051003

BACHELOR OF ENGINEERING in department of MECHANICAL ENGINEERING

from “GOVERNMENT COLLEGE OF ENGINEERING, SALEM’’, Done during the
period from 12/06/2023 to 06/07/2023.

Their performance, conduct and attendance during the period were found to be
good.

DATE:06/07/2023 SIGNATURE OF GUIDE

PLACE: NEYVELI

2
 NLC INDIA LIMITED
(“NAVRATNA – A GOVERNMENT OF INDIA ENTERPRISE”)
CERTIFICATE
This is to certify that the internship report entitled “OPERATION OF BOILER AND
TURBINE OF 500MW” IN NLC INDIA LIMITED is the Bonafide internship report
done by ABINASH A, in partial fulfillment of the requirements for the award of
Bachelor of Degree in Mechanical Engineering from GOVERNMENT COLLEGE
OF ENGINEERING, SALEM-11. (An autonomous institution affiliated to anna
university, Chennai, approved by AICTE, accredited by NAAC). During the period
from 12.06.2023 to 06.07.2023 at NNTPS, NLC INDIA LIMITED, NEYVELI.

EXTERNAL GUIDE

SHRI. A. JAYAPRAKASH
Dy. Chief Engineer/Mech,
NNTPS NLC India Ltd.

Permitted to submit the internship training report to college/university authorities

DATE:12/07/2023
PLACE: NEYVELI
CHIEF MANAGER \
LEARNING & DEVELOPMENT CENTRE,
NLC INDIA LIMITED,
NEYVELI.

3
 NLC INDIA LIMITED
(“NAVRATNA – A GOVERNMENT OF INDIA ENTERPRISE”)

DECLARATION

We hereby declare that the Internship entitled “OPERATION OF BOILER AND

TURBINE OF 500MW” IN NLC INDIA LIMITED NEYVELI, submitted to
department of MECHANICAL ENGINEERING in GOVERNMENT
COLLEGE OF ENGINEERING, SALEM-11 for the degree of bachelor of
Engineering in a reward of original work done by myself under the guidance of
Mr. A. JAYAPRAKASH, DEPUTY CHIEF ENGINEER/MECHANICAL NNTPS,
NLC India Limited, Neyveli.

This internship report is for reference only and no part of the report will be published
copied anywhere without the written permission from officials of NLCIL, Neyveli.

Signature of the Student

DATE:06/07/2023
PLACE: NEYVELI

4
 ACKNOWLEDGMENT

We express our sincere thanks to NLC INDIA LIMITED for providing us the opportunity to carry out
the Internship Training.

We sincerely thank SHRI. B. SURIANARAYANAN, CGM/NNTPS for giving permission to

undergo internship training at NNTPS, SHRI. G. SENTHILKUMAR, GM/NNTPS/NLCIL for
providing the guidance for the internship training program during the 25 days in NLCIL, NEYVELI.

We also express our sincere thanks to Shri. ABRAHAM GEORGE, GM/L&DC & Shri. K.
PRABAKARAN/CM/L&DC for learning & development center providing us the opportunity to carry
out the Internship Training in NLCIL, NEYVELI.

We acknowledge my sincere gratitude to Shri. A. JAYAPRAKASH /DCE/NNTPS/NLCIL, Shri.

M.K. ANAND BABU /DCE/NNTPS/NLCIL internship guide.

We sincerely thank the officials in the Field Administrative office for providing the accommodation
and providing permission to enter the NNTPS

We sincerely thank all the respectful dignitaries in the NNTPS for providing great support for
successfully completing the internship training in the NLCIL, NEYVELI

We sincerely thank Dr. R. MALAYALAMURTHI, PRINCIPAL/GOVERNMENT COLLEGE

OF ENGINEERING SALEM for providing this opportunity

We sincerely thanks Dr. T BALUSAMY/HOD/MECHANICAL DEPT/GOVERNMENT

COLLEGE OF ENGINEERING SALEM for providing this opportunity for successfully completing
the internship training.

5
 INDEX

CH. NO CONTENT PAGE NO

1 About NLCIL 7
2 Basic layout 12
3 Boiler and its components
14
Introduction to boiler
Air and flue gas system 17
Components of boiler 22
Firing system 27
Ash handling system 32
SGDMCW 33
4 Turbine and its components
Introduction To steam turbine 34
Main turbine 36
HP and LP bypass 39
Extractions from turbine 40
Lube oil system 42
Monitoring of turbine 45
TGDMCW 47
5 Conclusion and Feedback 48

6
 Chapter-1

About NLCIL

NLC India Limited (NLC) (formerly Neyveli Lignite Corporation Limited) is a central
public sector undertaking under the administrative control of the Ministry of Coal, Since
1959, Government of India. Where its core businesses are mining & power generation. It
annually produces about 32.1 MTPA of lignite from opencast mines at Neyveli in the state of
Tamil Nadu in southern India and at Barsingsar in Bikaner district of Rajasthan state. And
coal of 20.0 MTPA with a total mining capacity 52.1 MTPA at present.

It has
• Five thermal power stations with a power producing capacity of 3640 MW.
• 51 MW wind power plant.
• 1350.06 MW solar power plant in Tamil Nadu.
• 20 MW solar power plant in Andaman & nicobar islands.

which results in an overall power generating capacity of 5061.06 MW (excl. JVs) and
6061.06 MW (incl. JVs)

It is marching towards 17171 MW by 2030

Thermal power Capacity Units x capacity

Status
plants (MW) (MW)
TPS-I 600 (6x50) + (3x100) Not Active
TPS-II 1470 7x210 Active
TPS-I Expansion 420 2x210 Active
Barsingar TPS 250 2x125 Active
TPS-II Expansion 500 2x250 Active
NNTPP 1000 2x500 Active

Upcoming projects

➢ Bithnok Thermal Power Project (250 MW) with linked Bithnok Lignite Mine (2.25
MTPA), Rajasthan

➢ NLC Talabira TPP (NTTPP) Phase-I (3 X 800 MW)

7
 ➢ Thermal Power Station -II Second Expansion 2x660 MW with linked Mine-III (11.5
MTPA), Neyveli Tamilnadu

➢ 510 MW solar power project under CPSU scheme

Thermal Power Station I

The Neyveli Thermal Power Station I has configuration of 600 MW (6x50-MW units and
3x100-MW units). All these units were commissioned between May 1962 and September
1970. The plant is equipped with boilers from the Taganrog Metallurgical Plant, turbines
from LMZ and generators from Electrosila, imported from the Soviet Union under Indo-
Soviet assistance programme. It was planned that the Neyveli Thermal Power Station I will
be decommissioned between 2011 and 2014; however, in 2011 the period of operations was
extended for five years.
Two units of 210 MW capacity each were also added under Stage I expansion which are
under commercial operation.
After the construction of Neyveli New Thermal Power Station, the first units were
decommissioned and only the two 210 MW units remain in operation.

8
Thermal Power Station II
The 1470 MW Second Thermal Power Station consists of 7 units of 210 MW each. In February
1978, the Government of India sanctioned the Second Thermal Power Station of 630 MW
capacity (3 X 210 MW) and in February 1983, the Government of India sanctioned the Second
Thermal Power Station Expansion from 630 MW to 1470 MW with addition of 4 units of 210
MW each. The first 210 MW unit was synchronized in March 1986 and the last unit (Unit-VII)
was synchronized in June 1993. The power generated from Second Thermal Power Station
after meeting the needs of Second Mine is shared by the Southern states viz., Tamil
Nadu, Kerala, Karnataka, Andhra Pradesh and Union Territory of Puducherry.

Thermal Power Station I - Expansion

Thermal Power Station-I has been expanded (2 x 210 MW) using the lignite available from
Mine-I expansion. The scheme, TPS I Expansion, was sanctioned by the Government of India
in February 1996. Unit-I was synchronized in October 2002 and Unit-II in July 2003. The
power generated from this Thermal Power Station, after meeting the internal requirements, is
shared by the Southern States viz., Tamil Nadu, Kerala, Karnataka, and Union Territory of
Puducherry.

9
Barsingsar Thermal Power Station
The Government of India sanctioned the Barsingsar Thermal Power Station 250 MW (2 X 125
MW) in October 2004. The units were commissioned in December 2011 and in January 2012.
The power generated from this Thermal Power Station after meeting internal requirements is
shared by the DISCOMS of the state of Rajasthan.
Thermal Power Station II - Expansion

This Project is consisting of two units of 250 MW capacity each. Unit-II attained commercial
operation in April 2015 and Unit-I in July 2015. The lignite requirement is met through
expansion of Mine-II. The steam generators of this project employ eco-friendly Circulating
Fluidised Bed Combustion (CFBC) technology. This technology has been adopted for 250 MW
capacity units for the first time in India.

10
NEYVELI NEW THERMAL POWER STATION
NNTPS is India's first 500 MW Lignite Fired Boiler, it comprises of two units. Unit 1
was commissioned on 28th December, 2019 and Unit 2 was commissioned on 10th
February, 2021.
The salient features of the NNTPP Boiler are it is a Drum less Boiler and operates in
Sub-critical pressure (below 221 bar) and once-through tower type boiler (water is
converted into steam in cycle itself). The type of Lignite firing system is Tangential,
pulverized fuel firing system
For removal of bottom ash, After Burning Grate (ABG) and Submerged Slag Conveyor
(SSC) System are used.
The type of draft used for the boiler is Balanced Draft System consisting of 2 units of
FD and ID Fans (2 X 60 % of duty), along with 1 RAPH and SCAPH. Electrostatic
Precipitators have 4 Pass and 12 Electric field in each pass with collection efficiency
of 99.70% and exit SPM (Suspended Particulate Matter,) level of 50mg/Nm.
Similarly, the salient features of the Turbine-Generator package are it's a 500 MW
multi cylinder, horizontal, tandem compounded, Re-Heat, Regenerative, condensing
& throttle governing.
The HP Turbine has 17 reaction stages, double casing, single flow. The IP Turbine is
Double flow, 2X12 stages, double casing. The LP Turbine is double flow 2X6 stages
& double casing. Generator is 500 MW, 2 pole, 3-phase system with cylindrical rotor,
water cooled stator and Hydrogen cooled rotor.

Chapter-2

11
 Basic layouts

IPT

HRH

RH-2

RH-1

CEP- Condensate Extraction Pump IPT- Intermediate Pressure Turbine

GSC- Glance Steam Condenser LPT- Low Pressure Turbine
CPU- Condensate Polishing Unit HRH- Hot Reheat
LPH- Low Pressure Heater RH- Reheat
BFP- Boiler Feed Pump CRH- Cold Reheater
HPH- High Pressure Heater HPT- High Pressure Turbine
SH- Super Heater

12
General layout of modern steam turbine and T-S diagram

13
 Chapter – 3

Boiler and its components

Introduction to Boiler

Classification of boilers

• Drum or Drum-less
• Subcritical or supercritical

Drum boilers

A steam drum is a standard feature of a water-tube boiler.

It is a reservoir of water/steam at the top end of the water tubes.
The drum stores the steam generated in the water tubes and acts
as a phase-separator for the steam/water mixture.

Drum-less boilers

This is a drum-less and high-pressure boiler. This

boiler has a unique characteristic of an absence of steam
separating the drum. The entire process of heating,
steam generation, and superheating are done in a
single continuous tube

14
Subcritical boilers
Subcritical boilers, also known as conventional boilers, are a type of steam-
generating boiler used in power plants. They operate below the critical pressure and
temperature of water (less than 221.2 bar and 374.150C), which refers to the point where
water and steam can coexist without phase transition. Subcritical boilers are widely used, but
they have lower thermal efficiency compared to supercritical boilers. In this type of boiler
there will be formation of bubbles

Supercritical boilers
Supercritical boilers are advanced steam-generating boilers used in power plants.
They operate at above critical pressure and temperature (greater than 221.2 bar and
374.15oC), surpassing the critical point of water. Supercritical boilers offer higher thermal
efficiency, improved power output, and reduced emissions compared to subcritical boilers.
Here there will be no formation of bubbles and the water turns into stream in cycle itself

Pc= 221 bar

Tc= 374.15oC

15
Boiler technical data

Type : Once through, Benson type, balanced draft(FD fan + ID fan),

Tower type, tangential firing system.

Manufacturer : ALSTOM boilers Deutschland GmbH

Boiler Design Pressure : 199.1 kg/cm²

RH Design Pressure : 54.1 kg/cm²

Main Fuel : Lignite

Start Up Fuel : Light Diesel oil, Heavy Fuel oil

Burners Type : Tangential arranged Jet burners

Number of Burners : 8 Lignite and 8 Oil Burners

Mills Type : Beater wheel mills N280.36 S

Number Of Mills :8

The boiler mainly comprises of

• Air and flue gas system
• Boiler components
• Firing system
• Ash handling system
• SGDMCW

16
Air and flue gas system

Air system
Air is necessary thing in a steam power plant it does things like drying the pulverized wet
lignite, combustion, to avoid formation of pollutants in flue gas. We collect the air from
atmosphere which are at ambient condition with humidity and less temperature compared to
our requirements
We will first collect the using FD fan (forced draft) which present at the ground level. We have
two FD fan for each boiler. The flow rate of air is controlled using the adjustment propeller
blades and amount of air required is depends on the load.

So, we usually have two methods to pre heat the air

1) RAPH - Regenerative air pre-heating

In this we use regenerative heat exchanger to exchange heat between hot flue gas coming out
of economizer and the ambient air that coming from FD fan. Flue gas and air passes through a
circular rotating rotor with motor as prime mover which contains called matrix which absorbs
heat and releases heat to the air.
That matrix contains many baskets which is made corton steel and carbon steel which is
capable to store more amount heat. The air and flue gas flow in a counter flow direction. The
advantage of this is not only pre heating the air and it reduce flue gas temperate before it
reaches atmosphere

2) SCAPH - Steam coil air pre heating

17
During in the start of steam power plant we actually won’t have any flue gas to preheat the air
in RAPH instead we use SCAPH in which the air is passed over the coils where in hot stream
steam flows inside it. We actually get that hot steam using auxiliary boiler or from another
boiler present adjacent unit when it is on operation
We commonly use four types of air according to its use
i. Primary air
ii. Secondary air
iii. Overfire air
iv. Grate air

18
Primary air
Here the primary air is used for control the flue gas temperature that going to mill inlet. Used
for mill tempering.

Secondary air

As air supplied wet lignite (Primary air) is less in quantity for combustion it not sufficient for
complete combustion & some quantity of air must be supplied additionally to combustion so
Over fire air
It is mainly used to reduce the formation of pollutant like NOX in flue gas
Grate air
This air is supplied from the bottom of the furnace usually used to burn the unburnt lignite It
is used for secondary combustion in ABG (after burning grate).

FD fan details
Make : BHEL, rainpet.
Medium : atmospheric air
Location : outdoor
Fan design rating
Capacity (m3/s) : 350
Temp of medium : 50oC
Speed (rpm) : 990

FD fan lube oil system

Make : CENLUB industries limited
System flow rate : 40 LPM
Working pressure : 35 bar
Working fluid : ISO-VG-68
Oil cooler type : shell & tube type
Oil in /out temp : 60/45oC
Water flow rate :100LPM
Water in /out temp : 38/40oC

19
FLUE GAS SYSTEM

The flue gas is mainly used to

• Preheat the air in RAPH
• Preheat the feed water in economizer
• Used to dry the wet lignite and supplied during pulverization of lignite in mills using
FGRSD (flue gas re-suction duct)

Flue gas are removed with the help of Induced draft fans or ID fans. Which are are used in
systems such as steam boilers and thermal oil heaters to draw out and remove flue gases from
combustion chambers, by creating a vacuum of negative air pressure (typically -10 mm Hg).
This is achieved by using a blower to suck air through the combustion chamber and the rest
of the system, before discharging the air and flue gas through a stack or chimney.

Draft, is commonly referred to as the difference between the atmospheric pressure and the
pressure existing within a flue gas passage or the furnace of a boiler system. When the flow
of flue gas and air become influenced by the effect of a gradually decreasing pressure below
atmospheric pressure, this is referred to as induced draft.

20
Flue gas temperature, deg. BCMR TMCR
Celsius
Theoretical combustion zone temp 1543 1539
Furnace exit 1069 1048
SH -1 inlet 1069 1048
SH -1outlet 1024 1000
SH -3 inlet 1024 1000
SH -3 outlet 921 896
RH-2 inlet 921 896
RH-2 outlet 797 774
SH-2 inlet 797 774
SH-2 outlet 626 607
RH-1 inlet 797 774
RH-1 outlet 490 476
Economizer inlet 490 476
Economizer outlet 361 351
RAPH inlet 361 351
RAPH outlet 155 158
Electrostatic precipitator inlet 154 150
Electrostatic precipitator outlet 154 150
ID fan inlet 154 150
ID fan outlet 154 150
Stack inlet 154 150

21
Components of boiler

The furnace consists of several components like economizer superheater, reheater, cyclone
separators, soot blowers, and leveling vessel etc.

22
Economizer

The function of the economizer is to recover a portion of heat of the exhaust gases before the
flue gases enter the chimney and discharged to the atmosphere. The economizer is placed in
the path of the flue gases in between the boiler exit and entry to the RAPH. Feed water
coming from the boiler feed pump when passed through the economizer tubes absorbs the
heat in the exhaust gases. This increases the temperature of water entering the boiler. Due to
the high temperature of feed water, fuel consumption reduces, and this increases the overall
thermal efficiency of the boiler.

Cyclone separator

We have 4 cyclone separators for each boiler. It is a conical shaped device, which is used to
remove and separate water content from steam mixture. This is achieved by using vortex
separation. This makes an important role because the water that should not travel along with
the stream to the superheater pipe lines, if it happens staggering would happen and in which it
would lead to be damage the pipes. The quality of steam also increases by removing water
content.

The working this device is explain below

When water and steam mixture is fed into a cyclone chamber,

lighter particulates are carried along with the rotating steam
flow. However, heavier particulates, which are much denser,
are said to have too much inertia and are therefore unable to
follow the tight curves of the stream. As a result, the path of
heavier particulates remains uninfluenced by the high speed
of the rotating airflow and they instead continue to travel in
a straight line. This causes them to collide with the outer walls
of the cyclone chamber, breaking their path and resulting in
them falling to the bottom of the chamber, where they are then
collected and sent to levelling vessel.

23
Levelling vessel

It is an intermediate storage vessel for the recirculation water. The system levelling vessel
plus recirculation lines are designed to hod the full feedwater capacity for the opening time of
the startup drains control valve. From levelling vessel, the water is pumped to the feed water
line before economizer using boiler circulating pump.

Superheaters

The functions of the superheater are to remove the last traces of moisture from the saturated
steam coming out of boiler and to increase its temperature above saturation temperature.
Superheating increases overall cycle efficiency as well as avoids too much condensation in
the last stages of the turbine to avoid blade corrosion.

Clearly in the TS diagram given we can see two isentropic expansions (saturated steam )2 to
3 and (superheated steam)2a to 3a.

At the end of the expansion of saturated steam the quality of steam gets reduced more that of
expansion of superheated steam. Usually, we maintain dryness factor above 0.87 otherwise
corrosion will occur on the blades. And the relative velocity of water and stream are both
different so that at end stage of turbine blades would get damaged.

The material used in all these tubes are SA-213-T91 (seamless ferritic and austenitic alloy steel). And
we have three superheaters.

24
 Superheater SH-1 SH-2 SH-3
Heat transfer mode Radiative Convective Radiative
Type of flow counter parallel counter
Max steam side metal temperature oC 529 562 590
o
Steam inlet temp C (BCMR) 383 402 479
Steam outlet temp oC (BCMR) 414 500 540
Effective surface area m2 2842 10758 2411
Outer diameter, mm 38.1 44.5 44.5
Actual thickness used, mm 5.6 5.6 5.6
Total no of tubes 792 656 440

Reheater

In this method, the exhaust steam from the high-pressure turbine is reheated to high temp
around 565oC. After reheating, the steam is fed to the intermediate-pressure turbine for
further expansion and to do useful work and to low pressure turbine. The main purpose for
the reheating is to improve the cycle efficiency

The temperature of steam at IP turbine exhaust will be around 331.4 oC If we allow the HP
exhaust steam directly to the IP turbine then IP and LP turbines should be constructed larger
because as the steam expands specific volume increases, and then the stream will be already
wet it we continue to pass in IP turbine the blades will get damaged and corroded. And even
the stream may also condense

We two reheaters here and their tubes are made of the material SA-213-T11/T22/T91

25
 Reheater RH-1 RH-2
Max steam side metal temperature oC 611 607
Steam temp inlet oC (BCMR) 331 440
Steam temp outlet oC (BCMR) 472 568
Effective surface area 17293 5054
Outer diameter, mm 47.63 57
Design pressure, bar 56 55
Max operating pressure, bar 44 43
Total no of tubes 1476 720

Long retractable soot blowers (LRSB)

The products of combustion, namely, dust, soot, particulates, fly ash, carbon ash (cinder), etc.
cling to the water tubes, economizer tubes, air preheater tubes and superheater tubes which is
called clingers. These results in reduced heat transfer and boiler efficiency. Hence, these
deposits should be regularly removed for efficient working of boilers. This method of
removing soot is known as soot blowing.

Soot blower consists of a set of tubes fitted with nozzles carrying high-velocity jet of steam
or air. In the hotter parts of the boiler, the blower advances into the furnace, cleans the heat
transfer surfaces

26
Firing system

We have two firing system here

• lignite firing system
• Oil firing system

Lignite firing system

We totally have eight bunkers in which the lignite is stored which comes from lignite storage
plant, for each bunker there will be three feeders. The feeders supply the lignite according to
the load required by varying the motor speed in feeder. In which we can even supply lignite
with the help one feeder at time of service of other two.

From the feeder the lignite goes in the belt conveyor to each mill, we totally have 10
conveyors, for the mill 50 and 40 alone we use two conveyors which are also called long
conveyors

27
From the conveyors the wet lignite is supplied to mills. Here two beater type of mills are used
in each side of the boiler. There the four sides present in the boiler which are front, rear, right
and left. The two mills that present on each side will rotates on opposite direction.
In the mill the lignite gets finely pulverized according to the standards, there should be a
proper size maintained for pulverized lignite because the more the finer more the fly ash will
be produced so that we need to look more on ash handling.
Initially, the wet lignite is put on the mill and the flue gas also comes along with the lignite to
make it dry. The flue gas comes from the FGRSD (flue gas re suction duct present) above the
mill.

28
Mill rotor is connected to the double bearing which connected hydro coupling. The main
purpose hydro coupling is to vary the speed of the mill according to the load because we
can’t vary the speed of the motor, which is fixed that why we are using hydro coupling. Then
the pulverized lignite goes to classifier in which uncrushed lignite returns back to the mill and
remaining goes to the furnace.
The lignite is actually a low-grade fuel because its calorific value is less compared to other
form of lignite.

Solid fuel Calorific value (kJ/kg)

wood 10500
Peat 14650
Lignite 12500
Bituminous 32000
Anthracite 35500

Oil firing system

we usually use to types of oil for ignition
• HFO-heavy fuel oil
• LDO- light diesel oil
The calorific value of HFO is higher than the LDO, here they use eight oil burners and in that
we atomize the fuel while injecting.
For atomizing HFO we use steam.
For atomizing LDO we use air.

29
This firing system is mainly used on the start of the boiler. Even though the oil is not used,
the oil is pumped for all the time to the furnace and then comes back to the storage tank itself.
To keep the oil in the heated state the spiral coils are present around the tank in which the
stream passes inside the coil and goes to the vent.

First the oil is filled on the tank using separate unloading system.

From the tank oil first goes to the suction filter then to the pump, after the oil is gets heated
by the steam in the shell and tube exchanger and again it goes to another filter then to the
furnace to the injector. Then the unused oil comes back to the return lines to the tank.

We have three types of startups used for starting of a boiler.

• Cold startup
• Warm startup
• Hot startup

For the startup activity every plant is having their different theory and design. The
start-up procedures are mainly categorized depending on the Turbine conditions. As Turbine
is the most crucial equipment in the plant, more attention is given to the turbine. If
precautions are not taken properly during start-up then it may lead to turbine damage. The
nomenclatures for various types of start-up procedures are different depending on the
designs

30
Cold Startup :(If the HPT (high pressure turbine) casing metal temperature is less than150
degree C. then it is called the cold startup)

Warm Startup:(IftheHPTcasingmetaltemperatureisbetween150–350degree C.
Then it is Called the warm startup)

Hot Startup :(If the HPT casing metal temperature is above 350degree C. then it is
Called the Hot startup)

Very Hot Startup: in some plant very, hot startup is a new mode of light up. In which if
HPT Casing metal temperature is between 350–450degree C then it is called the hot
Start up. And above 450degree C of metal they called very hot start up.

In the same manner, in some plant shutdown timing of boiler is also important for light up
activity. For example, after 48 hour of shutdown the light-up is called the Cold Startup, but in
the same time it also has to satisfy the turbine casing metal temperature characteristic/criteria.
From 8 to 48 hours of shutdown is called Warm Startup and before 8 hours of shutdown it is
called the Hot Startup. This light up and shutdown terms vary from plant to plant and their data
may also be different for different startups.

The main difference between all the start-up types is that the steam temperature criteria. The
Steam temperature should be 50°C more than the turbine metal temperature. As compared
to Cold Startup, in Hot Startup, the soaking time (time required to maintain the differential
expansion in the turbine within a permissible limit) of the turbine is less because in Hot Startup,
already sufficient amount of metal temperature is there.

In Cold Startup, the load increase rate is also less as compared to hot startup. Because in cold
startup there is a chance of thermal deformation of the turbine (Thermal Stress) so we require
gradual heating of the material. The time for the Cold Startup is approximately 6 to 8 hours,
for Warm Startup this time is 3 to 6 hours and for Hot Startup, this time is 1-3 hours.

31
Ash handling system

We get two types of ash which are

• Bottom ash handled by submerged slag conveyor (SSC)
• Fly ash use electrostatic precipitator (ESP)

Submerged slag conveyor (SSC)

From the ABG the bottom ash is collected at the bottom of the furnace in the sluice path then
to the breaker in which the larger particles get breaks into smaller one then it is collected on
SSC which contains full of water to avoid flying of ash. The clingers also collected in the
bottom ash

Electrostatic precipitator (ESP)

With stringent air quality restriction by the governments, a majority of the power plants in the
world use electrostatic precipitators (ESPs) for dust removal. An ESP can handle large
volumes of flue gases accompanied low pressure drop and high collection efficiency
(99.5 per cent).

It facilitates easy removal of dust particles. It consists of two sets of electrodes:

the emitting or discharging electrode and collecting electrode.
The emitting electrodes are connected to negative polarity of high-voltage (20–100 kV) DC
source. The collecting electrodes are connected to the positive polarity of the source and
earthed.

When high voltage is applied, it generates a unidirectional non-uniform electric field having
greater magnitude at the discharge electrodes. This results in a blue luminous glow, called a
corona around them. This corona is an indication of negatively charged ionized gas molecules
that travel from discharge electrodes to grounded collection electrodes. The dust particles
thus get deposited on the collector electrodes and lose their charge. The remaining dust
particles cling to the electrode surface due to electrical resistivity, and are removed by
rapping the electrodes using rapping motors.

32
SGDMCW
SGDMCW- Steam generator demineralized cooling water

The main purpose of this system is to cool all the parts, lube oil etc. which are related boiler
side. First the hot DM water is passed to the plate heat exchanger in the auxiliary cooling
water comes from the auxiliary pump house, for that the source is the cooling water that
coming from cooling tower which goes to the condenser. The cold DM water goes to all
mills, ID fan, FD fan, boiler circulating pump. It contains two pumps in which one is standby
and four plate heat exchangers designed to withstand the pressure of 12 bar.

Auxiliary boiler

We also have an auxiliary boiler which common for both plant the purpose of auxiliary boiler
is to supply the steam for starting of the boiler. where the auxiliary boiler is only fueled by
the LDO.
The purpose of steam while firing the boiler is to
• Seal the turbine using glance steam to create vacuum in it so that steam can flow
• To pre heat the air in we need steam to be passed on the SCAPH
• For atomization of HDO
• For supply for the TDBFP

33
 Chapter – 4
Turbine and its components

Introduction to Steam Turbine

Steam turbine is one of the principal prime movers used for electric power generation. The
steam turbine obtains its motive power from change of momentum of a jet of steam flowing
over a curved vane. The steam jet exerts a pressure on the blade when it is moved over the
curved surface of the blade, owing to its centrifugal force. The centrifugal pressure is exerted
normal to the blade surface and acts along the whole length of the blade. The resultant of
centrifugal pressure, plus the effect of change of velocity, is the motive force on the blade.
In a steam turbine, a number of small blades are fixed to the rim of a revolving wheel or
rotor. High-velocity jets of steam are obtained by expansion through nozzles and are directed
on to the blades. The effective force of these jets, acting on the blades, rotates the wheel.
There are two types of steam turbine. Which are
• Impulse turbine
• Reaction turbine
Impulse turbine
In impulse turbine, high-velocity steam coming out from the nozzle strikes the blades fixed
on the periphery of the rotor. The passage of steam through the moving part of the turbine
(blades) takes place in such a manner that the pressure at the outlet end of the blade equals to
that at the inlet end. The net force acting on the blades results in change in momentum due to
which the turbine shaft rotates.

34
Reaction turbine
In this type of turbine, steam does not get expanded in the nozzles, but expanded as it flows
over the blades. Unlike impulse turbines, the blades are not symmetrical. The blades also act
as nozzles. The drop in pressure of the steam during its flow through nozzles and moving
blades results in an increase in the kinetic energy. The resulting propelling force gives a
rotary motion to the turbine rotor. Due to change of velocity, the rotating element exerts a
thrust or reaction on the blades tangentially. The reaction constitutes the driving force, and
hence is called reaction turbine.

What is the main difference between the reaction and impulse turbine?
And the main difference between the both the turbine is the pressure drop that occurs on each
stage of the reaction turbine we can even note this on the diagram of reaction turbine. But in
impulse turbine the pressure drop occurs on the nozzle only and the pressure remains constant
during the other stages.
Why we prefer steam turbine for prime mover?
Turbines are highly simplified in construction as no reciprocating parts are present. This
reduces the wear and tear of the parts due to friction, and hence results in less maintenance
and the balancing of masses is easier as turbine contains rotating masses that’s why we use
turbine as the prime mover rather than other prime movers like reciprocating engine.
Why we should use multi stage blade?
As the absolute velocity becomes very high in a single turbine, blade velocity also becomes
very high. As high velocity causes centrifugal stresses on the blades resulting in structural
failure, multistage is preferred to overcome these problems.

In this power plant they use reaction turbine with multistage.

35
Main turbine
They have used three set of turbines used in this power plant not only in this, in most steam
power plant we follow the same
HPT- High pressure turbine
IPT- Intermediate pressure turbine
LPT- Low pressure turbine

General Specifications:
Make : BHEL
Design : KWU, West Germany
Type : Three Cylinder Reheat Condensing Turbine
Stages : HPT 17 Reaction stages.
IPT 12 X 2 Reaction stages
LPT 6 X 2 Reaction stages

Valves : HPT -2 Main Stop and Control

Valves
IPT -2 Reheat Stop and Control
Valve
CRH line – 1 Swing Check
Valve
LPBP – 2 Bypass Stop and Control Valves
Direction of Rotation : ACW (Viewed from front pedestal
Towards Generator)
Rated load : 500 MW
Maximum load : 525 MW (valve wide open condition)
Rated Speed : 50 C/Sec
Maximum Speed l : 51.5 C/Sec (No Time Limitation)
Minimum Speed : 47.5 C/Sec (No Time Limitation)
Speed Exclusion Range (without load) : 7 to 47.5 C/Sec
Standard Over Speed Trip Setting : Max. 55.5 C/Sec

36
HPT

No of stages 17 Reaction stages

Type single/double flow Single

Material of the fixed First stage X 22 Cr Mo V 121

blades
Other stage X 20 Cr Mo 13

Material of the moving First stage X 22 Cr Mo V 121

blades
Other stage X 20 Cr Mo 13

Temperature of steam Inlet 540

in oC Outlet 331

Pressure of steam Inlet 166.7

in bar Outlet 39.41

Casing material GS-17 Cr. Mo V 511

Rotor material 28 Cr Mo N V 59

Load sharing 26 %

IPT
No of stages IPT 12 X 2 Reaction stages
Type single/double flow Double flow

Material of the fixed First stage X22 Cr MO V 121

blades
Other stage X 20 Cr Mo 13

Material of the moving blades X22 Cr MO V 121

Temperature of steam Inlet 568
in oC Outlet 307.8

Pressure of steam Inlet 42.83

in bar Outlet 6.83

Casing material GS-22 Mo 4

Rotor material 30 Cr Mo Ni V 511

Load sharing 34 %

37
LPT

No of stages LPT 6 X 2 Reaction stages

Type single/double flow double flow

Material of the fixed First stage X20 Cr 13

blades
Other stage X20 Cr Mo 13

Material of the moving blades X20 Cr 13

Temperature of steam Inlet 307.8
in oC Outlet 47.3

Pressure of steam Inlet 6.83

in bar Outlet 0.1080

Casing material R St.37-2N

Rotor material 26 Ni Cr. Mo V 145

Load sharing 40 %

TURBINE SEAL STEAM SYSTEM

The turbine gland sealing system (TGSS) prevents the escape of steam from the turbine shaft
and casing penetrations and the glands of main steam stop and control valves. This system
also prevents air leakage into the low-pressure turbine glands.

38
HP bypass and LP bypass

HP bypass and LP bypass

HP Bypass:
When the respective parameter values are not obtained (like during start up), The main steam
is not passed on to the HP Turbine because those blades and casing are designed to work on
specific parameters. So, until we get the specific parameters the steam is not passed onto Hp
Turbine (The steam is bypassed) before entering the HP Turbine into the CRH line. The CRH
line is designed to withstand a limited pressure and temperature, so the main steam which is
bypassed is passed on through a spray of water jet(source is from TDBFP) , so that the
parameter values are decreased accordingly to the CRH line.
This actually not only done at the startup of the plant but also during certain times like
tripping of any components due to axial shift of shaft, and during increase in temperature in
parts like bearings and pedestals and also lube oil temperature. Therefore, it is necessary to
provide cooling systems for each component.
LP Bypass:
Here also the respective parameter values are not obtained, the main steam from the Reheater
is not passed on to the IP Turbine as required parameters are not obtained. So The steam is
not passed onto IP Turbine (The steam is bypassed) and LP Turbine and is passed directly to
the Condenser. Before passing to the condenser, there will be a spray valve that helps to
reduce temperature in which the source of water spray is condensate extraction pump (CEP).

39
Extractions from Turbines

In steam power plants, it has become a standard practice to modify the usual cycle of
operation to increase the thermal efficiency. One such practice is to extract steam at one or
more points from a steam turbine when steam expands. This heat carried by steam is utilized
to heat the feed water.

The extracted steam produces heat by condensing either in a direct contact feed heater (FH)
or in surface condenser. This boiler is supplied with high-temperature feed water. This
process of tapping steam at intermediate points in the steam turbine is known as bleeding.

In here they use surface contact condensers to transfer the heat from the extracted steam to
the feed water. After the heat exchange, the steam will directly go to the flash tank.

We have Three number of extractions from LP Turbine which is passed to Three LP heaters.
Similarly, there are two extractions from the IP turbines to the HP heaters and also to the
deaerator and source of steam for TDBFP. And The extraction from the HP Turbine exhaust (
CRH line) is also used to heat specific HP heaters.

All the extracted steam that comes from the LP heaters with cascading network goes to the
LP flash tank which is situated near the condenser.

Similarly, the extracted steam from the HP heaters goes to the HP flash tank.

The extractions from Each turbine are tabulated below as follows

40
 Extractions Source Going To
1 LPT – 5th stage LPH-1
2 LPT – 3rd stage LPH-2
3 LPT – 2nd stage LPH-3
4 IPT Exhaust Deaerator (4.1) and TDBFP-A/B (4.2)
5 IPT –7th stage HPH – 5A/5B
6 CRH HPH – 6A/6B,

Extraction 1 : No valve
Extraction 2 : 1 swing check valve with actuator and
1 swing check valve without actuator.
Extraction 3 : 1 swing check valve with actuator and
1 swing check valve without actuator

Extraction 4.1 : 2 swing check valves with actuator.

Extraction 4.2 : 2 swing check valves with actuator
Extraction 5 : 1 swing check valve with actuator and
1 swing check valve without actuator.
Extraction 6 : No valve.

Parameter Pressure (bar) o

Temperatures ( C)
Initial steam 166.7 537
Before 1st stage of HPT 156.0 565
HP cylinder exhaust 42.83 331.4
IP cylinder stop valve Inlet 39.41 565
Extraction 6 42.83 331.4
Extraction 5 17.61 444
Extraction 4 6.83 307.8
Extraction 3 2.70 206.7
Extraction 2 1.418 146.0
Extraction 1 0.336 71.8
LP cylinder exhaust 0.1080 47.3

41
Lube oil system

The main purpose of the lube oil system is to reduce the friction in the bearings and to
maintain the temperature of the bearings. Here they have totally seven pedestals on which the
bearings are placed. The lube oil is supplied to the pedestals by auxiliary oil pumps (AOP) at
the beginning when the turbine reaches a certain speed the main oil pump pumps the oil from
the tank which is situated in front of the first pedestal.
Here the main components used are
• MOP
• AOP
• EOP
• Shell-Tube HX
• Centrifuge pump
• Duplex filter
• Temperature control valve
• Vapor extraction fan
The pumps are submerged in the tanks and the motor is situated above the tank. The oil is
first pumped to the temperature control valve where the load temperature oil is separated and
directly goes to the main turbine for lubrication. The hot oil goes to shell-tube HX for the
purpose of cooling. Here the cooling water is supplied from the TGDMCW.

42
After the cooling, the oil is transferred to Duplex filter (Filtration Particle size of 25 µm) and
then to the main turbine. The vapor which is formed inside the oil tank is extracted and
passed onto atmosphere using the vapor extraction fan in order to avoid increase of pressure
inside the tank.
Centrifuge pump
To continuously regulate the purity of the oil and to separate the denser molecules, the oil is
passed to centrifuge pump.

Centrifugal filtration or centrifugation is a process that is used to separate (and concentrate)

contaminants suspended in a liquid medium. A centrifuge will rotate the lubricating liquid at
high speeds to separate the particulates from the liquid.
JOP (Jack oil pump)
Due to the gravity, the horizontal shaft remains with the surface. So, in order to lift the shaft
from the surface, the oil is supplied with high pressure near the bottom of the shaft to make it
float or lifted.

The specification the lube oil system is listed below

43
 MOP AOP EOP AC JOP

Number
1 2 1 2
Make BHEL Mather & KBL Parker
Platt
Capacity
(LPM) 5250 6900 1800 111.6
Discharge Pr.
(bar) 8.56 6.43 2.3 180
Speed (RPM)
3000 1485 2950 1450
Drive AC
Turbine Motor DC Motor AC Motor

TG Main Lube Oil Tank

3
MOT capacity : 25/40 m
st
1 oil filling : 53 m3
3
Flushing oil quantity : 32 m
Tank filter element : 250 µm

Lube oil specifications (Turbine Oil ISO VG 46):

Oil Brand : Servo Prime 46 (IOC)
o
Kinematic viscosity : 41.4 – 50.6 cst at 40 C,
o
28 cst at 50 C
Viscosity index : 98 min
Flash point : > 200 0C
o
Pour point : ≤ -6 C
o
Specific gravity : 0.85 at 50 C

44
Monitoring of turbine
Motoring refers to the state when the generator propels the turbine at its designated speed
while the stop and control valves remain closed. During this mode of operation, specific
turbine components experience heating due to the windage power generated by the blades.
To avoid exceeding permissible temperatures and causing excessive heat buildup, the
motoring state should not be sustained for more than one minute. Additionally, if the
condenser's low vacuum limit of 0.3 bar is surpassed, motoring should not be extended
beyond 4 seconds.
The turbine will get tripped when the parameters that measured when leaves out of the
standard value. The measurements that are taken are
• Vacuum pressure
• Axial shift
• Differential expansions
• Vibrations
• Bearing temperature

Low vacuum trip standard settings:

We should maintain low vacuum because then only the steam flows

Electrical Low Vacuum Trip 0.3 bar

Electrical Low Vacuum Trip Bypass 0.6 bar
operation

Axial Shift:

Axial shift of a steam turbine is the shifting of turbine rotor in the forward and backward
direction due to steam thrust on blades of rotor. Reason is, Sudden change of load.
Sudden drop of vacuum.

Alarm Trip
± 0.5 mm ± 1 mm

45
Differential Expansions:

• It is the difference between the rotor expansion and the Casing Expansion.
• It is positive if rotor expands more than casing.
• It is negative if casing expands more than rotor.

HPT -5.0 to +3.5 mm

IPT -1.0 to +5.5 mm
Overall Expansion of IP + LP Rotor -3 to + 30 mm

Vibration:

The problem of vibration is generally originated when rotors in the turbines bend. This
bending often occurs during some of the turbine's operational evolutions, leading to
vibration or even system failure down the line

Absolute Brg. housing Absolute Shaft Vibration

Vibration (Peak to Peak) (Peak to Peak)
Standard Alarm setting 50 µm above normal level
Maximum Alarm setting 84 µm 200 µm
Limit Value for Tripping 106 µm 320 µm

Bearing temperature:

A higher operating temperature will cause the bearing lubricant to deteriorate at a faster
rate.

Sl. No Bearing Babbit Metal Temperature Alarm (°C) Shutdown at (°C)

a) Operation Temperature below 75°c 90 130
b) Operation Temperature 75°c to 85°c 100 130
c) Operation Temperature 85°c to 90°c 110 130
d) Operation Temperature above 90°c 115 130

46
TGDMCW

TGDMCW – Turbine generator demineralized cooing water

we have totally 3 pumps in TGDMCW System. The main purpose of this cooling water is to
provide cooling for all the turbine related components. It provides cooling for parts like stator
of generator and lube oil, TDBFP Etc., initially the hot DM water s pumped to the plate heat
exchangers (3 in no’s) to cool the DM water. Here the cold fluid comes from the cooling
tower.

TDBFP
TDBFP- turbine driven boiler feed pump
It consists of two pumps which is a booster pump and a main pump. For both this pump the
prime mover is steam turbine which is common for both the pump. It pumps the feed water
from the deaerator to HP heaters then to the economizer.
The source of extractions of TDBFP are
• From IP turbine extractions
• From CRH
• From Aux steam high temperature header
And the used steam goes to the condenser and some to the vents to the atmosphere
They also have MDBFP (Motor driven boiler feed pump) operated during in service of
TDBFP.

47
 Chapter-5
Conclusion

During my 25days of internship training at the NNTPS, I have gained invaluable knowledge
and hands-on experience that has significantly enriched my understanding of power
generation systems. Throughout this period, I have learned the following key aspects:

1. Power Plant Operations: I acquired a comprehensive understanding of the overall

operations of a thermal power plant, including the functioning of various equipment and
systems such as boilers, turbines, generators, condensers, and cooling systems. I learned
about their interconnections and the importance of maintaining optimal operating conditions.
2. Safety Protocols: Safety was of paramount importance during my training. I received
extensive training on safety protocols, hazard identification, emergency procedures, and the
proper use of personal protective equipment (PPE). I developed a strong awareness of
potential risks and the importance of adhering to safety guidelines to ensure a secure working
environment.
3. Maintenance and Troubleshooting: I gained practical experience in conducting routine
maintenance tasks, such as equipment inspections, lubrication, and cleaning. Additionally, I
learned about troubleshooting techniques to identify and resolve common issues that can arise
in power plant systems. This experience enhanced my problem-solving skills and taught me
the significance of preventive maintenance.
4. Efficiency and Optimization: I was exposed to the importance of efficiency and
optimization in power generation. I learned about monitoring and analyzing operational data
to identify opportunities for improvement, reduce energy losses, and enhance overall plant
efficiency. I also gained knowledge about implementing energy-saving measures and
optimizing system performance.
5. Teamwork and Communication: Working alongside experienced professionals and
fellow interns, I developed strong teamwork and communication skills. I actively participated
in team projects, collaborated on tasks, and effectively communicated ideas and findings.
This experience enhanced my ability to work in a collaborative environment and reinforced
the importance of clear and concise communication.

Overall, my internship training at the NNTPS provided me with a comprehensive

understanding of power plant operations, safety protocols, maintenance practices, efficiency
optimization, and teamwork. This hands-on experience has not only deepened my technical
knowledge but also equipped me with valuable skills that will be instrumental in my future
endeavors in the field of power generation.

48
 Feedback

The entire internship program was really great. We have learnt many things practically apart
from theory which we have learnt earlier. The assistance and guidance provided by all the
employees of the NLCIL was good, appreciable and interactive. It was a wonderful
experience we have gone through in this past 25 days.

Furthermore, we have experienced that it is of importance that education is objective and that
have to be aware of the industrial aspect of the topics. This internship program was not one
sided, but it was a way of sharing knowledge, ideas and opinions.

This internship is also good to find out what our strengths and weaknesses. This helped us to
defined what skills and knowledge we have to improve in the coming time. We can
confidently assert that the knowledge we gained through this internship is sufficient to
contribute towards our future endeavors.

49