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NTPC Limited (formerly National Thermal Power Corporation) (BSE: 532555, NSE: NTPC) is the largest Indian state-owned electric utilities company based in New Delhi, India. It is listed in Forbes Global 2000 for 2011 ranked it 348th[3] in the world. It is an Indian public sector company listed on the Bombay Stock Exchange in which at present the Government of India holds 84.5% (after divestment the stake by Indian government on 19th October, 2009) of its equity. With a current generating capacity of 39,174 MW, NTPC has embarked on plans to become a 75,000 MW company by 2017. It was founded on November 7, 1975. NTPC's core business is engineering, construction and operation of power generating plants and providing consultancy to power utilities in India and abroad. The total installed capacity of the company is 36,014 MW (including JVs) with 15 coal based and 7 gas based stations, located across the country. In addition under JVs, 5 stations are coal-based, and another station uses naphtha/LNG as fuel. By 2017, the power generation portfolio is expected to have a diversified fuel mix with coal based capacity of around 27,535 MW, 3,955 MW through gas, 1,328 MW through Hydro generation, about 1400 MW from nuclear sources and around 1000 MW from Renewable Energy Sources (RES). NTPC has adopted a multi-pronged growth strategy which includes capacity addition through green field projects, expansion of existing stations, joint ventures, subsidiaries and takeover of stations. NTPC has been operating its plants at high efficiency levels. Although the company has 19% of the total national capacity it contributes 29% of total power generation due to its focus on high efficiency. NTPCs share at 31 Mar 2 001 of the total installed capacity of the country was 24.51% and it generated 29.68% of the power of the country in 200809. Every fourth home in India is lit by NTPC. As at 31 Mar 2011 NTPC's share of the country's total installed capacity is 17.75% and it generated 27.4% of the power generation of the country in 201011. NTPC is lighting every third bulb in India. 170.88BU of electricity was produced by its stations in the financial year 2005 2006. The Net Profit after Tax on March 31, 2006 was 58.202 billion. Net profit after tax for the quarter ended June 30, 2006 was 15.528 billion, which is 18.65% more than that for the same quarter in the previous financial year. It is listed in Forbes Global 2000 for 2011 ranked it 348th[4] in the world. Pursuant to a special resolution passed by the Shareholders at the Companys Annual General Meeting on September 23, 2005 and the approval of the Central Government under section 21 of the Companies Act, 1956, the name of the Company "National Thermal Power Corporation Limited" has been changed to "NTPC Limited" with effect from October 28, 2005. The primary reason for this is the company's foray into hydro and nuclear based power generation along with backward integration by coal mining.
MAINPLANT GROUP They prepare the plan and develop the main plant which consists of the whole functioning structure that will form the basis of generation of power. This group deals with the approval of specification of Generator, ESP and MDBFP etc. SWITCHYARD GROUP This group consists of mainly electrical engineers who prepare the necessary list of items and equipments required to setup a switchyard. Initial prepare the Single Line Diagram (SLD) based on which the layout is developed the switchyard is actually laid.
SWITCH GEAR GROUP This group takes care of the switch gear and protection. This deals with the supply of power to various equipment and drives of the entire plant three various boards of different ratings. OFFSITE GROUP This group deals with balance of plant facilitates like Ash handling plant (HHP),coal handling Plant(CHP),CW(Cooling Water),DM Plant PT Plant ,cooling tower, Hydrogen plant.
TRANSFORMER GROUP They mainly take care of transformers. Various transformers (step up/step down). PROTECTION GROUP Set up the protective environment for all equipment related with relays which convey the information of fault in equipment. CABLING & LAYOUT They prepare the cabling schedules which are best suited to feed all the drives in plant. Takes care of lighting of whole power station prepare layout of different buildings in AUTOCAD software.
Boiler Systems
The boiler system comprises of: feed water system, steam system and fuel system. The Feed water system provides water to the boiler and regulates it automatically to meet the steam demand. Various valves provide access for maintenance and repair. The Steam system collects and controls the steam produced in the boiler. Steam is directed through a piping system to the point of use. The fuel system includes all equipment used to provide fuel to generate the necessary heat. The equipment required in the fuel system depends on the type of fuel used in the system.
WATER TUBE
Water tube or "water in tube" boilers in which the conditions are reversed with the water passing through the tubes and the hot gasses passing outside the tubes. These boilers can be of single- or multiple-drum type. These boilers can be built to any steam capacities and pressures, and have higher efficiencies than fire tube boilers. Training Report by Sayantan Roy 4
Turbine
Turbine, rotary engine that converts the energy of a moving stream of water, steam, or gas into mechanical energy. The basic element in a turbine is a wheel or rotor with paddles, propellers, blades, or buckets arranged on its circumference in such a fashion that the moving fluid exerts a tangential force that turns the wheel and imparts energy to it. This mechanical energy is then transferred through a drive shaft to operate a machine, compressor, electric generator, or propeller. Turbines are classified as hydraulic, or water, turbines, steam turbines, or gas turbines. Today turbine-powered generators produce most of the world's electrical energy. Windmills that generate electricity are known as wind turbines.
Deaerator
A deaerator is a device that is widely used for the removal of air and other dissolved gases from the feed water to steam generating boilers. In particular, dissolved oxygen in boiler feed waters will cause serious corrosion damage in steam systems by attaching to the walls of metal piping and other metallic equipment and forming oxides(rust). It also combines with any dissolved carbondioxide to form carbonicacid that causes further corrosion. Most deaerators are designed to remove oxygen down to levels of 7 ppb by weight (0.0005 cm/L) or less.
Heat Exchanger
Heat exchangers are equipment that transfers heat from one medium to another. The proper design, operation and maintenance of heat exchangers will make the process energy efficient and minimize energy losses. Heat exchanger performance can deteriorate with time, off design operations and other interferences such as fouling, scaling etc. It is necessary to assess periodically the heat exchanger performance in order to maintain them at a high efficiency level. Heat exchangers may be classified according to their flow arrangement. In parallel-flow heat exchangers, the two fluids enter the exchanger at the same end, and travel in parallel to one another to the other side. In Counter- flow heat exchangers the fluids enter the exchanger from opposite ends. The counter current design is most efficient, in that it can transfer the most heat. See countercurrent exchange. In across-flow heat exchanger, the fluids travel roughly perpendicular to one another through the exchanger.
Super Heater
A super heater is a device in a steam engine that heats the steam generated bytheboileragain, increasing itsthermal energy and decreasing the likelihood that it will condense inside the engine.
Economizer
Economizers, or in British English economisers, are mechanical devices intended to reduce energy consumption, or to perform another useful function like preheating a fluid. The term economizer is used for other purposes as well. In simple terms, an economizer is a heat exchanger.
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.
Electrical Generator
In electricity generation, an electrical generator is a device that converts mechanical energy to electrical energy, generally using electromagnetic induction. The reverse conversion of electrical energy into mechanical energy is done by a motor, and motors and generators have many similarities. A generator forces electric charges to move through an external electrical circuit, but it does not create electricity or charge, which is already present in the wire of its windings. It is somewhat analogous to a water pump, which creates a flow of water but does not create the water inside. The source of mechanical energy may be a reciprocating or turbine steam engine, water falling through a turbine or waterwheel, an internal combustion engine, a wind turbine, a hand crank, the sun or solar energy, compressed air or any other source of mechanical energy.
Electricity is generated in a power plant at 11kV (or 20 kV). 1. Voltage is stepped-up to 132 kV or 400 kV. 2. Electricity travels across long distances on transmission lines. 3. The sub-station decreases(steps-down) the voltage to 33 kV or sometimes 6kV. 4. The distribution transformer on the pole further reduces the voltage to the voltage required for hosehold.
Training Report by Sayantan Roy 7
Switchyard
It is a switching station which has the following credits : (i) Main link between Generating plant and Transmission system, which has a large influence on the security and reliability of the supply. (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. Switch yard and its construction is mainly laid by public private partnership, tenders are floated through news papers to the contractors. Project is build mainly through either Turn key System Item Rate System Some leading contractors includes : a) ABB b) Siemens c) Areva d) Schneider Electric e) BHEL f) Jyoti g) Alstom etc.
Switchyard Equipments
* Circuit breakers : Makes or automatically breaks the electrical circuits when fault occurs 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.
* Bus bar :
Conductors to which a number of circuits are connected.
The objective of this chapter is to describe the various technical alternatives and considerations while designing switchyard layout. Substation layout consists essentially in arranging a number of switchgear components in an orderly pattern governed by their function and rules of spatial separation as described in electrical single line diagram.
Pre requisites
i) Single line diagram must be finalized before designing the layout. ii) General Layout Plan of the Power project iii) Orientation of Line evacuation corridor.
Options / Alternatives
The layout will vary for the following: Switching schemes Type of insulation - Air Insulated/Gas Insulated.
Design Philosophy / Practice
For designing a switchyard layout, various aspects are considered which are described here under 1. Space around the switchyard. Adequate space should be allowed to provide for extension of the switchyard facilities when generating units or transmission lines are added in the future. The immediate surroundings should permit the routing of lines to the switchyard area from at least one direction without the need for heavy dead-end structures in the yard. 2. Switchyard location. The switchyard should be sited as near to the main plant as space permits, in order to minimize the length of control circuits and power feeders and also to enable use of service facilities located in the main plant. 3. Switchyard fencing. A chain link woven wire fence not less than 3.0 m height above toe wall, with lockable gates, should be provided to enclose the entire yard from safety point of view. 4. Clearance. The placement of equipment in EHV switchyard is greatly affected by the air clearances to be adopted. They are as follows: Earth Clearance: this is the clearance between live parts and earthed structures, walls, screens and ground. A minimum height of live conductors above ground must be maintained. Also there should be a certain minimum height of supports of various equipment (depending upon the fact that the bottom of any insulator has to be 2.5 meters above the ground level as statutory clearance). Phase Clearance: this is the clearance between live parts of different phases. Isolating Distance: this is the clearance between the terminals of an isolator and the connections thereto. Section Clearance: this is the clearance between live parts and the terminals of a work section. The limits of this work section, or maintenance zone, may be the
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ground or a platform from which the man works. The clearances to be selected are based on the insulation level. Insulation level is the test voltage value (both power frequency and impulse) which characterizes the insulation of the equipment with regards to its capability of withstanding the dielectric stresses. The insulation level is generally expressed by the value of the power frequency test voltage and the full wave impulse test voltage. The value of the minimum clearance required is a function of power frequency over-voltage and/or transient over voltage caused by switching or lightning. Lightning over voltages are critical for substation upto 220 kV and over voltages due to switching operations are important for 400 kV substations. In line with the recommendation of IE Rules/Indian Standard/ standardization committee recommendations. Considering conductor swing, attraction due to short circuit, maintenance requirement, dimensions of equipment available etc., the phase to phase spacing, sectional clearance and phase to earth clearances has been selected and as such the width of one bay as 54/27.0 m for 765/400kV respectively. Bay width for 132kV system is 12.0 m. Sectional clearance is achieved as phase to earth clearance + clearance to the ground from the lowest part of insulator. Deviation angle for terminal/take off gantry is kept as 30o in horizontal plane and 20o in vertical plane. 5. Equipment spacing. The spacing for the placement of equipment, between them is decided by considering 1) Ease of maintenance/removal of equipment 2) Equipment foundation & their cable trenches. 3) Distance between LA and equipment based on the protection reach of LA. The spacings are generally kept in order to achieve various clearances specified at Table-I. 6. Bus bars The bus bars of 765 kV switchyard can be made up of Quad AAC Bull conductor or equivalent Moose / 6 IPS (EH type). The bus bars of 400 kV switchyard are made up 4 IPS aluminium tube/ Quad Moose rated for 3000 A. The busbars of 220/132kV switchyard are made up of 3 IPS aluminium tube/ twin moose conductor. Busbars are placed at right angles to feeders. 7. Equipment Interconnection Equipment interconnection will be carried out with Quad AAC Bull conductor or 6 IPS (EH type) for 765kV and 4" IPS aluminium tube or twin ACSR Moose for 400kV. For 132kV system equipment interconnection will be carried out with 3 IPS aluminium tube/ Moose conductor. The bus post insulators shall be of solid core type with cantilever strength of 800 kg for 765/400kV system, 600kg for 220kV system and 500kg for 132kV system. 8. Spacer spans and locations The spacers will be located as away from the critical span as possible. The spacer location are based on the calculations of short circuit forces on strung bus and critical span (refer separate guide line). 9. Connection Level Place all equipment at ground level for ease of maintenance. Lower level connections can be of Rigid pipe or flexible conductor but upper level connections can be of strung type only. For aesthetic looks and similarity all same equipments be in one line as far as possible. For 765kV system, I-type design, there would be 3 levels viz first level or equipment. Level - 14m, second level or bus level - 26m and third level or jack bus
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level - 38m. For 400kV,D-type system there would be 2 levels viz first level or equipment level - 8 m, and jack bus level - 15 m. For 220kV system, there would be3 levels viz first level or equipment. Level 5.9m, second level or bus level 11.7 m and third level or jack bus level 16.2m. For 132kV system there would be 3 levels viz first level or equipment. Level 4.6m, second level or bus level 8.5 m and third level or jack bus level 12.2 m. Double insulator strings should be provided for upper level for safety reasons and to avoid busfaults due to conductor snapping. Connection to SwYard to the Generator Transformers & Station Transformers shall be generally through overhead conductors.If the distance between the swyard and the power Plant is more then intermediate Gantries are provided and strung upto Power Plant building to take the dropper to the Generator & Station Transformers.sometimes if stringing is not possible than Station Transformers are connested through EHV Cable. suspended on gantries or any live structure of the switchyard as per IE rules. The lighting along the road shall be achieved by providing suitable fixtures on lighting poles. Different illumination levels and type of lighting fixures and lighting design in Switchyard shall be as specified. Refer guideline on Lighting for more details. 14. Cabling Philosophy While preparing the cable layouts, consideration shall be given to the requirements of segregation, separation, operation, maintenance, safety, reliability, environment, erection, programme, convenience of cable laying and termination. The substation area should be properly graded so that rain water is drained away from the cable trenches. All cables used in switchyard are armoured type due to induced voltages. There are two types of cables used in a Switchyard viz. Power cables and control cables. The sizes for power cables vary from 31/2 X 35mm2 to 2cX 6 mm2 and for control cables it varies from 5c X2.5 mm2 to 27cX2.5 mm2. Refer guideline on cable routing in switchyard for more details. 15. Gravel Filling Gravel or surface material coverings, usually upto 150mm in depth, are useful in retarding the evaporation of moisture and thus in limiting the drying of topsoil layers during prolonged dry weather periods. Also covering the surface with gravel increase the surface resistance and thus reduces shock currents. 16. Earthing System Earthing system for the entire power plant switchyard and other areas shall be provided in accordance with IEEE-80 and IS 3043. The soil quality and other site conditions shall be assessed, and the grounding system will be designed for a life expectancy of at least forty (40) years. The sizing of earthing conductor would be based on the maximum ground fault current that is expected to occur during the design life of the station. Criterion in deciding spacing between buried earthmat conductors is to limit touch voltage and step voltages within permissible values. Refer guideline on earthing for more details. 17. Lightning Protection System Lightning protection system shall be designed in line with Razevig method for DSLP and other IE regulations. The system would comprise air terminations, down conductors, test links and earth connections. Lightning conductor shall be of galvanised steel (75X12 flat) when used above ground level & mild steel (40mm dia.)when used below ground level. Refer guideline on lightning protection for more details. 18. Steps in evolving a substation layout
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Laying out a substation involves a step by step procedure. Most important points to be considered are briefly described below: The important electrical parameters are established by the system design. The main parameters are: Voltage class and basic insulation level or switching surge level, site and climatic conditions, method of circuit connection and switching overvoltage conditions. The bus bar system diagram, the number of circuits and their purpose. i.e control of generators, transformers, feeders etc. the diagram should include details of extensions and future conversion to a different busbar system, if intended. The continuous current rating of the busbars and circuits. The short circuit rating of busbars and equipments. Particulars of reactors, neutral earthing equipment and reacting, interconnecting transformers required. Method of connection of circuits, whether by overhead lines or cables. Details of lightning protection equipment. Details of protective equipment, determining the instrument transformers requirements, carrier current equipment etc. The extent to which circuit and busbar outages for maintenance will be possible. 17. Lightning Protection System Lightning protection system shall be designed in line with Razevig method for DSLP and other IE regulations. The system would comprise air terminations, down conductors, test links and earth connections. Lightning conductor shall be of galvanised steel (75X12 flat) when used above ground level & mild steel (40mm dia.)when used below ground level. Refer guideline on lightning protection for more details. 18. Steps in evolving a substation layout Laying out a substation involves a step by step procedure. Most important points to be considered are briefly described below: The important electrical parameters are established by the system design. The main parameters are: Voltage class and basic insulation level or switching surge level, site and climatic conditions, method of circuit connection and switching overvoltage conditions. The bus bar system diagram, the number of circuits and their purpose. i.e control of generators, transformers, feeders etc. the diagram should include details of extensions and future conversion to a different busbar system, if intended. The continuous current rating of the busbars and circuits. The short circuit rating of busbars and equipments. Particulars of reactors, neutral earthing equipment and reacting, interconnecting transformers required. Method of connection of circuits, whether by overhead lines or cables. Details of lightning protection equipment. Details of protective equipment, determining the instrument transformers requirements, carrier current equipment etc.
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The extent to which circuit and busbar outages for maintenance will be possible. Some parameters which influence the form of the layout are determined by the local conditions. These are: The available land area, site and climate conditions, planning authority requirements and aesthetic considerations determine the type of substation. The direction of overhead line entry position available for terminal towers, location of transformers and reactors, etc. The availability of materials and the transport and access facilities. The capability and skill of the maintenance staff determines the importance of clarity of layout and simplicity of maintenance zoning. The first step in layout preparation is to make a fully detailed single line diagram. this should show the position of instrument transformers, surge diverters etc. and should include all future equipment also. the current rating of busbars and circuits and the short circuit rating of the equipment should be added to the diagram. Selecting components: Various equipment such as circuit breakers, isolators, etc. are selected to suit the ratings required and the preference of type and their overall dimensions are established. if it is intended at a later date to operate the equipment in terms of current or short circuit level, provisions should be made for this in determining the dimensions. While meeting all the needs established the following ideals should be aimed at in making the basic circuit layout. Minimum ground area Minimum quantities of conductor, joints and structure Minimum number of independent insulators, especially in the bus bar zone. After having determined the electrical clearance be used a rough circuit layout is made. Several possible alternatives are prepared from which the most suitable one will be selected. Some variation is needed, to meet the requirements of different types of circuit. It is also necessary to calculate short circuit and atmospheric forces to determine the stresses in conductors, insulators and structures. these held in deciding the most optimum dimensions. 19. Execution sequence for a substation a. Tower foundation b. Equipment foundation c. Laying of Cable trench d. Laying of Earthmat e. Support structure installation f. High level stringing g. Equipment installation h. Equipment interconnection i. Cabling layout j. Commissioning
References
Bus Bars
Bus bars are mainly of two types : Rigid Busbars. Pipes used for connecting various equipments Flexible Busbars. These are flexible wires used for long distance transmission. ACSR Aluminium Conductor Steel Reinforced. AAC All Aluminium Conductor Cable. Bus Bays Generally , D type is used for 400 kV Generally , I type is used for 765 kV However land area, size and dimensions play a role in selecting the bus bay type.
Bus Switching Schemes Bus Bar Schemes * Single Sectionalized bus * Main & Transfer bus * Sectionalized Main bus with Transfer bus * Sectionalized Double Main & Transfer bus Breaker Schemes * Ring bus * One and Half breaker * Double bus Double breaker Factors effecting the selection of Switching Scheme * System Security * Operational Flexibility * Simplicity of Protection arrangements * Ability to limit the Short Circuit levels * Maintenance * Ease of extension * Total land area * Cost
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Appendix-I
Bibliography
The contents are mainly developed from : a) PPF PMI Noida,NTPC Ltd. b) Substation Manual,Central Board of Irrigation and Power. c) Pipe Drafting and Design, Second Edition, by: Roy A. Parisher Robert A. Rhea
Acknowledgements
My training and this report would not have been a success without the cooperation and support of the following people, Mr Hirdesh Gupta, DGM ,PE- Electrical ,NTPC EOC Noida Mr Sanjay Kumar Gupta , PE- Electrical , NTPC EOC Noida Ms Ila Anand ,PE- Electrical ,NTPC EOC Noida Mr Abhishek Kumar , C&I, NTPC Badarpur Mr Sheelbhadra Parmar, C&I,NTPC Badarpur Mr Virendr Adhikari ,PE- Mechanical, NTPC EOC Noida All the staffs who helped in visiting the Substation at Noida. Officers at Human Resources Department. T & P KIIT University to give me the opportunity by issuing the NoObjection Certificate.
I am highly obliged by their kindness and cooperation shown to me during my training period.
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