A Summer Training Report On

Study Of Thermal Power Plant

At
NTPC TANDA

GH

UNDER THE GUIDANCE OF

PRAVEEN PRAJAPATI
ASST. MANAGER (O&M-BMD)

SUBMITTED BY:
Neha Kainat
​ (B.TECH- MECHANICAL ENGINEERING)

FEROZE GANDHI INSTITUTE OF

ENGINEERING AND TECHNOLOGY
RAEBARELI
 CERTIFICATE

This is to certify that Ms. Neha Kainat D/o Mohd. Jalil has under gone her summer
training. She has been excellent throughout in her training period.

Shri. RAKESH BAJAJ

AGM (O&M-BMD)
N.T.P.C./ Tanda
 PREFACE

As NTPC the biggest power generating company in our

country, so I opted to go there and do my training.

Big machines and sophisticated labs are the key features

of this power plant. I was sent to Boiler Maintenance
Department (BMD). The Unit Control Room was a treat
to watch with highly trained engineers. The working
culture and the atmosphere were great and everything
said and done was shown practically.

NTPC main core values, Mutual respect & trust,

Initiative & speed, Total quality, Customer focus.
Organizational pride neat & clean surrounding,
employee’s cooperation and a big canteen were the
beautifying factor of the plant.

I believe this experience would certainly

given my personality an all round boost for
it’s a totally different experience working
with a highly trained professionals.​
 ACKNOWLEDGEMENTS
I’m really thankful to my HOD for motivating me to
under go summer training that to in NTPC, TANDA. I
owe my sincere thanks to EDC to grant me the
permission to do training under such a trained and
qualified engineers.
I’m also thankful to Mr. Praveen Prajapati
(Asst. manager- BMD) for giving me the technical
knowledge how about various equipments used up in the
power plant. The staffs of various other departments
were equally co-operative and helpful. I also express my
sincere gratitude towards the Engineers, and other
personnel’s in the BMD department without their help
I would not have made this report.
Abstract
The power sector demand and supply balance in the country is
always tilted towards demand. The demand outstrips supply by a
substantial margin. And the peak demand supply gap is
substantially higher than base demand – supply position. In such
a condition the availability of a generating capacity is very vital.
A generating station in healthy condition not only supplies
electricity to end-users but also provides stability to regional
grid system for its proper functioning.
In Indian power sector, coal based thermal power generating
stations operate as base load stations and they provide major
chunk of the demand. Hence their availability is highly
desirable. These power plants have to undergo certain regulatory
outages as well as outages for necessary maintenance. These
outages are termed as planned outages. And all the other
outages, which cause unit outage, are forced or unplanned
outage. It is clear that the major reason for forced outage is tube
leakage in boiler pressure parts and Condenser tube leakage.
I did my summer training in NTPC TANDA in boiler
maintenance department (BMD) which is mandatory under uptu
rules after third year.
A BRIEF HISTORY OF NTPC TANDA

NTPC- Tanda is a coal based power station having

installed capacity of 440 MW. It is located on Faizabad –
Tanda road via Maya junction at Tanda in Ambedkar
Nagar District, Uttar Pradesh. The nearest railway station
is Akbarpur at 22 KM. The total land area is 1838 acres
out of which the main plant comprises 1013 acres. The
primary water source is river Saryu. NTPC took over the
plant from UPSEB on Jan 14, 2000. It has four units of
110MW each. The plant supplies power to nearby areas
Basti, Gorakhpur, Sultanpur 1 & 2 through 4 transmission
lines of 220 KV each. The plant consists of fuel system,
waste heat recovery boiler, cooling system, water
pre-treatment plant, demineralization plant and a large
switchyard. In line with the NTPC’s vision core values,
importance has been attached to quality, environment, and
occupational health and safety issues toward these: NTPC
Tanda is ISO-9001, ISO-14001, and OHSAS-18001
Certified Company. It is also practicing principle of 5S
for housekeeping.

Technical Features:-

➢ Installed capacity of the power station: 440MW

➢ Boilers : 4 Nos of radiant dry bottom, natural

Circulation, vertical water tube type with single reheats,
380 Tonnes/ hour of steam at
135kg/cm2 and 540​O​c
➢ Turbine and Turbo generator : 4 nos. of 110 MW
➢ Cooling system : Cooling towers
➢ Cooling water source :From Mehripur
pumping station of Tanda canal system and daryabad
link Channel.
➢ Cooling water temperature : 30​o​C
➢ Power transformers : 4 Nos125 MVA 1/220 KV.
Unit Overview
STEAM TURBINE :-

• Impulse Turbines
• An impulse turbine uses the impact force of the steam
jet on the blades to turn the shaft. Steam expands as it
passes through the nozzles, where its pressure drops
 and its velocity increases. As the steam flows through
the moving blades, its pressure remains the same, but

Its velocity decreases. The steam does not expand as it

flows through the moving blades.
i.e. IMPULSE TURBINE = In a stage of Impulse
turbine the pressure/Enthalpy drop takes place only in
Fixed blades and not in the moving blades.

• Reaction Turbines
• In the reaction turbine, the rotor blades themselves
are arranged to form convergent nozzles. This type of
turbine makes use of the reaction force produced as
the steam accelerates through the nozzles formed by
the rotor.
i.e. REACTION TURBINE = In a stage of Reaction
Turbine the Pressure/enthalpy drop takes place in both the
fixed and moving blades.

TURBINE COMPONENTS

1. CASING
2. ROTOR
3. BLADES
4. SEALING SYSTEM
5. STOP & CONTROL VALVES
6. COUPLINGS & BEARINGS
7. BARRING GEAR
8. TURBINE COMPONENTS

Velocity Compounded Turbines ​ :- Here the High

temperature, Pressure Steam is expanded in a single row
of fixed blades into very high velocity which is then fed
to 2 or 3 rows of moving blades with one each
guide/turning row placed in between the two moving
stages.
Pressure compounding Turbines​ :- Here the pressure is
dropped in stages and employs low velocity of Steam in
each stage. Each stage consists of Fixed blades( nozzles)
and moving blades​ .

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

Shrouds are used to prevent steam leakage & to guide

steam to next set of moving blades.

Three types of root arrangements are commonly used.

They are
(1) T-roots: for small blades;
(2) Fir Tree or serrated roots - for longer blades;
(3) Fork and Pin root: for longer blades shrunk on disc
type rotors.

• Integral shroud for are used for shorter blades and

shrunk fitting for larger blades.
• Lacing wires are also used to dampen the vibration and
to match frequencies in the longer blades.
• Since in the reaction type machine the pressure drop
also occurs across the moving blades it is necessary to
provide effective sealing at the blade tips.
 CLASSIFICATION OF TURBINE
ACCORDING TO STEAM PRESSURE

1. ​HP TURBINE​:-

The high press part consists of two horizontally divided

into concentric casings .The inner casings is placed in the
outer casing in such a way that it can be extended radial
and axially .Maintaining the alignment of the two casings
for all operating conditions. The fixed pt for the inner
casings in the radial direction is located between the
nozzle chambers Gland sealing between the incoming
steam line and the nozzle chamber also permits free
expansion of the casings.
 2. ​MP TURBINE​:-
The medium press casing consists of inner & outer casing
divided into top &bottom valves by a horizontal parting
plane. In case it doesn’t extend through the full length of
the casing .It covers only the first four stages the outer
guide wheels are assembled into the carriers suspended
from the outer casing. Steam exhausts s from the MP
Casing to the LP Casing at the top​.

3. LP TURBINE​ :-

​The low press casing is divided horizontally & comprised

of three parts connected by vertical flanges. The front part
of the LP Casing houses the rear MP &the front LP
bearings. The steam from the MP is admitted into LP
casing at its middle & the steam expands left & right. In
the middle part of the LP casings two tube nests of first &
second LP Heaters are mounted to heat the condensate.
To remove top casing dismount these nests first, & then
remove the nuts of the flanges.
 BOILER

In NTPC/Tanda “BABCOX & WILCOX BOILER”: the

boiler consists of metallic tubes where the water temp,
Rises and the water gets converted into steam.
The pulverized coal is fed to furnace where the coal is
burnt at a temp. Of the 1300​0​C-1500​0​C. The pulverized
coal is fed to the boiler furnace which the help of a PA
Fan that is primary air fan.

MAJOR PORTIONS OF BOILER​:

1-Boiler drum.
2-Water Wall
3-Economizer
4-Re-heater
5-Super heaters.
6-FD Fan
7-PA Fan
8-ID Fan
9-Air Pre-heater
Auxiliaries of Boiler​:-

PA FAN​:

The primary air fan pushes the coal & air mixture into the
furnace. The air is compressed at a very high pressure due
to which cyclones are formed containing powder or
Pulverized form of coal from coal mills, which falls in the
boiler. There are six mills for every 110 MW units known
as Mill- A, B, C, D, E & F.
The furnace boiler has very high pressure and the burning
of the coal tapes place in the boiler furnace. The burning
of the coal is initiated with the help of oil. The fuel is
ignited by the oil due to burning of oil the ignition
temperature of the coal is reached.
The efficiency of boiler is around 30 to 40% at least. The
boiler used in TANDA is​ ​Tilting tangential burner,
balanced Draught, fusion welded furnace natural
Circulation, dry bottom with direct fired Pulverized coal
from coal mill & with Steam reheating arrangement
30%HP, LP steam bypassing system has been included.

SUPER HEATER​:
It is meant to raise the steam temp. above the saturation
temp. dry absolving heat from the flue gas by increasing
the temperature of the medium the useful energy can be
recovered increases, these the efficiency of cycle also
increases – the steam temp. is heated upto 540​0​C

REHEATER​:

It is used to raise the temp. of steam from which part of

energy has been extracted in the high pressure Turbine.

This is another method of increasing eh cycle efficiency

which increases no of stages of reheating. Is require some
additional equipment such as boiler Turbine connecting
pipe, heating surface, boiler feed pump etc.

ECONOMIZER​:

It is steam generating but is it observe heat from the flue

gas and this adds to the sensitive heat to the feed
water boiler before the water enters exasperation of boiler.
It provides additional heating surface and this efficiency
is increased and this the fuel consumption is reduced. This
it is called economizer​.
FD FAN​:
The FD Fan is reknown as a forced draft for it is

Placed near the primary air fan. The FD Fan sucks the
cool present in the atmosphere and force it into the boiler
and it forces the hot air to be released in air.

ID FAN​:

It is also Known as induced fan. It is placed at the top of

chimney where it sucks the port air inside the chimney
and forces the cool air inside the chimney. It function as
an exhaust fan .

AIR PRE-HEATER​:

It is used during starting when flue gas enters the air

heater, which is low, and hence further heat extraction is
not possible and low temp. Corrosion fails these are
generally oval or round tubes carrying the steam to be
condensed.
 ​Theory Of BOILER:

Rankine cycle:-
The ​Rankine cycle​ is a cycle that converts heat into work.
The heat is supplied externally to a closed loop, which
usually uses water. This cycle generates about 80% of all
electric power used throughout the world, including
virtually all ​solar thermal​, ​biomass​, ​coal​ and
nuclear​ ​power plants​. It is named after ​William John
Macquorn Rankine​, a Scottish ​polymath​. The Rankine
cycle is the fundamental thermodynamic underpinning of
the ​steam engine​.

Physical layout of the four main devices used in the

Rankine cycle
A Rankine cycle describes a model of
steam-operated ​heat engine​ most commonly found
in ​power generation plants​. Common heat sources for
power plants using the Rankine cycle are the combustion
of ​coal​, ​natural gas​ and ​oil​, and ​nuclear fission​.

The Rankine cycle is sometimes referred to as a

practical ​Carnot cycle​because, when an efficient turbine is
used, the ​TS diagram​ begins to resemble the Carnot cycle.
The main difference is that heat addition (in the boiler)
and rejection (in the condenser) are ​isobaric​ in the
Rankine cycle and ​isothermal​ in the theoretical Carnot
cycle. A pump is used to pressurize the working fluid
received from the condenser as a liquid instead of as a
gas. All of the energy in pumping the working fluid
through the complete cycle is lost, as is most of the
energy of vaporization of the working fluid in the boiler.
This energy is lost to the cycle because the condensation
that can take place in the turbine is limited to about 10%
in order to minimize blade erosion; the vaporization
energy is rejected from the cycle through the condenser.
But pumping the working fluid through the cycle as a
liquid requires a very small fraction of the energy needed
to transport it as compared to compressing the working
fluid as a gas in a compressor (as in the ​Carnot cycle​).

Temperature at different stages of boiler

Ash Handling Plant
Basically there are two types of ash produced in the
power plant

1. Fly Ash.

2. Bottom Ash.

From all the coal that is burning in the boiler 45% ash is
formed in which fly ash content is 80% and bottom ash is
20%. Fly ash is taken through ID Fan to electro static
precipitator where through nozzles water is provided, as
temperature inside the boiler is high so in order to lower
this temperature. From ESP ash is taken out from hoppers
here the efficiency is 99.9% this ash is directly taken in
use in trucks and fed to cement factory rest are fine gas
which is blown off in air through chimney rest ash content
is mixed with water and taken to ash slurry house.
The bottom ash, which is obtained from the boiler, is
taken through hopper to scraper conveyor this conveyor
has large pieces of coal so it is taken to clinker grinder
where it is powdered then mixed with water.
Both bottom ash slurry and fly ash slurry are taken to pit
from where it is taken to pump house where they have &
ash slurry pumps and seal water pump.
Seal water pump is provided to maintain proper
preparation of water and ash it maintains the pressure of
20 kg/cm2. From here ash slurry is taken into ash dykes.
Specification sheet
Ash slurry pump - 160 KW
Seal water pump - 41 KW
HP Pump - 130 KW
LP Pump - 140 KW
HP Water pressure - 12 kg/cm2
LP Water pressure - 7 kg/cm2
Seal Water pressure - 20 kg/cm2
ESP :- ELECTRO STATIC PRECIPITATOR

It handles volume of gases from which said rearticulates

are to be removed their technical superiority clues in
low-pressure drop. For small particle size and creatively
easy removal of the collected particulates.

There are four stage of precipitation

I. Ionization of gases and charging of dust particles
II. Migration of the particle to be coveter
III. Deposition of charged particles on the collecting
surface.
IV. Dislodging of particles from the collecting surface.

The ESP consist of two sets of electrodes congest of two

sets of noises caved discharges or emitting electrodes and
other sets of noises caved collecting electrodes and are
placed in the center of pipes or midway between the
plates are connected usually to negative polarity of high
voltage of AC source of the order of 25-100 KV. The
collecting electrodes of positive polarity of the source are
grinded. The high electric field in the quaintly of the
committing electrodes creates corona discharges lone sing
the gas molecules. The dust particle entrained in the gas
acquires negative charge and experiences a force which
drives them forward the collecting electrodes others they
are deposited.
Electrostatic precipitation finds its applications as a no of
process and metallurgical industries. This is because it
can be designed in a larger no of types to suit the process
condition.