2013

TRAINING REPORT - BTPS

Nishant Groha

E.E. 3rd Year

Hindu College of Engineering VT No. VT1400 Roll No. 10/EE/2733

Certification

This is to certify that NISHANT GROHA (10/E/2733), student of 2010-2014 Batch of Electrical Engineering Branch in 3rd Year of Hindu College of Engineering, Sonipat has successfully completed his industrial training at BADARPUR THERMAL POWER STATION NTPC, New Delhi for six weeks from 25th June to 3rd August 2013. He has completed the whole training as per the training report submitted by him.

Training In-Charge Badarpur Thermal Power Station NTPC, Badarpur, New Delhi

CONTENTS
Acknowledgement

NTPC ABOUT THE COMPANY

BTPS (Badarpur Thermal Power Station), BADARPUR

EMD-I (Electrical Maintenance Department - I)

EMD-II (Electrical Maintenance Department - II)

Acknowledgement

With profound respect and gratitude, I take the opportunity to convey my thanks for permitting me to complete my training here. I extend my heartfelt thanks to Mr Gangadhar Thapa for providing me this opportunity to be a part of this esteemed organization. Im extremely grateful to all the technical staff of BTPS / NTPC for their co-operation and guidance that has helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted to them for this value addition in me. I would also like to thank the training in-charge of Hindu College of Engineering (Sonipat) and all the faculty members of electrical department for their effort of constant co-operation, which have been a significant factor in the accomplishment of my industrial training.

NISHANT GROHA HINDU COLLEGE OF ENGINEERING SONIPAT

NTPC (NATIONAL THERMAL POWER CORPORATION)

ABOUT
NTPC, India's largest power company, was set up in 1975 to accelerate power development in India. It is emerging as an Integrated Power Major, with a significant presence in the entire value chain of power generation business. NTPC is ranked 337th in the 2012, Forbes Global 2000 ranking of the Worlds biggest companies. With a current generating capacity of 41,184 MW, NTPC plans to become a 128,000 MW company by 2032.

OVERVIEW
Indias largest power company, NTPC was set up in 1975 to accelerate power development in India. NTPC is emerging as a diversified power major with presence in the entire value chain of the power generation business. Apart from power generation, which is the mainstay of the company, NTPC has already ventured into consultancy, power trading, ash utilisation and coal mining. NTPC is ranked 337th in the 2012, Forbes Global 2000 ranking of the Worlds biggest companies. NTPC became a Maharatna company in May, 2010, one of the only four companies to be awarded this status.

The total installed capacity of the company is 41,184 MW (including JVs) with 16 coal based and 7 gas based stations, located across the country. In addition under JVs, 7 stations are coal based & another station uses naphtha/LNG as fuel and 2 renewable energy projects. The company has set a target to have an installed power generating capacity of 1,28,000 MW by the year 2032. The capacity will have a diversified fuel mix comprising 56% coal, 16% Gas, 11% Nuclear and 17% Renewable Energy Sources(RES) including hydro. By 2032, non-fossil fuel based generation capacity shall make up nearly 28% of NTPCs portfolio. NTPC has been operating its plants at high efficiency levels. Although the company has 17.75% of the total national capacity, it contributes 27.40% of total power generation due to its focus on high efficiency.

In October 2004, NTPC launched its Initial Public Offering (IPO) consisting of 5.25% as fresh issue and 5.25% as offer for sale by Government of India. NTPC thus became a listed company in November 2004 with the Government holding 89.5% of the equity share capital. In February 2010, the

Shareholding of Government of India was reduced from 89.5% to 84.5% through Further Public Offer. The rest is held by Institutional Investors and the Public.

At NTPC, People before Plant Load Factor is the mantra that guides all HR related policies. NTPC has been awarded No.1, Best Workplace in India among large organisations and the best PSU for the year 2010, by the Great Places to Work Institute, India Chapter in collaboration with The Economic Times. The concept of Corporate Social Responsibility is deeply ingrained in NTPC's culture. Through its expansive CSR initiatives, NTPC strives to develop mutual trust with the communities that surround its power stations.

EVOLUTION
NTPC was set up in 1975 in 100% by the ownership of Government of India. In the last 30 years NTPC has grown into the largest power utility in India. In1997, Government of India granted NTPC status of 'Navratna' being one of the nine jewels of India, enhancing the powers to the Board of Directors. NTPC became a listed company with majority Government ownership of 89.5%. NTPC becomes third largest by market capitalisation of listed companies. The company rechristened as NTPC Limited in line with its changing business portfolio and transforms itself from a thermal power utility to an integrated power utility.

1975

1997

2004

2005

2008

National Thermal Power Corporation is the largest power generation company in India. Forbes Global 2000 for 2008 ranked it 411th the world.

2009

National Thermal Power Corporation is the largest power generation company in India. Forbes Global 2000 for 2008 ranked it 317th in the world.

2012

NTPC has also set up a plan to achieve a target of 50,000 MW generation capacity.

2017

NTPC has embarked on plans to become a 75,000 MW company by 2017.

VISION
To be the worlds largest and best power producer, powering Indias growth.

MISSION
Develop and provide reliable power, related products and services at competitive prices, integrating multiple energy sources with innovative and eco-friendly technologies and contribute to society.

Core Values BE COMMITTED

B E C O M M I T T E D Business Ethics Environmentally & Economically Sustainable Customer Focus Organisational & Professional Pride Mutual Respect & Trust Motivating Self & others Innovation & Speed Total Quality for Excellence Transparent & Respected Organisation Enterprising Devoted

STRATEGIES

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TECHNOLOGICAL INITIATIVE
Introduction of steam generators (boilers) of the size of 800 MW. Integrated Gasification Combined Cycle (IGCC) Technology. Launch of Energy Technology Centre -A new initiative for development of technologies with focus on fundamental R&D. The company sets aside up to 0.5% of the profits for R&D. Roadmap developed for adopting Clean Development Mechanism to help get / earn Certified Emission Reduction

PARTNERING GOVERNMENT IN VARIOUS INITIATIVES

Consultant role to modernize and improvise several plants across the country.

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 Disseminate technologies to other players in the sector. Consultant role partnership in excellence programme for improvement of PLF of 15 power stations of SEBs. Rural Electrification work under Rajiv Gandhi Gramin Vidyutikaran.

DIVERSIFIED GROWTH
As per new corporate plan, NTPC envisages to have an installed capacity of 128 GW by the year 2032 with a welldiversified fuel mix comprising 56% coal, 16% gas, 11% nuclear energy, 9% renewable energy and 8% hydro power based capacity. As such, by the year 2032, 28% of NTPCs installed generating capacity will be based on carbon free energy sources. Further, the coal based capacity will increasingly be based on high-efficient-low-emission technologies such as Supercritical and Ultra-Super-critical. Along with this growth, NTPC will utilize a strategic mix of options to ensure fuel security for its fleet of power stations. Looking at the opportunities coming its way, due to changes in the business environment, NTPC made changes in its strategy and diversified in the business adjacencies along the energy value chain. In its pursuit of diversification NTPC has developed strategic alliances and joint ventures with leading

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national and international companies. NTPC has also made long strides in developing its Ash Utilization business. Hydro Power: In order to give impetus to hydro power growth in the country and to have a balanced portfolio of power generation, NTPC entered hydro power business with the 800 MW Koldam hydro project in Himachal Pradesh. Two more projects have also been taken up in Uttarakhand. A wholly owned subsidiary, NTPC Hydro Ltd., is setting up hydro projects of capacities up to 250 MW. Renewable Energy: In order to broad base its fuel mix NTPC has plan of capacity addition of about 1,000 MW through renewable resources by 2017. Nuclear Power: A Joint Venture Company "Anushakti Vidhyut Nigam Ltd." has been formed (with 51% stake of NPCIL and 49% stake of NTPC) for development of nuclear power projects in the country. Coal Mining: In a major backward integration move to create fuel security, NTPC has ventured into coal mining business with an aim to meet about 20% of its coal requirement from its captive mines by 2017. The Government of India has so far allotted 7 coal blocks to NTPC, including 2 blocks to be developed through joint venture route. Power Trading: 'NTPC Vidyut Vyapar Nigam Ltd.' (NVVN), a wholly owned subsidiary was created for trading power leading to optimal utilization of NTPCs assets. It is the second largest power trading company in the country. In order to facilitate power trading in the country, National Power Exchange Ltd., a JV of NTPC,

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NHPC, PFC and TCS has been formed for operating a Power Exchange. Ash Business: NTPC has focused on the utilization of ash generated by its power stations to convert the challenge of ash disposal into an opportunity. Ash is being used as a raw material input by cement companies and brick manufacturers. NVVN is engaged in the business of Fly Ash export and sale to domestic customers. Joint ventures with cement companies are being planned to set up cement grinding units in the vicinity of NTPC stations. Power Distribution: NTPC Electric Supply Company Ltd. (NESCL), a wholly owned subsidiary of NTPC, was set up for distribution of power. NESCL is actively engaged in Rajiv Gandhi Gramin Vidyutikaran Yojana programme for rural electrification. Equipment Manufacturing: Enormous growth in power sector necessitates augmentation of power equipment manufacturing capacity. NTPC has formed JVs with BHEL and Bharat Forge Ltd. for power plant equipment manufacturing. NTPC has also acquired stake in Transformers and Electricals Kerala Ltd. (TELK) for manufacturing and repair of transformers.

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PERFORMANCE STATISTICS

NTPC ENVIRONMENT POLICY

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Since its inception NTPC has been at the forefront of Environment management. In November 1995, NTPC brought out a comprehensive document entitled NTPC Environment Policy and Environment Management System. Amongst the guiding principles adopted in the document is the companys pro-active approach to environment, optimum utilisation of equipment, adoption of latest technologies and continual environment improvement. The policy also envisages efficient utilisation of resources, thereby minimising waste, maximising ash utilisation and ensuring a green belt all-round the plant for maintaining ecological balance. ENVIRONMENT MANAGEMENT, OCCUPATIONAL HEALTH AND SAFETY SYSTEMS NTPC has actively gone for adoption of the best international practices on environment, occupational health and safety areas. The organisation has pursued the Environmental Management System (EMS) ISO 14001 and the Occupational Health and Safety Assessment System OHSAS 18001 at its different establishments. As a result of pursuing these practices, all NTPC power stations have been certified for ISO 14001 & OHSAS 18001 by reputed national and international certifying agencies. POLLUTION CONTROL SYSTEMS While deciding the appropriate technology for its projects, NTPC integrates many environmental provisions into the plant design. In order to ensure that NTPC complies with all the stipulated environment norms, following state-of-the-art pollution control systems / devices have been installed to control air and water pollution:

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Electrostatic Precipitators Flue Gas Stacks Low-NOX Burners Neutralisation Pits Coal Settling Pits / Oil Settling Pits DE & DS Systems Cooling Tower Ash Dykes & Ash Disposal Systems Ash Water Recycling System Dry Ash Extraction System (DAES) Liquid Waste Treatment Plants & Management System Sewage Treatment Plants & Facilities Environmental Institutional Set-up

Following are the additional measures taken by NTPC in the area of Environment Management: Environment Management During Operation Phase Monitoring of Environmental Parameters On-Line Data Base Management Environment Review Up gradation & Retrofitting of Pollution Control Systems Resources Conservation Waste Management Municipal Waste Management Hazardous Waste Management Bio-Medical Waste Management Land Use / Bio-diversity Reclamation of Abandoned Ash ponds Green Belts, Afforestation & Energy Plantations

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BTPS (BADARPUR THERMAL POWER STATION)

Badarpur Thermal Power Station is located at Badarpur area in NCT Delhi. The power plant is one of the coal based power plants of NTPC. The National Power Training Institute (NPTI) for North India Region under Ministry of Power, Government of India was established at Badarpur in 1974, within the Badarpur Thermal power plant (BTPS) complex.

POWER PLANT The Badarpur Thermal Power Station has an installed capacity of 705 MW. It is situated in south east corner of Delhi on Mathura Road near Faridabad. It was the first central sector power plant conceived in India, in 1965. It was originally conceived to provide power to neighbouring states of Haryana, Punjab, Jammu and Kashmir, U.P., Rajasthan, and

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Delhi. But since year 1987 Delhi has become its sole beneficiary. It was owned and conceived by Central Electric Authority. Its construction was started in year 1968, and the First unit was commissioned in 26 July 1973. The coal for the plant is derived from the Jharia Coal Fields. This was constructed under ownership of Central Electric Authority, later it was transferred to NTPC. It supplies power to Delhi city. It is one of the oldest plants in operation. Its 100 MW units capacity have been reduced to 95 MW. These units have indirectly fired boiler, while 210 MW units have directly fired boiler. All the turbines are of Russian Design. Both turbine and boilers have been supplied by BHEL. The boiler of Stage-I units are of Czech design. The boilers of Unit 4 and 5 are designed by combustion engineering (USA). The instrumentation of the stage I units and unit 4 are of The Russian design. Instrumentation of unit 5 is provided by M/S Instrumentation Ltd. Kota is of Kent design.

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In 1978 the management of the plant was transferred to NTPC, from CEA. The performance of the plant increased significantly and steadily after take over by NTPC till 2006, but now the plant is facing various issues. Being an old plant, Badarpur Thermal Power Station (BTPS) has little automation. Its performance is deteriorating due to various reasons, like aging, poor quantity and quality of cooling water etc. It receives cooling water from Agra Canal, which is an irrigation canal from Yamuna River. Due to rising water pollution, the water of Yamuna is highly polluted. This polluted water when goes into condenser, adversely affect life of condenser tubes, resulting in frequent tube leakages. This dirty water from tube leakage gets mixed into feed water cycle causes numerous problems, like frequent boiler tube leakages, and silica deposition on turbine blades. Apart from poor quality, the quantity of water supply is also erratic due to lack of co-ordination between NTPC and UP irrigation which manages Agra Canal. The quality of the coal supplied has degraded considerably. At worst times, there were many units tripping owing to poor quality. The poor coal quality also put burdens on equipment, like mills and their performance also goes down. The coal for the plant is fetched from far away, that makes the total fuel cost double of coal cost at coalmine. This factor, coupled with low efficiency due to aging and old design makes electricity of the plant costlier. With new splurge in no of power plant, the distribution company does not purchase full power from

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it. Presently the management is headed by Mr N. K. Kothari, General Manager. INSTALLED CAPACITY STAGE UNIT INSTALLED NUMBER CAPACITY (MW) FIRST 1 95 FIRST 2 95 FIRST 3 95 SECOND 4 210 SECOND 5 210

DATE OF STATUS COMMISSIONING July, 1973 August, 1974 March, 1975 December, 1978 December, 1981 Running Running Running Running Running

INTRODUCTION
A thermal power station is a power plant in which the primemover is steam driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed in a condenser and recycled to where it was heated; this is known as a Rankine cycle. The greatest variation in the design of thermal power stations is due to the different fuel source. Almost all coal, nuclear, geothermal, solar thermal electric and waste incineration plants, as well as many natural gas power plants are thermal. Natural gas is frequently combusted in gas turbines as well as boilers. The waste heat from a gas turbine can be used to raise steam, in a combined cycle plant that improves overall efficiency. Power plants burning coal, fuel oil, or natural gas are often called fossil-fuel power plants. Some biomass-fuel thermal power plants have appeared also. Non-nuclear thermal

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power plants, particularly fossil-fuel plants, which do not use co-generation, are sometimes referred to as conventional power plants. Commercial electric utility power stations are usually constructed on a large scale and designed for continuous operation. Electric power plants typically use three-phase electrical generators to produce alternating current (AC) electric power at a frequency of 50 Hz or 60 Hz. Large companies or institutions may have their own power plants to supply heating or electricity to their facilities. COAL TO ELECTRICITY: BASICS

COAL TO STEAM Coal from the coal wagons is unloaded in the coal handling plant. This coal is transported up to the raw coal bunkers with the help of belt conveyors. Coal is transported to Bowl mills by Coal Feeders. The coal is pulverized in the Bowl Mill, where it is ground to powder form. The mill consists of a round metallic table on which coal particles fall. This table is rotated with the help of a motor. There are three large steel

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rollers, which are spaced 120 apart. When there is no coal, these rollers do not rotate but when the coal is fed to the table it packs up between the rollers and thus forces the rollers to rotate. Coal is crushed by the crushing action between the rollers and rotating table. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold air mixtures from P.A. Fan. P.A. Fan takes atmospheric air, part of which is sent to AirPreheaters for heating while a part goes directly to the mill for temperature control. Atmospheric air from the F.D. Fan is heated in the air heaters and sent to the furnace as combustion air. Water from the boiler feed pump passes through economizer and reaches the boiler drum. Water from the drum passes through down corners 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 and density difference, the water rises up in the water wall tubes. Water is partly converted to steam as it rises up in the furnace. This steam and water mixture is again taken to the boiler drum where the steam is separated from water.

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Water follows the same path while the steam is sent to superheaters for super heating. The superheaters are located inside the furnace and the steam is superheated (540C) and finally it goes to turbine. Flue gases from the furnace are extracted by induced draft fan, which maintains balance draft in the furnace (-5 to -10 mm of wcl) with forced draft fan. These flue gases emit there heat energy to various super heaters in the pent house and finally [ass through air-preheaters and goes to electrostatic precipitators where the ash particles are extracted. Electrostatic precipitator consists of metal plates, which are electrically charged. Ash particles are attracted on to these plates, so that they do not pass through the chimney to pollute the atmosphere. Regular mechanical hammer blows cause the accumulated ash to fall to the bottom of the precipitator where they are collected in a hopper for disposal.

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STEAM TO MECHANICAL POWER From the boiler, a steam pipe conveys the steam to the turbine through a stop valve (which can automatically regulate the supply of steam in case of emergency) and through control valves that automatically regulate the supply of steam to the turbine. Stop valve and control valves are located in a steam chest and a governor, driven from the main turbine shaft, operates the control valves to regulate the amount of steam used (this depends upon the speed of the turbine and the amount of the electricity required from the generator). Steam from the control valves enters the high pressure cylinder of the turbine, where it passes through a ring of stationary blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on a disc secured to the turbine shaft. The second ring turns the shafts as a result of the force of steam. The stationary and moving blades together constitute a stage of turbine and in practice many stages are necessary, so that the cylinder contains a number of rings of stationary blades with rings of moving blades arranged between them. The steam passes through each stage in turn until it reaches the end of the high pressure cylinder and in its passage some of its heat energy is changed into mechanical energy. The steam leaving the high pressure cylinder goes back to the boiler for reheating and returns by a further pipe to the intermediate pressure cylinder. Here it passes through another series of stationary and moving blades. Finally, the steam is taken to the low pressure cylinders, each of which enters at the centre flowing outwards in opposite directions through the row of turbine blades through an

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arrangement called the double flow to the extremities of the cylinder. As the steam gives up its heat energy to drive the turbine, its temperature and pressure falls and it expands. Because of this expansion the blades are much larger and longer towards the low pressure ends of the turbine. MECHANICAL TO ELECTRICAL POWER As the blades of turbine rotate, the shaft of the generator, which is coupled to that of the turbine, also rotates. It results in rotation of the coil of the generator, which causes induced electricity to be produced. BASIC POWER PLANT CYCLE

A simplified diagram of a thermal power plant

The Thermal (steam) power plant uses a dual (vapour + liquid) phase cycle. It is a close cycle to enable the working fluid (water) to be used again and again. The cycle used is Rankine Cycle modified to include superheating of steam, regenerative feed water heating and reheats. The Rankine cycle is a cycle that converts heat into work. The heat is supplied externally to a closed loop, which usually uses water. This cycle generates about 90% of all electric

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power used throughout the world. The Rankine cycle is the fundamental thermodynamic underpinning of the steam engine. The Rankine cycle most closely describes the process by which steam-operated heat engines most commonly found in power generation plants generate power.

The efficiency of a Rankine cycle is usually limited by the working fluid. Without the pressure reaching super critical levels for the working fluid, the temperature range the cycle can operate over is quite small: turbine entry temperatures are typically 565C (the creep limit of stainless steel) and condenser temperatures are around 30C. This gives a theoretical Carnot efficiency of about 63% compared with an actual efficiency of 42% for a modern coal-fired power station. This low turbine entry temperature (compared with a gas turbine) is why the Rankine cycle is often used as a bottoming cycle in combined-cycle gas turbine power stations. One of the principal advantages the Rankine cycle holds over others is that during the compression stage relatively little

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work is required to drive the pump, the working fluid being in its liquid phase at this point. By condensing the fluid, the work required by the pump consumes only 1% to 3% of the turbine power and contributes to a much higher efficiency for a real cycle. The benefit of this is lost somewhat due to the lower heat addition temperature. Gas turbines, for instance, have turbine entry temperatures approaching 1500C. Nonetheless, the efficiencies of actual large steam cycles and large modern gas turbines are fairly well matched. FACTORS AFFECTING THERMAL CYCLE EFFICIENCY Thermal cycle efficiency is affected by following: Initial steam pressure. Initial steam temperature. Whether reheat is used or not, and if used reheat pressure and temperature. Condenser pressure. Regenerative feed water heating. THERE ARE FOUR PROCESSES IN THE RANKINE CYCLE. Process 1-2: The working fluid is pumped from low to high pressure. As the fluid is a liquid at this stage the pump requires little input energy. Process 2-3: The high pressure liquid enters a boiler where it is heated at constant pressure by an external heat source to become a dry saturated vapour. The input energy required can be easily calculated using steam tables. Process 3-4: The dry saturated vapour expands through a turbine, generating power. This decreases the temperature and pressure of the vapour, and some

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condensation may occur. The output in this process can be easily calculated using the Enthalpy-entropy chart or the steam tables. Ideally this process is isentropic i.e. entropy of steam doesnt change during this process, but in actual case there is increase in entropy of steam due to irreversibility and hence work extracted from turbine is less than the work in ideal case. Process 4-1: The wet vapour then enters a condenser where it is condensed at a constant pressure to become saturated liquid.

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ESSENTIALS OF STEAM POWER PLANT EQUIPMENT Steam is an important medium of producing mechanical energy. Steam has the advantage that, it can be raised from water which is available in abundance it does not react much with the materials of the equipment of power plant and is stable at the temperature required in the plant Steam is used to drive steam engines, steam turbines etc. Steam power station is most suitable where coal is available in abundance. Thermal electrical power generation is one of the major methods. Out of total power developed in India about 60% is thermal. For a thermal power plant the range of pressure may vary from 10 kg/cm2 to super critical pressures and the range of temperature may be from 250C to 650C.The average all India Plant load factor (P.L.F.) of thermal power plants in 1987-88 has be worked out to be 56.4% which is the highest P.L.F. recorded by thermal sector so far.

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Coal delivery equipment is one of the major components of plant cost. The various steps involved in coal handling are as follows: i. Coal delivery ii. Unloading iii. Preparation iv. Transfer v. Outdoor storage vi. Covered storage vii. In plant handling viii. Weighing and measuring ix. Feeding the coal into furnace. COAL DELIVERY: The coal from supply points is delivered by ships or boats to power stations situated near to sea or river whereas coal is supplied by rail or trucks to the power stations which are situated away from sea or river. The transportation of coal by trucks is used if the railway facilities are not available. II. UNLOADING: The type of equipment to be used for unloading the coal received at the power station depends on how coal is received at the power station. If coal is delivered by trucks, there is no need of unloading device as the trucks may dump the coal to the outdoor storage. Coal is easily handled if the lift trucks with scoop are used. In case the coal is brought by railway wagons, ships or boats, the unloading may be done by car shakes, rotary car dumpers, cranes, grab buckets and coal accelerators. Rotary car dumpers although costly are quite efficient for unloading closed wagons. I.

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III. PREPARATION: When the coal delivered is in the form of big lumps and it is not of proper size, the preparation (sizing) of coal can be achieved by crushers, breakers, sizers driers and magnetic separators. IV. TRANSFER: After preparation coal is transferred to the dead storage by means of the following system : BELT CONVEYOR: It consists of an endless belt moving over a pair of end drums (rollers). At some distance a supporting roller is provided at the centre. The belt is made, up of rubber or canvas. Belt conveyor is suitable for the transfer of coal over long distances. It is used in medium and large power plants. The initial cost of the system is not high and power consumption is also low. The inclination at which coal can be successfully elevated by belt conveyor is about 20. Average speed of belt conveyors varies between 200-300 rpm. This conveyor is preferred than other types.

The Old Coal Handling Plant at BTPS

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ADVANTAGES OF BELT CONVEYOR Its operation is smooth and clean. It requires less power as compared to other types of systems. Large quantities of coal can be discharged quickly and continuously. Material can be transported on moderates inclines.

COAL STORAGE The coal is stored by the following methods: i. STOCKING THE COAL IN HEAT: The coal is piled on the ground up to 10-12 m height. The pile top should be given a slope in the direction in which the rain may be drained off. The sealing of stored pile is desirable in order to avoid the oxidation of coal after packing an air tight layer of coal. Asphalt, fine coal dust and bituminous coating are the materials commonly used for this purpose. UNDER WATER STORAGE: The possibility of slow oxidation and spontaneous combustion can be completely eliminated by storing the coal under water. Coal should be stored at a site located on solid ground,

ii.

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iii.

well drained, free of standing water preferably on high ground not subjected to flooding. IN PLANT HANDLING: From the dead storage the coal is brought to covered storage (Live storage) (bins or bunkers). In plant handling may include the equipment such as belt conveyors, screw conveyors, bucket elevators etc. to transfer the coal.

STEAM GENERATOR/BOILER The boiler is a rectangular furnace about 50 ft. (15 m) on a side and 130 ft. (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60 mm) in diameter. Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the centre. 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 3,200 psi (22.1MPa). It is separated from the water inside a drum at the top of the furnace. The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to 1,000 F (540 C) to prepare it for the turbine. The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. The generator includes the economizer, the steam drum, and the chemical dosing equipment, and the furnace with its steam generating

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tubes and the superheater coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include: forced draft (FD) fan, air preheater (APH), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or baghouse) and the flue gas stack. For units over about 210 MW capacities, redundancy of key components is provided by installing duplicates of the FD fan, APH, fly ash collectors and ID fan with isolating dampers. On some units of about 60 MW, two boilers per unit may instead be provided.

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BOILER FURNACE AND STEAM DRUM Once water is inside the boiler or steam generator, the process of adding the latent heat of vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical reaction of burning some type of fuel. The water enters the boiler through a section in the convection pass called the economizer. From the economizer it passes to the steam drum. Once the water enters the steam drum it goes down the down comers to the lower inlet water wall headers. From the inlet headers the water rises through the water walls and is eventually turned into steam due to the heat being generated by the burners located on the front and rear water walls (typically). As the water is turned into steam/vapour in the water walls, the steam/vapour once again enters the steam drum. The steam/vapour is passed through a series of steam and water separators and then dryers inside the steam drum. The steam separators and dryers remove the water droplets from the steam and the cycle through the water walls is repeated.

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This process is known as natural circulation. The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot blowers, water lancing and observation ports (in the furnace walls) for observation of the furnace interior. Furnace explosions due to any accumulation of combustible gases after a tripout are avoided by flushing out such gases from the combustion zone before igniting the coal. The steam drum (as well as the superheater coils and headers) have air vents and drains needed for initial start-up. The steam drum has an internal device that removes moisture from the wet steam entering the drum from the steam generating tubes. The dry steam then flows into the superheater coils. Geothermal plants need no boiler since they use naturally occurring steam sources. Heat exchangers may be used where the geothermal steam is very corrosive or contains excessive suspended solids. Nuclear plants also

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boil water to raise steam, either directly passing the working steam through the reactor or else using an intermediate heat exchanger. FUEL PREPARATION SYSTEM In coal-fired power stations, the raw feed coal from the coal storage area is first crushed into small pieces and then conveyed to the coal feed hoppers at the boilers. The coal is next pulverized into a very fine powder. The pulverisers may be ball mills, rotating drum grinders, or other types of grinders. Some power stations burn fuel oil rather than coal. The oil must kept warm (above its pour point) in the fuel oil storage tanks to prevent the oil from congealing and becoming unpumpable. The oil is usually heated to about 100C before being pumped through the furnace fuel oil spray nozzles. Boilers in some power stations use processed natural gas as their main fuel. Other power stations may use processed natural gas as auxiliary fuel in the event that their main fuel supply (coal or oil) is interrupted. In such cases, separate gas burners are provided on the boiler furnaces. FUEL FIRING AND IGNITE SYSTEM From the pulverized coal bin, coal is blown by hot air through the furnace coal burners at an angle which imparts a swirling motion to the powdered coal to enhance mixing of the coal powder with the incoming preheated combustion air and thus to enhance the combustion. To provide sufficient combustion temperature in the furnace before igniting the powdered coal, the furnace temperature is raised by first burning some light fuel oil or processed natural

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gas (by using auxiliary burners and igniters provide for that purpose). AIR PATH External fans are provided to give sufficient air for combustion. The forced draft fan takes air from the atmosphere and, first warming it in the air preheater for better combustion, injects it via the air nozzles on the furnace wall. The induced draft fan assists the FD fan by drawing out combustible gases from the furnace, maintaining a slightly negative pressure in the furnace to avoid backfiring through any opening. At the furnace outlet and before the furnace gases are handled by the ID fan, fine dust carried by the outlet gases is removed to avoid atmospheric pollution. This is an environmental limitation prescribed by law, and additionally minimizes erosion of the ID fan.

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AUXILIARY SYSTEMS FLY ASH COLLECTION Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag filters (or sometimes both) located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators or bag filters. Generally, the fly ash is pneumatically transported to storage silos for subsequent transport by trucks or railroad cars. BOTTOM ASH COLLECTION AND DISPOSAL At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from the bottom of the furnace. This hopper is always filled with water to quench the ash and clinkers falling down from the furnace. Some arrangement is included to crush the clinkers and for conveying the crushed clinkers and bottom ash to a storage site.

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Hopper Assembly in BTPS

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BOILER MAKE-UP WATER TREATMENT PLANT AND STORAGE Since there is continuous withdrawal of steam and continuous return of condensate to the boiler, losses due to blow-down and leakages have to be made up for so as to maintain the desired water level in the boiler steam drum. For this, continuous make-up water is added to the boiler water system. The impurities in the raw water input to the plant generally consist of calcium and magnesium salts which impart hardness to the water. Hardness in the make-up water to the boiler will form deposits on the tube water surfaces which will lead to overheating and failure of the tubes. Thus, the salts have to be removed from the water and that is done by a WTP plant.

WATER DEMINERALISING TREATMENT PLANT (DM) A DM plant generally consists of cation, anion and mixed bed exchangers. The final water from this process consists essentially of hydrogen ions and hydroxide ions which is the

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chemical composition of pure water. The DM water, being very pure, becomes highly corrosive once it absorbs oxygen from the atmosphere because of its very high affinity for oxygen absorption. The capacity of the DM plant is dictated by the type and quantity of salts in the raw water input. However, some storage is essential as the DM plant may be down for maintenance. For this purpose, a storage tank is installed from which DM water is continuously withdrawn for boiler make-up. The storage tank for DM water is made from materials not affected by corrosive water, such as PVC. The piping and valves are generally of stainless steel. Sometimes, a steam blanketing arrangement or stainless steel doughnut float is provided on top of the water in the tank to avoid contact with atmospheric air. DM water make-up is generally added at the steam space of the surface condenser (i.e., the vacuum side). This arrangement not only sprays the water but also DM water gets deaerated, with the dissolved gases being removed by the ejector of the condenser itself. ELECTRIC GENERATOR The steam turbine-driven generators have auxiliary systems enabling them to work satisfactorily and safely. The steam turbine generator being rotating equipment generally has a heavy, large diameter shaft. The shaft therefore requires not only supports but also has to be kept in position while running. To minimize the frictional resistance to the rotation, the shaft has a number of bearings. The bearing shells, in which the shaft rotates, are lined with a low friction material like Babbitt metal. Oil lubrication is provided to further

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reduce the friction between shaft and bearing surface and to limit the heat generated.

BARRING GEAR OR TURNING GEAR Barring gear is the term used for the mechanism provided for rotation of the turbine generator shaft at a very low speed (about one revolution per minute) after unit stoppages for any reason. Once the unit is "tripped" (i.e., the turbine steam inlet valve is closed), the turbine starts slowing or "coasting down". When it stops completely, there is a tendency for the turbine shaft to deflect or bend if allowed to remain in one position too long. This deflection is because the heat inside the turbine casing tends to concentrate in the top half of the casing, thus making the top half portion of the shaft hotter than the bottom half. The shaft therefore warps or bends by millionths of inches, only detectable by monitoring eccentricity meters. But this small amount of shaft deflection would be enough to cause vibrations and damage the entire steam turbine generator unit when it is restarted. Therefore, the shaft is not permitted to come to a complete stop by a mechanism known as "turning gear" or "barring gear" that automatically takes over to rotate the unit at a pre-set low

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speed. If the unit is shut down for major maintenance, then the barring gear must be kept in service until the temperatures of the casings and bearings are sufficiently low. CONDENSER The surface condenser is a shell and tube heat exchanger in which cooling water is circulated through the tubes. The exhaust steam from the low pressure turbine enters the shell where it is cooled and converted to condensate (water) by flowing over the tubes as shown in the adjacent diagram. Such condensers use steam ejectors or rotary motor-driven exhausters for continuous removal of air and gases from the steam side to maintain vacuum. For best efficiency, the temperature in the condenser must be kept as low as practical in order to achieve the lowest possible pressure in the condensing steam. Since the condenser temperature can almost always be kept significantly below 100C, where the vapour pressure of water is much less than atmospheric pressure, the condenser generally works under vacuum. Plants operating in hot climates may have to reduce output if their source of condenser cooling water becomes warmer; unfortunately this usually coincides with periods of high electrical demand for air conditioning. The condenser generally uses either circulating cooling water from a cooling tower to reject waste heat to the atmosphere, or oncethrough water from a river, lake or ocean.

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FEEDWATER HEATER A Rankine cycle with a two-stage steam turbine and a single feed-water heater is shown ahead. In the case of a conventional steam-electric power plant utilizing a drum boiler, the surface condenser removes the latent heat of vaporization from the steam as it changes states from vapour to liquid. The heat content (btu) in the steam is referred to as Enthalpy. The condensate pump then pumps the condensate water through a feed-water heater. The feed-water heating equipment then raises the temperature of the water by utilizing extraction steam from various stages of the turbine. Preheating the feed-water reduces the irreversibilitys involved in steam generation and therefore improves the thermodynamic efficiency of the system. This reduces plant operating costs and also helps to avoid thermal shock to the boiler metal when the feed-water is introduced back into the steam cycle.

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SUPERHEATER As the steam is conditioned by the drying equipment inside the drum, it is piped from the upper drum area into an elaborate set up of tubing in different areas of the boiler. The areas known as superheater and reheater. The steam vapour picks up energy and its temperature is now superheated above the saturation temperature. The superheated steam is then piped through the main steam lines to the valves of the high pressure turbine.

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DEAERATOR A steam generating boiler requires that the boiler feed water should be devoid of air and other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the metal. Generally, power stations use a deaerator to provide for the removal of air and other dissolved gases from the boiler feed-water. A deaerator typically includes a vertical, domed deaeration section mounted on top of a horizontal cylindrical vessel which serves as the deaerated boiler feed-water storage tank.

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There are many different designs for a deaerator and the designs will vary from one manufacturer to another. The adjacent diagram depicts a typical conventional tray deaerator. If operated properly, most deaerator manufacturers will guarantee that oxygen in the deaerated water will not exceed 7 ppb by weight (0.005 cm/L). AUXILIARY SYSTEMS IN ELETRIC GENERATOR OIL SYSTEM An auxiliary oil system pump is used to supply oil at the startup of the steam turbine generator. It supplies the hydraulic oil system required for steam turbines main inlet steam stop valve, the governing control valves, the bearing and seal oil systems, the relevant hydraulic relays and other mechanisms. At a pre-set speed of the turbine during start-ups, a pump

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driven by the turbine main shaft takes over the functions of the auxiliary system. GENERATOR HEAT DISSIPATION The electricity generator requires cooling to dissipate the heat that it generates. While small units may be cooled by air drawn through filters at the inlet, larger units generally require special cooling arrangements. Hydrogen gas cooling, in an oil-sealed casing, is used because it has the highest known heat transfer coefficient of any gas and for its low viscosity which reduces windage losses. This system requires special handling during start-up, with air in the chamber first displaced by carbon dioxide before filling with hydrogen. This ensures that the highly flammable hydrogen does not mix with oxygen in the air. The hydrogen pressure inside the casing is maintained slightly higher than atmospheric pressure to avoid outside air ingress. The hydrogen must be sealed against outward leakage where the shaft emerges from the casing. Mechanical seals around the shaft are installed with a very small annular gap to avoid rubbing between the shaft and the seals. Seal oil is used to prevent the hydrogen gas leakage to atmosphere. The generator also uses water cooling. Since the generator coils are at a potential of about 15.75kV and water is conductive, an insulating barrier such as Teflon is used to interconnect the water line and the generator high voltage windings. Demineralised water of low conductivity is used.

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GENERATOR HIGH VOLTAGE SYSTEM The generator voltage ranges from 10.5 kV in smaller units to 15.75 kV in larger units. The generator high voltage leads are normally large aluminium channels because of their high current as compared to the cables used in smaller machines. They are enclosed in well-grounded aluminium bus ducts and are supported on suitable insulators. The generator high voltage channels are connected to step-up transformers for connecting to a high voltage electrical substation (of the order of 220 kV) for further transmission by the local power grid. The necessary protection and metering devices are included for the high voltage leads. Thus, the steam turbine generator and the transformer form one unit. In smaller units, generating at 10.5kV, a breaker is provided to connect it to a common 10.5 kV bus system.

OTHER SYSTEMS MONITORING AND ALARM SYSTEM Most of the power plants operational controls are automatic. However, at times, manual intervention may be required. Thus, the plant is provided with monitors and alarm systems that alert the plant operators when certain operating parameters are seriously deviating from their normal range.

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BATTERY SUPPLIED EMERGENCY LIGHTING & COMMUNICATION A central battery system consisting of lead acid cell units is provided to supply emergency electric power, when needed, to essential items such as the power plant's control systems, communication systems, turbine lube oil pumps, and emergency lighting. This is essential for safe, damage-free shutdown of the units in an emergency situation.

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BATTERY BANK IN UNIT 4 OF BTPS

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EMD-I (Electrical Maintenance Division I)

It is responsible for the maintenance of: 1. HT/LT MOTORS TURBINE & BOILER SIDE Boiler Side Motors: For Units 1, 2, 3 1. ID Fans 2. FD Fans 3. PA Fans 4. Mill Fans 5. Ball Mill Fans 6. RC Feeders 7. Slag Crushers 8. DM Make Up Pump 9. PC Feeders 10. Worm Conveyor 11. Furnikets

2 in no. 2 in no. 2 in no. 3 in no. 3 in no. 3 in no. 5 in no. 2 in no. 4 in no. 1 in no. 4 in no.

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For Stage Units 1, 2, 3 1. 2. 3. 4. 5. 6. 7. 8. 9. ID Fans FD Fans PA Fans Bowl Mills RC Feeders Clinker Grinder Scrapper Seal Air Fans Hydrazine & Phosphorous Dozing 2 in no. 2 in no. 2 in no. 6 in no. 6 in no. 2 in no. 2 in no. 2 in no. 2 in no.

2. 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 bunkers, from where it is send to furnace.

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

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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.

Wagon Tippler at BTPS

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 move 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 important 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

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conveyor is designed such as never to exceed half of the angle of response and comes out to be around 20 degrees.

Conveyor Belt carrying Coal in BTPS

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 SEPARATOR: 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 transferred.

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5) CRUSHER: 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 crusher. 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. 3. 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.

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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) CYCLONE SEPARATORS: It separates the pulverized coal from carrying medium. The mixture of pulverized coal vapour caters the cyclone separators. 6) THE TURNIKET: 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) MILL FANS: They are of 3 types: Six in all and are in 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

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 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

9) BOWL MILL: One of the most advanced designs of coal pulverisers presently manufactured. Motor Specification Squirrel cage induction motor Rating-340 KW Voltage-6600KV Current-41.7A Speed-980 rpm Frequency-50 Hz No-load current-15-16 A 4. NEW COAL HANDLING PLANT 1) WAGON TIPPLER: Motor Specification

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H.P- 75 HP Voltage- 415, 3 phase Speed -1480 rpm Frequency- 50 Hz Current rating- 102 A

2) COAL FEED TO PLANT: Feeder motor specification Horse power- 15 HP Voltage -415V, 3 phase Speed -1480 rpm Frequency -50 Hz 3) CONVEYORS: 10A, 10B 11A, 11B 12A, 12B 13A, 13B 14A, 14B 15A, 15B 16A, 16B 17A, 17B 18A, 18B 4) TRANSFER POINT 6 5) BREAKER HOUSE 6) REJECTION HOUSE

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7) RECLAIM HOUSE 8) TRANSFER POINT 7 9) CRUSHER HOUSE 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 too 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 labourers 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.

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5. SWITCH GEAR It makes or breaks an electrical circuit. 1) ISOLATOR: 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

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circuits. These equipment do not handle any appreciable current at all. Apart from these equipment there are a number of relays etc. which are used in switchgear.

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 the 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

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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 for high and medium capacity circuit breakers.

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

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 Motor Voltage-220 V/DC

2) AIR CIRCUIT BREAKER: In this the compressed air pressure around 15 kg per cm 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.

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iii. iv.

There is less burning of contacts since the duration is short and consistent. 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. The performance of gas. 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

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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

4) VACUUM CIRCUIT BREAKER: It works on the principle that vacuum is used to save the purpose of insulation and it implies that pressure of gas at which breakdown voltage is 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 Voltage12 KV

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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

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EMD-II (Electrical Maintenance Division II)

This division is divided as follows: GENERATOR AND AUXILIARIES GENERATOR FUNDAMENTALS The transformation of mechanical energy into electrical energy is carried out by the Generator. This section 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 this e.m.f. is given by the following expression. E = 4.44 /O*F*N volts

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O = 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 = P*n/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 were as high speed steam turbine driven generators have generally 2 poles. GENERATOR COMPONENT This deals with the two main components of the Generator viz. Rotor, its winding & balancing and stator, its frame, core & windings. 1. 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 stresses must operate in oil lubricated sleeve bearings supported by a structure mounted on foundations all of which possess complex dynamic behaviour peculiar to them. It is also an electromagnet and to give it the necessary magnetic strength the windings must carry a fairly high current. The passage of the current through the windings generates heat but the temperature must not be

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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 another 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. 2. 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 the 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.

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3. ROTOR BALANCING: 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. 4. 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.

5. STATOR CORE: The stator core is built up from a large number of 'punching or sections of thin steel plates.

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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 cold Rolling 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. 6. 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 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

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which water is circulated for cooling purposes. The water is fed to the windings through plastic tubes. 7. 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 section deals with the rotorhydrogen 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 the 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

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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, a liquid level indicator, hydrogen control panel, gas purity measuring and indicating instruments. The system is capable of performing the following functions: i. Filling in and purging of hydrogen safely without bringing in contact with air. ii. Maintaining the gas pressure inside the machine at the desired value at all the times. iii. Provide indication to the operator about the condition of the gas inside the machine i.e. its pressure, temperature and purity. iv. Continuous circulation of gas inside the machine through a drier in order to remove any water vapour that may be present in it. v. Indication of liquid level in the generator and alarm in case of high level. STATOR COOLING SYSTEM The stator winding is cooled by distillate. 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

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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 degrees Celsius. Rating of 95 MW GeneratorManufacture 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 winding connection - 3 phase Rating of 210 MW GeneratorManufacture by Bharat heavy electrical Limited (BHEL) Capacity - 247000 KVA Voltage (stator) - 15750 V Current (stator) - 9050 A Voltage (rotor) - 310 V Current (rotor) - 2600 V Speed - 3000 rpm Power factor - 0.85 Frequency - 50 Hz Hydrogen - 3.5 Kg/cm2

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 Stator winding connection - 3 phase star connection Insulation class -B TRANSFORMER

A transformer is a device that transfers electrical energy from one circuit to another by magnetic coupling without 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

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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 through a series of transformer by the time it reaches the consumer. BASIC PRINCIPLES

The principles of the transformer are illustrated by consideration of a hypothetical ideal transformer consisting of two windings of zero resistance around a core of negligible reluctance. A voltage applied to the primary winding causes a current, which develops a magneto motive force (MMF) in

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the core. The current required to create the MMF is termed the magnetizing current; in the ideal transformer it is considered to be negligible, although its presence is still required to drive flux around the magnetic circuit of the core. An electromotive force (MMF) is induced across each winding, an effect known as mutual inductance. In accordance with faradays law of induction, the EMFs are proportional to the rate of change of flux. The primary EMF, acting as it does in opposition to the primary voltage, is sometimes termed the back EMF. Energy losses An ideal transformer would have no energy losses and would have no energy losses, and would therefore be 100% efficient. Despite the transformer being amongst the most efficient of electrical machines with ex the most efficient of electrical machines with experimental models using superconducting windings achieving efficiency of 99.85%, energy is dissipated in the windings, core, and surrounding structures. Larger transformers are generally more efficient, and those rated for electricity distribution usually perform better than 95%. A small transformer such as plug-in power brick used for low-power consumer electronics may be less than 85% efficient. Transformer losses are attributable to several causes and may be differentiated between those originated in the windings, sometimes termed copper loss, and those arising from the magnetic circuit, sometimes termed iron loss. The losses vary with load current, and may furthermore be expressed as no load or full load loss, or at an intermediate loading. Winding resistance dominates load losses contribute to over 99% of the no-load loss can be significant, meaning that even an idle

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transformer constitutes a drain on an electrical supply, and lending impetus to development of low-loss transformers. Losses in the transformer arise from: Winding resistance current flowing through the windings causes resistive heating of the conductors. At higher frequencies, skin effect and proximity effect create additional winding resistance and losses. Hysteresis losses each time the magnetic field is reversed, a small amount of energy is lost due to hysteresis within the core. For a given core material, the loss is proportional to the frequency, and is a function of the peak flux density to which it is subjected. Eddy current Ferromagnetic materials are also good conductors, and a solid core made from such a material also constitutes a single short-circuited turn throughout its entire length. Eddy currents therefore circulate with in a core in a plane normal to the flux, and are responsible for resistive heating of the core material. The eddy current loss is a complex function of the square of supply frequency and inverse square of the material thickness. Magnetostriction Magnetic flux in a ferromagnetic material, such as the core, causes it to physically expand and contract slightly with each cycle of the magnetic field, an effect known as magnetostriction. This produces the buzzing sound commonly associated with transformers, and in turn causes losses due to frictional heating in susceptible cores. Mechanical losses In addition to magnetostriction, the alternating magnetic field causes fluctuating electromagnetic field between primary and secondary windings. These incite

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vibration within nearby metal work, adding to the buzzing noise, and consuming a small amount of power. Stray losses Leakage inductance is by itself loss less, since energy supplied to its magnetic fields is returned to the supply with the next half-cycle. However, any leakage flux that intercepts nearby conductive material such as the transformers support structure will give rise to eddy currents and be converted to heat. Cooling System Large power transformers may be equipped with cooling fans, oil pumps or water-cooler heat exchangers design to remove heat. Power used to operate the cooling system is typically considered part of the losses of the transformer.

Large Transformer with Cooling System

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Rating of transformer Manufactured by Bharat Heavy Electrical Limited No load voltage (HV) - 229 KV No load Voltage (LV) -10.5 KV Line current (HV) -315.2 A Line current (LV) - 873.2 A Temp rise - 45 Celsius Oil quantity - 40180 lit Weight of oil - 34985 Kg Total weight - 147725 Kg Core & winding - 84325 Kg Phase -3 Frequency - 50 Hz

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