A SUMMER TRAINING PRESENTATION

ONINDIRA GANDHI SUPER THERMAL POWER PROJECT (IGSTPP) NTPC POWER PLANT JHARLI

Submitted toMr. Vinod Kumar VermaMechanical Department

Submitted By:RAHUL AGARWAL (13ME60)RAKESH KUMAR YADAV(13ME61)KARTIK GUPTA (13ME32)

About NTPC NTPC was setup in 1975 with 100%

ownership by Government of India. In the last 30 years, NTPC has grown into the largest power utility in INDIA.

NTPC became a Maharatna company in May 2010.

The total installed capacity of the company is 47,228 MW (including JVs) with 18 coal based, 7 gas based stations and 1 Hydro based station. 9 Joint Venture stations are coal based and 9 renewable energy projects.

NTPC has plans to become 1,28,000MW company by 2032.

Installed CapacityREGION COAL GAS/Liquid Fuel Renewable TOTAL

Northern 9,015 2,344 35 11,394

Western 12,000 1,313 50 13,313

Southern 4,600 360 260 5,220

Eastern 9,470 - 10 9,480

Islands - - 5 5

Hydro - - - 800

JVs 4,999 1,967 - 6,966

Total 40,084 5,984 360 47,228

NTPC POWER PLANT JHARLI

INDIRA GANDHI SUPER THERMAL POWER PROJECT (IGSTPP) Aravali Power Company Pvt Ltd. (APCPL) is a Joint venture company with 50% share of NTPC Ltd, 25% of

Haryana Power Generation Company Ltd (HPGCL, Haryana State company), and 25% of Indraprastha Power Generation Company Ltd (IPGCL, DelhiState company). The company was registered on 21st Dec 2006.

APCPL has constructed a coal based power plant near Village Jharli, District- Jhajjar (Haryana) named Indira Gandhi Super Thermal Power Project (IGSTPP). Presently under Stage-I, power plant of 3x 500MW capacity is constructed, whose all 3 units are commissioned. There is a future provision of 2x 660 MW under Stage-II.

Main plant equipment of Boiler and Turbine was awarded to M/s BHEL on 7th July 2007. The First unit was commissioned on 31st October, 2010 in 39 months from the date of investment approval.This is the best achieved target for green field project. The Second unit was commissioned on 5th November, 2011, and the Third unit on 7th November, 2012. The Commercial operation declaration of first and second unit was done on 5th March, 2011 and 21st February, 2012 respectively. Third unit was declared commercialised on 26th April, 2013 & the station was dedicated to the Nation by Shri Jyotiraditya Scindia, the then Union Minister of State for Power (I/c).

PRINCIPLE OF THERMAL POWER PLANT The Rankine cycle is an idealized

thermodynamic cycle of a heat engine that converts heat into mechanical work.

This gives a theoretical maximum Carnot efficiency for the steam turbine alone of about 63% compared with an actual overall thermal efficiency of up to 42% for a modern coal-fired power station.

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.

1. Cooling tower 10. Steam Control valve 19. Superheater

2. Cooling water pump 11. High pressure steam turbine 20. Forced draught (draft) fan

3. transmission line (3-phase) 12. Deaerator 21. Reheater 4. Step-up transformer (3-phase) 13. Feedwater heater 22. Combustion air intake

5. Electrical generator (3-phase) 14. Coal conveyor 23. Economiser 6. Low pressure steam turbine 15. Coal hopper 24. Air preheater 7. Condensate pump 16. Coal pulverizer 25. Precipitator 8. Surface condenser 17. Boiler steam drum 26. Induced draught (draft) fan 9. Intermediate pressure steam turbine 18. Bottom ash hopper 27. Flue gas stack

Typical Diagram of a Coal-fired Thermal Power Station

Coal Handling System

Coal Mines Coal Transportation Wagon Tippler

Coal Handling System (Contd..)

Coal crusher Coal Drier (Draught System)Magnetic Separator

Coal Handling System (Contd..)

Coal Conveyor Coal Hopper Coal Feeder

Coal Handling System (Contd..)

Bowl mill Boiler Furnace

Water Treatment SystemRaw Water (Canal)

Reservoir Aerator Clariflocculater

Sand Gravity Filter

Drinking Water

DM plant Cooling Water Make-up

Boiler A boiler can be defined as a closed

vessel in which water or other fluid is heated under pressure.

Coal is burned inside the combustion chamber of boiler. The products of combustion are nothing but gases. These gases which are at high temperature vaporize the water inside the boiler to steam.

This steam at high pressure and temperature is used directly as a the working fluid in a prime mover to convert thermal energy to mechanical work and mechanical energy transmitted to alternator and electrical energy generated.

Although other fluids are sometimes used for these purposes, water is by far the most common because of its economy and suitable thermodynamic characteristics.

Types of BoilerFire Tube Boiler Water Tube Boiler

Auxiliary Components of BoilerEconomizer Air Preheater

Auxiliary Components of Boiler (Contd..)

Steam Drum Superheater

Auxiliary Components of Boiler (Contd..)

Induced Draft Fan(ID Fan) Forced Draft Fan(FD Fan)

STEAM TURBINE

165 ksc, 540°C

40 ksc, 350°C

45 ksc, 565°C 7-8 ksc, 350°C

6 ksc, 160°C

0.1 ksc, 45°C

0.1 ksc, 45°C

ΔT=10°C

5 3 2

2*121*17 2*6

(BFP)

Components of Steam Turbine Cycle1. High Pressure Turbine (HP Turbine)

2. Intermediate Pressure Turbine (IP Turbine)

3. Low Pressure Turbine(LP Turbine)

4. Condenser

5. Cooling Tower 6. Low Pressure Heater(LP Heater)

7. Deaerator 8. High Pressure Heater(HP Heater)

9. Motor Driven Boiler Feed Pump (MDBFP)

10. Turbine Driven Boiler Feed Pump (TDBFP)

High Pressure Turbine (HP Turbine) High pressure and temperature fluid

at the inlet of the turbine exit as lower pressure and temperature fluid. The difference is energy converted by the turbine to mechanical rotational energy, less any aerodynamic and mechanical in efficiencies incurred in the process.

The high pressure casing is made of creep resisting Chromium-molybdenum-vanadium(Cr-Mo-V) steel casting.

The turbine is equipped with emergency stop valves to cut of steam supply and with control valves to regulate supply.

It has 17 rotor blades with first impulse stage and others are reaction.

Intermediate Pressure Turbine (IP Turbine) Intermediate pressure turbine

having more pressure then L.P turbine and less than the high pressure turbine(H.P) . Its blade is larger than high pressure turbine.

The size of blades of I.P steam turbine is larger than H.P steam turbine , but smaller than L.P steam turbine.

It has inlet of the main steam line after the reheat process and in outlet main steam line straight goes to lp turbine.

It has 2*12 stage of blades and 7th stage steam line goes to TDBFP.

Low Pressure Turbine (LP Turbine) LP turbine is designed to be

a dual flow turbine. Steam enters the centre of the turbine from the crossover pipe and flows across the reaction blading in two opposite directions.

This configuration reduces axial thrust on the turbine and allows for a smaller turbine installation.

Titanium alloys offer high strength to intermediate temperatures at a density almost half that of steel and nickel-based super alloys.

LP blade is larger than HP & IP. 

Condenser It condenses the steam at the

exhaust of the turbine with the help of cooling water.

It creates a very low pressure (0.1ksc) at the exhaust of turbine, this helps in converting heat energy of the steam into mechanical energy in the prime mover.

Condensed steam can be used as feed water to the boiler.

Condenser tubes are made of Stainless steel and in no. of 24398.

Cooling water total flow = 54000/hr.

Cooling Tower

LP and HP Heater

Deaerator A steam generating boiler requires that the boiler

feed water should be devoid of air and other dissolved gases, particularly corrosive ones.

In order to avoid corrosion of the metal, power station uses a Deaerator, for the removal of air and other dissolved gases from the boiler feed water. A Deaerator has a vertical, domed deaeration

section mounted on a top of horizontal cylindrical vessel which serves as a deaerated boiler feed water storage tank

Boiler Feed Pumps (BFPs)MOTOR DRIVEN BOILER FEED PUMP (MDBFP) TURBINE DRIVEN BOILER FEED PUMP(TDBFP)

Plant Generator

Ash Handling System

SOURCES OF ASH

Burning of pulverized coal in furnace results in the generation of large quantity of ash. this ash constitutes of 80-90% of dry ash and 10-20% of bottom ash.

Fly ash is one of the residues generated in combustion, and comprises of fine particles that rises with the flue gases.

The percentage of ash in coal is 5% in good quality coal & about 40% in poor quality coal

A modern 1000MW plant produces about 4800 tons of ash daily.

Types of Ash HandlingFLY ASH HANDLING

1. Fly ash is considered to be collected in ESP Hoppers.

2. Fly ash from electrostatic precipitators or fabric bag filters (or sometimes both), located at the outlet of the furnace and before the induced draft fan, is extracted by Vacuum Pumps.

3. Generally, the fly ash is pneumatically transported to storage silos for subsequent transport by trucks or railroad cars

BOTTOM ASH HANDLING

1. Bottom ash resulting from the combustion of coal in the boiler falls into the bottom ash hopper having a hold up volume to store bottom ash.

2. The slurry formed is transported to slurry sump through pipes.

3. It has a hopper of over ground, refractory lined, water impounded, maintained level, double V-Section type/ W type steel- fabricated.

Electrostatic Precipitator (ESP) It is a device which removes dust or

other finely divided particles from flue gases by charging the particles inductively with an electric field, then attracting them to highly charged collector plates. Also known as precipitator. The process depends on two steps. In the first step the suspension passes through an electric discharge (corona discharge) area where ionization of the gas occurs. The ions produced collide with the suspended particles and confer on them an electric charge. The charged particles drift toward an electrode of opposite sign and are deposited on the electrode where their electric charge is neutralized.

It has an efficiency of 99.8 % and it is a very high power consuming device of about 1 kwh for 10 thousand m³ of flue gas.

Applications of Fly Ash1. Cement production

2. Road construction

3. Stabilization of soft soils

4. Bricks

5. Mineral filler in asphaltic concrete

6. Mine reclaimation