NTPC BADARPUR TRAINING

PROJECT REPORT
by RITIKA



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 17 coal-based and seven gas-based stations, located across the
country. In addition under JVs (joint ventures), six stations are coal-based,
and another station uses naphtha/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 national PLF rate of 78%).
NTPC operates from 55 locations in India, one location in Sri Lanka and 2
locations 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 Policy
NTPC 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 Ramagundam
Power 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 set
up Ash Utilization Division A.


"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 continued
commitment 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 below
have 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 62
nd
among the 250 largest Power Producers and
Energy Traders in the world by Platts in 2012.
In 2009, it received ICSI National Award for Excellence in Corporate
Governance.
It was listed in Forbes Global 2000 for 2012 at 384
th
rank in the
world.



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.



INSTALLATION UNITS
Stage
Unit
Number
Installed Capacity
(MW)
Date of
Commissioning
Status
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, 1981
Running



THERMAL POWER PLANT
A thermal power station is a power plant in which the prime
mover is steam driven. Water is heated, turns into steam and spins a steam
turbine which drives an electrical generator. After it passes through the
turbine, the steam is condensed in a condenser and recycled to where it
was heated; this is known as a Rankine cycle. The greatest variation in the
design of thermal power stations is due to the different fossil fuel resources
generally used to heat the water.
Commercial electric utility power stations are usually constructed on a
large scale and designed for continuous operation. Electric power plants
typically use three-phase electrical generators to produce alternating
current (AC) electric power at a frequency 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.



DIAGRAM OF A TYPICAL COAL-FIRED THERMAL POWER STATION

KEY:
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 pulveriser 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




DESCRIPTION

A typical coal-fired thermal power plant.

1. Coal is conveyed from an external stack and ground to a very fine
powder 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, where
steam 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.



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-phase
electrical 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.




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 the
plant 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.



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 hydrogen
gas.


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 the
help 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.




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