The Vindhyachal Thermal Power Station is located in Singrauli district in the Indian state of Madhya Pradesh. One of the coal-fired power stations of NTPC, it is the largest power station in India, with an installed capacity of 4,760 MW. The coal for the power plant is sourced from Nigahi mines, and the water is sourced from the discharge canal of Singrauli Super Thermal Power Station

1. Vocational Training report on:
VINDHYACHAL SUPER THERMAL POWER PLANT (4260 MW)
Submitted by :
Vinay Vishwakarma
Diploma Electrical
6th Semester

2. Acknowledgement
With deep reverence and profound gratitude I express my sincere thanks to Mr. Atul
Markhedkar, AGM (EMD) for giving me an opportunity to do training at
NTPC/VSTPP. Ialso would like to thank Mr. K.L. Barange, (EMD) who has helped
me at the working sites, explaining and giving me all the information I needed to
complete this report. I am also very much thankful to Mr. Vishnu Sen Assistant
General Manager(EMD), for helping me throughout the training. At last I would like
to convey my thanks to all the members of the staff of NTPC who have helped me at
every stage of training.
Training Period: 30 Jan 2015 to 13 Feb 2015.

3. INTRODUCTION
NTPC is the largest thermal power generating company of India. Vindhyachal
Thermal Power Plant is located in Singrauli at the state of Madhya Pradesh. This
Power station is one of the coal based plant of NTPC. It is one of the largest power
stations in India with installed capacity 4260 MW and one unit is in under construction.
The Coal is sourced from Nigahi Coal Mines and Dudhichua Mines. Sourceof Water is
taken from discharge of Singrauli Super Thermal Power Plant. The first unit of 210
MW plant is commissioned in 1987 by Russian support. Total land acquired is 6178
acres.
PROJECT COST
The approved costof Stage-I (6X210 MW) is Rs. 1460.37 crore with the per financing
by erstwhile USSR assistance amounting to 303.66 Million rouble.
The approved costof stage-II (2 X500 MW) is Rs. 2702 Crore. International assistance
from IBRD time-slice loan of US $ 400 Million has been utilized for part financing of
stage-II.
The approved costof stage-III (2 X 500 MW) is Rs.4125.00 Cr.
Vindhyachal is accredited with ESHQ (Environment Safety Health & Quality) for
following Environment management systems, Safety & Occupational Health
management systems & Quality management systems.

4. Stage
Unit
Number
Capacity (MW) Date of Commissioning
1st 1 210 1987 October
1st 2 210 1988 July
1st 3 210 1989 February
1st 4 210 1989 December
1st 5 210 1990 March
1st 6 210 1991 February
2nd 7 500 1999 March
2nd 8 500 2000 February
3rd 9 500 2006 July
3rd 10 500 2007 March
4th 11 500 2012 June
4th 12 500 2013 April
5th 13 500 Under construction
Total Thirteen 4760
5th stage is in under construction will complete on January 2016.

5. FLOW CHART OF 210 MW VINDHYACHAL SUPER THERMAL
POWER STATION
Power plant is divided into 3 cycle, they are:-
1. Fuel Cycle
2. Water Cycle
3. Steam Cycle
FUEL CYCLE
1. Coal Preparation from coal mill to boiler :
Fuel Preparation system: In coalpower plant, the raw feed coal from the coal
storage area is first crushed into small pieces and then with the help of conveyor
belt , it transfer to the hopper at the boiler. The coal is next pulverized into a very
fine powder, So that coal will undergo complete combustionduring combustion
process.

6. ** Pulverizer is a mechanical devices for the grinding of many different types of
materials. Forexample Coal is converted into Powder form.
2. Dryers : This is used to remove moisture from coal mainly wetted during
transport.
Presence of moisture in coal will result fall in efficiency of a plant and also emit
CO gas.
3. Magnetic Separator : It is used to separate the coal and magnetic material like
Iron or any other metal which is going to coalmill.
INDUCTION MOTOR used in COAL MILL
Duty Continuous
KW 525
Stator Volts 3300
StatorAmps 129
RPM 984
Frequency Hz 50
Phase 3
Power factor 0.9
Weight 5750 Kg
Rotortype Squirrel Cage
ECONOMISER
It is located below the LPSH in the boiler and above preheater. It is there to
improve the efficiency of boiler by extracting heat from flue gases to heat water
and send it to boiler drum.
Advantages of its :-
a. Fuel economy- used to save fuel & increase overall efficiency of boiler plant.

7. b. Reducing size of boiler- as the feed water is preheated in the economizer & enter
boiler tube at elevate temperature.
HEATER’S
1. Air Preheater – The heat taken out with the flue gases. It is a necessary
equipment for supply of hot air for drying the coal in pulverized fuel systems to
facilitate grinding and satisfactory combustion of fuel in the furnace.
2. Reheater- this section containing tubes heated by hot flue gases outsides the
tubes. Exhaust steam from the high pressure turbine is rerouted to go inside the
reheater tubes to pick up more energy to go drive intermediate or lower pressure
turbines.
3. Platen Superheater- Flat panels of tubes located in the upper part of the
furnace, where the gas temperature is high and receive very high radiation as well
as a heavy dust burden.
PLATEN SUPERHEATER AIR PREHEATER
The major Fan used in this plant are :-
4. Induced Draught Fan : The main function of the ID FAN is to suck the flue
gases coming out of the furnace via economizer, air heater and also collect the
ash particles and release into a atmosphere with the help of chimney.
Synchronous Motor is used in ID fan and rating are :-

8. KW -4525, PF-0.95 lead ,RPM- 580, Stator Volt -2*2300, Exct. Volt - 87 V,
Insln class- F, Phase -2*3, Hz -48.33, Connection- double star, Stator amps-
2*622 A, Weight -31000 kg.
5. Forced Draught Fan :For the burning of any substanceOxygen in needed. In
that way FD fan provides the Oxygen inside a boiler by which the coal
continuously burn and heats the water to convert into steam.
Induction Motor is used in FD fan
Duty – Continuous, KW – 1650, Stator volts – 11000, Stator amps- 106, RPM-
996, Phase-3, stator connection- star, Rotorconnection- -, Rotortype- Cage,
Insulation class-F, Weight- 11500 kg, Year- 2013.
6. Primary Air Fan : The main purposeof this fan is to create high pressure to
send pulverize coalinto the boiler to producea heat.
Induction motor is used in PA fan
Duty-Continuous, KW- 3500, Stator volt-11000, Stator amps-211, RPM-1495,
Phase-3, Hz-50, Insln class- F, PF-0.90 lag, efficiency-96.7%, Weight-15500 kg,
Rotortype- Cage type, Stator connection – star, RotorConn- .
FD fan PA fan

9. ELECTROSTATIC PRECIPITATOR
An Electrostatic Precipitator is a filtration device that removes fine particles, like
dust and smoke , from a flowing gas.
WATER CYCLE
HOT WELL OR STORAGE TANK
Hot well is storage tank where the water is stored and from where the water cycle is
starts. It is also a place where condensewater finally comes .After the steam process ,
hot water is discharge from here and taken out to cooling tower and then the water is
suck by Hot well .And the process continues.
Condensate Extract Pump CEP: A CEP is a specific type of pump used to
pump feed water into a steam boiler and also rising the temperature and pressure of a
water.
Main Ejector : The injector was originally used in the boilers of steamlocomotives for
injecting or pumping the boilerfeedwater into the boiler.
Low Pass Heater LPH : There are three LPH’s . Here the Temperature and Pressure
of water are rises up to 120 degree Celsius and 450 Kpa respectively. And outlet of this

10. is send to the Dearator which is kept in the height of about 45 meter from
ground.Dearator is tank in which hot water and steam is stored. Generated steam is
directly sent to boiler drum.
Boiler Feed Pump BFP:It is just after Dearator which provides high pressure180
Kg/cm2 to water. It is pump which is coupled with a motor.
High Pressure Heater HPH : It provides high temperature to hotted water up to 300
degree Celsius and feed to the boiler drum.
Boiler
1. A Boiler and Steam generator essentially is a container into which water can be
fed.
2. Water is converted into steam and can be taken out at desired Pressure,
Temperature, and Flow.
3. For this purposeboiler should have a facility to burn a fuel and release the heat.
The main function of boiler is stated as below :-
1. To convert chemical energy of the fuel into heat energy.
2. To transfer this heat energy to water for evaporation as well to steam for
Superheating.

11. Basic Component of Boiler
1. Furnace and Boiler
2. Steam and Superheating
a. Platen Super heater
b. Final Super heater
c. Reheater
d. Economizer
Steam Cycle
Boiler drum and function after that :-
 Feed Water is converted into Steam at very high Temperature about 540 degree
Celsius.
 Then steam is passes from Platen super heater and super heater, where it is totally
converted into dry steam.
 Under High Pressure and Temperature it is fed into High Pressure Turbine where
we get desired output .

12.  Rest steam is recollected and passing from Reheater and it provides 540 degree
celsius .
 At this temperature, it is passes from Intermediate Pressure Turbine and rest from
Low Pressure Turbine.
 Turbines Rotates and Generator is coupled with Turbine Shaft.
 And finally Generator generates a Electricity.
Steam Turbine
 A Steam Turbine is a device that extracts thermal energy from pressurized steam
and uses it to do mechanical work on a rotating shaft.
 And main output shaft is coupled with Electrical Generator shaft.
 Rated Output :500 MW
 Rated Speed :
 Steam Pressure :
 Steam Temperature : 540 degree Celcius
 Direction of Rotation : Clockwise
3 Turbine are always used in plant for increasing the efficiency
1. High Pressure Turbine
2. Intermediate Pressure Turbine
3. Low Pressure Turbine
Condenser
Condenser is basically a heat exchanger which condenses a steam and
converted into water. After expansion of steam in LP turbine it enters in the
condenser. In condenser there are many water tubes are provided to
condensate the steam.
Cooling tower
 The hot water from condenser outlet reaches to cooling tower.
 Cooling towers are evaporative coolers to remove the heat of water so that water
can be recirculating & can be reused.
 This heat of water is rejected to the atmosphere by evaporation.
 In NTPC modern types cooling tower uses in which cooling fan (suction) is
required to remove the heat of water.

13. Turbo generator is used in VSTPS.
Stage 1 means for 210 MW unit.
Specification :
 Rated Voltage: 15.75 kV
 Rated Power: 210 MW
 Rated KVA : 247 MVA
 Stator Current: 9067 A
 RotorCurrent: 2640 A
 Frequency: 50 Hz
 Connection: YY (DOUBLE -STAR)
 Power Factor: 0.85 LAG
 Rated H2 Pressure: 4KgF/cm2
 Operational Duty: S1
 Class of Insulation: B
Stage 2 means for 500 MW
 Rated Power: 500 MVA
 Rated KVA : 588MVA
 Stator Voltage: 21 kV
 Stator Current: 16200A
 Rotorcurrent: 4040A
 Rotorvoltage: 340V
 Rated H2 pressure: 3.5 bar(g)
 Power factor: 0.85 lag
 Stator winding cooling: Direct
water cooling(DM water)
 Stator core and rotor
 Cooling: Direct H2 cooling
 Rated Speed : 3000 rpm
 Frequency: 50 Hz
COOLING SYSTEM of GENERATOR
 Generator’s Rotoris cooled by Hydrogen Gas.
 Stator is cooled by Demineralized Water and Cooling Oil.
TRANSFORMER
As you well know that in generating station Step up Transformer is used.
For stage 1 : 15.7 KV is step up to 210 MW.
For stage 2: 21 KV is step up to 500 MW.
And this is known as Generator Transformer.
Major transformers in a power station
 Unit Auxiliary Transformer UAT
 Station Transformer
 Interconnecting Transformer ICT
 Construction Power Transformer CPT

14.  1.UAT Unit Auxiliary Transformer : The UAT draws its input from the main
bus ductconnecting generator to the generator transformer. It is used for the
working of large devices such as boilers, heavy motors etc. It uses the generated
15.75kV to convert into 6.6 kV in stage I and 21kv into 11kv & 6.6kv .This
supply is consuming by heavy motors, Switchgear, ESP, etc.
 2. Station Transformer : If a power of plant is fail . Then from other grid
power is taken to charge a 6.6 KV busbarfor the safety of turbine and generator
shaft. Because at high speed if a power gone, then by instantaneous change some
distortion will occurs on shaft.
 3.Interconnecting Transformer :It connects 400KV substation to 132 KV
substations.
 4. Construction Power Transformer : This is the transformer which gives the
output for construction in which the voltage required is 220 V.
Buchholz Relay

15. SWITCHYARD
It is a switching station which has the following credits:
 Main link between Generating plant and Transmission system, which has a large
influence on the security of the supply.
 Step-up and/or Step-downthe voltage levels depending upon the Network Node.
 Switching ON/OFF Reactive Power Controldevices, which has effect on Quality
of power.
Switchyard Equipment are:-
Transformer ,Circuit Breaker, Isolator, Instrument Transformer, Earth Switch,
Lightning Arrestor, Overhead Line, Wave Trap, Capacitor Voltage Transformer.
SWITCHGEAR
• Switchgear is one which makes or breaks the electrical supply. It operates in low
voltage.
• This is the protection device which control the equipment or machine ( either
heavy or small ) in the power system.
Switchgear Equipment are :-
Isolators, Switching Isolators, Circuit Breakers, Load Break Switches, Earth
Switch, Relays.

16. REACTOR
Reactors are also a transformer which is providing or consuming reactive power
which is occurring by Ferranti Effect.
Reactors connection are of two types :
 Series Reactor are used to controloverhauling current.
 Parallel Reactorare used to control over or under voltage which is producing
by Ferranti Effect.
BATTERY ROOM
The 220V DC system supplies direct current as sourceof operating power for
control, signaling, relays, tripping and closing of switchgears, emergency
motors of most important auxiliary systems.

17. Battery Room Reactor
CONCLUSION
The training at NTPC Vindhyachal was altogether an exotic
experience, since work, culture and mutual cooperation was excellent
here. Moreover fruitful result of adherence to quality control awareness
of safety and employees were fare which is much evident here.
Thank You.