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coal to electricity.........
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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……
TextText
Text
Text
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