NTPC

KHAHALGAON

PROJECT REPORT
BY:-NEERAJ KUMAR MAHESH
CIVIL ENGINEERING
ROLL NO:-15120
REG NO:-15101108021
 CONTENTS

 Introduction
 Coal Handling
 Boiler & Auxillary
 Turbine System
 Ash Handling
 Off- site
 NTPC OPERATION &MAINTENANCE

 Boiler Maintenance Department

 Turbine Maintenance Department
 Ash Handling Departament
 Off-site Maintenance Departament
 INTRODUCTION

India’s largest power company ,NTPC was set up in 1975 to accelerate

power development in india.NTPC is emerging as a diversified power
major with presence in the entire value chain of the power
generation
,which is the mainstary of the company ,NTPC has already ventured
into consultancy.power trading,Ash utilisation and coal mining

kahalgaon super thermal power station (khstpp) is located in kahalgaon

in Bhagalpur district of bihar.The power plant is one of the coal based
power plant of NTPC.
CAPACITY :- The Total installed capacity of the plant is 2340 mw.
 NTPC, Khstpp Project
Location : Kahalgaon ,Dist-Bhagalpur(Bihar),813214
Total Land : 3,360 acres
Land for plant : 883 acres
Land for township : 432 acres
Land for Ash dyke :1395 acres
Configuration : stage -1 (4*210 MW)
: stage -2: phase 1 (2*500 MW)
: Phase 2 (1*500 MW)
Sourse of coal : Rajmahal coal field of ECL
Fuel Requirement : 4.1 million ton per year stage -1
: 6.62 million ton per year for stage
-2
: 3 million ton per year for stage -2
Sourse of water : Ganga River
 NTPC

Make of water Requirement : 7500 m3/hr (stage-1)

: 6000 m3/hr (stage-2)
Cooling water system : closed cycles induced Draft
cooling tower
Approved capacity : stage 1. 840 mw + stage 2. 500 mw
Commersilation :unit 1.-(210 mw) march ,1992
: unit 2.- (210 mw) march, 1994
: unit 3.- (210 mw) march ,1995
: unit 4.- (210 mw) march , 1996
:unit 5.-(500 mw) march ,2007
:unit 6.- (500 mw) march ,2008
: unit 7- (500 mw) june, 2009
 Coal Handling System Equipment
 Wagon Trippler
 Conveyor Belt
 Pulleys
 Take Ups
 Skirt Board
 Scrappers
 Magnetic seprator
 Vibrating screen
 Crushers
 CRUSHERS
To crush the coal from 200mmto 20mm size received
from vibrating screen
Crusher hammer are made of MAGNEESE STEEL .
Hammer row -4(stage 1)
(a)Row-1 & 2 =18 hammer each
(b)Row-3&4=20 hammers each

No of hammer in each Crusher-

•stage-1 = 76 hammers
•stage-2 = 92 hammers
•Weight of each hammer=18.5kg
•Crushing motor rating -740kw/3.3kv
•Life of hammer =4 lac MT of coal
•N o r m a l capacity=600 tons/hr
PMI Re v ision 0 0 9
CONVEYOR
BELTS
Made of diff. Layers or piles of fabric duck with
rubber protected by a rubber cover on both sides &
edges.
Fabric duck are designed to withstand tension created
in carrying the load .
 Nylon rubber cover protect the fabric duck.

 Material =fire resistant

grade.
 Belt Width=1600 mm.
 Strength= 1000/1250 kN.
 Belt speed=3.2-3 m/s.
 Belt length=20km.

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  NTPC
PULLEYS

•Made of mild steel.

• Rubber coating is used to increase friction

• factor between belt & pulley (rubber lagging

•Shell dia-500mm.
•Shaft dia-1400mm.
•Pulley length-1800mm.
•Shaft length-2350mm(bearing centre to
centre)
PMI Revision 00 11
 DRIVE UNIT
 NTPC

 Motors coupled to reduction gear with the help

of flexible/fluid coupling on the high speed shaft of
the Gear box
 Flexible coupling on the input side

TAKE UPS
Take up pulley to facilitates –

Necessary tension for the drive to operate the belt

Sag at a point where requires horse power will be

at a minimum and load will move with least
disturbance over idlers
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  NTPC

SKIRT BOARD
Used with chutes at trail end.

Guides material centrally on the belt while loading

until it has settle down on the belt

SCRAPPERS

Placed at discharge pulley in order to clean the

carrying side of belt.
 It avoids the wear of return idlers due to build
up
material.

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 BOILER MAINTENANACE DEPARTMENT
 BOILER:-
 Steam generating device for specific purpose.
 Capable to meet variation in load demand.
 Capable of generating steam in a range of operating pressure and
temperature.
 For utility purpose ,it should generate steam uninterrupediy at
operating pressure and temperature for running steam turbine.
 BOILER/STEAM GENERATOR :-
 Raw material for design of boiler
 1.coal frommines 0 Generating heat energy
 2. Ambient air 0 Air for combustion
 3. Water from natutal resources (river ,ponds ) 0 Working fluid for
steam
generation possessing heat energy

 A 500 MW steam generator consumers about 8000 tonnes of coal every
day.
 It will be considered if it requires about 200 cubic meter of D M water
in a day
.
 BOILER AUXILARIES
There are three part of Boiler :-
1.Milling system
2.Rotatory part
3.pressure part
 1.MILLING SYSTEM:-
 Coal Bunker:- These are in process storage silos used for storing crushed
coal from the coal handling system .generally,these are made of welded steel
plates normally these are six such bunker supplying coal of the
corresponding mills
.Those are located on top of the mill so as aid in gravity feeding of coal.
 Coal feeder:- Each mill is provided with a drag link chain/rotary /gravametic
feeder to transport raw coal from the bunker to the inlet chute leading to mill
at desired rate .
 MILLS:- These are six mill (25persent capacity each) for every 200mw unit
,located adjacent to the furnace at (o) m level .There mills pulverise coal to
be desired fineness to be feed to the furnace for combustion.
 It is used to crush the coal into powder form (80 micron).These are 10
mills for the 500mw unit ,located adjacent to the furnace at o level .These
mills pulverised coal to the desined fineness to be fed to the furnace for
combustion.
 CLASSIFICATION OF MILLS

VERTICAL SPINDLE TUBE

BOWL/ PRESSURIZED
BALL & RACE

XRP E MILLS MPS

(BHEL) (BABCOCK)
 NTPC

2.ROTATORY PART :-
 P A Fan : The primary air fan (2 per unit -50 percent
capacity each ) are designed for handling atmospheric air
upto a temperature of 50 deg c .These fan are located at (0)
m level near the boiler .
 F.D Fan :- The forced draft fans (2 per unit -50 percent
capacity each) are designed for handling secondary air for
the boiler
.These fan are located at “o “ m level near the P A fan.
 I D Fan:- There are two indused Draft fans per boiler
located between the electrostatic precipitator and the
chimney . These fans are used for sucking flue
gas from furnace
 TURBINE MAINTENANCE DEPARTMENT (TMD)

 TURBINE :- A steam turbine is a rotating device which converts thermal

energy into mechanical energy.

 OPERATING PRINCIPLE :- A steam turbine has two main part -1) cylinder
(stater) and the rotor . The cylinder or rotor is a steel or cast iron housing
usually divided at the horizontal centre line.its havies are bolted together for
easy access .The cylinder contains fixed blade carred by rotor .each fixed
biade set is mounted in diphram located in front of each disc on the rotor or
directly in the casing . A disc and diphram pair a turbine stage.steam turbine
can have many stage the rotor is a rotating shaft carries the moving blades
.on the outer edges of either disc or drum . The blade rotate as the rotor
revolves
.The rotor of a large steam turbine consists of high intermediate ,low
pressure turbine section .
In a multiple stage ,steam at the high pressure and
high temperature enter s the first row of fixed blades or nozzle through an
inlet value .As the steam passes through the fixed blades or nozzles it
expands and its velocity increases the high velocity jet of steam strkes the
first set of moving blades.
1 2 3 4 5 6 7

HPT LPT
IP
T GENERATOR
EXCITER
THREE STAGE TURBINE :
• HIGH PRESSURE TURBINE (HPT)
• INTERMEDIATE PRESSURE TURBINE (IPT) CONDENSER
• LOW PRESSURE TURBINE (LPT)

SEVEN NOS JOURNAL BEARINGS

BEARING N0. 2 THRUST CUM JOURNAL BEARING

FOUR NOS RIGID COUPLINGS BETWEEN

• HP-IP TURBINE
• IP-LP TURBINE
• LP-GENERATOR
•GENERATOR - EXCITER
SINGLE STEAM FLOW OF TWO SHELL (CASING) DESIGN
OUTER CASING IS OF BARREL TYPE AND HAS NEITHER ON AXIAL OR RADIAL FLANGE. DUE
TO THE PERFECT SYMMETRIC DESIGN OF THE OUTER CASING AND UNIFORM WALL
THICKNESS AT ALL SECTIONS, PREVENTS MASS CONCENTRATIONS WHICH WOULD CAUSED
HIHG THERMAL STRESSES AND REMAINS LEAK PROOF DURING QUICK CHANGES IN
TEMPERATURE DURING START UP AND SHUT DOWN.

THE INNER CASING IS AXIALLY SPLIT IS ALMOST CYLINDRICAL IN SHAPE AS THE JOINTS
FLANGES ARE RELIEVED BY HIGHER PRESSURE ACTING FROM THE OUT SIDE.
CASING IS MADE OF CREEP RESISTING CHROMIUM-MOLYBDENUM-VANADUIUM (Cr-Mo-V)
STEEL CASTING.

THE TURBINE HAS 2 MAIN STOP VALVES (ESV) AND 2 CONTROL VALVES (CV)LOCATED
SYMMETRICALLY TO THE RIGHT AND LEFT OF THE CASING. THE VALVES ARE ARRANGED IN
PAIRS WITH ONE STOP VALVE AND ONE CONTROL VALVE IN A COMMON BODY. EACH ESV
AND CV HAS A DEDICATED HYDRAULIC SERVOMOTOR.

 THE STEAM LINES FROM ESV & CV ARE CONNECTED TO THE INLET CONNECTIONS OF
THE OUTER CASING BY BREECH NUTS.

 THE EXHAUST END OF HPT HAS A SINGLE OUT LET CONNECTION FROM BOTTOM.
 ASH HANDLING DEPARTMENT
WHAT IS ASH ?
Ash is the residue remaining after the coal has been
incinerated to constant weight under standard
conditions.
 Ash is oxidised form of the mineral matters present in

coal.
 Typical ash composition : SiO2, Al2O3, Fe2O3, CaO,

MgO etc.
 Coal with more SiO2 & Al2O3, Ash MP > 1400ºC

 Coal with more Fe2O3, CaO & MgO, Ash MP <

1100ºC
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WHY ASH HANDLING?

 Ash content of Indian coal used in power station is

about 30 to 40 %.
 A typical 2000 MW station produce around 9000T to

12000T of ash per day.

 This huge amount of ash needs to be disposed off

continuously.
 Necessary care to be taken for preventing

pollution

 Ash Handling system takes care the above requirement

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Fly Ash Handling System
FA is collected from Air heater hopper, Eco hopper and
ESP hopper.
 Either through flushing apparatus or hydrobactur

system.
In Flushing apparatus system ash is allowed to fall in
flushing apparatus under gravitation.
Water jet in flushing apparatus carries away the ash to FA
trench
 High pressure jets further carries it to FA sump.
 Series pumping carries the ash slurry to FA pond.

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Bottom ash Handling System
 BA can be collected at furnace bottom as Wet or Dry form.
 Wet bottom ash system consists of i)Trough seal, ii)BA

gate, iii)Hopper, iv)Scrapper Conveyer, v)Clinker grinder,

vi)BA trench, vii)BA tank, viii)BA pump, ix)BA pond.
 Dry BA consists of i)Trough seal, ii)BA gate, iii)Hopper,

iv)Scrapper Conveyer, v)Clinker grinder, vi)Silo.

 Trough seal : A channel around the furnace bottom

filled with water where the furnace bottom end is

immersed in water. This is to prevent air ingression in the
boiler during operation.

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Overburden Surge Pile

Coal Seam Pulverize (-150)

Electrostatic Precipitator Boiler

Flue Gas Flue Gas
Fly Ash
Fly Ash Bottom
Ash

Bottom
Fly Ash
Ash
Smoke
Stack

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Ash volumes and properties
Furnace ESP
(1300 - 1500 C)

Economizer Electrostatic Stack

Precipitator
Air
preheater
Pulverize APH
d

Stage A: 80 %
Coal

Stage B: 17 %
Stage C: 3 %
Coal Bottom Ash Eco Ash APH Ash Fly ash
100 % 10-20 % 1% 1% 80-90 % Ash
Fineness
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 OFF-SITE DEPARTMENT
 Water Treatment
 Cooling Tower
Why water treatment?
Raw water contains many dissolved minerals and
organic materials.
At high temperature certain minerals left scaling on
the tube metal of the boiler and cause permanent
damage.
Some dissolved minerals leads to corrosion of tube metals.
Some leads to foaming
At high pressure and temperature an element, silica can
be carried away with steam causing damage to turbine low
pressure stage.
A Thermal Power Station needs water of varying quality
for different process and hence the requirement.
The performance and life expectancy of the station
greatly depends on water chemistry compliance.
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Type of water treatment
the type of demineralization process chosen for a
power
station depends on three main factors :
The quality of the raw water.
The degree of deionisation i.e. treated water quality
Selectivity of resins.

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Steps of treatment process
Aeration of raw water
Adding chemicals for bacteria removal
Adding chemicals for sedimentation of
suspended particles
Flocculation
Filtration
Ion Exchange process
water treatment process is generally made up of
two sections :
Pretreatment section
Demineralisation section

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 Description Stage-I Stage-II
Tower Type Induced Induced
Draft Multi Draft Multi Fill
Fill Counter Counter Flow
Flow
Make M/S Gammon M/S NPCC
India Ltd.
Circulating water flow 30,000 33,000 M3/hr.
/ tower M3/hr./tower.
Hot CW inlet temp. 43oC 42oC
Cold CW Out let temp. 33oC 33oC
Range 10oC 9oC
 COOLING
FAN
Description Stage-I Stage-II
Type Axial Flow Axial Flow
No. of fans / tower 16 12
Diameter 24 feet 28 feet
No. of blade 6 7
Blade angle 13o 13o
Fan speed 151 Rpm 118 Rpm
Absorbed power 35 KW 56 KW
NTPC
 NTPC

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