NTPC TRAINING REPORT
PREPARED BY: SHYAM SUNDARAN 08BEE146 VIT VELLORE
TABLE OF CONTENTS Content
Acknowledgement Abstract About the Company Introduction Safety and Disaster Management Control and Instrumentation dept. Maintenance and Planning dept. Operations (Mech.) Operations (Electrical) Conclusions References
Page No.
3 4 5 6 8 14 18 19 28 33 34
2
TABLE OF CONTENTS Content
Acknowledgement Abstract About the Company Introduction Safety and Disaster Management Control and Instrumentation dept. Maintenance and Planning dept. Operations (Mech.) Operations (Electrical) Conclusions References
Page No.
3 4 5 6 8 14 18 19 28 33 34
2
ACKNOWLEDGMENT
I woul would d like like to than thank k the the mana manage geme ment nt of NTPC for their their support during the duration of my training in the organisation. I woul would d also also like like to than thank k the the empl employ oyee eess at NTPC for their their invalu invaluabl ablee suppor supportt and guidan guidance ce withou withoutt which which this this projec projectt couldn’t have been completed successfully. I would also like to than thank k my prof profes esso sors rs for for thei theirr whol wholee hear hearte ted d moti motiva vati tion on and and guidance which has gone a long way in the success of this project.
3
ABSTRACT
This report contains the details of findings and observations during the course of training at NTPC-Faridabad. This also contains the details of the plant with an insight into its working and maintenance. Every effort has been made to present this report in a factual and in a precise manner. This report contains the working and the role of the various departments which work 24x7 in order to make the plant work in an efficient and safe manner.
4
ABOUT THE COMPANY NTPC Limited is the largest thermal power generating company of India. A public sector company, it was incorporated in the year 1975 to accelerate power development in the country as a wholly owned company of the Government of India. At present the GOI holds around 89.5% of the total equity shares of the company and the balance 10.5% by the FIIs, Banks, Public and others. Within a span of 35 years, NTPC has emerged as a fully national power company with power generation facilities in all the regions of the country. The chat below shows the growth of the company till the year 2007.
NTPC’s core business is engineering, construction and operation of power plants. It also provides consultancy in the 5
area of power plant construction and power generation to companies in India and abroad.
INTRODUCTION
NTPC-Faridabad was approved on 25th July 1997. The total project cost was 1163 crores INR. The plant was fully functional in the year 2000 with an installed capacity of 432 MW. The plant under an agreement with the Harayana government supplies the entire power generated to the state of Haryana only.
Salient Features of this project are: 1. Project: Faridabad Gas Power Project 2. Location: Village Mujedi, P. O. Neemka, Faridabad, Haryana 3. Plant Capacity: 432 MW 4. Plant Configuration: Gas Turbine 1 - 138 MW Gas Turbine 2 - 138 MW Steam Turbine - 156 MW 5. Mode of Operation: Base Load 6. Fuel: Natural Gas 7. Alternate Fuel: Naphtha / HSD 8. Average Gas requirement: 2 million cubic meters per day 9. Fuel Source: HBJ pipe line (through GAIL)
6
10. Cooling water: Rampur Distributory source 11. Naphtha Storage: 2 tanks of 800 Kl. Capacity each. 12. HSD Storage: 1 tank of capacity 400 Kl. 13. Power Evacuation: 2X220 KV Double circuit lines to220KV BBMB sub-station at Samaipur (Ballabgarh) 2X220 KV Double Circuit lines to 220 KV HVPN sub-station at Palla (Faridabad)
NTPC-Faridabad is a power (electricity) generating company with installed plant capacity of 432 MW. The plant configuration is as under:
Gas Turbine -1 138 MW Gas Turbine -2 138 MW Steam Turbine 156 MW
The mode of operation is “Base Load”. Natural Gas is used as main fuel. Naphtha is used as an alternate fuel. Average gas requirement is two million cubic meters per day. Gas Authority of India Ltd. supplies Natural Gas to the plant through their H.B.J. Gas pipeline. The electricity generated is supplied to the state of Haryana. The liquid fuel which is used during a gas shortage is supplied to NTPC-Faridabad by Indian Oil Co. (IOCL). Water which is an important pre-requisite for any thermal power plant is obtained through the Agra canal which runs through the Faridabad city.
7
The Gas turbines used at NTPC–Faridabad is obtained from SIEMENS which is the OEM(Original Equipment Manufacturer). The model used in this plant is V 94.2(model-3).
SAFETY & DISASTER MANGEMENT AT FGPP
“PREVENTION IS BETTER THAN CURE”
Types of Hazards in Industries: 1. Mechanical 2. Electrical 3. Physical 4. Chemical They are explained as follows:
8
Mechanical Due to moving parts
–
Rotors, blades,
Flywheels, Pulleys, Belts, Couplings, Cams, Spindles, Chains, Cranks, Gears, Sprockets, Shafts, Rods Where Mechanical Hazards Occur The point of operation Power transmission apparatus
9
Safeguarding strategies
1. Guards i) Fixed ii) Interlocked iii) Adjustable iv) Self-adjusting
2. Devices i) It may stop the machine if a hand or any part of the body is inadvertently placed in the danger area. ii) Restrain or withdraw the operator's hands from the danger area during operation. iii) Require the operator to use both hands on machine controls. iv) Provide a barrier which is synchronized with & Distance 3. Location the i) Walls operating cycle of the machine in order. ii) Barriers/Fences iii) Height above worker iv)Size of stock (single end feed, punching) v)Controls (positioned at a safe distance)
10
4. Feeding & injection i)Automatic Feeding ii)Semi-Automatic Feeding iii)Automatic Ejection iv)Semiautomatic Ejection v) Robots
5. Miscellaneous Aids i) Awareness barriers ii) Ropes iii) Shields iv) Holding tools v) Push sticks or blocks
ELECTRICAL HAZARDS
1. Direct-Direct electrocution. 2. Indirect-Damages due to current. E.g. Fire. 3. Induction-Electromagnetic field.
PRECAUTIONS 1. Wires at safe distances from workers. 2. Automatic system-Much effective than the manual method. 3. Reducing exposure time. 11
PHYSICAL
1. Heat 2. Light 3. Noise 4. Fire 5. Pollution
Precautions HeatReduce exposure time. Water coolers at every place.
Light Personal protective equipments.
Noise Acoustic materials. Personal protective equipments.
Fire • •
Fire extinguishers at all critical points in the plant. In house fire station managed by the CISF.
12
FIRE FIGHTING SYSTEM: NTPC-Faridabad has full-fledged Fire Fighting System to safeguard against any kind of eventuality. It has fire fighting hydrant system, which remains operational round-the-clock. It has fully automatic system involving state-of-art technology to fight against any kind of fire arising due to gas/naphtha leak. Also, there is Natural Gas Leak Detection System, Naphtha Leak Detection System.
CHEMICAL HAZARDS
1. Industry specific. 2. Dust, ash are the by-products. 3. NTPC-Faridabad- chlorine, alkali, acids. 4. No problem of waste disposal as the main by-product is water.
PRECAUTIONS 1. Leakage detectors at each chemical tanks. 2. Chlorine physically detected by Ammonia. 3. Chlorine siren should be present.
13
GENERAL SAFETY MEASURES 1. Automated plant reduces the risk of human error. 2. Skilled labour must be employed as their knowledge reduces chances of mistakes 3. Regular check-up of the plant and the machinery should be done at regular periods by the MTP dept. 4.Personal protective equipments such as helmets must used in the plant. 5.Adequate banners and signage must be present to make the people aware of the hazards and the dangers around. 6.Regular drills and training must be given to the employees to deal with any kind of emergencies.
14
CONTROL & INSTRUMENTATION DEPARTMENT
The Control & Instrumentation Department(C&I) is responsible for the operation and of all the electronic sensors, actuators and controllers besides maintaining the pressures, temperatures, level and the flow in the various tanks, pipes and also in the various heat exchangers present in the plant.
The main functions of the C&I dept. at NTPCFaridabad are: 1.Measurement and display of various parameters. 2.To control the various parameters by Automatic feedback controlling which involves the taking of decision based on inputs from measurements by the processor. 3.Protection of various equipments(pumps, generators etc..) and workers from hazards by automatically tripping a cycle when hazardous conditions are reached. 4.Alarm generation in case of a mechanical or an electrical failure. The Faridabad plant has outsourced its automaton to various companies on a Package Based Deal. The C&I dept. besides also undertakes the modifications or upgradadion of it’s systems.
15
The C&I dept. uses various instruments in its functioning. They can be broadly classified as: 1. Sensors 2. Controllers 3. Actuators
Sensors 1.
Sensors are instruments used for measurement purposes.
2. They measure various parameters and convert them to electrical output which is supplied to controllers. 3. This data is then displayed which aid the engineers make the judicious decisions. These sensors measure the following parameters: 1. Level of fluids in pipes and tanks. E.G: LVDT can be used for this measurement 2. Flow of fluids such as fuel steam etc. Done by sensors such as Venturimeters or Rotameters. 3. Pressure in tanks and pipes also can be measured It’s done by sensors such as Gauges, Pressure Switches, Capacitive Transducer etc. 4. Temperatures can be measured anywhere in the system. Instruments such as Thermocouples and RTDs are used.
16
Controllers
These are devices which receive data from the sensors, process it and give instruction to the actuators based on the processed data. They are analogous to the human brain.
Various types of control systems used at NTPCFaridabad are:
1. Single control system This consists of a single processor which controls the entire process. This system is not quite efficient as it draws large amount of power and also if the processor fails then the entire unit has to stop. 2. Distributed control system This consists of various processors which are responsible for various parts of the process and have a channel of communication between them enabling them to work efficiently. Such a system is more efficient and is favoured. DCS is extensively used within the plant to control various processes of the plant.
17
Actuators Actuators are analogous to motor organs like hands or legs of the body. Actuators are the instruments which are responsible for carrying out control commands from the controller like closing of a valve etc.
Actuators are of manly three types:
1.
Pneumatic Actuators
These actuators carry out mechanical tasks using compressed air. These are very accurate but are not very strong and get damaged easily. The pressure in it is in the range of 3-15 psi.
2. Hydraulic Actuators These use the pressure of compressed oil to perform their tasks. These actuators are quite strong but lack a high degree of accuracy.
3. Electronic Actuators These make use of electronic motors to perform their tasks.
18
MAINTENANCE & PLANNING DIVISION (MTP)
It is basically divided into two other divisions namely:
1. Mechanical maintenance 2. Electrical maintenance This dept. is needed because of the below stated reasons: 1. To take up the daily maintenance of the plant as per schedule. 2. It is not possible to maintain the plant daily so a schedule is needed which is drawn up by this dept. 3. It takes up rectifying work in case of a machine or an electrical failure. 4. It is responsible for the overhauling of the plant. 5. It monitors the condition and the working of the plant to check if everything is working well. 6.
It arranges for spares from the OEM(Original Equipment Manufacturer) and also from other suppliers.
7.
This dept. also oversees the work of the workshop within the pant whose work is to manufacture small parts.
8.
The MTP also undertakes the regular calibration of all the instruments and the sensors.
9. There is a weekly meeting for contracts and material in the dept.
19
OPERATIONS (MECHANICAL)
The O&M(mech) dept. at NTPC- Faridabad takes care of day to day running the mechanical components of the plants in a safe and in an efficient manner. The main mechanical components are listed below: 1. Gas Turbine 2. Steam Turbine 3. Pumps 4. Heat Recovery Steam generator( HRSG)
GAS TURBINE
PRINCIPLE OF GAS TUBINE: 1. 2. 3. 4.
Works on Brayton Cycle It is an open cycle process Isentropic compression and expansion takes place. Constant pressure heat addition takes place.
The Gas Turbine used at NTPC-Faridabad is V94.2 (model-3) is manufactured by SIEMENS, Germany which is the OEM.
20
VIEW OF THE TURBINE AND THE COMPRESSOR COUPLED TO IT MANUFACTURED BY SIEMENS
21
A VIEW OF THE AIR SUCKING MECHANISM FOR THE COMPRESSOR AT NTPC-FARIDABAD
22
Schematic of a steam power plant
SCHEMATIC OF A STEAM POWER PLANT
23
LINE DIAGRAM SHOWING GAS TO ELECTRICITY CONVERSION AT NTPC-FARIDABAD
24
STEAM TURBINE Manufactured by BHEL-India. The flue gases from the gas turbine are passed through the Heat Recovery Steam generator(HRSG) since the gases have high thermal energy and are at a temperature of upto 540 degrees. The flow chart of the steam build up is shown below:
Start up steam flow steam
HP reducing station, start-up flash tank steam
Reheater (for cooling) steam
LP bypass station (reducing station) steam
injection water
saturated steam
condenser
25
A VIEW OF THE STEAM TURBINE GENERATOR
26
HEAT RECOVERY STEAM GENERATOR(HRSG)
When the plant is running in open cycle i.e. when the gas turbine is only running then the efficiency is a mere 30% but if we run the plant in a closed combined cycle which includes the gas as well as the steam turbines then we can achieve an efficiency of about 50%. Thus it is profitable to run the plant in a combined cycle mode. The flow diagram of a combined cycle power plant is given below:
COMBINED CYCLE PLANT HEAT 45.9 %
GT POWER(30%)
STG POWER(15.9%) STACK LOSS(14%)
FUEL(100%)
GAS TURBINE
EXHAUST HEAT(67%)
CONDENSER LOSS(34.3%)
MISC.LOSS(3%) MISC.LOSS(2.8%)
27
HRSG CONSTRUCTION
28
OPERATIONS (ELECTRICAL)
The OPERATONS (ELECTRICAL) dept. at NTPCFaridabad takes care of the running of the electrical systems as well as maintaining them.
The electrical overview of the plant is shown below:
CONTROL ROOM
HV SYSTEM
STEP UP TRANSFORMER
LV SWITCHGEAR AC & DC AUXILIARY SYSTEMS
HV- BREAKER
CONTROL SYSTEMS
2 AUX. TRANSF.
1
PROTECTION
GOVERNOR GENERATOR BREAKER
1
SYNCHRONIZING
2
PT’s & CT’s
SYNCHRONOUS GENERATOR
TURBINE
STAR POINT CUBICLE
STATIC STARTER
EXCITATION SYSTEM
EXCITATIONTRANSFORMER
29
General Classification of Electrical Systems ELECTRICAL SYSTEMS AC 50 Hz SUPPLY SYSTEM 220 KV 3 PHASE FOR BULK POWER TRANSMISSION 10.5 KV,15.75 KV 3 PHASE GENERATOR OUTPUT VOLTAGE 6.6 KV 3 PHASE FOR STATION AUXILLIARIES
D/C SYSTEM 220 V FOR UPS & EMERGENCY SYSTEMS 24 V FOR SOLENOIDS, CONTROLLERS 48 V DC IN SWITCHYARD
415 V 3 PHASE FOR LOW VOLTAGE AUXILLIARIES 240 V SINGLE PHASE SUPPLY
Generally the D/C systems are placed to draw power for starting of the systems of the plant in case of a grid failure.
30
DETAILS OF THE GAS TURBINE GENERATOR
Apparent power Active Power Current Voltage Speed Frequency Power Factor Stator Winding Rated Field current Rated Field Voltage
170.12MVA 144.6MW 9354A 10.5KV+/-5% 3000rpm 50Hz 0.85 YY 833A 410V
31
DETAILS OF THE STEAM TURBINE GENERATOR
Apparent power Active Power Current Voltage Speed Frequency Power Factor Stator Winding Rated Field current Rated Field Voltage
188.23MVA 160MW 6900A 15.75KV+/-5% 3000rpm 50Hz 0.85 YY 798A 432V
32
TRANSMISSION DETAILS
220 KV Switch yard at FGPS
1. 3 Nos Generator Circuits (GT-1,2,ST) 2. 2 Nos Palla lines 3. 2 Nos Samaypur lines 4. Bus coupler 5. Transfer bus coupler
220KV SWITCH YARD -FGPP
SAMAYPUR-1& 2
PALL-1&2
BUS-1
B/C
BUS-2 TRANSFER BUS
TBC
GT-1
GT2
ST
33
CONCLUSION To summarise the above mentioned report all the departments were thoroughly studied and all the information was gathered regarding the plant and its auxiliary units. The purpose of this training was to get an insight into the functioning of a power plant with particular emphasis on its electrical systems. Finally I would mention the exemplary service that the management and the staff of NTPC give to the nation.
REFERENCES 34
