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

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  • Though India has got the largest coal reserves in the world (260 billion tonnes), but the quality is poor. If Grade A is best, E is worst; then Indian coal stand in grade D.
    What is the calorific value of Indian coal ?
    The Calorific value of Indian coal ranges from 4000-5000 Kcal/kg. Apart from low calorific value,  Indian coal suffers from high ash content (15-45 %) which is about 30-40%. The only good thing about Indian coal is its low sulphur content.
  • The quality of coal based on the carbon content are
    Grade A : Graphite–the highest and best quality
    Grade B : Anthracite
    Grade C : Bituminous
    Grade D : Lignite –Indian coal.
    Grade E : Peat
  • Bharat heavy electrical limited .
  • Electro Static Precipitator is used to remove minute ash particle through force induced by electronic charge.
    ESP are mandatory for power plants for Polution control.
  • Drag forse of super heated steem is 1.
  • A condenser is a device or unit used to condense a substance from its gaseous to its liquid state, typically by cooling it. In so doing, the latent heat is given up by the substance, and will transfer to the condenser coolant.
  • The turbo-generator forms the heart of a power plant.It is the most vital and expensive equipment of a power plant complex and is generally housed inside a turbo-generator building.A turbo-generator consists of a turbine,generator and other auxiliaries like condenser,pipelines carrying superheated steam etc. Turbo-generator falls under high speed rotary type machines and its capacity varies from 2 MW to 2000MW.
  • If lode angle should be zero then generator will be stopped and it create probllem on generation of power .
  • A substation is a part of an electrical generation, transmission, and distribution system, where voltage is transformed from high to low, or the reverse, or many other important functions.
  • The term switchgear, refers to the combination of electrical relays, fuses , circuit breakers, contactors etc used to isolate/ control electrical equipment.
    Switchgear is used both to de-energize equipment to allow work to be done and to clear faults downstream.
  • 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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