BADARPUR THERMAL POWER STATION NEW DELHI

SUMMER TRAINING REPORT

(N.T.P.C. BADARPUR, NEW DELHI : from 28th May 2012 to 30th June, 2012)

SUBMITTED BY: POOSHAN B.Tech. VII SEM. ELECTRICAL ENGINEERING MarwarEngineeringCollege & Research Centre,Jodhpur

INDEX
1. Introduction 1.1 NTPC 1.2 Badarpur Thermal Power Station 2. Operation

3. Electrical Maintenance Division-I 3.1HT/LT Switch Gear 3.2HT/LT Motors 4. Electrical Maintenance Division-II 4.1 Generator 4.2 Transformer & Switchyard 4.3 Protection 5. Conclusion

ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training here. I do extend my heartfelt thanks to Mr. Manmohan Singh (HR-EDC)for providing me this opportunity to undergo the training programme under the able guidance of NTPC engineers. I would also give special thanks Mr .S.P. Vashishth(DGM-EMD I) and Mr.S.K.Marwaha (DGM-EMD II ).I would thank to Er. Rajat Garg (HT/LT Switchgear), Er. Saurabh Garg (LT /HT Motor), Mr.B.P. Sinha(Supdt.,Switchyard) & under whose able guidance I completed my training. All these people were of immense importance regarding the knowledge and supports for the well furnished equipments. Special gratitude towards Mr. Sunil Kumar who provided us the best moral support which I was in need for. I am extremely grateful to all the technical staff of BTPS/NTPC for their co-operation and guidance that helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted of them for this value addition in me. I would also like to thank the training incharge of Marwar Engineering College & Research Centre, Jodhpur and all the faculty member of Electrical department for their effort of constant co-operation. Which have been significant factor in the accomplishment of my industrial training.

Training at BTPS
I was appointed to do eight-week training at this esteemed organization from 28th May to 30th June 2012. In these five weeks I was assigned to visit various division of the plant which were 1. Operation 2. Electrical maintenance division I (EMD-I) 3. Electrical maintenance division II (EMD-II) This five-week training was a very educational adventure for me. It was really amazing to see the plant by your self and learn how electricity, which is one of our daily requirements of life, is produced. This report has been made by self-experience at BTPS. The material in this report has been gathered from my textbooks, senior student report, and mannual provided by training department. The specification & principles are at learned by me from the employee of each division of BTPS.

1. INTRODUCTION 1.1 ABOUT NTPC

Established in 1975, NTPC the largest power company of the country has been consistently powering the growth of India. With an installed capacity of 30,144 MW, it contributes 28.6% of the nations power generation with only 18.79% of Indias total installed capacity. An ISO 9001:2000 certified company, it is worlds sixth largest thermal power generator and second most efficient in capacity utilization. The corporation recorded a generation of 206.94 billion units (bus) in 2008-09, an increase of 3.03% over 2007-08, through 13 coal based and 7 gas based power plants spreads all over the country. Rated as one of the Best companies to work for in India it has developed in to a multi-location and multi fuel Company over the past three decades. Driven by its vision to lead, it has charted out an ambitious growth plan of becoming a 40,000 MW plus company by 2012. 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, Government of India holds 89.5% of the total equity shares of the company and FIIs, Domestic Banks, Public and others hold the balance 10.5%. With in a span of 31 years, NTPC has emerged as a truly national power company, with power generating facilities in all the major regions of the country.

1.2 ABOUT BADARPUR THERMAL POWER STATION

Address

Badarpur,New Delhi 110 044

Installed capacity Derated Capacity Location Coal Source Water Source Beneficiary States Unit Sizes Units Commissioned

720 MW 705 MW New Delhi Jharia Coal Fields Agra Canal Delhi 3X95 MW 2X210 MW Unit I- 100 MW - July 1973 Unit II- 100 MW August 1974 Unit III- 100 MW March 1975 Unit IV - 210 MW December 1978 Unit V - 210 MW - December 1981 Ownership of BTPS was transferred to NTPC with from 01.06.2006 through GOIs

International Assistance effect . Gazette Notification

2.1 PRINCIPLE OF OPERATION

For each process in a vapour power cycle, it is possible to assume a hypothetical or ideal process which represents the basis intended operation and do not produce any extraneous effect like heat loss. 1. For steam boiler, this would be a reversible constant pressure heating process of water to form steam. 2. For turbine, the ideal process would be a reversible adiabatic expansion of steam. 3. For condenser, it would be a reversible a constant pressure heat rejection as the steam condenser till it becomes saturated liquid. 4. For pump, the ideal process would be the reversible adiabatic compression of liquid ending at the initial pressure. When all the above four cycles are combined, the cycle achieved is called RANKINE CYCLE. Hence the working of a thermal power plant is based upon Rankine cycle with some modification.

2.2 ELECTRICITY FROM COAL

Fig. Typical diagram of a coal fired thermal power station

Coal from the coal wagons is unloaded with the help of wagon tipplers in the C.H.P. this coal is taken to the raw coal bunkers with the help of conveyor belts. Coal is then transported to bowl mills by coal feeders where it is pulverized and grind in the powdered form. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold mixture P.A fan. This fan takes atmospheric air, a part of which is sent to pre heaters while a part goes to the mill for temperature control. Atmospheric air from F.D fan in the air heaters and sent to the furnace as combustion air. Water from boiler feed pump passes through economizer and reaches the boiler drum . Water from the drum passes through the down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four

sides of the furnace. Due to heat density difference the water rises up in the water wall tubes. This steam and water mixture is again taken to the boiler drum where the steam is sent to super heaters for super heating. The super heaters are located inside the furnace and the steam is super heated (540 degree Celsius) and finally it goes to the turbine. Flue gases from the furnace are extracted from the induced draft fan, which maintains balance draft in the furnace with F.D fan. These fuel gases heat energy to the various super heaters and finally through air pre heaters and goes to electrostatic precipitators where the ash particles are extracted. This ash is mixed with the water to from slurry is pumped to ash pond. The steam from boiler is conveyed to turbine through the steam pipes and through stop valve and control valve that automatically regulate the supply of steam to the turbine. Stop valves and controls valves are located in steam chest and governor driven from main turbine shaft operates the control valves the amount used. Steam from controlled valves enter high pressure cylinder of turbines, where it passes through the ring of blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on the disc secured in the turbine shaft. The second ring turns the shaft as a result of force of steam. The stationary and moving blades together.

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Fig. Flow diagram

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2.2.2

Main components of the thermal power station are as follows :-

1. Cooling water pump 2. Three-phase transmission line 3. Step up transformer 4. Electrical Generator 5. Low pressure steam 6. Boiler feed water pump 7. Surface condenser 8. Intermediate pressure steam turbine 9. Steam control valve 10. High pressure steam turbine 11. Deaerator Feed water heater 12. Coal conveyor 13. Coal hopper 14. Coal pulverizer 15. boiler steam drum 16. Bottom ash hoper 17. Super heater 18. Forced draught(draft) fan 19. Reheater 20. Combustion air intake 21. Economizer 22. Air preheater 23. Precipitator 24. Induced draught(draft) fan 25. Flue gas stack

The description of some of the components written above is described as follows: 1. Cooling towers Cooling Towers are evaporative coolers used for cooling water or other working medium to near the ambivalent web-bulb air temperature. Cooling tower use evaporation of water to reject heat from processes such as cooling the circulating water used in oil refineries, Chemical plants, power plants and building cooling, for example. The tower vary in size from small roof-top units to very large hyperboloid structures that can be up to 200 meters tall and 100 meters in diameter, or rectangular structure that can be over 40 meters tall and 80 meters long. Smaller towers are normally factory built, while larger ones are constructed on site. The primary use of large , industrial cooling tower system is to remove the heat absorbed in the circulating cooling water systems used in power plants , petroleum refineries, petrochemical and chemical plants, natural gas processing plants and

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other industrial facilities . The absorbed heat is rejected to the atmosphere by the evaporation of some of the cooling water in mechanical forced-draft or induced draft towers or in natural draft hyperbolic shaped cooling towers as seen at most nuclear power plants. 2.Three phase transmission line Three phase electric power is a common method of electric power transmission. It is a type of polyphase system mainly used to power motors and many other devices. A Three phase system uses less conductor material to transmit electric power than equivalent single phase, two phase, or direct current system at the same voltage. In a three phase system, three circuits reach their instantaneous peak values at different times. Taking one conductor as the reference, the other two current are delayed in time by one-third and two-third of one cycle of the electrical current. This delay between phases has the effect of giving constant power transfer over each cycle of the current and also makes it possible to produce a rotating magnetic field in an electric motor. At the power station, an electric generator converts mechanical power into a set of electric currents, one from each electromagnetic coil or winding of the generator. The current are sinusoidal functions of time, all at the same frequency but offset in time to give different phases. In a three phase system the phases are spaced equally, giving a phase separation of one-third one cycle. Generators output at a voltage that ranges from hundreds of volts to 30,000 volts. At the power station, transformers: step-up this voltage to one more suitable for transmission. After numerous further conversions in the transmission and distribution network the power is finally transformed to the standard mains voltage (i.e. the household voltage). The power may already have been split into single phase at this point or it may still be three phase. Where the step-down is 3 phase, the output of this transformer is usually star connected with the standard mains voltage being the phase-neutral voltage. Another system commonly seen in North America is to have a delta connected secondary with a center tap on one of the windings supplying the ground and neutral. This allows for 240 V three phase as well as three different single phase voltages( 120 V between two of the phases and neutral , 208 V between the third phase ( known as a wild leg) and neutral and 240 V between any two phase) to be available from the same supply. 3.Electrical generator An Electrical generator is a device that converts kinetic energy to electrical energy, generally using electromagnetic induction. The task of converting the electrical energy into mechanical energy is accomplished by using a motor. The source of mechanical energy may be a reciprocating or turbine steam engine, , water falling through the turbine are made in a variety of sizes ranging from small 1 hp (0.75 kW) units (rare) used as mechanical drives for pumps, compressors and other shaft driven equipment , to 2,000,000 hp(1,500,000 kW) turbines used to generate

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electricity. There are several classifications for modern steam turbines. Steam turbines are used in all of our major coal fired power stations to drive the generators or alternators, which produce electricity. The turbines themselves are driven by steam generated in Boilers or steam generators as they are sometimes called. Electrical power station use large stem turbines driving electric generators to produce most (about 86%) of the worlds electricity. These centralized stations are of two types: fossil fuel power plants and nuclear power plants. The turbines used for electric power generation are most often directly coupled to their-generators .As the generators must rotate at constant synchronous speeds according to the frequency of the electric power system, the most common speeds are 3000 r/min for 50 Hz systems, and 3600 r/min for 60 Hz systems. Most large nuclear sets rotate at half those speeds, and have a 4-pole generator rather than the more common 2-pole one. Energy in the steam after it leaves the boiler is converted into rotational energy as it passes through the turbine. The turbine normally consists of several stage with each stages consisting of a stationary blade (or nozzle) and a rotating blade. Stationary blades convert the potential energy of the steam into kinetic energy into forces, caused by pressure drop, which results in the rotation of the turbine shaft. The turbine shaft is connected to a generator, which produces the electrical energy. 4.Boiler feed water pump A Boiler feed water pump is a specific type of pump used to pump water into a steam boiler. The water may be freshly supplied or retuning condensation of the steam produced by the boiler. These pumps are normally high pressure units that use suction from a condensate return system and can be of the centrifugal pump type or positive displacement type. Construction and operation Feed water pumps range in size up to many horsepower and the electric motor is usually separated from the pump body by some form of mechanical coupling. Large industrial condensate pumps may also serve as the feed water pump. In either case, to force the water into the boiler; the pump must generate sufficient pressure to overcome the steam pressure developed by the boiler. This is usually accomplished through the use of a centrifugal pump. Feed water pumps usually run intermittently and are controlled by a float switch or other similar level-sensing device energizing the pump when it detects a lowered liquid level in the boiler is substantially increased. Some pumps contain a two-stage switch. As liquid lowers to the trigger point of the first stage, the pump is activated. I f the liquid continues to drop (perhaps because the pump has failed, its supply has been cut off or exhausted, or its discharge is blocked); the second stage will be triggered. This stage may switch off the boiler equipment (preventing the boiler from running dry and overheating), trigger an alarm, or both.

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5. Steam-powered pumps Steam locomotives and the steam engines used on ships and stationary applications such as power plants also required feed water pumps. In this situation, though, the pump was often powered using a small steam engine that ran using the steam produced by the boiler. A means had to be provided, of course, to put the initial charge of water into the boiler(before steam power was available to operate the steam-powered feed water pump).the pump was often a positive displacement pump that had steam valves and cylinders at one end and feed water cylinders at the other end; no crankshaft was required. In thermal plants, the primary purpose of surface condenser is to condense the exhaust steam from a steam turbine to obtain maximum efficiency and also to convert the turbine exhaust steam into pure water so that it may be reused in the steam generator or boiler as boiler feed water. By condensing the exhaust steam of a turbine at a pressure below atmospheric pressure, the steam pressure drop between the inlet and exhaust of the turbine is increased, which increases the amount heat available for conversion to mechanical power. Most of the heat liberated due to condensation of the exhaust steam is carried away by the cooling medium (water or air) used by the surface condenser. 6. Control valves Control valves are valves used within industrial plants and elsewhere to control operating conditions such as temperature,pressure,flow,and liquid Level by fully partially opening or closing in response to signals received from controllers that compares a set point to a process variable whose value is provided by sensors that monitor changes in such conditions. The opening or closing of control valves is done by means of electrical, hydraulic or pneumatic systems 7. Deaerator A Dearator is a device for air removal and used to remove dissolved gases (an alternate would be the use of water treatment chemicals) from boiler feed water to make it non-corrosive. A dearator typically includes a vertical domed deaeration section as the deaeration boiler feed water tank. A Steam generating boiler requires that the circulating steam, condensate, and feed water should be devoid of dissolved gases, particularly corrosive ones and dissolved or suspended solids. The gases will give rise to corrosion of the metal. The solids will deposit on the heating surfaces giving rise to localized heating and tube ruptures due to overheating. Under some conditions it may give to stress corrosion cracking. Deaerator level and pressure must be controlled by adjusting control valves- the level by regulating condensate flow and the pressure by regulating steam flow. If operated properly, most deaerator vendors will guarantee that oxygen in the 15

deaerated water will not exceed 7 ppb by weight (0.005 cm3/L) 8. Feed water heater A Feed water heater is a power plant component used to pre-heat water delivered to a steam generating boiler. Preheating the feed water reduces the irreversible involved in steam generation and therefore improves the thermodynamic efficiency of the system.[4] This reduces plant operating costs and also helps to avoid thermal shock to the boiler metal when the feed water is introduces back into the steam cycle. In a steam power (usually modeled as a modified Ranking cycle), feed water heaters allow the feed water to be brought up to the saturation temperature very gradually. This minimizes the inevitable irreversibilitys associated with heat transfer to the working fluid (water). A belt conveyor consists of two pulleys, with a continuous loop of material- the conveyor Belt that rotates about them. The pulleys are powered, moving the belt and the material on the belt forward. Conveyor belts are extensively used to transport industrial and agricultural material, such as grain, coal, ores etc.

9. Pulverizer A pulverizer is a device for grinding coal for combustion in a furnace in a fossil fuel power plant. 10. Boiler Steam Drum Steam Drums are a regular feature of water tube boilers. It is reservoir of water/steam at the top end of the water tubes in the water-tube boiler. They store the steam generated in the water tubes and act as a phase separator for the steam/water mixture. The difference in densities between hot and cold water helps in the accumulation of the hotter-water/and saturated steam into steam drum. Made from high-grade steel (probably stainless) and its working involves temperatures 390C and pressure well above 350psi (2.4MPa). The separated steam is drawn out from the top section of the drum. Saturated steam is drawn off the top of the drum. The steam will re-enter the furnace in through a super heater, while the saturated water at the bottom of steam drum flows down to the mud-drum /feed water drum by down comer tubes accessories include a safety valve, water level indicator and fuse plug. A steam drum is used in the company of a mud-drum/feed water drum which is located at a lower level. So that it acts as a sump for the sludge or sediments which have a tendency to the bottom.

11. Super Heater 16

A Super heater is a device in a steam engine that heats the steam generated by the boiler again increasing its thermal energy and decreasing the likelihood that it will condense inside the engine. Super heaters increase the efficiency of the steam engine, and were widely adopted. Steam which has been superheated is logically known as superheated steam; non-superheated steam is called saturated steam or wet steam; Super heaters were applied to steam locomotives in quantity from the early 20th century, to most steam vehicles, and so stationary steam engines including power stations. 12. Economizers Economizer, or in the UK economizer, are mechanical devices intended to reduce energy consumption, or to perform another useful function like preheating a fluid. The term economizer is used for other purposes as well. Boiler, power plant, and heating, ventilating and air conditioning. In boilers, economizer are heat exchange devices that heat fluids , usually water, up to but not normally beyond the boiling point of the fluid. Economizers are so named because they can make use of the enthalpy and improving the boilers efficiency. They are a device fitted to a boiler which saves energy by using the exhaust gases from the boiler to preheat the cold water used the fill it (the feed water). Modern day boilers, such as those in cold fired power stations, are still fitted with economizer which is decedents of Greens original design. In this context they are turbines before it is pumped to the boilers. A common application of economizer is steam power plants is to capture the waste hit from boiler stack gases (flue gas) and transfer thus it to the boiler feed water thus lowering the needed energy input , in turn reducing the firing rates to accomplish the rated boiler output . Economizer lower stack temperatures which may cause condensation of acidic combustion gases and serious equipment corrosion damage if care is not taken in their design and material selection. 13. Air Preheater Air preheater is a general term to describe any device designed to heat air before another process (for example, combustion in a boiler). The purpose of the air preheater is to recover the heat from the boiler flue gas which increases the thermal efficiency of the boiler by reducing the useful heat lost in the fuel gas. As a consequence, the flue gases are also sent to the flue gas stack (or chimney) at a lower temperature allowing simplified design of the ducting and the flue gas stack. It also allows control over the temperature of gases leaving the stack. 14. Precipitator An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that removes particles from a flowing gas (such As air) using the force of an induced electrostatic charge. Electrostatic precipitators are highly efficient filtration devices, and can easily remove fine particulate matter such as dust and smoke from the air steam. 17

ESPs continue to be excellent devices for control of many industrial particulate emissions, including smoke from electricity-generating utilities (coal and oil fired), salt cake collection from black liquor boilers in pump mills, and catalyst collection from fluidized bed catalytic crackers from several hundred thousand ACFM in the largest coal-fired boiler application. The original parallel plate-Weighted wire design (described above) has evolved as more efficient ( and robust) discharge electrode designs were developed, today focusing on rigid discharge electrodes to which many sharpened spikes are attached , maximizing corona production. Transformer rectifier systems apply voltages of 50-100 Kilovolts at relatively high current densities. Modern controls minimize sparking and prevent arcing, avoiding damage to the components. Automatic rapping systems and hopper evacuation systems remove the collected particulate matter while on line allowing ESPs to stay in operation for years at a time. 15. Flue gas stack A Flue gas stack is a type of chimney, a vertical pipe, channel or similar structure through which combustion product gases called fuel gases are exhausted to the outside air. Fuel gases are produced when coal, oil, natural gas, wood or any other large combustion device. Fuel gas is usually composed of carbon dioxide (CO2) and water vapor as well as nitrogen and excess oxygen remaining from the intake combustion air. It also contains a small percentage of pollutants such as particulates matter, carbon mono oxide, nitrogen oxides and sulfur oxides. The flue gas stacks are often quite tall, up to 400 meters (1300 feet) or more, so as to disperse the exhaust pollutants over a greater aria and thereby reduce the concentration of the pollutants to the levels required by governmental environmental policies and regulations. When the fuel gases exhausted from stoves, ovens, fireplaces or other small sources within residential abodes, restaurants , hotels or other stacks are referred to as chimneys

2.3 COAL, WATER & STEAM CYCLE

2.3.1 COAL CYCLE

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C.H.P Plant Boiler section 1. R.C Feeder:

Bunker

R.C Feeder

Pulverization mill

It is an induction motor driven device, which determine the Quantity of coal enter in the pulverize mill. 2. Pulverization mill: Pulverization means exposing a large surface area to the

action of oxygen .Two Types of mill are used in the plant. 3. Ball mill: A ball mill operates normally under suction. A large drum partly filled with steel balls, is used in this mill .The drum is rotated slowly while coal is fed in to it .The ball pulverize the coal by crushing. This type of mill is used in stage-1. 4. Contact mill: This mill uses impact principle. All the grinding elements and the primary air fan are mounted on a single shaft. The flow of air carries coal to the primary stage where it is reduced to a fine granular state by impact with a series of hammers. This type of mill is used in stage-2.

2.3.2 WATER CYCLE

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D.M Plant

Hot well Derater

C.E.P Pump Boiler Feed Pump

Low Pressure Heater 1, 2, 3,4 High Pressure Heater 5, 6,7 Economizer Boiler Drum.

Feed Regulating station

1. DERATER: Feed strong tank of water To produce sufficient pressure before feeding to B.F.D.Filter the harmful chemicals. 2. FEED REGULATING STATIONS: Control the quantity of water in to boiler drum. 3. ECONOMISER: Flux gases coming out of the boilers carry lot of heat. An economizer extracts a part of this heat from the flue gases and uses it for heating the feed water.

4. DRAFTS SYSTEM: In forced draft system the fan is installed near the base of the boiler furnace. This fan forces air through the furnace, economizer, air preheater and chimney. In an induced draft system, the fan is installed near the base of Chimney.

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2.3.3

STEAM CYCLE Ring Header H.P Turbine L.P Turbine Boiler Drum (Steam chamber) Reheater condenser

Boiler Drum Super Heater I.P Turbine

1. BOILER: Boiler drum consists two chambers water chamber, steam chamber. Before Entering in super heater the steam is going in to boiler drum, where the boiler drum filtered the moisture and stored in to water chamber. 2. SUPER HEATER: The function of super heater is to remove the last traces of moisture from the saturated steam leaving the tube boiler. The temperature is approx.530 oC. 3. TURBINE: Steam turbine converts the heat energy in to mechanical energy and drives the alternator. The velocity attained during expansions depends on initial and final heat content of the steam. Turbine having number of stages in which the pressure drops takes place.

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2.4 COAL HANDLING PLANT (C.H.P)

The old coal handling plant caters to the need of units 2,3,4,5 and 1 whereas the latter supplies coal to units 4 and V.O.C.H.P. supplies coal to second and third stages in the advent coal to usable form to (crushed) form its raw form and send it to bunk The coal arrives in wagons via railways and is tippled by the wagon tipplers into the hoppers. If coal is oversized (>400 mm sq) then it is broken manually so that it passes the hopper mesh. From the hopper mesh it is taken to the transfer point TP6 by conveyor 12A ,12B which takes the coal to the breaker house , which renders the coal size to be 100mm sq. the stones which are not able to pass through the 100mm sq of hammer are rejected via conveyors 18A,18B to the rejection house . Extra coal is to sent to the reclaim hopper via conveyor 16. From breaker house coal is taken to the TP7 via Conveyor 13A, 13B. Conveyor 17A, 17B also supplies coal from reclaim hopper, From TP7 coal is taken by conveyors 14A, 14B to crusher house whose function is to render the size of coal to 20mm sq. now the conveyor labors are present whose function is to recognize and remove any stones moving in the conveyors . In crusher before it enters the crusher. After being crushed, if any metal is still present it is taken care of by metal detectors employed in conveyor 10 2.4.1 Major Components 1. Wagon Tippler: Wagons from the coal yard come to the tippler and are emptied here. The process is performed by a slip ring motor of rating: 55 KW, 415V, 1480 RPM. This motor turns the wagon by 135 degrees and coal falls directly on the conveyor through vibrators. Tippler has raised lower system which enables is to switch off motor when required till is wagon back to its original position. It is titled by weight balancing principle. The motor lowers the hanging balancing weights, which in turn tilts the conveyor. Estimate of the weight of the conveyor is made through hydraulic weighing machine.ers, from where it is send to furnace. Motor Specification H.P 75 HP (ii) Voltage 415, 3 phase (iii) Speed 1480 rpm (iv) Frequency 50 Hz (v) Current rating 102 A

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2. Conveyor: There are 14 conveyors in the plant. They are numbered so that their function can be easily demarcated. Conveyors are made of rubber and more with a speed of 250-300m/min. Motors employed for conveyors has a capacity of 150 HP. Conveyors have a capacity of carrying coal at the rate of 400 tons per hour. Few conveyors are double belt, this is done for imp. Conveyors so that if a belt develops any problem the process is not stalled. The conveyor belt has a switch after every 25-30 m on both sides so stop the belt in case of emergency. The conveyors are 1m wide, 3 cm thick and made of chemically treated vulcanized rubber. The max angular elevation of conveyor is designed such as never to exceed half of the angle of response and comes out to be around 20 degrees.

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3. Zero Speed Switch:It is safety device for motors, i.e., if belt is not moving and the motor is on the motor may burn. So to protect this switch checks the speed of the belt and switches off the motor when speed is zero. 4. Metal Separators: As the belt takes coal to the crusher, No metal pieces should go along with coal. To achieve this objective, we use metal separators. When coal is dropped to the crusher hoots, the separator drops metal pieces ahead of coal. It has a magnet and a belt and the belt is moving, the pieces are thrown away. The capacity of this device is around 50 kg. .The CHP is supposed to transfer 600 tons of coal/hr, but practically only 300-400 tons coal is transfer

5. Crusher House The plant has four nos. of crushers each capable of crushing coal of 200mm size at the rate of 600T/hr. the crusher with hammer tips is symmetrical in size and shape on either side. In case of wearing out of one side, the other can be used by turning over the tips. These crushers are placed in the crusher house, which have special strong foundations to bear the vibrations due to running of the crushers Both the plants use TATA crushers powered by BHEL. Motors. The crusher is of ring type and motor ratings are 400 HP, 606 KV. Crusher is designed to crush the pieces to 20 mm size i.e. practically considered as the optimum size of transfer via conveyor. 6. Rotatory Breaker: OCHP employs mesh type of filters and allows particles of 20mm size to go directly to RC bunker, larger particles are sent to crushes. This leads to frequent clogging. NCHP uses a technique that crushes the larger of harder substance like metal impurities easing the load on the magnetic separators.

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2.4.2 MILLING SYSTEM 1. RC Bunker: Raw coal is fed directly to these bunkers. These are 3 in no. per boiler. 4 & tons of coal are fed in 1 hr. the depth of bunkers is 10m. 2. RC Feeder: It transports pre crust coal from raw coal bunker to mill. The quantity of raw coal fed in mill can be controlled by speed control of aviator drive controlling damper and aviator change. Feeder motor specification (i) Horse power 15 HP (ii) Voltage 415V,3 phase (iii) Speed 1480 rpm (iv) Frequency 50 Hz

3. Ball Mill: The ball mill crushes the raw coal to a certain height and then allows it to fall down. Due to impact of ball on coal and attraction as per the particles move over each other as well as over the Armor lines, the coal gets crushed. Large particles are broken by impact and full grinding is done by attraction. The Drying and grinding option takes place simultaneously inside the mill. 4. Classifier:It is an equipment which serves separation of fine pulverized coal particles medium from coarse medium. The pulverized coal along with the carrying medium strikes the impact plate through the lower part. Large particles are then transferred to the ball mill. 5. Cyclone Separators: It separates the pulverized coal from carrying medium. The mixture of pulverized coal vapour caters the cyclone separators. 6. The Tturniket: -

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It serves to transport pulverized coal from cyclone separators to pulverized coal bunker or to worm conveyors. There are 4 turnikets per boiler. 7. Worm Conveyor: It is equipment used to distribute the pulverized coal from bunker of one system to bunker of other system. It can be operated in both directions.

8. Mills Fans: It is of 3 types: Six in all and are running condition all the time. (a) ID Fans: Located between electrostatic precipitator and chimney. Type-radical Speed-1490 rpm Rating-300 KW Voltage-6.6 KV Lubrication-by oil (b) FD Fans: Designed to handle secondary air for boiler. 2 in number and provide ignition of coal. Type-axial Speed-990 rpm Rating-440 KW Voltage-6.6 KV (c)Primary Air Fans: Designed for handling the atmospheric air up to 50 degrees Celsius, 2 in number And they transfer the powered coal to burners to firing. Type-Double suction radial Rating-300 KW Voltage-6.6 KV Lubrication-by oil Type of operation-continuous

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9. Bowl Mill: One of the most advanced designs of coal pulverizes presently manufactured. Motor specification squirrel cage induction motor Rating-340 KW Voltage-6600KV Curreen-41.7A Speed-980 rpm Frequency-50 Hz No-load current-15-16 A

CHP then normally follows three coal paths: 1. Path A from track hoppers to bunkers. 2. Path B from track hoppers to stockyard. 3. Path C from stockyard to bunkers.

Path A

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Path-B

Path C

Figure: 3.1 coal paths for C.H.P

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3. EMD I (Electrical Maintenance division I)

I was assigned to do training in Electrical maintenance division I from 28th May 2012 to 16th June 2012. This two week of training in this division were divided as follows.

It is responsible for maintenance of: 1. Boiler side motors 2. Turbine side motors 3. Outside motors 4. Switchgear

3.1 LT/HT MOTOR

1. Boiler side motors: For stage 1, units 1, 2, 3

1.1D Fans 2.F.D Fans 3.P.A.Fans 4.Mill Fans 5.Ball mill fans 6.RC feeders 7.Slag Crushers 8.DM Make up Pump

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9.PC Feeders 10.Worm Conveyor 11.Turnikets

For stage 2 units 1, 2, 3

1.I.D Fans 2.F.D Fans 3.P.A Fans 4.Bowl Mills 5.R.C Feeders 6.Clinker Grinder 7.Scrapper 8.Seal Air Fans 9.Hydrazine and Phosphorous Dozing

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3.2 SWITCH GEARIt makes or breaks an electrical circuit. 1. Isolation: A device which breaks an electrical circuit when circuit is switched on to no load. Isolation is normally used in various ways for purpose of isolating a certain portion when required for maintenance. 2. Switching Isolation: It is capable of doing things like interrupting transformer magnetized current, interrupting line charging current and even perform load transfer switching. The main application of switching isolation is in connection with transformer feeders as unit makes it possible to switch out one transformer while other is still on load. 3. Circuit Breakers: One which can make or break the circuit on load and even on faults is referred to as circuit breakers. This equipment is the most important and is heavy duty equipment mainly utilized for protection of various circuits and operations on load. Normally circuit breakers installed are accompanied by isolators 4. Load Break Switches: These are those interrupting devices which can make or break circuits. These are normally on same circuit, which are backed by circuit breakers. 5. Earth Switches: Devices which are used normally to earth a particular system, to avoid any accident happening due to induction on account of live adjoining circuits. These equipments do not handle any appreciable current at all. Apart from this equipment there are a number of relays etc. which are used in switchgear.

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3.2.1 LT Switchgear It is classified in following ways:1. Main Switch:Main switch is control equipment which controls or disconnects the main supply. The main switch for 3 phase supply is available for tha range 32A, 63A, 100A, 200Q, 300A at 500V grade. 2. Fuses: With Avery high generating capacity of the modern power stations extremely heavy carnets would flow in the fault and the fuse clearing the fault would be required to withstand extremely heavy stress in process. It is used for supplying power to auxiliaries with backup fuse protection. Rotary switch up to 25A. With fuses, quick break, quick make and double break switch fuses for 63A and 100A, switch fuses for 200A, 400A, 600A, 800A and 1000A are used. 3. Contractors: AC Contractors are 3 poles suitable for D.O.L Starting of motors and protecting the connected motors. 4. Overload Relay: For overload protection, thermal over relay are best suited for this purpose. They operate due to the action of heat generated by passage of current through relay element. 5. Air Circuit Breakers: It is seen that use of oil in circuit breaker may cause a fire. So in all circuits breakers at large capacity air at high pressure is used which is maximum at the time of quick tripping of contacts. This reduces the possibility of sparking. The pressure may vary from 50-60 kg/cm^2 for high and medium capacity circuit breakers.

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3.2.2 HT SWITCH GEAR:1. Minimum oil Circuit Breaker: These use oil as quenching medium. It comprises of simple dead tank row pursuing projection from it. The moving contracts are carried on an iron arm lifted by a long insulating tension rod and are closed simultaneously pneumatic operating mechanism by means of tensions but throw off spring to be provided at mouth of the control the main current within the controlled device. Type-HKH 12/1000c Rated Voltage-66 KV Normal Current-1250A Frequency-5Hz Breaking Capacity-3.4+KA Symmetrical 3.4+KA Asymmetrical 360 MVA Symmetrical Operating Coils-CC 220 V/DC FC 220V/DC Motor Voltage-220 V/DC 2. Air Circuit Breaker: In this the compressed air pressure around 15 kg per cm^2 is used for extinction of arc caused by flow of air around the moving circuit . The breaker is closed by applying pressure at lower opening and opened by applying pressure at upper opening. When contacts operate, the cold air rushes around the movable contacts and blown the arc. It has the following advantages over OCB:i. Fire hazard due to oil are eliminated. ii. Operation takes place quickly. iii. There is less burning of contacts since the duration is short and consistent. iv. Facility for frequent operation since the cooling medium is replaced constantly. Rated Voltage-6.6 KV Current-630 A Auxiliary current-220 V/DC 3. SF6 Circuit Breaker: This type of circuit breaker is of construction to dead tank bulk oil to circuit breaker but the principle of current interruption is similar o that of air blast circuit breaker. It simply employs the arc extinguishing medium namely SF6. the performance of gas . When it is broken down under an electrical stress. It will quickly reconstitute

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itself Circuit Breakers-HPA Standard-1 EC 56 Rated Voltage-12 KV Insulation Level-28/75 KV Rated Frequency-50 Hz Breaking Current-40 KA Rated Current-1600 A Making Capacity-110 KA Rated Short Time Current 1/3s -40 A Mass Approximation-185 KG Auxiliary Voltage Closing Coil-220 V/DC Opening Coil-220 V/DC Motor-220 V/DC SF6 Pressure at 20 Degree Celsius-0.25 KG SF6 Gas Per pole-0.25 KG

4. Vacuum Circuit Breaker: It works on the principle that vacuum is used to save the purpose of insulation and it implies that pr. Of gas at which breakdown voltage independent of pressure. It regards of insulation and strength, vacuum is superior dielectric medium and is better that all other medium except air and sulphur which are generally used at high pressure. Rated frequency-50 Hz Rated making Current-10 Peak KA Rated Voltage-12 KV Supply Voltage Closing-220 V/DC Rated Current-1250 A Supply Voltage Tripping-220 V/DC Insulation Level-IMP 75 KVP Rated Short Time Current-40 KA (3 SEC) Weight of Breaker-8 KG

4. EMD II

(Electrical Maintenance division II)

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I was assigned to do training in Electrical maintenance division II from 18st June 2012 to 30th June 2012. This two week of training in this division were divided as follows. 1. Generator 2. Transformer &switchyard 3. protection 4. Lightning

4.1 Generator
The transformation of mechanical energy into electrical energy is carried out by the Generator. This Chapter seeks to provide basic understanding about the working principles and development of Generator. Working Principle The A.C. Generator or alternator is based upon the principle of electromagnetic induction and consists generally of a stationary part called stator and a rotating part called rotor. The stator housed the armature windings. The rotor houses the field windings. D.C. voltage is applied to the field windings through slip rings. When the rotor is rotated, the lines of magnetic flux (viz magnetic field) cut through the stator windings. This induces an electromagnetic force (e.m.f.) in the stator windings. The magnitude of the generated voltage per phase is given by the following expression. E = 4.44fN volts = Strength of magnetic field in Webers. f = Frequency in cycles per second or Hertz. N = Number of turns in a coil of stator winding f = Frequency = Pn/120 Where P = Number of poles n = revolutions per second of rotor. From the expression it is clear that for the same frequency, number of poles increases with decrease in speed and vice versa. Therefore, low speed hydro turbine drives generators have 14 to 20 poles where as high speed steam turbine driven generators have generally 2 poles. Pole rotors are used in low speed generators, because the cost advantage as well as easier construction.

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Generator component This Chapter deals with the two main components of the Generator viz. Rotor, its winding & balancing and stator, its frame, core & windings. Rotor The electrical rotor is the most difficult part of the generator to design. It revolves in most modern generators at a speed of 3,000 revolutions per minute. The problem of guaranteeing the dynamic strength and operating stability of such a rotor is complicated by the fact that a massive non-uniform shaft subjected to a multiplicity of differential tresses must operate in oil lubricated sleeve bearings supported by a structure mounted on foundations all of which possess complex dynamic be behavior peculiar to themselves. It is also an electromagnet and to give it the necessary magnetic strength he windings must carry a fairly high current. The passage of the current through the windings generates heat but the temperature must not be allowed to become so high, otherwise difficulties will be experienced with insulation. To keep the temperature down, the cross section of the conductor could not be increased but this would introduce nother problems. In order to make room for the large conductors, body and this would cause mechanical weakness. The problem is really to get the maximum amount of copper into the windings without reducing the mechanical strength. With good design and great care in construction this can be achieved. The rotor is a cast steel ingot, and it is further forged and machined. Very often a hole is bored through the centre of the rotor axially from one end of the other for inspection. Slots are then machined for windings and ventilation. Rotor winding Silver bearing copper is used for the winding with mica as the insulation between conductors. A mechanically strong insulator such as micanite is used for lining the slots. Later designs of windings for large rotor incorporate combination of hollow conductors with slots or holes arranged to provide for circulation of the cooling gas through the actual conductors. When rotating at high speed. Centrifugal force tries to lift he windings out of the slots and they are contained by wedges. The end rings are secured to a turned recess in the rotor body, by shrinking or screwing and supported at the other end by fittings carried by the rotor body. The two ends of windings are connected to slip rings, usually made of forged steel, and mounted on insulated sleeves. Rotor balancing 37

When completed the rotor must be tested for mechanical balance, which means that a check is made to see if it will run up to normal speed without vibration. To do this it would have to be uniform about its central axis and it is most unlikely that this will be so to the degree necessary for perfect balance. Arrangements are therefore made in all designs to fix adjustable balance weights around the circumference at each end. Stator Stator frame: The stator is the heaviest load to be transported. The major part of this load is the stator core. This comprises an inner frame and outer frame. The outer frame is a rigid fabricated structure of welded steel plates, within this shell is a fixed cage of girder built circular and axial ribs. The ribs divide the yoke in the compartments through which hydrogen flows into radial ducts in the stator core and circulate through the gas coolers housed in the frame. The inner cage is usually fixed in to the yoke by an arrangement of springs to dampen the double frequency vibrations inherent in 2 pole generators. The end shields of hydrogen cooled generators must be strong enough to carry shaft seals. In large generators the frame is constructed as two separate parts. The fabricated inner cage is inserted in the outer frame after the stator core has been constructed and the winding completed. Stator core: The stator core is built up from a large number of 'punching" or sections of thin steel plates. The use of cold rolled grain-oriented steel can contribute to reduction in the weight of stator core for two main reasons: a) There is an increase in core stacking factor with improvement in lamination coldRolling and in cold buildings techniques. b) The advantage can be taken of the high magnetic permeance of grain-oriented steels of work the stator core at comparatively high magnetic saturation without fear or excessive iron loss of two heavy a demand for excitation ampere turns from the generator rotor.

Stator Windings Each stator conductor must be capable of carrying the rated current without overheating. The insulation must be sufficient to prevent leakage currents flowing between the phases to earth. Windings for the stator are made up from copper strips wound with insulated tape which is impregnated with varnish, dried under vacuum and hot pressed to form a solid insulation bar. These bars are then place in the stator slots and held in with wedges to form the complete winding which is connected together at each end of the core forming the end turns. These end turns are rigidly braced and packed with blocks of insulation material to withstand the heavy forces

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which might result from a short circuit or other fault conditions. The generator terminals are usually arranged below the stator. On recent generators (210 MW) the windings are made up from copper tubes instead of strips through which water is circulated for cooling purposes. The water is fed to the windings through plastic tubes. Generator Cooling System The 200/210 MW Generator is provided with an efficient cooling system to avoid excessive heating and consequent wear and tear of its main components during operation. This Chapter deals with the rotor-hydrogen cooling system and stator water cooling system along with the shaft sealing and bearing cooling systems. Rotor Cooling System The rotor is cooled by means of gap pick-up cooling, wherein the hydrogen gas in the air gap is sucked through the scoops on the rotor wedges and is directed to flow along he ventilating canals milled on the sides of the rotor coil, to the bottom of the slot where it takes a turn and comes out on the similar canal milled on the other side of the rotor coil to the hot zone of the rotor. Due to the rotation of the rotor, a positive suction as well as discharge is created due to which a certain quantity of gas flows and cools the rotor. This method of cooling gives uniform distribution of temperature. Also, this method has an inherent advantage of eliminating the deformation of copper due to varying temperatures. Hydrogen Cooling System Hydrogen is used as a cooling medium in large capacity generator in view of its high heat carrying capacity and low density. But in view of its forming an explosive mixture with oxygen, proper arrangement for filling, purging and maintaining its purity inside the generator have to be made. Also, in order to prevent escape of hydrogen from the generator casing, shaft sealing system is used to provide oil sealing. The hydrogen cooling system mainly comprises of a gas control stand, a drier, an liquid level indicator, hydrogen control panel, gas purity measuring and indicating instruments, The system is capable of performing the following functions : Filling in and purging of hydrogen safely without bringing in contact with air. Maintaining the gas pressure inside the machine at the desired value at all the times. Provide indication to the operator about the condition of the gas inside the machine i.e. its pressure, temperature and purity. 39

Continuous circulation of gas inside the machine through a drier in order to remove any water vapour that may be present in it. Indication of liquid level in the generator and alarm in case of high level.

Stator Cooling System The stator winding is cooled by distillate. Which is fed from one end of the machine by Teflon tube and flows through the upper bar and returns back through the lower bar of another slot? Turbo generators require water cooling arrangement over and above the usual hydrogen cooling arrangement. The stator winding is cooled in this system by circulating demineralised water (DM water) through hollow conductors. The cooling water used for cooling stator winding calls for the use of very high quality of cooling water. For this purpose DM water of proper specific resistance is selected. Generator is to be loaded within a very short period if the specific resistance of the cooling DM water goes beyond certain preset values. The system is designed to maintain a constant rate of cooling water flow to the stator winding at a nominal inlet water temperature of 40 deg.C.

Rating of 95 MW Generator Manufacture by Bharat heavy electrical Limited (BHEL) Capacity - 117500 KVA Voltage - 10500V Speed - 3000 rpm Hydrogen - 2.5 Kg/cm2 Power factor - 0.85 (lagging) Stator current - 6475 A Frequency - 50 Hz Stator wdg connection - 3 phase

40

Rating

of

210MW

Generator

Capacity Voltage(stator) Current(stator) Voltage(rotor) Current(rotor) Speed P.f. Frequency Hydrogen Stator Insulation wdg

connection class 3

247000 15750 9050 310 2600 3000 50 3.5 phase star

KVA V A V V rpm 0.85 Hz Kg/cm2 connection B

The 200 MW generator is a 3-phase, horizontally mounted 2-pole cylindrical rotor type, synchronous machine driven by steam turbine. The stator windings are cooled by de-mineralized water flowing through the hollow conductor while the rotor winding is cooled by hydrogen gas. Fans mounted on the generator rotor facilitate the circulation of the H2 inside the machine requiring cooling. 4 coolers mounted inside the machine cool the H2 gas.The generator winding is insulated by epoxy thermo- setting type insulation. It is provided with static excitation system. 2 H2 driers are provided to facilitate moisture removal. H2 is circulated through them via the fans in dry condition. Normally one drier is kept in service and other is in standby. Liquid Level Detectors (LLDs) are provided to indicate liquid in the generator casing, to indicate whether oil is leaking or water. It can be drained through drain valves. H2 gas purity is to be maintained at more than 99%. The cooling water system consists of 2x100% duty AC motor driven pumps, 2x100% duty water coolers, 2x100% duty mechanical filters, 1x100% duty

41

magnetic filter, expansion tank, polishing unit and ejector system. The stator water pump drive the water through coolers, filters and winding and finally discharges into the expansion tank situated at a height of about 5m above the TG floor. It is maintained at a vacuum of about 250mm Hg by using water ejectors. A gas trap is provided in the system to detect any traces of hydrogen gas leaking into the stator water system. To prevent leakage of hydrogen from generator housing, ring type seals are provided at the both ends of the generator. The seal ring is free to adjust its position according to shaft position.

4.1.1 SPECIFICATIONS Maximum Continuous KVA rating ~~ Rated Terminal Voltage ~~ Rated Stator Current ~~ Rated Power Factor ~~ Excitation Voltage at MCR condition ~~ 310 V Excitation Voltage at MCR condition ~~ 2600 A Excitation voltage at no load ~~ Excitation current at no load ~~ Rated speed ~~ Rated frequency ~~ Efficiency at MCR condition ~~ Short circuit ratio ~~ 102 V 917 A 3000 rpm 50 c/s 98.49% 0.49 9050 A 0.85 lag 235300 KVA 15750 V

Direction of rotation from slip ring ~~ Anti clockwise Phase connection ~~ No. of terminals brought out ~~ Generator gas volume ~~ Nominal pressure of H2 ~~ Nominal temp of cold gas ~~ Purity of hydrogen ~~ 42 Double star 9(6 neutral, 3 phase) 56 m 3 3.5 Kg/cm 2 40 0 C (Alarm) > 97% (min)

 Relative humidity of H2 ~~ Hot gas temp ~~ Stator water flow 1. Normal ~~ 2. Alarm ~~ 3. Trip ~~ Stator water conductivity 1.Normal ~~ 2.High ~~ 3.Trip ~~

60 % 75 0C

27 + 3 m 3 / hr 21 m 3 / hr 13 m 3 / hr < 5.0 mho/ cm 13.3 mho/ cm 13 m 3 / hr

Stator water expansion tank volume ~~ 200-300 mm wcl

Nominal consumption of cooling water 1. At 35 0C ~~ 95 m 3 / hr 110 m 3 / hr 130 m 3 / hr 40 0C 65 0C 2. At 37 0C ~~ 3. At 40 0C ~~ Seal oil outlet temperature 1. Normal ~~ 2. Alarm ~~

Safety Valve release (AC seal oil pump) ~~ 9 Kg/cm 2 0Safety Valve release (DC seal oil pump) ~~ 9 Kg/cm 2 4.1.2 GENERATOR PROTECTION The core of an electrical power system is generator. During operating conditions certain components of the generator are subjected to increase stress and therefore, could fail, referred to as faults. It can be internal fault or external fault depending upon whether they are inside or outside of the machine. The machine with fault must be tripped immediately. The corrective measures against generators abnormal operation are taken care by stubborn system.

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4.1.3TASK OF THE PROTECTIVE SYSTEM: Detect abnormal condition or defect. Limit its scope by switching to isolate the defect. Alarm the operating staff. Unload and/or trip the machine immediately.

4.1.4 PROTECTIVE DEVICES The choice of protective equipment for the generator should precisely understand the type of fault and do the necessary preventive measures for avoiding it. Electrical protection Differential protection: Earth fault protection: Stator earth fault Rotor earth fault Stator Inter turn fault Over voltage Generator Transformer Protections Buchholz Protection Winding Temperature High Oil Temperature High Fire Protection Bus Bar Protection

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4.2 TRANFORMER A transformer is a device that transfers electrical energy from one circuit to another by magnetic coupling with out requiring relative motion between its parts. It usually comprises two or more coupled windings, and in most cases, a core to concentrate magnetic flux. An alternating voltage applied to one winding creates a time-varying magnetic flux in the core, which includes a voltage in the other windings. Varying the relative number of turns between primary and secondary windings determines the ratio of the input and output voltages, thus transforming the voltage by stepping it up or down between circuits. By transforming electrical power to a high-voltage,_low-current form and back again, the transformer greatly reduces energy losses and so enables the economic transmission of power over long distances. It has thus shape the electricity supply industry, permitting generation to be located remotely from point of demand. All but a fraction of the worlds electrical power has passed trough a series of transformer by the time it reaches the consumer.

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46

After the electricity is generated by the turbogenerators of Unit-1 to 3 (generating 10.5KV) & Unit 4 & 5(generating 15.75 KV),it is sent to the Generating Transformer(G.T.) and Unit-Auxiliary Transformer(U.A.T.) at the same time.

4.2.1 Generating Transformer Stepsup this voltage of 10.5 & 15.75KV to a higher voltage of 220 KV (hence, working as a step-up Transformer).This voltage of 220 KV is then transmitted to switchyard. 4.2.2 Unit-Auxiliary Transformer (U.A.T.) Steps-down this voltage of 15.75/21 KV to a comparatively lower voltage of 6.9 KV which is required to run the auxiliaries of the Main Plant such as I.D. Fan, P.A. Fan, F.D. Fan and other auxiliary motors. Each unit has its own separate G.T. & U.A.T. 4.2.3 STATION TRANSFORMER There is one more Transformer known as station transformer used only for initializing the start-up of the station (Main Plant).It is very beneficial during emergency situations such as tripping of Units, shut-down etc. It gets the supply in its primary from 220 KV switchyard, steps-down it to 6.6 KV which is used for starting various equipments & devices used in the Main Power Plant. 4.2.4RATINGS 1. GENERATING TRANSFORMER

Type of cooling: Rating H.V.(MVA): Rating L.V.(MVA): 47

O.F.W.F. 200 200

 No-load Voltage (KV): H.V. L.V. Line current(Amps.): H.V. L.V. Temperature rise(C): Oil Windings Phase: Frequency (Hz): Connection symbol: Makers Serial No: Electrical Specification No: Year of manufacture: Core & winding(Kg.): Weight of Oil(Kg.): Total weight (Kg.): Oil quantity(l.): Transport weight(Kg.): Untanking weight(Kg.): 50 60 1 50 YND11 60046 600626 1985 123050 27500 179500 29540 138000 12000 866.0 9523.8 400/3 21

2. UNIT AUXILIARY TRANSFORMER Rating (KVA): Cooling: KV (At no load): 48 Method % 12000/16000 ONAN/ONAF 75/100

H.V. L.V. Amperes: H.V. L.V. Phases: Vector group: Temp.rise (C): Tap oil Winding Total Mass(Kg.): Untanking Mass(Kg.): Mass of Oil(Kg.): Volume of Oil(l.): Transport Mass with Oil(Kg.): Manufactures Serial No: Year of manufacture: Frequency(Hz): 3. STATION TRANSFORMER Rating(KVA): Amperes: H.V. L.V. KV at no-load: H.V. L.V. Phases: H.V. & L.V. H.V. & L.V. H.V. & L.V.

15.75 6.9 439.8/586.53 1004.1/1338.8 Three DY 1

40 50 37700 19200 7100 8250 30000 37893 1982 50

19000/25000/31500

83.1/109.3/137.8 1589.8/2091.8/2635.7 132 6.9 3

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 Vector group: H.V. & L.V. Temp. rise(C): Tap Oil Winding Frequency(Hz): Total Mass(Kg.): Untanking Mass(Kg.): Mass of Oil(Kg.): Volume of Oil(l.): Transport Mass with Oil(Kg.): Insulation level(KVp): H.V./H.V.N. L.V. Cooling Methods: % Manufactures Serial No: Year of manufacture:

YNYO

40 55 50 63000 29000 17000 19600 47000

550/170 60 ONAN/ONAF/OFAF 60/80/100 37899 1980

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4.3 SWITCHYARD
Switchyard is considered as the HEART of the Power Plant. Power generated can be worthful only if it is successfully transmitted and received by its consumers. Switchyard plays a very important role as a buffer between the generation and transmission. It is a junction, which carries the generated power to its destination (i.e. consumers). Switchyard is basically a yard or an open area where many different kinds of equipments are located (isolator, circuit breaker etc), responsible for connecting & disconnecting the transmission line as per requirement (e.g. any fault condition). Power transmission is done at a higher voltage. (Higher transmission voltage reduces transmission losses). 4.3.1 SWITCHYARD EQUIPMENTS 1. LIGHTENING ARRESTOR: It is a protective device, which protects the costly equipments such as overhead lines, poles or towers, transformer etc. against lightening. As the name suggests it arrests the lightening of very high voltage (crores of KV) and dump it into the ground. It works on the principle of easy path for the flow of current.L.A. is connected in parallel with the line with its lower end connected and the upper end projected above the pole of tower. 2. LIGHTENING MOST: It is present at the highest point, at the topmost tower of the switchyard and is connected together by wires forming a web. The reason for its presence at the topmost point is to grasp the lightening before it can come, fall and damage the costly equipments present in the switchyard.

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3. WAVE TRAP: It is equipment used to trap the high carrier frequency of 500 KHz and above and allow the flow of power frequency (50 Hz). High frequencies also get generated due to capacitance to earth in long transmission lines. The basic principle of wave trap is that it has low inductance (2 Henry) & negligible resistance, thus it offers high impedance to carrier frequency whereas very low impedance to power frequency hence allowing it to flow in the station. 4. CIRCUIT BREAKER: It is an automatic controlling switch used in power house, substation & workshop as well as in power transmission during any unwanted condition (any fault condition-earth fault, over-current, flashover, single phasing,). During such condition it cuts down the supply automatically by electromagnetic action or thermal action. It can be used in off-load as well as on-load condition. When a circuit breaker is operated by sending an impulse through relay, C.B. contact is made or broken accordingly. During this making and breaking, an arc is produced which has to be quenched; this is done by air, oil, SF6 gas etc. Depending on the medium being used C.B.s can be categorized into various types.In SSTPS for 400 KV/132 KV switchyard only 4 main types are being used: ABCB (Air operated circuit breaker):operated as well as arc quenched through air. Air operated SF6 circuit breaker:operated through air but arc quenching done through SF6 gas. MOCB (Minimum oil circuit breaker):operated through spring action but arc quenching done through oil (Aerosol fluid oil). Hydraulic operated SF6 circuit breaker:operated through hydraulic oil and arc quenching done through SF6 gas.

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Hydraulic operated SF6 circuit breaker is the most efficient due to following reasons:1. Less maintenance. 2. Arc quenching capability of SF6 gas is more effective than air. 3. Heat transfer capacity is better in this C.B. 5. ISOLATOR: An isolator is also a switching device used to disconnect the line. As the name suggests it isolate the line from the supply. It is always used in OFF-LOAD condition. Whenever any fault occurs in the equipments present in the line, in order to remove the fault or replace the device first of all supply is disconnected. But even after the disconnection of the supply, the line remains in charged mode so before working on the device (to remove fault) isolator should be made open. Depending on the structure there are mainly two types of isolators: Pantagraph isolator. Centre-break isolator (also known as Sequential isolator). Pantagraph is generally used in buses whereas Centre-break (Sequential) is used in line. Isolators may be operated in air (pneumatic), electrically or even manually. 6. P.T (Potential Transformer): This Transformer is connected in parallel with the line with one end earthed. It is only used for voltage measurement by stepping-down the voltage to the required measurable value.

7. C.T (Current Transformer): This Transformer is used for basically two major functions: Metering which means current measurement.

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 Protection such as over current protection, overload earth fault protection, Bus-bar protection, Bus differential protection.

5. Conclusion
On completion of my vocational training at Badarpur Tharmal Power Station, Delhi, I have come to know about how the very necessity of our lives nowadays i.e., electricity is generated. What all processes are needed to generate and run the plant on a 24x7 basis. NTPC Delhi is one the plants in India to be under highest load factor for the maximum duration of time and that to operating at highest plant efficiencies. This plant is an example in terms of working efficiency and management of resources to all other thermal plants in our country. The operating plf of the NTPC as compared to the rest of country is the highest with 87.54% the highest since its inception. The training gave me an opportunity to clear my concepts from practical point of view with the availability of machinery of such large rating.

REFERENCE & SOURCES: Old EDC training reports from Nalanda Library. Internet. Reference books of related topics. Guidence of incharge of individual department of the NTPC.

THANK YOU

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