ntpc lnct training report (autosaved)

Industrial Training Report

Department of Electronics and Telecommunication Engineering, Lakshmi Narain College of Technology, Bhopal1

Chapter 1

Introduction



Chapter 1

Introduction

NTPC is the largest thermal power generating company of India. A Public sector

company wholly owned by government of India. It was incorporated in the year 1975 to

accelerate power development in the country. Within a span of 30 years, NTPC has

emerged as a truly national power company, with power generating facilities in all the

major regions of the country. NTPC contributes 28.5% of the country’s entire power

generation and hence today lights up every fourth bulb in the country. It is the third

largest Maharatna company of India after Coal India LTD and ONGC.

With ambitious growth plans to become a 56000MW power company by 2017, NTPC the

largest power utility of India has already diversified into hydro sector. 18 NTPC stations

have already been accredited with the ISO 14001 certification. In keeping with its well

focused environment protection policy, NTPC has set up a “Centre for Power Efficiency

and Environmental protection” (CENPEEP) which functions as a resource centre for

development and dissemination of latest technologies in environmental management.

In a remarkable achievement, the recently conducted Business Today –Hewitt Associate

Best Employers survey 2003 ranked NTPC the 3rd best among major companies in India.

1.1 Company Profile

NTPC, Kahalgaon super thermal power project is one of the most prestigious flagships of

NTPC striving ahead to bridge the country generation gap especially in the north region.

Kahalgaon Super Thermal Power Station (KhSTPP) is located in Kahalgaon in Bhagalpur

district of Bihar. It has secured ISO 14001 and ISO 9002 certificate in the field of

environment and power generation but also in various other fields. On September 2002 it

made glorious achievement by ensuring production up to 2340 MW. In 2007 total

production of , Kahalgaon became 4260MW by adding 2 units of each 500MW. Now,

NTPC , Kahalgaon is the largest power plant of India. It has won number of awards from



government of India for proper utilization and consumption and has bagged the safety

awards presented by U.S.A. and British safety council.

1.1.1 Objectives

NTPC plans to broad base generation mix by evaluating conventional and alternate

sources of energy to ensure long run competitiveness and mitigate fuel risks.

1.1.2 Vision

“To provide green power through locally available resources at affordable price,

promoting clean energy”

1.1.3 Coal Source Of NTPC, , Kahalgaon

Eastern Coalfields Ltd (ECL) mines at piparwar mines north karanpura (Jharkhand)

1.1.4 Fuel Oil Source

Indian oil corporation ltd. (IOCL), COLD (customer operated lubricant and oil deposit)

at Jayant.

1.1.5 Water Source

Ganga river

1.1.6 Beneficiary States

Bihar, West Bengal,.Nepal

1.1.7 International Assistance

USSR and World Bank under time slice loan.

Table 1.1 Units Commissioned

1. Unit 1 210MW October 1987

2. Unit 2 210MW July 1988

3. Unit 3 210MW February 1989



4. Unit 4 210MW December 1989

5. Unit 5 500MW March 1990

6. Unit 6 500MW February 1991

7. Unit 7 500MW 1998



Chapter 2

Services and Major Functions Of The

Organization



Chapter 2

Services and Major Functions of the Organization

NTPC is proud of the fact that it has successfully explored more than one way to

generate power. Other than thermal power, it operates in hydro and gas regions too. As a

natural progression of its in-depth understanding of the power sector and formidable

track record, NTPC has now ventured into three related fields namely Consultancy for

the power sector, setting up a training institute for the same and R&D.

2.1 Consultancy

The Consultancy Wing of NTPC, with an ISO 9001:2000 accreditation, undertakes all the

previous Consultancy and turnkey project contracts for Domestic and International

clients in the different phases of Power plants With the string of achievements behind it,

NTPC has emerged as the acknowledged leader in engineering, construction, O&M,

RLA/R&M and management of power projects.

As a result of the phenomenal success achieved by NTPC in executing its own power

projects, many utilities from India and abroad started approaching NTPC to gain from

the rich experience gained by NTPC. With this in view NTPC formally established its

Consultancy Wing in 1989.

Since then NTPC Consultancy has secured 490 orders from Domestic & International

Clients.

NTPC is registered as a consultant with several leading international development and

financial institutions such as The World Bank, The Asian Development Bank, The

African Development Bank and UNDP.

NTPC's vast pool of technically qualified and managerial manpower is well supported by

excellent infrastructure and knowledge management facilities to deliver the client time

bound, qualitative and cost effective solution meeting the global standards.

At NTPC, we offer consultancy services related to infrastructure sector business such as:



Fossil fuel based thermal power plants

Combined cycle power plants

Cogeneration plants

Water supply and treatment

Environment engineering and management

An entire gamut of services is offered in the areas mentioned above. These are:

Owner's Engineer Services

Lender's Engineer Services

Environment Engineering and Management

Procurement Services

Project Management

Quality Assurance and Inspection Services

Materials Management

Construction Management, Erection and Commissioning

Financial Systems and Modeling

Operation and Maintenance

Restoration, Efficiency Improvement and Renovation and Modernization

HRD and Training

Research and Development

Information Technology

Management Consultancy

Commercial Consultancy

2.2 International Marketing



Towards the end of last century, many countries started structural changes in their

infrastructure sectors. Many countries decided to un-bundle their hitherto government

controlled power sector. Further, in order to meet the growing demand for power,

privatization of power projects emerged as the most outstanding choice. These actions of

many progressive governments resulted in a number of opportunities for private players

in power sector. These include development of power projects as Independent Power

Producers (IPP).

Keeping its proactive tradition, NTPC launched a separate International Marketing to

meet the varied needs of IPPs and other International clients who are looking for a world

class service in power sector. The International Marketing is fully backed by NTPC’s

three decades of experience and expertise. The Marketing is especially tuned to meet the

requirements of International clients in terms of quick response, flexible service options

and to deliver value for money.

Fig. 2.1 Consultancy Services



2.2.1 NETRA (NTPC Energy Technology Research Alliance)

NTPC is a technology driven company and is fully aligned to the needs of adapting to

emerging technologies and upgrading the technologies through R&D. The company is

particularly sensitive to R&D and paradigm shift which it can make. Towards this, NTPC

has a multi-pronged approach. NETRA (NTPC Energy Technology Research Alliance)

has come into existence in 2009 after merging of R&D center (Established in 1981) and

Energy Technologies.

The focus areas are: Climate change, waste management, new & renewable energy,

efficiency improvement and cost reduction besides providing scientific support to NTPC

and external utilities for improving availability, reliability and efficiency.

The focus is on developing cutting edge technologies by carrying out applied research

which will manifest into cost reduction and environment protection. NETRA is

networked with Institutes/organizations for research related to development of cost

economic technologies in the field of Climate change, New & Renewable energy,

efficiency & reliability enhancement of thermal power generation and CO2

mitigation/fixation. It is also in the dialogue with many International

institutes/organizations for networking in these areas.

Initiatives are taken to develop technologies for reducing forced outages, installing

intelligent online monitoring of critical components, understanding the likely damages

due to corrosion and providing appropriate solutions etc. Effort is being made for

reducing cost of generation by either increasing the overhaul cycle or reducing overhaul

duration through correct and proper health assessment of critical components,

developing diagnostic tools and ensures environmental & safety compliances. The prime

thrust is towards clean and economic power generation. The Patents have been filed in

the areas of climate change, waste management etc.

Research Advisory Council (RAC) comprising of eminent scientists and experts from

India and abroad has been constituted to steer NETRA for high end research. In-house



Scientific Advisory Council (SAC) has also been constituted to provide directions

improving plant performance & reducing cost of generation.

The key expertise lies in providing scientific support to stations for improving their life,

performance and developing technologies for clean & economic power generation for the

sustainable growth of power sector.

NETRA is a Member of IEA GHG R&D Program France, IERE Japan & CSLF France.

NETRA is National Boiler Board Certified RLA Agency.

2.3 Power Management Institute

NTPC runs a state-of-the-art Power Management Institute (PMI), at NOIDA. PMI has

over the years trained a large number of professionals from NTPC, State Electricity

Boards and other power utilities in the country. Also, participants in PMI programmes

have come from various South Asian and Middle Eastern countries.

With a wide range of expertise and experience acquired over the years, PMI offers

programme in the following categories:

Enhancing General Management Competence and Skills: The programmes

included in this category develop the knowledge, attitude, behaviour and skills of

the participants from the perspective of general management of the enterprise.

Enhancing Technical Expertise: These programmes are designed to impart

emerging technologies and practices that augment technical skills and

competencies.

Upgrading Functional Skills: The programmes in this category cater to the

functional areas of the organization like HR, Finance, Materials, Contracts etc

Managing Information Technology: IT enablement is a key determinant of

organization success and these programmes provide the required knowledge and

skills.

Induction Level Training Programmes: A key area of expertise is the Induction

level training programme for newly recruited executive trainees in Engineering,

Chemistry, IT, Finance and Human Resources



Employee Development Programmes: Programmes are conducted for the

Supervisors and Workmen of our Corporate Centre Office in the areas of

powerplant familiarization, attitude, quality, finance and IT.



2.3.1 Installed Capacity

Present installed capacity of NTPC is 43,128 MW (including 5,974 MW through JVs)

comprising of 38 NTPC Stations (17 Coal based stations, 7 combined cycle gas/liquid

fuel based stations), 7 Joint Venture stations (6 coal based and one gas based) and 7

renewable energy projects.

Table 2.1 Installed Capacity

NO. OF PLANTS CAPACITY (MW)

NTPC Owned

Coal 17 33,015

Gas/Liquid Fuel 7 4,044

Renewable energy

projects7 95

Total 31 37,154

Owned By JVs

Coal & Gas 7 5,974

Total 38 43,128



Table 2.2 Regional Spread of Generating Facilities

REGION COAL GAS Renewable TOTAL

Northern 9,015 2,334 20 11,369

Western 10,840 1,313 50 12,203

Southern 4,600 370 15 4,975

Eastern 8,560 - 10 8,570

JVs 4,034 1,967 - 6,001

Total 37,049 5,984 95 43,128

Table2.3 Coal Based Power Stations

COAL BASED(Owned

by NTPC)STATE

COMMISSIONED

CAPACITY(MW)

1. Singrauli Uttar Pradesh 2,000

2. Korba Chhattisgarh 2,600

3. Ramagundam Andhra Pradesh 2,600



4. Farakka West Bengal 2,100

5. Vindhyachal Madhya Pradesh 4,260

6. Rihand Uttar Pradesh 3,000

7. Kahalgaon Bihar 2,340

8. Dadri Uttar Pradesh 1,820

9. Talcher Kaniha Orissa 3,000

10. Feroze Gandhi, Unchahar Uttar Pradesh 1,050

11. Talcher Thermal Orissa 460

12. Simhadri Andhra Pradesh 2,000

13. Tanda Uttar Pradesh 440

14. Badarpur Delhi 705

15. Sipat Chhattisgarh 2,980

16. Mauda Maharashta 1,000

17. Barh Bihar 660

Total 33,015

Fig 2.2 Installed Capacity

Department of Electronics and Telecommunication

2.4 Renewable Energy

Renewable energy (RE) is being perceived as an alternative source of energy for “Energy

Security” and subsequently “Energy Independence” by 2020. Renewable energy technologies

provide not only electricity but offer

2.4.1 Portfolio of Renewable Power

NTPC has also formulated its business plan of capacity addition of about 1,000 MW thru

renewable resources by 2017. In this endeavour, NTPC has already commissioned

PV Projects and another 15 MW Solar PV and 8 MW Small Hydro Projects are under

implementation


ment of Electronics and Telecommunication Engineering, Lakshmi Narain College of Technology, Bhopal



provide not only electricity but offer an environmentally clean and low noise source of power.

Portfolio of Renewable Power


renewable resources by 2017. In this endeavour, NTPC has already commissioned



Narain College of Technology, Bhopal15



an environmentally clean and low noise source of power.


renewable resources by 2017. In this endeavour, NTPC has already commissioned 95 MW Solar




CHAPTER 3

Brief about the Annual Report and

Organisational Policies



Chapter 3

Brief about the Annual Report and Organisational Policies

3.1 Annual Report

Figure 3.1 depicts the annual report of NTPC in previous two years

Fig 3.1 Annual Report of NTPC



3.2 Organizational Policies

There are a range of policies undertaken by NTPC

Fig. 3.2 Vision, Mission and Core Values of NTPC



3.1.1 Environment Policy & Environment Management System

For NTPC, the journey extends much beyond generating power. Right from its inception,

the company had a well defined environment policy. More than just generating power, it

is committed to sustainable growth of power. They are as follows:

National Environment Policy: The Ministry of Environment and Forests and

the Ministry of Power and NTPC were involved in preparing the draft

Environment Policy (NEP) which was later approved by the Union Cabinet in

May 2006. Since its inception NTPC has been at the forefront of Environment

management. In November 1995, NTPC brought out a comprehensive document

entitled ‘NTPC Environment Policy and Environment Management System.

Amongst the guiding principles adopted in the document are the company's pro-

active approach to environment, optimum utilization of equipment, adoption of

latest technologies and continual environment improvement. The policy also

envisages efficient utilization of resources, thereby minimizing waste, maximizing

ash utilization and ensuring a green belt all around the plant for maintaining

ecological balance.

Environment Management, Occupational Health and Safety Systems:

NTPC has actively gone for adoption of the best international practices on

environment, occupational health and safety areas. The organisation has pursued

the Environmental Management System (EMS) ISO 14001 and the Occupational

Health and Safety Assessment System OHSAS 18001 at its different

establishments. As a result of pursuing these practices, all NTPC power stations

have been certified for ISO 14001 & OHSAS 18001 by reputed national and

international certifying agencies.

Pollution Control Systems: While deciding the appropriate technology for its

projects, NTPC integrates many environmental provisions into the plant design. In

order to ensure that NTPC complies with all the stipulated environment norms,

following state-of-the-art pollution control systems / devices have been installed

to control air and water pollution:

Electrostatic Precipitators



Flue Gas Stacks

Low-NOX Burners

Neutralisation Pits

Coal Settling Pits / Oil Settling Pits

DE & DS Systems Cooling Tower

Ash Dykes & Ash Disposal Systems

Ash Water Recycling System

Dry Ash Extraction System (DAES)

Liquid Waste Treatment Plants & Management System

Sewage Treatment Plants & Facilities

Environmental Institutional Set-up

Following are the additional measures taken by NTPC in the area of Environment

Management:

Environment Management During Operation Phase

Monitoring of Environmental Parameters

On-Line Data Base Management

Environment Review

Upgradation & Retrofitting of Pollution Control Systems

Resources Conservation

Waste Management



Municipal Waste Management

Hazardous Waste Management

Bio-Medical Waste Management

Land Use / Bio-diversity

Reclamation of Abandoned Ash ponds

Green Belts, Aforestation & Energy Plantations

The NTPC is not just the leading power generating company in the country. It is also one

of the topmost public sector undertakings which have been playing a dynamic role in

transforming the lives of the people in various regions locating its projects. Its sustained

work for the resettlement and rehabilitation of the affected people as also the community

development programmes in the adjoining villages is a testimony to the deep

commitment of NTPC to its corporate social responsibility. In the process, NTPC

projects have helped in imparting high growth to the local village economy, apart from

improving the standard of living of the project affected persons and the villagers. NTPC’s

CSR programmes have been continuously improving upon the resettlement and

rehabilitation work through a process of consultations with the affected people and

various non-government organizations.



Fig 3.3 Sustainable Policy



Chapter 4

Different Departments and Close

Relationships



Chapter 4

Different Departments and Close Relationships

NTPC being the largest power plant of India has several departments which are

interrelated to each other. All these departments act together to perform all the

functions of the organization.

4.1 Departments of NTPC

NTPC has several departments, nearly 45 departments in all. They are as follows:

GM Cell

Vigilance cell

TSD

Field Energy

Planning & System

Business & Excellence

Safety

Field Quality & Assurance

Info Tech Department

EMG Department

AVD Department

Project

CCD Department

C& I Erection

Commissioning

Town Administration

C&M Department

Purchase

Stores

Contract Cell

F&A



Human Resources

EDC Department

Hospital

Operation & Maintenance Department

Research & Management Department

EEMG Department

Operation Department

O&M Civil

Chemistry

MTP Department

Maintenance

BMD Department

ASH Handling

Central Workshop

Auto Base

MM-TMD

MM-TMD-OS

EMD

C&I- Maintenance

FM

CHP

Merry Go Round

4.2 Subsidiaries & Joint Ventures

The names of Joint Ventures/Subsidiaries and their areas of operation/business are given

below:



Table 4.1 Joint Ventures

S.No.Company Name

(Incorporated on)

Promoters

Equity holding

Capacity

(MW)Objective

Power Generation

1.

NTPC-SAIL

Power Company

Pvt. Ltd.

(08.02.1999)

NTPC-50%

SAIL-50%814

To operate & maintain the

Captive power plants of

Durgapur, Rourkela &

Bhillai

2.

Aravali Power

Company Private

Ltd.

(21.12.2006)

NTPC-50%

IPGCL-25%

HPGCL-25%

1500

To set up & operate 3X500

MW Indira Gandhi Super

Thermal Power Project at

Jhajjar, Haryana.

3.

NTPC Tamil

Nadu Energy

Company Ltd.

(23.05.2003)

NTPC-50%

TNEB-50%1500


MW Coal based power

project at Vallur, Tamil

Nadu

4.

Meja Urja Nigam

Private Ltd.

(02.04.2008)

NTPC-50%

UPRVUNL-50%1320


MW power project at Meja

Tehsil in Allahabad district

in UP

6.

Ratnagiri Gas and

Power Pvt. Ltd.

(08.07.2005)

NTPC & GAIL -

32.47% each ,

IFIs-18.13%

MSEB Holding

Co.-16.93%

1967

To own & operate the

assets of erstwhile Dabhol

power plant in Ratnagiri

1967 MW and 5 MMTPA

LNG Re-gasification



terminal

7.

Trincomalee

Power Co. Ltd.

(26.09.2011)

NTPC-50%

Ceylon

Electricity Board-

50%

500

For setting up 2X250 MW

coal based power plant in

Trincomalee Region in Sri

Lanka

8.

Bangladesh-

India Friendship

Power Company

Pvt. Ltd.

(31.10.2012)

NTPC-50%

Bangladesh

Power

Development

Board- 50%

1320

Setting up and

implementing coal based

Power plant (s) in

Bangladesh

9.

Anushakti

Vidhyut Nigam

Ltd.

(27.11.2010)

NTPC – 49 %

NPCIL – 51 %-

Development of nuclear

power projects in the

country.

10.

Pan Asian

Renewables Pvt.

Ltd.

(14.10.11)

NTPC-50%

ADB-25%

Kyuden-25%

-

Development of 500 MW

of Renewable Power

generation resources in

India.

Power Equipment Manufacturing

11.

NTPC BHEL

Power Projects Pvt

Ltd.

(28.04.2008)

NTPC-50%

BHEL-50%

To take up EPC contracts and

manufacturing of equipments for

power plants and other infrastructure

projects in India & abroad

12. BF-NTPC Energy NTPC-49% To initially take up manufacturing of



Systems Ltd.

(19.06.2008)

Bharat Forge

Ltd.-51%

castings, forgings, fittings, high

pressure piping required for power

projects and other industries and

Balance of Plant (BOP) equipment

13.

Transformer &

Electricals Kerala

Ltd. (44.6% shares

acquired by NTPC

on 19.06.2009)

NTPC-44.6%

Govt. of Kerala-

55.39%

Banks-0.01%

For manufacturing and repair of high

voltage transformers and associated

equipment.

Power Services

14.

National Power

Exchange Ltd.

(11.12.2008)

NTPC - 16.67 %

NHPC - 16.67 %

PFC - 16.66 %

BSE - 16.66 %

TCS - 19.04 %

IFCI – 5.72 %

MEENAKSHI-

4.77%

DPSC - 3.81 %

To set up and operate power exchange.

Keeping in view the change in market

scenario and the fact that NTPC’s

objective of joining NPEX was not

achieved so far, NTPC Board in its

meeting held on November 7th, 2012,

approved the proposal of NTPC’s exit

from NPEX. The decision of NTPC to

exit from NPEX has been

communicated to other promoters of

NPEX.

15.

Utility Powertech

Ltd.

(23.11.1995)

NTPC-50%

Reliance

Infrastructure

Ltd.-50%

To take up assignments of

construction, erection and supervision

in power sector and other sectors in

India and abroad

16.NTPC-Alstom

Power Services

NTPC-50%

Alstom Power

To take up Renovation &

Modernisation assignments of Power



Private Ltd.

(27.09.1999)

50% Plants both in India & SAARC

countries

17.

National High

Power Test

Laboratory Private

Ltd.

(22.05.2009)

NTPC-20%

NHPC-20%

PGCIL-20%

DVC-20%

CPRI-20%

For setting up an online High Power

Test Laboratory for short-circuit test

facility in the country.

18.

Energy Efficiency

Services Ltd.

(10.12.2009)

NTPC-25%

PFC-25%

PGCIL-25%

REC-25%

To carry out and promote the business

of Energy Efficiency, Energy

Conservation and Climate Change.

Coal Mining

19.

International Coal

Ventures Pvt. Ltd.

(20.05.2009)

NTPC, RINL &

NMDC -14.28%

each

SAIL & CIL-

28.58% each

For sourcing coking coal and thermal

coal from abroad.

However, opportunities for

identification of thermal coal were

limited. Therefore NTPC decided to

opt out of this.

Permission from Ministry of Power

taken for opting out of JV.NTPC

Board has approved the proposal for

withdrawal from ICVL. Letter issued to

ICVL for withdrawal.

ICVL is in the process of obtaining

cabinet clearance on the same.



20.

NTPC-SCCL

Global Venture

Pvt. Ltd.

(30.07.2007)

NTPC-50%

Singareni

Collieries Co.

Ltd.-50%

To undertake the development and

O&M of coal blocks and integrated

coal based power projects in India and

overseas.

21.

CIL NTPC Urja

Pvt Ltd

(27.04.2010)

NTPC – 50%

CIL – 50%

Development, operation and

maintenance of coal blocks and

integrated coal based power plants.

Table 4.2 Subsidiaries

S.No.Company Name

(Incorporated on)

Promoters

Equity

holding

Objective

Power Generation

1.Bhartiya Rail Bijlee Company Ltd.

(22.11.2007)

NTPC-

74%

Indian

Railways-

26%

To set up a power plant

of 1000 MW to meet the

requirements of Railways.

2.Kanti Bijlee Utpadan Nigam Ltd.

(06.09.2006)

NTPC-

65%

BSEB-35%

To take up and operate

Muzaffarpur Thermal

Plant in Bihar.

3.

NTPC Hydro Limited, a wholly-

owned subsidiary of NTPC

Limited, has been merged with the

NTPC-

100%

To set up hydro power

projects up to 250 MW

capacity. It has merged



NTPC Limited, its Holding

Company

with NTPC.

Distribution

4.NTPC Electric Supply Co. Ltd.

(21.08.2002)

NTPC-

100%Distribution of power.

Trading

5.NTPC Vidyut Vyapar Nigam Ltd.

(01.11.2002)

NTPC-

100%Trading of power & Ash.



Chapter 5

Organizational Structures



Chapter 5

OrganizationalStructures

Fig 5.1 Organizational Structure of NTPC



Chapter 6

Process Flow



Chapter 6

Process Flow

Following processes take place during power generation in NTPC

6.1 Generation of Coal to Electricity

Electricity generation takes place in following three broad steps

6.1.1 Coal to Steam

A modern boiler pulverizes coal at rate up to 200 tones per hour. From the coal store,

fuel is carried on a conveyor belt and discharged by means of coal tipper into the bunker.

It thus falls, perhaps through a weather, into the coal pulverizing mill, where it is ground

to a power as fine as flour. The mill usually consists of a round metal table on which large

steel rollers or balls that crushes it.

Fig 6.1 Boiler Parts

Air is drawn from the top of the boiler house by the forced draught fan and passed

through the air pre heaters, to the hot air duct. From here some of the air passes directly

to the burners and the remainder is taken through the primary air fan to the pulverizing

mill, where it is mixed with the powdered coal, blowing it along pipes to the burners of

the furnace. Here it mixes with the rest of the air and burns the condensate in the



economizer and then pass through the air pre heaters, to the electrostatic precipitator.

Finally they are drawn by the induced draught fan into the main flue and to the chimney.

The electrostatic precipitator consists of metal plates, which are electrically charged. Dust

and grit in the flue gasses are attracted on to these plates, so that they do not pass up the

chimney to pollute the atmosphere. Regular mechanical hammer blows cause the

accumulation of ash, dust and grit to fall to the bottom of the precipitator where they

collect in a hopper for disposal. Additional accumulation is also collected in the hoppers

beneath the furnace. The ash is either sold for use in road and building constructions or

piped as slurry.

Fig 6.2 Coal to Electricity

6.1.2 Steam to Mechanical Power

As from the fig. it is clear that a steam pipe (1) conveys steam to the turbine through a

stop valve and through control valves (2) that automatically regulate the supply of steam

to the turbine. Stop valve and control valve are located in a steam chest and a governer

(3) driven from the main turbine shaft (4), operates the control valve to regulate the

amount or steam used.

Steam from the control valve enters the high pressure cylinder of the turbine where it

passes through a ring of stationary blade (5) fixed to the cylinder wall (6). These act as

Department of Electronics and Telecommunication

nozzles and direct the steam onto a second ring of moving blades (7) mounted on a disc

secured to turbine shaft. This second ring turns shaft as a result of the force of steam.

The stationary and moving blades together constitute a `stage` of the turbine and in

practice many stages are necessary so that the cylinder contains no. of rings of s

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

some of its heat energy is changed into mechanical energy. The steam l

pressure cylinder goes back to the boiler from reheating (8) and return by a further pipe

(9) to the I.P. cylinder. Here it passes through another series of stationary and moving

blades. Finally the steam enters to L.P. cylinder. As the steam g

drive the turbine, its temperature and pressure falls and it expands. Because of this

expansion the blades are much larger and longer towards the low

turbine. The turbine shaft usually rotates at 3000r.p.m.

When as much energy as possible has been extracted from the steam it is exhausted

directly to the condenser. The condenser consists of a large vessel containing some 20000

tubes, each about 25mm in diameter. Cold water from the cooling towers is circulated

through these tubes and as the steam from the turbine passes around them it is rapidly

condensed into water-condensate. Because water has a much smaller comparatively

volume then steam, a vacuum is created in the condenser. This allows the steam to be

used down to pressure below that of normal atmosphere and more energy can be utilized.

From the condenser, the extraction pump pumps the condensate through low pressure


ment of Electronics and Telecommunication Engineering, Lakshmi Narain College of Technology, Bhopal


ecured to turbine shaft. This second ring turns shaft as a result of the force of steam.


practice many stages are necessary so that the cylinder contains no. of rings of s


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 l



blades. Finally the steam enters to L.P. cylinder. As the steam gives up its heat energy to


expansion the blades are much larger and longer towards the low-pressure ends of the

turbine. The turbine shaft usually rotates at 3000r.p.m.

Fig 6.3 Steam to Mechanical Power





condensate. Because water has a much smaller comparatively


d down to pressure below that of normal atmosphere and more energy can be utilized.



Narain College of Technology, Bhopal37


ecured to turbine shaft. This second ring turns shaft as a result of the force of steam.


practice many stages are necessary so that the cylinder contains no. of rings of stationary


pressure cylinder and in its passage

some of its heat energy is changed into mechanical energy. The steam leaving high-



ives up its heat energy to


pressure ends of the





condensate. Because water has a much smaller comparatively


d down to pressure below that of normal atmosphere and more energy can be utilized.




feed heaters. It further passes through feed heaters to the economizer and the boiler for

re conversion into steam.

A power station generating 2000MW of electricity requires about 227500m3 of water per

hour for cooling purpose. Where cooling towers are used, about one hundredth part of

the cooling water evaporates and a certain amount is returned to its source to carry away

any impurities that collect. Most of it however is re circulated.

Fig 6.4 Various Steps

6.1.3 Mechanical Power to Electricity

The power generated by the turbine is given to generator, which is coupled with shaft of

turbine. Generator converts this power into electricity by the rule of Mutual Induction.

The electricity produced by the generator is given to the switchyard, which collects,

control and finally distribute it through long transformers and cables.



Fig 6.5 Thermal Power Plant

6.2 Raw Water to Demineralized Water

As the water is the basic requirement of the plant so initially water is treated in order to

remove scales, corrosion and priming foaming problems.

Water treatment process done in two sections:

1. Pretreatment Section :- Pretreatment plant remove the suspended solids such as

clay, slit, organic and inorganic matter, plants and other microscopic organism by

passing water in aerator, clarifier, filter bed.

2. Demineralization Section: - Pretreated water is now feed into DM plant in which

dissolved solids are removed (cations & anions) by passing pretreated water in

activated carbon filter. Cation exchanger, degassed water storage tank, anion

exchanger and then to mixed bed.



Fig 6.4 DM Water Plant



Chapter 7

Assignment Completed During Training



Chapter 7

Assignment Completed During Training

Several assignments were also given during the training period to understand the

importance and functioning of the control and instrumentation department. For safe &

efficient operation of power plant, it is of paramount importance to monitor all power

plant parameter such as: temperature, pressure, flow, level, etc. In a power plant control

& instrumentation is synonymous to the nerves & brain of human being. All the

parameters is measured and communicated to control room. The processing is done in

control room and commands were given to field control drives to attain the desire plant

conditions. In Vindhyachal advanced distributed digital control, monitoring and

information sys (DDCMIS) has been provided.

The assignment given to us are as follows which will be described later on

Study of FCX-A Series Transmitter

Study of Dead Weight Tester

Study of various measuring instruments for flow and level.

Study of closed loop control system.

8.1 Study of FCX-A Series Transmitter

The FCX-A Series transmitter which is available as an analog or smart type, detects the

differential pressure or pressure of various fluids, converts it into a current of 4 to 20 mA

DC & transmits it. All the adjustment function is incorporated in the transmission unit

for making adjustments easy & exact. In the smart type, transmitter setting as range &

damping time constant etc can be changed from HHC (Hand Held Communicator).

Operating principle is shown in the block diagram below. The input pressure is changed

into an electrostatic capacitance in the detecting unit. The change proportional to the

pressure which undergoes amplification & signal conditioning in transmission unit & it

then gives output as current of range 4 to 20 mA. Diaphragm & Sensor Unit is called



detecting unit & measuring circuit & operational amplification unit togetherly are called as

transmission unit.

Fig 7.1 Block Diagram Of Operating Principle

8.2 Study of Dead Weight Tester

Dead weight tester is an apparatus to check the accuracy of the instrument . It takes into

account all the parameters like sensitivity linearity accuracy etc. Piston/Cylinder on left

hand connection & Gauge stand on right hand connection. Bench should be 0.9m high.

OPERATION

Load the weight carrier with the weight equivalent to the desired pressure

Fill & apply pressure until piston rises & head is floating weights should be rotated

by hand.

If there were no leaks, the piston head would float for many minutes. After the test is

finished stop weights rotating, wing backs the screw pump & opens the valves. Now

residual pressure is relieved.

PISTON/CYLINDER



Pressure is force per unit area. Dead weight pressure testers use measurements of force &

area to produce pressure to calibrate instruments with great accuracy. Force is delivered

from weight & area.

If Area = 1/8 in sq.

Weight=12.5 pound

Pressure=100 lb/in2

Piston, cylinder & weights together are called DEAD WEIGHT BALANCE.

Effective area is the average of piston & cylinder area.

There is small gap between piston & cylinder i.e. when the piston rotates in the cylinder

pressure medium forms a bearing eliminating friction & metallic contacts between the

two. If the gap is too small, piston will not spin at low pressure but it will spin if gap is

medium. If the gap is too large there will be leakage between the two.

PERFORMANCE depends on the accuracy with which the piston & cylinder are

manufactured. They are generally made of tool steel.

In air heaters, made of high chromium steel, as the moisture corrosion doesn’t affect

them.

WEIGHTS

Weights are manufactured of Martens tic stainless steel. Piston weights are manufactured

to give appropriate force when subject to gravitational acceleration (9.80665 m/sec2) &

in air of density 1.2 kg/m3.

ACCURACY

An unknown area can be known by connecting them hydraulically under pressure.

Pressure of system = WD/AD = WK/AK

AD – UNKNOWN PRESSURE

AK – KNOWN PRESSURE

These are calculated on account of fact that effective area or piston/cylinder increases



with pressure. Accuracy takes into account the buoyancy of weights in air & buoyancy of

parts of piston immersed in liquid.

8.3 Study Of Closed Loop Control System

The CLCS shall interact with its MS function blocks and shall perform close loop control

and information function. The sys shall accept the execute commands from CRT/Key

boards and hard wired A/M station located in unit control room and make available data

for display to CRT and printing on printers. All the control loops of one unit are

implemented in 17 functional groups. Each functional group consists of an independent

& dedicated controller along with associated hardware.

The functional requirements of the control are as under

Co-coordinated Control system (CCS).

Automatic boiler Controls.

Balance of Plant Control.

8.3 Study of Piping of Transmitter for Flow and Level Measuring

Devices

All primary measuring instruments are installed include: temperature sensing element/

wells/ cold junction compensation boxes, Flow sensing elements (orifice plates, flow

nozzles etc), electronic transmitter, flue gas analysis instruments, Vibration Monitoring

System, local indicators, process actuator switches, electro/ pneumatic converters, coal

bunker level indicating system.

The secondary instruments like recorders. Indicators, analyzer monitors, integrators and

electrical meters etc. are mounted on control panels to provide maximum accessibility,

optimum operability. The instruments are arranged such that, failure of any device will

not cause any malfunction towards operation.

Flow measurement (in case of gas): Place the transmitter above the differential

pressure source.



Flow measurement (in case of liquids): Place the transmitter below the

differential pressure source. Make the piping so that the gas in the impulse pipe is

not delivered to the transmitter& incorporate gas reservoirs as required.

Flow measurement (in case of steam): Set the two condensers at the same

height near the process tap. Fill the line between the condensers & the transmitter

with the condensed water.

Pressure measurement (in case of liquid): Zero point can be checked with a

manifold valve installed.

Pressure measurement (in case of gas): Mount the transmitter above the

process pipes preventing the moisture from entering the inside if the transmitter.

Level measurement in case of wet leg: For measurement, connect the highest

liquid level tapping of the tank with the low-pressure side of the transmitter, and

the lowest liquid level tapping of tank with the high-pressure side of the

transmitter.

In case of dry leg: For an open tank, leave the low-pressure side of the

transmitter open to atmosphere



CHAPTER 8

Conclusion



Chapter 8

Conclusion

The training session was very educational and informative. Being a MAHARATNA

company, NTPC have good harmonic relationship and co-ordination between the staff

members. As the vocational training seem laborious job to get in touch with the activities.

It was nobility of people to provide the information and required theoretical background

at their continuous job hour. Most of the equipments were technically strong for huge

production. Doing training in NTPC, I hope it would be useful in my future not only in

academic but also in professional carrier. Electricity is much more than just another

commodity. It is the life-blood of the economy and our quality of life. Failure to meet the

expectations of society for universally available low-cost power is simply not an option.

As the world moves into the digital age, our dependency on power quality will grow

accordingly. The infrastructure of our power delivery system and the strategies and

policies of our insurers must keep pace with escalating demand. Unfortunately, with the

regulators driving toward retail competition, the utility business priority is competitiveness

(and related cost-cutting) and not reliability.



Chapter 9

Problems & Difficulties Encountered &

Guidelines for Betterment & Suggestions



Chapter 9

Problems & Difficulties Encountered & Guidelines for

Betterment & Suggestions

Being the largest power plant of India, NTPC still is facing several issues and difficulties

related to coal supply, electricity and safety issues. These problems are as follows:

The country’s largest power utility is seeking coal concessions abroad as domestic

sources are not able to meet its growing demand. Indian coal also has high ash

content, which reduces the efficiency of power plants (restricting the power that

can be generated from one tonne of coal). Domestic coal, however, is 30-40%

cheaper than imports, depending on the quality.

NTPC is facing problems in awarding an equipment contract. The equipment will

help NTPC improve plant efficiency and achieve economies of scale. By 2032,

about half the country’s generation capacity is expected to be coal-based. To

mitigate the shortfall, India is planning to set up a bulk of its capacity on

supercritical and advanced ultra-supercritical equipment, which are more efficient.

NTPC requires an acre of land per megawatt.

NTPC is also facing severe problems on the norms of start-up electricity. This

electricity to start the whole plant is provided by the state government after lots of

efforts.

Water scarcity due to shortage of rain has also been encountered as one of the

biggest problem of NTPC plant. The water providing source Rihand Dam had

dried up due to shortage of rain and thereby hinders the production of electricity.

Several safety issues have also been recorded in past in NTPC, Vindhyachal plant

despite of the Safety Department present in the plant.



These problems however cannot be resolved completely but however can be sorted to a

certain extent by following ways:

NTPC must try to acquire the lands surrounding its area by giving the rural proper

jobs and penalties so that they may be able to get equipment contracts easily.

Water shortage can be sorted if NTPC has its own storage tanks and even if they

recycle and use the water.

Electricity can be easily resolved by its good relationship with the state

government which provide them electricity to start the plant and further for any

other requirements.

Coal problems can be sorted by the bulk storage of coal when available and to be

used during its shortage specially during monsoon season.