ABOUT NTPC

NTPC, India's largest power company, was set up in 1975 to

accelerate power development in India. It is emerging as an'
Integrated Power Major, with a significant presence in the
entire value chain of power generation business.
With a current generating capacity of 34,854 MW, NTPC has
embarked on plans to become a 75,000 MW company by
2017.
Presently, NTPC generates power from Coal and Gas.
With an installed capacity of 34,854 MW, NTPC is
the largest power generating major in the country.
NTPC BADARPUR
Badarpur thermal power plant started
working with a single 95 MW unit. There
were two more units installed in next two
consecutive years. Now it has total 5 units
with total capacity of 720 MW.

UNIT NUMBER INSTALLED
CAPACITY(MW)
1 95 MW
2 95 MW
3 95 MW
4 210 MW
5 210 MW
Coal to electricity
The basic steps in generation of electricity from coal is carried out
in three stages:
Coal to steam
Steam to mechanical power
Mechanical power to electrical power


RANKINE CYCLE

Rankine cycle is a basic thermodynamic
cycle that converts heat into work.
Rankine cycle describes a model of
operation of steam heat engines most
commonly found in power generation
plants.


T-s diagram of a Rankine cycle operating between pressures 0-06 bar and 50 bar.
there
are 4 stages in rankine cycle each changing the state of fluid.

Process 1-2: The working fluid is pumped from low pressure to high pressure,
as the fluid is in liquid state at this stage it requires more input.

Process 2-3:The high pressure liquid enters the boiler where it is heated at
constant pressure by an external heat source to become a dry saturated vapor.

Process 3-4: The dry saturated vapor expands through a turbine, generating
power. This decreases the temperature and pressure of the vapor, and some
condensation may occur

Process 4-1: The wet vapor then enters a condenser where it is condensed at a
constant pressure and temperature to become a saturated liquid.
In an ideal Rankine cycle the pump and turbine would be isentropic i.e. the
pump and turbine would generate no entropy and hence maximize the net work
output.
Coal Handling Plant
This plant transfers the coal to the
boiler and also stores the coal in the
bunker.
Wagon tipplers are employed to unload
the coal wagons into coal hopper.
Vibrating screen are used for controlled
removal of coal from coal hopper.
We receive coal in the form of odd
lumps. These lumps are to be crushed
to required sizes which is done by the
coal crusher.
Electromagnetic separator performs
the function of separation of iron and
magnetic impurities from the coal.
Wagon tippler
Vibrating screen
Conveyor belt
Electromagnetic
separator
Coal crusher
Coal bunker
Wagon tippler
Coal wagons containing coal

There are three operational cycles working in CHP:
1. Normal Bunkering Cycle: Shifting of the coal received from coal
wagons directly to coal bunkers
2. Coal stacking: when there is no requirement of coal in the coal bunker
even then CHP has to unload the received coal which is stacked at open
ground called yard.
3. Coal reclaiming: as and when coal wagons are not available, the
requirement of the coal bunker is fulfilled from the stacked coal. this is
called reclaiming cycle.

Boiler Maintenance Department

Coal from the coal wagons are unloaded in the coal handling plant. This
coal is transported up to the coal bunker with the help of conveyor belts.
coal is taken to the bowl mill by coal feeders. The coal is pulverized in the
bowl mill and ground to powdered form.
The mill consists of the round metallic table on which coal particles fall. The
table is rotated with the help of motor. There are three large steel rollers
which are spaced 120 apart.
When there is no coal, The rollers do not rotate but when but when the coal
is fed to the table it packs up between roller and the table and these forces
the rollers to rotate. Coal is crushed by the crushing action between the
rollers and the rotating table.
This crushed coal is taken away to the furnace through coal pipes with the
help of hot and cold air mixture from P.A. fan. P.A. Fan takes atmospheric
air, a part of which is sent to air-pre heaters for heating while a part goes
directly to the mill for temperature control. Atmospheric air from F.D. Fan is
heated in the air heaters and sent to the furnace as combustion air.

Water from the boiler feed pump passes through economizer and reaches the boiler drum. Water
from the drum passes through down comers and goes to the bottom ring header. Water from the
bottom ring header is divided to all the four sides of the furnace


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


Water follows the same path while the steam is sent to super heaters for superheating and finally
goes to the turbine.


Flue gases from the furnace are extracted by induced draft fan .These flue gases emit their heat
energy to various super heaters in the pent house and finally pass through air-preheater and goes
to electrostatic precipitators where the ash particles are extracted.








Steam Boiler

Turbine maintainence department
A steam turbine has two main parts:
Stator:it contains fixed blades ,vanes and nozzles that directs the steam
into the moving blades carried by rotor.

Rotor : a rotor is a rotating shaft that carries the moving blades on the
outer edges on either discs or drum. The blade rotates as the rotor
revolves.
As the steam passes through the fixed blades or nozzles, it expands and
its velocity increases.



The high velocity jet of stream strikes the first
set of moving blades. The K.E of the steam
changes to mechanical energy causing the
shaft to rotate. The steam that enters the next
row of moving blades. As the steam flows
through the turbine, its pressure and
temperature decreases while its volume
increases.

The path of steam
Superheated steam
H.P turbine
Reheater
I.P turbine
L.P turbine
Condenser
Condensate Extraction Pump
Ejector
GSC-1
LPH- 1
GSC-2
LPH-2
LPH-3
LPH-4
Deareator
Boiler Feed Pump
HPH-5
HPH-6
HPH-7
Feed Regulating Station

Condenser: To condense the steam.
Condensate extraction pump: The condensate water is drawn from the
condenser by the extraction pump.
Gland steam cooler: The seals around the rotating shaft on steam
turbines are many in several ways but all leak a small amount of steam to
the atmosphere. To capture this steam, many of the seals have small
condensers to capture this steam.
Deareator: A deaerator is a device that is widely used for the removal of air
and other dissolved gases from the feed water to steam-generating boilers.


Main Turbine
The 210 MW turbine comprises of H.P, I.P
and L.P cylinders. The superheated steam
from the boiler passes through the
emergency stop valve and control valve
before entering the H.P turbine. After
expanding in the 12 stages in the H.P
turbine the steam returns to the boiler for
reheating. The reheated steam from the
boiler enters the I.P turbine via control
valves and after expanding enters the I.P
turbine in the l.P stage the steam expands in
opposite direction to counteract the trust and
then enters the condenser.

The cooling water flowing through the
condenser tubes condenses the steam and
the condensate is collected in the hot well of
the condenser.
Plant Auxiliary Maintenance
Water circulation system: The water is
circulated from the drum and then comes
back to the drum where the water is
separated from the steam and directed to
the super heater.
Types of water circulation system:
1. Natural circulation system
2. Forced circulation system
Ash handling Plant

Hydraulic Ash Handling System: The hydraulic system carries the ash with
the flow of water with high velocity through a channel and finally dumps into a
sump. The hydraulic system is divided into:
Low velocity system
High velocity system
In the low velocity system the ash from the boilers falls into a stream of water
flowing into the sump. The ash is carried along with the water and they are
separated at the sump. In the high velocity system a jet of water is sprayed to
quench the hot ash. Two other jets force the ash into a trough in which they are
washed away by the water into the sump .Hydraulic Ash handling system is
used at the Badarpur Thermal Power station.

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

WATER TREATMENT PLANT
Water treatment plants used in thermal power plants used in thermal power
plants are designed to process the raw water to water with a very low
content of dissolved solids known as demineralized water.

Pretreatment Section: Pretreatment plant removes the suspended solids
such as clay, silt, organic and inorganic matter, plants and other microscopic
organism. The suspended solids can either be separable solids or 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.

demineralisation

This filter water is now used for demineralizing purpose and
is fed to cation exchanger bed. But before that it needs to be
dechorinated. This can be done in the following ways:
by passing through activated carbon filter
injecting along the flow of water an equivalent amount of
sodium sulphite through some stroke pumps.

The residual chlorine should be remove as it interferes with
the resin.
A DM plant generally consists of cation, anion and mixed bed
exchangers. The final water from this process consists
essentially of hydrogen ions and hydroxide ions which is the
chemical composition of pure water. The DM water, being
very pure, becomes highly corrosive once it absorbs oxygen
from the atmosphere because of its very high affinity for
oxygen absorption. Some storage is essential as the DM plant
may be down for maintenance. For this purpose, a storage
tank is installed from which DM water is continuously used.


Compressor house
Instrument air is required for operating various burners and other devices
etc in the 210 MW units.
INSTUMENT AIR SYSTEM:
Control air compressors have been installed for supplying moisture free dry
air required for instrument.
Air-Drying Unit
Air contains moisture which tends to condense, and causes trouble in
operation of various devices by compressed air. Therefore drying of air is
accepted widely in case of instrument air. The absorption towers are
adequately filled with specially selected silica gel and activated alumina
while one tower is drying the air.





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