The document provides details about Vikash Baghel's vocational training report on thermal power plants at NTPC Korba in Chhattisgarh, India. It discusses the key components and processes of a thermal power plant including the coal handling plant, main plant components like the boiler, turbine and generator, the basic power plant cycle, and safety aspects. NTPC Korba has an installed capacity of 2600MW and uses coal sourced from local mines to generate electricity.

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NATIONAL THERMAL POWER CORP. KORBA (C.G.)
( SUBMITTED ON COMPLETION OF VOACATIONAL TRAINING AT
NTPC,KORBA )
VOCATIONAL TRAINING REPORT
ON
“THERMAL POWER PLANT”
SUBMITTED BY
VIKASH BAGHEL
EEE (7TH SEM)
CIT, RAIPUR
GUIDED BY
A.K. SHARMA
(J.E. OF NTPC, KORBA)

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Content:-
 Introduction
 Coal Handling Plant(CHP) :-
1. Coal source
2. Crushing
3. Pulverization
4. Furnace (burning step)
5. Ash handling plant (AHP)
Main Plant:- 1. Boiler
2. Steam
3. Turbine
4. Generator
5. Transformer
 Basic power plant cycle
 Safety
 Advantages
 Disadvantages

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INTRODUCTION:-
 NTPC is a Maharatna Company .
 Approved capacity – 2600MW.
 Installed capacity – 2600 MW.
 Location – Korba , Chhattisgarh.
 Approved investment – 2448.49 crore.
 Coal source – Kusmunda block , Gevra Mines.
 Water source – Hasdeo River.
 Beneficiary states - MadhyaPradesh , Chhattisgarh ,Maharashtra , Gujrat.

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COAL SOURCE:-
 In NTPC korba coal source take by Gevra mines and Kusmunda block through
trains & by road . And this coal size is approx 200mm.
 Koorba is connected to other parts of India through national and state highways.
The city is directly connected to Raipur, Bilaspur, Durg, Bhilai
Nagar, Rajnandgaon.
 Korba is also well with national highwys like NH200 etc.
 It is also connected to Champa, the nearest railway junction on the Howrah-
Nagpur-Mumbai line.
 The stations comes under South East Central Railway Zone. It is directly
connected to Bilaspur which the Divisional Headquarter by rail and road
through Katghora-Pali-Ratanpur

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NTPC limited :-
 Presently, NTPC generates power from Coal. With an installed capacity of 26,00 MW,
NTPC is the largest power generating major in the country. It has also diversified into
hydro powercoal mining ,power equipment manufacturing, oil & gas exploration,
power trading & distribution. With an increasing presence in the power value chain,
NTPC is well on its way to becoming an “Integrated Power Major
leading the nation’s power generation league, NTPC has remained committed to the
environment. It continues to take various pro-active measures for protection of the
environment and ecology around its projects. NTPC was the first among power utilities in
India to start Environment Impact Assessment (EIA) studies and reinforced it with
Periodic Environmental Audits.
 NTPC is the largest thermal power generating companyof India .A Public sector Company
wholly owned bygovernment of India. It was incorporated in the year 1975 to accelerate
power development in the country.Within a span of 30 years, NTPC has emerged as a
trulynational power company, with power generatingfacilities in all the major regions of th
e country.Contributing 26% of the country’s entire power generation. NTPC today lights
up every fourth bulb inthe country.With ambitious growth plans to become a56000MW
power company by 2017, NTPC the largest power utility of India has already diversified
into hydrosector. 18 NTPC stations have already been accreditedwith the ISO 14001
certification. In keeping with its wellfocused environment protection policy, NTPC has set
up a “Centre for Power Efficiency and Environmentalprotection” (CENPEEP) which
functions.Resourcecentre for development and dissemination of latesttechnologies in
environmental management. At present,Government of India holds 89.5% of the total
equityshares of the company and the balance 10.5% is held byFIIs, Domestic Banks,
Public and others. Within a span
 32 years, NTPC has emerged as a truly national power company.

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GROWTH OF NTPC’

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NTPC’ IN INDIA :-
Present installed capacity of NTPC is 47,228 MW (including 6,966 MW through
JVs/Subsidiaries).
 comprising of 44 NTPC Stations
 (18 Coal based stations)
 7 combined cycle gas/liquid fuel based stations.
 1 Hydro based station.

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Layout of NTPC :-

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WORKING OF A THERMAL POWER PLANT.
 Korba is connected to other parts of India through national and state highways. The city
is directly connected to Raipur, Bilaspur, Durg, Bhilai Nagar Rajnandgaon. Korba is also
well with national highwys like NH200 etc.
 Korba railway station is connected to Champa, the nearest railway junction on
the Howrah-Nagpur-Mumbai line.
 The stations comes under South East Central Railway Zone. It is directly connected
to Bilaspur which the Divisional Headquarter by rail and road through Katghora-Pali-
Ratanpur.
 The 50.7 km (32 mi) ,1,676 mm (5 ft 6 in) broad gaugewas constructed between 1953
and 1956, electrified in 1987 and 1988, and extended to Gevra Road railway station in
1988 and 1989.
 New line surveys of Indian Railway were taken during 2012 and 2013, and included a
line from Renukoot-Korba via Ambikapur Katghora and Korba-Ranchi. A Rankine
cycle with a two-stage steam turbine and a single feed water heater.
 The energy efficiency of a conventional thermal power station, considered salable energy
produced as a percent of the heating value of the fuel consumed, is typically 33% to
48%. As with all heat engines, their efficiency is limited, and governed by the laws
of thermodynamics. By comparison, most hydropower stations in the United States are
about 90 percent efficient in converting the energy of falling water into electricity.
 The energy of a thermal not utilized in power production must leave the plant in the form
of heat to the environment. This waste heat can go through a condenser and be disposed
of with cooling water or in cooling towers. If the waste heat is instead utilized for district
heating, it is called co-generation. An important class of thermal power station are
associated with desalination facilities; these are typically found in desert countries with
large supplies of natural gas and in these plants,

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Pulverizing :-
 A pulverized coal-fired boiler is an industrial or utility boiler that generates thermal
energy by burning pulverized coal (also known as powdered coal or coal dust since it is
as fine as face powder in cosmetic makeup) that is blown into the firebox.
 The basic idea of a firing system using pulverised fuel is to use the whole volume of
the furnace for the combustion of solid fuels.
 Coal is ground to the size of a fine grain, mixed with air and burned in the flue gas flow.
 Biomass and other materials can also be added to the mixture.
 Coal contains mineral matter which is converted to ash during combustion.
 The ash is removed as bottom ash and fly ash. The bottom ash is removed at the
furnacebottom.
 This type of boiler dominates the electric power industry, providing steam to drive large
turbines.
 Pulverized coal provides the thermal energy which produces about 50% of the world's
electric supply.
 The concept of burning coal that has been pulverized into a fine powder stems from the
belief that if the coal is made fine enough, it will burn almost as easily and efficiently as a
gas.
 The feeding rate of coal according to the boiler demand and the amount of air available
for drying and transporting the pulverized coal fuel is controlled by computers.
 Pieces of coal are crushed between balls or cylindrical rollers that move between two
tracks or "races."
 The raw coal is then fed into the pulverizer along with air heated to about 650 degrees F
from the boiler.
 As the coal gets crushed by the rolling action, the hot air dries it and blows the usable
fine coal powder out to be used as fuel.

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FURNANCE:-
 Controls semiautomatic furnaces and auxiliary equipment to produce carbon black by
partial combustion of crude oil, natural gas, or mixture of both
Notifies UNIT OPERATORS to start or shut down equipment.
 In units, such as reactors, quenchers, precipitators, cyclones, and filters to maintain
efficient production.
 Monitors pyrometers, recording meters, and other gauges to verify process conditions as
indicated by control panel instruments.
 Turns valves and moves switches on central control panel to regulate temperature,
pressure, and flow of fuel and air in reactors, and to transfer accumulated carbon black
through auxiliary units to produce carbon black of specified type and grade.
 Tours plant area to verify that equipment is operating as indicated by central control
panel.
 Records instrument readings in operating log and reports abnormal conditions to
supervisory personnel.
 Gives directions to crew during manual operation of equipment to maintain production or
verify accuracy of instrument zed controls.

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ASH COLLECTIONS:-
ASH HANDLING PLANT :-
 Ash handling refers to the method of collection, conveying, interim storage and load out
of various types of ash residue left over from solid fuel combustion processes.
 The most common types of ash include bottom ash, bed ash, fly ash and ash clinkers
resulting from the combustion of coal, wood and other solid fuels.
 Ash handling systems may employ pneumatic ash conveying or mechanical ash
conveyors.

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 A typical pneumatic ash handling system will employ vacuum pneumatic ash collection
and ash conveying from several ash pick up stations-with delivery to an ash storage silo
for interim holding prior to load out and transport.
 Pressurized pneumatic ash conveying may also be employed. Coarse ash material such as
bottom ash is most often crushed in clinker grinders (crushers) prior to being transported
in thrash conveyor system.
 Very finely sized fly ash often accounts for the major portion of the material conveyed in
an ash handling system.
 It is collected from bughouse type dust collectors, electrostatic precipitators and other
apparatus in the flue gas processingstream.
 Ash mixers (conditioners) and dry dustless telescopic devices are used to prepare ash for
transfer from the ash storage silo to transport vehicles.
BOILER:-
 A boiler is a closed vessel in which water or other fluid is heated.
 The fluid does not necessarily boil. (In NTPC, the term "furnace" is normally used if the
purpose is not to actually boil the fluid.)
 The heated or vaporized fluid exits the boiler for use in various processes or heating
applications, including water heating, central heating, boiler-bas bar power
generation, cooking, and sanitation.
 In order to fully understand what a given boiler needs for treatment, a basic study of its
supply water must be done first.
 Three types of impurities exist in all supplies and can cause a wide range of problems in
boilers and kilns.
 These impurities are suspended solids, dissolved solids, and dissolved gasses.
 Water picks up the impurities from the ground it contacts and the air through which it
falls.
 The type of impurity depends on contact time, and stream velocity.

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 The amount of rainfall and where the rain occurs on the watershed can and does result in
changes in the character of the water throughout the year.
 Water supplies typically come from one of two sources, ground water or surface water.
.
 A boiler or steam generator is a device used to create steam by applying heat
energy to water. Although the definitions are somewhat flexible, it can be said that older
steam generators were commonly termed boilers and worked at low to medium pressure
(1–300 psi or 6.895–2,068.427 kPa) but, at pressures above this, it is more usual to speak
of a steam generator.
 A boiler or steam generator is used wherever a source of steam is required. The form and
size depends on the application: mobile steam engines such as steam locomotives.

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.
Fig – boiler arrangement of thermal power plant

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STEAM GENERATOR:-
 Type of steam generator unit used in coal-fired power plants
 The steam generator or boiler is an integral component of a steam engine when
considered as a prime mover.
 However it needs be treated separately, as to some extent a variety of generator tapes can
be combined with a variety of engine units.
 A boiler incorporates a firebox or furnace in order to burn the fuel and generate heat.
 The generated heat is transferred to water to make steam, the process of boiling.
 This produces saturated steam at a rate which can vary according to the pressure above
the boiling water.
 The higher the furnace temperature, the faster the steam production.
 The saturated steam thus produced can then either be used immediately to produce power
via a turbine and alternator, or else may be furthersuperheated to a higher temperature.

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TURBINE:-
 A thermal power station is a power plant in which heat energy is converted to electric
power.
 In most of the world the turbine issteam-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 Ranking cycle.
 The greatest variation in the design of thermal power stations is due to the different heat
sources, fossil fuel dominates here, although nuclear heat energy and solar heat energy
are also used.
 Some prefer to use the term energy center because such facilities convert forms
of heat energy into electrical energy.
 Certain thermal power plants also are designed to produce heat energy for industrial
purposes of district heating, or desalination of water, in addition to generating electrical
power. Globally, fossil-fuel power stations produce a large part of man-made
CO2 emissions to the atmosphere, and efforts to reduce these are varied and widespread.
 The condenser condenses the steam from the exhaust of the turbine into liquid to allow it
to be pumped. If the condenser can be made cooler, the pressure of the exhaust steam is
reduced and efficiency of the cycle increases.
 Diagram of a typical water-cooled surface condenser.
 The surface condenser is a shell and tube heat exchanger in which cooling water is
circulated through the tubes. The exhaust steam from the low pressure turbine enters the
shell where it is cooled and converted to condensate (water) by flowing over the tubes as
shown in the adjacent diagram. Such condensers use steam ejectors or rotary motor-
driven exhausts for continuous removal of air and gases from the steam side to maintain
vacuum.

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 For best efficiency, the temperature in the condenser must be kept as low as practical to
maintain the lowest possible pressure.
BASIC POWER PLANT CYCLE:-
 The thermal (steam) power plant uses a dual (vapor +liquid) phase cycle.
 It is a closed cycle to enable theworking fluid (water) to be used again and again.
 Thecycle used is “Ranking Cycle” modified to includesuper heating of
steam, regenerative feed water heatingand reheating of steam Figure 1A shows this cycle
andis self explanatory.

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SAFETY:-
 Safe working and operation of any plant, machinery is first priority and it is a cumulative
effort of the manager, safety officer, head of department of concerned department,
supervisors and workers etc.
 This provides a better end result in minimizing the accidents.
 Finding out comparative result and performance of the team past few year accidents.
 Hence we need some techniques for measuring safety measures and to provide safety
measuring rating.
 Such type of rating and monitoring help to identify the weakness in implementation of
safety program in plant and providing a more strong safety program.
 The rating and measurement of safety performance is useful to all people in management
to know the progress of safety culture in their power plant .
 It provides and promotes safety in all incident like road safety, home safety, industrial
safety and safety at the sea and the sky.
 The industries are paying huge amount every year in terms of Workmen compensation,
wage and incentives and other benefits.
 Many insurance companies also pay the huge amount for accident injuries, deaths, and
property damage.
 In how if they know the real measurement of safety performance they may try to suggest
necessary safety measures to reduce the premium amount.
 Quantitative monitoring is more powerful tool to identify the severity of accident.
 This gives a proper value and clear indication about the most and least unsafe work in
terms of safety.
 Along with it also gives information about the money and man -days lost due to
accidents.
 This will help us to concentrate on that area that needs more attention and to provide
remedial action to stop or minimize the various losses due to accidents.
 In this work we are focusing on the quantitative measures of various safety performance.

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ADVANTAGES:-
 The fuel used is quite cheap.
 Less initial cost as compared to other generating plants.
 It can beinstalled at any place iirespective of the existence of coal. The coal can be
transported to the site of the plant by rail or road.
 It require less space as compared to Hydro power plants.
 Cost of generation is less than that of diesel power plants.
DISADVANTAGES:-
 It pollutes the atmosphere due to production of large amount of smoke and fumes.
 It is costlier in running cost as compared to Hydro electric plants.