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NTPC

A Warm
To All
A Presentation on

NTPC
Coal to Electricity
Prepared by Tejasvi Anant (Mechanical)
India’s largest power company,
NTPC was set up in 1975.
NTPC became a Maharatna
company in May, 2010.
NTPC ventured into c...
NTPC INSTALLED CAPACITY

Source – www.ntpc.co.in
KSTPS
OVERVIEW
Korba Super Thermal Power Plant
Country

India

Location

Jamanipali, Chhattisgarh

Commission date

1983

Owner(s)

Natio...
Korba Super Thermal Power Plant is located at Jamanipali in Korba district in the
Indian state of Chhattisgarh. The power ...
KORBA A SUCCESS STORY……
Clearance By Govt. Of India

-

Jan’1978.

ANDROID
Unit size, Stage-I 3 xText Stage-II 3 WINDOWS
2...
KORBA
KORBA SUPER THERMAL POWER STATION
IS AN ISO 9001(2000), IS0 14001, ISO 18001, OHSAS & 5S CERTIFIED, 2600MW
POWER STA...
COAL TO ELECTRICITY
Coal to Electricity ….. Basics
Pollutants

Super Heated
Steam

Coal
Heat
Loss

Heat Loss
In
Condenser

ASH

Chemical
Energ...
COAL TO ELECTRICITY
M

IN E S
M

G

R

T R A C K H O

P P E R

C R U S H E R
B U N K E R
P U L V E R IZ E R
B O

IL E R

T...
MINES
 MINES: GEVRA(SOUTH EASTERN COALFIELD LTD)
 TYPE:

OPEN CAST MINES

 COAL SIZE :<100MM
 TYPE OF COAL: E& F GRADE
MINED COAL BY SURFACE MINER
GRADING OF COAL
GRADE
A
B
C
D
E
F
G

KCAL/KG
>6200
5600-6200
4490-5600
4200-4490
3360-4200
2400-3360
1300-2400
MINES
TWO SILOS AT MINES END OF CAPACITY:2400 TONS
LOADING FACILITY
WEIGHING FACILITY
SILO
MGR
(MERRY GO ROUND SYSTEM)
MGR

(MERRY GO ROUND SYSTEM)
 CAPTIVE RAIL TRANSPORTATION SYSTEM LINKING
MINES AND PLANT
 MOST ECONOMIC & RELIABLE
 LOA...
MGR

(MERRY GO ROUND SYSTEM)
SILOS
TRACK
HOPPERS

RAIL TRACK

MINES END

NTPC
END

TOTAL TRACK LENGTH:

34.80 KM

LENGTH O...
MGR

(MERRY GO ROUND SYSTEM)
 ONE WAGON CAPACITY: 60-65 TONS
 ONE RAKE : 34 WAGONS~ 2000 TONS
 TOTAL RAKES IN A DAY~ 19...
MGR
(MERRY GO ROUND SYSTEM)
WAGON
MGR
(MERRY GO ROUND SYSTEM)
WAGON
MGR

(MERRY GO ROUND SYSTEM)
SPEED OF WAGONS DURING LOADING:0.8 KM/HR
TOTAL TIME FOR LOADING :35-40 MINUTES
TRAVEL TIME...
TRACK HOPPERS
 UNDERGROUND HOPPER AT POWER STN END
FOR UNLOADING
 TRACK HOPPER 1&2 FOR ST-1(200MW) AND
ST-2 (500MW) RESP...
TRACK HOPPERS

HOPPER HOLE
TRACK HOPPERS
TRACK HOPPERS
HOPPER OPNNING
CONCRETE AND STEEL 
PLATE

CONVEYOR BELTS

BELT SUPPOTER
TRACK HOPPERS
 WAGON UNLOADING : BY OPENING BOTTOM
DISCHARGE HOPPERS
 DISCHARGE HOPPER: PNEUMATIC OPERATION WITH
EXTERNA...
CHP
COAL HANDLING PLANT
 TRANSPORTS COAL FROM TRACK HOPPERS TO
BUNKERS AT MAIN PLANT
 THROUGH PADDLE FEEDERS,CONVEYOR BE...
CHP
COAL HANDLING PLANT
PADDLE FEEDERS:
  TRANSFERS COAL FROM TRACKHOPPERS
ON TO CONVEYOR BELTS:
 4 NOS IN EACH TRACK HO...
PADDLE FEEDER
CHP
COAL HANDLING PLANT
CONVEYOR BELT
 TRANSPORTS COAL FROM ONE PLACE TO OTHER
 CAPACITY: 2000 TON/HR
 MATERIAL:COMPOUN...
CONVEYOR BELT
CHP
COAL HANDLING PLANT
CRUSHER
 CRUSHES COAL FROM 100 mm SIZE TO <20 mm SIZE
 FOUR CRUSHER EACH IN ST-1&ST-2
 TWO CRUS...
CRUSHER
HAMMER

SECTION
PART
CHP
COAL HANDLING PLANT
TRACK
HOPPER
STACKYARD

CRUSHE
R

TO BUNKERS
CHP
COAL HANDLING PLANT
STACKING & RECLAIMING
 STACKING WHEN EXCESS COAL
 RECLAMING DURING LEAN PERIOD
 STACKER- RECLAI...
STACKER/RECLAIMER
STACKER/RECLAIMER
CHP
COAL HANDLING PLANT
BUNKERS
 6 BUNKERS (EACH 390 TON CAP) IN A 200 MW UNIT
 9 BUNKERS (EACH 900 TON CAP) IN A 500 MW...
BUNKERS
MAIN PLANT
BUNKER

FEEDER

PULVERIZER
feeder pannel

Silo gate

Coal
Bunker
COB Switch
Load cell

Motor

Conveyor Belt

Coal Feed Pipe
Clean Out Conveyor
Encode...
MAIN PLANT
FEEDER
 TRANSFERS COAL FROM BUNKERS TO
MILL/PULVERIZER
 VARIABLE SPEED
 DC OR AC MOTOR DRIVEN
MAIN PLANT
MILL/PULVERIZER
 PULVERIZES COAL FROM 20 MM SIZE TO 200 MESH
SIZE i.e> 70% SHOULD PASS THRU 200 MESH(200
HOLES...
Mills (Bowl Mill)
BOWL MILL :
Coal discharge
Coal from bunker
Classification
Hot Air Damper
Hot Air
of desired
Gate
fineness Coal
Hot Air
Du...
BOILER: AIR & FLUE GAS PATH
BUNKER

PA FAN

FEEDER
APH

ESP
ID FAN

BOILER
MILL

FD FAN

C
H
I
M
N
E
Y
BOILER
(200 MW)
• Manufacturer:

BHEL, CE Design

• Type: Natural circulation, Balance
draft, Corner fired, Tilting,
Tange...
DPNL
SHTR

Platen SHTR

Drum

Reheater
S
C
R
E
E
n
Gooseneck

LTSH

Chimney

Downcomer
waterwall

Fireball

Economiser

ID...
Water Walls
BOILER COMBUSTION

DPNL
SHTR

Platen SHTR

Drum

Reheater
S
C
R
E
E
n
Gooseneck

LTSH

Chimney

Downcomer
waterwall

Fireb...
Header
Boiler Drum
M.S

C.R.H

500mw

H.
R.
H

FROM F.R.S
BOTTOM RNG HDR& Z-PANEL
1ST PASS W.W O/L HDRS
2ND PASS UPPER C-HDR

1ST PASS W.W
RO...
Air Preheater
Boiler circuit with Precipitator
ELECTROSTATIC
PRECIPITATOR
 ESP -Working Principle
SCHEMATIC DIAGRAM
Electrostatic Precipitator
415 V
3 Phase
Supply
C A C A C

Electronic
Controller

High Voltage
Rectifier...
Electrostatic Precipitator (ESP)

No of Fields
No of Hoppers
Dust Concentration (I/L)
(O/L)
Efficiency
Key equipments

: 4...
Chimney
PLANT-1
BASIC WATER & STEAM CYCLE OF POWER
PLANT
RYB

HPT

IPT

LPT
EXC

S
H

R R
H H

GEN.

S
H
COND

LTSH

CEP

ECO

LPH
1,2,3

...
 Steam power plants operate
on Modified Rankine Cycle,
DM water as working fluid.
w/w

 Sensible heat is added in
Heater...
MAIN PLANT
TURBINE
THREE CYLINDER: HP,IP AND LP CYLINDER
ROTATES AT 3000 RPM (DECIDED BY GRID FREQ
AND GENERATOR POLE)
n...
TURBINE
• HP TURBINE (SINGLE FLOW)
• IP TURBINE( DOUBLE FLOW)
• LP TURBINE (DOUBLE FLOW)

NO OF STAGE (200 MW Turbines)
• ...
HP TURBINE

(SECTIONAL VIEW)
HP turbine rotor….
HP turbine inner casing….
Work Done in Turbine….
IP Rotor….
IP Inner casing
IP Outercasing
LP Turbine
Layout of Turbine-Generator
HPT

IPT
LPT

TG Bearings

Generator

TG Bearings
Condenser
Condenser

Hot well
GENERATOR
Magnetic field around a current carrying conductor
and
Direction of the field
B(Φ)

N
N

N

N
S

S
2πr

SS
Rotor field and its traveling with rotation
Generator

S

N
Generator

S
S

δ

S

N

N
N

Load angle δ
Locking of stator and rotor fields -*- δ between rotor field & resultant field
Rated parameters:
Maximum continuous KVA rating
247 MVA
Maximum continuous KW rating
210 MW
Rated Terminal Voltage
15.75 K...
November 26, 2013

PMI Revision 00

103
1. STATOR WATER SYSTEM
2. SEAL OIL SYSTEM
3. H2 GAS SYSTEM
4. EXCITATION SYSTEM***
H.T. MOTORS
Cold Air I/L
External fan mounted at fan
NDE side
BFP ( Stage I)
CW I/L

CW O/L

2 no. of Coolers

Cooling fan 2
no.s (DE/NDE)
mounted on
motor shaft
MAIN PLANT
GENERATOR & GENERATOR TRANSFORMER

15.75 KV

GENERATOR

OUTGOIN
G
LINE

400 KV

GENERATOR
TRANSFORMER

CIRCUIT ...
Generator Transformer
Korba Vindh’l -1A

K-Bhilai-1

K-Bhilai-2

K-Bhatapara

Tie Transf # 4

K-Korba (W)

K-Birsingpur -1 & 2
Korba-Vindh’l -2
...
Switchyard
Circuit Breaker
Isolators
Switchyard One line Diagram

Transfer Bus 400 KV
Main Bus II
Main Bus I

Bus
Isolator
CB

GT
20.5/400KV
Gen Bay

CB

CB
Tr...
Western Region Power Map
KORBA
NTPC Korba CW/CT system at a glance

126
CW scheme…
Reservoir/ River

Canal

Intake
Trash rack

Cooling tower

TWS
CT pumps
Hot Pond

CW pumps
Condenser
Open Cycle

Stage-II

Stage-I

3X500 MW

CT- II

3 X 200 MW
CWPH-I

Hasdeo Barrage
RBC Darri Gate
open
Pragat
i
Nagar
Regu...
Total Closed Cycle

Stage-II

CT- II

Stage-I

3X500 MW

Hasdeo
Barrage
RBC Darri
Gate open
for makeup

3 X 200 MW
CWPH-I
...
Induced Draft Cooling Tower
Natural Cooling Tower
Partial Closed Cycle

Stage-II

CT- II

Pragati
Nagar
Regulator

Stage-I

3X500 MW

Hasdeo Barrage
RBC Darri Gate
partiall...
ASH GENERATION AND CLASSIFICATION
CHIMNEY
COAL
BUNKER
BOILER

ECO /APH
HOPPERS

ESP
HOPPERS

MILLING SYSTEM

BOTTOM ASH CO...
Ash volumes and properties
Furnace

ESP

(1300 - 1500°C)

Eco
nom
izer

100 %

Fineness

Bottom Ash

10-20 %

Eco Ash APH ...
Ash Dyke

ASPs

Overflow

BATPs
ASH

FLOW

DIAGRAM (AS PER DESIGN)

Stage –II ASPH

Booster ASPH

ASP
5A

5B

5C

BASP

Stage- II
ASL # 5

4A

4B

4C

3B
...
Escape
channel to
Kasai nala

TP-6
BOOSTER
PUMP
HOUSE

N

Overflow
Lagoon

TP-8

TP-7

LAGOON-II

Return water to
BPH ( 3 ...
DHANRAS ASH DYKE
WHITE
HOUSE

889
938

865

847

779

810

774

915
721

998
ASH LINES

684

54321

1
WELL
5

LAGOON-II
3
...
ASH LAGOON

139
A6

A12

A18

A24

FLY ASH EVACUATION
DRY MODE
Basic scheme for one ESP pass

Air and Seal water exhaust to
atmosphere

A1...
November 26, 2013

PMI Revision 00

143
How Generated electricity
reached customer
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')
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NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')

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NTPC KORBA CHHATTISGARH coal to electricity by tejasvi anant (tan 90')

  1. 1. NTPC A Warm To All
  2. 2. A Presentation on NTPC Coal to Electricity Prepared by Tejasvi Anant (Mechanical)
  3. 3. India’s largest power company, NTPC was set up in 1975. NTPC became a Maharatna company in May, 2010. NTPC ventured into consultancy, power trading, ash utilisation and coal mining. NTPC has been awarded No.1, Best Workplace in India among large organisations and the best PSU for the year 2010.
  4. 4. NTPC INSTALLED CAPACITY Source – www.ntpc.co.in
  5. 5. KSTPS OVERVIEW
  6. 6. Korba Super Thermal Power Plant Country India Location Jamanipali, Chhattisgarh Commission date 1983 Owner(s) National Thermal Power Corporation Power station information Primary fuel Coal Generation units 7 Power generation information Installed capacity 2,600 MW
  7. 7. Korba Super Thermal Power Plant is located at Jamanipali in Korba district in the Indian state of Chhattisgarh. The power plant is one of the Coal based power plants of NTPC. The coal for the power plant is sourced from Kusmundha and Gevra Mines. Source of water for the power plant is Hasdeo River. Stage Unit Number Installed  Capacity (MW) Date of  Commissioning 1st 1 200 1983 March 1st 2 200 1983 October 1st 3 200 1984 March 2nd 4 500 1987 May 2nd 5 500 1988 March 2nd 6 500 1989 March 3rd 7 500 2010 December Total Seven 2600
  8. 8. KORBA A SUCCESS STORY…… Clearance By Govt. Of India - Jan’1978. ANDROID Unit size, Stage-I 3 xText Stage-II 3 WINDOWS 200+ x Text 500+ Stage-III 1 x 500, Total Capacity – 2600 MW. 1st 200MW Unit commissioned - 1st Mar’83 (in 48 months from award date). SYMBIAN Text 1st 500MW Unit commissioned - 31st May’87 BLACK (in 57 months from award date) Text BERRY Stage-III commissioned on - 21st March’11
  9. 9. KORBA KORBA SUPER THERMAL POWER STATION IS AN ISO 9001(2000), IS0 14001, ISO 18001, OHSAS & 5S CERTIFIED, 2600MW POWER STATION LOCATED AT JAMNIPALI VILL. OF KORBA DIST. IN CHHATTISGARH. IT IS A COAL FED STATION & WATER IS SOURCED FROM HASDEO BARRAGE.
  10. 10. COAL TO ELECTRICITY
  11. 11. Coal to Electricity ….. Basics Pollutants Super Heated Steam Coal Heat Loss Heat Loss In Condenser ASH Chemical Energy Thermal Energy Kinetic Energy Turbine Torque Mech. Energy Loss Electrical Energy Alternating current in Stator Elet. Energy Loss
  12. 12. COAL TO ELECTRICITY M IN E S M G R T R A C K H O P P E R C R U S H E R B U N K E R P U L V E R IZ E R B O IL E R T U R B IN E G G E N E R A T O E N E R A T O S W R R T R A N S F O IT C H Y A R D /G R M R ID E R
  13. 13. MINES  MINES: GEVRA(SOUTH EASTERN COALFIELD LTD)  TYPE: OPEN CAST MINES  COAL SIZE :<100MM  TYPE OF COAL: E& F GRADE
  14. 14. MINED COAL BY SURFACE MINER
  15. 15. GRADING OF COAL GRADE A B C D E F G KCAL/KG >6200 5600-6200 4490-5600 4200-4490 3360-4200 2400-3360 1300-2400
  16. 16. MINES TWO SILOS AT MINES END OF CAPACITY:2400 TONS LOADING FACILITY WEIGHING FACILITY
  17. 17. SILO
  18. 18. MGR (MERRY GO ROUND SYSTEM)
  19. 19. MGR (MERRY GO ROUND SYSTEM)  CAPTIVE RAIL TRANSPORTATION SYSTEM LINKING MINES AND PLANT  MOST ECONOMIC & RELIABLE  LOADING : FAST,ACCURATE & MAXIMUM UTILISATION  UNLOADING: FAST AND EASY  
  20. 20. MGR (MERRY GO ROUND SYSTEM) SILOS TRACK HOPPERS RAIL TRACK MINES END NTPC END TOTAL TRACK LENGTH: 34.80 KM LENGTH OF LOAD LINE: 14.86 KM LENGTH OF EMPTY LINE: 19.94
  21. 21. MGR (MERRY GO ROUND SYSTEM)  ONE WAGON CAPACITY: 60-65 TONS  ONE RAKE : 34 WAGONS~ 2000 TONS  TOTAL RAKES IN A DAY~ 19  WAGON TYPE: BOTTOM DISCHARGE (PNEUMATIC)
  22. 22. MGR (MERRY GO ROUND SYSTEM) WAGON
  23. 23. MGR (MERRY GO ROUND SYSTEM) WAGON
  24. 24. MGR (MERRY GO ROUND SYSTEM) SPEED OF WAGONS DURING LOADING:0.8 KM/HR TOTAL TIME FOR LOADING :35-40 MINUTES TRAVEL TIME: 30 + 30 MINS  
  25. 25. TRACK HOPPERS  UNDERGROUND HOPPER AT POWER STN END FOR UNLOADING  TRACK HOPPER 1&2 FOR ST-1(200MW) AND ST-2 (500MW) RESPECTIVELY  TRACK HOPPER –1 : 3000 TON  TRACK HOPPER –2 : 3200 TON
  26. 26. TRACK HOPPERS HOPPER HOLE
  27. 27. TRACK HOPPERS
  28. 28. TRACK HOPPERS HOPPER OPNNING CONCRETE AND STEEL  PLATE CONVEYOR BELTS BELT SUPPOTER
  29. 29. TRACK HOPPERS  WAGON UNLOADING : BY OPENING BOTTOM DISCHARGE HOPPERS  DISCHARGE HOPPER: PNEUMATIC OPERATION WITH EXTERNAL DC SUPPLY  TOTAL UNLOADING TIME:~25 MINS
  30. 30. CHP COAL HANDLING PLANT  TRANSPORTS COAL FROM TRACK HOPPERS TO BUNKERS AT MAIN PLANT  THROUGH PADDLE FEEDERS,CONVEYOR BELTS, CRUSHERS ETC  ALSO STACKS THE COAL IN STACKYARD AND RECLAIMS WHEN NEEDED
  31. 31. CHP COAL HANDLING PLANT PADDLE FEEDERS:   TRANSFERS COAL FROM TRACKHOPPERS ON TO CONVEYOR BELTS:  4 NOS IN EACH TRACK HOPPER 1&2  ELECTRICALLY DRIVEN
  32. 32. PADDLE FEEDER
  33. 33. CHP COAL HANDLING PLANT CONVEYOR BELT  TRANSPORTS COAL FROM ONE PLACE TO OTHER  CAPACITY: 2000 TON/HR  MATERIAL:COMPOUND OF NYLON/POLYESTER ETC WITH RUBBER COATING.  100% STANDBY
  34. 34. CONVEYOR BELT
  35. 35. CHP COAL HANDLING PLANT CRUSHER  CRUSHES COAL FROM 100 mm SIZE TO <20 mm SIZE  FOUR CRUSHER EACH IN ST-1&ST-2  TWO CRUSHER RUNS AT A TIME
  36. 36. CRUSHER
  37. 37. HAMMER SECTION PART
  38. 38. CHP COAL HANDLING PLANT TRACK HOPPER STACKYARD CRUSHE R TO BUNKERS
  39. 39. CHP COAL HANDLING PLANT STACKING & RECLAIMING  STACKING WHEN EXCESS COAL  RECLAMING DURING LEAN PERIOD  STACKER- RECLAIMER IS USED
  40. 40. STACKER/RECLAIMER
  41. 41. STACKER/RECLAIMER
  42. 42. CHP COAL HANDLING PLANT BUNKERS  6 BUNKERS (EACH 390 TON CAP) IN A 200 MW UNIT  9 BUNKERS (EACH 900 TON CAP) IN A 500 MW UNIT  TRIPPER CONVEYORS FOR TRANSFERING COAL FROM CONVEYOR TO BUNKER
  43. 43. BUNKERS
  44. 44. MAIN PLANT BUNKER FEEDER PULVERIZER
  45. 45. feeder pannel Silo gate Coal Bunker COB Switch Load cell Motor Conveyor Belt Coal Feed Pipe Clean Out Conveyor Encoder
  46. 46. MAIN PLANT FEEDER  TRANSFERS COAL FROM BUNKERS TO MILL/PULVERIZER  VARIABLE SPEED  DC OR AC MOTOR DRIVEN
  47. 47. MAIN PLANT MILL/PULVERIZER  PULVERIZES COAL FROM 20 MM SIZE TO 200 MESH SIZE i.e> 70% SHOULD PASS THRU 200 MESH(200 HOLES/SQ.INCH)~ 75 MICRON  BOWL ROTATED BY MOTOR AND 3 ROLLERS AT 120 DEG APART (BOWL MILL)  PULVERIZED COAL IS TAKEN TO BOILER BY HOT+COLD PRIMARY AIR
  48. 48. Mills (Bowl Mill)
  49. 49. BOWL MILL : Coal discharge Coal from bunker Classification Hot Air Damper Hot Air of desired Gate fineness Coal Hot Air Duct Dropping of undesired coarse Coal Classifying System Scraper Housing Cold Air Pulverized Coal Air flow Door Inspection Gear Housing Coal Mill
  50. 50. BOILER: AIR & FLUE GAS PATH BUNKER PA FAN FEEDER APH ESP ID FAN BOILER MILL FD FAN C H I M N E Y
  51. 51. BOILER (200 MW) • Manufacturer: BHEL, CE Design • Type: Natural circulation, Balance draft, Corner fired, Tilting, Tangential
  52. 52. DPNL SHTR Platen SHTR Drum Reheater S C R E E n Gooseneck LTSH Chimney Downcomer waterwall Fireball Economiser ID fan APH Bottom Ash ESP
  53. 53. Water Walls
  54. 54. BOILER COMBUSTION DPNL SHTR Platen SHTR Drum Reheater S C R E E n Gooseneck LTSH Chimney Downcomer waterwall Fireball Economiser ID fan APH Bottom Ash ESP
  55. 55. Header
  56. 56. Boiler Drum
  57. 57. M.S C.R.H 500mw H. R. H FROM F.R.S BOTTOM RNG HDR& Z-PANEL 1ST PASS W.W O/L HDRS 2ND PASS UPPER C-HDR 1ST PASS W.W ROOF I/L HEADER 2nd PASS LOWER C-HDRS LTSH I/L HEADER LTSH O/L HEADER D.P.I/L HEADER D.P.O/L HEADER S.H. HEADER R.H.HEADER 2 ND PASS ROOF O/L HDR(REAR ECONOMISER
  58. 58. Air Preheater
  59. 59. Boiler circuit with Precipitator
  60. 60. ELECTROSTATIC PRECIPITATOR
  61. 61.  ESP -Working Principle
  62. 62. SCHEMATIC DIAGRAM Electrostatic Precipitator 415 V 3 Phase Supply C A C A C Electronic Controller High Voltage Rectifier Transformer Electrostatic Precipitator
  63. 63. Electrostatic Precipitator (ESP) No of Fields No of Hoppers Dust Concentration (I/L) (O/L) Efficiency Key equipments : 48 : 96 : 63.1 gm/NM3 : 40 mg/NM3 : 99.937% : ERM, GDRM,CERM heaters, Collectors & Emitters
  64. 64. Chimney
  65. 65. PLANT-1
  66. 66. BASIC WATER & STEAM CYCLE OF POWER PLANT RYB HPT IPT LPT EXC S H R R H H GEN. S H COND LTSH CEP ECO LPH 1,2,3 BOILER BFP HPH 5,6 DEARATOR
  67. 67.  Steam power plants operate on Modified Rankine Cycle, DM water as working fluid. w/w  Sensible heat is added in Heaters + economiser  Steam generation takes place in waterwall.  Heat transfer in furnace and enclosed superheater takes place thru radiation. HPH+Eco T SH RH HPT IPT BFP LPT LPH CEP condenser S
  68. 68. MAIN PLANT TURBINE THREE CYLINDER: HP,IP AND LP CYLINDER ROTATES AT 3000 RPM (DECIDED BY GRID FREQ AND GENERATOR POLE) n=120f/P n=speed, f=frequency of grid, P=no of poles of generator
  69. 69. TURBINE • HP TURBINE (SINGLE FLOW) • IP TURBINE( DOUBLE FLOW) • LP TURBINE (DOUBLE FLOW) NO OF STAGE (200 MW Turbines) • HP TURBINE (25 STAGE) • IP TURBINE( 20+20 STAGE) • LP TURBINE(8+8 STAGE)
  70. 70. HP TURBINE (SECTIONAL VIEW)
  71. 71. HP turbine rotor….
  72. 72. HP turbine inner casing….
  73. 73. Work Done in Turbine….
  74. 74. IP Rotor….
  75. 75. IP Inner casing
  76. 76. IP Outercasing
  77. 77. LP Turbine
  78. 78. Layout of Turbine-Generator HPT IPT LPT TG Bearings Generator TG Bearings
  79. 79. Condenser
  80. 80. Condenser Hot well
  81. 81. GENERATOR
  82. 82. Magnetic field around a current carrying conductor and Direction of the field
  83. 83. B(Φ) N N N N S S 2πr SS Rotor field and its traveling with rotation
  84. 84. Generator S N
  85. 85. Generator S S δ S N N N Load angle δ Locking of stator and rotor fields -*- δ between rotor field & resultant field
  86. 86. Rated parameters: Maximum continuous KVA rating 247 MVA Maximum continuous KW rating 210 MW Rated Terminal Voltage 15.75 KV Rated Stator Current 9050 A Rated Power Factor 0.85 Lag Excitation voltage at MCR condition 310 V Excitation current at MCR condition 2600 A Excitation voltage at no load 102 V Excitation current at no load 917 A Rated speed 3000 RPM Rated frequency 50 Hz.
  87. 87. November 26, 2013 PMI Revision 00 103
  88. 88. 1. STATOR WATER SYSTEM 2. SEAL OIL SYSTEM 3. H2 GAS SYSTEM 4. EXCITATION SYSTEM***
  89. 89. H.T. MOTORS
  90. 90. Cold Air I/L External fan mounted at fan NDE side
  91. 91. BFP ( Stage I) CW I/L CW O/L 2 no. of Coolers Cooling fan 2 no.s (DE/NDE) mounted on motor shaft
  92. 92. MAIN PLANT GENERATOR & GENERATOR TRANSFORMER 15.75 KV GENERATOR OUTGOIN G LINE 400 KV GENERATOR TRANSFORMER CIRCUIT BREAKER 400 KV BUS IN SWITCHYARD
  93. 93. Generator Transformer
  94. 94. Korba Vindh’l -1A K-Bhilai-1 K-Bhilai-2 K-Bhatapara Tie Transf # 4 K-Korba (W) K-Birsingpur -1 & 2 Korba-Vindh’l -2 K-Sipat Bus Section G Unit # 3 200MW G Unit # 2 200MW G Unit # 1 200MW G Tie Trans# 1 Unit # 4 500MW G Unit # 5 500MW G Tie Trans#2 Unit # 6 500MW G Tie Trans#3 Unit # 7 500MW Under Construction Proposed
  95. 95. Switchyard
  96. 96. Circuit Breaker
  97. 97. Isolators
  98. 98. Switchyard One line Diagram Transfer Bus 400 KV Main Bus II Main Bus I Bus Isolator CB GT 20.5/400KV Gen Bay CB CB Transfer Bus Bay Feeder Bay
  99. 99. Western Region Power Map KORBA
  100. 100. NTPC Korba CW/CT system at a glance 126
  101. 101. CW scheme… Reservoir/ River Canal Intake Trash rack Cooling tower TWS CT pumps Hot Pond CW pumps Condenser
  102. 102. Open Cycle Stage-II Stage-I 3X500 MW CT- II 3 X 200 MW CWPH-I Hasdeo Barrage RBC Darri Gate open Pragat i Nagar Regula tor CWPH-II Hot pond Emergency Exit CT- I Charpara Cross Regulator open
  103. 103. Total Closed Cycle Stage-II CT- II Stage-I 3X500 MW Hasdeo Barrage RBC Darri Gate open for makeup 3 X 200 MW CWPH-I Pragati Nagar Regulator CWPH-II Hot pond CT- I Charpara Cross Regulator totally closed
  104. 104. Induced Draft Cooling Tower
  105. 105. Natural Cooling Tower
  106. 106. Partial Closed Cycle Stage-II CT- II Pragati Nagar Regulator Stage-I 3X500 MW Hasdeo Barrage RBC Darri Gate partially open. 3 X 200 MW CWPH-I CWPH-II Hot pond Emergency Exit CT- I Charpara Cross Regulator Partially open
  107. 107. ASH GENERATION AND CLASSIFICATION CHIMNEY COAL BUNKER BOILER ECO /APH HOPPERS ESP HOPPERS MILLING SYSTEM BOTTOM ASH COARSE ASH FLY ASH
  108. 108. Ash volumes and properties Furnace ESP (1300 - 1500°C) Eco nom izer 100 % Fineness Bottom Ash 10-20 % Eco Ash APH Ash 1% 1% Stage A: 80 % Stage B: 17 % Stage C: 3 % APH Pulverized Coal Coal Electrostatic Precipitator S t a c k Fly Ash 80-90 % Ash 134
  109. 109. Ash Dyke ASPs Overflow BATPs
  110. 110. ASH FLOW DIAGRAM (AS PER DESIGN) Stage –II ASPH Booster ASPH ASP 5A 5B 5C BASP Stage- II ASL # 5 4A 4B 4C 3B 3C ASL #3 2A 2B 2C 1A 1B 1C 1A ASL #4 3A 2A ASL#2 ASL#1 ASP 4 3 2 STAGE-I ASPH 1 Stage -I 1C 1D 2B 2C 2D 3B 3C 3D 4A 4B 4C 4D 5C 5D 5A ASL # 1 ASL#3 1B 3A ASL # 2 ASL#4 Dhanras dyke ASP : BASP : ASL : BASL : 5B Ash Slurry Pump Booster Ash Slurry Pump Ash Slurry Line Booster Ash Slurry Line BASL #1 BASL #2 BASL #3 BASL #4 BASL #5 Dhanras Ash Dyke
  111. 111. Escape channel to Kasai nala TP-6 BOOSTER PUMP HOUSE N Overflow Lagoon TP-8 TP-7 LAGOON-II Return water to BPH ( 3 lines) Normal spillway Emergency discharge (below spillway) TP-5 MOHAN TALKIES ‘X’ ROAD BULGI ‘X’ ROAD PTSPlant ROAD TP-4 TP-3 FCI ‘X” TP-2 TP-1 To BCPP MGR ‘X’ D C Stg.II Ash Slurry P/H KORBA KATGHORA ROAD POINT A B C D TP-1 TP-2 TP-3 TP-4 TP-5 TP-6 TP-7 TP-8 TP-9 Distance from Stg.II ASPH (meters.) 00.0 28.0 560.0 754.9 1091.9 1227.2 2007.4 2239.6 3717.5 8379.1 9506.3 12305.0 13739.0 Elevation 289.4 291.4 299.2 300.2 298.2 297.5 300.9 298.0 297.5 302.8 315.7 323.0 340.0 LAGOON-I TP-9 End Point & Starting of garlanding B A KSTPS Plant Area Ash Pipe route to Booster pump house and to Dhanras Dyke Hasdeo river
  112. 112. DHANRAS ASH DYKE WHITE HOUSE 889 938 865 847 779 810 774 915 721 998 ASH LINES 684 54321 1 WELL 5 LAGOON-II 3 R W 2 657 4 L SPILLWAY P.N.330 1942 LAGOON-IB LAGOON-IA P.N.6 1977 268 258 TOTAL VALVE-32 INDEX * P.N.6 P.N.236 P.N.39 P.N.58 P.N.88 P.N.1666 RIVER HASDEV P.N.188 * * * * DATE-
  113. 113. ASH LAGOON 139
  114. 114. A6 A12 A18 A24 FLY ASH EVACUATION DRY MODE Basic scheme for one ESP pass Air and Seal water exhaust to atmosphere A1 A7 A13 A19 VACUUM PUMPS A1 , A2 BGF BGF-Bag filter BUFFER HOPPER TACs AIR LOCK TANKS A1 , A2 ASH Transportaion lines to Silo
  115. 115. November 26, 2013 PMI Revision 00 143
  116. 116. How Generated electricity reached customer

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