A

Training Report
On
NATIONAL THERMAL POWER CORPORATION
(NTPC) DADRI, GAZIABAD

Submitted To: Submitted By:

Er. Sachin Chaudhary Kapil Yadav
Er. Amit Chaudhary EC IVth Year

SUBHARTI INSTITUTE OF TECHNOLOGY &

ENGINEERING NH-58, SUBHARTIPURAM,
MEERUT

1
 ACKNOWLEDGEMENT

Training is one of the important aspects in the career

of an engineering student. It is basically to strengthen
the theoretical concept through this training gets
acquainted with the latest tech. and recent
developments.
Firstly I convey my sincere thanks to sr. engineer of
C&I thermal. Their help and cooperation was
omnipotent and in compatible throughout the training
period. I convey special regards to Mr. MAHESH
KUMAR for providing me the opportunity to
undergo this training.

KAPIL YADAV

2
 CONTENT

TOPIC PAGE NO.

1. Introduction 04-06

2. Thermal power plant 07-10

3. Cooling Towers 11-14

4. Boilers 15-17

5. Turbines 18-25

6. Blades 26

7. Power generation 27-39

8. Automation & 40-58

Control system

3
 NTPC
AN INTRODUCTION

 The National Thermal Power Corporation was

established in 1975 to play a major in the Indian
power sector. Today with an installed capacity of
more than 30,000MW the corporation is looking
ahead with an ambitious corporate plan to
achieve a capacity of 50,000MW by year 2012.

 Operating 13 coal based and 7 gas based stations,

NTPC with its share of about 19% of India’s
total capacity generates 24.4% of the country’s
power.

 Every milestone achieved is a dream come true

for its 23,000 dedicated employees working in its
plants across the country.

4
 NTPC - DADRI

 The station has an installed capacity of 1669MW

of power-840 MW from coal based units and 829
MW from gas based units.

 Towards sustainable development and Eco

friendly power generation, the station has taken
up task under the green house gas pollution
prevention project (GEP project).

 The station has bagged ISO 14001 &ISO9002

certification during the financial year 1999-2000.

5
1. STATION CAPACITY - 840 MW

2. COAL CONSUMPTION - 3.66 Million T/Year

3. ASH GENERATION - 1.5 Million T / Year

4. ASH DISPOSAL - Dry Ash System

5. DRY ASH SYSTEM - Vac. Extraction

& PR transportation
6. WATER REQMT. FOR
ASH CONDITIONING - 20 % By Weight

7. ASH MOUND AREA - 375 Acres

6
 INTRODUCTION

• Thermal power plants contribute maximum to

generate the power for our country

• Thermal power plants constitute 75.43% of the

total installed captive and non-captive power
generation in INDIA.

• In thermal generating station coal, oil, natural

gas, etc are employed as primary source of
INDIA.

7
 Study of thermal power
station

A thermal power station is a power plant in

which the prime mover is steam driven. Water is
heated, turns in to steam and spins a steam
turbine which either 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
Rankin cycle.

THERMAL POWER PLANT

8
Site requirements

The basic requirements of the conventional

thermal power station are decided on the type,
size and other essential specifications of the
station to be constructed. It is necessary to know
the capacity of the plant that will be required, for
the immediate development as well as for the
period to follow thereafter. The capacity of the
plant for immediate development (5-7 years
ahead) gives the instruction for planning.

COOLING TOWERS
9
There are four cooling towers in the NTPC
Dadri.

 In the cooling towers there are thousands of

filters presented which are used for
condensed the steam.
 Steams enter into the tower and condensed
and then it converted into small droplets of
water.

 These water is collected into a storage tank

for the reuse.

10
Electricity Generation From
Thermal Power Plant

11
 ENERGY CONSERVATION

 Three numbers 500 LPD solar water heaters

are installed at guest house and plant
canteen.

 Solar photo voltaic street light system and

six solar photo voltaic traffic warning lights
have been installed and are functional at
NCPS.

 It focus is on Optimising auxiliary power

consumption, reducing consumption of fuel
oil and lubrication Oil, reducing specific
coal consumption by improving heat rate,
reducing DM water consumption.

12
 CENTRAL CONTROL ROOM

The central control room serves as a focal point

for controlling and monitoring the plant for gas
turbine, waste heat recovery boilers, steam
turbine and mechanical auxiliaries

The control room contains the following

facilities:

1.A unit control deck for each module.

2.An electrical control mimic board for the

station power evacuation.

3.A backup control panel for each module,

and

4.A plant common services panel.

13
 WHAT IS A BOILER?

• “BOILER” means any closed vessel

exceeding 22.75 liters in capacity which is
used expressly for generating steam under
pressure and includes any mounting or other
fitting attached to such vessel, which is
wholly or partly under pressure when steam
is shut off.

MAIN FUNCTION OF BOILER

14
• Converts the chemical energy of the fuel to
thermal energy in the furnace
• Converts the water under pressure into
steam which is the working fluid for the
turbines.

STEAM

WATER
BOILER
COAL FLUE GAS

CO, CO2, H2, H2O,

O2
AIR
ASH

15
 IPSV1IPCV 1
FROM RH

Natural
TURBINE LAYOUT
Controlled
Circulation Circulation
ESV CV1
1

CRH

EXCI
GENERATOR
TER
4 5 6
1 2 3
IPT LPT
HPT 1X17 2X12 2X6

TO LP HEATERS

CONDEN
LPBYPASS

TURBINE COMPONENTS

• CASING
• ROTOR
• BLADES
• SEALING SYSTEM
• STOP & CONTROL VALVES
• COUPLINGS & BEARINGS

16
Turbine Casings

HP Turbine Casing

 outer casing: a barrel-type without axial or

radial flange.
 Barrel-type casing suitable for quick startup

and loading.
 The inner casing--- cylindrical , axially split.
 The inner casing is attached in the horizontal
and vertical planes in the barrel casing so
that it can freely expand radially in all
directions and axially from a fixed point
(HP-inlet side).

IP Turbine Casing

 The casing of the IP turbine is split

horizontally and is of double-shell
construction.
 Both are axially split and A double flow
inner casing is supported in the outer casing
and carries the guide blades.
17
  Provides opposed double flow in the two
blade sections and compensates axial thrust.
• Steam after reheating enters the inner casing
from Top & Bottom.

Anchor Point of Turbine

• Purpose: Taking care of thermal expansions
and contractions of the machine during
thermal cycling.
• The fixed points of the turbine are as
follows:
• The bearing housing between the IP and LP
turbines.
• The rear bearing housing of the IP turbine.
• The longitudinal beam of the I.P turbine.
• The thrust bearing in rear bearing casing of
H.P turbine.

18
TURBINE

19
 LP TURBINE
Rear Bearing Pedestal: The bearing pedestal is
situated between the LP turbine and generator.
Its function is to bear the LP rotor.

The bearing pedestal contains the following

turbine components:
• Journal bearing
• Shaft vibration pick-up
• Bearing pedestal vibration pick-up

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 BLADES

 most costly element of turbine

 blades fixed in stationary part are called
guide blades/nozzles and those fitted in
moving part are called rotating/working
blades.
 blades have three main parts
• Aerofoil: working part
• Root
• Shrouds
• shroud are used to prevent steam leakage &
to guide steam to next set of moving blades.

21
 6. How Does A Combined-Cycle
Power Plant Work?

Power Generation:

Air Inlet
 The amount of air needed for combustion is
800,000 cubic feet per minute. This air is
drawn though the large air inlet section
where it is cleaned, cooled and controlled, in
order to reduce noise.

Turbine-Generators:

 The air then enters the gas turbine where it

is compressed, mixed with natural g as and
ignited, which causes it to expand. The
pressure created from the expansion spins
the turbine blades, which are attached to a
shaft and a generator, creating electricity.
 Each gas turbine produces 185 megawatts
(MW) of electricity.

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 The blades are attached to a rotor, which
spins the generator, and makes electricity.
Think of a generator as a huge spinning
magnet inside a coil of wire. As the magnet
spins, electricity is created in the wire loops.

Heat Recovery Steam Generator(HRSG)

• The hot exhaust gas exits the turbine at

about 1100 degrees Fahrenheit and then
passes through the Nooter Erickson, Heat
Recovery Steam Generator (HRSG).
• In the HRSG, there are 18 layers of 100-foot
tall tube bundles, filled with high purity
water. The ho t exhaust gas coming from the
turbines passes through these tube bundles,
which act like a radiator, boiling the water
inside the tubes, and turning that water into
steam. The gas then exits the power plant
through the exhaust stack at a much cooler
180 degrees, after having given up most of
its heat to the steam process.

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• About 1 million pounds of steam per hour is
generated in this way and sent over to the
steam turbine through overhead piping.

Steam Turbine

• The steam turbine is a Siemens

Westinghouse KN Turbine Generator,
capable of producing up to 240 MW. It is
located on top of the condenser, across from
the cooling tower.
• Steam enters the turbine with temperatures
as high as 1000 degrees Fahrenheit and
pressure as strong as 2,200 pounds per
square inch. The pressure of the steam is
used to spin turbine blades that are attached
to a rotor and a generator, producing
additional electricity, about 100 megawatts
per HRSG unit.
• After the steam is spent in the turbine
process, the residual steam leaves the
turbine at low pressure and low heat, about
100 degrees. This exhaust steam passes into
a condenser, to be turned back into water.
24
 • By using this “combined-cycle” process,
two gas turbines and one steam turbine, we
can produce a total of about 600 megawatts
of electricity.

Emissions Control

Selective Catalytic Reduction (SCR)

• To control the emissions in the exhaust gas

so that it remains within permitted levels as
it enters the atmosphere, the exhaust gas
passes though two catalysts located in the
HRSG.
• One catalyst controls Carbon Monoxide
(CO) emissions and the other catalyst
controls Oxides of Nitrogen, (NOx)
emissions.

Aqueous Ammonia
• In addition to the SCR, Aqueous Ammonia
(a mixture of 22% ammonia and 78% water)
is injected into system to even further reduce
levels of NOx.

25
Best Available Control Technology
(BACT)
• Our annual average concentration of NOx is
only 2 parts per million, which is considered
the “best available control technology” or
BACT by the Air Board.
• As exhaust gas passes out of the exhaust
stack, it is continuously sampled and
analyzed, assuring that permit limits are
being met.
• With this kind of clean, modern technology,
the exhaust stack is only 145 feet high,
compared to 500 feet, the height required by
older power plants that use less efficient
emission technology.
• Environmental and health organizations
recognize this technology as a benefit to the
community. The local chapters of the
American Lung Association and Sierra Club
both support the Metcalf Energy Center.

26
Transmission of generated power
onto the Grid

Transformers

 The Gas Turbine and Steam Turbine

generators produce power at 13,000 volts.
 The transformers take the generated 13,000
volts and “transform” them to 230,000 volts,
which is the required voltage needed for
transmission to the nearby tower that s ends
power to the substation.
 A small amount of generation is directed to
“Auxiliary transformers” which “transform”
the generated voltage to a lower voltage, so
it may be used by the plant to power our
own pumps, fans, and motors. The Metcalf
Energy Center requires 12 – 15 megawatts
to operate.

Switchyard

27
 From each transformer, the power passes
underground into our switchyard. The power
from all of the generators comes together
there, where it is measured, metered and
directed onto the grid.
 The proximity of the site to a large, existing
PG&E substation makes it a good place to
build a power plant and the nearest
transmission tower is only about 200 feet
away.

Condenser and Cooling Tower

 The purpose of the condenser is to turn low

energy steam back into pure water for use in
the Heat Recovery Steam Generator.
 The purpose of the cooling tower is to cool
the circulating water that passes through the
condenser. It consists of ten cells with large
fans on top, inside the cone-like stacks, and
a basin of water underneath.
 We process and treat the Title 22 recycled
water after receiving it from the City, before
using it in our cooling tower. The cool basin

28
 water absorbs all of the heat from the
residual steam after being exhausted from
the steam turbine and it is then piped back to
the top of the cooling tower.
 As the cool water drops into the bas in, hot
wet air goes out of the stacks. Normally, hot
moist air mixes with cooler dry air, and
typically a water vapor plume can be
formed, one that may travel hundreds of feet
in the air and be seen from miles away. The
California Energy Commission considered
this visually undesirable in this community
so we added a “Plume Abatement” feature,
louvers along the topsides of the tower that
control the air flow.
 The cooling tower evaporates about three-
fourth of the processed, recycled water, then
we send about one-fourth of it back through
the sewer lines for re-treatment by the City.
 The Metcalf Energy Center purchases 3 to 4
million gallons per day of recycled water
from the City of San Jose. Evaporation of
this water assists the City in adhering to
their flow cap limits and helps to protect the
sensitive saltwater marsh habitat of the San

29
 Francisco Bay environment from receiving
too much fresh, recycled water.
Water Tanks, Control Room

Water Tanks

 The largest tank is the Service Water tank. It

contains 470,000 gallons of water to be used
for drinking, fire fighting and for the high
purity water train. The water from the
service water tank is pumped to the water
treatment building where it then passes
through a reverse osmosis unit, a membrane
decarbonater, and mixed resin bed
demineralizers to produce up to 400 gallons
per minute of ultra pure water.
 The pure water is then stored in the smaller
365,000-gallon tank until it is turned into
steam for making electricity.

Control Room

 From the control room, the plant operators

monitor and operate the facility, via the

30
 plant’s “Distributed Control System”, with
the click of a mouse, vie wing graphic
representations of all MEC systems on
various screens.
 The system gives operators both audible and
visual signals to keep them informed of
plant conditions at all times and to
determine when preventative maintenance is
required.

7.AUTOMATION AND CONTROL

SYSTEM

AUTOMATION: THE DEFINITION

The word automation is widely used today in

relation to various types of applications, such as
office automation, plant or process automation.

This subsection presents the application of a

control system for the automation of a process /
plant, such as a power station. In this last
application, the automation actively controls the

31
plant during the three main phases of operation:
plant start-up, power generation in stable or put
During plant start-up and shut-down, sequence
controllers as well as long range modulating
controllers in or out of operation every piece of
the plant, at the correct time and in coordinated
modes, taking into account safety as well as
overstressing limits.

During stable generation of power, the

modulating portion of the automation system
keeps the actual generated power value within
the limits of the desired load demand.

During major load changes, the automation

system automatically redefines new set points
and switches ON or OFF process pieces, to
automatically bring the individual processes in
an optimally coordinated way to the new desired
load demand. This load transfer is executed
according to pre- programmed adaptively
controlled load gradients and in a safe way.

AUTOMATION: THE BENEFITS

32
The main benefits of plant automation are to
increase overall plant availability and efficiency.
The increase of these two factors is achieved
through a series of features summarized as
follows:
 Optimization of house load consumption

during plant start- up, shut-down and

operation, via:
 Faster plant start-up through elimination
of control errors creating delays.
 Faster sequence of control actions
compared to manual ones. Figures 1
shows the sequence of a rapid restart
using automation for a typical coal-fired
station. Even a well- trained operator
crew would probably not be able to
bring the plant to full load in the same
time without considerable risks.
 Co-ordination of house load to the
generated power output.

 Ensure and maintain plant operation,

even in case of disturbances in the control
system, via:

33
  Coordinated ON / OFF and modulating
control switchover capability from a sub
process to a redundant one.
 Prevent sub-process and process
tripping chain reaction following a
process component trip.

 Reduce plant / process shutdown time for

repair and maintenance as well as repair
costs, via:

 Protection of individual process

components against overstress (in a
stable or unstable plant operation).
 Bringing processes in a safe stage of
operation, where process components
are protected against overstress

PROCESS STRUCTURE

Analysis of processes in Power Stations and

Industry advocates the advisability of dividing
the complex overall process into individual
functions. This division of the process in clearly
defined groups, termed as FUNCTIONAL
34
GROUPS, results in a hierarchical process
structure. While the hierarchical structure is
governed in the horizontal direction by the
number of drives (motorized valves, fans,
dampers, pumps, etc) in other words the size of
the process; in the vertical direction, there is a
distinction made between three fundamental
levels, these being the:

Drive Level
Function Group Level
Unit Level.

To the Drive Level, the lowest level, belong the

individual process equipment and associated
electrical drives.

The Function Group is that part of the process t

hat fulfils a particular defined task e.g., Induced
Draft Control, Feed Water Control, Blooming
Mill Control, etc. Thus at the time of planning it
is necessary to identify each function group in a
clear manner by assigning it to a particular
process activity. Each function group contains a
combination of its associated individual

35
equipment drives. The drive levels are
subordinate to this level. The function groups
are combined to obtain the overall process
control function at the Unit Level.

The above three levels are defined with regard to

the process and not from the control point of
view.

CONTROL SYSTEM STRUCTURE

The primary requirement to be fulfilled by any

control system architecture is that it be capable
of being organized and implemented on true
process oriented lines. In other words, the
control system structure should map on to the
hierarchy process structure.

BHEL’s PROCONTROL P®, a microprocessor

based intelligent remote multiplexing system, m
meets this requirement completely.

SYSTEM OVERVIEW

36
The control and automation system used here is
a micro based intelligent multiplexing system.
This system, designed on a modular basis,
allows tightening the scope of control hard ware
to the particular control strategy and operating
requirements of the process.

Regardless of the type and extent of process to

control provides system uniformity and integrity
for:

Signal conditioning &

transmission
Modulating controls.

CONTROL AND MONITORING

MECHANISMS

There are basically two types of Problems faced

in a Power Plant:

• Metallurgical
• Mechanical

37
Mechanical Problem can be related to Turbines
that is the max speed permissible for a turbine is
3000 rpm, so speed should be monitored and
maintained at that level

Metallurgical Problem can be view as the max

Inlet Temperature for Turbine is 1060oC so
temperature should be below the limit.

Monitoring of all the parameters is necessary

for the safety of both:
• Employees
• Machines

So the Parameters to be monitored are:

 Speed
 Temperature
 Current
 Voltage
 Pressure
 Eccentricity
 Flow of Gases
 Vacuum Pressure

38
  Valves
 Level
 Vibration.
PRESSURE MONITORING

Pressure can be monitored by three types of

basic mechanisms

 Switches
 Gauges
 Transmitter type

For gauges we use Bourden tubes: The

Bourdon Tube is a non liquid pressure
measurement device. It is widely used in
applications where inexpensive static pressure
measurements are needed.

A typical Bourdon tube contains a curved tube

that is open to external pressure input on one end
and is coupled mechanically to an indicating
needle on the other end, as shown schematically
below.

39
Typical Bourdon Tube Pressure Gages
Transmitter types use transducers (electrical to
electrical normally) they are used where
continuous monitoring is required normally
capacitive transducers are used.

For Switches pressure switches are used and

they can be used for digital means of monitoring
as switch being ON is referred as high and being
OFF is as low.

All the monitored data is converted to either

Current or Voltage parameter.

The Plant standard for current and voltage are as

under

 Voltage: 0 – 10 Volts range

 Current: 4 – 20 milli Amperes

We use 4mA as the lower value so as to check

for disturbances and wire breaks.

Accuracy of such systems is very high.

40
  ACCURACY: + - 0.1 %.

The whole system used is SCADA based.

ALARM

We use DDCMIC control for this process.

Programmable Logic Circuits (PLCs) are used in
the process as they are the heardt of
Instrumentation.
Pressure Electricity AND Level High level
Electricity OR HL switch Start low Pressure in
line LL switch pump Stop Pressure Electricity

BASIC PRESSURE CONTROL

MECHANISM

Hence PLC selection depends upon the

Criticality of the Process

TEMPERATURE MONITORING:

We can use Thermocouples RTDs are used for

low temperatures.

41
 Thermocouple selection depends upon two
factors:

 Temperature Range
 Accuracy Required

Normally used Thermocouple is K Type

Thermocouple:

Chromel (Nickel-Chromium Alloy) /Alumel

(Nickel-Aluminium Alloy).

This is the most commonly used general

purpose thermocouple. It is inexpensive and,
owing to its popularity, available in a wide
variety of probes. They are available in the −200
°C to +1200 °C range. Sensitivity is
approximately 41 µV/°C.

RTDs are also used but not in protection systems

due to vibration al errors.

42
We pass a constant current through the RTD. So
that if R changes then the Voltage also changes.

RTDs used in Industries are Pt100 and Pt1000

Pt100: 0 0C – 100 Ω (1 Ω = 2.5 0C)

Pt1000: 0 0C - 1000Ω

Pt1000 is used for higher ac curacy.

The gauges used for Temperature measurements

are mercury filled Temperature gauges.

For Analog medium thermocouples are used.

And for Digital medium Switches are used

which are basically mercury switches.

FLOW MEASUREMENT

Flow measurement does not signify much and is

measured just for metering purposes and for
monitoring the processes

ROTAMETERS
43
A Rotameter is a device that measures the flow
rate of liquid or gas in a closed tube. It is
occasionally misspelled as rotometer.

It belongs to a class of meters called variable

area meters, which measure flow rate by
allowing the cross sectional area the fluid travels
through to vary, causing some measurable
effect.

A rotameter consists of a tapered tube, typically

made of glass, with a float inside that is pushed
up by flow and pulled down by gravity. At a
higher flow rate more area (between the float
and the tube) is needed to accommodate the
flow, so the float rises. Floats are made in many
different shapes, with spheres and spherical
ellipses being the most common. The float is
shaped so that it rotates axially as the fluid
passes. This allows you to tell if the float is
stuck since it will only rotate if it is not.

For Digital measurements Flap system is used.

44
For Analog measurements we can use the
following methods:

 Flow meters
 Venurimeters/ Orifice meters
 Turbines
 Mass flow meters (oil level)
 Magnetic Flow meter (water level)
 Ultrasonic Flow meters

Selection of flow meter depends upon the

purpose, accuracy and liquid to be measured so
different types of meters used.

Turbine types are the simplest of all.

They work on the principle that on each rotation

of the turbine a pulse is genera ted and that pulse
is counted to get the flow rate.

VENTURIMETERS
Referring to the diagram, using Bernoulli s
equation in the special case of incompressible

45
fluids (such as the approximation of a water jet),
the theoretical pressure drop at the constriction
would be given by (ρ/2)(v22 - v12).

And we know that ate of flow is given by:

Flow = k √ (D.P)

Where DP is Differential Pressure or the

Pressure Drop.

CONTROL VALVES

A valve is a device that regulates the flow of

substances (either gases, fluidized solids,
slurries, or liquids) by opening, closing, or
partially obstructing various passageways.
Valves are technically pipe fittings, but usually
are discussed separately.

Valves are used in a variety of applications

including industrial, military, commercial,
residential, transportation. Plumbing valves are
the most obvious in everyday life, but many
more are used.

46
Some valves are driven by pressure only; they
are mainly used for safety purposes in steam
engines and domestic heating or cooking
appliances. Others are used in a controlled way,
like i n Otto cycle engines driven by a camshaft,
where they play a major role in engine cycle
control.
Many valves are controlled manually with a
handle attached to the valve stem. If the handle
is turned a quarter of a full turn (90°) between
operating positions, the valve is called a quarter-
turn valve. Butterfly valves, ball valves, and
plug valves are often quarter-turn valves. Valves
can also be controlled by devices called
actuators attached to the stem. They can be
electromechanical actuators such as an electric
motor or solenoid, pneumatic actuators which
are controlled by air pressure, or hydraulic
actuators which are controlled by the pressure
of a liquid such as oil or water.

So there are basically three types of valves that

are used in power industries besides the handle
valves. They are:

47
• Pneumatic Valves – they are air or gas
controlled which is compressed to turn or
move them

• Hydraulic valves – they utilize oil in place

of Air as oil has better compression
• Motorized valves – these valves are
controlled by electric motors.

48