NTPC Ltd.

KAHALGAON
VOCATIONAL TRAINING AT THERMAL POWER STATION
 NTPC-Kahalgaon At a Glance

 4 x 210 MW USSR make units

 3 x 500 MW BHEL make units.
 ST-II Phase - 1 ---- 2 x 500 MW

 ST-II Phase - 2 ---- 1 x 500 MW

 OVERVIEW
 NTPC KAHALGAON TAKES COAL FROM LALMATIYA COAL MINES.
 AFTER RECEIVING THE COAL ,IT IS PULVERISED IN COAL
HANDLING PLANT
 THROUGH CONVEYOR BELTS , ITS BEING SENT TO MILLING
SYSTEM WHERE IT IS GRINDED.
 THEN IT IS BEING SENT TO BOILER BY PA (PRE-AIR) FAN SYSTEM
 DM WATER IS SENT TO THE BOILER TUBES BY BFP SYSTEM
 OXYGEN IS SENT THROUGH FD FAN AND HERE THE WATER IS
CHANGED TO STEAM FORM WHICH IS USED TO ROTATE THE
TURBINE AT 3000 RPM
 THE GENERATOR ROTOR IS COUPLED WITH THE SAME TURBINE
AND HENCE IT GENERATE ELECTRICAL POWER.
 AND THE POWER IS SENT TO THE GRID
 System covered
1) Boiler
2) Turbine
3) Generator
4) HT/LT aux. power distribution
system
5) DC system and battery
6) Switch yard
7) Electrical Lab
 BOILER
 SUPPLIED BY: 200 MW Unit USSR/
500MW Units BHEL
 Type- Natural circulation, Dry bottom,
Balanced draft, Convective Reheat, Solid
fuel with direct, Tangential fired,
Pulverized fuel system.
 BOILER MAIN AUXILLIARIES: MILL, PA FAN , ID FAN,
FD FAN, ASH WATER PUMP, SEAL AIR FAN, SCANNER
AIR FAN, SCREW CONVEYOR, CLINKER GRINDER.
 TURBINE

200MW LMZ USSR MAKE

AND 500MW BHEL MAKE
 Type- K 210-130-8, Impulse reaction, Tandem
compound, Reheat type, Closed cycle with
regenerative bleeding.
 Turbine used are-
1. high pressure turbine (HPT)
2. Intermediate pressure turbine (IPT)
3. Low pressure turbine (LPT)

Turbine auxiliaries: BFP, CEP, GAS COOLER, STATOR

WATER PUMP, SEAL OIL, LUBE OIL PUMP.
 Details Of Generator
4 x 210 MW USSR make units
Power ---247.059MVA, 210MW
Rated voltage ---15.75KV
Rated current---9056A,
Power factor--0.85pf (lag)
Efficiency--98.55%
Speed and frequency---3000rpm, 50Hz
3 x 500 MW BHEL make units.
Rated Output – 500MW, 588MVA
Rated Terminal voltage – 21kV
Rated Stator current – 16166 A
speed and frequency – 3000 rpm and 50Hz
Rated power factor – 0.85 (Lag)
 GENERATOR
Turbo Generators used in NTPC, Kahalgaon are 210 MW AND
500 MW .
Main Parts:
Rotor: cylindrical type, shaft and body forged in one piece
from Nickel-chromium- Vanadium-molybdenum steel.
Slots are milled out axially. Dynamically balanced with
high degree of accuracy up to 20% over speed for 2
minutes. Critical speed is at 1200rpm (1370rpm) and 2.7
and 3.0 times this speed.

Stator: cold rolled grain oriented silicon steel,

mechanically strong to withstand internal pressure of
explosion of hydrogen and air mixture
Winding: 3 phase, double layer, short chorded, single
turn, two parallel winding (double star).
 Excitation system

 Function of Excitation system?

 Creating and strengthening the magnetic
field of the generator by passing DC
through the filed winding.
 Importance of Excitation system?
 With large alternators in the power
system, excitation plays a vital role in the
management of voltage profile and
reactive power in the grid thus ensuring
‘Stability’
EXCITATION PRINCIPLE

ROTOR

STATOR
 SCHEMATIC OF EXCITATION SYSTEM

PT
AUN2, AVN2
AVR

220V DC SUPLLY
AU AU
CT M1 M2 AUN1, AVN1

RS11 Q21

R10

M
R11 UM1 UM2 U U
G G E
N1 N2
R F
Q1 V
1
QE1

QE11 KM1 FROMDCDB

Q22
FROMSTANDBY EXCITOR

QE12
 Brushless excitation

FIELD BREAKER R
Y
ARMATURE
ROTATING B
DIODES

FIELD
(PM)

MAIN GENERATOR
PILOT
EXCITER EXCITER
Components of Brush less Excitation
System
•Three Phase Main Exciter.
•Three Phase Pilot Exciter.
•Regulation cubicle
•Rectifier Wheels
•Exciter Coolers
•Metering and supervisory equipment.
PMG
MAIN EXCITER
EXCITER ROTOR
 AVR / DVR
 TYPES OF AVR/DVR

 Single channel AVR system

 Dual channel AVR system

 Twin channel AVR system

TYPES OF AVR SYSTEM-

 Single channel AVR : It consists of two controllers one is

automatic and the other is manual and both the controllers
are fed from the same supply

 Dual channel AVR : It consists of two controllers in the same

manner as the previous case i.e. one automatic voltage
controller and one manual controller. we have different
power supply, gate control and pulse amplifier units for
each of the controllers. Reliability is more in this case than
previous one since a fault in either gate control unit or
pulse amplifier or power supply in single channel AVR will
cause failure of whole unit, but in dual channel AVR this
can be avoided by switching to another channel.

 Twin channel AVR system: This system almost resembles

the dual channel AVR but the only difference is that
here we have two automatic voltage regulators
instead of one automatic voltage regulator and one
manual Voltage regulator
 GENERATOR PROTECTION SYSTEM

GENERATOR PROTECTION COMPRISES

1. GENERATOR & ITS EXCITATION SYSTEM
2. GENERATOR TRANSFORMER
3. UNIT TRANSFORMER
4. AUXILLARIES AND THEIR CHANGEOVER TO
SERVICE TRANSFORMER SUPPLY.
5. Generator Protection divided in Three Groups
based on their function CLASS-A / CLASS-B/
CLASS-C
Class A: The Class A will cause
the following actions
 Trip the steam turbine
 Trip both the 400kv breakers
connected with the unit.
 Trip the Field breaker
 Trip both the UT LV Breakers and will
initiate Fast change over
Class B: The Class B will cause
the following actions

 Trip both the 400kv breakers

connected with the unit.
 Trip the Field breaker
 Trip both the UT LV Breakers and will
initiate Fast change over
Class C: The Class C will cause
the following action

 Trip both the 400kv breakers

connected with the unit.
PROTECTIVE RELAYS
HT/LT SWITCHGEAR FOR
AUXILARY SUPPLY
SINGLE LINE DIAGRAM OF HT SWITCHGEAR
132KV
SWYD
STN#1

STN#2
132KV/6.6KV Generator G.T,
63MVA 250MVA

15.75/400KV
BVO1 BWO1
UAT, 40MVA
15.75KV/6.6K
.V
BCO
UAT UAT
BV02

BL02 BL01
STN
B/C, BL -12
I/C I/C SWGR

BM02 BM01

B/C, BM -12
(B) (A)

4BB 4BA 3BB 3BA 2BA 2BB 1BA 1BB

 BRIEF DESCRIPTION OF 6.6KV HT.SW.GR OF MAINPLANT
SCHEME

 6.6KV switcher of Kahalgaon is designed and supplied by Russia. Each Unit

consists of Two 6.6KV bushes, Named as BA & BB. Every bus is charged by
two sources, namely station or Reserve Incomer and UAT or working
Incomer. These Incomer are charged by two transformers, i.e. 63 MVA
Station Transformer (ST) & 40 MVA Unit Auxiliary Transformer (UAT). The
ST is charged from Switch Yard 132 KV bus and UAT is charged from its
Unit Generator at 15.75KV. These transformers are having double
secondary windings of 6.6KV.
 Generally, the buses are loaded on UAT, when the units are in running
condition. When unit trips, Station comes into service by AUTO-CHANGE
OVER SCHEME (ACO). The ACO scheme operates following condition:
 When Group - I protection of Unit operates,
 When Group - II protection of Unit operates,
 Under voltage in the bus, &
 Mechanical Problem in UAT breaker.
 The Control Circuit takes care of Closing & Tripping of the breaker. It also
checks per missives of C&I and Electrical before closing the breaker. Apart
from above, control circuit gives close or trip command to other equipment,
e.g. LT incomers, in case of Transformer feeders.

 The Protection circuit is the heart of any electrical system. For all
protection circuit, current is drawn from CT of the Breaker Cabinet and it is
fed to all protective relays. Following are the major protections used in our
6.6KV Switch Gear:

 Earth fault protection.

 Short circuit protection (Current Cut - Off),
 Overload Protection,
 Arcing Protection,
 Differential Current Protection (Only in BFP feeders),
 Under Voltage Protection (Only in Selected feeders),
 Bucholtz Protection ( Only in Transformer feeders),
 Temperature (WTI / OTI) Protection (Only in Transformer feeders),
 Oil Level (MOG) Protection (Only in Transformer feeders),
 Maximum Protection (Only in Transformer feeders).
 All the above protection circuit is having a flag relay in series, so that it may
be defected easily which protection has been operated.
  FUNCTION OF RELAYS

 Over current relay: - When a fault occurs, the current

flowing in the system increases, in most cases the fault
current will be many times the normal local current. By
using a relay responding to the amount of current in the
circuit it is possible to detect the fault and locate and
isolate the faulty section.
 Differential Relays: - This principle is widely used to
protect generators, transformers, transmission lines and
station buses. The method compares the current
entering and leaving the equipment being protected.
Under normal conditions when there is no fault in the
protected section, these two currents are identical.
When the fault occurs the currents being compared will
no longer be equal. By measuring its in difference
between the currents entering and leaving it is possible
to determine the fault.
 Directional Relay: - When a fault occurs it affects the direction of
current flow in the system. In some of the protective schemes the
direction of current flow is used to obtain selective action of the
relays.
 Under Voltage Relay: - One effect of a short circuit is reduction
of system voltage. A relay that measures voltage can be used to
detect the fault.
 Distance Relay: - In this type of protective relay, the ratio of
voltage to current is measured, By this means the relay can detect a
fault and determine the distance between relay and fault.
 Balanced current Relay:- When two identical transmission lines
operate in parallel, the currents in the two lines are equal. If a fault
occurs on one line the currents become unbalanced. This condition
can be used to detect the fault.
 Timer Relay: - The factor of time aids in determining what part of
system is to be disconnected after occurrence of a fault. For
example, transmission line protection utilizes this principle of zones
in distance relays by providing timers.
 DC IS THE NERVOUS SYSTEM OF
ELECTRICAL
EQUIPMENTS CONTROL AND PROTECTION

 DC SYSTEM COMPRISES OF :
 1. DCDB

 2. CHARGER.

 3. BACKUP BATTERY BANK.

 LEAD ACID BATTERY
 NI-CD BATTERY BANK
BATTERY VOLTAGES & SP GRAVITY MONITORING
SWITCHYARD AND DIFFERENT
SWITCHING EQUIPMENTS
 SINGLE LINE DIAGRAM OF 400 KV SWYD
KAHALGAON
ICT 2 BSF 1
BSF 3
BSF 4 MTN 2 FKK
BSF 2 MTN 1 FKK 1 PAT 2 U#6
2

552 852 1752 3252

2052 2952

9 2 3 3
2 3
4 7 5 8 1 3 6
652 1 1 3
5 5 5 3
2 6 5 5 5 4 5
2 2 2 0
5 2 2 2 5 2
5
2 2
2

400 KV BUS 1

400 KV BUS 2
1 1 2
2 3 2 2
3 5 2
1 5 2 4 3
5 5 5 7 4
5 2 5 5 7
2 2 2 5 0
2 1452 2 2 5 3
2 5
2 9
2
5
2
1152 1
252 1 5
0 5
5 2
2 4152

ICT 1 U# 1 BR# 1 U#2 U#3 BR#2 U#4 U#5 U#7

PAT 1
 What is a Switchyard ?
It is a switching station which has the following credits :

(i) Main link between Generating plant and

Transmission / Distribution system.

(ii) Step-up and/or Step-down the voltage levels

depending upon the Network Node.

(iii) Switching ON/OFF Reactive Power Control

devices, which has effect on Quality of power.

(iv) Switching ON/OFF different lines with safety

and security.
 SWITCHYARD EQUIPMENTS
Equipments commonly found in switchyard :
1. Lightening arrestor
2. Current transformer
3. Voltage transformer
4. Power transformers / I.C.T.
5. Bus bar and clamp fittings
6. Support structure
7. Isolators
8. Circuit Breaker
9. Wave traps
10. Earthing switch
 Functions of various equipment :

* Transformers :
- Transforms the voltage levels from higher to lower level
or vice versa, keeping the power constant.
* Circuit breakers :
- Makes or automatically breaks the electrical circuits under
Loaded condition.
* Isolators :
- Opens or closes the electrical circuits under No-load
conditions.
* Instrument transformers :
- For stepping-down the electrical parameter (Voltage or
Current) to a lower and safe value for Metering and Protection
logics.
* Earth switch :
- Used to connect the charged body to ground to discharge the trapped
charge to have a safe maintenance zone.
 * Lightning arrestors :
- Safe guards the equipment by discharging the high
currents due to Lightning.
* Overhead earth wire :
- Protects the O/H transmission line from Lightning
strokes.
* Bus bar :
- Conductors to which a number of circuits are connected.
* Wave Traps/Line traps :
- Used in PLCC circuits for Communication and
telemetering.
* Reactive Power control devices :
- Controls the reactive power imbalance in the grid by
switching ON/OFF the Shunt Reactors, Shunt Capacitors etc.,
* Current Limiting Reactors :
- Limits the Short circuit currents in case of faulty conditions.
VIEW OF 400 KV
SWYD
 SWYD
EQUIPMENTS
 Current transformers

 FUNCTION :

- To step-down the high magnitude of

current to a safe value to incorporate
Measuring and Protection logics
- Current transformers are used for the
instrumentation, protection or metering of
power systems.
 VT / CVT
 FUNCTION :
- To step-down the high magnitude of
voltage to a safe value to incorporate
Measuring and Protection logics.
 Voltage transformers serve a number of
functions in a power system. VT‘s are used
for the operation of many types of
instrumentation and relay protective
systems. They measure voltage and in
conjunction with CT , they measure power.
They feed synchronizing equipment. They
can be used as coupling capacitors in
power line carrier network.
 LIGHTNING ARRESTORS
 FUNCTION :
- To discharge the high voltage surges in the
power system due to lightning to the ground.
 Apparatus to be protected :
* Overhead lines………Earth/Ground wires
* HV equipment………LAs
* Substation…………...Lightning Masts, Earth
wires
 FEATURES OF EARTH SWITCHES

 SAFETY DEVICE.
 USED TO GROUND THE PARTICULAR SECTIONS
REQUIRED FOR MAINTENANCE.
 GROUND INDUCTION VOLTAGES.
 INTERLOCKED WITH BREAKERS AND
ISOLATORS
 CAN OPERATE FROM LOCAL ONLY
 MOTOR DRIVEN AS WELL AS HAND DRIVEN
 FEATURES OF ISOLATORS
 OPERATES UNDER NO LOAD CONDITION
 INTERLOCKED WITH BREAKERS AND
EARTHSWITCHES
 SHOULD WITHSTAND EXTREME WIND
PRESSURES
 MOTOR DRIVEN AND HAND DRIVEN
 LOCAL AS WELL AS REMOTE OPERATION
POSSIBLE
 ISOLATES SECTIONS FOR MAINTENANCE
 USED TO SELECT BUS BARS
 CT SWITCHING FOR BUS BAR PROTECTION
 ELECT LABORATORY
 Function: To carry out the testing and
calibration of different Elect. equipments.
 Instrument : Multimeter, Megger, Tong
tester, Ductor meter, LCR meter, DSO,
DLRO, Tan-Delta Test Kit, OIL BDV Test
Kit, Automatic Battery discharge Kit,
Automatic Relay test kit, Primary Current
Inj Kit, HV Test Kit, Cable Fault Locator,
IC Tester, Motor checker, Leakage
Current tester, Power analyzer.
Thank you