ntpc korba chhattisgarh coal to electricity by tejasvi anant (tan 90')

A WarmA Warm

To AllTo All

NTPC

A Presentation on

NTPCCoal to Electricity

Prepared by - Tejasvi Anant (Mechanical)

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.

NTPC INSTALLED CAPACITY

Source – www.ntpc.co.in

KSTPS OVERVIEW

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

Stage Unit NumberInstalled

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

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.

KORBA A SUCCESS STORY……

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ANDROIDWINDOWS

SYMBIAN

BLACKBERRY

Clearance By Govt. Of India - Jan’1978.

Unit size, Stage-I 3 x 200+ Stage-II 3 x 500+

Stage-III 1 x 500, Total Capacity – 2600 MW.1st 200MW Unit commissioned - 1st Mar’83

(in 48 months from award date).1st 500MW Unit commissioned - 31st May’87 (in 57 months from award date)

Stage-III commissioned on - 21st March’11

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.

KORBA

COAL TO ELECTRICITY

Coal to Electricity ….. Basics

Coal

Chemical Energy

Super Heated Steam

Pollutants

Thermal Energy

Turbine Torque

Heat Loss In Condenser

Kinetic Energy

Electrical Energy

Alternating current in Stator

Mech. Energy Loss

ASHHeat

Loss

Elet. Energy Loss

COAL TO ELECTRICITY

S W ITC H Y A R D /G R ID

G E N E R A TO R TR A N S F O R M E R

G E N E R A TO R

TU R B IN E

B O IL E R

P U L V E R IZ E R

B U N K E R

C R U S H E R

TR A C K H O P P E R

M G R

M IN E S

MINES

MINES: GEVRA(SOUTH EASTERN COALFIELD LTD)

TYPE: OPEN CAST MINES

COAL SIZE :<100MM

TYPE OF COAL: E& F GRADE

MINED COAL BY SURFACE MINER

GRADING OF COAL

GRADE KCAL/KG

A >6200

B 5600-6200

C 4490-5600

D 4200-4490

E 3360-4200

F 2400-3360

G 1300-2400

MINES

TWO SILOS AT MINES END OF CAPACITY:2400 TONS

LOADING FACILITY

WEIGHING FACILITY

SILOSILO

MGR(MERRY GO ROUND SYSTEM)

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

MGR(MERRY GO ROUND SYSTEM)

MINES END

NTPC END

TRACK HOPPERS

SILOS

TOTAL TRACK LENGTH: 34.80 KM

LENGTH OF LOAD LINE: 14.86 KM

LENGTH OF EMPTY LINE: 19.94 KM

RAIL TRACK

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)

MGR(MERRY GO ROUND SYSTEM)

WAGON

MGR(MERRY GO ROUND SYSTEM)

WAGON

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

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

TRACK HOPPERS

HOPPER HOLE

TRACK HOPPERS

TRACK HOPPERS

HOPPER OPNNING

CONCRETE AND STEEL PLATE

CONVEYOR BELTS

BELT SUPPOTER

TRACK HOPPERS

WAGON UNLOADING : BY OPENING BOTTOM DISCHARGE HOPPERS

DISCHARGE HOPPER: PNEUMATIC OPERATION WITH EXTERNAL DC SUPPLY

TOTAL UNLOADING TIME:~25 MINS

CHPCOAL 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

CHPCOAL HANDLING PLANT

TRANSFERS COAL FROM TRACKHOPPERS ON TO CONVEYOR BELTS:

4 NOS IN EACH TRACK HOPPER 1&2

ELECTRICALLY DRIVEN

PADDLE FEEDERS:

PADDLE FEEDER

CHPCOAL 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

CONVEYOR BELT

CHPCOAL 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

CRUSHER

HAMMER

SECTION PART

TRACK HOPPER

CRUSHER

TO BUNKERS

STACKYARD

CHPCOAL HANDLING PLANT

CHPCOAL HANDLING PLANT

STACKING & RECLAIMING

STACKING WHEN EXCESS COAL

RECLAMING DURING LEAN PERIOD

STACKER- RECLAIMER IS USED

STACKER/RECLAIMER

STACKER/RECLAIMER

CHPCOAL 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

BUNKERS

PULVERIZER

FEEDER

BUNKER

MAIN PLANT

Clean Out Conveyor

Coal Bunker

Coal Feed Pipe Coal Feed Pipe

Motor

Encoder Encoder

Load cell Load cell

Silo gate Silo gate feeder pannel feeder pannel

COB Switch COB Switch

Conveyor BeltConveyor Belt

MAIN PLANT

FEEDER

TRANSFERS COAL FROM BUNKERS TO MILL/PULVERIZER

VARIABLE SPEED

DC OR AC MOTOR DRIVEN

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

Mills (Bowl Mill)

Hot Air Gate

Cold Air

Inspection Door Coal Coal MillMill

Hot Air Duct

Scraper Housing

Hot Air Damper

Gear Housing

Classifying System

Coal from bunkerCoal discharge

Air flow

Classification of desired

fineness Coal

Pulverized Coal

Dropping of undesired

coarse Coal

BOWL MILL :

MILL

BUNKER

FEEDER

ESP

ID FAN

APH

PA FAN

FD FAN

CHI

MNEY

BOILER

BOILER: AIR & FLUE GAS PATH

BOILER(200 MW)

• Manufacturer: BHEL, CE Design

• Type: Natural circulation, Balance draft, Corner fired, Tilting, Tangential

DPNLSHTR

Platen S

HT

R

SCREEn

LTSH

ESPAPH

ID fan

Chimney

Economiser

Bottom Ash

Downcomer

Drum

waterwallFireball

Gooseneck

Reheater

Water WallsWater Walls

DPNLSHTR

Platen S

HT

R

SCREEn

LTSH

ESPAPH

ID fan

Chimney

Economiser

Bottom Ash

Downcomer

Drum

waterwallFireball

Gooseneck

Reheater

BOILER COMBUSTION

HeaderHeader

Boiler DrumBoiler Drum

BOTTOM RNG HDR& Z-PANEL 1ST PASS W.W

1ST PASS W.W O/L HDRS ROOF I/L HEADER

2ND PASS UPPER C-HDR 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

2ND PASS ROOF O/L HDR(REAR ECONOMISER

M.S

H.R.HC.R.H

FROM F.R.S

500mw

Air PreheaterAir Preheater

Boiler circuit with Precipitator

ELECTROSTATIC PRECIPITATOR

ESP -Working PrincipleESP -Working Principle

SCHEMATIC DIAGRAM

Electrostatic Precipitator

ElectronicController

High Voltage Rectifier Transformer

415 V3 PhaseSupply

Electrostatic Precipitator

AC C A C

Electrostatic Precipitator (ESP)

No of FieldsNo of Fields : 48: 48No of HoppersNo of Hoppers : 96 : 96Dust Concentration (I/L)Dust Concentration (I/L) : 63.1 gm/NM3: 63.1 gm/NM3

(O/L)(O/L) : 40 mg/NM3: 40 mg/NM3EfficiencyEfficiency : 99.937%: 99.937%Key equipmentsKey equipments : ERM, GDRM,CERM : ERM, GDRM,CERM

heaters, Collectors & Emittersheaters, Collectors & Emitters

Chimney

PLANT-1

HPT

IPT LPT

EXC

GEN.

CEP

COND

LPH1,2,3

DEARATOR

BFP

HPH5,6

R Y B

ECO

LTSH

RH

RHS

H

SH

BASIC WATER & STEAM CYCLE OF POWER PLANT

BOILER

Steam power plants operate on Modified Rankine Cycle, DM water as working fluid.

Sensible heat is added in Heaters + economiser

Steam generation takes place in waterwall.

Heat transfer in furnace and enclosed superheater takes place thru radiation.

condenserCEP

LPH

BFP

HPH+Ecow/w

SHHPT

IPT

RH

LPT

S

T

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

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)

HP TURBINE(SECTIONAL VIEW)

HP turbine rotor….

HP turbine inner casing….

Work Done in Turbine….

IP Rotor….

IP Inner casing

IP Outercasing

LP Turbine

Layout of Turbine-Generator

LPTGenerator

IPTHPT

TG Bearings TG Bearings

Condenser

Condenser

Hot well

GENERATOR

Magnetic field around a current carrying conductor and

Direction of the field

S

N

S

N

2πr

B(Φ)

N

SS

N

Rotor field and its traveling with rotation

S

N

Generator

Generator

S

NN

S N

Sδ

Load angle δLocking of stator and rotor fields -*- δ between rotor field & resultant field

Rated parameters:Maximum continuous KVA rating 247 MVAMaximum continuous KW rating 210 MWRated Terminal Voltage 15.75 KVRated Stator Current 9050 ARated Power Factor 0.85 LagExcitation voltage at MCR condition 310 VExcitation current at MCR condition 2600 AExcitation voltage at no load 102 VExcitation current at no load 917 ARated speed 3000 RPMRated frequency 50 Hz.

April 11, 2023 PMI Revision 00 103

1. STATOR WATER SYSTEM

2. SEAL OIL SYSTEM

3. H2 GAS SYSTEM

4. EXCITATION SYSTEM***

H.T. MOTORS

External fan mounted at fan NDE side

Cold Air I/L

BFP ( Stage I)

CW I/L

CW O/L

2 no. of Coolers

Cooling fan 2 no.s (DE/NDE) mounted on motor shaft

MAIN PLANT

GENERATOR & GENERATOR TRANSFORMER

400 KV BUS IN SWITCHYARD

GENERATOR TRANSFORMER

GENERATOR

15.75 KV 400 KV

CIRCUIT BREAKER

OUTGOINGLINE

Generator Transformer

Unit # 5500MW

Unit # 2200MW

Tie Trans# 1

K-Bhilai-2

Korba Vindh’l -1A

K-Korba (W) K-Sipat

K-Bhatapara

Korba-Vindh’l -2

K-Birsingpur -1 & 2

Unit # 4500MW

Unit # 6500MW

Unit # 7500MW

Tie Trans#2

Tie Trans#3

Tie Transf # 4

Unit # 3200MW

Unit # 1200MW

Under Construction

Proposed

K-Bhilai-1

Bus Section

G G G G G G G

Switchyard

Circuit Breaker

Isolators

Switchyard One line DiagramTransfer Bus 400 KV

Main Bus II

Main Bus I

CB CBCB

GT20.5/400KV

Gen Bay Feeder Bay

BusIsolator

Transfer Bus Bay

Western Region Power MapKORBA

NTPC Korba CW/CT system at a glance

126

CW scheme…

Reservoir/ River Canal Intake

Trash rack

TWS

CW pumps

Condenser

Hot Pond

CT pumps

Cooling tower

Hasdeo Barrage RBC Darri Gate

open

Stage-II3X500 MW

Stage-I3 X 200 MW

Hot pond CT- I

CT- IIOpen Cycle

Pragati

Nagar Regula

torCWPH-I

CWPH-II

Charpara Cross Regulator open

Emergency Exit

Hot pond

CT- I

CT- IITotal Closed Cycle

Pragati Nagar

Regulator

Stage-II3X500 MW

Stage-I3 X 200 MW

CWPH-I

CWPH-II

Hasdeo Barrage

RBC Darri Gate open

for makeup

Charpara Cross Regulator totally closed

Induced Draft Cooling Tower

Natural Cooling Tower

Hasdeo Barrage RBC Darri Gate partially open.

Hot pond CT- I

CT- IIPartial Closed Cycle

Pragati Nagar

RegulatorStage-II3X500 MW

Stage-I3 X 200 MW

CWPH-I

CWPH-II

Charpara Cross Regulator Partially open

Emergency Exit

ASH GENERATION AND CLASSIFICATION

COALBUNKER

BOTTOM ASH COARSE ASH FLY ASH

CHIMNEY

ESPHOPPERS

ECO /APH HOPPERS

MILLING SYSTEM

BOILER

134

Ash volumes and propertiesAsh volumes and properties

ESP

Pulverized

Coal

Furnace (1300 - 1500°C)

ElectrostaticPrecipitator

Sta

ge A

: 80

%S

tag

e B

: 17

%80-90 %

Sta

ge C

: 3

%

Fly Ash

Econo

mizer

Eco Ash APH Ash

1 % 1 %

Stack

Fineness

Bottom AshCoal10-20 %100 % Ash

APH

Overflow

BATPs

Ash Dyke

ASPs

Stage –II ASPH Booster ASPH Dhanras dyke S t a g e - I I ASL # 5 BASL #1

ASL #4 BASL #2 ASL #3 BASL #3 ASL # 2 BASL #4

ASL # 1 BASL #5 ASL#4

ASL#3 ASL#2 ASL#1 S t a g e - I

STAGE-I ASPH

ASP 5A 5B 5C 4A 4B 4C 3A 3B 3C 2A 2B 2C 1A 1B 1C

Dhanras Ash Dyke

ASP : Ash Slurry Pump BASP : Booster Ash Slurry Pump ASL : Ash Slurry Line BASL : Booster Ash Slurry Line

BASP 1A 1B 1C 1D 2A 2B 2C 2D 3A 3B 3C 3D 4A 4B 4C 4D 5A 5B 5C 5D

ASP 4 3 2 1

ASH FLOW DIAGRAM (AS PER DESIGN)

POINT Distance from Stg.II ASPH

(meters.) Elevation

A 00.0 289.4 B 28.0 291.4 C 560.0 299.2 D 754.9 300.2 TP-1 1091.9 298.2 TP-2 1227.2 297.5 TP-3 2007.4 300.9 TP-4 2239.6 298.0 TP-5 3717.5 297.5 TP-6 8379.1 302.8 TP-7 9506.3 315.7 TP-8 12305.0 323.0 TP-9 13739.0 340.0

Overflow Lagoon

Return water to BPH ( 3 lines)

TP-8

TP-7

BOOSTER PUMP HOUSE

TP-6

KORBA KATGHORA ROAD

LAGOON-I

LAGOON-II

Hasdeo river

D C B A KSTPS Plant Area

Ash Pipe route to Booster pump house and to Dhanras Dyke

TP-9 End Point & Starting

of garlanding

TP-2

TP-1

TP-5 MOHAN TALKIES ‘X’ ROAD

BULGI ‘X’ ROAD

TP-4

TP-3

Stg.II Ash Slurry P/H

PTS-Plant ROAD

To BCPP

N

MGR ‘X’

FCI ‘X”

Escape channel to Kasai nala

Normal spillway

Emergency discharge (below spillway)

DHANRAS ASH DYKE

WHITE HOUSE

LAGOON-II

LAGOON-IALAGOON-IB

INDEX

* ****

DATE-

ASH LINES

54321

RIVER HASDEV

RWL

P.N.6

P.N.39P.N.58 P.N.88

SPILLWAY

WELL

TOTAL VALVE-32

4

5

1942

1977

P.N.188P.N.1666

P.N.236

258

268

P.N.6

P.N.330

23

1

774

721

684

657

779810847865 889938 915

998

139

ASH LAGOON

FLY ASH EVACUATION DRY MODE

Basic scheme for one ESP pass

TACs ASH Transportaion lines to Silo

BUFFER HOPPER

VACUUM PUMPS A1 , A2

A6

A1

A12

A7 A13

AIR LOCK TANKS A1 , A2

A18

A19

A24

BGF-Bag filter

Air and Seal water exhaust to atmosphere

BGF

April 11, 2023 PMI Revision 00 143

How Generated electricity reached customer