Vocational training in NTPC

Vocational training report on THE COUNTRY’S LARGEST THERMAL POWER STATION BARH SUPER THERMAL POWER STATION(3330 MW)

SUBMITTED BY:- MOHINDRA AMARNATH B.TECH

CHEMICAL ENGINEERING SATHYABAMA UNIVERSITY

Acknowledgement

With deep reverence and profound gratitude I express my sincere thanks to Mr. H.K.SINHA (MANAGER) for giving me an opportunity to do training at NTPC/BSTPP. I also would like to thank Mr. VINAY KR. SHARMA(AGM) who has helped me for the need. I am also very much thankful to Mr. BIRENDRA KR. SINGH(JUNIOR ENGINEER) for helping me throughout the training and others who has supported me at the working sites, explaining and giving me all the information I needed to complete this report.At last I would like to convey my thanks to all the members of the staff of NTPC who have helped me at every stage of training.

Training Period: 15th DEC. 2014 to 30th DEC.2014

Contents

1. Acknowledgement

2. Introduction to NTPC

3. About BSTPS

4. Coal to electricity basic

5. Complete description of Power plant

6. Coal Handling Plant

7.Conclusion

8.Reference

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. Contributing 28.5% of the country’s entire power generation. NTPC today lights up every fourth bulb in the country. 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.

NTPC-Barh

STATION PROFILE LOCATION: Barh station of NTPC is located in Barh in the Indian State of Bihar.NTPC Barh is located barely 4 KM east of the Barh sub-division on NH-31. CAPACITY: Stage-I –Built by Russian Firm TechnoPromoExport has 1980MW(3*660MW) Stage-II –Built by BHEL & has 1320 MW(2*660MW).

SHARE TO BIHAR:Bihar’s share is 1183MW from NTPC Barh (26% from stage 1 and 50% from stage 2).

LAND:The main Power plant & the township is spread over an area of 1186 acres. The legal progression of 1186 acres of land has been acquired for setting up the main power plant & its township which includes 12 villages.

FOUNDATION:STAGE 1: PM Atal Bihari Vajpayee on March 6,1999.STAGE 2: Former Union Power Minister Sushil Kr Shinde on May 29,2006.

PROJECT COST:The plant is to produce 3,300MW of power at a cost of over Rs 26,000 crore.The total approved cost of stage 1(660MW*3) has Rs 8692.97 crore.The total approved cost of stage 2(unit 1) plant is Rs 7688.12 crore.

COAL:Inland Waterways Authority of India received bids in 2013 September for coal movement on 1620km National Waterway 1(India) from Haldia to NTPC’s Barh which is about 1000 km away.

STAGE UNITNUM-BER

CAPACITY(MW)

EPC contractor

STATUS

Ist 1 660 TechnoPromoExport

Delayed as Technopromoexport is saying it has entered a loss-making contract and is asking for $570 million before it can fulfil itsObligation to which NTPC objected.

Ist 2 660 TechnoPromoExport DELAYED

Ist 3 660 TechnoPromoExport DELAYED

IInd 1 660 BHEL(2013 NOV) Commissioned in 2013 November but commercial production yet to start as there are technical issue of multiple tube leakage which is yet to be resolved as of April 2014.This is the first 660MW unit supplied by BHEL. Commercial operation starts in Nov 2014 after resolving faults.

IInd 2 660 BHEL DELAYED

TOTAL 5 3330 - -

FIG: - COAL TO ELECTRICITY....BASICS

COMPLETE DESCRIPTION OF POWER PLANT

The coal from mines is received at track hopper in CHP through BOBR Wagons. The unloaded coal (max. size 250 mm2) is scooped into conveyor by Rotary Plough Feeders & is passed through suspended magnet, magnetic separators, and metal detectors, to ensure that sized coal, free of foreign material is supplied. Then it is sent to Crusher House for further crushing to 25- mm2 size. After crushing, the coal again screened for elimination of extraneous materials, weighed and sent to boiler bunkers. Excess coal, if any, is sent to coal yard for stacking. It then falls through a weigher into the Bowl Mill where it is pulverized. The mill usually consists of a round metal table on which large steel rollers or balls are positioned. The table revolves, forcing the coal under the rollers or balls which crush it. Air is drawn from the top of the boiler house by the FD Fan and passed through the RAH, and then send to boiler for burning of coal. PA Fan takes air from atmosphere and distributes them into 2 parts one send to RAH for heating and other fed directly to Mill blowing coal along pipes to boiler furnace. The boiler consists of a large number of tubes extending the full height of the structure and the heat produced raises the temperature of the water circulating in them to form superheated steam which passes to the Boiler drum. The steam is fed through the outlet valve to the HP Turbine(High Pressure turbine) at around 540°C.After this, it is returned to the boiler and reheated before being passed through the IP & LP Turbine(Intermediate and Low Pressure Turbine).The water fed into boiler is DM water.

. From the turbine the steam passes into Condenser to be turned back into water. This is pumped through CEP which sends water through GSC, LPH, and HPH for further heating and BFP then sends it to the Economizer where the temperature is raised sufficiently for the condensate to be returned to the lower half of the steam drum of the boiler. The flue gases produced in boiler are used to reheat the condensate in the Economizer and then passes through the RAH to the ESP where ash is collected. Finally, they are drawn by the ID Fan into the main flue and to the chimney. From the boiler, a steam pipe conveys steam to the turbine through a stop valve (which can be used to shut off steam in an emergency) and through control valves that automatically regulate the supply of the steam to the turbine. The turbine shaft usually rotates at 3000 RPM. This speed is determined by the frequency of the electricity system and the number of poles of machine (2- pole machine here). Cold water from OAC is circulated through the condenser tubes and as the steam from the turbine passes round them it is rapidly condensed into water. Water which gets heated up in condenser by cooling steam is sent to Cooling tower and then left into OAC from where it can be further used. The electricity is produced in turbo generators and is fed through terminal connections to Generator Transformer, those steps up the voltage to 400kv. From here conductors carry it to Switchyard from where it is sent for use.

Coal Handling Plant• Coal is the prime input for a thermal power plant, accounting for about 67% of the total energy consumption in the country .

• Coal is a combustible black or brownish-black sedimentary rocks.

• Each Thermal Power Project has been linked to a particular coal mine to meet its coal requirements.

Objectives of Coal Handling Plant are Transportation and Handling of Coal. Arrangement for transferring of coal from coal- wagons to coal-

bunker or coal stock yard. Supply of Crushed coal to bunker

At power plant, coal is unloaded in track hoppers of length 200- 250m normally. The unloading mechanism used in NTPC is Bottom Open Box type Rake (BOBR). Paddle Feeder is used to used to feed coal to conveyor belt from track hopper. After separation of magnetic particles from coal, it is carried to the Crusher House through conveyor belts and after that it is either stored at Stack Yard to be carried to coal bunker for burning.

CONCLUSIONSIndustrial training being an integral part of engineering curriculum provides not only easier understanding but also helps acquaint an individual with technologies. It exposes an individual to practical aspect of all things which differ considerably from theoretical models. During my training, I gained a lot of practical knowledge which otherwise could have been exclusive to me. The practical exposure required here will pay rich dividends to me when I will set my foot as an Engineer. The training at NTPC Barh was altogether an exotic experience, since work, culture and mutual cooperation was excellent here. Moreover fruitful result of adherence to quality control awareness of safety and employees were fare which is much evident here.

BIBLIOGRAPHY Annual reports of NTPC House magazines of NTPC WEBSITES:-

1.WWW.GOOGLE.COM 2.WWW.NTPC.CO.IN 3.NTPC/BSTPP(intranet) 4.WWW.WIKIPEDIA.COM