Industrial Training at NTPC

BTPS Badarpur
Design Specification

Date of Submission :..

Submitted to: Himanshu Jha

Mechanical Engineering Department
Submitted by: Akash Mishra
Roll No: ME/11/705

Design Specification (ME)

Table of Contents
1. APPROVED BY...........................................................................................3
2. DESIGN CONSIDERATIONS........................................................................4
2.1.

ASSUMPTIONS AND DEPENDENCIES......................................................................4

2.2.

GENERAL CONSTRAINTS........................................................................................5

2.3.

GOALS AND GUIDELINES.......................................................................................5

3. DESIGN AND CALCULATIONS.....................................................................6

3.1.

DRAWING OF THE EACH COMPONENT BEING USED..............................................6

3.2.

DESIGN AND CALCULATION OF THE COMPONENT BEING USED............................7

4. FABRICATION /ASSEMBLING...................................................................10
5. WORKING OF THE PROJECT.....................................................................11.

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Design Specification (ME)

1. Approved By
Approvals should be obtained from faculty/ HOD
Faculty comments :
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
_____________________________________________________________________

Faculty name:

faculty signature

_____________________________

__________________________

Project coordinator

project coordinator signature

_____________________________

__________________________

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Design Specification (ME)

2. Design Considerations
A thermal powerplant is basically based on the Rankine Cycle. Rankine Cycle is a
thermodynamic power cycle. In this section we will describe many of the issues which
need to be addressed or resolved before attempting to devise a complete design
solution.

2.1.

Assumptions and Dependencies

Before attempting to study about a thermal power plant let us first define the Rankine
Cycle on which a Thermal Power Station is based.

Rankine Cycle:-

Rankine cycle is the idealized cycle for steam power plants. This cycle is shown on p-v,
T-v, h-s, diagram in the above figures. It consists of following processes:
Process 1-4: Water from the condenser at low pressure is pumped into the boiler at
high pressure. This process is reversible adiabatic.
Process 4-5: Water is converted into steam at constant pressure by the addition of heat
in the boiler.
Process 6-3: Bleed water taken for regeneration .
Process 5-7: Reversible adiabatic expansion of steam in the steam turbine.

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Process 7-1: Constant pressure heat rejection in the condenser to convert condensate
into water.
The steam leaving the boiler may be dry and saturated, wet or superheated.

2.2.

General Constraints

As we know the theoretical description of a cycle may differ from the practical description.
While ideally the cycle is assumed to be without losses in practical the losses do occur.
Hence we need a modification in our thermodynamic cycle to make it worth working. The
powerplant is hence constructed by applying certain amendments. Some of the problems
that a thermal power station faces before its setting up are as follows :
1. Land Availability : Land availaibility is a really crucial factor in order to setup a
powerplant. To setup a powerplant a good landscape has to be selected. The primitive
requirements for selecting a landscape are follows :
i.

Coal Availability : For the setting up of a powerplant i.e a thermal powerplant

which is coal based the availability of coal is a must because it is a chief raw
material .

ii.

Water Availability : Without proper water supply the imagination of a plant is

not possible . Water is inevitable and is needed in a huge quantity for a
powerstation . Hence a river or a canal must be present besides.

iii.

Transportation : A good connected land is preferable.

iv.

Environment : The environment around is also crucial.

2.3.

Goals and Guidelines:

The goals of a thermal powerstation are to provide cheap electricity and pollution free
electricity to the people and proper distribution. Generally the plant follows the guidelines as
provided by the government . The company has to follow ISO standards.

3. Design and Calculations :

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As the plant is based on the cycle hence a typical structure of a thermal powerplant is as
follows :
A Coal powered station :-

Typical diagram of a coal-fired thermal power station

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 turbin 18. Bottom ash hopper

27. Flue gas stack

DESCRIPTION :COAL TO STEAM

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Coal from the coal wagons is unloaded in the coal handling plant. This coal is
transported up to the raw coal bunkers with the help of belt conveyors. .
Coal - How much Coal required for a 100 MW plant per year =
Power Plant Wattage x Coal unit/ Hr x Hr/ Yr = :
100 x (Per unit Heat Required/ Coal Heat Value) x (24 x 365) = 100 x (10.765/ 20) x 8760
kg/ Yr = 471.51 x 1000 kg/ Yr = 471.51 mT/ Yr
Coal is transported from the mine to loading place .Wagon Tripler Transported through
conveyors into bunkers . From bunkers the coal is sent into mills i.e bowl mills where the
coal gets pulverized or powdered .The powdered coal is then put into furnace and burnt .The
heat generated is used to heat water, steam, air etc .
BOILER COAL BUNKER :
Boiler Coal Coal bunker supplies coal to pulverizing fuel mills. Each bunker can hold 1,000
tonnes of coal, and there may be six to eight bunkers per unit .Power station coal is not as
lumpy as coal used in the home. Typically around half of it is less than 12.5 millimeters
across and 95% is less than 50 millimeters . That is the powdered coal passes through a sieve
with so many holes in square inch area. It is better than the face powder in terms of size
COAL FEEDERS :
The variable speed coal feeder feeds coal from the bunkers to the mill . It uses a conveyor to
move coal through a fixed gap at a precisely controlled speed. Varying the speed controls the
amount of coal supplied to the boilers. These are precision bits of equipment that have to
move exact amounts of coal .They can move 40 tonnes of coal in an hour .
THE MILL :
The mill consists of a round metallic table on which coal particles fall. This table is rotated
with the help of a motor. There are three large steel rollers, which are spaced 120 apart.
When there is no coal, these rollers do not rotate but when the coal is fed to the table it packs
up between the roller and the table and this forces the roller to rotate. Coal is crushed by the
crushing action between the rollers and the rotating table .
This crashed coal is taken away to the furnace through coa pipes with the help of hot and cold
air mixture from the prmary air fans .

PRIMARY AIR FAN:

The P.A. fan takes atmospheric air, a part of which is sent to the air preheaters for heating
while a part goes directly to the mill for temperature control. Fan makes air to blow the coal
from the mill to the boiler, called the primary air, is supplied by a large fan driven by a
variable speed motor .
When mixed with a stream of air the powdered coal behaves more like a gas than a solid .
Primary air does two jobs heating the coal powder and secondly lifting it into the furnace
through pipelines.
Boiler light-up spark plug provides the initial ignition. Light Diesel oil is then fed to the
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Design Specification (ME)

burner and it catches fire .This is followed by heavy furnace oil (HFO), once a stable flame
is established the coal/air mix is blown through the burner where it lights spontaneously The
oil are then shut off. Burner position, coal flow and air flow are controlled to achieve desired
output of temperature, pressure and flow.
BOILER :
To produce steam each boiler converts energy, in the form of coal, into steam The boiler is
lined with steel tubing in which pure boiler feed water is turned to steam by the heat created
from the burning of coal .Each boiler is as high as 60 mts and weighs about 40,00,000 kg
(4000 T)Inside the boiler there is enough steel tubing to stretch the 500 kilometres and they
are joined together by about 20,000 joints Pressure inside the tubes could be about hundred
times that of cars wheel pressure .
Water from the boiler feed pump passes through economiser and reaches the boiler drum.
ECONOMISER :Flue gases leaving the superheater and reheater still contain useful energy . Water from the
high pressure feed heaters is heated in the economizer from 250C to 290C before it
continues to the steam drum Having given up its last heat in the boiler, the flue gases move
on to the air heater31. Drum After leaving the economizer, the feed water reaches the drum,
which is a cylindrical vessel at the top of the boiler From here the water flows by natural
circulation through downpipes into the boiler Saturated steam collects here ready to go to the
superheater does the important function of -separating steam from a mixture of steam and
water .
CONTROL VALVES :Control valves are valves used within industrial plants and elsewhere to control operating
conditions such as temperature,pressure,flow,and liquid Level by fully partially opening or
closing in response to signals received from controllers that compares a set point to a
process variable whose value is provided by sensors that monitor changes in such
conditions. The opening or closing of control valves is done by means of electrical, hydraulic
or pneumatic systems
DAERATOR :-

Dearator is a device for air removal and used to remove dissolved gases (an alternate would
be the use of water treatment chemicals) from boiler feed water to make it non-corrosive. A
deaerator typically includes a vertical domed deaeration section as the deaeration boiler feed
water tank.
A Steam generating boiler requires that the circulating steam, condensate, and feed water
should be devoid of dissolved gases, particularly corrosive ones and dissolved or suspended
solids. The gases will give rise to corrosion of the metal. The solids will deposit on the
heating surfaces giving rise to localized heating and tube ruptures due to overheating. Under
some conditions it may give to stress corrosion cracking. Deaerator level and pressure must
be controlled by adjusting control valves- the level by regulating condensate flow and the

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pressure by regulating steam flow. If operated properly, most deaerator vendors will
guarantee that oxygen in the deaerated water will not exceed 7 ppb by weight (0.005 cm3/L) .
FEED WATER HEATER:A Feed water heater is a power plant component used to pre-heat water delivered to a steam
generating boiler. Preheating the feed water reduces the irreversible involved in steam generation
and therefore improves the thermodynamic efficiency of the system. This reduces plant operating
costs and also helps to avoid thermal shock to the boiler metal when the feed water is introduces
back into the steam cycle. In a steam power (usually modeled as a modified Ranking cycle), feed
water heaters allow the feed water to be brought up to the saturation temperature very gradually.
This minimizes the inevitable irreversibilitys associated with heat transfer to the working fluid
(water). A belt conveyor consists of two pulleys, with a continuous loop of material- the conveyor
Belt that rotates about them. The pulleys are powered, moving the belt and the material on the
belt forward. Conveyor belts are extensively used to transport industrial and agricultural material,
such as grain, coal, ores etc.
PULVERISER:
A pulveriser is a device for grinding coal for combustion in a furnace in a fossil fuel power plant.
BOILER STEAM DRUM:
Drums are a regular feature of water tube boilers. It is reservoir of water/steam at the top end of
the water tubes in the water-tube boiler. They store the steam generated in the water tubes and act
as a phase separator for the steam/water mixture. The difference in densities between hot and cold
water helps in the accumulation of the hotter-water/and saturated steam into steam drum.
Made from high-grade steel (probably stainless) and its working involves temperatures 390 C
and pressure well above 350psi (2.4MPa). The separated steam is drawn out from the top section
of the drum. Saturated steam is drawn off the top of the drum. The steam will re-enter the furnace
in through a super heater, while the saturated water at the bottom of steam drum flows down to
the mud-drum /feed water drum by down comer tubes accessories include a safety valve, water
level indicator and fuse plug. A steam drum is used in the company of a mud-drum/feed water
drum which is located at a lower level. So that it acts as a sump for the sludge or sediments which
have a tendency to the bottom.

SUPER HEATER:
A Super heater is a device in a steam engine that heats the steam generated by the boiler again
increasing its thermal energy and decreasing the likelihood that it will condense inside the engine.
Super heaters increase the efficiency of the steam engine, and were widely adopted. Steam which
has been superheated is logically known as superheated steam; non-superheated steam is called
saturated steam or wet steam; Super heaters were applied to steam locomotives in quantity from
the early 20th century, to most steam vehicles, and so stationary steam engines including power
stations.
AIR PREHEATERS:
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Air preheater is a general term to describe any device designed to heat air before another process
(for example, combustion in a boiler). The purpose of the air preheater is to recover the heat from
the boiler flue gas which increases the thermal efficiency of the boiler by reducing the useful heat
lost in the fuel gas. As a consequence, the flue gases are also sent to the flue gas stack (or
chimney) at a lower temperature allowing simplified design of the ducting and the flue gas stack.
It also allows control over the temperature of gases leaving the stack.
ESPS:
An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that removes
particles from a flowing gas (such As air) using the force of an induced electrostatic charge.
Electrostatic precipitators are highly efficient filtration devices, and can easily remove fine
particulate matter such as dust and smoke from the air steam. ESP s continue to be excellent
devices for control of many industrial particulate emissions, including smoke from electricitygenerating utilities (coal and oil fired), salt cake collection from black liquor boilers in pump
mills, and catalyst collection from fluidized bed catalytic crackers from several hundred thousand
ACFM in the largest coal-fired boiler application. The original parallel plate-Weighted wire
design (described above) has evolved as more efficient ( and robust) discharge electrode designs
were developed, today focusing on rigid discharge electrodes to which many sharpened spikes are
attached , maximizing corona production. Transformer rectifier systems apply voltages of 50100 Kilovolts at relatively high current densities. Modern controls minimize sparking and prevent
arcing, avoiding damage to the components. Automatic rapping systems and hopper evacuation
systems remove the collected particulate matter while on line allowing ESP s to stay in operation
for years at a time.
FUEL GAS STACK:
A Fuel gas stack is a type of chimney, a vertical pipe, channel or similar structure through which
combustion product gases called fuel gases are exhausted to the outside air. Fuel gases are
produced when coal, oil, natural gas, wood or any other large combustion device. Fuel gas is
usually composed of carbon dioxide (CO2) and water vapor as well as nitrogen and excess
oxygen remaining from the intake combustion air. It also contains a small percentage of
pollutants such as particulates matter, carbon mono oxide, nitrogen oxides and sulfur oxides.

4. Fabrication:
The main work for the fabrication of a power plant is
1. Setting up a coal handling plant for the thermal power plant.
2. Complete civil work, fabrication and erection of building structural and equipment
supply ,erection, testing and commissioning.
3. Civil work involves approximate 30.000 cubic metres concreteand buildingstructure
approximately 3800 MT.

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Design Specification (ME)

4. Supply and installation of Rotary Plough Feeder,Stacker,Wagon Tippler with side arm
charger,Crusher ,,truflo feeders , belt feeders and vibro feeders.
5. Setting up some utility system for dust suppression ,dust suppression/extraction, fire
fighting and ventilation system.
6. In total there are four transfer points ,a drive horse,crusher house and a sampling
station.
7. To install all the key order,, i.e to supply all conveying equipment and undertake all
electrical work.

5.

Working of a PowerPlant
COAL TO STEAM
Coal from the coal wagons is unloaded in the coal handling plant. This coal is
transported upto the raw coal bunkers with the help of belt conveyors. Coal is transported
to bowl mills by coal feeders. The coal is pulverized in the bowl mill, where it is ground
to a powder form. The mill consists of a round metallic table on which coal particles fall.
This table is rotated with the help of a motor. There are three large steel rollers, which are
spaced 120 apart. When there is no coal, these rollers do not rotate but when the coal is
fed to the table it packs up between the roller and the table and this forces the roller 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 the primary air (P.A.) fan. The P.A. fan takes atmospheric air, a part
of which is sent to the air preheaters for heating while a part goes directly to the mill for
temperature control. Atmospheric air from forced draft (F.D.0 fan is heated in the air
heaters and sent to the furnace as combustion air.
Water from the boiler feed pump passes through economiser and reaches the
boiler drum. Water from the drum passes through down comers and goes to bottom ring
header. Water from the bottom ring header is divided to all the four sides of the furnace.
Due to heat and the density difference water rises up in the water wall tubes. Water is
partly converted into steam as it rises up in the furnace. This steam and water mixture is
again taken to the boiler drum where the steam is separated from water. Water follows the
same path while steam is sent to the superheaters for superheating. The superheaters are

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located inside the furnace and the steam is superheated (540C) and finally goes to the
turbine.
Flue gases from the furnace are extracted by the induced draft (I.D.) fan, which
maintains a balanced draft in the furnace with F.D. fan. These flue gases emit their heat
energy to various superheaters in the plant house and finally pass through the air
preheaters and goes to the electrostatic precipitator where the ash particles are extracted.
Electrostatic precipitators consist of metal plates, which are electrically charged. Ash
particles are attracted to these plates, so that they do not pass through the chimney to
pollute the atmosphere. Regular mechanical hammer blows cause the accumulation of ash
to fall to the bottom of the precipitator where they are collected in a hopper for disposal.
This ash is mixed with water to form slurry and is pumped to ash dyke.
STEAM TO MECHANICAL POWER
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 steam to the turbine. Stop valves and control valves
are located in the steam chest and a governor, driven from the main turbine shaft, operates
the control valves to regulate the amount of steam used (this depends upon the speed of
the turbine and the amount of electricity required from the generator).
Steam from the control valves enters the high pressure cylinder of the turbine,
where it passes through a ring of stationary blades fixed to the cylindrical wall. These act
as nozzles and direct the steam into a second ring of moving blades mounted on a disc
secured to the turbine shaft. This second ring turns the shafts as a result of the force of the
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 a number of rings of
stationary 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 pressure cylinder and in its
passage some of its heat energy is changed into mechanical energy. The steam leaving the
high pressure cylinder goes back to the boiler for reheating and returns by a further pipe
to the intermediate pressure cylinder. Here it passes through another series of stationary
and moving blades.Finally, the steam is taken to the low pressure cylinders, each of which
it enters at the center flowing outwards in opposite directions through the rows of turbine
blades an arrangement known as double flow to the extremities of the cylinder. As the
steam gives up its heat energy to drive the turbine, its temperature and pressure fall and it
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expands. Because of this expansion the blades are much larger and longer towards the low
pressure end of the turbine.
The turbine shaft usually rotates at 3,000 rpm. This speed is determined by the
frequency of the electrical system used in the country. In India, it is the speed at which a
2- pole generator is driven to generate alternating current at 50 Hz. When as much energy
as possible has been extracted from the steam it is exhausted directly to the condenser.
This runs the length of the low pressure part of the turbine and may be beneath or on
either side of it. The condenser consists of a large vessel containing some 20,000 tubes,
each about 25 mm in diameter. Cold water from the water source i.e. the Rihand
Reservoir is circulated through these tubes and as the steam from the turbine passes round
them it is rapidly condensed into water condensate. Because water has a much smaller
comparative volume than steam, a vacuum is created in the condenser. This allows the
steam pressure to reduce down to pressure below that of the normal atmosphere and more
energy can be utilized.
From the condenser, the condensate is pumped through low pressure heaters by the
extraction pump, after which its pressure is raised to boiler pressure by the boiler feed
pump. It is further passed through feed heaters to the economiser and the boiler for
reconversion into steam. The cooling water drawn from the reservoir is returned directly
to the source after use.
MECHANICAL POWER TO ELECTRICITY
The turbine shaft is mechanically coupled to the generator rotor shaft through thrust
bearings. The steam rotates the turbine at 3000 rpm thus the rotor of the generator also
rotates at 3000 rpm. This speed is necessary to generate electricity at a frequency of 50
Hz with a two pole turbo- generator.The rotor carries the field winding over it. This field
winding is excited by a DC excitation system. The supply to the excitation system is
tapped from the unit auxiliary transformer. The flux generated by this field current cuts
the armature coil. The armature coil is star- star connected and is induced with three
phase emf. The emf is tapped with the help of slip rings and brushes. This emf is carried
over to the generator transformer through a bus duct. The bus duct is voltage transformer
grounded.
The generator transformer has delta connection in the primary side and star connection in
the secondary side. The generator bus supplies electric power per phase to the three-phase
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Design Specification (ME)

transformer or bank of three single-phase transformers. These transformers transmit

electric power to the switchyard for further transmission. These transformers also supply
the unit auxiliary transformers required for the working of various electric motors, pumps
and other equipments installed in the unit.
TRANSMISSION
The electricity is usually produced in the stator windings of large modern generators and
is fed through terminal connections to one side of a generator transformer that steps up
the voltage to 400KV. From here conductors carry it to a series of three switches
comprising of an isolator, a circuit breaker and another isolator.
The circuit breaker, which is a heavy- duty switch capable of operating in a fraction of
second, is used to switch off the current flowing to the transmission lines. Once the
current has been interrupted the isolators can be opened. These isolate the circuit breaker
connected to its terminals. Here after the maintenance or repair work can be carried out
safely. From the circuit breakers the current is taken to the busbar conductors, which run
the length of the switching compound and then to another circuit breaker with its
associated isolators, before being fed to the Grid. Each generator in a power station has its
own transformer, circuit breaker and associated isolators but the electricity generated is
fed into a common set of busbars. Circuit breakers work like combined switches and
fuses but they have certain special features and are very different from the domestic
switch and fuse. When electrical current is switched off by separating two contacts, an arc
is created between them. At the voltage use in homes, this arc is very small and lasts for a
fraction of a second but at very high voltages used for transmission, the size and power of
the arc is considerable and it must be quickly quenched to prevent damage. Three phase,
four-wire system is used for large power transmission, as it is cheaper than the singlephase two-wire system that supplies the home. Also power is generated in a three-phase
system.
The center of the power station is the control room. Here the engineers monitor
the output of electricity, supervising and controlling the operation of generating plant and
high voltage switchgear and directing power to the grid system as required.

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