This document is a report submitted by Khagesh Kumar Chandra detailing his vocational training project at the NTPC Limited Sipat Super Thermal Power Station from June 21, 2012 to June 18, 2012. The project involved gaining an overview of the power plant including topics like super critical technology, basic power plant equipment and operations, boilers, turbines and their maintenance. Khagesh thanks the guides and HR department for organizing the training program and declares the report contains his original work.

1. VOCATIONAL TRAINING PROJECT WORK
PROJECT TITLE: SIPAT SUPER THERMAL POWER STATION
DURATION: FROM 21/06/2012 TO18/06/2012
DETAILS OF STUDENT:
NAME: KHAGESH KUMAR CHANDRA
ROLL NO: 3353710033
COLLEGE: SSITM, BHILAI
YEAR: 2012
PROJECT LOCATION:
NTPC LIMITED, SIPAT
DISTT: BILASPUR
CHHATTISGARH - 495555

2. ACKNOWLEDGEMENT
I am truly thankful to all the faculties/guides that imparted the
lectures on various subjects/topics and took us to the plants in
a guided study along with the detailed explaining about the
plant and the machinery.
I would also like to thank the Human resource department for
permitting and organizing the training program for us.
Signature
Date- 18/06/2012
Name- KHAGESH KUMAR CHANDRA
Roll no. - 3353710033
College- SSITM, BHILAI.
Branch- MECHANICAL
Year- 2012

4. CERTIFICATE
THIS IS TO CERTIFY THAT MR. KHAGESH KUMAR CHANDRA HAS
ATTENDED THE VOCATIONAL TRAINING PROGRAM FROM 18 may TO 21
June YEAR 2012 AND HAS PREPARED THE PROJECT REPORT.
HIS/HER CONDUCT HAS BEEN “GOOD” DURING THE RAINING
DURATION.
PROJECT GUIDED:
NAME
DESIGNATION
DEP/SECTION

5. DECLARATION
THE PROJECT WORK TITLED: SIPAT THERMAL POWER PROJECT
HAS BEEN CARRIED OUT AND THE REPORT PREPARED BY ME
DURING 21 may TO 18 June UNDER THESUPERVISION OF
GUIDES AT NTPC LTD/SIPAT SUPER THERMAL POWER PROJECT
AND ORGANISED BY EMPLOYEE DEVELOPMENT CENTER,
HUMAN RESOURCE DEPARTMENT.
THIS IS THE ORIGINAL WORK CARRIED OUT BY ME AND HAS
NEITHER BEEN TAKEN FROM ANY OTHER SOURCE NOR BEEN
SUBMITTED TO ANY INSTITUTE OR ORGANISATION AS A
FULFILMENT OF ANY OTHER CURRICULUM.
SIGNATURE
DATE: 18/06/2012
NAME: KHAGESH KUMAR CHANDRA
ROLL NO. : 3353710033
COLLEGE: SSITM, BHILAI
BRANCH: MECHANICAL
YEAR/SEM: 2ND
/4TH

6. PROJECT WORK
LOCATION: NTPC LTD, SIPAT
DURATION: FROM 21/06/2012 TO 18/06/2012
DISCIPLINE: MECHANICAL ENGINEERING
TOPICS COVERED:
1
.
Overview of power plant
2
.
Super critical technology
3
.
Power plant equipments
4
.
Boiler
5
.
Turbine and its maintenance
SIGNATURE
DATE: 18/06/2012

7. NAME: KHAGESH KUMAR CHANDRA:
ROLL NO. : 335371003
COLLEGE: SSITM, BHILAI
BRANCH: MECHANICAL
YEAR/SEM: 2ND
/4TH
INDEX
S.
No.
TOPIC
1. NTPC and its joint ventures
2. Super critical technology
3. Basic of power plant
4. Boiler
5. Turbine
6. Working of steam turbine

8. 7. condenser
8. Turbine maintenance
9.
10.
11.
oUR vISION:
”tO bE tHE

9. wORLD’S
lARGEST aND
bEST pOWER
pRODUCER,
pOWERING
iNDIA’S
gROWTH.”
NTPC limited
A maharatan company.

10. Established in November 1975 for the nation’s
sustainable power development.
Core business is engineering, construction and
operation of power generating plant and
providing consultancy to power utilities.
Listed on BSE and government of India holds a
stake of 84.5%.
Total installed capacity of 34194 MW (as on 31
march 2011) with 15 coal based & 7 gas based
station and set to become 1, 28,000 MW
company by 2032.
Capacity under construction 14740 MW
(approx) & PPA for more than 66000 MW.
With a share of 17.75% of India’s installed
capacity. Generates about 27.4% of India’s total
generation.|~|
Ranked 138th
position in Fortune 500 in 2009.
NTPC Limited and Its Joint Ventures

11. NTPC hydro is formed to enter into hydel
power sector.
NTPC Electric Supply Company Ltd is formed to
enter into power distribution & rural
electrification.
NTPC Vidyut Vyapar Nigam Limited formed for
power trading.
Bhartiya Rail Bijlee Company Ltd formed to
construct & operate power plants for railways.
Three joint Venture Company with SAIL to
operate and maintain its captive power plants.
To sustain the generation NTPC Ltd is also
foraying in to coal mining.
JV with ALsthom Power Generation AG to take
up renovation and modernization of power
plants.|~|
Utility Power tech Ltd a JV with BSES to take up
construction, erection and supervision works in
power sector.

12. NTPC Tamilnadu Energy Company Ltd (JV).
Ratnagiri Gas & Power pvt ltd (JV).
Meja Urja Nigam pvt ltd (JV).
Aravali power company pvt ltd (JV).
NTPC-BHEL Power projects pvt ltd (JV).
SIPAT SUPER THERMAL POWER STATION
Sipat thermal power project is a cynosure of
power generation of India.
Situated in the vicinity of Bilaspur city.
Pioneer of adopting super critical technology in
India.
India’s first 765 KV transmissions.
Installed capacity 2890 MW
Stage 1-3*660 MW
Stage 2-2*500 MW
Water source – Hasdeo right bank canal

13. Coal linkage – Dipika mines, SECL.
WHY SUPER-CRITICAL TECHNOLOGY?
To reduce emission for each Kwh of electricity
generated: Superior Environmental.
1% rise in efficiency reduces the CO2 emission
by 2-3%.
The most economical way to enhance
efficiency.
To achieve fuel cost saving: Economical
Operating Flexibility.
Reduces the boiler size/MW.
To reduce start-up time.

14. Basics of a thermal Power Plant:

15. UNDERSTANDING SUB-SUPER CRITICAL
TECNOLOGY:

16. Water when heated to sub critical temperature,
pressure increases until it starts boiling.
This temperature remains constant till all the
water converted to steam.
When all liquid converted to steam than again
temperature starts rising.
Sub critical boiler typically has a mean (boiler
drum) to separate steam and water.
The mass of this boiler drum, which limits the
rate at which the sub critical boiler responds to
the load changes.

17. Too great a firing rate will result in high thermal
stresses in the boiler drum.
UNDERSTANDING SUPER CRITICAL
TECHNOLOGY:
When Water is heated at constant pressure
above the critical pressure, its temperature will
never be constant.
No distinction between the liquid and gas, the
mass density of the two phases remain same.
No stage where the water exists as two phases
and requires separation: No Drum.
The actual location of the transition from liquid
to steam in a once through super critical boiler
is free to move with different condition: Sliding
Pressure Operation.

18. BOILER DEFINITION:
Steam Boiler are defined as ‘Any closed vessel
exceeding 22.75 liters in capacity which is used
expressively for generating steam under
pressure and includes any mounting or other
fitting attaches to such vessel, which is wholly,
or partly under pressure when the steam is
shut off.
BOILER SPECIFICATIONS:
Controlled Circulation with Rifle Tubing, Dry
Bottom, Radiant Reheat, Single Drum, and Top
Supported, Balanced Draft Furnace. (BHEL)
Tilting, Tangential type firing.
Steam Generating Cap. Of 1675 T/Hr at 172 ksc
& 540o
c.
Furnace volume 16424 m3
.
Depth = 15.8m

19. Width = 19.2m
Efficiency = 84.4%
Sucks flue gas and Throws out via Chimney.
Creates Negative Pr. in Ducts & Furnace.
Maintain Furnace draft.
Double Suction & Single Discharge Radial Fan.
Arrangement of Main Boiler
Economizer (3 stage)
Boiler drum
Down comers & BCW pumps
Water wall & SCWs
LTSH
Divisional panel
Final SH
Reheater

20. Safety valves
Burner and igniters
BAHs
Economizer
Boiler economizers are feed-water heater in
which the heat from waste gases is
recovered to raise the temperature of feed-
water supplied to the boiler.
6o
c raise in feed water temperature, by
economizers corresponds to 1% saving in
fuel consumption.
220 C reduction in flue gas temperature
increases boiler efficiency by 1%.
Location and Arrangement:
Ahead of air-heater in 2nd
pass below LTSH

21. Following the primary super-heater
Counter-flow arrangement
Horizontal placement (facilitate draining)
Supported to prevent sagging, undue
deflection and expansion.
Stop valve and non-return valves
incorporated to ensure recirculation in
case of no feed-flow.
Ash hopper below as flue gas takes a
turn.
Boiler Arrangement:

22. Super heater Specifications:
LTSH Divisional
Panel
Platen Stage
No. of rubber 744 432 400
Outer Dia 44.5 44.5 54
Joining Butt Butt Butt
Max Steam
Temp
405K(H)
444K(P)
513K 553K

23. Max Gas
Temp
405(H)
469(P)
524K 629K
TURBINE AND ITS AUXILLARIES
Steam Turbines of following OEM’S are running
in NTPC
LMZ (Russia)
KWU, Siemens (Germany)
ABB-Alston (Germany)
GEC-Alston (UK)
SKODA, (chezkoslovakia)
MHI (Japan)
GE(USA)
ANSALDO(Italy)

24. TYPES OF TURBINE
IMPULSE TURBINE- In a stage of Impulse
turbine the pressure/enthalpy drop takes
place only in fixed blades and not in the
moving blades.
REACTION TURBINE- In a stage of Reaction
Turbine the Pressure/Enthalpy drop takes
place in both the fixed and moving blades.
WORKING OF STEAM TURBINE:
A steam turbine works on the principle of
conversion of high pressure & temperature
steam into high kinetic energy, thereby
giving torque to a moving rotor.
For above energy conversion there is a
requirement of converging/converging-

25. diverging sections.
Such above requirement is built up in the
space between two consecutive blades of
fixed of fixed and moving blades rows.
THURST BALANCING
Thurst bearing.
IP/LP double flow(axial thurst-nullified)
Balancing disc.
TURBINE LUBE OIL SYSTEM
MOP: when turbine speed is>2840 rpm,
MOP will take over
Turbine lube oil is supplied by MOP pr. Is
2.6 ksc.
MOPS also supply---1.governing oil 2.make
up to seal oil system 3.barring gear oil
4.oil for LP bypass.

26. AOP1: When turbine trips, AOP1 will come
into service if speed<2840rpm or header
pr<4.8ksc
AOP2: will come into service if pr<4.5 ksc or
AOP1 trips
EOP: if pr< 1.1 ksc, in case of total AC failure
JOP: cut in-510 rpm. Barring gear v/v-cut in
210 rpm, cut out 240 rpm.
Condenser (it is a heat exchanger)
Specification: 76mm of hg vacuum (-0.9 ksc
gauge pr) is maintained in condenser.

27. For maintaining vacuum we need:
CW flow (provided by CW p/p, CW flow
3000 m3
/hour)
Air evacuation system(ejectors & turbine
sealing system)
Reduce steam loading (load, any v/v to
condenser passing).
Dirty tube.
STEAM TURBINE
Generator rated speed 3000 rpm
Generator manufacturer Electrosila
No. of bleedings 8
Length of the turbine 36.362m
No. of stages
HPT 17
IPT 11x2

28. LPT1 5x2
LPT2 5x2
Total 59
TURBINE MAINTAINNACE
Steam Turbine Blading
Steam turbines produce power by converting
the energy in steam provided from a boiler
or heat recovery steam generator (HRSG)
into rotational energy as the steam passes
through a turbine Stage. A turbine stage
normally consists of a row of stationary
blading and a row of rotating Blading. The
purpose of the stationary blading is to direct
the flow of the passing steam to the Rotating
blading at the proper angle and velocity for
the highest efficiency and extraction of
Power. The purpose of the rotating blading is
to convert the directed mass flow and steam
Velocity into rotational speed and torque.
Stationary blading may be referred to as

29. nozzles, Vanes, stators, partitions, and
stationary blading while rotating blades may
be referred to as Buckets, blades, and
rotating blading. A turbine may have a single
row or stage of stationary and rotating
blading or may have multiple rows or stages
of blading.|~|
Why to go to location
regularly?
ALL PARAMETERS ARE NOT AVAILABLE IN UCB

30. PERSONAL RELATIONSHIP WITH EQUIPMENTS
PHYSICAL STATUS IS NOT KNOWN
TO IDENTIFY ABNORMAL BEHAVIOR
INSTRUMENTATION STATUS
LEAKAGES
Turbine
Main Turbine
HP
IP
LP
Turbine driven BFP
Points to check for
Abnormal sound
Vibration
Expansions

31. Leakages (Oil, Steam, Water)
Oil flows
Pressures and Temperatures
--------------|~|---------------