industrial training in ntpc

8/11/2019 Industrial Training in Ntpc

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INDUSTRIAL TRAINING

REPORT ON

N.T.P.C DADRI

(2014-2015)

SUBMITTED BY: PIYUSH UPPAL

ROLL NO: 12111502811

BRANCH: ELECTRONICS & COMMUNICATION


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Training at NTPC DADRI

I was appointed to do 4 week training at this esteemedorganization from 18th June to 18st July, 2014. I was assigned tovisit the divisions of the plant, which were:

Gas power plant.Instrumentation and control room.

These 4 weeks training was a very educational adventure for me.

It was really amazing to see the plant by yourself and learn howelectricity, which is one of our daily requirements of life, isproduced. This report has been made by my experience at NTPCDadri.

The material in this report has been gathered from my textbook,senior student reports and trainers manuals and power journalsprovided by training department. The specification and principles

are as learned by me from the employees of each division ofNTPC Dadri.


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GENESIS OF NTPC

Establishedin 1975 forbulksupply of cost effective power

forrapid growthof India

Oneof the best performing

NavaratnaPSUs

15 Coal, 7 Gas based & 4 in

Joint Venture PowerStations

InstalledCapacity more 33,000

MW & a Maha Ratna company

construction

Plannedto become 75,000MW+

companybyYear 2017

Dadri


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Strategies of NTPC


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JOURNEY OF NTPC


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TOTAL CAPACITY

OFN.T.P.C DADRI

(A)THERMAL1)04x210 MW=840 MW

2)02X490 MW=980 MWTOTAL=1820 MW

(B)GAS =817 MW(C) SOLAR =05 MW

GRAND TOTAL=2642 MW


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DADRI GAS POWER STATION


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STATION SALIENT FEATURES:


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INPUTS FOR GAS STATION

FuelNatural gas (Primary) HSD (Alternate fuel)

Source of gas- APM, PMT:ONGC/RIL/BRITISH GAS

RLNG :GAIL, IOCL,GSPCL.

KG-D6 : RIL

TRANSPORTATION :From GAIL through HBJ Pipeline &

RGTL.

Source of HSD : IOCL, HPCL, BPCL through Rly. rakes.


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WATER FOR GAS STATION

SOURCE:UPPER GANGA CANAL

Consumptive requirement : 50 60 Cusec


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MAIN COMPONENTS OF GAS TURBINES

POWER GENERATING PLANT:

Starting system

Air intake system

Fuel supply system

Compressor

Combustion chamber

Gas turbine

Gas turbine exhaust diffuser/Diverter damper/Chimney

Lub oil supply system

Control oil supply system

Turbo generator

Generator circuit breaker

Generator transformer

Control and instrumentation system


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ADVANTAGES OF GAS TURBINE

Environment Friendly

Less installation Period

High Efficiency (60% )

Less manpower requirements

Quicker response time

Faster Acceleration/deceleration

Modular replacement

Less vibrations

Less area required

No by Product like ash.


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DISADVANTAGES OF GAS

TURBINE

High cost of maintenance.

High frequency of inspection/overhauling.

Hot gas path components under highthermal stress.

Variation in output due to external factorslike ambient pressure, temp, relativehumidity, Grid Frequency.

Running on secondary fuel or frequentstart stop reduces the components life.


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WHY COAL?

Advantages of Coal Fuel Abundantly available in India Low cost Technology for Power Generation well developed

Easy to handle, transport, store and use

Shortcomings of Coal Low Calorific Value Large quantity to be Handled

Produces pollutants, ash Disposal of ash is Problematic Reserves depleting fast

Indias Coal Reserves are estimated to be 255billion tonnes. Present consumption is about 450

million tonnes.

Cost of coal for producing 1 unit of electricity (Costof coal Rs 1000/MT) is Rs 0.75.

Cost of Gas for producing 1 unit of electricity (Costof Gas Rs 6/SMC) is Rs 1.20


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COAL PROPERTY

1. Moisture - Air dried-5 to 7%

- Total moisture-10 to 12%2. Ash - Washed coal-below 35%

- Raw coal-38-40%3. VM(Volatile matter)- 20-26%(Hydro carbons i.e; ethen etc.)

4. Fixed Carbon - 25-27%

5. C.V.(Calorific value) - 3600-3800 kcal/kg

COAL GRADE- Decided on UHV (Utilized H Value):-A - Above 6201 Kcal/kg

B - 5601-6200C - 4941-5600D - 4201-4940E - 3361-4200F - 2401-3360G - 1301-2400

Ungraded-Below1300


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COAL TRANSPORTATION

SYSTEM

Source of Coal - Piparwar block of NorthKaranpura coal field ofEastern coal field

Means of - RailwayTransportation

Route of Rly - KhalariGarwa road-Seonnogar-Mughal Sarai

Allahabad-Kanpur-AligarhDadri-Plant Unloading area

Total distance - 1124 km from khalori to Dadriwith electrified track fromSeonnogar

Type of wagon -1. BOBR (Bogy Open BottomRapid Discharge Wagon) OR2. Box-N (3 doors on each side)3. Box-C (5 -do- )

No of wagons/ rake - 59 wagons of 60-65 toncapacity

No of rake reqd/day - 8 to 9Total cycle time of - Approximately 6 days

One rakeType of locos - WDM-2 (2600 Hp)


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CRUSHER HOUSE

No & make of Crusher- 4, Pennsylvenia,USA

Type & size - Ring granulators,TKKGN-48093

Main crusher Capacity- 875 tonne/hr each

Max. coal size - 250 mmbefore crusher

Coal size after crusher- 20 mm Motor rating - 800hp (597kw)

Make - Kirloskar Elect Ltd.Power supply - 6.6kv, 30, 58HZ,RPM - 743Full load ampere - 69 AInsulation class - F

No. of hammers - 60


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CONVEYOR

No. of belt conv - 16 Design/rated capacity - 1540 tph/1400 tph Conv Capacity - 700 - 1400

Belt speed - 2.63.36m/sec Belt width - 1000 - 1400mm Fabric type - Nylon-Nylon/ EP(Polamide-Synthetic) No of plies - 4 Belt rating - 6301250 Cover grade - Fire Resistant No of belt weigher - 6 No of metal detector - 4 No of sampling unit - 4 No & type of magnetic - 4, suspended type

Separator (ILMS)No of magnetic separator- 2


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Coal to Electricity ..

Basics

Polluta

nts

Coal

He

at ASH

Lo

ss

Sup

er

Heated

Steam

Heat

Loss In

Conden

ser

Turbine

Torque

Mech.

Energy

Loss

Alternating

current inStator

Elet.

Energy

Loss

Chemi

cal

Energ

y

Therm

al

Energ

y

Kineti

c

Energ

y

Electri

cal

Energy


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STOCK YARD

Capacity - 45 days coal of stage-1requirement 5,00,000 m3of coal approx.

No of coal plies in - 4Stockyard

Length/height of - 470m/10meach plies


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MVW (MEDIUM VELOCITION WATER)SPRAY SYSTEM FOR COAL CONVEYOR

Type of system - Deluge valve operated && actuation MVW spray system auto-matic

(A) (electrical), remote,manual & local manual

(Mechanical) Spray density - 10.2 lph /m2(of floor area +

return belt area)

Water pressure/ - 10.4 bar/5.0barDV Operating Pr.

Type of detection - QBD,LHSC & infra Red detectorssystem

Type of spray nozzlesa) for floor protection Open head up right

sprayers with K-79

(Metric)V-1b) for return belt - Open head directionalprotection sprayers with K-46

Water reqd per zone - Limited to approx410 m3/hr

No of zone sprayed - Adjacent three nos.at a time


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SALIENT FEATURES OF NTPC,

DADRI

Largest dry ash disposal system in India.

Largest switch yard in India.

Largest gas station in India.

Unique storage of dry ash by constructingash mound (the only one in Asia)


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Inputs for Coal Station

Washed Coal supplyfrom NorthKaranpura coalfields CCL inJharkhand,about 1200 kms from site.

Transportation Indian Railways. Consumption

3.66 Million tonnes per annum.


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Environment Management System atNTPC Dadri

The station is certified for ISO 14001, ISO 9001, IS18001 & SA 8000 and is committed to sustenanceand continual improvement in Environmentmanagement , Quality management, Safetymanagement and Social accountability.

NTPC Dadri is the first ISO 14001 certified power

station amongst NTPC units since 1999.

Initially Certification body was DNV & nowcertification body is BIS.

Validity of current certificate is up to 21-03-2012. Now it is integrated with other ISO/IS systems. i.e.

ISO 9001, IS 18001 since 2007.


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OPERATION OF A POWER PLANT

Basic PrincipleAs per FARADAYs Law-Whenever the amount of magnetic flux

linked with a circuit changes, an EMF is produced in the circuit.Generator works on the principle of producing electricity. To changethe flux in the generator turbine is moved in a great speed with steam.

To produce steam, water is heated in the boilers by burning the

coal.

In a dadri Thermal Power Station, steam is produced and used tospin a turbine that operates a generator.

Water is heated, turns into steam and spins a steam turbine which

drives an electrical generator.

After it passes through the turbine, the steam is condensed in

a condenser.

The electricity generated at the plant is sent to consumers through

highvoltage power lines

The Dadri Thermal Power Plant has Steam Turbine-Driven

Generators which has a collective capacity of 1820MW.

The fuel being used is Coal which is supplied from the Piparwar

Mines,Jharkhand.

Water supply is given from the Upper Ganga Canal.


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Basic Steps of Electricity Generation

The basic steps in the generation of

electricityfrom coal involves following steps:

Coal to steam

Steam to mechanical power

Mechanical power to electrical power


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PARTS OF A POWER PLANT


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PARTS OF A POWER PLANT

1. Cooling tower2. Cooling water pump3. Transmission line (3-phase)4. Unit transformer (3-phase)5. Electric generator (3-phase)6. Low pressure turbine7. Condensate extraction pump

8. Condenser9. Intermediate pressure turbine10. Steam governor valve11. High pressure turbine12. Deaerator13. Feed heater14. Coal conveyor15. Coal hopper16. Pulverised fuel mill17. Boiler drum18. Ash hopper19. Super heater20. Forced draught fan21. Reheater22. Air intake

23. Economiser24. Air preheater25. Precipitator26. Induced draught fan27. Flue Gas


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PROTECTION &

TRIPPING

1. Sequence tripping

2. ZSS (Zero Speed Switch)3. BSS (Belt Sway Switch)4. PCS (Pull Cord Switch)5. MD (Metal Detector)6. MVW Spray (for Fire protection)


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MOTORSAC MOTORS:

Squirrel cage motor

Wound motor

Slip ring induction motor

In modern thermal power plant three phase squirrel cage induction motorsare used but sometimedouble wound motor is used when we need high starting torque e.g. in ballmill.

THREE PHASE INDUCTION MOTOR

Ns (speed) =120f/p

Stator can handle concentrated single layer winding, with each coil

occupying one stator slot

The most common type of winding are:

DISTRIBUTED WINDING :

This type of winding is distributed over a number of slots.

DOUBLE LAYER WINDING :

Each stator slot contains sides of two different coils.SQUIRREL CAGE INDUCTION MOTOR

Squirrel cage and wound cage have same mode of operation. Rotor

conductors cut the rotatingstator magnetic field. an emf is induced across the rotor winding, currentflows, a rotor magnetic fieldis produced which interacts with the stator field causing a turning motion.The rotor does not rotateat synchronous speed, its speed varies with applied load. The slip speedbeing just enough to enablesufficient induced rotor current to produce the power dissipated by themotor load and motor losses.


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BEARING AND LUBRICATION:

A good bearing is needed for trouble free operation of motor. Since it is verycostly partof the motor, due care has to be taken by checking it at regular intervals. So

lubricatingplays an important role. Two types of lubricating are widely used

Oil lubrication

Grease lubrication

Insulation

INSULATIONWinding is an essential part so it should be insulated. Following types ofinsulation arewidely usedINSTRUMENTS SEENMICROMETERThis instrument is used for measuring inside as well as outside diameter ofbearing.MEGGARThis instrument is used for measuring insulation resistance.VIBRATION TESTERIt measures the vibration of the motor. It is measured in three dimensions-axial, verticaland horizontal.


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SWITCH GEAR

Switchgear is one that makes or breaks the electrical circuit.

It is a switching device that opens & closes a circuit that defined as apparatus usedfor switching, Lon rolling & protecting the electrical circuit & equipments.

The switchgear equipment is essentially concerned with switching & interrupting

currents either under normal or abnormal operating conditions.

The tubular switch with ordinary fuse is simplest form of switchgear & is used to con

& protect& other equipmentsin homes, offices etc.

For circuits of higher ratings, a High Rupturing Capacity (H.R.C) fuse in condition wi

a switch may serve the purpose of controlling & protecting the circuit.

However such switchgear cannot be used profitably on high voltage system (3.3 KV

for 2 reasons.

Firstly, when a fuse blows, it takes some time to replace it & consequently there is

interruption of service to customer.

Secondly, the fuse cannot successfully interrupt large currents that result from the H

Voltage System.

In order to interrupt heavy fault currents, automatic circuit breakers are used.

There are very few types of circuit breakers in B.P.T.S they are VCB, OCB, and SF6

circuit breaker.

The most expensive circuit breaker is the SF6 type due to gas.

There are various companies which manufacture these circuit breakers: VOLTAS,

JYOTI, and KIRLOSKAR.

Switchgear includes switches, fuses, circuit breakers, relays & other equipments.

In low tension switch gear thermal over load relays are used whereas in high tension

different types of relays are used.


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THE EQUIPMENTS THAT NORMALLY FALLIN THIS CATEGORY ARE:-

ISOLATOR

Isolator cannot operate unless breaker is open

Bus 1 and bus 2 isolators cannot be closed simultaneously

The interlock can be bypass in the event of closing of bus coupler breaker.

No isolator can operate when the corresponding earth switch is on

SWITCHING ISOLATOR

Switching isolator is capable of:

Interrupting charging current

Interrupting transformer magnetizing current

Load transformer switching. Its main application is in connection with the

transformer feeder as the unit makes it possible to switch gear one transformerwhile the other is still on load.

CIRCUIT BREAKER

One which can make or break the circuit on load and even on faults is referredto as circuit breakers. This equipment is the most important and is heavy dutyequipment mainly utilized for protection of various circuits and operations onload. Normally circuit breakers installed are accompanied by isolators.

LOAD BREAK SWITCHES

These are those interrupting devices which can make or break circuits. These

are normally on same circuit, which are backed by circuit breakers

EARTH SWITCHESDevices which are used normally to earth a particular system, to avoid any

accident happening due to induction on account of live adjoining circuits. Theseequipments do not handle any appreciable current at all. Apart from thisequipment there are a number of relays etc. which are used in switchgear.


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Low Tension SWITCH GEAR

MAIN SWITCH

Main switch is control equipment which controls or disconnects the main

supply. The main switch for 3 phase supply is available for the range 32A, 63A,100A, 200Q, 300A at 500V grade.

FUSES

With Avery high generating capacity of the modern power stations extremely

heavy carnets would flow in the fault and the fuse clearing the fault would be

required to withstand extremely heavy stress in process. It is used for supplyingpower to auxiliaries with backup fuse protection. With fuses, quick break, quickmake and double break switch fuses for 63A and 100A, switch fuses for200A,400A, 600A, 800A and 1000A are used.

CONTACTORS

AC Contractors are 3 poles suitable for D.O.L Starting of motors and

protecting the connected motors.

OVERLOAD RELAY

For overload protection, thermal overload relay are best suited for this

purpose. They operate due to the action of heat generated by passage of currentthrough relay element.

AIR CIRCUIT BREAKERS

It is seen that use of oil in circuit breaker may cause a fire. So in all circuits

breakers at large capacity air at high pressure is used which is maximum at thetime of quick tripping of contacts. This reduces the possibility of sparking. The

pressure may vary from 50-60kg/cm^2 for high and medium capacity circuitbreakers


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CONTRACTOR USED IN NTPC

THERMAL OVERLOAD RELAY


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The main constituents of CHP plant are:-

WAGON TIPPLER

Wagon from coal yard come to the tippler and emptied here. There are 2

wagon tipplers in the OCHP.CONVEYER

Conveyer belts are used in the OCHP to transfer coal from one place toother as required ina convenient & safe way.

ZERO SPEED SWITCH

It is used as a safety device for the motor i.e. if the belt is not moving & themotor is ON, then it burns to save the motor. This switch checks the speed

of the belt & switches off the motor when speed is zero.METAL DETECTOR

As the conveyer belt take coal from wagon to crusher house, no metalpiece should go along with coal. To achieve this objective, metal detectors& separators are used.

CRUSHER HOUSE

Both the plants i.e. OCHP & NCHP use TATA crusher powered by BHELmotor. Crusher is designed to crush the pieces to 20 mm size i.e. practically

considered as the optimum size for transfer via conveyer.ROTARY BREAKER

If any large piece of metal of any hard substances like metal impuritiescomes in the conveyer belt which cause load on the metal separator, thenthe rotary breaker rejects them reducing the load on the metal detector.

PULL GUARD SWITCH

These are the switches which are installed at every 10m gap in a

conveyer belt to ensure the safety of motors running the conveyer belts. Ifat any time some accident happens or coal jumps from belt and startscollecting at a place, then the switch can be used.


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ELECTRICAL MAINTENANCE

DEPARTMENTII (EMD-II)

It includes:

GeneratorsTransformers

Switch yard


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GENERATORS

The generator works on the principle of electromagnetic

induction. There are two components

Stator and rotor. The rotor is the moving part and the

Stator is the stationary part. The rotor, which has field

winding, is given an excitation through a set of

3000rpm to give the required frequency of HZ. The rotor is

cooled by Hydrogen gas, which is locallyManufactured by the plant and has high heat carrying capacity

of low density. If oxygen and hydrogen get mixed then they will

form very high explosive and to

Prevent their combining in any way there is seal oil system.

The stator cooling is done by de-mineralized

(DM) water through hollow conductors. Water is fed by one

end by Teflon tube. A boiler and a turbine are coupled to

electric generators. Steam from the boiler is fed to the turbine

through the connecting pipe.

Steam drives the turbine rotor.

The turbine rotor drives the generator rotor which turns

the electromagnet within the coil of wire conductors.

Carbon dioxide is provided from the top and oil is provided

from bottom to the generator. With the help

of carbon dioxide the oil is drained out to the oil tank.


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RATINGS OF THE GENERATORSUSED

Turbo generator 100MW

TURBO GENERATOR 210 MW

The 100 MW generator generates 10.75 KV and

210 MW generates 15.75 KV. The voltage is

stepped up to 220 KV with the help of generatortransformer and is connected to the grid.The voltage is stepped down to 6.6 KV with the

help of UNIT AUXILLARY TRANSFORMER (UAT)

and this voltage is used to drive the HT motors. The

voltage is further stepped down to 415 V and then

to 220 V and this voltage is used to drive Lt Motors.


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TRANSFORMERS

It is a static machine which increases or decreases the AC voltagewithout changing the frequency of the supply.It is a device that:

Transfer electric power from one circuit to another.

It accomplishes this by electromagnetic induction.

In this the two electric circuits are in mutual inductive influence of each

other.

WORKING PRINCIPLE:It works on FARADAYSLAWOF ELECTROMAGNETIC INDUCTION (selfor mutual induction depending on the type of transformer).


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COOLING OF TRANSFORMERSOF LARGE MVA

As size of transformer becomes large, the rateof the oil circulating becomes insufficient todissipate all the heat produced & artificialmeans of increasing the circulation by electricpumps. In very large transformers, special

coolers with water circulation may have to beemployed.

TYPES OF COOLING:Air cooling

Air Natural (AN)Air Forced (AF)Oil immersed coolingOil Natural Air Natural (ONAN)Oil Natural Air Forced (ONAF)Oil Forced Air Natural (OFAN)

Oil Forced Air Forced (OFAF)Oil immersed Water coolingOil Natural Water Forced (ONWF)Oil Forced Water Forced (OFWF)


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MAIN PARTS

OFTRANSFORMER

1. Secondary Winding2. Primary Winding.3. Oil Level

4. Conservator5. Breather6. Drain Cock7. Cooling Tubes.8. Transformer Oil.9. Earth Point10. Explosion Vent

11. Temperature Gauge.12. Buchholz Relay13. Secondary Terminal14. Primary Terminal


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SWITCH YARD

As we know that electrical energy cant be stored like cells, so what wegenerate should be consumed instantaneously. But as the load is notconstants therefore we generate electricity according to need i.e. thegeneration depends upon load. The yard is the places from where theelectricity is send outside. It has both outdoor and indoor equipments.OUTDOOR EQUIPMENTS

BUS BAR.

LIGHTENING ARRESTERWAVE TRAP

BREAKER

CAPACITATIVE VOLTAGE TRANSFORMER

EARTHING ROD

CURRENT TRANSFORMER.

POTENTIAL TRANSFORMER

LIGHTENING MASKS

INDOOR EQUIPMENTS:

RELAYS.

CONTROL PANELS

CIRCUIT BREAKERS


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BUS BARBus bars generally are of high conductive aluminum conforming toIS-5082 or copper of adequate cross section. Bus bar located in airinsulated enclosures & segregated from all other components .Busbar is preferably cover with polyurethane.BY PASS BUSThis bus is a backup bus which comes handy when any of thebuses become faulty. When any operation bus has fault, this bus isbrought into circuit and then faulty line is removed there byrestoring healthy power line.LIGHTENING ARRESTOR

It saves the transformer and reactor from over voltage and overcurrents. It grounds the overload if there is fault on the line and itprevents the generator transformer.WAVE TRAPWAVETRAP is connected in series with the power (transmission)line. It blocks the high frequency carrier waves (24 KHz to 500KHz) and let power waves (50 Hz - 60 Hz) to passthrough.BREAKER

Circuit breaker is an arrangement by which we can break thecircuit or flow of current. A circuit breaker in station serves thesame purpose as switch but it has many added and complexfeatures. The basic construction of any circuit breaker requires theseparation of contact in an insulating fluid that servers twofunctions:

extinguishes the arc drawn between the contacts when circuit

breaker opens.

It provides adequate insulation between the contacts and from

each contact to earth.


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EARTHING RODNormally un-galvanized mild steel flats are used for earthling.Separate earthing electrodes are provided to earth the lightening

arrestor whereas the other equipments are earthed by connectingtheir earth leads to the rid/ser of the ground mar.CURRENT TRANSFORMERIt is essentially a step up transformer which step down the currentto a known ratio. It is a type of instrument transformer designed toprovide a current in its secondary winding proportional to thealternating current flowing in its primary.POTENTIAL TRANSFORMER

It is essentially a step down transformer and it step downs thevoltage to a known ratio.RELAYSRelay is a sensing device that makes your circuit ON or OFF. Theydetect the abnormal conditions in the electrical circuits bycontinuously measuring the electrical quantities, which aredifferent under normal and faulty conditions, like current, voltagefrequency. Having detected the fault the relay operates to

complete the trip circuit, which results in the opening of the circuitbreakers and disconnect the faulty circuit.There are different types of relays:Current relayPotential relayElectromagnetic relayNumerical relay etc.AIR BREAK EARTHING SWITCH

The work of this equipment comes into picture when we want toshut down the supply for maintenance purpose. This help toneutralize the system from induced voltage from extra highvoltage. This induced power is up to 2KV in case of 400 KV lines.


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FIRE PROTECTION IN

COAL HANDING

PLANT


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FIRE HYDRANT SYSTEM

Fire Hydrant SYSTEM

Spacing 45 M max.

External Fire Escape Staircases.


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FIRE WATER PUMPS

MAIN HYDRANT PUMPS (03 NOS MOTORDRIVEN,O1 ENGINE DRIVEN) HORIZONTALCENTRIFUGAL PUMP, CAPACITY:410METRECUBE PER HOUR, HEAD 105MWC

MAIN SPRAY PUMPS (01 NO MOTORDRIVEN, 01 NO ENGINE DRIVEN)-HORIZONTAL CENTRIFUGAL PUMP,CAPACITY:410 METRE CUBE PER HOUR,HEAD 120 MWC.

JOCKEY PUMPS (02 NO MOTOR DRIVEN)-

HORIZONTAL CENTRIFUGAL PUMP,

CAPACITY:75METRE CUBE PER HOUR, HEAD105MWC BOOSTER PUMPS (01 NO MOTORDRIVEN AND 01 NO ENGINE DRIVEN)HORIZONTAL CENTRIFUGAL PUMP,

CAPACITY:171METRE CUBE PER HOUR, HEAD45MWC


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FIRE PROTECTION

Deluge valve


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THANK YOU

industrial training in ntpc

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