ntpc project

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NTPC BADARPUR TRAININGPROJECT REPORTby RITIKA


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ABOUT NTPC

NTPC Limited (formerly known as National Thermal Power Corporation

Limited) is the largest power generating major in the country. Set up in

1975 to accelerate power development in India, NTPC has emerged as a

diversified power major with presence in the entire value chain of the

power generation business.

The company also undertakes consultancy and turnkey project contracts

that comprise of engineering, project management, construction

management and operation and management of power plants. The

company has also ventured into oil and gas exploration and coal mining

activities.

The total installed capacity of the company is 42,454 MW (including JVs)

with 17coal-based and sevengas-based stations, located across the

country. In addition under JVs (joint ventures), six stations are coal-based,

and another station usesnaphtha/LNG as fuel. Although the company has

approx. 18% of the total national capacity it contributes to over 27% of

total power generation due to its focus on operating its power plants at

efficiency levels (approx. 83% against the nationalPLF rate of 78%).

NTPC operates from 55 locations in India, one location in Sri Lanka and 2locations in Bangladesh. In India, it has 8 head quarters.

ITS VISION: To be the world's largest and best power producer, powering

India's growth.

ITS MISSION: Develop and provide reliable power, related products and

services at competitive prices, integrating multiple energy sources with

innovative and eco-friendly technologies and contribute to society.

NTPC Environment PolicyNTPC is committed to the environment, generating power at minimal

environmental cost and preserving the ecology in the vicinity of the plants.

NTPC has undertaken massive a forestation in the vicinity of its plants.

The massive a forestation by NTPC in and around its RamagundamPower station (2600 MW) have contributed reducing the

temperature in the areas by about 3C.

NTPC has also taken proactive steps for ash utilization. In 1991, it setup Ash Utilization Division A.
http://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Naphthahttp://en.wikipedia.org/wiki/Liquified_natural_gashttp://en.wikipedia.org/wiki/Plant_load_factorhttp://en.wikipedia.org/wiki/Plant_load_factorhttp://en.wikipedia.org/wiki/Liquified_natural_gashttp://en.wikipedia.org/wiki/Naphthahttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Coal


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"Centre for Power Efficiency and Environment Protection- CENPEE"has been established in NTPC with the assistance of United States

Agency for International Development- USAID. CENPEEP is efficiency

oriented, eco-friendly and eco-nurturing initiative - a symbol of

NTPC's concern towards environmental protection and continuedcommitment to sustainable power development in India.

NTPC is the second largest owner of trees in the country after the Forest

department.

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, various

state-of-the-art pollution control systems / devices as discussed belowhave been installed to control air and water pollution.

Electrostatic Precipitators Flue Gas Stacks Low-NOX Burners Coal Settling Pits/ Oil Settling Pits DE & DS Systems Cooling Towers Ash Dykes & Ash disposal Systems Ash Water Recycling System Dry Ash Extraction System Liquid Waste Treatment Plants & Management System Sewage Treatment Plants & Facilities

AWARDS AND RECOGNITION

NTPC was ranked 62ndamong the 250 largest Power Producers andEnergy Traders in the world byPlatts in 2012.

In 2009, it received ICSI National Award for Excellence in CorporateGovernance.

It was listed inForbes Global 2000 for 2012 at 384thrank in theworld.
http://en.wikipedia.org/wiki/Plattshttp://en.wikipedia.org/wiki/Forbes_Global_2000http://en.wikipedia.org/wiki/Forbes_Global_2000http://en.wikipedia.org/wiki/Platts


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BADARPUR THERMAL POWER STATION

The Ministry of Power set up the Badarpur Thermal Power Station(BTPS) in 1967 to meet the growing demand of power in the northern

region. The power plant is one of the coal based power plants of NTPC. It

had an installed capacity of 720 MW in December 1981 which was de-rated

to 705 MW in January 1990.

The Badarpur Power Plant has 5 generation units installed with 3 units of

95 MW capacity and 2 units of 210 MW capacity.

The power is supplied to a 220 KV network that is a part of the northern

grid. The circuits through which the power is evacuated from the plant are:1. Mehrauli

2. Okhla

3. Ballabgarh

4. Indraprastha

5. UP (Noida)

6. Jaipur

It is one of the oldest plant in operation. Its 100 MW units capacity have

been reduced to 95 MW. These units have indirectly fired boiler, while 210

MW units have directly fired boiler. All the turbines are of Russian Design.

Both turbine and boilers have been supplied by BHEL. The boiler of Stage-I

units are of Czech. design. The boilers of Unit 4 and 5 are designed by

combustion engineering (USA). The instrumentation of the stage I units and

unit 4 are of The Russian design. Instrumentation of unit 5 is provided by

M/S Instrumentation Ltd. Kota, is of Kent design.


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INSTALLATION UNITS

StageUnit

Number

Installed Capacity

(MW)

Date of

CommissioningStatus

First 1 95 July, 1973 Running

First 2 95 August, 1974 Running

First 3 95 March, 1975 Running

Second 4 210 December, 1978 Running

Second 5 210 December, 1981Running
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THERMAL POWER PLANT

A thermal power station is apower plant in which theprime

mover issteam driven. Water is heated, turns into steam and spins asteam

turbine which drives anelectrical generator.After it passes through theturbine, the steam iscondensed in acondenser and recycled to where it

was heated; this is known as aRankine cycle.The greatest variation in the

design of thermal power stations is due to the differentfossil fuel resources

generally used to heat the water.

Commercialelectric utility power stations are usually constructed on a

large scale and designed for continuous operation. Electric power plants

typically usethree-phaseelectrical generators to produce alternating

current (AC) electric power at afrequency of 50 Hz.

COAL BASED POWER PLANTS

When coal is used for electricity generation, it is usually pulverised and

then burned in a furnace with a boiler. The furnace heat converts

boiler water to steam, which is then used to spin turbines which turn

generators and create electricity.The thermodynamic efficiency of this process has been improved over time.

Standard steam turbines have topped out with some of the most advanced

reaching about 35% thermodynamic efficiency for the entire process,

which means 65% of the coal energy is waste heat released into the

surrounding environment. Old coal power plants, especially grandfathered

plants, are significantly less efficient and produce higher levels of waste heat.

About 40% of the world's electricity comes from coal.
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DIAGRAM OF A TYPICAL COAL-FIRED THERMAL POWER STATION

KEY:

1.Cooling tower

10. SteamControl

valve 19.Superheater

2. Cooling water pump11. High

pressuresteam turbine

20. Forced draught

(draft)fan

3.transmission line (3-

phase)12.Deaerator 21. Reheater

4. Step-uptransformer (3-

phase)13.Feedwater heater

22.Combustion air

intake

5.Electrical generator (3-

phase) 14.Coalconveyor 23.Economiser6. Low pressuresteam

turbine15.Coal hopper 24.Air preheater

7.Condensate pump 16.Coal pulveriser 25.Precipitator

8.Surface condenser 17.Boiler steam drum26. Induced draught

(draft)fan

9. Intermediate

pressuresteam turbine18.Bottom ash hopper 27.Flue gas stack
http://en.wikipedia.org/wiki/Cooling_towerhttp://en.wikipedia.org/wiki/Control_valvehttp://en.wikipedia.org/wiki/Control_valvehttp://en.wikipedia.org/wiki/Superheaterhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Electrical_power_transmissionhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Deaeratorhttp://en.wikipedia.org/wiki/Transformerhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Feedwater_heaterhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Electrical_generatorhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Conveyorhttp://en.wikipedia.org/wiki/Economiserhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Air_preheaterhttp://en.wikipedia.org/wiki/Condensate_pumphttp://en.wikipedia.org/wiki/Pulverizerhttp://en.wikipedia.org/wiki/Electrostatic_precipitatorhttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Steam_drumhttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Bottom_ashhttp://en.wikipedia.org/wiki/Flue_gas_stackhttp://en.wikipedia.org/wiki/Flue_gas_stackhttp://en.wikipedia.org/wiki/Bottom_ashhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Steam_drumhttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Electrostatic_precipitatorhttp://en.wikipedia.org/wiki/Pulverizerhttp://en.wikipedia.org/wiki/Condensate_pumphttp://en.wikipedia.org/wiki/Air_preheaterhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Economiserhttp://en.wikipedia.org/wiki/Conveyorhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Electrical_generatorhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Feedwater_heaterhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Transformerhttp://en.wikipedia.org/wiki/Deaeratorhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Electrical_power_transmissionhttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Superheaterhttp://en.wikipedia.org/wiki/Control_valvehttp://en.wikipedia.org/wiki/Control_valvehttp://en.wikipedia.org/wiki/Cooling_tower


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DESCRIPTION

A typical coal-fired thermal power plant.

1. Coal is conveyed from an external stack and ground to a very finepowder by large metal spheres in the pulverized fuel mill .

2. There it is mixed with preheated air driven by the forced draught fan.

3. The hot air-fuel mixture is forced at high pressure into the boiler where

it rapidly ignites.

4. Water of a high purity flows vertically up the tube-lined walls of the

boiler, where it turns into steam, and is passed to the boiler drum, wheresteam is separated from any remaining water.

5. The steam passes through a manifold in the roof of the drum into the

pendant superheater where its temperature & pressure increase rapidly to

around 200 bar & 570C, sufficient to make the tube walls glow a dull red.

6. The steam is piped to the high-pressure turbine, the first of a three-stage

turbine process.

7. A steam governor valve allows for both manual control of the turbine

and automatic set point following.

8. The steam is exhausted from the high-pressure turbine, and reduced in

both pressure and temperature, is returned to the boiler reheater.

9. The reheated steam is then passed to the intermediate pressure turbine,

and from there passed directly to the low pressure turbine set.

10. The exiting steam, now a little above its boiling point, is brought into

thermal contact with cold water (pumped in from the cooling tower) in the

condenser, where it condenses rapidly back into water, creating near

vacuum-like conditions inside the condenser chest.

11. The condensed water is then passed by a feed pump through a

deaerator, and prewarmed, first in a feed heater powered by steam drawn

from the high pressure set, and then in the economiser, before being

returned to the boiler drum.


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12. The cooling water from the condenser is sprayed inside a cooling tower,

creating a highly visible plume of water vapour, before being pumped back

to the condenser in cooling water cycle.

13. The three turbine sets are coupled on the same shaft as the three-phaseelectrical generator which generates an intermediate level voltage

(typically 20-25 kV).

14. This is stepped up by the unit transformer (4) to a voltage more

suitable for transmission (typically 250-500 kV) and is sent out onto the

three-phase transmission system.

15. Exhaust gas from the boiler is drawn by the induced draft fan through

an electrostatic precipitator and is then vented through the chimney stack.


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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 a field winding, is given a excitation through a set of

3000 rpm to give the required frequency of HZ.

The rotor is cooled by Hydrogen gas, which is locally manufactured by theplant 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.


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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.

Hydrogen gas is used to cool down the rotor. Lube oil is used to cool the bearings. DM water is used to cool the stator. Seal oil is used to prevent hydrogen leakage Seal oil coolers are present to cool the seal oil Hydrogen dryer are used which removes the moisture from

hydrogen gas and then is supplied to the generator.

Clarified water in cooling tower is used to cool down the hydrogengas.

RATINGS OF THE GENERATORS USED

3 Turbo generators of 95 MW 2 Turbo generators of 210 MW

The 95 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 generator transformer

and is connected to the grid. The voltage is stepped down to 6.6 KV with thehelp 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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HYDROGEN COOLED GENERATOR 100MW

MAKE -BHEL, Haridwar CAPACITY -117,500 KVA POWER -100,000 KW STATOR VOLTAGE -10,500 V STATOR CURRENT -6475 A STATOR WINDING CONNECTION- 3 PHASE DOUBLE STAR SPEED -3000rpm POWER FACTOR -0.85 FREQUENCY -50 HZ EXCITATION -280 V HYDROGEN PRESSURE -2.5KG/CM SQ. (GAUGE)

TURBO GENERATOR 210MW

MAKE -BHEL, Haridwar CAPACITY -247,000 KVA POWER -210,000 KW STATOR VOLTAGE -15,750 V STATOR CURRENT -9050 A

ROTOR VOLTAGE -310 V ROTOR CURRENT-2600 A SPEED -3000 rpm POWER FACTOR -0.85 FREQUENCY -50 HZ EXCITATION -310 V GAS PRESSURE -3.5 kg/cm

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