National Thermal Power Corporation Limited.

VOCATIONAL SUMMER REPORT

(17/06/2019 – 16/07/2019)

NTPC Farakka, Nabarun, Murshidabad, West Bengal

(742236)
Ph:-(03485 252 131)

SUBMITTED BY:- SOUVIK GHOSH

UNIQUE CODE :- VT/2019/II/34
DEPARTMENT OF ELECTRICAL ENGINEERING
COOCHBEHAR GOVERNMENT ENGINEERING COLLEGE

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 ACKNOWLEDGEMENT

I AM TRULY THANKFUL TO ALL THE FACULTIES/GUIDES

[SHRI ACHINTYA BISWAS – ASST MANAGER ( O&M/EMD) ]
WHO IMPARTED THE LECTURE ON VARIOUS TOPICS /
SUBJECTS AND TOOK ME TO THE PLANT IN A GUIDED STUDY
VISIT ALONG DETAILED EXPLATION ABOUT THE PLANT AND
ITS MACHINERY.
I WOULD LIKE TO EXPRESS MY GRATITUDE TOWARDS THE
HUMAN RESOURCE DEPARTMENT/EMPLOYEE DEVELOPMENT
CENTER FOR PERMITTING AND ORGANISING THE TRAINNING
PROGRAMME FOR ME.
MY GRATITUDE AND APPRICIATION ALSO GO TO MY FATHER
IN DEVELOPING THE PROJECT AND PEOPLE WHO HAVE
WILLINGLY HELPED ME OUT WITH THEIR ABILITIES.

DATE:-11/07/2019 NAME:- SOUVIK GHOSH

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 INDEX:

Sl. No. Particulars Page No.

1. Introduction 2-4

2. Journey of NTPC 5

3. Concept 6-9

4. Boiler Maintenance Department 10

5. Plant Auxiliary Maintenance 11-12

6. Turbine Maintenance Department 13

7. Coal Handling Department 14

8. Turbo Generator 15

9. Switch Yard and Equipments 16-20

10. Conclusion & Bibliography 21

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INTRODUCTION:
ABOUT THE PLANT
National Thermal Power Corporation, NTPC, the largest power company in
India, was setup in 1975 to power development in the country.

It is among the world’s largest and most efficient power generation companies.
In Forbes list of World’s 2000 largest companies for the year 2007, NTPC
occupies 411th place.

NTPC has installed capacity of 29,394 MW. It has 15 coal based power stations
(23,395 MW), 7 gas based power stations (3,955MW) and 4 power stations in
joint ventures (1,794 MW). The company has power generating facilities in all
major regions of the country. It plans to be a 75,000 MW company by 2017.

NTPC has gone beyond the thermal power generation. It has diversified into
hydro power, coal mining, power equipment manufacturing, oil and gas
exploration, power trading and distribution. NTPC is now in the entire power
value chain and is poised to become an Integrated Power Major. NTPC’s share
on 31 March, 2008 in the total installed capacity of the country was 19.1% and it
contributed 28.50% of the total power generation of the country during 2007-08.
NTPC has set new benchmarks for the power industry both in the area of power
plant constructions and operations. With its experience and expertise in the
power sector, NTPC is extending consultancy services to various organizations
in the power business. It provides consultancy in the area of power plant
constructions and power generation to companies in India and abroad. It is
assumed that every fourth home in India is lit by NTPC.

Farakka Super Thermal Power Station is situated at a distance of 350 km away

from Kolkata in North Bengal in the tusks of nature. It is spread on both side of
holy Ganga covering total area of 4330 acres. Its coal source is eastern coalfields
from the Rajmahal coalmines y the assistance of merry-go-round. Farakka
NTPC gets water from feeder canal of the Farakka Barrage Project. The installed
units are (3*200 MW) and (2*500 MW) hence a total of 1600 MW transport.
One new unit of (1*500 MW) project has been commercialized on 2012.

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Technological Initiative

I. Introduction of steam generators (boilers) of the size of 500 MW.

II. Integrated Gasification Combined Cycle (IGCC) Technology.
III. Launch of Energy Technology Centre- A n e w i n i t i a t i v
e for development o f technologies with focus on fundamental
R&D.

Corporate Social Responsibility

• As a responsible corporate citizen NTPC has taken up

number of CSR initiatives.
• NTPC Foundation formed to address Social issues at national level
• NTPC has framed Corporate Social
Responsibility Guidelines committing up to 0.5% of
net profit annually for Community Welfare.
• The welfare of project affected persons and the local
population around NTPC projects are taken care of
through well drawn Rehabilitation and Resettlement
policies.

Partnering government in various initiatives

▪ Consultant role to modernize and improvise

several plants across the country.
▪ Disseminate technologies to other players in the sector
▪ Consultant role “Partnership in
Excellence” Program for
improvement of PLF of 15

Environment Management

➢ All stations of NTPC are ISO 14001 certified.

➢ Various groups to care of environmental issues.
➢ The Environment Management Group.
NTPC is the second largest owner of trees in the country after the Forest department

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Concept:
There are basically three main units of a thermal power plant:

1. Steam generator or Boiler

2. Steam Turbine

3. Electric Generator

We have discussed about the processes of electrical generation further. A

complete detailed description of the three units is given further.

Stage No. Capacity No. of Generators Total Capacity

1. 200 MW 3 600 MW

2. 500 MW 2 1000 MW

3. 500 MW 1 500 MW

Coal is conveyed (14) from an external stack and ground to a very fine powder
by large metal spheres in the pulverized fuel mill (16). There it is mixed with
preheated air (24) driven by the forced draught fan (20). The hot air-fuel mixture
is forced at high pressure into the boiler where it rapidly ignites. Water of a high
purity flows vertically up the tube-lined walls of the boiler, where it turns into
steam, and is passed to the boiler drum, where steam is separated from any
Remaining water. The steam passes through a manifold in the roof of the drum \
into the pendant superheated (19) where its temperature and pressure increase
rapidly to around 200bar and 540°C, sufficient to make the tube walls glow a
dull red. The steam is piped to the high pressure turbine (11), the first of a three-
stage turbine process. A steam governor valve ( I 0) allows for both manual
control of the turbine and automatic set-point following. The steam is
exhausted from the high pressure turbine, and reduced in both pressure and
temperature, is returned to the boiler re-heater (21 ). The reheated steam is
then passed to the intermediate pressure turbine (9), and from there passed
directly to the low pressure turbine set (6). The exiting steam, now a little
above its boiling point, is brought into thermal contact with cold water
(pumped in from the cooling tower) in the condenser (8), where it condenses

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 rapidly back into water, creating near vacuum-like conditions inside the
condenser chest. The condensed water is then passed by a feed pump (7)
through a de-aerator (12), and pre-warmed, first in a feed heater (13) powered
by steam drawn from the high pressure set, and then in the economizer (23
), before being returned to the boiler drum. The cooling water from the
condenser is sprayed inside a cooling tower (1), creating a highly visible plume
of water vapor, before being pumped back to the condenser (8) in cooling
water cycle. The three turbine sets arc sometimes coupled on the same shaft
as the three-phase electrical generator (5) which generates an intermediate
level voltage (typically 20-25 kV). This is stepped up by the unit transformer (4)
to a voltage more suitable for transmission (typically 250-500 kV) and is
sent out onto the three-phase transmission system (3). Exhaust gas from the
boiler is drawn by the induced draft fan(26) through an electrostatic
precipitator (25) and is then vented through the chimney stack (27).

COAL TO ELECTRICITY: BASICS

The basic steps in the generation of coal to electricity are shown below

Coal to Steam

Coal from the coal wagons is unloaded in the coal handling plant. This Coal is
transported up to the raw coal bunkers with the help of belt conveyors. Coal is
transported to Bowl mills by Coal Feeders. The coal is pulverized in the Bowl
Mill, where it is ground to powder form. The mill consists of a round metallic
table on which coal particles fall. This table is rotated with the help of a motor.
There are three large steel rollers, which are spaced 120 apart. When there is no
coal, these rollers do not rotate but when the coal is fed to the table it packs up
between roller and the table and these forces the rollers to rotate. Coal is crushed
by the crushing action between the rollers and the rotating table. This crushed
coal is taken away to the furnace through coal pipes with the help of hot and
cold air mixture from P.A. Fan.

Fan takes atmospheric air, a part of which is sent to Air pre-heaters

for heating while a part goes directly to the mill for temperature
control. Atmospheric air from F.D. Fan is heated in the air heaters
and sent to the furnace as combustion air.

Water from the boiler feed pump passes through economizer and reaches the
boiler drum. Water from the drum passes through down comers and goes to the
bottom ring header. Water from the bottom ring header is divided to all the four
sides of the furnace. Due to heat and density difference, the water rises up in the

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water wall tubes. Water is partly converted to steam as it rises up in the furnace.
This steam and water mixture is again taken to the boiler drum where the steam
is separated from water.

Water follows the same path while the steam is sent to super-heaters for
superheating. The super-heaters are located inside the furnace and the steam is
superheated (540 C) and finally it goes to the turbine.

Flue gases from the furnace are extracted by induced draft fan, which
maintains balance draft in the furnace (-5 to –10 mm of wall) with forced draft
fan. These flue gases emit their heat energy to various super heaters in the pent
house and finally pass through air pre-heaters and goes to electrostatic
precipitators where the ash particles are extracted. Electrostatic Precipitator
consists of metal plates, which are electrically charged. Ash particles are
attracted on to these plates, so that they do not pass through the chimney to
pollute the atmosphere. Regular mechanical hammer blows cause the
accumulation of ash to fall to the bottom of the precipitator where they are
collected in a hopper for disposal.

Steam to Mechanical Power

From the boiler, a steam pipe conveys steam to the turbine through a stop valve
(which can be used to shut-off the steam in case of emergency) and through
control valves that automatically regulate the supply of steam to the turbine.
Stop valve and control valves are located in a steam chest and a governor, driven
from the main turbine shaft, operates the control valves to regulate the amount of
steam used. (This depends upon the speed of the turbine and the amount of
electricity required from the generator).
Steam from the control valves enters the high pressure cylinder of the turbine,
where it passes through a ring of stationary blades fixed to the cylinder wall.
These act as nozzles and direct the steam into a second ring of moving blades
mounted on a disc secured to the turbine shaft. The second ring turns the shafts
as a result of the force of steam. The stationary and moving blades
together constitute a ‘stage’ of turbine and in practice many stages are necessary, so
that the
cylinder contains a number of rings of stationary blades with rings of moving
blades arranged between them. The steam passes through each stage in turn until
it reaches the end of the high- pressure cylinder and in its passage some of its
heat energy is changed into mechanical energy.

The steam leaving the high pressure cylinder goes back to the boiler for reheating
and

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 returns by a further pipe to the intermediate pressure cylinder. Here it passes
through another series of stationary and moving blades.

Finally, the steam is taken to the low-pressure cylinders, each of which

enters at the centre flowing outwards in opposite directions through the rows of
turbine blades through an arrangement called the ‘double flow’- to the
extremities of the cylinder. As the steam gives up its heat energy to drive the
turbine, its temperature and pressure fall and it expands. Because of this
expansion the blades are much larger and longer towards the low pressure ends
of the turbine.

Mechanical Power to Electrical Power

As the blades of turbine rotate, the shaft of the generator, which is coupled to
that of the turbine, also rotates. It results in rotation of the coil of the generator,
which causes induced electricity to be produced.

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 I. BOILER MAINTENANCE DEPARTMENT
Boiler and Its Description

The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls are
made of a web of high pressure steel tubes about 2.3 inches (60 mm) in diameter. Pulverized
coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming
a large fireball at the centre. The thermal radiation of the fireball heats the water that circulates
through the boiler tubes near the boiler perimeter. The water circulation rate in the boiler is three
tofour times the throughput and is typically driven by pumps. As the water in the boiler circulates
it absorbs heat and changes into steam at 700 deg F and 3200 psi.

The saturated steam is introduced into superheat pendant tubes that hang in the hottest
part of the combustion gases as they exit the furnace. Here the steam is superheated to
1,000 °F (540°C) to prepare it for the turbine. The steam generating boiler has to
produce steam at the high purity, pressure and temperature required for the steam
turbine that drives the electrical generator.
The generator includes the economizer, the steam drum, the chemical dosing
equipment, and the furnace with its steam generating tubes and the super-heater coils.
Necessary safety valves are located at suitable points to avoid excessive boiler
pressure. The air and flue gas path equipment include: forced draft (FD) fan, air pre-
heater (APH), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic
precipitator or bag house) and the flue gas stack.

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 II. PLANT AUXILIARY MAINTENANCE

ASH HANDLING PLANT

The widely used ash handling systems are:

i. Mechanical Handling System

ii. Hydraulic System
iii. Pneumatic System
iv. Steam Jet System

Fly Ash Collection

Fly ash is captured and removed from the flue gas by electrostatic
precipitators or fabric bag filters (or sometimes both) located at the outlet of
the furnace and before the induced draft fan. The fly ash is periodically
removed from the collection hoppers below the precipitators or bag filters.
Generally, the fly ash is pneumatically transported to storage silos for
subsequent transport by trucks or railroad cars.

Bottom Ash Collection and Disposal

At the bottom of every boiler, a hopper has been provided for collection of
the bottom ash from the bottom of the furnace. This hopper is always filled
with water to quench the ash and clinkers falling down from the furnace.
Some arrangement is included to crush the clinkers and for conveying the
crushed clinkers and bottom ash to a storage site.

. WATER TREATMENT PLANT

As the types of boiler are not alike their working pressure and operating
conditions vary and so do the types and methods of water treatment. Water
treatment plants used in thermal power plants used in thermal power plants
are designed to process the raw water to water with a very low content of
dissolved solids known as ‘de-mineralized water’. No doubt, this plant has to
be engineered very carefully keeping in view the type of raw water to the
thermal plant, its treatment costs and overall economics.

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INDUSTRIAL FANS

FD Fan

The fan, normally of the same type as ID Fan, consists of the following components:

i. Silencer
ii. Inlet Bend
iii. Fan Housing
iv. Impeller with blades and setting mechanism
ID Fan
The induced draft fans are generally of axial impulse type
Impeller nominal diameter is of the order of
2500 mm. The fan consists of the following
sub-assemblies:

i. Suction Chamber
ii. Inlet Vane Control
iii. Impeller
iv. Outlet Guide Vane Assembly

Primary Air Fan

PA Fan if flange-mounted design, single stage suction, NDFV type, backward

curved bladed radial fan operating on the principle of energy transformation
due to centrifugal forces. Some amount of
the velocity energy is converted to pressure energy in the spiral casing. The fan is
driven at a
constant speed and varying the angle of the inlet vane control controls the flow.
The special feature of the fan is that is provided with inlet guide vane control
with a positive and precise link mechanism.

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III. TURBINE MAINTENANCE DEPARTMENT

The 200MW turbine is a cylinder tandem compounded type machine comprising

of H.P. and I.P and L.P cylinders. The H.P. turbine comprises of 12 stages the
I.P turbine has 11 stages and the L.P has four stages of double flow. The H.P and
I.P. turbine rotor are rigidly compounded and the I.P. and L.P rotor by lens type
semi flexible coupling. All the 3 rotors are aligned on five bearings of which the
bearing number is combined with thrust bearing.

The main superheated steam branches off into two streams from the boiler and
passes through the emergency stop valve and control valve before entering the
governing wheel chamber of the H.P. Turbine. After expanding in the 12 stages
in the H.P. turbine then steam is returned in the boiler for reheating.

The reheated steam from boiler enters I.P. turbine via the interceptor valves and
control valves and after expanding enters the L.P stage via 2 numbers of cross
over pipes.

In the L.P. stage the steam expands in axially opposed direction to counteract the
thrust and enters the condenser placed directly below the L.P. turbine. The
cooling water flowing through the condenser tubes condenses the steam and the
condensate the collected in the hot well of the condenser.

The condensate collected the pumped by means of 3x50% duty condensate

pumps through L.P heaters to de-aerator from where the boiler feed pump
delivers the water to the boiler through H.P. heaters thus forming a closed cycle.

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 IV. COAL HANDLING DEPARTMENT
As coal is the prime fuel for thermal power plant, adequate emphasis should be
given for its proper handling and storage. Also it is equally important to have a
sustained flow of this fuel to maintain uninterrupted power generation. Coal is
used as the fuel because of the following advantages.

Advantages of coal as fuel:

i. Abundantly available in India

ii. Low Cost
iii. Technology for power generation well developed.
iv. Easy to handle, transport, store and use.

COAL CYCLE

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 ELECTRICAL ASPECT
TURBO GENERATOR
A turbo generator set or turbine generator set is the compound of a steam
turbine or gas turbine shaft-connected to a fast running electric generator for the
generation of electric power. Large steam-powered turbo generators provide the
majority of the world's electricity and are also used by steam-powered turbo-
electric ships.[1]
Small turbo-generators with gas turbines are often used as auxiliary power units (APU,
mainly for aircraft). For base loads diesel generators or gas engines are usually
preferred, since they offer better fuel efficiency, however, such stationary engines have
a lower power density and are built only up to about 10 MW power per unit.
The efficiency of larger gas turbines (50 MW or more) can be enhanced by using
a combined cycle, where the remaining energy of hot exhaust gases is used to
generate steam which drives another steam turbine on same shaft or a separate
generator set.

GENERATION TRANSFORMER

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SwitchYard
Definition-
It is switching station with incoming and outgoing feeders but without the transformer. It is a
type of substation but incoming feeders and outgoing feeders are of same voltage level. Some
times, the out door area of a substation where the circuit breakers are located are also called
switchyard of the substation.
A switchyard connects and disconnects lines on the grid for various regions. The operations
and equipment are essentially all at the same voltage level.

SwitchYard Equipment
•Transmission conductor
•Lightning Arrester
•Capacitor Voltage
Transformer
•Wave Trap
•Earth Switch
•Isolator
•Line Reactor
•Current Transformer
•Circuit Breaker
•Bus Bar
• Post Bus Insulator
•Corona Ring
•Static VAr Compensator
•ICT

Transmission Conductor
•Application : To provide conducting medium
and connecting substation.
Specification:
•Stranded wire is used for decreasing skin effect.
•Material Used: ACSR Moose
•Nominal Voltage: 400kv
•Max. Systemvoltage:420kv

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Lightning Arrester
A Surge Arrestor is a voltage-sensitive device that it
operates in principle, as a non-liner resistor.
It is a protective device which conducts the high
voltage surges on the power systems to the ground.

ISOLATORS
Isolator is an off load device which is operated by remote control or local.
Isolators provided in switchyard are central break type.

Earth switch
Earth switch is required to
discharge the trapped charges on the
line & consists of vertical break.
Earth switch can only be operated
locally.

BUS BAR
The flow of electrical power between
incoming and outgoing circuits takes place
through the bus bars.
These are junction points carrying huge
power’
These are copper rods or thin walled tubes

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operating at constant voltage.
Wave traps
Wave traps are used for communication purpose
during fault conditions.
Wave traps offer high impedance path for high
frequency signals & low impedance path for power
frequency current.

POST INSULATORS
These provides necessary insulation between line
conductors and supports and thus prevent the leakage
of current from conductors to earth.

Corona Ring
To distribute the electric field gradient and lower
its maximum values below the corona threshold
preventing corona discharge.

CURRENT TRANSFORMERS
Used for measuring high value currents.
Designed to provide a current in its
secondary coil proportional to current
flowing in its primary coil.
Primary winding consists of very few turns.
Secondary winding consists of large no. of
turns.
Current to be measured is passes through
Primary winding.

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Capacitor Voltage Transformer
Also known as Potential transformer
Used to step down extra high voltage signals and provide
a low voltage signal, for measurement or to operate a
protective relay.

TRANSFORMER
Used to step down /step up the voltage .
In switchyard it is used step down to
11kv from 440kv of bus bars.

Line Reactor
It is used under the light load
condition to compensate the
capacitive Var of long lines.

Static VAr Compensator(SVC)

One of the FACTS devices.
Used to stabilization of voltage of line .
It provide and compensate the reactive
power of line under variation of load.
Thyristor controlled device.
Removes 5th and 7th harmonics of line.

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CIRCUIT BREAKERS
These are switching devices, design to close or
open an electrical circuit under normal or
abnormal conditions.
It is on load device.
For arc quenching medium SF6 used .
Spring SF6 circuit breaker
Hydraulic circuit breaker
Pneumatic circuit breaker

Relay
Relay detects the faulty element in
the integrated power system and
removes it with the help of circuit
breaker from the remaining healthy
system as quickly as possible to
avoid the damage.

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CONCLUSION:-
Thermal Power Engineering is a very demanding at this point of time. Initials investments to
build a thermal plant are low compared to other power plants. So about 73% of electricity
generated in India is coming from coal based thermal power unit.

A thermal power unit should be built at a place where it is possible to get large amount of
water as well as coal. It should be placed at a far distance from locality for environment
concern.

We have done 4 weeks industrial training in NTPC Farakka Ltd. And gathered a lot of
information regarding machines, type of work etc . This report is mainly based on NTPC
Farakka Ltd. (power plant). All data and specification are gathered from the plant.

Students can learn a lot from different books about various subjects such as operations of a
plant, various constituents of plant, power production, power distribution etc. but a practical
experience helps in better understanding and enhancement of knowledge in various subjects. I
am grateful to NTPC Farakka for organizing this vocational training.

In the end, I would like to say that it was a very big opportunity for me to intern in FSTPS. I
am thankful to all the people at FSTPS with whom I have worked, for teaching e through their
personal experiences and helping in improving my technical skills and concept.

BIBLIOGRAPHY:-
• Power Plant Engineering

• WWW.GOOGLE.COM
• Notes taken during the entire Vocational Training

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