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PRIVATE LIMITED
INDIRA GANDHI SUPER THERMAL POWER PROJECT
JHAJJAR , HARYANA
A TRAINING REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF
THE DEGREE OF
BACHELOR OF TECHNOLOGY
(Mechanical & Automation Engineering)
SUBMITTED TO
AMITY UNIVERSITY, RAJASTHAN
SUBMITTED BY
Vijay Kumar
A20405413119
28-05-16 to 27-06-16
BACHELOR OF TECHNOLOGY
(Mechanical & Automation Engineering)
SUBMITTED TO
AMITY UNIVERSITY, RAJASTHAN
SUBMITTED BY
Vijay Kumar
A20405413119
28-05-16 to 27-06-16
ACKNOWLEDGEMENT
I would like to place on record my deep sense of gratitude to Er. Sarfaraj Ali, HR manager
and Ranbir Singh for vocational training for his support during the start of my training.
I express my sincere gratitude to Anil Sir, Water Treatment Manager for his stimulating
guidance, and continuous encouragement .
I also wish to extend my thanks to Er. B.L Thakur ,O.P Sharma, Rahul Sharma, Rinku Sir and
other workers for guiding and providing the knowledge related to machinery and processes.
I am extremely thankful to Dr. DD Shukla, Director, ASET, for encouragement and I am also
thankful to the faculty members of Mechanical & Automation Engineering department for
providing the opportunity to get the knowledge .
Signature of Student
Vijay Kumar (9896254423)
CERTIFICATE
I hereby certify that I have completed the Four weeks Training in partial fulfillment of the
requirements for the award of Bachelor of Technology in Mechanical & Automation
Engineering. I did my training at Indira Gandhi Super Thermal Power Station from 2805-16 to 27-06-16.
The matter presented in this Report has not been submitted by me for the award of any other
Degree elsewhere.
Signature of Student
Vijay Kumar (9896254423)
Signatures
Examined by:
SAMPLE SHEET
CERTIFICATE
TABLE OF CONTENTS
Page No.
Acknowledgement
CHAPTER 1
ABOUT COMPANY
IGSTPP
PLANT LAYOUT
CHAPTER 2
STEAM GENERATOR
BOILER
BOILER ASSESORIES
11
STEAM CIRCULATION
17
CHAPTER 3
FUEL OIL SYSTEM
22
MILL
24
27
ELECTROSTATIC PRECIPITATOR
29
32
CHAPTER 4
TURBINE
33
HP TURBINE
36
IP TURBINE
37
LP TURBINE
38
TURBOGENERATOR
38
CHAPTER 5
COOLING TOWER
40
DM WATER
42
COAL HANDLING
43
CHAPTER 1
ABOUT COMPANY
Indias 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
business. Apart from power generation, which is the mainstay of the
company, NTPC has already ventured into consultancy, power trading, ash
utilization and coal mining. NTPC ranked 317th in the 2009, Forbes Global
2000 ranking of the Worlds biggest companies.
to have a diversified fuel mix with coal based capacity of around 53000
MW, 10000 MW through gas, 9000 MW through Hydro generation, about
2000 MW from nuclear sources and around 1000 MW from Renewable
Energy Sources (RES). NTPC has adopted a multi-pronged growth strategy
which includes capacity addition through green field projects, expansion of
existing stations, joint ventures, subsidiaries and takeover of stations.
NTPC has been operating its plants at high efficiency levels. Although the
company has 18.10% of the total national capacity it contributes 28.60%
of total power generation due to its focus on high efficiency. In October
2004, NTPC launched its Initial Public Offering (IPO) consisting of 5.25% as
fresh issue and 5.25% as offer for sale by Government of India. NTPC thus
became a listed company in November 2004 with the government holding
89.5% of the equity share capital. The rest is held by Institutional Investors
and the Public. The issue was a resounding success. NTPC is among the
largest five companies in India in terms of market capitalization.
NTPC Ltd. has been named a Platts Top 250 Global Energy Company for
the year 2009. NTPC Ltd. was awarded the No.1 Independent Power
Producer (IPP) in Asia and No. 10 in overall performance among the energy
VISION
A world class integrated power major, powering India's growth with increasing
global presence.
MISSION
Develop and provide reliable power related products and services at competitive prices,
integrating multiple energy resources with innovative & Eco-friendly technologies and
contribution to the society. View of a well flourished power plant Core Values.
Business Ethics
Customer Focus
Organizational & Professional Pride
Mutual Respect & Trust
Innovation & Speed
Total Quality for Excellence
ABOUT IGSTPP:
Capacity
Status
Equity Sharing
Location
Site Jharli is 35 km from Jhajjar district of Haryana and 100 km (approx.) from Delhi.
Beneficiary
Haryana, Delhi, Himachal Pradesh, Jammu & Kashmir, Punjab, Rajasthan, Uttar Pradesh, Uttarakhand, Andhra
Pradesh, Kerala and Telangana.
Coal Linkage
As on date, coal linkage made from Mahanadi Coalfield Ltd.,Eastern Coalfield Ltd. & Northern Coalfield Ltd.
Water Source
Power
Through two associated 400 KV Double Circuit transmission system to Daulatabad (Haryana) and Mundka
Evacuation
(Delhi).
A.
Special Feature
Drum type sub critical boiler Pressure 178 Kg/Sq cm and steam Temp 540 deg (MS) & 568 deg (RH).
B.
KWU turbine with Single reheats, having 17 stages in HP, 12X2 stages in IP and 6X2 stages in LP.
C.
D.
Water being stored intwo reservoirs built on 350 Acresland and provided with HDPE lining. Each has
storage capacity of 35 Lac Cum.
E.
100% Dry Ash collection from ESP hoppers and disposal by High concentration Slurry Disposal
system (HCSD) and dry ash system.
F.
Ash water recirculation system is installed to re-use the ash slurry disposal over flow water
G.
RO Plant for recycling the waste water of station to ensure zero effluent discharge.
H.
STEAM GENERATOR
500 MW
Boiler also known as steam generator is used to convert water into steam
using the heat given by the fuel.
The plant uses super-critical steam generation, with water instantly being
converted into steam without passing through the boiling phase. The
boiler used has following unique features:Start up and low load system-separator and collecting vessel in place
of drum.
New materials for high temperature and pressure applications.
Larger size components for large unit sizes.
Furnace walls small tube diameters (spiral and vertical walls).
Parameters
Stage-1
Steam Temp./Pressure at SH
outlet
568
256Kg/cm2
2100T/Hr
Steam Temp./Pressure at RH
596
outlet
59.5Kg/cm2
1691T/Hr
No. of fans
No. of mills
Composition
Temp Range
Used in
SA 210 C
C = 0.35%,Si =
1.06%,
289.7 0 C To 340.4
C
Economizer
304.9 0 C To 457.1 C
LTRH
P=0.048%,S=
0.058
SA209T12
SA
T23
492 0 C To 540 C
LTRH, RH FINAL
SH FINAL, SH PLATEN
SA
T91
T22
2.25%Cr, 1%Mo
492 0 C To 540 C
RH FINAL, SH FINAL,
FC SPACER TUBES
340 0 C To 411.2 C
VERTICAL FURNACE
REAR WALL, SCREEN
FURNACE REAR
WALL,HGR, SPIRAL
WALL,FURNACE REAR
ARCH,
The boiler is having salient design features some of them are as following:Two pass.
9
Principle of Operation: This plant works on the rankine cycle. The water is
heated above its critical point so that it changes into steam without
boiling. Critical is a thermodynamic expression describing the state of a
substance beyond which there is no clear distinction between the liquid
and gaseous phase.
ADVANTAGES OF SUPERCRITICALTECHNOLOGY
The principal advantages of supercritical steam cycle are:
Reduced fuel costs due to improved thermal efficiency
Reduced CO2 emissions by about 15% compared with typical existing
sub critical plant
Well-proven technology with excellent availability, comparable with that
of existing sub critical plant
Very good part-load efficiencies, typically half the drop in efficiency
experienced by sub critical plant.
10
Mass flow rate thru all heat transfer circuits from Eco. inlet to SH
outlet is kept same unlike drum type boilers except at low loads.
The fundamental difference lies in heat absorbing surface or
evaporation portion of the unit.
Ring Header: - The function of ring header is to pass the water to spiral
11
Separator: - The main work of the separator is to separate the wet steam
from dry steam. The wet steam is send to storage tank and the dry steam
to super heaters.
1. Storage Tank: - This is used to store the wet steam coming from
12
Super heater
Super Heater Arranged In 3 Stages:
from
its
Super heaters are often divided into more than one stage.
The enthalpy rise of steam in a given section should not exceed
o 250 420 kJ/kg for High pressure (> 17 MPa)
o < 280 kJ/kg for medium pressure(7 Mpa 17 MPa)
o < 170 kJ/kg for low pressure (< 7 MPa)
Platen Superheater
13
saturation
types.
The Pendant SH is always arranged in the horizontal crossover duct.
Pendant SH tubes are widely spaced due to high temperature and ash
is soft.
Transverse pitch : S1/d > 4.5
Longitudinal pitch: S2/d > 3.5.
The outside tube diameter : 32 51mm
Tube thickness : 3 7mm
14
Desuperheater
flue gas path does the reheating of the returned steam. The reheat steam
is at a much lower pressure than the super heated steam but the final
reheater temperature is greater than superheated steam temperature.
Reheating to high temperatures improves the output and efficiency of the
Power Plant. Final Reheater temperature is 596C for this boiler. Reheat
steam pressure is 59.5 Kg/cm2.
Reheate
r
Air Preheater
The purpose of the air preheater is to recover the heat from the boiler flue
gas which increases the thermal efficiency of the boiler by reducing the
useful heat lost in the flue gas. As a consequence, the flue gases are also
sent to the flue gas chimney at a lower temperature, allowing simplified
design of the ducting and the flue gas chimney. It also allows control over
the temperature of gases leaving the chimney (to meet emissions
16
Airpreheat
er
17
The feed water coming from boiler feed pump is first supplied at
economizer inlet header in which the feedwater is heated using the flue
gases remaining heat. The temperature of water increases from 291C to
305C. After that this heated water goes into economizer outlet header
from where it goes to the ring header or furnace lower header. The water
then flows through the spiral and vertical water tubes and heated up into
wet steam. Thereafter it goes into the separator. The wet steam is sent to
economizer through the storage tank for recirculation. The dry steam then
circulates through back pass sidewall tubes and back pass upper side wall
header. Then it circulates through the super heater platen assemblies and
super heater for super heating of steam above its critical temperature. The
super heated steam of temperature 540Cthe goes to high pressure
turbine for expansion. The steam after expansion again comes into boiler
for reheating. The steam is reheated into reheater assemblies up to
temperature of 568Cand then it is send to expand in intermediate and
low pressure turbines. After that the steam condenses into condenser and
18
then again fed to boiler using boiler feed pump and feed water regulatory
system.
S.H. DIVISION
ECONOMIZER
TUBES
SEPARATORS
STORAGE
TANK
BOILER
BACKPASS UPPER
HEADE
S.H. PLATEN
R.H. LOW.
HEADER &
PIPE
19
HORIZONTAL
ASSEMBLIES
ASSEMBLIES
R.H. FINISHING
OUTLET
R.H. FINISHING
ASSEMBLY
20
50
593
247
HPT
D
D
2.08
0.98
1
172.
1
LPH3
IP
T
565
LPH2
102.
2
L
P
T
B
0.37
7
LPH1
CONDENSER
GSC
CE
P
Drain
cooler
Steam line
PRESSURE
Feedwater line
Drip line
steam/water
21
TEMPERATURE
F
D
BOILER
H
A
C
75.9
1
53.2
0
23.93
DE
ARA
TO
R
480.4
382.
4
HPH8
334.
0
(I)
HPH7
HPH6
(I)
(I)
LPH
4
L
75.9
1
53.2
0
23.93
480.4
382.
4
HPH8
(II)
334.
0
HPH7
HPH6
(II)
( II)
TDBF
P
PRESSURE
TEMPERATURE
22
Oil Burners
The types of oil used in the oil burners are:
a) Light Diesel Oil
23
24
MILLS
The coal is pulverized using bowl mills so that it can be used in the boiler
furnace. Total 9 mills are used in this boiler, 4 on one side and 5 on the
other side of the boiler .these mills are arranged upto 9 elevation .the coal
coming through the conveyer belt goes into bowl mill where it is
pulverized upto 200 mesh. Then it is blown up using the hot primary air
supplied from PA Fan. Then this coal is fed into the boiler from four corners
with the help of four outlet pipes from the bowl mill. The air required for
burning of coal is provided by wind box on which the hot secondary air is
supplied from the Air Preheater.
Height
25.766M
27.267M
28.768M
30.269M
31.770M
33.271M
34.772M
36.273M
37.773M
For startup and temperature maintaince oil burners are used in the boiler. 20 oil
guns are placed upto five elevations resulting in four oil guns at each elevation.
25
Elevation
26.517M
28.018M
31.020M
34.022M
37.024M
PULVERISER DATA
Type of mill:
Bowl Mill
Size of mill:
HP 1103
9 (Nine)
696 / 1000
Deg C 66 to 90
26
Role of Mills
Produces Pulverized coal 80% of which passes through 200 mesh
Air mixed with Pulverized coal (PF) is carried to the coal nozzle in the
wind box assembly.
PF from coal nozzle is directed towards the centre of boiler burning
zone
Pre-heated secondary air enters boiler and surrounds the PF and help
in combustion
Bowl mill
27
Impact Firing: This is the arrangement with the type of burner used
with slag tap furnaces where the ash is kept in a molten state on the
furnace floor and tapped off as and when necessary.
28
Tangential firing
DRAFT SYSTEM
Most boilers now depend on mechanical draft equipment rather than natural
draft. This is because natural draft is subject to outside air conditions and
temperature of flue gases leaving the furnace, as well as the chimney height. All
these factors make proper draft hard to attain and therefore make mechanical
draft equipment much more economical.
There are three types of mechanical draft:
Induced draft: This is obtained one of three ways, the first being the "stack
effect" of a heated chimney, in which the flue gas is less dense than the
ambient air surrounding the boiler. The denser column of ambient air forces
combustion air into and through the boiler. The second method is through
29
use of a steam jet. The steam jet oriented in the direction of flue gas flow
induces flue gasses into the stack and allows for a greater flue gas velocity
increasing the overall draft in the furnace. This method was common on
steam driven locomotives which could not have tall chimneys. The third
method is by simply using an induced draft fan (ID fan) which removes flue
gases from the furnace and forces the exhaust gas up the stack. Almost all
induced draft furnaces operate with a slightly negative pressure.
Forced draft: Draft is obtained by forcing air into the furnace by means of a
fan (FD fan) and ductwork. Air is often passed through an air heater; which,
as the name suggests, heats the air going into the furnace in order to
increase the overall efficiency of the boiler. Dampers are used to control the
quantity of air admitted to the furnace. Forced draft furnaces usually have a
positive pressure.
Balanced draft: Balanced draft is obtained through use of both induced
and forced draft. This is more common with larger boilers where the flue
gases have to travel a long distance through many boiler passes. The
induced draft fan works in conjunction with the forced draft fan allowing the
furnace pressure to be maintained slightly below atmospheric.
In this boiler balanced draft system is used both ID Fan and FD Fan are used in
this boiler for this type of system.
Induced Draft Fan. The hot flue gases from the furnace are drawn out by the
Induced draft fan. The gases pass through the various heating surfaces of the
boiler, the Electrostatic Precipitator and discharges to the atmosphere at the top
of the stack. Induced Draft Fan provides the energy for this flow of flue gases. The
Induced
Draft
Fan
is
normally
located
adjacent
to
the
Stack.
Forced Draft Fan supplies most of the Combustion air. This fan takes air from the
atmosphere and blows it into the furnace through air ducts. The Air Heater heats
the air before it enters the Furnace.
30
The ash content in the Indian coal is of the order of 30 to 40%. When coal is fired
in boiler, ashes are liberated and about 90% of coal is carried out by flue gases. If
these gases are allowed in atmosphere it will create an air pollution and hence
health hazards. Hence it is necessary to precipitate the dust from flue gas and in
this process electrostatic precipitator finds a place in boiler.
The additional advantage obtained because of ESP is that the wear of I.D. Fan
blades is reduced due to precipitation of dust. The ESP is efficient in precipitation
of particles from submicron to large sizes of particles and hence they are
preferred to mechanical precipitators. These dust-laden gases pass through an
electrostatic precipitator that collects most of the dust. Cleaned gas then passes
out of the precipitator and through a stack to the atmosphere. Precipitators
typically collect 99.9% or more of the dust from the gas stream. Precipitators
function by electro statically charging the dust particles in the gas stream. The
charged particles are then attracted to and deposited on plates or other
collection devices. When enough dust has accumulated, the collectors are shaken
31
to dislodge the dust, causing it to fall with the force of gravity to hoppers below.
The dust is then removed by a conveyor system for disposal or recycling.
Discharge electrodes emit charging current and provide voltage that generates
an electrical field between the discharge electrodes and the collecting plates. The
electrical field forces dust particles in the gas stream to migrate toward the
collecting plates. The particles then precipitate onto the collecting plates.
Collecting plates are designed to receive and retain the precipitated particles
until they are intentionally removed into the hopper. Collecting plates are also
part of the electrical power circuit of the precipitator. These collecting plate
functions are incorporated into the precipitator design. Plate baffles shield the
precipitated particles from the gas flow while smooth surfaces provide for high
operating voltage. Collecting plates are suspended from the precipitator casing
and form the gas passages within the precipitator.
32
34
TURBINE
A turbine is a rotary engine that extracts energy from a fluid flow and
converts it into useful work. A working fluid contains potential energy
(pressure head) and kinetic energy (velocity head). The fluid may be
compressible or incompressible. Several physical principles are employed
by turbines to collect this energy. The turbine is of two types:
35
But both turbines have some shortcomings the impulse turbine cannot be
used due to following reasons:-
36
As the steam flows through the nozzle its pressure falls from inlet
pressure to the exit pressure (atmospheric pressure, or more usually,
the condenser vacuum). Due to this higher ratio of expansion of
steam in the nozzle the steam leaves the nozzle with a very high
velocity. The steam leaving the moving blades is a large portion of the
maximum velocity of the steam when leaving the nozzle.
The enthalpy drop is in the nozzle hence the rotor velocity is very high
such a high velocity cannot be used for electricity production.
Hence the turbine used in this plant is both impulse and reaction type. The
turbine used in STAGE-1 is having four turbine casings. One high pressure
casing, one intermediate pressure casing and two low pressure casings.
LMZ
impulse and reaction
1
1
37
LPC:
Type of arrangement:
Tandem
Directly coupled to generator
Type of governing:
Nozzle governing
CRITICAL Speeds:
820, 1360, 1753, 1812, 2386, 3950, 4180 RPM
HP Turbine
The super heated steam coming from the boiler expands into the high
pressure turbine in total 17 stages. The steam expansion occurs in single
flow and the in series i.e. the steam expands firstly in 9 stages then in 8
stages. The extraction of steam is done after 13th stage and at exhaust for
heating the feed water through HPH7 and HPH8.
540C
296.76C
247 Ksc
47.62 Ksc
16
38
IP Turbine
The super heated steam after expansion in HPT is send to boiler for
reheating. The reheated steam then expands in intermediate pressure
turbine in 22(11*2) stages. The expansion occurs in double flow.
568C
212C
42.85Ksc
3.10Ksc
11*2
None
LP Turbine
The reheated steam after expanding in IPT goes into two LPTs for further
expansion. The low pressure turbine is double flow and each LP turbine
consist 10(5*2) stages.
212.59C
39
49.05C
3.10 Ksc
0.104 Ksc
(5*2)*2
None
3rd stage extraction to LPH2.
GENERATOR
40
and high rotational speed. Every reduction in the purity of the hydrogen
coolant increases windage losses in the turbine; as air is 14 times denser
than hydrogen, each 1% of air corresponds to about 14% increase of
density of the coolant and the associated increase of viscosity and drag. A
purity drop from 97 to 95% in a large generator can increase windage
losses by 32%; this equals to 685 kW for a 907 MW generator. The
windage losses also increase heat losses of the generator and the
associated cooling problems. The flammability limits (4-93) % of hydrogen
in air at normal temperature, wider at high temperatures, its auto ignition
temperature at 571C, its very low minimum ignition energy, and its
tendency to form explosive mixtures with air, require provisions to be
made for maintaining the hydrogen content within the generator above
the upper or below the flammability limit at all times, and other hydrogen
safety measures. When filled with hydrogen, overpressure has to be
maintained as inlet of air into the generator could cause a dangerous
explosion in confined space.
COOLING TOWERS
The steam extracted from the low pressure turbine must be cooled down
before it can be used again in the boiler. The volume of the steam coming
42
from the turbine is very large so a lot work needs to be done if this has to
be pumped again in the boiler. The cooling of steam is done by using the
water coming through the C.W. pump. The water flows through the tubes
in the condenser and get heated up cooling the circulating steam.
The cooling tower is consists of large fans at the top an the hot water is
sprayed under it , it is break down into small droplets using the fins that
are made of PVC. Every unit has two towers and each tower has 12 fans.
The cold water is supplied from cooling tower through a circulating water
channel. The six motors used in C.W. pump house provide the required
head to water to come through the condenser at cooling tower. The water
43
The C.W. Pump house has pumps .These pumps are used to provide the
head to the cold water to circulate through the condenser and pass
through the cooling tower.
D.M.WATER SYSTEM
Demineralization or Deionization is the process of removing mineral salts
from water by using the ion exchange process. With most natural water
44
45
The overall layout of the CHP is mentioned below:1. Wagon tripper unloads the coal from the railway wagons into the
storage space for the coal.
2. There are two types of railway wagons which are used to supply coal
in the power plants. One type of wagon opens from the bottom to
unload the coal and the other type of the wagon has to be inverted
sideways by the wagon tripper.
3. The wagon tripper which is used at NTPC Barh has the capacity of 24
tips per hour.
4. Dust extraction and dust compression is performed before the initial
point of the conveyor.
5. Dust extraction means to remove the coal dust from the coal to be
sent to the conveyor.
6. Dust suppression means to deposit the dust bye suppressing it
before the coal is fed into the conveyor.
7. Any extra coal, if comes, is led into the stacker from which the coal
is used in case of shortage.
8. Then the coal is loaded on the conveyor.
9. The conveyor has the following specifications:Length - 450 meters
Width 50 meters
46
Height 30 meters
Inclination 14 degrees
10.
12.
Pedal feeder has the capacity of 2400 metric tones per hour.
14.
Pedal feeder is a fan like structure with scoops which loads the
Then the coal is fed into the crusher house where the coal is
There are bunkers on two sides for each boiler; five on one
There are mills in each bunker and these mills serve the
backward.
21.
47
coal which has come from the railway wagons. Coal is of two grades
A grade and B grade.
23.
48