A SUMMER TRAININGPRESENTATION 0N

NATIONAL THERMAL POWER PLANT

KAHALGAON (BIHAR)
 CONTENTS
 Introduction
Coal Handling
Boiler &Auxillary
 Turbine System
 Ash Handling
 Off- site
 NTPC OPERATION &MAINTENANCE

 Boiler Maintenance Department

 Turbine Maintenance Department
 Ash Handling Departament
 Off-site Maintenance Departament
 INTRODUCTION

India’s largest power company ,NTPC was set up in 1975 to accelerate

power development in india.NTPC is emerging as a diversified power
major with presence in the entire value chain of the power generation
,which is the mainstary of the company ,NTPC has already ventured into
consultancy.power trading,Ash utilisation and coal mining

kahalgaon super thermal power station (khstpp) is located in kahalgaon in

Bhagalpur district of bihar.The power plant is one of the coal based power
plant of NTPC.
CAPACITY :- The Total installed capacity of the plant is 2340 mw.
 Coal Handling System Equipment
 Wagon Trippler
 Conveyor Belt
 Pulleys
 Take Ups
 Skirt Board
 Scrappers
 Magnetic seprator
 Vibrating screen
 Crushers
 CRUSHERS
To crush the coal from 200mmto 20mm size received
from vibrating screen
Crusher hammer are made of MAGNEESE STEEL .
Hammer row -4(stage 1)
(a)Row-1 & 2 =18 hammer each
(b)Row-3&4=20 hammers each

No of hammer in each Crusher-

•stage-1 = 76 hammers
•stage-2 = 92 hammers
•Weight of each hammer=18.5kg
•Crushing motor rating -740kw/3.3kv
•Life of hammer =4 lac MT of coal
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 CONVEYOR BELTS
Made of diff. Layers or piles of fabric duck with rubber
protected by a rubber cover on both sides & edges.
Fabric duck are designed to withstand tension created in
carrying the load .
Nylon rubber cover protect the fabric duck.

 Material =fire resistant grade.

 Belt Width=1600 mm.
 Strength= 1000/1250 kN.
 Belt speed=3.2-3 m/s.
 Belt length=20km.

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 NTPC
PULLEYS

•Made of mild steel.

• Rubber coating is used to increase friction

• factor between belt & pulley (rubber lagging

•Shell dia-500mm.
•Shaft dia-1400mm.
•Pulley length-1800mm.
•Shaft length-2350mm(bearing centre to
centre)
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 NTPC
DRIVE UNIT
 Motors coupled to reduction gear with the help
of flexible/fluid coupling on the high speed shaft of the
Gear box
 Flexible coupling on the input side

TAKE UPS
Take up pulley to facilitates –

Necessary tension for the drive to operate the belt

Sag at a point where requires horse power will be

at a minimum and load will move with least
disturbance over idlers
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 NTPC

SKIRT BOARD
Used with chutes at trail end.

Guides material centrally on the belt while loading

until it has settle down on the belt

SCRAPPERS

Placed at discharge pulley in order to clean the

carrying side of belt.
 It avoids the wear of return idlers due to build up
material.

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 BOILERAUXILARIES
There are three part ofBoiler :-
1.Milling system
2.Rotatory part
3.pressure part
 1.MILLING SYSTEM:-
Coal Bunker:- These are in process storage silos used for storing crushed coal
from the coal handling system .generally,these are made of welded steel plates
normally these are six such bunker supplying coal of the corresponding mills
.Those are located on top of the mill so as aid in gravity feeding of coal.
Coal feeder:- Each mill is provided with a drag link chain/rotary /gravametic
feeder to transport raw coal from the bunker to the inlet chute leading to mill at
desired rate .
MILLS:- These are six mill (25persent capacity each) for every 200mw unit
,located adjacent to the furnace at (o) m level .There mills pulverise coal to be
desired fineness to be feed to the furnace for combustion.
It is used to crush the coal into powder form (80 micron).These are 10
mills for the 500mw unit ,located adjacent to the furnace at o level .These mills
pulverised coal to the desined fineness to be fed to the furnace for combustion.
 CLASSIFICATION OF MILLS

VERTICAL SPINDLE TUBE

BOWL/ PRESSURIZED
BALL & RACE

XRP E MILLS MPS

(BHEL) (BABCOCK)
1 2 3 4 5 6 7

HPT LPT
IP
T GENERATOR
EXCITER
THREE STAGE TURBINE :
• HIGH PRESSURE TURBINE (HPT)
• INTERMEDIATE PRESSURE TURBINE (IPT) CONDENSER
• LOW PRESSURE TURBINE (LPT)

SEVEN NOS JOURNAL BEARINGS

BEARING N0. 2 THRUST CUM JOURNALBEARING

FOUR NOS RIGID COUPLINGS BETWEEN

• HP-IP TURBINE
• IP-LP TURBINE
• LP-GENERATOR
•GENERATOR - EXCITER
SINGLE STEAM FLOW OF TWO SHELL (CASING) DESIGN
OUTER CASING IS OF BARREL TYPE AND HAS NEITHER ON AXIAL OR RADIAL FLANGE. DUE
TO THE PERFECT SYMMETRIC DESIGN OF THE OUTER CASING AND UNIFORM WALL
THICKNESS AT ALL SECTIONS, PREVENTS MASS CONCENTRATIONS WHICH WOULD CAUSED
HIHG THERMAL STRESSES AND REMAINS LEAK PROOF DURING QUICK CHANGES IN
TEMPERATURE DURING START UP AND SHUT DOWN.

THE INNER CASING IS AXIALLY SPLIT IS ALMOST CYLINDRICAL IN SHAPE AS THE JOINTS
FLANGES ARE RELIEVED BY HIGHER PRESSURE ACTING FROM THE OUT SIDE.
CASING IS MADE OF CREEP RESISTING CHROMIUM-MOLYBDENUM-VANADUIUM (Cr-Mo-V)
STEEL CASTING.

THE TURBINE HAS 2 MAIN STOP VALVES (ESV) AND 2 CONTROL VALVES (CV)LOCATED
SYMMETRICALLY TO THE RIGHT AND LEFT OF THE CASING. THE VALVES ARE ARRANGED IN
PAIRS WITH ONE STOP VALVE AND ONE CONTROL VALVE IN A COMMON BODY. EACH ESV
AND CV HAS A DEDICATED HYDRAULIC SERVOMOTOR.

 THE STEAM LINES FROM ESV & CV ARE CONNECTED TO THE INLET CONNECTIONS OF
THE OUTER CASING BY BREECH NUTS.

 THE EXHAUST END OF HPT HAS A SINGLE OUT LET CONNECTION FROM BOTTOM.
•THE IP TURBINE IS OF DOUBLE FLOW CONSTRUCTION WITH TWO NOS
HORIZONTALLY SPLIT CASINGS ( INNER & OUTER CASING).

•THE HOT REHEATED (HRH) STEAM INTERS THE INNER CASING AT THE
MID SECTION FROM TOP AND BOTTOM AND EXPENDS IN OPPOSITE SIDE
IN TWO BLADE SECTIONS AND COMPENSATE AXIALTHRUST.

• THE INNER CASING CARRIES THE STATIONARY BLADING.

•THE IP STOP AND CONTROL VALVES 2 NOS ARE SUPPORTED ON THE

FOUNDATION COVER PLATE BELOW EL 17.00 M FLOOR IN FRONT OF
TURBINE –GEN UNIT.

• CASING IS MADE OF CREEP RESISTING CHROMIUM-MOLYBDENUM-

VANADUIUM (Cr-Mo-V) STEEL CASTING.

•THE SHAFT IS MADE OF HIGH CREEP RESISTANCE Cr-Mo-V STEEL

FORGING.
•LP TURBINE CASING CONSISTS OF DOUBLE FLOW UNIT AND HAS A TRIPLE SHELL
WELDED CASING.

•THE OUTER CASING CONSISTS OF FRONT AND REAR WALLS, TWO LATERAL
LONGITUDINAL SUPPORT BEAMS AND THE UPPER DOME AND CONNECTED TO
CONDENSER BY WELDING.

•THE INNER-INNER & INNER-OUTER CASING CARRIES THE TURBINE GUIDE

BLADES AND DIFFUSER.

•STEAM ADMITTED TO THE LP TURBINE INNER CASING FROM IP TURBINE FROM

BOTH LEFT AND RIGHT SIDE HORIZONTALLY. EXPANSION JOINTS ARE INSTALLED
IN THE STEAM PIPING TO PREVENT ANY UNDESIRABLE DEFORMATION OF THE
CASINGS DUE TO THERMAL EXPANSION OF THE STEAM PIPING.
HP TURBINE MOVING AND STATIONARY BLADES :
• HP TURBINE BLADING CONSISTS OF 17 REACTION STAGES WITH 50 %
REACTION.
• BLADES ARE HAVING THREE MAIN PARTS :
1. AEROFOIL : IT IS THE WORKING PART OF THE BLADE WHERE STEAM
EXPANSION TAKES PLACE.
2. ROOT : TI IS THE PORTION OF THE BLADE WHICH IS HELD WITH ROTOR OR
CASING
3. SHROUDS : END PORTION OF BLADES ARE HELD TOGETHER
• THE STATIONARY AND MOVING BLADES OF ALL STAGES ARE PROVIDED WITH
INVERTED T-ROOTS. ALL THESE BLADES ARE PROVIDED WITH INTEGRAL
SHROUDS WHICH AFTER INSTALLATION FORM A CONTINUOUS SHROUD.
• THE MOVING AND STATIONARY BLADES ARE INSERTED INTO THE
CORRESPONDING GROOVES IN THE SHAFT AND INNER CASING. THE
INSERTION SLOT IN THE SHAFT IS CLOSED BY A LOCKING BLADE WHICH IS
FIXED BY GRUB SCREWS.

• SEALING STRIPS ARE CAULKED INTO THE INNER CASING AND THE SHAFT TO
REDUCE LEAKAGES LOSSES AT THE BLADE TIPS.
IP TURBINE MOVING AND STATIONARY BLADES :

•IPTURBINE BLADING CONSISTS OF 12 REACTION STAGES PER FLOW WITH 50 %

REACTION.

•THE STATIONARY AND MOVING BLADES OF ALL STAGES ARE PROVIDED WITH INVERTED
T-ROOTS. ALL THESE BLADES ARE PROVIDED WITH INTEGRAL SHROUDS WHICH AFTER
INSTALLATION FORM A CONTINUOUS SHROUD.

•THE MOVING AND STATIONARY BLADES ARE INSERTED INTO THE CORRESPONDING
GROOVES IN THE SHAFT AND INNER CASING. THE INSERTION SLOT IN THE SHAFT IS
CLOSED BY A LOCKING BLADE WHICH IS FIXED BY GRUB SCREWS.

• SEALING STRIPS ARE CAULKED INTO THE INNER CASING AND THE SHAFT TO REDUCE
LEAKAGES LOSSES AT THE BLADE TIPS.
LP TURBINE MOVING AND STATIONARY BLADES (FIRST 3
STAGES) :
•LPTURBINE BLADING CONSISTS OF 6 REACTION STAGES PER FLOW WITH 50
% REACTION.

•THE STATIONARY AND MOVING BLADES OF FIRST THREE STAGES ARE

PROVIDED WITH INVERTED T-ROOTS. ALL THESE BLADES ARE PROVIDED WITH
INTEGRAL SHROUDS WHICH AFTER INSTALLATION FORM A CONTINUOUS
SHROUD. FIRST THREE GUIDE BLADES ARE MOUNTED ON INNER-INNER CASING.

•THE MOVING AND STATIONARY BLADES ARE INSERTED INTO THE

CORRESPONDING GROOVES IN THE SHAFT AND INNER CASING. THE INSERTION
SLOT IN THE SHAFT IS CLOSED BY A LOCKING BLADE WHICH IS FIXED BY GRUB
SCREWS.

•SEALING STRIPS ARE CAULKED INTO THE INNER CASING AND THE SHAFT TO
REDUCE LEAKAGES LOSSES AT THE BLADE TIPS.
CONDENSER IS A SURFACE TYPE CONDENSER WITH TWO PASS ARRANGEMENT. COOLING
WATER IS PUMPED INTO EACH OF CONDENSER PASS BYVERTICAL CW PUMPS THROUGH THE
INLET PIPE. WATER ENTERS THE INLET CHAMBER OF FRONT WATER BOX AT THE BOTTOM
PASSES HORIZONTALLY THROUGH THE TITANIUM TUBES TO THE WATER BOX AT THE OTHER
END, TAKES A TURN PASSES THROUGH THE UPPER CLUSTER OF THE TUBES AND REACHES THE
OUT LET CHAMBER AT THE TOP IN THE FRONT WATER BOX AND LEAVES THE CONDENSER
THROUGH OUTLET PIPE.
STEAM EXHAUSTED FROM THE LP TURBINE WASHING THE OUTSIDE OF THE
CONDENSER TUBES LOSSES ITS LATENT HEAT TO THE COOLING WATER AND CONVERTED
INTO WATER IN THE STEAM SIDE OF THE CONDENSER. THIS CONDENSATE COLLECTS IN THE
HOTWELL, WELDED TO THE BOTTOM OF THE CONDENSER.

CONDENSER DESIGN DATA :

•COOLING WATER FLOW : 54300 M3/Hr.
• COOLING WATER SURFACE AREA : 35603 M2
•NO. OF COOLING TUBES : 24398 NOS ( CONDENSING ZONE:22688 NOS AND AIR COOLING
ZONE :1710 NOS)
•TUBE MATERIAL : TITANIUM SB-338 GRADE-II
• MAIN TUBE PLATE : MS WITH TITANIUM CLADED.
• WATER BOX : MS WITH FRE LINING ( GLASS FIBRE REINFORCED EPOXY LINING) OF 3MM
THICKNESS.
 ASH HANDLING DEPARTMENT
WHAT IS ASH ?
Ash is the residue remaining after the coal has been
incinerated to constant weight under standard
conditions.
 Ash is oxidised form of the mineral matters present in
coal.
 Typical ash composition : SiO2, Al2O3, Fe2O3, CaO,

MgO etc.
 Coal with more SiO2 & Al2O3, Ash MP > 1400ºC
 Coal with more Fe2O3, CaO & MgO, Ash MP < 1100ºC

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WHY ASH HANDLING?

 Ash content of Indian coal used in power station is

about 30 to 40 %.
 A typical 2000 MW station produce around 9000T to
12000T of ash per day.
 This huge amount of ash needs to be disposed off

continuously.
 Necessary care to be taken for preventing pollution

 Ash Handling system takes care the above requirement

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Fly Ash Handling System
FA is collected from Air heater hopper, Eco hopper and
ESP hopper.
Either through flushing apparatus or hydrobactur system.

In Flushing apparatus system ash is allowed to fall in

flushing apparatus under gravitation.
Water jet in flushing apparatus carries away the ash to FA
trench
High pressure jets further carries it to FAsump.
Series pumping carries the ash slurry to FApond.

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Bottom ash Handling System
 BA can be collected at furnace bottom as Wet or Dry form.
 Wet bottom ash system consists of i)Trough seal, ii)BA
gate, iii)Hopper, iv)Scrapper Conveyer, v)Clinker grinder,
vi)BA trench, vii)BA tank, viii)BA pump, ix)BA pond.
 Dry BA consists of i)Trough seal, ii)BA gate, iii)Hopper,
iv)Scrapper Conveyer, v)Clinker grinder, vi)Silo.
 Trough seal : A channel around the furnace bottom
filled with water where the furnace bottom end is
immersed in water. This is to prevent air ingression in the
boiler during operation.

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Overburden Surge Pile

Coal Seam Pulverize (-150)

Electrostatic Precipitator Boiler

Flue Gas Flue Gas
Fly Ash
FlyAsh BottomAsh

Bottom
FlyAsh
Ash
Smoke
Stack

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Ash volumes and properties
Furnace ESP
(1300 - 1500 C)

Economizer Electrostatic Stack

Precipitator
Air
preheater
Pulverize APH
d

Stage A: 80 %
Coal

Stage B: 17 %
Stage C: 3 %
Coal Bottom Ash EcoAsh APH Ash Fly ash
100 % 10-20 % 1% 1% 80-90 % Ash
Fineness
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 OFF-SITE DEPARTMENT
 Water Treatment
 Cooling Tower
Why water treatment?
Raw water contains many dissolved minerals and organic
materials.
At high temperature certain minerals left scaling on the
tube metal of the boiler and cause permanent damage.
Some dissolved minerals leads to corrosion of tube metals.
Some leads to foaming
At high pressure and temperature an element, silica can be
carried away with steam causing damage to turbine low
pressure stage.
AThermal Power Station needs water of varying quality for
different process and hence the requirement.
The performance and life expectancy of the station greatly
depends on water chemistry compliance .
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Type of water treatment
the type of demineralization process chosen for a power
station depends on three main factors :
The quality of the raw water.
The degree of deionisation i.e. treated water quality
Selectivity of resins.

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Steps of treatment process
Aeration of raw water
Adding chemicals for bacteria removal
Adding chemicals for sedimentation of suspended
particles
Flocculation
Filtration
Ion Exchange process
water treatment process is generally made up of two
sections :
Pretreatment section
Demineralisation section

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NTPC
NTPC