Savitribai Phule Pune University

A report on
Industrial Visit to
Nashik Thermal Power Station (NTPS)

Guided by
Prof. Jitendra B. Satpute
Prof. Mukesh A. Mane

Department of Mechanical Engineering

Suman Ramesh Tulsiani Technical Campus
Faculty of Engineering, Khamshet, Pune.

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ACKNOWLEDGEMENT:

On behalf of the entire B.E Mechanical branch, we take this opportunity to offer our sincere
thanks to Prof. Jitendra B. Satpute & Prof. Mukesh A. Mane for organising this industrial visit.
We also thank NTPC, Nashik for allowing us to visit the Thermal Power Plant & guiding us at
every step. We would also like to thank Dr. Haribhau G. Phakatkar, Principal of SRTTC,
Khamshet & Prof.Yogesh R.Ingole, HOD of Mechanical Department of SRTTC, Khamshet.

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Sr No. Particulars Page No.

1. Introduction to NTPS, Nashik 4

2. Overview of the plant 5

3. Technical Specification 5

6. Conclusion 11

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INTRODUCTION:

Nashik Thermal Power Plant is located at Eklahare village near Nashik in Maharashtra. The
power plant is one of the coal based power plants of Maharashtra State Power Generation
Company (Mahagenco).

Nashik Thermal Power Station has an installed capacity of 140*2+210*3=910 MW. The first unit
was commissioned in 1970. The cost of unit including civil works was Rs 56.5 crores and the
second unit also commissioned with the same cost under the first stage. The second stage
consists of three units of 210 MW each was commissioned in the later years. The power station
campus includes self-contained township with all amenities. The entire land consists of 474
hectares. The power plant has got ISO Certification on April 2002.

Maharashtra State Power Generation Company (Mahagenco) is planning to deploy 660 MW

super-critical units at the same location just like the current plant. This project will be stationed
adjacent to the existing stage-I plant (2 x 140 MW) site at village Eklahare. Land requirement for
the proposed project is about 36.6 hectares. The coal sources will be from Mahanadi coal blocks
by MahaGuj Collieries s. The total cost of the project is around Rs 4,390 crore, 20% contribution
will be by the State Government amounting to Rs 878 crore. The remaining funds will be
supported from several lending institutions. It is on the BhusawalKalyan section of Central
Railway. Coal-based thermal power stations consume large quantities of coal. The Nasik
Thermal Power Station consumed 4,626,000 tonnes of coal in 2006-07. Around 80 per cent of
the domestic coal supplies in India are meant for coal based thermal power plants and coal
transportation forms 42 per cent of the total freight earnings of Indian railways.

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OVERVIEW OF THE PLANT:

In a coal based power plant coal is transported from coal mines to the power plant by railway in
wagons or in a merry-go-round system. Coal is unloaded from the wagons using wagon tippler
units, to a moving underground conveyor belt. This coal from the mines is of no uniform size. So
it is taken to the Crusher house and crushed to a size of 20mm. From the crusher house the coal
is either stored in dead storage (generally 40 days coal supply) which serves as coal supply in
case of coal supply bottleneck or to the live storage(8 hours coal supply) in the raw coal bunker
in the boiler house. Raw coal from the raw coal bunker is supplied to the Coal Mills by a Raw
Coal Feeder. The Coal Mills or pulverizer pulverizes the coal to 200 mesh size. The powdered
coal from the coal mills is carried to the boiler in coal pipes by high pressure hot air. The
pulverized coal air mixture is burnt in the boiler in the combustion zone. Generally in modern
boilers tangential firing system is used i.e. the coal nozzles/ guns form tangent to a circle. The
temperature in fire ball is of the order of 1300C. The boiler is a water tube boiler hanging from
the top. Water is converted to steam in the boiler and steam is separated from water in the boiler
Drum. The saturated steam from the boiler drum is taken to the Low Temperature Superheater,
Platen Superheater and Final Superheater respectively for superheating. The superheated steam
from the final superheater is taken to the High Pressure Steam Turbine (HPT). In the HPT the
steam pressure is utilized to rotate the turbine and the resultant is rotational energy. From the
HPT the out coming steam is taken to the Reheater in the boiler to increase its temperature as the
steam becomes wet at the HPT outlet. After reheating this steam is taken to the Intermediate
Pressure Turbine (IPT) and then to the Low Pressure Turbine (LPT). The outlet of the LPT is
sent to the condenser for condensing back to water by a cooling water system. This condensed
water is collected in the Hotwell and is again sent to the boiler in a closed cycle. The rotational
energy imparted to the turbine by high pressure steam is converted to electrical energy in the
Generator.

TECHNICAL SPECIFICATIONS:

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MAJOR COMPONENTS SPECIFICATIONS:

1. Steam Turbine:

a. 210 MW Turbine at Nashik is three cylinders (HP, IP, LP) Tandem compound
with nozzle governing, condensing & regenerative feed heating type.
b. The HPT comprises of 12 stages, the first stage being governing stage.
c. The IPT comprises of 11 stages.
d. The LPT has 4+4 stages .Steam enters at middle & flows in opposite paths having
four stages.
e. Turbine rotors are supported on five bearings .The common bearing of HP & IP
rotor is a combined journal & radial thrust bearing. Rest four bearings are journal
bearings.

2. OIL SUPPLY SYSTEM: -

A single oil supply system lubricates & cools the bearing, governs the machine
operates the hydraulic actuators & safety and protective devices & drives the
hydraulic turning gear.

TABLE:-OIL PUMP SPECIFICATIONS

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3. GENERATOR:-

In electricity generation, a generator is a device that converts mechanical energy to electrical

energy for use in an external circuit. The source of mechanical energy may vary widely from a
hand crank to an internal combustion engine and turbine used in power plants. Generators
provide nearly all of the power for electric power grids.

FIG. GENERATOR
FIG. TURBO GENERATOR TRANSFORMER

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4. STEAM CONDENSING SYSTEM:-

STEAM CONDENSING SYSTEM COMPONENTS: -

Condenser vi.
i. Boiler feed pump
Cooling tower vii.
ii. Make up water pump
Hot well viii.
iii. Deaerator
ix.
Condenser cooling water pump
iv. Air Ejector
x.
Condensate air extraction pump
v. Drain Cooler
xi.
Air extraction pump
Feed Water Heaters (HP/LP Heaters)
xii.
xiii. Condenser Data: -
xiv.
xv. MAKE xvi. BHEL
xvii. COOLING SURFACE AREA xviii. 14650 M
xix. NO. OF COOLING TUBES xx. 15652
xxi. LENGTH OF COOLING TU xxii. 10M
xxiii. DIA.OF COOLING TUBE xxiv. 30/28 MM
xxv. NO.OFWATERPATHSFOREACH xxvi.
xxvii. CONDENSER xxviii. 2
xxix. DESIGNED CONSUMPTION OF
COOLING xxx.
xxxii. 27000
xxxi. WATER M/HR
xxxiii. QUANTITY OF STEAM xxxiv. 150 TO 500
CONDENSING T/HR
xxxv. MAIN EJECTOR xxxvi. 2 NOS.
xxxviii. 1
xxxvii. STARTING EJECTOR NO
xxxix.
xl. Table: Condenser Technical Specifications
xli.
xlii.
xliii.
xliv. 5. BOILER FEED WATER PUMP:-
xlv.
xlvi. A boiler feed water pump is a specific type of pump used to pump feed water into a
steam boiler. The water may be freshly supplied or returning condensate produced as a result of
the condensation of the steam produced by the boiler. These pumps are normally high pressure

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units that take suction from a condensate return system and can be of the centrifugal pump type
or positive displacement type.
xlvii.
xlviii.
xlix.
l. Boiler Feed Pump Data: -
li.
lii.
liii. MOT lvi.
OR liv. lv. PUMP lvii.
lxi.
lviii. lix. lx. lxii.

lxiv. BHEL , lxvi. BHEL,HYDER

lxiii. MAKE HARDWAR lxv. MAKE ABAD
lxvii. CAPA
CITY lxviii. 4000 KW lxix. TYPE lxx. 200 KHI
lxxi. VOLT lxxiii. NO.OF lxxiv.
AGE lxxii. 6.6 KV STGES 6 lxxv.
lxxvi. CURR lxxviii. S
ENT lxxvii. 408 AMP PEED lxxix. 4320 RPM
lxxx. SPEE lxxxii. LUBRICA lxxxiii. FORC
D lxxxi. 1485 RPM TION ED lxxxvii.
lxxxiv. lxxxv. lxxxvi. lxxxviii.

lxxxix. xciii. 1830

xc. xci. HEAD xcii.MLC
xciv. xcvi. DISCHAR xcviii. 430
xcv. GE xcvii.
T/HR
xcix.
c.
ci. Table:-BFP Technical Specifications
cii.
ciii.
civ. 6. ASH HANDLING PLANT
cv.
cvi.
cvii. Indian coal has
cviii.
Calorific Value- 5000 Kcal/ Kg.

Fixed Carbon 38%

Volatile Matter 26%

Moisture 8%

Ash Content 28%.
cxiii.
TYPES OF COAL ASH: -
cxiv.
cxv. Coal ash is the residue of the coal combustion process involved in the thermal
power plants.
cxvi.
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cxvii. The types of coal ash from coal based thermal power plants are:
cxviii.
i. Fly Ash: - Collected from different rows of electrostatic precipitator.
cxix.
ii. Bottom Ash: - Collected at the bottom of boiler furnace.
cxx.
iii. Pond Ash: - Mixture of bottom ash and fly ash as available in ash disposal ponds.
cxxi.
cxxii.
cxxiii.
FLY ASH SYSTEM: -
cxxiv.
cxxv. The system for all units is identical and following description is applied to both
the units the water compounded bottom ash hopper receives the bottom ash from the furnace
from where it is stores and discharged through the clinker grinder. Two slurry pumps are
provided which is common to all units & used to make slurry and further transportation to
ash dyke through pipeline.
cxxvi.
cxxvii. Ash particles are separated by passing through electrical field (Electrostatic
Precipitator).
cxxviii.
cxxix. Components in ESP: -
cxxx.
Discharge electrode (-ve)
cxxxi.
Collecting electrode (+ve )
cxxxii.
Rapping mechanism
cxxxiii.
Fly ash hopper
cxxxiv.
High tension voltage equipment
cxxxv.

cxxxvi.
cxxxvii.
cxxxviii.
cxxxix.
cxl.
cxli.
cxlii.
cxliii.
cxliv.
cxlv.
cxlvi.
cxlvii.
cxlviii.
cxlix.
cl.

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FIG. SCHEMATIC OF
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cli.
clii.
cliii.
cliv.
clv.
clvi.
clvii.
clviii.
clix.
clx.
clxi.
clxii. Common causes of unsatisfactory performance of ESP are:
clxiii.

Excessive gas volume
Poor gas distribution

Overloading
Flashover and electrical
Ineffective rapping instability

Overfilling of dust hoppers Discharge wire breakage

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CONCLUSION:-

The Industrial Visit to the Nashik Thermal Power Plant, Nashik was successful. We
received insight of the whole plant right from the raw material (coal) procurement,
processing, combustion and generation & transmission of electricity. The whole process was
explained in-detail by the representative with detailed description about each equipment with
their specifications. A doubt solving session with the Control Room Incharge cleared all our
queries. This kind of industrial exposure helped us to absorb the theoretical aspects of
Thermal & Fluid Power Engineering more efficiently. We would highly appreciate more such
visits in the future.