PROJECT WORK ON FUZZY BASED PERFORMANCE EVALUATION OF DC SHUNT MOTOR WORK CARRIED OUT AT NTPC Limited, RAMAGUNDAM PROJECT

SUBMITTED UNDER THE SUPERVISION OF D. ANANDA RAO, Sr.Supdt(EM) BY K.MANOGYA 06251A0215 SHRAAVYA SIRPA 06251A0247

G.NARAYANAMMA INSTITUTE OF SCIENCE AND TECHNOLOGY, HYDERABAD

CERTIFICATE

This is to certify K.MANOGYA & SHRAAVYA SIRPA, B.Tech 2nd year, Department of Electrical and Electronics and Engineering Sciences, ,G.Narayanamma Institute of Technology

HYDERABAD have undergone IN PLANT TRAINING WORK from 14.05.2008 to 31.05.2008 on the project entitled GENERATOR OF 200 MW AND OVERALL VIEW OF RAMAGUNDAM SUPER THERMAL POWER STATION at NTPC Limited, Ramagundam. Under my guidance and supervision at Electrical Maintenance Department, I was impressed with good performance of the student in their interest in learning about Electrical Engineering applied in the power plant.

Date: 31/05/2008 In Plant Co-ordinator D. ANANDA RAO, Sr.Supdt(EM) NTPC, RAMAGUNDAM

ACKNOWLEDGEMENT
It is a great privilege for us to submit our deep sense of gratitude and indebtedness this Ramagundam super thermal power station, a flagship unit of the esteemed organization of National Thermal Power Corporation Limited., for giving us this opportunity to carry out in plant training the following topic GENERATOR OF 200 MW AND OVERALL VIEW OF RAMAGUNDAM SUPER THERMAL POWER STATION. I acknowledge with heart felt thanks and gratitude to the several gentle men who have given their valuable time for completion of my project. I acknowledge my sincere gratitude to Shri BV. SUBRAMANYAM, DGM (EM) for providing the opportunity to work in NTPC RAMAGUNDAM and giving us a rich experience in completing the project. I express my thanks to my project guide Shri D. ANANDA RAO, Sr. Supdt (EM) for his valuable and timely suggestions during my project. I extend my sincere thanks to Shri V. SEETARAM, MANAGER (Safety) & Shri K.KISHAN, Jr. Officer(Safety) and I also extend my thanks to the Staff of EM dept . I would like to thank Shri E. Nandakishore, DGM(HR-EDC), Shri P M G V. SRINIVAS, Sr. Manager, (HR EDC) , Shri MVR. Sharma, Sr. Officer (HR-EDC), Shri Keshavulu, Sub. Officer(HR-EDC), Shri E. Vishnuvardhan Rao, Sub. Officer(HR-EDC) and other staff of EDC for giving an opportunity to complete the project work. I sincerely express my gratitude and respect to all those who guided, inspired and helped me in the completion of the project. I am grateful to them who are generous and cooperative during our project.
K.MANOGYA SHRAAVYA SIRPA

NTPC
NTPC is the major power utility, generating over one fourth of the total thermal power in the country. NTPC established in 1975 and its mission has been to construct commission and operate power projects most economically and efficiently. NTPC has chalked out a capacity addition program of adding ambitious 33,000MW by installing a number of coal and gas based power plants in the next-ten years. APPROVAL OF RSTPS: RSTPS was declared by government of India in 1978. Late Sri Morarji Desai, the then PM laid the foundation stone of RSTPS. RSTPS began commercial operation by 1983. PLANT LOCATION AND LAYOUT: NTPC Ramagundam is located at a latitude of 18-46E and longitude of 7626N. River Godavari flows west to east. The site is accessible to NH7. The plant occupies an area of 10,000 acres. The reservoir which serves as the intake water source for power is located at the south. The ash disposal area and the township are located to the west and north west respectively. NTPC is the largest power generating company in India presently lighting every fourth bulb in the country, embarks on its most ambitious expansion plans. It aims to be a 33,000 MW. The NTPC at RSTPS generates power through three units of 200 MW each, three units of 500 MW each and one unit of 500 MW. The power generated here is used for domestic and industrial purposes in Andhra Pradesh and other neighbouring states. Situated in a sparingly populated area at Jyothinagar of Ramagundam, in Karimnagar District of Andhra Pradesh. Ramagundam is selected for establishing a thermal power plant as the site is having following facilities. Availability of well flourished coal mines.

 Continuous water supply Coal transport facilities DISTRIBUTION OF ELECTRICITY Total Capacity of Ramagundam NTPC is 2600 MW of stage 1, 2 & 3 (i.e. units 1, 2, 3, 4, 5, 6 & 7) distributing electricity to the following states STATE MW % AGE ANDHRA PRADESH 610 MW 29 % TAMIL NADU 470 MW 22 % KARNATAKA 345 MW 16 % KERALA 245 MW 12 % GOA 100 MW 5% PONDICHERY 50 MW 2% Remaining 250 MW is un-allocated and can be given to any State, but at present it is being sent to A.P. Total capacity of stage III (unit VII) is 500 MW distributing electricity to following states:STATE ANDHRA PRADESH TAMIL NADU KARNATAKA KERALA PONDICHERY MW 145.86 MW 118.20 MW 86.76 MW 1.61 MW 12.57 MW % AGE 29 % 23 % 17 % 12 % 2.5 %

Remaining 75 MW is un-allocated. SALIENT FEATURES OF RSTPS Installed capacity 2600 MW Coal Source Singareni coalfields Coal consumption per day 33,000 tones approx Water Source Pochampad Reservoir Transmission System 2457 Kim's of 440 KV line Total land 10,000 acres Total Investment 1,702.18 Corers Length of MGR track 21 Kim's Height of Chimney 210 mts for stage I 225 mts for state II

Ultimate manpower requirement Daily Production COMMISSIONING SCHEDULES State I State II State III UNIT NO. 1 2 3 4 5 6 7

275 mts for stage III 1843 62.4 MU

CAPACITY 200 MW 200 MW 200 MW 500 MW 500 MW 500 MW 500 MW

COMMISSIONED 1983-84 1984-85 1987 88 1989 90 1991 -92 1993 94 2004

Recognizing its excellent performance and vast potential, Government of the India has identified NTPC as one of the jewels of Public Sector 'Navratnas'a potential global giant. Inspired by its glorious past and vibrant present, NTPC is well on its way to realize its vision of being "one of the worlds largest and best power utilities, powering India's growth".

RSPTS
Ramagundam super thermal power station spread over 10,000 acres of land is situated in Karimnagar district of A.P. It has an installed capacity of 2600 MW having 3*200 MW and 3*500 MW and 1*500MW units in three stages. This is biggest power station in southern India supplying power to all the southern states. The generating units are connected to 400 KV switchyard through the step up generator transformer. The local coal surface for RSTPS is the south Godavari fields. The water required is obtaining from pochampadu reservoir. The five states Andhra Pradesh, Tamil Nadu, Karnataka, Kerala and Goa along with the union territory of Pondicherry are benefited by RSTPS.

SALIENT FEATURES OF RSTPS

Installed capacity

Coal source Coal consumption per year Water source Transmission system Total land Total investment Length of MGR track

: : : : : : : :

2600 MW Singareni coal fields 10 MT/year Pochampadu reservoir 2475 Km. Of 400 KV 10,000 acres 2075 Crores 21 Km

 Height of chimney

210 mt. Stage-1 225 mt. Stage-2 270 mt. Stage-3 1,843

Ultimate man power requirement

PERFORMANCES AND ACHEIVEMENTS:

NTPC, Ramagundam was accredited with ISO 14001 certification for confirming to International standard of environmental management system. The station achieved British safety council award for safety and the runner up award in environmental protection from council of power utilities. It achieved Raj Bhasha award for the year 1998-1999 for the first time NTPC featured in 1997 edition of the Limca Book of Records as the largest thermal power plant suppliers and the first to construct and commission the HVDC transmission link in the country.

POWER GENERATION PROCEDURE THERMAL POWER PLANT

IN

Coal is the chief fuel in thermal power plants. The generation of electricity from coal can be classified into the following stages: Coal to Steam Steam to Mechanical Energy Mechanical Energy to Electrical Energy
CHEMICAL ENERGY THERMAL ENERGY MECHANICAL ENERGY ELECTRICAL ENERGY

COAL

BOILER

TURBINE

GENERATOR

COAL TO STEAM COAL HANDLING Coal from the coal wagons is unloaded in the coal handling plant, here the coal is crushed. The transfer of coal takes place by merry go round system, in which loading and unloading will take place within 12-20 minutes. This coal is transported up to the raw coal bunkers with the help of belt conveyers. Coal bunkers are made up of welded steel plates, they are process storage silos. Coal is transported to Bowl Mills by coal feeders. These coal feeders are of two types, volumetric and gravimetric. The coal is pulverized in the Bowl mills, where it is ground to a powder form. The BOWL MILL is one of the most advanced designs of coal pulverizer presently manufactured. The advantages of this mill are: Lower power consumption. Reliability Minimum maintenance Wide capacity The mill consists of a round metallic table on which coal particles fall. This table is rotated with the help of a motor. There are three large steel rollers, which are spaced 120 degrees apart. When there is no coal, these rollers do not rotate but when the coal is fed to the table it packs up between roller and the table and this force the rollers to rotate. Coal is crushed by the crushing

action between the rollers and rotating table. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold air mixture from Primary Air Fan. The P.A. Fan takes atmospheric air from F.D Fan is heated in the air heaters and sent to the furnace as combustion air. PRIMARY AIR FAN: It is a high transmission motor. The powdered coal has to be lifted up to the furnace level against gravity force using the P.A fans. The PAF sucks air from atmosphere (pressurizes it) and sends it to coal mills through primary air pre-heater (PAPH) which heats up this pressurized air. FORCED DRAFT FAN: This Forced draft fans take air from atmosphere, pressurize it and send it into the boiler, prior to sending to furnace. STEAM CIRCUIT Water from the boiler feed pump passes through the economizer and reaches the boiler drum. Water from the drum passes through down comers and goes to bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat and the density difference the water rises up in the water wall tubes. Water is partly converted to steam as it rises up in the furnace. This steam and water mixture is again taken to the boiler drum where the steam is separated from the water. Water follows the same path while the steam is sent to super heaters for super heating. The super heaters are located inside the furnace and the steam is superheated (540 deg.) and finally it goes to the turbine. ECONOMIZER: The function of the economizer in a steam-generating unit is to absorb heat from the flue gases and add this as sensible heat to the feed water before the water enters the evaporative circuit of the boiler. The economizer is continuous loop type and water flows in upward direction and gas in the downward direction. BOILER DRUM: The boiler drums forms apart of the circulation system of the boiler. The first and primary one being that of separating steam from the mixture of water and steam discharged into it. Secondly, the drum houses all equipments used for the purification of steam after being separated from water. This purification equipment is commonly referred to as the Drum Internals. The steam separated in the boiler drum is sent to super heater where it achieves the required temperature and pressure. The water from

boiler drum is passed to boiler walls through water circulating pumps. As the temperature of these is of the order of 1300 deg. C and at low density this hot water goes into the boiler drum, where the steam and water are separated. The boiler drum also reduces the dissolved solid contents of the steam to below the prescribed limit of 1 ppm. DRUM INTERNALS: The drum internals may consists of baffle arrangements, devices which change the direction of flow of steam and water mixture, separators employing spinning action for removing water from steam or steam purifiers as washers and screen dryers. These devices are used in conjunctions with others to remove impurities from the steam leaving the boiler drum. RISER TUBES: A riser tube is a tube through which water and steam pass from an upper water wall header to a steam drum. SUPER HEATER: The dry steam entering into the super heater from the boiler gets heated up to a temperature of 535 deg. C and a pressure of 170.5 Kg/square cm by gaining heat from furnace, from super heater, the steam is passed to the high pressure turbine (HPT) to rotate the shaft, which is coupled to the generator. The rate of steam entering into the high-pressure turbine is 1590 tones per hour. The outlet temperature and pressure of the steam coming out from the super heater is 540 deg Celsius and pressure is 157 Pascal for H.P units REHEATER: This is the part of the boiler, which receives steam back from the turbine after it has given up some of its heat energy in the high-pressure section of the turbine. The re-heater raises the temperature of the steam, usually to its original value, for further expansion in the turbine. The purpose of this reheating is to add energy to the partially used steam. DM WATER PLANT: water used in plant has to be demineralized so that the scale formation in the plant can be avoided if not it causes imbalance in the turbine blades and reduces the equipment lifetime this affects the efficiency of the plant. This process is carried out in D.M.Water plant. Firstly, alum is added to remove turbidity, then chlorine to remove organic wastes from the water this mixture is made to settle for 3 hours where flakes are formed and then removed. Then it is sent to activated carbon filter for adsorption of remaining chlorine. Then it is further sent to weak acid cation chamber, strong acid cation chamber then to weak base anion, strong base

anion through degasser tower for demineralization. at last it is sent to mixed bed for reduction of conductivity. Then this water is stored in demineralized storage tanks for further use.

FLUE GASES AND ASH CIRCUIT Flue gases from the furnace are extracted by I.D fan, which maintains balance draft in the furnace with F.D Fan. These flue gases emits their heat energy to various super heaters in the pant house and finally passes trough air pre-heaters and goes to electrostatic precipitators where the ash particles are extracted. Electrostatic precipitators consist of metal plates, which are electrically charges. Ash particles are attracted on to these plates, so that they do not pass through the chimney to pollute the atmosphere. Regular mechanical hammers blows cause the accumulation of ash to fall to the bottom of the precipitators where they are collected in a hopper for disposal. This ash is mixed with water to form slurry and is pumped to ash pond. But nowadays 80% of the ash is used in formation of ash bricks which is cheaper and stronger than the normal bricks other 20% is sent into the atmosphere through the chimney. AIR PRE-HEATERS: Air pre-heater transfer heat from flue gases to cold primary and/or secondary air by means of rotating heating surface elements. ELECTROSTATIC PRECIPITATORS: The ash content in the Indian coal is of the order of 30% to 40%. When coal is fired in the boiler, ashes are liberated and about 80% of ash is carried along with the flue gas. If these ashes are allowed to atmosphere, it will create an air pollution thereby resulting in health hazards, hence it is necessary to precipitate the dust from the flue gas and in this process electrostatic precipitator finds a place in the boiler (in a 200 MW boiler, we will be burning about 110 tons of coal per hour roughly and if the coal contains 30% ash, the ashes carried along with the flue gas will be of the order of 27 tons/hr.) The additional advantage obtained because of the installation of precipitator is that the wear of the ID fan blades are reduced due to precipitation of dust, resulting in reduced maintenance work in ID fan. The electrostatic precipitator is efficient in precipitation of particles form sub micron to large sizes of particles and hence they are preferred to mechanical precipitators. The efficiency of modern ESPs is of the order of 99.9%.

CHIMNEY: The flue gas is extracted from the electrostatic precipitator by the ID fan. This flue gas is then sent to the outside from the chimney. These chimneys are constructed in such a way that the gas is released at a great height to minimize the air pollution. The height of the chimneys in a typical thermal power plant is 250 mts.

STEAM TO MECHANICAL POWER A steam pipe conveys steam to the turbine through a stop valve (which can be sued to shut off steam in an emergency) and through control valves that automatically regulate the supply of steam to the turbine. Stop valve and control valves are located in a steam chest and a governor, driven from the main turbine shaft, operates the control valves to regulate the amount of steam used. (This depends upon the speed of the turbine and the amount of electricity required from the generator). Steam from the control valves enters the high-pressure cylinder of the turbine, where it passes through a ring of stationary blades fixed to the cylinder wall. These act as nozzles and direct steam into a second ring of moving blades mounted on a disc secured to the turbine shaft. This second ring turns the shafts as a result of the force of the steam. The stationary and moving blades together constitute a stage of the turbine and in practice many stages are necessary, so that the cylinder contains a number of rings of stationary blades with rings of moving blades arranged between them. The steam passes through each stage in turn until it reaches the end of the highpressure cylinder and in its passage some of its heat energy is changed into mechanical energy. The turbine has three stages high pressure, intermediate pressure and low pressure stages .firstly, the steam enters H.P turbine then the steam is lead to the boiler to again increase its temperature and pressure and then led to the I.P turbine thereafter to L.P turbine where the system is double flow kind, where temperature and pressure are lost. The steam almost reduces to droplets thereby the system rotates the shaft of the turbine which is coupled to the generator. The steam leaving the high-pressure cylinder goes back to the boiler for reheating and returns by a further pipe to the intermediate pressure cylinder. Here it passes through another series of stationary and moving blades.

Finally, the steam is taken to the low pressure cylinders, each of which it enters at the center flowing outwards in opposite directions through the rows of turbine blades an arrangement known as double flow to the extremities of the cylinder. As the steam gives up its heat energy to drive the turbine, its temperature and pressure fall and it expands. Because of this expansion the blades are much larges and longer towards the low-pressure ends of the turbine. The turbine shaft usually rotates at 3,000 revolutions per minute. This speed is determined by the frequency of the electrical system used in this country and is the speed at which a 2-pole generator must be driven to generate alternating current at a frequency of 50 cycles per second. When as much energy as possible has been extracted from the steam it is exhausted directly to the condenser. This runs the length of the low-pressure part of the turbine and may be beneath or on either side of it. The condenser consists of a large vessel containing some 20,000 tubes, each about 25 mm in diameter. Cold water from the river, estuary, sea or cooling tower is circulated through these tubes and as the steam from the turbine passes round them it is rapidly condensed into water condensate. Because water has a much smaller comparative volume than steam, a vacuum is created in the condenser. This allows the steam to reduce down to pressure below that of the normal atmosphere and more energy can be utilized. From the condenser, the condensate is pumped through low-pressure heaters by the extraction pump, after which its pressure is raised to boiler pressure by the boiler feed pump. It is passed through further feed heaters to the economizer and the boiler for re-conversion into steam. Where the cooling water for power stations is drawn from large rivers, estuaries or the coast, it can be returned directly to the source after use. Power stations situated on smaller rivers and inland do not have such vast water resources available, so the cooling water is passed through cooling towers (where the heat is removed by evaporation) and re-used. MECHANICAL ENERGY TO ELECTRIC ENERGY

The mechanical energy is converted in to the electrical energy in the generator of the power plant. This conversion takes place through the principle of dynamically induced EMF and in accordance with the Maxwells laws of Electromagnetic Induction. The principle of these generators is exactly the opposite of the motors in which electrical energy is converted into mechanical energy. ENERGY CONVERSION CHART
Chemical energy in the fuel is released when the fuel is burnt and is

converted into heat energy. It is known fact that when coal is burnt heat is produced C + O2 CO2 + Heat energy The heat energy is conveyed through the tubes of water there by changing the water to steam The heat energy in the steam is changed to mechanical energy in the turbine. The mechanical energy in turn is changed into electrical energy in the generator.

GENERATOR:
The transformation of Mechanical Energy into Electrical Energy is carried out by the Generator. WORKING PRINCIPLE: The A.C. Generator or Alternator is based upon the principle of Electromagnetic induction and consists generally of stationary part called stator and a rotating part called rotor. The stator houses the armature windings. The rotor houses the field windings. DC voltage is applied to the field windings. When rotor is rotated , the lines of magnetic (i.e. magnetic field) cut through the stator windings. This induces an Electromotive Force in the stator windings. DESIGN AND GENERATOR: CONSTRUCTIONAL FEATURES OF

STATOR: The three phase armature winding of the generator is housed inside the stator which comprises of a stator frame, end shields and the bushing compartment. Since Hydrogen (an explosive gas) is used as coolant, the frame is made rigid. To prevent eddy current losses the internal housing and ribs are made of non-magnetic steel and frame is made of structural steel. TERMINAL BOX: The phase and neutral leads of 3-phase stator winding are brought out of the generator through six bushings located in the terminal box. Hydrogen coolers are arranged vertically inside the turbine end stator end shield. The stator end shields contain the shaft seal and bearing components. STATOR CORE: Stator core is made of thin lamination. The segments that from the lamination layer are punched from 0.5mm and then coated with insulating varnish. Spaces are used in between to allow the cold gas flow for efficient cooling. Core is spring mounted on stator frame. STATOR WINDING: The three phase stator winding is a fractional pitch two layer type consisting of individual bars. Ripple springs are used on top and side of the bar to reduce vibration. Micalastic insulation is used for stator bars. ROTOR SHAFT: The rotor shaft consisting of a rotor body, two shaft journals and integrally forced flange coupling to connect rotor to turbine and exciter. The rotor body circumference holds the field winding. The cooling of rotor is effected by admitting cold gas through conductors. The hydrogen gas for cooling is circulated by one axial flow fan located on the turbine end shaft journal. GENERATOR BEARINGS: The rotor shaft is supported on sleeve bearings having forced oil lubrication from turbine oil system . the generator bearings are provided with a hydraulic shaft lift oil system to reduce bearings friction during start up. SHAFT SEAL: The rotor shaft ends are brought out through shaft seals. The seals are ring type.

FEATURES OF 200MW GENERATOR: 1) It contains 60slots, 2poles, 2layers armature winding. 2) Both rotor and stator are hydrogen and air cooled. 3) Static excitation system using thyristor and taking supply from output. 1) 2) 3) 4) Field flashing is supplied for excitation build up. Very fast response of the order of 40ms. Additional bearing is not required. Generator transformer comprises of single phase units and a HV neutral side bushing is connected to generator transformer neutral. 5) More maintenance as slip rings and brushes are required. Also over hang vibrations are very high, resulting in faster wear and tear. 6) The generated voltage is 18KV and stepped up to 400KV.
SPECIFICATIONS OF 200 MW ALTERNATOR:

Rated power Generator voltage Speed Phase Frequency Power factor Connection Insulation class Coolant Manufacture Excitation type Duty

: : : : : : : : :

200MW : 18KV 3000 rpm 3-phase : 50Hz 0.85 lag Y connection : F Hydrogen ANSALDO(Italy) Static excitation Continuous duty

EXCITATION SYSTEM: BASIC FUNCTION: To meet the excitation power requirements of generator under all operating conditions, i.e., to provide required DC current to the field of the generator. Why Excitation is required ?

Excitation i.e. d.c supply given to rotor windings of generator produces magnetic field by poles formation and when rotated, it produces rotating field /flux, which when cut by conductors produces voltage. OTHER FUNCTIONS: Voltages and reactive power control. Maintaining field current and stead state operating point. Ensure that capacity limits of generator are not exceeded. Enhancement of steady state stability. Improving transient stability after faults. Quick recovery of voltage after faults. Satisfactory parallel operation of generators

TYPE OF EXCITATION SYSTEMS 1. DC excitation 2. AC excitation 3. Static excitation At NTPC-Jyothinagar, static excitation is used in units 1, 2 and 3 (all 200 MW systems) and brush less excitation is used in units 4, 5, 6 and 7 (all 500 MW systems) DC EXCITATION : These categories utilize DC generators as sources of excitation power and provide current through slip rings. It consists of DC commutator exciter, Which supplies DC to the main generator field windings through slip rings. Frequent wear and tear produced by the slip rings and the sparking nuisance of the commutator made the necessity to go for other type of exciters mainly brushless exciters. AC EXCITATION SYSTEM : These categories utilize Alternators as source of main excitation power, with rotating rectifiers the need for slip rings and brushes is eliminated ,and the DC power is directly fed to the main generator

field. Armature of the AC exciter, with a permanent magnet rotor rotates with the exciter armature and the diode rectifiers, the rectified output of the pilot exciter stator energizes the stationary field, which in turn control the field of the main generator. Such a system referred to as Brushless Excitation System. STATIC EXCITATION SYSTEM: All components in these systems are static or stationary. Static rectifiers supply the excitation current directly to the field of the main synchronous generator through slip rings. Supply of power to the rectifiers is from the main generator through a transformer to step down the voltage to an appropriate level.It comprises of the following: 1) 2) 3) 4) 5) 6) Rectifier Transformer Thyristor Bridge Field Flashing Unit Field Discharge Resistor Field Breaker Automatic Voltage Regulator

Rectifier Transformer Type Capacity Voltage i) High voltage side ii) Low voltage side Phase Percentage impedence Frequency Type of cooling Mode of connection between low voltage terminals and thyristor converter Weight of the transformer Overall dimension : : 5100Kg 1400*1100*1100mm : : : : : : : : : EXHK 1500KVA 18KV 705V 3 phase 8% 50C/S Air Bars

Rectifier Assembly Type Rated rectified voltage Rated rectified current Ceiling voltage rating Ceiling current rating Ceiling duty duration SCR base temperature at rated output : : : : : : : : : : ANSALDO 438volts 1327Amp 876volts 2654Amp 10 sec 125 C 2*1200 volts 1.5volts 3-Phase bridge type : 1400volts : 100%

Rated PIV Maximum voltage drop across Rectifier Type of connection Over voltage withstand capacity on DC side Percentage spare capacity of rectifiers On the basis of generator rotor rated Full load excitation Wheather field supression arrangement provided

: : : :

yes 32KW 15KW 5520*2380(+820)* 1100mm

Total loss in excitation system at rated output Cooling power requirement for thyristor converter Overall dimension of assembly AUTOMATIC VOLTAGE REGULATOR Manufacturer Type : :

ANSALDO MGT-1

 Power supply to the regulator Range of voltage adjustment(%) i) in auto position ii) in manual position Frequency range of operation Temperature range of operation Accuracy Dead band Response time

: : :

15 volts

85 to 110% 25 to 110% : 47 to 53 Hz : 0 to 40 C : +0.5 0 0.03 sec

: :

RECTIFIER TRANSFORMERS: The excitation power is taken from generator output . the rectifier transformer steps down voltage from generator voltage to lower level. Suitable from SCR bridge and the power is transferred through field breaker to generator field. The rectified transformer should have high reliability as failure of same will cause shut down of unit. It is chosen suitably to rated excitation current continuously and ceiling current for 10 seconds. THYRISTOR BRIDGE: The Thyristor bridge consists of N+1 bridges connected in parallel, where N is number of bridges meet the ceiling requirements . By changing the firing angle of thyristor, variable output is obtained. These bridges are equipped with protection devices and failure of one bridge cause alarm. Each bridge comprises of six thyristors, working as fully controlled bridge. In case of second bridge current is limited to preset value. Failure of third bridge will trip and rapidly de-excite the machine. FIELD FLASHING UNIT: For initial build up of excitation Field Flashing unit is required. It comprises of 415V AC supply taken from station supply with rectifier, filter circuit and one 220V DC supply unit. As the voltage level

reaches a preset value of approximately 30% this switch over to Manual channel takes place and the field flashing unit is taken out. At a level of 70%, the excitation further build up by using Auto channel. FIELD BREAKER: The field breaker is selected to carry the full load excitation continuously. It should also be suitable break the maximum field current in case of 3-phase short circuit. DISCHARGE RESISTOR: This is used to dissipate the energy stored in the rotor at the time of tripping of generator. RELAYS: The job of a relay is to discriminate between a fault within its zone of protection and all other system conditions. It must act energize that trip coil of its associated circuit breakers and provide security against faults tripping for fault out side zones. A relay is made secure and dependable by designing into it a logical decision making capability such that it produce correct output. GENERATOR PROTECTIONS INTRODUCTION The heart of an electric power generating station utility is the synchronous generator. The parameters of these typical machines are in high availability and reliable operation of these large plants connected to 132KV, 220KV, 400KV networks is of great importance in sustaining the grid connecting number of utilities and maintaining power system stability. Therefore, the protection of generators involves the considerations of harmful abnormal operating conditions. The machines and its auxiliaries are supervised by

monitoring devices to keep the incidences of abnormal working conditions down to minimum, despite monitoring, electrical and mechanical faults may occur. The most important point to be considered when designing a protection scheme is to reduce the down time & the cost of repairing the machine following a fault condition. In order to minimize the fault damage the generator protection should have adequate sensitivity to detect the fault conditions for which it is provided and should be sufficiently fast in operation to clear the fault in such time period so as to avoid the instability of the power system. NTPC generating stations are designed to clear all such faults by the protection systems within 80 milliseconds.

General requirements for the protection relays are.

1. 2. 3. 4. 5. 6. Type of the relay electromechanical or static or numerical. Conformation to standards IS IS: 3231, IS:868 AND IEC255 Type of mounting of the really on the panel Flush or Projection. Provisions are made for easy isolation of trip circuits for testing and maintenance. Suitable for efficient and reliable operation of the protection scheme. All the protection relays, auxiliary relays and timers except the lockout relays and interlocking relays are provided with self reset contacts. The trip lockout relays and interlocking relays are manual reset type. The protection and control equipment and circuitry are arranged to provide two independent high performance and reliable protection systems with separate DC supplies. Separate CT/VT cores and separate cables to obtain 100% reliability. Blind zones are completely eliminated. Associated trip relays of the two systems are separate having sufficient number of contacts for all the functions. Each protection system shall energize both the trip coils of the circuit breaker.

7.

8.

GENERATOR HAZARDS:
The generator are prone to the following Stator insulation failure

Over voltage Rotor Faults Loss of synchronism Over/under frequency Over Load Unbalance Loading Loss of Excitation Out of step ( or Pole slip ) Reverse Power Inadvertent Energisation

Following Protections are provided for generator and generator transformer. These protection functions are clubbed in-group A or group B. Each group is independent of each other in respect of CT / CVT core, DC supply, cables. Failure of one group shall not affect in the performance of the other group.

AUXILIARIES
Auxiliaries form nucleus for the efficient running of a generating unit and the total load on auxiliaries in a power station is of the order of 7 % to 9 % of the plant capacity or the actual power generated, depending on station load pf. The generating plant is no more reliable than its auxiliaries and as such for high availability of plant auxiliaries; it is essential that reliability of electric supply should be ensured for feeding these auxiliaries. Further total reliability of this system is a function of the inherent reliability of individual equipment, the main scheme of auxiliary power supply including standby supply, schemes of electrical protection and schemes of thermal/technological control.

Classification of Auxiliaries
The auxiliaries in a thermal power station can be broadly divided into two parts: Unit Auxiliaries Station Auxiliaries

Unit auxiliaries are those, which are directly associated with the
generating unit such as ID and FD Fans, boiler feed pumps, coal mills, mill fans, circulating water pumps etc.

Station auxiliaries are those, which are required for general station
services such as coal and ash handling system, lighting system, waterpurifying system. In a power plant there are many equipments which need full proof standby in the event of AC supply failure e.g. oil pump for TG bearings, seal oil pump for Generator etc. Also there are protections, relays etc. which require DC supply. The DC power is supplied by the batteries, which normally float with the rectifier system by the absolute protection. Batteries are also used to provide illumination in certain sensitive areas where otherwise work will come to standstill TRANSFORMERS A transformer is a static (or stationary) piece of apparatus by means of which electric power in one circuit is transformed to electric power of the same frequency in another circuit. It can raise or lower the voltage in a circuit but with a corresponding decrease or increase in current. Principle of a transformer In its simplest form, it consists of two inductive coils, which are electrically separated but magnetically linked through a path of low reluctance as shown. The two coils possess high mutual inductance. If one coil is connected to a source of alternating voltage, an alternating flux is set up in the laminated core and it produces mutually induced emf. If the second coil circuit is closed, a current flows in it and so electrical energy is transferred from the first coil to the second coil. The first coil, in which electrical energy is fed from the ac supply mains, is called primary winding, while the second coil is known as secondary winding. The necessity of the transformer arises when voltages are required to be changed. For example, the generated voltage of the alternators will be around 18 KV but for all important purposes it will be transmitted in order of 400KV.hence is the requirement of a transformer.

Transformers Constructional Features

The simple elements of a transformer consist of two coils having mutual inductance and a laminated steel core. The two coils are insulated from each other and the steel core. Other parts are (a) suitable container for the assembly core and windings, (b) Suitable medium for insulating the core and its windings from tits container and (c) suitable bushings for insulating and bringing out the terminals of the winding from the tank. The transformers are of two general types: distinguished from each other by the manner in which the primary and secondary coils are placed around the laminated steel core. They are (a) shell type and (b) core type The transformer used in 200MW plant is a shell type transformer . It is an oil forced air forced and oil natural air natural transformer i.e. the type of cooling it utilizes. In the 500MWt stage It uses three single phase transformers one each for three phases(R, Y, B). Transformers are protected by making use of sprinkler system, soak pit (capacity 2000 liters) etc. Over hanging protection is used for the protection of the plant in between the generators and the switch yard. The power is generated at 18KV. There are two transformers. One a step up transformer which steps up the voltage to 400KV for transmission purposes and the other which steps down the voltage to 6.6KV for internal purposes i.e. to supply power to auxiliary equipment used for various purposes like excitation system, running of unit control rooms, auxiliaries etc.

ELECTRICAL SWITCHGEAR
What are switchgears? In simple language switchgear is one, which makes or breaks an electrical circuit. Numerous problems encountered in erection, testing and commissioning of the switchgear and various precautions are to be taken in operation and maintenance of he switchgear. The equipments, which normally fall in this category, are Isolators

Switching isolators Circuit breakers Load break switches Earth switches

An isolator is one, which can break an electric circuit when the circuit is to be switched on no-load. These are normally used in various circuits for the purposes of isolating a certain portion when required for maintenance etc. Switching Isolators are capable of Interrupting transformer magnetized currents Interrupting line charging current Load transfer switching Its main application is in connection with transformer feeder as this unit makes it possible to switch out one transformer while the other is still on load. Its main purpose is to be used in place of air blast circuit breaker to switch generators in and out of service, where the noise from the circuit breakers had proved troublesome to bear. A circuit breaker is one, which can break or make the circuit on load and even on faults. The equipment is most important and is heavy-duty equipment mainly utilized for protection of the various circuits and operation at load. Normally Circuit Breakers are installed accompanied by isolators. Load break switches are those interrupting devices, which can make or break circuits at rated current. These are normally installed on the same circuit or on he circuits which are backed up by circuit breakers. Earth switches are devices, which are normally used to earth a particular system to avoid accident, which may happen due to induction on account of live adjoin circuit. These do not handle any appreciable current at all. Earth switches in the switchyard are simple mechanically operated switches, the purpose of which is to earth the bus if required for the purpose eliminating induced voltage in the particular bay on account of

parallel running live conductors. It is always accompanied by an Auxiliary Switch to provide interlock and indication contact.

RSTPS 400 KV SWITCH YARD

400 KV Switchyard of Ramagundam Super Thermal Power Station is the most vital switching station in the southern Grid 2600 MW of Bulk Power generated by three 200 MW Units and three 500 MW Units plus 1*500MW units of NTPC Ramagundam is evacuated for supplying to the southern states. Switchyard consists of two 400 KV bus bar systems fed by 6 Nos. of generator feeders, 7 No of 400 KV feeders, 3 No of 220 KV feeders and two nos. of 132 Kv feeders as shown in the single line diagram of 400 Kv switch yard. In addition to the above, three nos. of Tie Transformers, five nos. of Auto Transformers and two nos. of Shunt Reactors are provided as shown in the switchyard line diagram. AUTO TRANSFORMERS Five Auto Transformers with on Load Tap Changers are provided to interconnect the 400 Kv system of NTPC and 220/132 Kv system of AP Transco, Malyalapally sub station TIE TRANSFORMER Three nos. of Tie Transformers are provided for feeding power to station auxiliaries like Cooling water & Raw water pumps, Coal Handling & water treatment Plants, Ash & Fuel Handling pumps, Cooling towers and lighting requirements of station & colony. SHUNT REACTORS

Long lines when lightly loaded, the receiving end voltage raises, due to Ferranti effect. Shunt Reactors produce lagging MVAR there by control the receiving end voltages during lightly loaded conditions. Shunt reactors also limit the short circuit fault levels.

SWITCHYARD EQUIPMENT
Brief description about switchyard equipment is given below. CIRCUIT BREAKER

It is an automatic device capable of making and breaking an Electrical Circuit under normal and abnormal conditions such as short circuits. SF6 is the arc quenching media for all the 400 KV and 220 KV breakers installed in the switchyard. Pneumatic operating system is provided in AEG, ABB and NGEF make breakers and Hydraulic operating system is provided in BHEL make breakers. Breaker provided in 132 KV lines is of Minimum oil type operating on spring charge mechanism. 1.5 break system is employed, that is 3 circuit breakers for two feeders.

ISOLATORS

Isolator is an off load device provided in conjunction with circuit breaker to disconnect the equipment or the section, which is to be isolated from all other live parts. The isolators provided in the switchyard are of central break type. The operation of Isolators can be done from control room (remote) or local. Motorized operation for opening & closing of Isolator is provided, however Isolators can also be opened & closed manually in the even of non-availability of motorized operation. EARTH SWITCH

Earth switch is mounted on the isolator base on the line side or breaker side depending upon the position of the isolator. The earth switch usually comprises of a vertical break switch arm with the contact, which engages with the isolator contact on the line side. Earth switch is required to discharge the trapped charges on the line or equipment (under shut own) to

earth for maintaining safety. Earth switch can be operated only from local either by electrical operation or manually. It is usually placed at one meter depth 40mm in cross-section, with resistance <1 ohm.

BUS BAR

Bus bar is an Aluminium tube of 4 IPS having wall thickness of 0.4, where all incoming and outgoing feeders are connected in a schematic way to enable smooth operation and Maintenance of equipment without any interruption to the system. At RSTPS one and half breaker scheme is provided for 200 MW generator feeders and 400 KV outgoing lines, Twobreaker scheme is provided for 500 MW generator feeders.

SURGE / LIGHTING ARRESTERS

Surge Arresters are provided to ground the over voltage surges caused by switching and lighting surges. Surge Arresters provide leakage path to the ground whenever the system voltage rises above the specified value. They are equipped with surge monitors which measures the leakage currents and a counter to record the number of surges taken place.

CURRENT TRANSFORMER (CT)

Current Transformers are provided to step down the current to low values suitable for measuring protection and control instruments. Current Transformers also isolate measuring and protective devices from high system voltage. CTs in the switchyard consist of five secondary cores. Core 1&2 are used for busbar protection, 4 & 5 are for main 1&2 protection and core 3 is for measuring instruments. CAPACITIVE VOLTAGE TRANSFORMER (CVT)

CVTs step-down the system voltage to sufficiently low value (110 V) for measuring, protection and synchronizing circuits. CVT has a H.F. terminal point for receiving & transmitting the high frequency signals for carrier protection and communication.

WAVE TRAP

Wave Trap is a parallel resonant circuit tuned to the carrier frequency connected in series with the line conductor at each end of the protected transmission line section. Wave trap offers high impedance path for high frequency signals and low impedance path for power frequency current. This keeps carrier signal confined to the protected line section and does not allow the carrier signals to flow into the neighboring sections.

SWITCH YARD CONTROL ROOM EQUIPMENT

The control room is the place where the conditions of the system are monitored, controls initiated and operations are integrated. Control room consists of the following equipment. CONTROL PANELS RELAY PANELS INDICATING & RECORDING INSTRUMENT GENERATION DATA ACQUISITION AND MONITORING SYSTEM (GDAMS) EVENT LOGGER Event Logger recognizes the changes in signal-input states, plus time data allocation for sequential recording of events. It displays the events in a time sequential of 1/ sec, such as opening/closing of breaker poles, Isolator poles, E/S etc. pressure high/low of air, SF6, N2 Oil etc. This is one of the important diagnostic equipment available to operation staff to understand the type of emergency in a flick of a second.

MASTER CLOCK One maser clock is provide in switchyard control room to synchronize the timings of all the Event loggers, DAS ( Data Acquisition system of units),Disturbance Recorders, clocks provided in control rooms, etc., to maintain a uniform time, so that the sequence of events can be recorded and analyzed to know the cause of disturbance.

DISTURBANCE RECORDER

Equipment D/R is the most vital diagnostic equipment in analysis of post fault trappings.

FAULT LOCATOR

When a line tripped on fault, the Fault Locator provided in the Relay panel indicates the approximate distance of the fault location so that Maintenance group easily tract the fault and clear it. PLCC ( power line carrier communication )

In order to achieve fast clearance and correct discrimination for faults in 400 KV transmission network, it is necessary to signal between the points at which protection relays are connected. PROTECTIVE RELAYS A relay detects the faulty element in the integrated power system and removes it, with the help of the circuit breaker, from the remaining healthy system as quickly as possible to avoid damage and maintain security or reliability of supply in the healthy system. The quality of relaying depends on its sensitivity, selectivity, speed and reliability. Varieties of protection relays are provided to protect EHV lines and Transformers.