SUMMER INTERNSHIP REPORT

Submitted to
Amity SchooI of Engineering & TechnoIogy

Guided By:

Submitted By:

Mr. Atul Sharma

Abhishek kaushik

Department MAE

A2325312028

ASET

7-MAE-5Y

Amity University, Uttar Pradesh

ACKNOWLEDGEMENT

I Abhishek Kaushik(A2325312028) ,expresses deep regards to my guide Mr.Atul Sharma for his
exemplary guidance, monitoring & constant encouragement throughout the course of this Summer
Internship. The bIessing, help & guidance given by his time to time .
I expresses a deep sense of gratitude to my program Leader Mr. Sumit Sharma, for his cordial
support, help and his effort that help in competing various problem during my summer internship.

CERTIFICATE
This is to certify that Mr. Abhishek kaushik, (A2325312028), student of B.Tech(MAE)+M.Tech(AE) in
ASET (Department) has done summer internship in National Thermal Power Plant Cooperation" as
a part of Summer internship in Third year program of Bachelor of Technology + Master of
TechnoIogy in MechanicaI & Automation Engineering from Amity SchooI of Engineering &
TechnoIogy, Amity University, Noida, Uttar Pradesh under my supervision.

Mr. Atul Sharma

Dept. Of MechanicaI & Automation Engineering
ASET, Noida.

INDEX

NTPC OVERVIEW

MAIN BOILER

BOILER MAINTENANCE DEPARTMENT

COAL HANDLING SYSTEM

PLANT AUXILLARY MAINTENANCE (PAM)

TURBINE MAINTENANCE DEPARTMENT (TMD)

MAINTENANCE PLANT DIVISION (MPD)

Abstract

NTPC is a power plant where coal heated and turned into heat, further the heat energy is
converted into electrical energy. The process due to which the heat energy turned into electrical
energy is explained in following steps

First the coal is grinded into powder and then transferred to boiler for burning. Coal is

grinded , as it will increase its surface area and complete burning of coal take place
Burning of coal produce gases and ash. As the coal burns to produce the gases, the ash

falls at the bottom of boiler.

Now the exhaust gases enter exhaust stack which contain equipments for filtering the air
before emitting , it to atmosphere. The exhaust plume are built at certain height , so that

surrounding air doesnt get impure.

Coal heated to produce heat energy , the pipes are coiled around boiler which contain
water, due to high temperature the water converts into steam , which due to high pressure

drive the steam towards the steam turbine.

Now the heat energy is converted into mechanical energy by steam turbine. A shaft is
connected to steam turbine and steam generator . The mechanical energy is connected

into electrical energy by electromagnetic process.

The electrical energy is further converted into high voltage by a transformer , with the help
of power lines the electrical energy is delivered to different region, where another
transformer is present to convert into usable voltage.

NTPC OVERVIEW

NTPC Limited is one of largest thermal power generating cooperation in India. It is a public
sector company established in 1975 to meet power requirement in country. At the present stage,
Indian government hold 89%of the total shares of the cooperation and the rest is held by FIIs ,
domestic banks.
In past 31 years, it truly come up as national power source , with power generating facility across
the country. NTPC is a combination of engineering, construction and operation of power generating
plant.. NTPC has set new league for power generating industry for power plant efficiency and
operations.
NTPC is committed to environment cost and preserving the eco environment in vicinity of the plant.
Now the ash formed in converting coal into heat energy, a large amount of ash is formed , NTPC
suggested utilizing the residual ash in cement making, cellular concrete , building material.
NTPC can be termed as a centre for power efficiency and environmental friendly company. NTPC
badarpur consist of 6 unit for producing power. Two to three unit work together for producing power.
6 units consist of two 210MW and four 95MW capacity for producing large amount power.
For producing power the plant totally depend upon the below maintenances and if any one of them
doesnt work correctly or inefficiently, then unit is under maintenance and some are changed
accordingly. If the problem is major then the machine are replaced.
Some important parts of the plant that require constant maintenances

Boiler maintenance
Plant auxiliary maintenance
Turbine maintenance

MAIN BOILER

BOILER Boiler are so designed to transfer heat from external combustion source contained within
boiler itself.
The heat generating unit consist of furnace in which coal is burnt. The advantage being that it also
consist of water cooler liquid inside pipes, superheaters, air heater and economizer, the term
steam generator plays important role in apparatus.

ARRANGEMENT OF MAIN BOILER(210MW)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Economizer
Boiler Drum
Down comers
Water walls
Water wall platen
Primary super heater
Platen super heater
Final super heater
Reheater
Burner
11. Igniters

FURNACE
It is a space where combustion of fuel take place and from where combustion product is
transfer to the proper boiler. It is a space where combustion take in a constant or controlled
force.

BOILER DRUM
It is a space inside boiler that separate the water inside the walls from the generated
stream in furnace walls and also to reduce the solid content of the steam.

ECONOMIZER
It is a continuous unfinned loop and water flows in upward direction whereas the gas in
downward direction. The economizer lies in the rear gas pass of the boiler below the rear
superheater.

SUPERHEATER
It consist of 3 stages
1st stage- Horizontal superheating is done with the help of convection mixed flow type with
the upper bank.
2nd stage Convection is done with the help of radiant parallel flow type.
3rd stage Superheating is done with the help of convection parallel flow type.

REHEATER
It reheat the steam coming out with high pressure turbine to 540degree C.
The reheater is composed of two different section. The front pendant section and rear
pendant section.

IGNITER
Ignition inside boiler take place with help of 12 side eddy oil igniter per boiler. The atomized
air from igniter is taken away with help plant of air compressor system arrangement.

BURNERS
There are total 24 burners for corner firing and 12 oil burner are provided in b/w the two
pulverized fuel burners. The coal burner system runs in such a manner that six mills
supplies the burnt coal from the four corners. The oil burner fed the oil which is 25% more
heated then normal one.

COAL BUNKER
This is a place from coal is stored after coal are crushed into small pieces. Generally, these
are made of welded steel plate.
There are six such bunkers supplying coal , these are located on the top of the mills so as
to take advantage of gravity that help in supplying the coal.

10

COAL BUNKER

COAL FEEDER
Coal feeder is present to transport rock coal from the bunker to the inlet boiler, at uniform rate.

MILLS
There are 6 mills for every 210 MW unit located nearest to the furnace. These mills contain
pulverize coal to the desire fineness, which can be directly sent to boiler for combustion
process.

PRIMARY DRAFT FAN

The primary air are designed for handling atmospheric air upto a desire temperature of 50
degree C, these fans are located at inlet of boiler.

AIR PRE-HEATER
It transfer heat from exhaust gases to cold primary and secondary air by mean of rotating
heating surface elements. This prevent additional arrangement and same exhausting air
can be used for heating purpose, thus also help in increasing the efficiency of the system.
Below this regenerative type air pre-heater is present that help in preheating.

11

FORCE DRAFT FAN

The forced draft fan are designed for exhausting the high temperature gases from the
boiler. These fans are located near the primary draft fan.

INDUCED DRAFT FAN

There are 2 induced draft fan present for single boiler located b/w ESP and the chimney.
These fan are used for sucking flue gases from the furnace.

CHIMNEY
These are tall structure used for exhausting the gases so that the surrounding air remain
clean. These are build to the height of 150 to 220m.

BOILER CLASSIFICATIONS

USE- Its characteristics vary according to the service performed.

FIRING The boiler may be fired or unfired pressure vessel.
CIRCULATION the major pats of boiler are operated with natural convection.
FURNACE POSITION As it is a external combustion device , combustion take place

outside the region of boiling water.

HEAT SOURCE Heat source can be derived from fuel combustion, utilization of nuclear

energy.
MATERIAL It is controlled by boiler code.

CATEGORIES OF BOILER
Steel boiler
Firetube boiler
Water tube boiler
Natural Circulation boiler
Positive Circulation boiler
Cast Iron boiler

12

Straight tube boiler

Shell type boiler

BOILER SITE IN NTPC

13

14

15

BOILER MAINTENANCE DEPARTMENT

It is observed that after the maintenance of boiler and other related equipment . The main part of
boiler are the furnace, during burning of fuel , steam is generated from water and is being
transferred to turbine. Steam is sent for superheating. After superheating it is sent to turbine.

MODE OF FIRING - In 210 MW unit direct firing of coal is done. Tangential firing has
an advantage of increasing more temperature.

BURNERS To focus on flame so as to burn coal. There are 24 burners placed among
4 corners.

OIL GUN - To provide oil to the burner and placed between two burner to sustain flame.
BALL MILL It help in crushing raw coal, Where coal gets crushed due to impacts of
ball. Grinding is done by moving of particle over each other.

COAL HANDLING SYSTEM

There are three coal paths
PATH A :- directly convey of coal from track hopper to boiler
PATH B :- from track hopper to stockyard
PATH C :- from stock yard to boiler bunker.

COAL HANDLING PLANT

Coal
Unloading system

16

Conveyor system
Crushing system
Feeding system
Stacking system
Magnetic separator/ metal detector
Bin/chute vibratory system
Coal weighment
Coal sampling
Fire fighting system
Dust suppression system
Dust extraction system

COAL STORING SITE , NTPC

17

NTPC COAL TRANSFER LAYOUT

18

PAM (PLANT AUXILARY MAINTENANCE)

It consist of various maintenance work outside main plant essential for proper running of plant.
1. WATER TREATMENT PLANT It is used to provide de- mineralized water to boiler. The
water comes from agra canal. As it contain impurities it becomes important to filter the
water.

TYPES OF IMPURITIES IN WATER

1. REMOVAL OF SUSPENDED IMPURITY- for small amount water is stored and made it
to stand still then impurities settle down at bottom of water. If impurities are more, then
alum is added for purifying purpose.
REMOVAL OF ORGANIC MATTER- It include bacteria and microorganism. Chlorination
is done at high pressure. Gas is not directly feed. Chlorine clozine is done through ejector,
which consist of convergent-divergent nozzle.

2. REMOVAL OF DISSLOVED IMPURITIES- To remove impurities and minerals like

calcium carbonate, calcium bicarbonate, magnesium bicarbonate, phosphorous etc.
This is achieved by activated carbon filter, cation exchange, digasifier ,anion
exchanger, mixed bed.

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COMPRESSOR HOUSE
TYPES :1. PLANT AIR OR STATION AIR - It is impure and contain moisture, oil particle etc used
for general purpose like sand blasting, filter cleaning of main oil tank , light oil
atomization in ignition gun.

2. INSTRUMENTATION AIR At end of 4th unit two KG khosal made instrument air
compressor.

TMD-(TURBINE MAINTENANCE DEPARTMENT)

This department helping in proper functioning and maintenance of turbine and turbine used for
production of power are impulse and reaction turbine.
Many large turbine uses both impulse and reaction turbine blading. These combustion turbine
usually have impulse balding during high- pressure end, and reaction turbine at the low pressure
end. The blade length and size increases throughout the turbine to use the expanding stream
efficiency. Blade rows require seals to prevent steam leakage where the pressure drops. Seals for
impulse blading are located b/w the rotor the diaphragm to stop leakage past the nozzle. Seals for
reaction blading are located at the tip of both fixed and moving blade.

STEAM CYCLE
The thermal power plant produces power by using a dual phase cycle(liquid and vapour mix). It is
a closed cycle that continuously uses the working fluid (water) . The cycle used is modified rakine
cycle.

20

Bled Steam Extraction: - For regenerative system, number of non regulated extraction are
taken from High Pressure, Induced Pressure and Low Pressure turbine.

FACTORS OVERALL EFFICIENCY

Efficiency is affected by following

Initial Steam Pressure

Initial Steam Temperature
Condenser pressure
Regenerative feed water heating

TURBINE AUXILIARIES
CONDENSOR

There are two condenser at the entrance and two exhausters at the rear of the low
pressure turbine. These are specific type condenser with two pass entering and leaving
arrangement. Cooling water spilled into each condenser by water pump.

EJECTORS
It is used to evacuate air and other non condensing gases from the condenser and thus
maintain the vacuum inside the condenser.

21

CIRCULATING WATER PUMP

The pump which supply the cooling water to the condenser are called circulating water
pump. There are two such pump for each unit.These pump are normally vertical, wet pit,
mixed flow type. Designed for continuous heavy duty.

FACTORS AFFECTING THERMAL CYCLE EFFICIENCY

22

1.
2.
3.
4.

Initial Steam Pressure

Initial Steam Temperature
Condenser pressure
Regenerative feed water heating

CLASSIFICATION OF TURBINE
Turbine can be classified into different types depending on their function. This has been
briefly explained below-

According Pressure stage

Single Pressure Stage With one or more velocity stages usually of small power
capacities, these turbines are commonly used for operating centrifugal

compressors.
Multi Pressure Stage- Impulse and Reaction stage turbine are made in wide range
power capacities varying from small to high ranges.

According to the direction of steam flow

Axial Flow Turbine The turbine in which steam flows in a direction II to the axis of the

turbine.
Radial Flow Turbine- The turbine in which steam flows perpendicular to the axis of the
turbine with one or more low pressure stages in such turbine being axial .

According to the number of cylinder1.

2.
3.
4.

Single- cylinder turbine

Double cylinder turbine
Three- cylinder turbine
Four- cylinder turbine

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Multi cylinder turbine in which rotor mounted on the same shaft and coupled to single generator
are single stage shaft turbine. Turbine with separate rotor shaft for each cylinder placed parallel to
each other are multi axial turbine.

ACCORDING TO THE METHOD OF GOVERNING

Turbine with throttle governing in which fresh steam enters through one or more (depend

wholly on power) simultaneously operated throttle valves.

Turbine with nozzle governing in which fresh steam enter through two or more
consecutive opening.

HEAT DROP PROCESS

Condensing turbine with regeneration: In this turbine steam pressure is less than outside

temperature.The total number of such extractions usually vary from 2-3 to 8.9.
Condensing turbine with one or two intermediate stages extraction at specific pressure for

industrial and heating process.

Back pressure turbine- The exhaust steam which is utilized for industrial or heating
purpose. To the type of turbine with deteriorated vacuum, can also be added the exhaust
steam of which may be used for heating and other purposes.

Topping Turbine : These turbine are also just like back pressure type with the difference
that the exhaust steam from these is further utilized in medium and low pressure
condensing turbine.

Low- pressure turbine in which exhaust steam from reciprocating steam engines, power

hammers, presses etc. is utilized for power generation purpose.

Mixed pressure turbine with two or three pressure stages, with supply of exhaust steam to
its intermediate stage.

ACCORDING TO THE STEAM INLETCONDITIONS

1.
2.
3.
4.

Low pressure turbine, using steam at pressure of 1.2 to 2 atm.

Medium pressure turbine, using steam at pressure of upto 40 atm.
High pressure turbine, utilizing steam pressure above 40 atm.
Turbine of very high pressure, utilizing steam at pressure of 170 atm and higher and

higher temperature of 535 degree C .

5. Turbine of supercritical pressure, using steam at pressure of 255 atm and above.

24

ACCORDING TO THEIR USAGE IN INDUSTRY

Turbines with variable speed: Turbine of such type can be seen in train, ships.
All these different types of turbine described above depending on their speed of rotation are
either coupled directly or through a reduction gear to the driven machine.

BOTTOM ASH SYSTEM

The ash is constantly, transferred to respective clinker grinder with the help of scraper chain
conveyor, which reduce the lump size to the required fineness.

The main types of hopper used in power station are explained below-

Water Filter Hoppers- This consist of tank made of steel plate. The bottom ash from the
boiler falls into the water filled tank and is immediately quenched large pieces of ash break
up due to the thermal shock, thus the ash collected will be of fairly small size and during
the disposal not much difficultly in terms of crushing aspects will be encountered. These
hoppers may or may not be lined with refractory. The lined hoppers present difficulties with
regard to the maintenance of refractory which goes off to frequently due to temperature
variation. The unlined hoppers have problem on corrosion for which special coating are
recommended.

Quencher Cooled Ash Hoppers- This uses a sense of quenchers located near the top of the
hoppers which provide fine spray of water. This ensures that the ash is cooled sufficiently
to prevent after combustion and smattering within the hoppers. The spray water also keeps
the refractory lining of the hopper cool.

Fly Ash System- The flushing apparatus are provided under hoppers , economizer hopper,
air-preheater hopper, and stack hoppers. The fly ash is normally removed by the
precipitators and bags present at the outlet of furnace. The remaining fly ash is removed fall
inside the precipitators present below the furnace.

25

Ash Water System-.. The bin that contain ash is seperated from the no water bins is
transported for dumping. The recirculation system should be used when availability of water
is high enough and no limitation of time, as the require for separating water and ash take
more time.

26

MPD-MAINTENANCE PLAN DIVISION

This department basically works for proper working and full efficiency working of plant. They take
care of every single part of plant and various categories on which they work are:

Routine Maintenance
Periodic Maintenance
Capital Maintenance
Break Down Maintenance
Preventive Maintenance
Opportunity Maintenance
Predictive Maintenance

27

REFERENCES

WIKIPEDIA
SLIDESHARE
NTPC SITE
UNITED CONVEYOR
WORLD COAL

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