CONTENTS

TITLE ABOUT NTPC ABOUT NTPC BADARPUR BASIC POWER PLANT CYCLE COAL CYCLE BOILER PULVERIZER BOILER AUXILIARIES TURBINE TURBINE AUXILIARIES ASH HANDLING PLANT WATER TREATMENT PLANT CONTROL STRUCTURE PUMP HOUSE CONCLUSION

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ABOUT NTPC
Indias Largest Power Company NTPC was established in 1975 to accelerate power development in India .NTPC is emerging as a diversified power major with presense in the entire value chain of the power generation business . Apart from power generation ,which is the mainstay of the company. NTPC ventured into consultancy ,power trading ,ash utilization & coal mining .NTPC become a Maharatna company in May 2010,one one othe only four company to be awarded this status . The total installed capacity of the company is 34,854 MW(including JVs)with 15 coal based and 7 gas based stations ,located across the country. In addition under JVs 5 station are coal based and another station uses naptha/LNG as fuel. NTPC has been operating its plant at high efficiency levels. Although the company has 17.75% of total national capacity ,it contributes 27.40% of total power generation due to its focus on high efficiency.

NTPC OWNED 15 COAL BASED PLANTS 27,535 MW capacity 07 GAS/LIQUID FUEL BASED PLANTS 3,955 MW capacity

OWNED BY JVs

5 COAL BASED JVs of 1,424 MW capacity 1 GAS BASED JVS of 1940 MW capacity.

VISION A world class integrated power major, powering Indias growth with increasing global presence. MISSION Provide good value to potential sellers and develop commercial arrangements .Enable NTPC to maintain optimal generation level through mutually beneficial trading. Provide viable alternatives to buyers for meeting their demands. Plan and establish a Power Exchange at National Level using state-of-the-art technology. CORE VALUES

Business Ethics Customer Focus Organizational & Professional Pride Mutual Respect and Trust Innovation & Speed Total Quality for Excellence

ABOUT NTPC BADARPUR

NTPC BADARPUR is one of the coal based thermal power plant of NTPC. It has a installed capacity of 705 MW. The first unit was commissioned in 1973.The coal for this plant comes from Jharia coal mines. This was constructed under ownership of Delhi Vidyut Board. Later it was transferred to NTPC . INSTALLED CAPACITY UNIT INSTALLED CAPACITY 1 2 3 4 5 95 MW 95 MW 95 MW 210 MW 210 MW DATE OF COMMISIONING JULY,1973 AUGUST,1974 MARCH,1975 DECEMBER,1978 DECEMBER,1981 RUNNING RUNNING RUNNING RUNNING RUNNING STATUS

65 MW is consumed in the power plant itself .640 MW is fed into the grid and distributed to the desired stations. A thermal power plant requires mainly two things coal and water. TURNAROUND CAPABILITIY The expertise in R&M and performance turnaround was developed and built up by NTPC with the operational turnaround of Badarpur TPS through scientifically engineered R&M initiatives. The PLF of the power station improved from 31.94% at the time of the takeover to 86.46% for the year 2007-08.

BASIC POWER PLANT CYCLE

The thermal power plant uses Rankine cycle. It is a closed cycle to enable the working fluid to be used again and again. It is modified to include superheating of steam, regenerative feed water heating and reheating of steam.

Process 1-2: The working fluid is pumped from low to high pressure, as the fluid is a liquid at this stage the pump requires little input energy. Process 2-3: The high pressure liquid enters a boiler where it is heated at constant pressure by an external heat source to become a dry saturated vapour. Process 3-3: The dry vapour is superheated. Process 3-4: The superheated vapour expands through a turbine, generating power. This decreases the temperature and pressure of the vapor, and some condensation may occur. The output in this process can be easily calculated using the Enthalpy-entropy chart or the steam tables. Process 4-1: The wet vapor then enters a condenser where it is condensed at a constant temperature to become a saturated liquid.

COAL CYCLE
From Jharia mines Railway Wagons BTPS Wagon Tippler Magnetic Separator Furnace RC Feeder RC Bunker Coal Stock Yard Crusher House Bowl Mill Coal is used as a main fuel in thermal power station. It is transported from coal mines to the power plants by railway wagons. Coal brought by railways is unloaded with the help of wagon tippler in a coal hopper. The movement of wagons are controlled by automatic in-haul and out-haul bettle chargers. This coal is then feeded on coal conveyor belt through vibrating feeder. These feeders are of electro-magnetic type and controls the rate of feeding required for bunkering. By the various combinations of conveyor belts ,coal is conveyed to the surge hopper of a crusher house. Before the coal comes to the crusher house, the ferrous materials which comes along with the coal is taken out with the help of suspended and rotating type magnetic separators. Non-ferrous materials like stones shells,wood etc. are removed manually. From surge hopper, coal is fed to the coal crusher through mechanical feeder. Here coal is crushed to the size of 20-25 mm. This sized coal is then sent to coal bunkers through various belts and finally coal trippers and stored for further processing of coal for combustion in boiler furnace. This cycle is known as bunkering cycle. If bunkers are full or coal is not required due any means on units, then coal is diverted to the stack yard with the help of stacking conveyor belts. This cycle is known as stacking cycle. If coal is not available from any means of coal transportation and coal is urgently required for the unit, then the stacked coal is diverted to the bunkers with the help of reclaiming belts. This cycle is known as reclaiming cycle. TYPES OF STORAGE There are two types of storage available: a) Live Storage: Storage from which coal may be withdrawn to supply to combustion equipment with little or no remanding in live storage. This storage consists of about 24 to 30 hrs of coal requirement of plant and usually a covered storage in the plant near the boiler furnace. The live storage can be provided with bunkers & coal bins.
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b) Dead Storage: Stored for future use. Mainly it is for longer period of time and it is mandatory to keep a back of fuel for specified amount of days depending upon its requirement. MAJOR CONSTITUENTS OF COAL HANDLING PLANT ARE: a) Wagon Tippler: It is used to unload the railway wagons.
b) Idlers: These essentially consists of rolls made out of seamless steel tube enclosed

fully at each end and fitted with stationary shaft ,anti friction bearings and seals. They support the belt and enable it to travel without much friction losses and also keep the belt properly trained.
c) Conveyor Belt: The conveyor belt consists of layers of piles of fabric duck,

impregenated with rubber and protected by a rubber cover on both sides and edges. The fabric duck supplies the strength to withstand the tension created in carrying the load while the cover protects the fabric carcass. Heat resistant belting is always recommended for handling higher temperature. There are 14 conveyor belts in the plant. They are numbered so that their function is easily demarcated.
d) Crusher: The role of crusher is to crush the coal from 200 mm to 20 mm size of coal

received from the vibrating screen. This is accomplished by means of granulators of ring type. There are about 37 crushing elevations; each elevation has 4 granulators-2 of plain type and 2 of tooth type, arranged alternately. The granulators are made of manganese steel because of their work hardening property. The coal enters the top of the crusher and is crushed between rotating granulators and fluid case path. The crushed coal through a chute falls on belt feeder. Normally these crushers have a capacity round 600 tonnes/ hr.
e) Magnetic Separator: This is an electromagnet placed above the conveyor to

attract magnetic materials. Over this magnet there is one conveyor to transfer these materials to chute provided for dumping at ground level. Because of this, continuous removal is possible. It can remove any ferrous impurity from 10 gms to 50 kg.
f) Vibrating Feeder: It is used to feed the coal on the underground conveyor belt from

where coal goes to bunker. Coal from the stockyard with the help of bulldozer is

taken to the vibrating feeder via reclaim hopper and underground conveyor belts. A tripper is provided in the conveyor to stack the material at desired location on either side or along the conveyor with the help of chute or chute fitted with the tripper itself. The tripper is provided with wheels, which move on rails parallel to conveyor.
g) Scrappers : These are located at the bottom end of the conveyor belts. Conveyor

belts carry sometimes carry wet coal and due to presence of moisture dirt sticks on the belt which led to false running of conveyors, to avoid this type of false movement scrappers are used at the bottom edge of each end which removes dirt or dust stick to the belts.

BOILER
A Boiler or steam generator essentially is a container into which water can be fed and steam can be taken out at desired pressure, temperature and flow. This calls for application of heat on the container. For that the boiler should have a facility to burn a fuel and release the heat. The functions of a boiler thus can be stated as:1. To convert chemical energy of the fuel into heat energy 2. To transfer this heat energy to water for evaporation as well to steam for superheating.

Fig :showing boiler and its components or auxiliaries The boiler used in a thermal power plant is water tube boiler. WATER TUBE BOILER In this type, the water tubes are arranged inside a furnace in a number of possible

configurations: often the water tubes connect large drums, the lower ones containing water and the upper ones, steam and water; in other cases, such as a monotube boiler, water is circulated by a pump through a succession of coils. This type generally gives high steam production rates, but less storage capacity than the above. Water tube boilers can be designed to exploit any heat source and are generally preferred in high pressure applications since the high pressure water/steam is contained within small diameter pipes which can withstand the pressure with a thinner wall. WORKING Feed water is fed to the boiler drum through the economiser. Water then enters in bottom ring header through six numbers of down comers. In boiler furnace, coal is fired with fuel oil. The heat energy developed by combustion of coal in furnace is utilized for the evaporation of water in water walls. As the density of steam is lower than water ,this water steam mixture enters in boiler drum without help of any pump. This is called natural circulation. In boiler drum, steam is separated from the mixture in three steps i.e. cyclone separators (Primary separators) ,secondary separators and screen dryers (Final separators). Steam that comes out of boiler is called saturated steam. This saturated steam is then passed through number of superheaters i.e. primary, platen and final for superheating of steam to a temperature of 540 C (Pressure being 138 Kg/cm2 ).When coal is burned in the boiler furnace, hot flue gases passes through the first pass and then to the second pass to the exit of boiler. Economiser and primary superheaters are placed in second pass one above the other, economiser being placed at the exit. The temperature of the flue gases in the combustion zone is 1200-1400C and after furnace 1000C . The temperature of flue gas gradually decreases to 400C when it leaves second pass. The flue gas then goes trough air pre heaters where its temp. drops down to 140C. Primary and secondary air is passed trough the air heater to increase the temp. This hot secondary air is sent to the furnace through wind box and hot primary air is sent to coal mill for heating pulverised coal and to transfer it upto the furnace. Boiler is sealed from the bottom by seal water arrangement to prevent any ingress of atmospheric air into the boiler. Bottom of the boiler is shaped like a hopper. Bottom ash falls in the bottom hopper and after crushing it is transferred to ash handling plant .Fly ash along with the flue gases goes through ESP where fine ash is taken out and send to the ash handling plant for further processing to the ash bunds.Boiler drum, superheater and reheaters are fitted with safety valves for safety against the high pressures of the steam. Water attemperation system is provided for controlling the temperature of main and reheat steam. Burner tilting
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arrangement is also provided to control the temperature of steam. Soot blowers are provided at different location of boiler to clean the boiler tubes .

PULVERIZER
A pulverizer is a mechanical device used for the grinding of different types of materials. For example, they are used to pulverize coal for combustion in the steam generating furnaces of thermal power plants.

TYPES OF PULVERIZER a) BALL AND TUBE MILLS(LOW SPEED): A ball mill is a pulverizer that consists of a horizontal rotating cylinder, up to three diameters in length, containing a charge of tumbling or cascading steel balls, pebbles, or rods.A tube mill is a revolving cylinder of up to five diameters in length used for fine pulverization of ore, rock, and other such materials; the material, mixed with water, is fed into the chamber from one end, and passes out the other end as slime (slurry).Both types of mill include liners that protect the cylindrical structure of the mill from wear. Thus the main wear parts in these mills are the balls themselves, and the liners. The balls are simply "consumed" by the wear process and must be re-stocked, whereas the liners must be periodically replaced. The ball and tube mills are low-speed machines that grind the coal with steel balls in a rotating horizontal cylinder. Due to its shape only, people call it as Tube Mill and due to use of Grinding Balls for crushing, it is called Ball Mill. Hence, is the name Ball Tube Mill. These Mills are also designated as BBD4772, Where- B Broyer (Name of inventor). B Boulet (French word for Balls). D Direct firing. 47 Diameter of shell (in Decimeters) i.e. 4.7m dia. 72 Length of shell (in Decimeters) i.e. 7.2 m length.
b) RING AND BALL MILL(MEDIUM SPEED): This type of mill consists of two

rings separated by a series of large balls, like a thrust bearing. The lower ring rotates, while the upper ring presses down on the balls via a set of spring and adjuster assemblies, or pressurised rams. The material to be pulverized is introduced into the center or side of the pulverizer (depending on the design). As the lower ring rotates, the balls to orbit between the upper and lower rings, and balls roll over the bed of coal on the lower ring. The pulverized material is carried out of the mill by the flow of air moving through it. The size of the pulverized particles released from the grinding section of the mill is determined by a classifer separator - if the coal is fine enough to be picked up by the air, it is carried through the classifier. Coarser particles return to be further pulverized. c) VERTICAL ROLLER MILL(MEDIUM SPEED): Similar to the ring and ball mill, this mill uses large "tires" to crush the coal. These are usually found in utility plants. Raw coal is gravity-fed through a central feed pipe to the grinding table where it flows outwardly by centrifugal action and is ground between the rollers and table.
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Hot primary air for drying and coal transport enters the windbox plenum underneath the grinding table and flows upward through a swirl ring having multiple sloped nozzles surrounding the grinding table. The air mixes with and dries coal in the grinding zone and carries pulverized coal particles upward into a classifier. Fine pulverized coal exits the outlet section through multiple discharge coal pipes leading to the burners, while oversized coal particles are rejected and returned to the grinding zone for further grinding. Pyrites and extraneous dense impurity material fall through the nozzle ring and are plowed, by scraper blades attached to the grinding table, into the pyrites chamber to be removed. Mechanically, the vertical roller mill is categorized as an applied force mill. There are three grinding roller wheel assemblies in the mill grinding section, which are mounted on a loading frame via pivot point. d) BOWL MILL (MEDIUM SPEED): Similar to vertical roller mill,it also uses tires to crush coal.

BOILER AUXILIARIES
FURNACE Furnace is primary part of boiler where the chemical energy of fuel is converted to thermal energy by combustion. Furnace is designed for efficient and complete combustion. Major factors that assist for efficient combustion are amount of fuel inside the furnace and turbulence, which causes rapid mixing between fuel and air. In modern boilers, water-cooled

furnaces are used. BOILER DRUM A boiler drum is a standard feature of a water-tube boiler. It is a reservoir of water/steam at the top end of the water tubes. The drum stores the steam generated in the water tubes and acts as a phase-separator for the steam/water mixture. The difference in densities between hot and cold water helps in the accumulation of the "hotter"-water/and saturated-steam into the steam-drum. Made from high Carbon Steel with high tensile strength and its working involves temperatures around 320oC and pressures well above 350 psi(2.4MPa). The separated steam is drawn out from the top section of the drum and distributed for process. Further heating of the saturated steam will make superheated steam normally used to drive a steam turbine. Saturated steam is drawn off the top of the drum and re-enters the furnace in through a superheater. The steam and water mixture enters the steam drum through riser tubes, drum internals consisting of demister separate the water droplets from the steam producing dry steam. The saturated water at the bottom of the steam drum flows down through the downcomer pipe, normally unheated, to headers and water drum. Its accessories include a safety valve, water-level indicator and level controller. Feed-water of boiler is also fed to the steam drum through a feed pipe extending inside the drum, along the length of the steam drum. ECONOMISER Economisers are mechanical devices intended to reduce energy consumption, or to perform another useful function like preheating a fluid. The term economizer is used for other purposes as well. In simple terms, an economizer is a heat exchanger. Modern-day boilers, such as those in coal-fired power stations, are still fitted with economizers which are descendants of Green's original design. In this context they are often referred to as feedwater heaters and heat the condensate from turbines before it is pumped to the boilers. The economizer also prevents flooding of the boiler with liquid water that is too cold to be boiled given the flow rates and design of the boiler.A common application of economizers in steam powerplants is to capture the waste heat from boiler stack gases (flue gas) and transfer it to the boiler feedwater. This raises the temperature of the boiler feedwater thus lowering the needed energy input, in turn reducing the firing rates to accomplish the rated boiler output.
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Economizers lower stack temperatures which may cause condensation of acidic combustion gases and serious equipment corrosion damage if care is not taken in their design and material selection. AIR PREHEATER An air preheater (APH) is a general term to describe any device designed to heat air before another process (for example, combustion in a boiler) with the primary objective of increasing the thermal efficiency of the process. They may be used alone or to replace a recuperative heat system or to replace a steam coil.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 stack (or chimney) at a lower temperature, allowing simplified design of the ducting and the flue gas stack. It also allows control over the temperature of gases leaving the stack (to meet emissions regulations, for example). COAL MILLS There are six mills for every 210 MW unit ,located adjacent to the furnace at zero meter level. These mills pulverize coal to the desired fineness to be fed to the furnace for combustion. Ball mills are used for 95 MW unit and bowl mills are used for 210 MW. COAL FEEDER Each mill is provided with a drag link chain/rotary/gravimetric feeder to transport raw coal from the bunker to the inlet chute, leading to mill at a desired rate. ELECTROSTATIC PRECIPITATOR An electrostatic precipitator (ESP), or electrostatic air cleaner is a particulate collection device that removes particles from a flowing gas (such as air) using the force of an induced electrostatic charge. Electrostatic precipitators are highly efficient filtration devices that minimally impede the flow of gases through the device, and can easily remove fine particulate matter such as dust and smoke from the air stream. In contrast to wet scrubbers which apply energy directly to the flowing fluid medium, an ESP applies energy only to the particulate matter being collected and therefore is very efficient in its consumption of energy (in the form of electricity).From air preheater this flue gases (mixed with ash) goes to ESP.

The precipitator has plate banks (A-F) which are insulated from each other between which the flue gases are made to pass. The dust particles are ionized and attracted by charged electrodes. The electrodes are maintained at 60KV.Hammering is done to the plates so that fly ash comes down and collect at the bottom. The fly ash is dry form is used in cement manufacture. REHEATER Power plant furnaces may have a reheater section containing tubes heated by hot flue gases outside the tubes. Exhaust steam from the high pressure turbine is rerouted to go inside the reheater tubes to pickup more energy to go drive intermediate or lower pressure turbines. WATER WALLS Water flows to the water walls from the boiler drum by natural circulation. The front and the two side water walls constitute the main evaporation surface absorbing the bulk of radiant heat of the fuel burnt in the chamber. The front and rear walls are bent at the lower ends to form a water-cooled slag hopper. The upper part of the chamber is narrowed to achieve perfect mixing of combustion gases. The water walls tubes are connected to headers at the top and bottom. The rear water walls tubes at the top are grounded in four rows at a wider pitch forming the grid tubes. SUPERHEATER Whatever type of boiler is used, steam will leave the water at its surface and pass into the steam space. Steam formed above the water surface in a shell boiler is always saturated and cannot become superheated in the boiler shell, as it is constantly in contact with the water surface. If superheated steam is required, the saturated steam must pass through a superheater. This is simply a heat exchanger where additional heat is added to the saturated steam. In water-tube boilers, the superheater may be an additional pendant suspended in the furnace area where the hot gases will provide the degree of superheat required .In other cases, for example in CHP schemes where the gas turbine exhaust gases are relatively cool, a separately fired superheater may be needed to provide the additional heat.

INDUCED DRAFT FAN(I.D) This fan is of axial impulse type. Impeller nominal diameter is of the order of 2500 mm. This fan is used to suck the flue gases and remove them through chimney.The outlet guides are
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fixed in between the case of the diffuser and the casing. These guide vanes serve to direct the flow axially and to stabilize the draft-flow caused in the impeller. These outlet blades are removable type from outside. During operation of the fan itself these blades can be replaced one by one. Periodically the outlet blades can be removed one at a time to find out the extent of wear on the blade. If excessive wear is noticed the blade can be replaced by a new blade. FORCED DRAFT FAN This fan provides secondary air or extra air to the furnace for burning of the coal. PRIMARY AIR FAN This fan sucks air from the atmosphere and then this air is taken to air preheater for heating. The hot air is then supplied to bowl mill to remove moisture from the coal and to take it to the furnace for burning.

TURBINE
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam,

and converts it into rotary motion. Its modern manifestation was invented by Sir Charles Parsons in 1884. It has almost completely replaced the reciprocating piston steam engine primarily because of its greater thermal efficiency and higher power-to-weight ratio. Because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generator about 80% of all electricity generation in the world is by use of steam turbines. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible process. There are two types of steam turbines namely impulse and reaction turbine: IMPULSE TURBINE An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These jets contain significant kinetic energy, which the rotor blades, shaped like buckets, convert into shaft rotation as the steam jet changes direction. A pressure drop occurs across only the stationary blades, with a net increase in steam velocity across the stage.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 has a large portion of the maximum velocity of the steam when leaving the nozzle. The loss of energy due to this higher exit velocity is commonly called the "carry over velocity" or "leaving loss". REACTION TURBINE 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. Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the stator as a jet that fills the entire circumference of the rotor. The steam then changes direction and increases its speed relative to the speed of the blades. A pressure drop occurs across both the stator and the rotor, with steam accelerating through the stator and decelerating through the rotor, with no net change in steam velocity across the stage but with a decrease in both pressure and temperature, reflecting the work performed in the driving of the rotor.

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WORKING OF TURBINE 210 MW turbine is condensing, tandem compound, three cylinder, horizontal, disc and diaphram type with nozzle governing and regenerative feed water heating. The double flow L.P. Turbine (LPT) incorporates multi exhaust in each flow.The complete turbine assembly is mounted on pedestals and sole plates which are designed to ensure that the components are free to expand whilst correct alignment is maintained under all conditions. Live steam from boiler enters two emergency stop valves (ESV) of high-pressure turbine (HPT). From ESVs steam flows to the four-control valves (CV) mounted on the casing of HPT at the middle bearing side. Control valves in turn feed the steam to nozzle boxes located inside the HPT. The HPT comprises of 12 stages, the first stage being governing stage. The steam flow in HPT being in reverse direction, the blades in HPT are designed for anticlockwise rotation when viewed in the direction of steam flow. After passing through HP turbine, steam flows to boiler for reheating and reheated steam comes to the intermediate pressure turbine (IPT) through two-interceptor valves (IV) and four control valves mounted on IPT itself. The I.P.turbine has 11 stages. HP & IP rotors are connected by rigid coupling and have a common bearing. After flowing through IPT, steam enters the middle part of low-pressure turbine through two crossover pipes. In LP turbine, steam flows in apposite paths having four stages in each path. After leaving the LP turbine the exhaust steam condenses in the surface condenser welded

directly to the exhaust part of the LP turbine.The rotors of IP & LP turbine are connected by a semiflexible coupling. The direction of rotor is clockwise when viewed from the front bearing and towards generator. The three rotors are supported on five bearings. The common bearing of HP & IP rotor is a combined journal and radial thrust bearing. The anchor point of turbine is located at the middle foundation frame of the front exhaust part of low-pressure cylinder. The turbine expands towards the front bearing by nearly 32 mm and towards generator by 3 mm in steady state operation at full load with rated parameters. The turbine is equipped with barring gear which rotates the rotors of turbine for providing uniform heating during starting and uniform cooling during shut down. In order to heat the feed water in the regenerative cycle of the turbine, condensate from the hot well of condenser is pumped by the condensate extraction pumps, and supplied to the deaerator through ejectors, gland steam cooler, four numbers of LP heaters, and gland cooler. From deaerator the feed water is supplied to boiler by boiler feed pump through three numbers of HP heaters. Extracted steam from various points of turbine is utilised to heat the condensate in heat exchanger.

TURBINE AUXILIARIES
CONDENSER

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The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be pumped. If the condenser can be made cooler, the pressure of the exhaust steam is reduced and efficiency of the cycle increases. The functions of a condenser are:1) To provide lowest economic heat rejection temperature for steam. 2) To convert exhaust steam to water for reserve thus saving on feed water requirement. 3) To introduce make up water. We normally use surface condenser although there is one direct contact condenser as well. In direct contact type exhaust steam is mixed with directly with D.M cooling water. CONDENSATE EXTRACTION PUMP(CEP) The function of these pumps is to pumps out the condensate to the desecrator through ejectors, gland steam cooler, and L.P. heaters. These pumps have four stages and since the suction is at a negative pressure, special arrangements have been made for providing sealing. This pump is rated generally for 160m3 hr. at a pressure 13.2 Kg/cm2. GLAND STEAM COOLER Gland steam cooler has been provided to suck and cool the air steam mixture from the gland seats. It employs a small ejector for which the working medium is steam of low parameters, which can be taken either from the deaerator or auxiliary source. The pressure and temperature of this steam should of this steam is retrieved to the fullest possible extent as the gland steam cooler is also interposed in the condensate heating cycle thereby improving overall efficiency of the cycle. L.P HEATERS Turbine has been provided with non-controlled extractions which are utilized for heating the condensate, from turbine bleed steam. There are 410w pressure heaters in which the last four extractions are used. L.P. Heater-1 has two parts LPH-1A and LPH-1B located in the upper parts of condenser A and condenser B respectively. These are of horizontal type with shell and tube construction. L.P.H. 2, 3 and 4 are of similar construction and they are mounted in a row at 5M level. They are of vertical construction with brass tubes the ends of which are expanded into tube plate. The condensate flows in the "U" tubes in four passes and extraction steam washes the outside of the tubes. Condensate passes thru' these four L.P. heaters in

succession. These heaters are equipped with necessary safety valves in the steam space level indicator for visual level indication of heating steam condensate pressure vacuum gauges for measurement of steam pressure etc DEAERATOR A deaerator is a device that is widely used for the removal of air and other dissolved gases from the feedwater to steam-generating boilers. In particular, dissolved oxygen in boiler feedwaters will cause serious corrosion damage in steam systems by attaching to the walls of metal piping and other metallic equipment and forming oxides (rust). Water also combines with any dissolved carbon dioxide to form carbonic acid that causes further corrosion. Most deaerators are designed to remove oxygen down to levels of 7 ppb by weight (0.005 cm/L) or less.Deaeration is based on two scientific principles. The first principle can be described by Henry's Law. Henry's Law asserts that gas solubility in a solution decreases as the gas partial pressure above the solution decreases. The second scientific principle that governs deaeration is the relationship between gas solubility and temperature. Easily explained, gas solubility in a solution decreases as the temperature of the solution rises and approaches saturation temperature. A deaerator utilizes both of these natural processes to remove dissolved oxygen, carbon dioxide, and other non-condensable gases from boiler feedwater. The feedwater is sprayed in thin films into a steam atmosphere allowing it to become quickly heated to saturation. Spraying feedwater in thin films increases the surface area of the liquid in contact with the steam, which, in turn, provides more rapid oxygen removal and lower gas concentrations. This process reduces the solubility of all dissolved gases and removes it from the feedwater. The liberated gases are then vented from the deaerator. BOILER FEED PUMP A boiler feedwater pump is a specific type of pump used to pump feedwater into a steam boiler. The water may be freshly supplied or returning condensate produced as a result of the condensation of the steam produced by the boiler. These pumps are normally high pressure units that take suction from a condensate return system and can be of the centrifugal pump type or positive displacement type.Feedwater pumps range in size up to many horsepower and the electric motor is usually separated from the pump body by some form of mechanical coupling. Large industrial condensate pumps may also serve as the feedwater pump. In either case, to force the water into the boiler, the pump must generate sufficient pressure to overcome the steam pressure developed by the boiler. This is usually accomplished through
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the use of a centrifugal pump. H.P. HEATERS These are regenerative feed water heaters operating at high pressure and located by the side of turbine. These are generally vertical type and turbine bleed steam pipes are connected to them. HP heaters are connected in series on feed waterside and by such arrangement, the feed water, after feed pump enters the HP heaters. The steam is supplied to these heaters form the bleed point of the turbine through motor operated valves. These heaters have a group bypass protection on the feed waterside. In the event of tube rupture in any of the HPH and the level of the condensate rising to dangerous level, the group protection device diverts automatically the feed water directly to boiler, thus bypassing all the 3 H.P. heaters.

ASH HANDLING PLANT

The ash produced in the boiler is transported to ash dump area by means of sluicing type hydraulic ash handling system, which consists of Bottom ash system, Ash water system and Ash slurry system. BOTTOM ASH SYSTEM In the bottom ash system the ash discharged from the furnace bottom is collected in two water compounded scraper through installed below bottom ash hoppers. The ash is continuously transported by means of the scraper chain conveyor onto the respective clinker grinders which reduce the lump sizes to the required fineness. The crushed ash from the bottom ash hopper from where the ash slurry is further transported to operation, the bottom ash can be discharged directly into the sluice channel through the bifurcating chute bypass the grinder. The position of the flap gate in the bifurcating chute bypasses the grinder. The position of the flap gate in the bifurcating chute is to be manually changed. FLY ASH SYSTEM The flushing apparatus are provided under E.P. hoppers (40 No.s), economizer hoppers (4 No.s), air pre heaters (2 No.s), and stack hoppers (4 No.s),. The fly ash gets mixed with flushing water and the resulting slurry drops into the ash sluice channel. Low pressure water is applied through the nozzle directing tangentially to the section of pipe to create turbulence and proper mixing of ash with water. For the maintenance of flushing apparatus plate valve is provided between apparatus and connecting tube. ASH WATER SYSTEM High pressure water required for bottom ash hopper quenching nozzles, bottom ash hopper spraying, clinker grinder sealing scraper bars, cleaning nozzles, bottom ash hopper seal through flushing, economizer hopper flushing nozzles and sluicing trench jetting nozzles is tapped from the high pressure water ring mainly provided in the plant Low pressure water required for bottom ash hopper seal through make up, scraper conveyor make up, flushing apparatus jetting nozzles for all fly ash hoppers excepting economizer hoppers, is trapped from low pressure water rings mainly provided in the plant area.

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ASH SLURRY SYSTEM Bottom ash and fly ash slurry of the system is sluiced upto ash pump along the channel with the acid of high pressure water jets located at suitable intervals along the channel.

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 are designed to process the raw water to water with very low in dissolved solids known as "demineralised 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. Actually, the type of demineralization process chosen for a power station depends on three main factors: The quality of the raw water. The degree of de-ionization i.e. treated water quality Selectivity of resins.

Water treatment process which is generally made up of two sections: Pretreatment section Demineralization section

PRETREATMENT SECTION Pretreatment plant removes the suspended solids such as clay, silt, organic and inorganic matter, plants and other microscopic organism. The turbidity may be taken as of two types of suspended solids in water. Firstly, the separable solids and secondly the non separable solids (colloids). The coarse components, such as sand, silt etc, can be removed from the water by simple sedimentation. Finer particles however, will not settle in any reasonable time and must be flocculated to produce the large particles which are settleable. Long term ability to remain suspended in water is basically a function of both size and specific gravity. The settling rate of the colloidal and finely divided (approximately 001 to 1 micron) suspended matter is so slow that removing them from water by plain sedimentation is tank shaving ordinary dimensions is impossible. Settling velocity of finely divided and collide particles under gravity also are so small that ordinary sedimentation is not possible. It is necessary, therefore, to use procedures which agglomerate the small particles into larger aggregates, which have practical settling velocities. The term "Coagulation" and "flocculation" have been used indiscriminately to
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describe process of turbidity removal. "Coagulation" means to bring together the suspended particles. The process describes the effect produced by the addition of a chemical Al (SP) g to a colloidal dispersion resulting in particle destabilization by a reduction of force tending to keep particles apart. Rapid mixing is important at this stage to obtain. Uniform dispersion of the chemical and to increase opportunity for particles to particle contact. This operation is done by flash mixer in the c1ariflocculator. Second stage of formation of settle able particles from destabilized colloidal sized particles termed a "flocculation". Here coagulated particles grow in size by attaching to each other. In contrast to coagulation where the primary force is electrostatic or intrinsic,under the influence of gravity anomaly be removed. flocculation" occurs by chemical bridging. Flocculation is obtained by gentle and prolonged mixing which converts the submicroscopic coagulated particle into discrete, visible & suspended particles. At this stage particles are large enough to settle rapidly under the influence of gravity anomaly be removed. If pretreatment of the water is not done efficiently then consequences are as follows: Si02 may escape with water which will increase the anion loading. Organic matter may escape which may cause organic fouling in the anion exchanger beds. In the 'pre-treatment plant chlorine addition provision is normally made to combat organic contamination. Cation loading may unnecessary increase due to addition of Ca(OH)2 in excess of calculated amount for raising the pH of the water for maximum floe formation and also AKOrDg may precipitate out. If less than calculated amount of Ca(OH)2 is added, proper pH flocculation will not be obtained and silica escape to demineralization section will occur, thereby increasing load on anion bed.

DEMINERALIIZATION This filter water is now used for demineralizing purpose and is fed to cation exchanger bed, but enroute being first dechlorinated, which is either done by passing through activated carbon filter or injecting along the flow of water, an equivalent amount of sodium sulphite through some stroke pumps. The residual chlorine which is- maintained in clarification plant to remove organic matter from raw water is now detrimental to action resin and must be eliminated before its entry to this bed. Normally, the typical scheme of demineralization up to the .mark against an average surface water, is three bed system with a provision of removing gaseous carbon dioxide from water before feeding to Anion Exchanger. Now, let us see, what happens actually in each bed when water is passed from one to another. Resins, which are built on synthetic matrix of a styrene divinely benzene copolymer, are manufactured in such a way that these have the ability to, exchange one ion for another, hold it temporarily in chemical combination and give it to a strong electrolytic solution. Suitable treatment is also given to them in such a way that a particular resin absorbs only a particular group of ions. Resins, when absorbing and releasing cationic portion of dissolved salts, is called cation, exchanger resin and when removing anionic portion is called anion exchanger resin. Present trend is of employing 'strongly acidic cation exchanger resin and strongly basic anion exchanger resin in a DM Plant of modern thermal power station. We may see that the chemically active group in a cationic resin is SOx-H (normally represented by RH) and in an anionic resin the active group is either tertiary amine or quaternary ammonium group (normally the resin is represented by ROH). The reaction of exchange may be further represented as below : Cation Exchange RH + Na2SO4 RNa + H2SO4 The above stated reactions take place in the cation exchanger.Chlorides,sulphates,nitrates and bicarbonates of sodium,potassium,calcium and magnesium are changed into form of RNa,RK etc resin gets completely exhausted when it completely turns into RNa form and it is regenerated bybackwash with acid as stated by the equation Exhausted resin + acid = fresh resin + salt
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RNa +HCL = RH +NaCl Anion Exchange ROH + H2SO4 R2SO4 + H2O The above stated reactions take place in the anion exchanger. Mineral acids left in the water after passage through anion exchanger changes into form of R2SO4,RCl etc resin gets completely exhausted when it completely turns into RCl form and it is regenerated by backwash with base as stated by the equation: Exhausted resin + base = fresh resin + salt RCl + NaOH = ROH + NaCl The water from the ex-cation contains carbonic acid also sufficiently, which is very weak acid difficult to be removed by strongly basic anion resin and causing hindrance to remove silicate ions from the bed. It is therefore a usual practice to remove carbonic acid before it is led to anion exchanger bed. The ex-cation water is trickled in fine streams from top of a tall tower packed with, rasching rings, and compressed air is passed from the bottom. Carbonic acid breaks into C03 and water mechanically (Henry's Law) with the carbon dioxide escaping into the atmosphere. The water is accumulated in suitable storage tank below the tower, called degassed water dump from where the same is led to anion exchanger bed, using acid resistant pump. The ex-anion water is fed to the mixed bed exchanger containing both cationic resin and anionic resin. This bed not only takes care of sodium slip from cation but also silica slip from anion exchanger very effectively. The final output from the mixed bed is extraordinarily pure water having less than 0.2/Mho conductivity 7.0 and silica content less than 0.02 pm. Any deviation from the above quality means that the resins in mixed bed are exhausted and need regeneration, regeneration of the mixed bed first calls for suitable, back washing and settling, so that the two types of resins are separated from each other. Lighter anion resin rises to the top and the heavier cation resin settles to the bottom. Both the resins are then regenerated separately with alkali and acid, rinsed to the desired value and air mixed, to mix the resin again thoroughly. It is then put to final rinsing till the desired quality is obtained.

Internal Treatment This final D.M effluent is then either led to hot well of the condenser directly as make up to boilers, or being stored in D.M. Water storage tanks first and then pumped for make up purpose to boiler feed. As the D.M. Water has a good affinity to absorb carbon dioxide and oxygen, and both are extremely harmful to metal surfaces for their destruction like corrosion, these have to be removed before it is fed to boiler. This is being done in desecrator. Still the residual oxygen which is remaining in the water is neutralized by a suitable doze of hydrazine, at the point after desecrator. To have further minimum corrosion, the pH of feed water is to be maintained at around 9.0 for which purpose ammonia in suitable doze is added to this make up water at a point along with hydrazine as stated above.

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CONTROL STRUCTURE PUMP HOUSE (CSPH)

The CSPH is just located near the entrance of BTPS at the left side of the way, the basic work of CSPH is to treat the raw water coming from the lake ,this water is first treated in CSPH and then delivered to the other units such as WTP, cooling tower etc. The water received from lake is totally dirty and full of hard and thick impurities. This pump house contain following pumps: Chlorine pump-2(for chlorination of water) HP pump-6(for boiling of water) LP pump-3(for EP pump house) Fire pump-(incase of fire breakdown) TWS pump-3(for screening of water) CRW pump-3(supply water for water treatment)

This house is known as control house because amount of water to be supplied for treatment is controlled from this house with the help of these pumps. Generally 2 CRW pumps out of 3pumps remains open.similarly,1 FS ,2 LP,4 HP,1 TWS pumps remains open. If more water is needed then others pumps are opened.

CONCLUSION
I learnt the practical application of basic principles of thermodynamics and also got opportunity to understand the working of boilers, turbines, mills, fans and many other industrially important mechanical devices .The staff of NTPC Badarpur was a gem of staffs as they helped and guided me throughout my journey in NTPC.I learned a lot of working disciplines required ina thermal power plant such as wearing of helmets, shoes etc

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