PROJECT REPORT Summer Training

BADARPUR THERMAL POWER STATION

Submitted by:
ANKIT PRUSTY B.Tech (E.E.E) GURU TEGH BAHADUR INSTITUTE OF TECHNOLOGY

This is to certify that ANKIT PRUSTY, student of Electrical & Electronics Branch ; Guru Tegh Bahadur Institute Of Technology has successfully completed his industrial training at Badarpur Thermal power station New Delhi for six weeks from 20th June to 30th July 2011 He has completed the whole training as per the training report submitted by him.

Training Incharge BTPS/NTPC NEW DELHI

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 Mrs. RACHNA SINGH for providing me this opportunity to be a part of this esteemed organization. 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 GURU TEGH BAHADUR INSTITUTE OF TECHNOLOGY and all the faculty member of Electrical & Electronics 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 6 week training at this esteemed organization from 20th June to 30th July 2011. In these 6 weeks, I was assigned to various divisions of the plant which were:Electrical Maintenance Department- I (EMD-I) Electrical Maintenance Department- II (EMD-II) Control & Instrumentation (C&I) These 6 weeks training was a very educational adventure for me. It was really amazing to see the plant by yourself and learn how electricity, which is one of our daily requirements of life, is produced. This report has been made by my experience at BTPS. The material in this report has been gathered from senior student reports and trainers and manuals and power journals provided by training department. The specification and principles are as learned by me from the employees of each division of BTPS

Ankit Prusty

NTPC
NTPC Limited (formerly National Thermal Power Corporation) is the largest stateowned power generating company in India. Forbes Global 2000 for 2010 ranked it 341th in the world. It is an Indian public sector company listed on the Bombay Stock Exchange although at present the Government of India holds 84.5% (after divestment the stake by Indian government on 19th October, 2009) of its equity. With a current generating capacity of 34894 MW, NTPC has embarked on plans to become a 75,000 MW company by 2017. It was founded on November 7, 1975. NTPC's core business is engineering, construction and operation of power generating plants and providing consultancy to power utilities in India and abroad. The total installed capacity of the company is 34894 MW (including JVs) with 15 coal based and 7 gas based stations, located across the country. In addition under JVs, 5 stations are coal based & another station uses naphtha/LNG as fuel. NTPC has adopted a multi-pronged growth strategy which includes capacity addition through green field projects, expansion of existing stations, joint ventures, subsidiaries and takeover of stations. NTPC has been operating its plants at high efficiency levels. Although the company has 18.79% of the total national capacity it contributes 28.60% of total power generation due to its focus on high efficiency. NTPC s share at 31 Mar 2001 of the total installed capacity of the country was 24.51% and it generated 29.68% of the power of the country in 2008 09. Every fourth home in India is lit by NTPC. As at 31 Mar 2011 NTPC's share of the country's total installed capacity is 17.75% and it generated 27.4% of the power generation of the country in 2010 11. NTPC is lighting every third bulb in India. 170.88BU of electricity was produced by its stations in the financial year 2005 2006. The Net Profit after Tax on March 31, 2006 was INR 58,202 million. Net Profit after Tax for the quarter ended June 30, 2006 was INR 15528 million, which is 18.65% more than for the same quarter in the previous financial year. 2005). Pursuant to a special resolution passed by the Shareholders at the Company s Annual General Meeting on September 23, 2005 and the approval of the Central Government under section 21 of the Companies Act, 1956, the name of the Company "National Thermal Power Corporation Limited" has been changed to "NTPC Limited" with effect from October 28, 2005. The primary reason for this is the company's foray into hydro and nuclear based power generation along with backward integration by coal mining.

POWER BURDEN
India, as a developing country is characterised by increase in demand for electricity and as of moment the power plants are able to meet only about 60 75% of this demand on an yearly average. The only way to meet the requirement completely is to achieve a rate of power capacity addition (implementing power projects) higher than the rate of demand addition. NTPC strives to achieve this and undoubtedly leads in sharing this burden on the country. NTPC Limited is divided in 8 headquarters:-

Sr. No. 1 2 3 4 5 6 7 8 NCRHQ ER-I, HQ ER-II, HQ NRHQ SR HQ WR-I HQ Hydro HQ WR-II HQ

Headquarter Delhi Patna Bhubaneswar Lucknow Hyderabad Mumbai Delhi Raipur

City

NTPC PLANTS

THERMAL-COAL BASED
Sr. No. 1 2 3 4 5 6 Singrauli Korba Ramagundam Farakka Vindhyachal Rihand City State Uttar Pradesh Chhattisgarh West Bengal Uttar Pradesh Inst.Capacity 2,000 2,600 2,100 2,000

Andhra Pradesh 2,600 Madhya Pradesh 3,260

7 8 9 10 11 12 13 14 15 16 17 18

Kahalgaon Dadri Talcher Unchahar Talcher Thermal Simhadri Tanda Badarpur Sipat Sipat (erection phase) Mouda (erection phase)

Bihar Uttar Pradesh Orissa Uttar Pradesh Orissa Uttar Pradesh Delhi Chhattisgarh Chhattisgarh Maharashtra

2,340 2,310 3,000 1,050 460 440 705 1000 1980 750 1000 (2x500 MW) Total 25,815

Andhra Pradesh 1,500

Bongaigaon (erection phase) Assam

GAS BASED
Sr. No. 1 2 3 4 5 6 7 Total Anta Auraiya Kawas Dadri Jhanor Kayamkulam Faridabad City State Rajasthan Uttar Pradesh Gujarat Uttar Pradesh Gujarat Kerala Haryana 413 652 645 817 648 350 430 3995 Installed Capacity

NTPC HYDEL
The company has also stepped up its hydroelectric power (hydel) projects implementation. Currently the company is mainly interested in the North-east India wherein the Ministry of Power in India has projected a hydel power feasibility of 3000 MW.

OVERVIEW OF ELECTRIC POWER IN INDIA TOTAL INSTALLED CAPACITY THERMAL POWER HYDRO POWER NUCLEAR POWER : 85000MW : 55000MW : 22000-23000MW : 5000-6000MW

NON CONVENTIONAL RESOURCES ACCOUNT FOR REMAINING PART INSTALLED CAPACITY OF NTPC : 17800MW INSTALLED CAPACITY OF BTPS : 720MW INSTALLED CAPACITY OF DVC POWER REQUIRED BY DELHI : 625MW : 22000-25000MW

BADARPUR THERMAL POWER STATION(BTPS)

Badarpur Thermal Power Station has an installed capacity of 705 MW. The First unit was commissioned in July 1973. The coal for the plant is derived from the Jharia Coal Fields. This was constructed under ownership of Delhi Vidyut Board. Latter it is transferred to NTPC. The generation of the plant can be divided into 2 phases i.e. PHASE- I and PHASE-II. The first phase was built up in the year 1973, it consist of set of 3 unit of 95 MW. The second phase consists of 2 units of 210 MW. Thus total capacity of station becomes 705 MW. The coal is supplied from Jahria coal Fields and the Agra Canal is the water source for various purposes. Delhi is the states that get the supply from plant. The corporation manages the plant since April 15th 1978. At the time of changeover of management the installed capacity was 285 MW and under NTPC 2 more unit of 210 MW, each were erected and commissioned. By the way NTPC is the front-runner in the power sector presently having a total installed capacity of 16910 MW. The power is supplied to a 220 KV network that is a part of the northern grid. The ten circuits through which the power is evacuated from the plant are: 1. Mehrauli 2. Okhla 3. Ballabgarh 4. Indraprastha 5. UP (Noida)

6. Jaipur

INSTALLED CAPACITY
Stage Unit Number First First First First First 1 2 3 4 5 Installed Capacity (MW) 95 95 95 210 210 Date of Commissioning July, 1973 August, 1974 March, 1975 December, 1978 December, 1981 Status Running Running Running Running Running

The water is taken from Agra Irrigation Canal and is used for cooling. There are also towers provided so that the plant can operate in the closed cycle. BTPS is designed and engineered by the Central Water and Power Commission (Central Electricity Authority). The station has completed 25 years of operation on July 26, 1998 after generating 69648 million units. Under N.T.P.C. the thermal plants availability factor of coal station from 78.21% in 1985-86 to 90.065 in 1999-2000. The plant load factor also increased from 70% in 1992-93 to 80.4% in 1999-2000. The installed capacity also increased by 42.6% in last seven years. Strength went up by 10.2%.Thus, a tremendous increase in the generation of power was completed in a very short span of time. The improvement in station has been due to adoption of N.P.T.C. s comprehensive maintenance system. The major factor that has been affecting the performance of the plant is the poor and inconsistent quality of coal, cooling water and low voltage condition in the grid.

STATION LOCATION:
Badarpur is situated only 20 km away from Delhi. The plant is located on the left side of the National Highway (Delhi-Mathura Road) and it comprises of 430 hectares (678 acres) bordered by the Agra Canal from East and by Mathura-Delhi Road from West. However, the area for ash disposal is done in the Delhi Municipal limit and is maintained with the help of Delhi Development Authority. The plant is also close to the project of 220 kv Double Circuit Transmission line between the I.P. station and Ballabgarh Cooling Water is obtained from Agra Canal for the cooling system. Additional 60 cusecs channel has also been constructed parallel to the Agra Canal so as to obtain uninterrupted water supply during the slit removing operation in Agra Canal.

THERMAL POWER PLANT LAYOUT:

The above diagram is the layout of a simplified thermal power plant and the below is also diagram of a thermal power plant.

The above diagram shows the simplest arrangement of Coal fired (Thermal) power plant.

Main parts of the plant are 1. Coal conveyor 2. Stoker 3. Pulverizer 4. Boiler 5. Coal ash 6. Air preheater 7. Electrostatic precipitator 8. Smoke stack 9. Turbine 10. Condenser 11. Transformers 12. Cooling towers 13. Generator 14. High - Voltage power lines

BASIC OPERATION: A thermal power plant basically works on Rankine cycle.

RANKINE CYCLE
The theoretical basic cycle for the simple steam turbine power plant is the Rankine cycle which is closed one. It include superheating, regenerative feed water heating and reheating. The rankine cycle is a thermodynamic cycle which converts heat into work. The heat is supplied externally to a closed loop, which usually uses water as the working fluid.

DESCRIPTION OF RANKINE CYCLE

A simple layout and processes of the Rankine Cycle.

 

A rankine cycle needs four main parts for operating the cycle i.e. Water feed pump, boiler, turbine and condenser. A rankine cycle describes a model of the operation of steam heat engine which is found in power generation plant. Common heat sources for power plant using the rankine cycle are coal, natural gas, oil, nuclear energy. The rankine cycle is sometimes referred to as a practical Carnot cycle when an efficient turbine is used. The main difference is that a pump is used to pressurize liquid instead of gas. This requires about 100 times less energy than that compressing a gas in a compressor (as in CARNOT CYCLE). The efficiency of a rankine cycle is usually limited by the working fluid. Without the pressure going super critical the temperature range cycle can operate over a quite small, turbine entry temp are typically 565C [the creep limit of stainless steel] and condensor temperature are around 30C. This gives a theoretical Carnot efficiency of around 63% compared with an actual efficiency of 42% for a modern coal-fired power station. This low turbine entry temperature is why the rankine cycle is often used as a bottoming cycle in combined cycle gas turbine power stations. The working fluid in rankine cycle follows a closed loop and is re-used constantly. The water vapor often seen billowing from power station is generated by the cooling system and represents the waste heat that could not be converted to useful work. While many substances could be used in the rankine cycle, water is usually the fluid of choice due to its favorable properties such as nontoxic, unreactive chemistry, abundance and low cost as well as its thermodynamic properties.

COAL CONVEYOR:
This is a belt type of arrangement. With this coal is transported from coal storage place in power plant to the place nearby boiler.

STOKER:
The coal which is brought nearby boiler has to put in boiler furnace for combustion. This stoker is a mechanical device for feeding coal to a furnace.

PULVERIZER:
The coal is put in the boiler after pulverization. For this pulverizer is used. A pulverizer is a device for grinding coal for combustion in a furnace in a power plant.

TYPES OF PULVERIZERS
BALL AND TUBE MILL
Ball mill is a pulverizer that consists of a horizontal rotating cylinder, up to three diameters in length, containing a charge of tumbling or cascading steel balls, pebbles, or rods. Tube mill is a revolving cylinder of up to five diameters in length used for fine pulverization of ore, rock, and other such materials; the material, mixed with water, is fed into the chamber from one end, and passes out the other end as slime.

RING AND BALL

This type consists of two rings separated by a series of large balls. The lower ring rotates, while the upper ring presses down on the balls via a set of spring and adjuster assemblies. Coal is introduced into the center or side of the pulverizer (depending on the design) and is ground as the lower ring rotates causing the balls to orbit between the upper and lower rings. The coal is carried out of the mill by the flow of air moving through it. The size of the coal particles released from the grinding section of the mill is determined by a classifier separator. These mills are typically produced by B&W (Babcock and Wilcox).

BOILER:
Now that pulverized coal is put in boiler furnance. Boiler is an enclosed vessel in which water is heated and circulated until the water is turned in to steam at the required pressure. Coal is burned inside the combustion chamber of boiler. The products of combustion are nothing but gases. These gases which are at high temperature vaporize the water inside the boiler to steam. Sometimes this steam is further heated in a superheater as higher the steam pressure and temperature the greater efficiency the engine will have in converting the heat in steam in to mechanical work. This steam at high pressure and temperature is used directly as a heating medium, or as the working fluid in a prime mover to convert thermal energy to mechanical work, which in turn may be converted to electrical energy. Although other fluids are sometimes used for these purposes, water is by far the most common because of its economy and suitable thermodynamic characteristics.

FIRE TUBE BOILERS:

In fire tube boilers hot gases are passed through the tubes and water surrounds these tubes. These are simple, compact and rugged in construction. Depending on whether the tubes are vertical or horizontal these are further classified as vertical and horizontal tube

boilers. In this since the water volume is more, circulation will be poor. So they can't meet quickly the changes in steam demand. High pressures of steam are not possible, maximum pressure that can be attained is about 17.5kg/sq cm. Due to large quantity of water in the drain it requires more time for steam raising. The steam attained is generally wet, economical for low pressures. The output of the boiler is also limited.

WATER TUBE BOILERS:

In these boilers water is inside the tubes and hot gases are outside the tubes. They consist of drums and tubes. They may contain any number of drums (you can see 2 drums in fig).Feed water enters the boiler to one drum (here it is drum below the boiler).This water circulates through the tubes connected external to drums. Hot gases which surround these tubes will convert the water in tubes in to steam. This steam is passed through tubes and collected at the top of the drum since it is of light weight. So the drums store steam and water (upper drum).The entire steam is collected in one drum and it is taken out from there (see in layout fig).As the movement of water in the water tubes is high, so rate of heat transfer also becomes high resulting in greater efficiency. They produce high pressure, easily accessible and can respond quickly to changes in steam demand. These are also classified as vertical, horizontal and inclined tube depending on the arrangement of the tubes. These are of less weight and less liable to explosion. Large heating surfaces can be obtained by use of large number of tubes. We can attain pressure as high as 125 kg/sq cm and temperatures from 315 to 575 centigrade.

SUPERHEATER:
Most of the modern boilers are having superheater and reheater arrangement. Superheater is a component of a steam-generating unit in which steam, after it has left the boiler drum, is heated above its saturation temperature. The amount of superheat added to the steam is influenced by the location, arrangement, and amount of superheater surface installed, as well as the rating of the boiler. The superheater may consist of one or more stages of tube banks arranged to effectively transfer heat from the products of combustion. Superheaters are classified as convection , radiant or combination of these.

REHEATER:
Some of the heat of superheated steam is used to rotate the turbine where it loses some of its energy. Reheater is also steam boiler component in which heat is added to this intermediate-pressure steam, which has given up some of its energy in expansion through the high-pressure turbine. The steam after reheating is used to rotate the second steam turbine (see Layout fig) where the heat is converted to mechanical energy. This mechanical energy is used to run the alternator, which is coupled to turbine, there by generating electrical energy.

CONDENSER:
Steam after rotating steam turbine comes to condenser. Condenser refers here to the shell and tube heat exchanger (or surface condenser) installed at the outlet of every steam turbine in Thermal power stations of utility companies generally. These condensers are heat exchangers which convert steam from its gaseous to its liquid state, also known as phase transition. In so doing, the latent heat of steam is given out inside the condenser. Where water is in short supply an air cooled condenser is often used. An air cooled condenser is however significantly more expensive and cannot achieve as low a steam turbine backpressure (and therefore less efficient) as a surface condenser. The purpose is to condense the outlet (or exhaust) steam from steam turbine to obtain maximum efficiency and also to get the condensed steam in the form of pure water, otherwise known as condensate, back to steam generator or (boiler) as boiler feed water. Why it is required? The steam turbine itself is a device to convert the heat in steam to mechanical power. The difference between the heat of steam per unit weight at the inlet to turbine and the heat of steam per unit weight at the outlet to turbine represents the heat given out (or heat drop) in the steam turbine which is converted to mechanical power. The heat drop per unit weight of steam is also measured by the word enthalpy drop. Therefore the more the conversion of heat per pound (or kilogram) of steam to mechanical power in the turbine, the better is its performance or otherwise known as efficiency. By condensing the exhaust steam of turbine, the exhaust pressure is brought down below atmospheric pressure from above atmospheric pressure, increasing the steam pressure drop between inlet and

exhaust of steam turbine. This further reduction in exhaust pressure gives out more heat per unit weight of steam input to the steam turbine, for conversion to mechanical power. Most of the heat liberated due to condensing, i.e., latent heat of steam, is carried away by the cooling medium. (water inside tubes in a surface condenser, or droplets in a spray condenser (Heller system) or air around tubes in an air-cooled condenser). Condensers are classified as (i) (ii) Jet condensers or contact condensers Surface condensers.

In jet condensers the steam to be condensed mixes with the cooling water and the temperature of the condensate and the cooling water is same when leaving the condenser; and the condensate can't be recovered for use as feed water to the boiler; heat transfer is by direct conduction. In surface condensers there is no direct contact between the steam to be condensed and the circulating cooling water. There is a wall interposed between them through heat must be convectively transferred. The temperature of the condensate may be higher than the temperature of the cooling water at outlet and the condensate is recovered as feed water to the boiler. Both the cooling water and the condensate are separately with drawn. Because of this advantage surface condensers are used in thermal power plants. Final output of condenser is water at low temperature is passed to high pressure feed water heater, it is heated and again passed as feed water to the boiler. Since we are passing water at high temperature as feed water the temperature inside the boiler does not decrease and boiler efficiency also maintained.

COOLING TOWERS:
The condensate (water) formed in the condenser after condensation is initially at high temperature. This hot water is passed to cooling towers. It is a tower- or building-like device in which atmospheric air (the heat receiver) circulates in direct or indirect contact with warmer water (the heat source) and the water is thereby cooled (see illustration). A cooling tower may serve as the heat sink in a conventional thermodynamic process, such as refrigeration or steam power generation, and when it is convenient or desirable to make final heat rejection to atmospheric air. Water, acting as the heat-transfer fluid, gives up heat to atmospheric air, and thus cooled, is recirculated through the system, affording economical operation of the process. Two basic types of cooling towers are commonly used. One transfers the heat from warmer water to cooler air mainly by an evaporation heat-transfer process and is known as the evaporative or wet cooling tower.

Evaporative cooling towers are classified according to the means employed for producing air circulation through them: atmospheric, natural draft, and mechanical draft. The other transfers the heat from warmer water to cooler air by a sensible heattransfer process and is known as the nonevaporative or dry cooling tower. Non-evaporative cooling towers are classified as air-cooled condensers and as aircooled heat exchangers, and are further classified by the means used for producing air circulation through them. These two basic types are sometimes combined, with the two cooling processes generally used in parallel or separately, and are then known as wetdry cooling towers. Evaluation of cooling tower performance is based on cooling of a specified quantity of water through a given range and to a specified temperature approach to the wet-bulb or dry-bulb temperature for which the tower is designed. Because exact design conditions are rarely experienced in operation, estimated performance curves are frequently prepared for a specific installation, and provide a means for comparing the measured performance with design conditions.

ECONOMISER:
Flue gases coming out of the boiler carry lot of heat. Function of economiser is to recover some of the heat from the heat carried away in the flue gases up the chimney and utilize for heating the feed water to the boiler. It is placed in the passage of flue gases in between the exit from the boiler and the entry to the chimney. The use of economiser results in saving in coal consumption, increase in steaming rate and high boiler efficiency but needs extra investment and increase in maintenance costs and floor area required for the plant. This is used in all modern plants. In this a large number of small diameter thin walled tubes are placed between two headers. Feed water enters the tube through one header and leaves through the other. The flue gases flow out side the tubes usually in counter flow.

AIR-PREHEATER:
The remaining heat of flue gases is utilized by air preheater. It is a device used in steam boilers to transfer heat from the flue gases to the combustion air before the air enters the furnace. Also known as air heater; air-heating system. It is not shown in the lay out. But it is kept at a place nearby where the air enters in to the boiler. The purpose of the air preheater is to recover the heat from the flue gas from the boiler to improve boiler efficiency by burning warm air which increases combustion efficiency, and reducing useful heat lost from the flue. As a consequence, the gases are also sent to the chimney or stack at a lower temperature, allowing simplified design of the ducting and stack. It also allows control over the temperature of gases leaving the stack (to meet emissions regulations, for example).After extracting heat flue gases are passed to electrostatic precipitator.

ELECTROSTATIC PRECIPITATOR:
It is a device which removes dust or other finely divided particles from flue gases by charging the particles inductively with an electric field, then attracting them to highly charged collector plates. The process depends on two steps. In the first step the suspension passes through an electric discharge (corona discharge) area where ionization of the gas occurs. The ions produced collide with the suspended particles and confer on them an electric charge. The charged particles drift toward an electrode of opposite sign and are deposited on the electrode where their electric charge is neutralized. The phenomenon would be more correctly designated as electro-deposition from the gas phase. The use of electrostatic precipitators has become common in numerous industrial applications. Among the advantages of the electrostatic precipitator are its ability to handle large volumes of gas, at elevated temperatures if necessary, with a reasonably small pressure drop, and the removal of particles in the micrometer range. Some of the usual applications are: (1) removal of dirt from flue gases in steam plants; (2) cleaning of air to remove fungi and bacteria in establishments producing antibiotics and other drugs, and in operating rooms; (3) cleaning of air in ventilation and air conditioning systems; (4) removal of oil mists in machine shops and acid mists in chemical process plants; (5) cleaning of blast furnace gases; (6) recovery of valuable materials such as oxides of copper, lead, and tin; and (7) separation of rutile from zirconium sand.

SMOKE STACK:
A chimney is a system for venting hot flue gases or smoke from a boiler, stove, furnace or fireplace to the outside atmosphere. They are typically almost vertical to ensure that the hot gases flow smoothly, drawing air into the combustion through the chimney effect (also known as the stack effect). The space inside a chimney is called a flue. Chimneys may be found in buildings, steam locomotives and ships. In the US, the term smokestack (colloquially, stack) is also used when referring to locomotive chimneys. The term funnel is generally used for ship chimneys and sometimes used to refer to locomotive chimneys. Chimneys are tall to increase their draw of air for combustion and to disperse pollutants in the flue gases over a greater area so as to reduce the pollutant concentrations in compliance with regulatory or other limits.

GENERATOR:
An alternator is an electromechanical device that converts mechanical energy to alternating current electrical energy. Most alternators use a rotating magnetic field. Different geometries - such as a linear alternator for use with sterling engines - are also occasionally used. In principle, any AC generator can be called an alternator, but usually the word refers to small rotating machines driven by automotive and other internal combustion engines.

TRANSFORMERS:
It is a device that transfers electric energy from one alternating-current circuit to one or more other circuits, either increasing (stepping up) or reducing (stepping down) the voltage. Uses for transformers include reducing the line voltage to operate low-voltage devices (doorbells or toy electric trains) and raising the voltage from electric generators so that electric power can be transmitted over long distances. Transformers act through electromagnetic induction; current in the primary coil induces current in the secondary coil. The secondary voltage is calculated by multiplying the primary voltage by the ratio of the number of turns in the secondary coil to that in the primary.

FUNDAMENTALS PARTS OF THERMAL POWER PLANT

FUNDAMENTAL PARTS: Boiler Steam turbine Condenser

BOILER
Steam generator or a boiler is a closed pressure vessel used for generation of steam under pressure. A boiler is usually made of steel in which the chemical energy of fuel is converted by combustion in to heat and this heat energy of products of combustion is transferred to water so as to produce steam. When steam is used in power generation, it is generated at high pressure and in large quantities due to high efficiency requirements. The design of such boiler is quite intricate and it depends upon the type of fuel used and its capacity. In a boiler, the working fluid i.e. Water receives heat due to combustion of fuel and is converted into steam at constant pressure. Its efficiency is around 90%. A boiler is a device for generating steam, which consists of two principal parts; the furnace, which provides heat, usually by burning a fuel and the boiler proper a device in which the heat changes water into steam. The steam or hot fluid is then recalculated out of the boiler for use in various processes in heating.

y BOILER OPERATION:
The boiler is a rectangular furnace about 50 ft on a side and 130 ft tall. Its wall is made of a web of high pressure steel pressure tubes about 2.3 inches in diameter. Pulverized coal is air blown into the furnace from fuel nozzle at the four corners and it rapidly burns, forming a large fire ball at the centre. The thermal radiation of the fire ball heats the water that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the boiler is three to four times the throughput and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700*F (370*c) and 3200 psi (22.1 Mpa). It is separated from the water inside a drum at the top of the furnace. The saturated steam is introduced into superheat pendent tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to1000*F (540*c) to prepare it for the turbine Proper treatment of boiler feed water is an important part of operating and maintaining a boiler system. As steam is produced, dissolved solids become concentrated and form deposits inside the boiler. This leads to poor heat transfer and reduce the efficiency of the boiler.

STEAM TURBINE
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion. Its modern manifestation was invented by Sir Charles Parsons in 1884. It has almost completely replaced the reciprocating piston system engine (invented by Thomas Newcomerand greatly improved by James watt) primarily because of its greater thermal efficiency and higher power to weight ratio. Because the turbine generates the rotary motion, it is particularly suited to be used to drive an electrical generator -about 80% of all electricity generation in the world is by use of steam turbines. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible process.

TYPES OF STEAM TURBINE

Steam turbines 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 2000000 hp (1,500,000 kw) turbines used to generate electricity. There are several classifications for modern steam turbines like impulse or reaction type turbine

IMPULSE TURBINES
An impulse turbine has fixed nozzle that orient the steam flow into high speed jets. These jets contain significant kinetic energy, which the rotor blades, shaped like buckets, convert into shaft rotation as the steam jets changes direction. A pressure drop occurs across only the stationary blades, with a net increase in steam velocity across the stage. As the steam flow through the nozzle its pressure falls from steam chest pressure to condenser pressure (or atmosphere pressure). Due to this relatively higher ratio of expansion of steam in the nozzle the steam leaves the nozzle with a very high velocity. The steam leaving the moving blades is a large portion of the maximum velocity of the steam when leaving the nozzle. The loss of the energy due to this higher exit velocity is commonly called the "carry over velocity" or "leaving loss".

REACTION TURBINES
In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles. The type of turbines makes use of the reaction force produced as the steam accelerates through the nozzle formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the stator as a jet that fills the entire circumference of the rotor. The steam then changes direction and increase its speed relative to the speed of blades. A pressure drop occurs both the stator and rotor, with steam accelerating through the stator and decelerating through the rotor, with no net change in steam velocity across the stage but with a decrease in both pressure and temperature, reflecting the work performed in the driving of the rotor.

CONDENSER
A condenser is a device or unit used to condense a substance from its gaseous it its liquid state, typically by cooling it. In so doing, the latent heat is given up by the substance, and will transfer to the condenser coolant. Condenser are typically heat exchangers which have various deigns and come in many sizes ranging from rather small (hand-held) to very large industrial-scale units used in plant processes. For example, a refrigerator uses a condenser to get rid of heat extracted from the interior of the unit to the outside air. Condensers are used in air conditioning, industrial chemical process such as distillation, steam power plants and other heat-exchange systems. The function of the condenser is to condense exhaust steam from the steam turbines by rejecting the heat of vaporization to the cooling water passing through the condenser. The temperature of the condensate determines the pressure in the steam/condensate side of the condenser. This pressure is called the turbine backpressure and is usually a vacuum. Decreasing the condensate temperature will result in a lowering of the turbine backpressure

Electrical maintenance division 1

it includes:

y OCHP/NCHP y HT/LT Switchgear y Motors

I was assigned to do training in this division from 20th June to 25th June.

COAL HANDLING PLANT (CHP)

The coal handling plant consists of two plants:  Old Coal Handling Plant (OCHP)  New Coal Handling Plant (NCHP) The OCHP supplies coal to Unit- I, II, III & NCHP supplies coal to Unit- IV and V.

COAL SUPPLIED AT BTPS

Coal is supplied to BTPS by Jharia coal mines. It is non-cooking coal and has following specifications:Moisture- less than 8% Volatile matter- 17% to 19% Ash- 35%-40% Calorific Value- 4500 to 5300 Kcal/kg Coal is received in railway box racks containing 20-42 wagons in each rack. Capacity of each box wagon is about 55 ton. These wagons are placed on 2 wagon tippler in OCHP & one wagon tippler in NCHP, in total 3, capacity 80 ton each.

COAL CYCLE

OLD COAL HANDLING PLANT (OCHP) KEY DIAGRAM

The main constituents of OCHP plant are:-

WAGON TIPPLER
Wagon from coal yard come to the tippler and emptied here. There are 2 wagon tipplers in the OCHP. The tippler is tilted to about 137 - 141 so that coal from the wagon is emptied into the hopper. Elliptics feeder is used in OCHP. Total 8 feeders are used, 4 in each hopper. Slip Ring Induction Motor is used to operate a wagon tippler. This type of IM is used in the tippler because of its high resistance, low speed & high torque characteristics. The rating of the motor used is: Power Voltage Current Speed Phase Frequency Three types of wagon tipplers are used:a) ROTASIDE: - It is used for open type wagons in which each wagon carries around 5056 tons of coal. The wagon is tilted by 150 to put the coal in the unloading hopper. b) ROTARY: - In this case the unloading hopper is placed directly under the tippler table. This is also used to tilt the wagon tippler to 180 . c) ROCKING TYPE: - It is used for close type wagons. In this hoppers is placed by the side of end rocking is provided to facilitate unloading of coal at corners of the wagon. 55 Kw 415V 102A 1480rpm 3
50Hz

CONVEYER
Conveyer belts are used in the OCHP to transfer coal from one place to other as required in a convenient & safe way. All the belts are numbered accordingly so that their function can be easily demarcated. These belts are made of rubber & move with a speed of 250-300 m/min. Motor employed for the conveyer has a capacity of 150 HP. These conveyers have a capacity of carrying the coal at the rate of 400 ton/hr.

ZERO SPEED SWITCH

It is used as a safety device for the motor i.e. if the belt is not moving & the motor is ON, then it burns to save the motor. This switch checks the speed of the belt & switches off the motor when speed is zero.

METAL DETECTOR
As the conveyer belt take coal from wagon to crusher house, no metal piece should go along with coal. To achieve this objective, metal detectors & separators are used. In the OCHP, these MD s are installed in the conveyer belts 2A & 2B.

CRUSHER HOUSE
Both the plants i.e. OCHP & NCHP use TATA crusher powered by BHEL motor. Crusher is of ring type and the motor is a HT motor of rating 400HP & 6.6 KV. Crusher is designed to crush the pieces to 20 mm size i.e. practically considered as the optimum size for transfer via conveyer.

ROTARY BREAKER
If any large piece of metal of any hard substances like metal impurities comes in the conveyer belt which cause load on the metal separator, then the rotary breaker rejects them reducing the load on the metal detector.

STACKER-CUM-RECLAIMER
It is used for stacking & reclaiming the coal from the stockyard in case of unavailability of wagons from coal mines.

PLOUGH FEEDER
These plough feeders are generally installed under slot bunkers or hoppers. These are used to plough the coal to the belt from the coal fed from stockyard. These feeders used in this power station are generally of rotary type.

TRIPPERS
Trippers are provided in the conveyer to collect the material at desired location on either side or along the conveyer with the help of chute/ducts fitted with tripper itself. The motor in the tripper can make it move both in forward and reverse direction.

PULL GUARD SWITCH

These are the switches which are installed at every 10m gap in a conveyer belt to ensure the safety of motors running the conveyer belts. If at any time some accident happens or coal jumps from belt and starts collecting at a place, this switch can be moved to NO(normally open) position from NC (normally closed) position to stop conveyor belt from moving. At this time the problem can be corrected & then again the switch can be moved to NC (normally closed) position for normal working again.

INTERLOCKS: The CHP is normally spread over a wide area with centralized control room. Elaborate scheme is therefore provided. If due to any emergency either the conveyor belt or the motor has to be stopped, due to this interlocking all the other motors connected to it will automatically stop & will not work till signal is given from the control room. The control & protection scheme normally includes:  A hooter system to warn that the plant is going to be started. The plant can be started only after a definite time after the hooter is energized.  Sequential starting of conveyor system and tripping of all proceeding system if any equipment in the chain is tripped.  Tripping of conveyor from speed switch for protection against belt slippage.

SEQUENTIAL OPERATION OF OCHP: I. Unloading the coal. II. Crushing & storage. III. Conveying to boiler bunkers. a) Coal arrives to plant via road, rail, sea, and river or canal route from collieries. Most of it arrives by rail route only in railway wagons. Coal requirement by this plant is approximately 10,500 metric ton/day. b) This coal is tippled into hoppers. If the coal is oversized (400 mm sq), then it is broken manually so that it passes the hopper mesh where through elliptic feeder it is put into vibrators & then to conveyor belt 1A & 1B. c) The coal through conveyor belts 1A & 1B goes to the crusher house. Also the extra coal is sent to stockyard through these belts. d) In the crusher house the small size coal pieces goes directly to the belt 2A & 2B whereas the big size coal pieces are crushed in the crusher & then given to the belts 2A & 2B. e) The crushed coal is taken to the bunker house via the conveyor belts 3A & 3B where it can be used for further operations.

NEW COAL HNDLING PLANT (NCHP) KEY DIAGRAM

The main constituents of NCHP plant are:Most of the constituents of the NCHP are the same as that of OCHP.

WAGON TIPPLER
In NCHP there is only one wagon tippler. In this it takes 52 sec to raise a wagon, 10 sec to empty the wagon completely & then again 52 sec to bring the tippler down. A semi circular huge WT gear is used to run the tippler. Protocol cameras have been installed for safety to ensure that no moving creature or object is near the wagon which is on the tippler.

COAL FEEDER TO THE PLANT

Vibro feeders are installed below the hopper which helps in putting the coal to the conveyor belts. There are 2 conveyor belts & 3 vibro feeder per plant, so in total there are 6 vibro feeders. Given below are the feeder motor specifications: Power Voltage Speed 15HP 415V 1450rpm

CONVEYOR TURNING POINT-6 BREAKER HOUSE

This house is required to render the coal size to 100mm sq. A 415W LT motor is used in the breaker house.

REJECTION HOUSE
The coal comes to breaker house via conveyor belts 12A & 12B. Now in the breaker house the huge stones & metal impurities are separated & sent to reject bin house through belts 18A & 18B.

RECLAIM HOPPER
It is the stockyard in which coal is stored for emergency purposes. Around 3 lakh ton of coal can be stored in it.

TURNING POINT 7 CRUSHER HOUSE EXIT SEQUENTIAL OPERATION OF NCHP:a) Coal arrives in wagons and tipples into hoppers. b) If the coal is oversized (400mm sq), then it is broken manually so that it passes through the hopper mesh. c) From hopper it is taken to TP-6 12A & 12B. d) Conveyors 12A & 12B take the coal to the breaker house which renders the coal size to be 100 mm sq. e) Metal separator & metal detector are installed in conveyor belts 14A/B & 15A/B respectively to remove the metal impurities. f) Stones which are not able to pass through the 100mm sq mesh of hammer are rejected via 18A & 18B to the rejection house. g) Extra coal is sent to the reclaim hopper via conveyor 16A & 16B. h) From TP-7, coal is taken by conveyor 14A & 14B to the crusher house whose function is to render size of the coal to 20mm sq.

SPECIFICATIONS OF MOTORS USED IN NCHP:I. II. III. Crusher: - BHEL ILAT/12B HD/02, 736rpm, 550Kw, 6600V. Wagon Tippler: - 5D315l, 98Kw slip ring motor. Conveyors: 1) 11A/B, 12A/B: - 125Kw, 315m, 1485rpm. 2) 13A/B: - 55Kw, 250m, 1480rpm. 3) 14A/B, 15A/B: - 150Kw, 355m, 1485rpm. 4) 16A/B, 17A/B: - 110Kw, 315m, 1485rpm. 5) 18A/B: - 37Kw, 225m, 1470rpm. Rotary Breaker: - 110Kw, 315m, 1485rpm Belt Feeder: - 15Kw, 180L, 1445rpm Reversible Belt Feeder: - 18.7Kw, 200L, 1485rpm VF 1-6: - 7.5Kw, 160m, 1485rpm VF 7-8: - 15Kw, 180L, 1485rpm VF 9-12: - 11Kw,160L, 1485rpm WSP Crusher House: - 15Kw, 160m, 4000rpm WSP Breaker House: - 7.5Kw, 132m, 1865rpm

IV. V. VI. VII. VIII. IX. X. XI.

XII. XIII.

Metal Separator: - 5KV, 132m, 1410rpm Spray Precipitator: - 18.5Kw, 200L, 3000rpm

SAFETY DEVICES FOR BELT CONVEYORS

Sometimes the belt is wet due to any reason, so it may not run due to reduced friction. A switch senses this and prevents the belt from choking. Sometime any accident may occur which requires the belt to stop, the pull cords are pulled to stop the conveyor. This system starts again only when the pull cords are rest. There is a push button in the control room from where the belt can be stopped in case of emergency stoppage. Other equipments are pulley. Pulleys are made of mild steel, rubber logging is provided to increase the friction factor between the pulley and belt.

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.

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. In ball mill coal is converted to powdered form and due to pneumatic action the powdered form of coal is transferred upwards.

4. CLASSIFIER:
It is 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. MILL FAN
From ball mill the powdered coal is sucked through mill fan.

6. CYCLONE SEPARATORS
It separates the pulverized coal from carrying medium. The mixture of pulverized coal vapour caters the cyclone separators tangentially in the upper part of the separator. Due to decrease in the velocity the centrifugal action, the pulverized coal separated from the vapour & falls down to the lower epical part.

7. THE TURNIGATE
It serves to transport pulverized coal from cyclone separators to pulverized coal bunker or to worm conveyors. There are 4 turnigates per boiler.

8. 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.

INTRODUCTION
Switchgear is one that makes or breaks the electrical circuit. It is a switching device that opens & closes a circuit that defined as apparatus used for switching, Lon rolling & protecting the electrical circuit & equipments. The switchgear equipment is essentially concerned with switching & interrupting currents either under normal or abnormal operating conditions. The tubular switch with ordinary fuse is simplest form of switchgear & is used to control & protect & other equipments in homes, offices etc. For circuits of higher ratings, a High Rupturing Capacity (H.R.C) fuse in condition with a switch may serve the purpose of controlling & protecting the circuit. However such switchgear cannot be used profitably on high voltage system (3.3 KV) for 2 reasons. Firstly, when a fuse blows, it takes some time to replace it & consequently there is interruption of service to customer. Secondly, the fuse cannot successfully interrupt large currents that result from the High Voltage System. In order to interrupt heavy fault currents, automatic circuit breakers are used. There are very few types of circuit breakers in B.P.T.S they are VCB, OCB, and SF6 gas circuit breaker. The most expensive circuit breaker is the SF6 type due to gas. There are various companies which manufacture these circuit breakers: VOLTAS, JYOTI, and KIRLOSKAR. Switchgear includes switches, fuses, circuit breakers, relays & other equipments.

THE EQUIPMENTS THAT NORMALLY FALL IN THIS CATEGORY ARE:1. ISOLATOR

An isolator is one that can break the electrical circuit when the circuit is to be switched on no load. These are used in various circuits for isolating the certain portion when required for maintenance etc. An operating mechanism box normally installed at ground level drives the isolator. The box has an operating mechanism in addition to its contactor circuit and auxiliary contacts may be solenoid operated pneumatic three phase motor or DC motor transmitting through a spur gear to the torsion shaft of the isolator. Certain interlocks are also provided with the isolator. These are Isolator cannot operate unless breaker is open. Bus 1 and bus 2 isolators cannot be closed simultaneously. The interlock can be bypass in the event of closing of bus coupler breaker. No isolator can operate when the corresponding earth switch is on

1. 2. 3. 4.

2. SWITCHING ISOLATOR
Switching isolator is capable of: 1. Interrupting charging current. 2. Interrupting transformer magnetizing current. 3. Load transformer switching. Its main application is in connection with the transformer feeder as the unit makes it possible to switchgear one transformer while the other is still on load.

3. CIRCUIT BREAKER
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.

 LT SWITCHGEAR
In LT switchgear there is no interlocking. 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. 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.

 HT SWITCHGEAR

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 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 to that of air blast circuit breaker. It simply employs the arc extinguishing medium namely SF6. When it is broken down under an electrical stress, it will quickly reconstitute 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

4. VACUUM CIRCUIT BREAKER

It works on the principle that vacuum is used to save the purpose of insulation and. In 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

MOTORS
Motors can be classified as AC and DC.

AC MOTORS
1. Squirrel cage motor 2. Wound motor 3. Slip ring induction motor In modern thermal power plant three phase squirrel cage induction motors are used but sometime double wound motor is used when we need high starting torque e.g. in ball mill.

THREE PHASE INDUCTION MOTOR

Ns (speed) =120f/p Stator can handle concentrated single layer winding, with each coil occupying one stator slot. The most common type of winding are:

1. DISTRIBUTED WINDING :
This type of winding is distributed over a number of slots.

2. DOUBLE LAYER WINDING :

Each stator slot contains sides of two different coils.

SQUIRREL CAGE INDUCTION MOTOR

Squirrel cage and wound cage have same mode of operation. Rotor conductors cut the rotating stator magnetic field; an emf is induced across the rotor winding, current flows, a rotor magnetic field is produced which interacts with the stator field causing a turning motion. The rotor does not rotate at synchronous speed, its speed varies with applied load. The slip speed being just enough to enable sufficient induced rotor current to produce the power dissipated by the motor load and motor losses.

BEARINGS AND LUBRICATIONS

A good bearing is needed for trouble free operation of motor. Since it is very costly part of the motor, due care has to be taken by checking it at regular intervals. So lubricating plays an important role. Two types of lubricating are widely used

1. Oil lubrication 2. Grease lubrication 3.

INSULATION
Winding is an essential part so it should be insulated. Following types of insulation are widely used

TYPES OF INSULATION
CLASS EFFECTIVE TEMP UPTO WHICH THEY ARE

(DEGREE CENTIGRADE)

Y A E B F H C
 F class insulation is generally preferred.

90 105 120 130 155 180 more than 180

MAIN MOTOR USED IN BOILER AND OFF SIDE AREA

1. ID FAN(2 PER UNIT)
It is located between EP and chimney used for creating induced draft in the furnace.

2. PA FAN(2 PER UNIT)

It is used for handling atmospheric air up to temperature 50 degree centigrade

3. FD FAN(2 PER UNIT)

It is used for handling secondary air for the boiler.

4. SCANNER FAN(2 PER UNIT)

It is required for requisite air for scanner cooling.

5. IGNITOR FAN
It supplies air for cooling of igniters.

INSTRUMENTS SEEN
1. MICROMETER
This instrument is used for measuring inside as well as outside diameter of bearing.

2. MEGGAR
This instrument is used for measuring insulation resistance.

3. VIBRATION TESTER
It measures the vibration of the motor. It is measured in three dimensions-axial, vertical and horizontal.

Electrical maintenance division 2

It includes:

y GENERATORS & TRANFORMERS y SWITCHYARD y ESP

I was assigned to do training in this division from 27th June to 2nd July.

GENERATORS
The generator works on the principle of electromagnetic induction. There are two components stator and rotor. The rotor is the moving part and the stator is the stationary part. The rotor, which has a field winding, is given a defence colony excitation through a set of 3000rpm to give the required frequency of HZ. The rotor is cooled by Hydrogen gas, which is locally manufactured by the plant and has high heat carrying capacity of low density. If oxygen and hydrogen get mixed then they will form very high explosive and to prevent their combining in any way there is seal oil system. The stator cooling is done by de-mineralised (DM) water through hollow conductors. Water is fed by one end by Teflon tube. A boiler and a turbine are coupled to electric generators. Steam from the boiler is fed to the turbine through the connecting pipe. Steam drives the turbine rotor. The turbine rotor drives the generator rotor which turns the electromagnet within the coil of wire conductors. Carbon dioxide is provided from the top and oil is provided from bottom to the generator. With the help of carbon dioxide the oil is drained out to the oil tank.

Hydrogen gas is used to cool down the rotor. Lube oil is used to cool the bearings. DM water is used to cool the stator. Seal oil is used to prevent hydrogen leakage Seal oil coolers are present to cool the seal oil Hydrogen dryer are used which removes the moisture from hydrogen gas and then is supplied to the generator.  Clarified water in cooling tower is used to cool down the hydrogen gas.      

RATINGS OF THE GENERATORS USED

 Turbo generator 100MW  TURBO GENERATOR 210 MW The 100 MW generator generates 10.75 KV and 210 MW generates 15.75 KV. The voltage is stepped up to 220 KV with the help of generator transformer and is connected to the grid. The voltage is stepped down to 6.6 KV with the help of UNIT AUXILLARY TRANSFORMER (UAT) and this voltage is used to drive the HT motors. The voltage is further stepped down to 415 V and then to 220 V and this voltage is used to drive Lt Motors.

TURBO GENERATOR 100MW

MAKE CAPACITY POWER STATOR VOLTAGE STATOR CURRENT SPEED POWER FACTOR FREQUENCY EXCITATION BHEL, Haridwar 117,500 KVA 100,000 KW 10,500 V 6475 A 5 0.85 50 HZ 280 V

TURBO GENERATOR 210 MW

MAKE CAPACITY POWER STATOR VOLTAGE STATOR CURRENT SPEED POWER FACTOR FREQUENCY EXCITATION GAS PRESSURE BHEL, Haridwar 247,000 KVA 210,000 KW 15,750 V 9050 A 5000 rpm 0.85 50 HZ 310 V 3.5 kg/cm2

TRANSFORMERS

INTRODUCTION
It is a static machine which increases or decreases the AC voltage without changing the frequency of the supply. It is a device that: Transfer electric power from one circuit to another. It accomplishes this by electromagnetic induction. In this the two electric circuits are in mutual inductive influence of each other.

WORKING PRINCIPLE:
It works on FARADAY S LAW OF ELECTROMAGNETIC INDUCTION (self or mutual induction depending on the type of transformer).

EMF EQUATION:
E= 4.4 f N
Volts N= number of turns
= max flux in core f= frequency of AC input (Hz)

MAIN PARTS
CONSERVATOR:It is used generally to conserve the insulating property of the oil from deterioration & protect the transformer against failure on account of bad quality of oil.

SILICAGEL DEHYDRATING BREATHER:It is used to prevent entry of moisture inside the transformer tank. The breather consists of silicagel.

GAS OPERATED RELAY (BUCHHOLZ RELAY):It is a gas actuated relay used for protecting oil immersed transformer against all types of faults. It indicates presence of gases in case of some minor fault & take out the transformer out of circuit in case of serious fault.

BUSHINGS:It is made from highly insulating material to insulate & to bring out the terminals of the transformer from the container. The bushings are of 3 types: a) Porcelain bushings used for low voltage transformer. b) Oil filled bushings used for voltage upto 33KV. c) Condensed type bushings used for voltage above 33KV.

OIL GUAGE:
Every transformer with an oil guage to indicate the oil level. The oil guage may be provided with the alarm contacts which gave an alarm the oil level has dropped beyond permissible height due to oil leak etc.

TAPPINGS:The transformer are usually provided with few tappings on secondary side so that output voltage can be varied for constant input voltage.

RADIATORS:- It increases the surface area of the tank & more heat is thus
radiated in less time.

WINDINGS TEMPERATURE INDICATOR (OIL GUAGE):- Device which

indicates the temperature of winding of transformer & possible damage to the transformer due too overload can be prevented.

CONSTRUCTIONAL FEATURES:
3
transformer is constructed in the core type construction. For reducing losses a smaller thickness of lamination is used. For the above reason it is also called cold-rolled steel instead hot-rolled steel is used. High flux densities (1.4 to 1.7 Wb/sq m) are used in the core of power transformer which carry load throughout. For high voltage winding, disc type coils are used.

CLASSIFICATION:
(I) ACCORDING TO THE CORE:
a) Core type transformer b) Shell type transformer c) Berry type transformer

(II) ACCORDING TO PHASES:

a) 1
transformer b) 3
transformer

(III) ACCORDING TO THE PURPOSE FOR WHICH USED:

a) b) c) d) e) Distribution transformer Transmission transformer Generator transformer Station transformer Unit Auxiliary transformer (UAT)

COOLING OF TRANSFORMERS OF LARGE MVA:

As size of transformer becomes large, the rate of the oil circulating becomes insufficient to dissipate all the heat produced & artificial means of increasing the circulation by electric pumps. In very large transformers, special coolers with water circulation may have to be employed.

TYPES OF COOLING:
AIR COOLING:
1. Air Natural (AN) 2. Air Forced (AF)

OIL IMMERSED OIL COOLING:

1. 2. 3. 4. Oil Natural Air Natural (ONAN) Oil Natural Air Forced (ONAF) Oil Forced Air Natural (OFAN) Oil Forced Air Forced (OFAF)

OIL IMMERSED WATER COOLING:

1. Oil Natural Water Forced (ONWF) 2. Oil Forced Water Forced (OFWF)

MAIN PARTS OF TRANSFORMER

i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. Secondary Winding Primary Winding Oil Level Conservator Breather Drain Cock Cooling Tubes Transformer Oil Earth Point Explosion Vent Temperature Gauge Buchholz Relay Secondary Terminal Primary Terminal

GENERATOR TRANSFORMER (125 MVA UNIT-I & UNIT-III)

RATING TYPE OF COOLING TEMP OF OIL TEMP WINDING KV (no load) 125MVA OFB 45^C 60^C HV-233 KVA LV-10.5 KVA LINE AMPERES HV-310 A LV-6880 PHASE FREQUENCY THREE 50 HZ

IMPEDANCE VOLTAGE VECTOR GROUP INSULATION LEVEL

15% Y DELTA HV-900 KV LV-Neutral-38

CORE AND WINDING WEIGHT WEIGHT OF OIL TOTAL WEIGHT OIL QUANTITY

110500 Kg 37200 Kg 188500 Kg 43900 lit

GENERATOR TRANSFORMER (166 MVA UNIT-IV)

RATING TYPE OF COOLING TEMP OF OIL TEMP WINDING VOLTS AT NO LOAD 240MVA ON/OB/OFB 45 C 60 C HV-236000 LV-A5750 LINE AMPERES HV-587 A LV-8798 PHASE FREQUENCY IMPEDANCE VOLTAGE VECTOR GROUP CORE AND WINDING WEIGHT WEIGHT OF OIL THREE 50 HZ 15.55% Y DELTA 138800 Kg 37850 Kg

TOTAL WEIGHT OIL QUANTITY GUARANTEED MAX TEMP DIVISION YEAR

234000 Kg 42500 lit 45 C KERELA 1977

UNIT AUXILIARY TRANSFORMER (UAT)

Unit I & V- 12.5 MVA The UAT draws its input from the main bus-ducts. The total KVA capacity of UAT required can be determined by assuming 0.85 power factor & 90% efficiency for total auxiliary motor load. It is safe & desirable to provide about 20% excess capacity then circulated to provide for miscellaneous auxiliaries & possible increase in auxiliary.

STATION TRANSFORMER
It is required to feed power to the auxiliaries during start ups. This transformer is normally
rated for initial auxiliary load requirements of the unit in typical cases; this load is of the order of 60% of the load at full generating capacity. It is provided with on load tap changer to cater to the fluctuating voltage of the grid.

NEUTRAL GROUNDED TRANSFORMER

This transformer is connected with supply coming out of UAT in stage-2. This is used to ground the excess voltage if occurs in the secondary of UAT in spite of rated voltage.

As we know that electrical energy can t be stored like cells, so what we generate should be consumed instantaneously. But as the load is not constants therefore we generate electricity according to need i.e. the generation depends upon load. The yard is the places from where the electricity is send outside. It has both outdoor and indoor equipments.

OUTDOOR EQUIPMENTS
1. BUS BAR 2. LIGHTENING ARRESTER 3. WAVE TRAP 4. BREAKER 5. CAPACITATIVE VOLTAGE TRANSFORMER 6. EARTHING ROD 7. CURRENT TRANSFORMER 8. POTENTIAL TRANSFORMER 9. LIGHTENING MASK

INDOOR EQUIPMENTS
1. RELAYS 2. CONTROL PANELS 3. CIRCUIT BREAKERS

y BUS BAR
Bus bars generally are of high conductive aluminum conforming to IS-5082 or copper of adequate cross section .Bus bar located in air insulated enclosures & segregated from all other components .Bus bar is preferably cover with polyurethane.

y BY PASS BUS
This bus is a backup bus which comes handy when any of the buses become faulty. When any operation bus has fault, this bus is brought into circuit and then faulty line is removed thereby restoring healthy power line.

y LIGHTENING ARRESTOR
It saves the transformer and reactor from over voltage and over currents. It grounds the overload if there is fault on the line and it prevents the generator transformer. The practice is to install lightening arrestor at the incoming terminal of the line.We have to use the lightning arrester both in primary and secondary of transformer and in reactors. A meter is provided which indicates the surface leakage and internal grading current of arrester.

y WAVE TRAP
Power line carrier communication (PLCC) is mainly used for telecommunication, teleprotection and tele-monitoring between electrical substations through power lines at high voltages, such as 110 kV, 220 kV, and 400 kV. PLCC integrates the transmission of communication signal and 50/60 Hz power signal through the same electric power cable. The major benefit is the union of two important applications in a single system. WAVE TRAP is connected in series with the power (transmission) line. It blocks the high frequency carrier waves (24 KHz to 500 KHz) and let power waves (50 Hz - 60 Hz) to pass through.

y BREAKER
Circuit breaker is an arrangement by which we can break the circuit or flow of current. A circuit breaker in station serves the same purpose as switch but it has many added and complex features. The basic construction of any circuit breaker requires the separation of contact in an insulating fluid that servers two functions:

1. It extinguishes the arc drawn between the contacts when circuit breaker opens. 2. It provides adequate insulation between the contacts and from each contact to earth.

y CAPACITATIVE VOLTAGE TRANSFORMER

A capacitor voltage transformer (CVT) is a transformer used in power systems to step-down extra high voltage signals and provide low voltage signals either for measurement or to operate a protective relay. It is located in the last in the switchyard as it increases the ground resistance. Finally the voltage from CVT in the switchyard is sent out from the station through transmission lines.

y EARTHING ROD
Normally un-galvanized mild steel flats are used for earthing. Separate earthing electrodes are provided to earth the lightening arrestor whereas the other equipments are earthed by connecting their earth leads to the rid/ser of the ground mar.

y CURRENT TRANSFORMER
It is essentially a step up transformer which step down the current to a known ratio. It is a type of instrument transformer designed to provide a current in its secondary winding proportional to the alternating current flowing in its primary.

y POTENTIAL TRANSFORMER
It is essentially a step down transformer and it step downs the voltage to a known ratio.

y RELAYS
Relay is a sensing device that makes your circuit ON or OFF. They detect the abnormal conditions in the electrical circuits by continuously measuring the electrical quantities, which are different under normal and faulty conditions, like current, voltage frequency. Having detected the fault the relay operates to complete the trip circuit, which results in the opening of the circuit breakers and disconnect the faulty circuit. There are different types of relays: 1. 2. 3. 4. Current relay Potential relay Electromagnetic relay Numerical relay etc.

y AIR BREAK EARTHING SWITCH

The work of this equipment comes into picture when we want to shut down the supply for maintenance purpose. This help to neutralize the system from induced voltage from extra high voltage. This induced power is up to 2KV in case of 400 KV lines.

ELECTROSTATIC PRECIPITATOR
An electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate collection 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 that minimally impede the flow of gases through the device, and can easily remove fine particulate matter such as dust and smoke from the air stream. In contrast to wet scrubbers which apply energy directly to the flowing fluid medium, an ESP applies energy only to the particulate matter being collected and therefore is very efficient in its consumption of energy (in the form of electricity). The most basic precipitator contains a row of thin vertical wires, and followed by a stack of large flat metal plates oriented vertically, with the plates typically spaced about 1 cm to 18 cm apart, depending on the application. The air or gas stream flows horizontally through the spaces between the wires, and then passes through the stack of plates. A negative voltage of several thousand volts is applied between wire and plate. If the applied voltage is high enough an electric (corona) discharge ionizes the gas around the electrodes. Negative ions flow to the plates and charge the gas-flow particles.

The ionized particles, following the negative electric field created by the power supply, move to the grounded plates. Particles build up on the collection plates and form a layer. The layer does not collapse, thanks to electrostatic pressure (given from layer resistivity, electric field, and current flowing in the collected layer).

This division basically calibrates various instruments and takes care of any faults occur in any of the auxiliaries in the plant. It has following labs: 1. MANOMETRY LAB 2. PROTECTION AND INTERLOCK LAB 3. PYRO METRY LAB 4. FURNACE SAFETY SUPERVISORY SYSTEM(FSSS) 5. ELECTRONICS TEST LAB This department is the brain of the plant because from the relays to transmitters followed by the electronic computation chipsets and recorders and lastly the controlling circuitry, all fall under this. I was assigned to do training in this division from 4th July to 30th July.

MANOMETRY LAB 1. TRANSMITTERS

It is used for pressure measurements of gases and liquids, its working principle is that the input pressure is converted into electrostatic capacitance and from there it is conditioned and amplified. It gives an output of 4-20 ma DC. It can be mounted on a pipe or a wall. For liquid or steam measurement transmitters is mounted below main process piping and for gas measurement transmitter is placed above pipe.

2. MANOMETER
Its a tube which is bent, in U shape. It is filled with a liquid. This device corresponds to a difference in pressure across the two limbs.

3. BOURDEN PRESSURE GAUGE

Its an oval section tube. Its one end is fixed. It is provided with a pointer to indicate the pressure on a calibrated scale. It is of 2 types: (a) Spiral type: for Low pressure measurement. (b) Helical Type: for High pressure measurement.

PROTECTION AND INTERLOCK LAB

1. INTERLOCKING
It is basically interconnecting two or more equipments so that if one equipments fails other one can perform the tasks. This type of interdependence is also created so that equipments connected together are started and shut down in the specific sequence to avoid damage. For protection of equipments tripping are provided for all the equipments. Tripping can be considered as the series of instructions connected through OR GATE. When a fault occurs and any one of the tripping is satisfied a signal is sent to the relay, which trips the circuit. The main equipments of this lab are relay and circuit breakers.

2. RELAY
It is a protective device. It can detect wrong condition in electrical circuits by constantly measuring the electrical quantities flowing under normal and faulty conditions. Some of the electrical quantities are voltage, current, phase angle and velocity.

3. FUSES
It is a short piece of metal inserted in the circuit, which melts when heavy current flows through it and thus breaks the circuit. Usually silver is used as a fuse material because: a) The coefficient of expansion of silver is very small. As a result no critical fatigue occurs and thus the continuous full capacity normal current ratings are assured for the long time. b) The conductivity of the silver is unimpaired by the surges of the current that produces temperatures just near the melting point. c) Silver fusible elements can be raised from normal operating temperature to vaporization quicker than any other material because of its comparatively low specific heat.

4. MINIATURE CIRCUIT BREAKER

They are used with combination of the control circuits to. a) Enable the staring of plant and distributors. b) Protect the circuit in case of a fault. In consists of current carrying contacts, one movable and other fixed. When a fault occurs the contacts separate and are is stuck between them. There are three types of - MANUAL TRIP - THERMAL TRIP - SHORT CIRCUIT TRIP

HIGH TENSION CONTROL CIRCUIT

For high tension system the control system are excited by separate D.C supply. For starting the circuit conditions should be in series with the starting coil of the equipment to energize it. Because if even a single condition is not true then system will not start.

LOW TENSION CONTROL CIRCUIT

For low tension system the control circuits are directly excited from the 0.415 KV A.C supply. The same circuit achieves both excitation and tripping. Hence the tripping coil is provided for emergency tripping if the interconnection fails.

3. PYROMETER LAB
(1) LIQUID IN GLASS THERMOMETER
Mercury in the glass thermometer boils at 340 degree Celsius which limits the range of temperature that can be measured. It is L shaped thermometer which is designed to reach all inaccessible places.

(2) ULTRA VIOLET CENSOR

This device is used in furnace and it measures the intensity of ultra violet rays there and according to the wave generated which directly indicates the temperature in the furnace.

(3) THERMOCOUPLES
This device is based on SEEBACK and PELTIER effect. It comprises of two junctions at different temperature. Then the emf is induced in the circuit due to the flow of electrons. This is an important part in the plant.

(4) RTD (RESISTANCE TEMPERATURE DETECTOR)

It performs the function of thermocouple basically but the difference is of a resistance. In this due to the change in the resistance the temperature difference is measured. In this lab, also the measuring devices can be calibrated in the oil bath or just boiling water (for low range devices) and in small furnace (for high range devices).

4. FURNACE SAFETY AND SUPERVISORY SYSTEM LAB (FSSS)

This lab has the responsibility of starting fire in the furnace to enable the burning of coal. For first stage coal burners are in the front and rear of the furnace and for the second and third stage corner firing is employed. Unburnt coal is removed using forced draft or induced draft fan. The temperature inside the boiler is 1100 degree Celsius and its height is 18 to 40 m. It is made up of mild steel. An ultra violet sensor is employed in furnace to measure the intensity of ultra violet rays inside the furnace and according to it a signal in the same order of same mV is generated which directly indicates the temperature of the furnace. For firing the furnace a 10 KV spark plug is operated for ten seconds over a spray of diesel fuel and pre-heater air along each of the feeder-mills. The furnace has six feeder mills each separated by warm air pipes fed from forced draft fans. In first stage indirect firing is employed that is feeder mills are not fed directly from coal but are fed from three feeders but are fed from pulverized coalbunkers. The furnace can operate on the minimum feed from three feeders but under not circumstances should any one be left out under operation, to prevent creation of pressure different with in the furnace, which threatens to blast it.

5. ELECTRONICS LAB
This lab undertakes the calibration and testing of various cards. It houses various types of analytical instruments like oscilloscopes, integrated circuits, cards auto analyzers etc. Various processes undertaken in this lab are: 1. Transmitter converts mV to mA. 2. Auto analyzer purifies the sample before it is sent to electrodes. It extracts the magnetic portion.

6. ANNUNCIATIN CARDS
They are used to keep any parameter like temperature etc. within limits. It gets a signal if parameter goes beyond limit. It has a switching transistor connected to relay that helps in alerting the UCB. Control and Instrumentation Measuring Instruments In any process the philosophy of instrumentation should provide a comprehensive intelligence feedback on the important parameters viz. Temperature, Pressure, Level and Flow. This Chapter Seeks to provide a basic understanding of the prevalent instruments used for measuring the above parameters.

TEMPERATURE MEASUREMENT
The most important parameter in thermal power plant is temperature and its measurement plays a vital role in safe operation of the plant. Rise of temperature in a substance is due to the resultant increase in molecular activity of the substance on application of heat; which increases the internal energy of the material. Therefore there exists some property of the substance, which changes with its energy content. The change may be observed with substance itself or in a subsidiary system in thermodynamic equilibrium, which is called testing body and the system itself is called the hot body.

EXPANSION THERMOMETER
Solid Rod Thermometers a temperature sensing - Controlling device may be designed incorporating in its construction the principle that some metals expand more than others for the same temperature range. Such a device is the thermostat used with water heaters The mercury will occupy a greater fraction of the volume of the container than it will at a low temperature. Under normal atmospheric conditions mercury normally boils at a temperature of (347C). To extend the range of mercury in glass thermometer beyond this point the top end of a thermometer bore opens into a bulb which is many times larger in capacity than the bore. This bulb plus the bore above the mercury, is then filled with nitrogen or carbon dioxide

gas at a sufficiently high pressure to prevent boiling at the highest temperature to which the thermometer may be used. Mercury in Steel the range of liquid in glass thermometers although quite large, does not lend itself to all industrial practices. This fact is obvious by the delicate nature of glass also the position of the measuring element is not always the best position to read the result.

Types of Hg in Steel Thermometers are:

Most common and simplest type .

y Bourdon Tube

More sensitive and used where compactness is necessary.

y Spiral type

Most sensitive and compact. Pointer may be mounted direct on end of helix which rotates, thus eliminating backlash and lost motion. Linkages, which only allow the pointer to operate over a selected range of pressure to either side of the normal steam pressure.

y Helical Type

CYCLES INVOLVED
FEED WATER CYCLE

PRIMARY AIR CYCLE

FUEL GAS CYCLE

SECONDARY AIR CYCLE