INDUSTRIAL TRAINING REPORT

(21st May 2012 30th June 2012) On

NTPC BADARPUR

Submitted By: RAHUL ROY Roll No. 0902038 Branch Electrical Engineering

ACKNOWLEDGEMENT

With profound respect and gratitude, I take the opportunity to convey my thanks to Ms. Rachna Singh Bhal, DGM-HR, BTPS for allowing me to pursue my industrial training in BTPS (NTPC Badarpur). I am also extremely grateful to Mr. G. D. Sharma, TRAINING INCHARGE, BTPS for his peerless guidance during the entire training period. I extend my heartfelt thanks to the entire management of BTPS as well for their co-operation and help during my stay in this esteemed organization.

RAHUL ROY

CONTENTS

Introduction to NTPC

Introduction to BTPS

Operation Of a Thermal Power Plant

Electrical Maintenance Division I (EMD I)

Electrical Maintenance Division II (EMD II)

INTRODUCTION TO NTPC

ABOUT NTPC ~
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 ranked 341st in the 2010, Forbes Global 2000 ranking of the Worlds biggest companies. With a current generating capacity of 39,174 MW, 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. 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 ranked 341st in the 2010, Forbes Global 2000 ranking of the only four companies to be awarded this status. The total installed capacity of the company is 39,174 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 naptha/LNG as fuel. The company has set a target to have an Worlds biggest companies. NTPC became a Maharatna company in May, 2010, one of the

installed power generating capacity of 1, 28, 000 MW by the year 2032. The capacity will 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

have a diversified fuel mix comprising 56% coal, 16% Gas, 11% Nuclear and 17% Renewable

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. best PSU for the year 2010, by the Great Places to Work Institute, India Chapter in

NTPC has been awarded No.1, Best Workplace in India among large organisations and the

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. Future Capacity Additions: NTPC has formulated a long term Corporate Plan upto 2032. In line with the Corporate Plan, the capacity addition under implementation stage is presented below: PROJECT Coal 1. Indira Gandhi STPP- JV with IPGCL & HPGCL (500) Haryana 2. Simhadri II Unit - IV( 500) 3. Vallur I -JV with TNEB ( 500) 4. Vallur Stage-I Phase-II -JV with TNEB ( 1 x 500) 5. Bongaigaon(3 x 250) 6. Mauda 7. Rihand Stage-III(500) 8. Vindhyachal-IV (500) 9. Muzaffarpur Expansion (2x195) JV with BSEB 10. Nabinagar TPP-JV with Railways (4 x 250) 11. Barh II (2 X 660) 12. Barh I (3 X 660) Hydro 1. Koldam HEPP ( 4 x 200) 2. Tapovan Vishnugad HEPP (4 x 130) 3. Singrauli CW Discharge(Small Hydre) Total Himachal Pradesh Uttarakhand Uttar Pradesh 800 520 8 9,768 Andhra Pradesh Tamilnadu Tamilnadu Assam Maharashta Uttar Pradesh Madhya Pradesh Bihar Bihar Bihar Bihar 500 500 500 500 750 500 500 500 390 1000 1320 1980 STATE MW

POWER GENERATION ~ Presently, NTPC generates power from Coal and Gas. With an installed capacity of 39,174 MW, NTPC is the largest power generating major in the country. It has also diversified into hydro power, coal mining, power equipment manufacturing, oil & gas exploration, power on its way to becoming an Integrated Power Major. Installed Capacity: Be it the generating capacity or plant performance or operational efficiency, NTPCs Installed Capacity and performance depicts the companys outstanding performance across a number of parameters. trading & distribution. With an increasing presence in the power value chain, NTPC is well

NTPC Owned Coal Gas/Liquid Fuel Total Owned By JVs Coal & Gas Grand Total Coal Based Power Stations: 7 30 16 7 23

No. Of Plants

MW 30,855 3,955 34,810 4,364 39,174

With 16 coal based power stations, NTPC is the largest thermal power generating company in the country. The company has a coal based installed capacity of 30,855 MW. COAL BASED (Owned by NTPC) 1. Singrauli 2. Korba 3. Ramagundam 4. Farakka 5. Vindhyachal 6. Rihand 7. Kahalgaon 8. Dadri 9. Talcher Kaniha STATE Uttar Pradesh Chhattisgarh Andhra Pradesh West Bengal Madhya Pradesh Uttar Pradesh Bihar Uttar Pradesh Orissa COMMISSIONED CAPACITY(MW) 2,000 2,600 2,600 2,100 3,760 2,500 2,340 1,820 3,000

10. Feroze Gandhi, Unchahar Uttar Pradesh 11. Talcher Thermal 12. Simhadri 13. Tanda 14. Badarpur 15. Sipat 16. Mauda Total Orissa Andhra Pradesh Uttar Pradesh Delhi Chhattisgarh Maharashta

1,050 460 2,000 440 705 2,980 500 30,855

COAL BASED (Owned by JVs) 1. Durgapur 2. Rourkela 3. Bhilai 4. Kanti 5. IGSTPP, Jhajjar 6. Vallur Total

STATE West Bengal Orissa Chhattisgarh Bihar Haryana Tamil Nadu

COMMISSIONED CAPACITY 120 120 574 110 1000 500 2,424

Gas/Liquid Fuel Based Power Stations: The details of NTPC gas based power stations is as follows: GAS BASED (Owned by NTPC) 1. Anta 2. Auraiya 3. Kawas 4. Dadri 5. Jhanor-Gandhar 6. Rajiv Gandhi CCPP Kayamkulam 7. Faridabad Total COMMISSIONED CAPACITY(MW) 413 652 645 817 648 350 430 3,955

STATE Rajasthan Uttar Pradesh Gujarat Uttar Pradesh Gujarat Kerala Haryana

GAS BASED (Owned by JVs) 1. RGPPL Total

STATE Maharashtra

COMMISSIONED CAPACITY 1940 1940

Hydro Based Power Projects (Under Implementation): NTPC has increased thrust on hydro development for a balanced portfolio for long term sustainability. The first step in this direction was taken by initiating investment in Koldam Other hydro project under construction is Tapovan Vishnugad. HYDRO BASED 1. Koldam (HEPP) 2. Tapovan Vishnugad (HEPP) 3. Singrauli CW Discharge(Small Hydro) STATE Himachal Pradesh Uttarakhand Uttar Pradesh APPROVED CAPACITY(MW) 800 520 8 1,328 Hydro Electric Power Project located on Satluj river in Bilaspur district of Himachal Pradesh.

Total

INTRODUCTION TO BTPS
ABOUT BTPS ~
Badarpur Thermal Power Station (BTPS) 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, sole beneficiary. It was owned and conceived by Central Electric Authority (CEA). Its Jammu and Kashmir, U.P., Rajasthan, and Delhi. But since year 1987 Delhi has become 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.

Currently it has 5 units with 3 units, each of 95 MW capacity and 2 units, each of 210 MW capacity. The 95 MW units have indirectly fired boilers while 210 MW units have directly fired boilers. All the turbines are of Russian Design. Both turbine and boilers have been supplied by BHEL. The boiler of Stage-I Units (Units 1, 2 and 3) are of Czech design. The of the Stage-I Units and Unit 4 are of Russian design; and the Instrumentation of Unit 5, provided by M/S Instrumentation Ltd. Kota, is of Kent design. In 1978 the management of the plant was transferred to NTPC from CEA. The performance of the plant increased significantly and steadily after the ownership was transferred to NTPC with effect from June 1, 2006. Being an old plant, Badarpur Thermal Power Station (BTPS) has little automation. It receives cooling water from Agra Canal. boilers of Units 4 and 5 are designed by Combustion Engineering (USA). The instrumentation

(BADARPUR THERMAL POWER PLANT)

ORGANIZATION CHART ~
Installed capacity Derated Capacity Annual Load Factor (2011-12) Annual Load Factor (Maximum) Location Coal Source Water Source Beneficiary States Unit Sizes 720 MW 705 MW 78 % 88 % New Delhi Jharia Coal Fields Agra Canal Delhi 3 X 95 MW 2 X 210 MW Units Commissioned Unit I - 95 MW - July 1973

Unit II - 95 MW - August 1974 Unit III - 95 MW - March 1975 Unit IV - 210 MW - December 1978 Unit V - 210 MW - December 1981

OPERATION OF A THERMAL POWER PLANT

In thermal power plants, the heat of combustion of fossil fuels (coal, oil or gas) is utilised by the boilers to raise steam at high pressure and temperature. The steam so produced is used in driving the steam turbines or sometimes steam engines coupled to generators and thus in generating electrical energy. Steam power plant basically operates on the Rankine Cycle. Coal is burnt in a boiler, which converts water into steam. The steam is expanded in a turbine, which produces mechanical power driving the alternator coupled to the turbine. The steam after expansion in prime mover (turbine) is usually condensed in a condenser to be fed into the boiler again. In practice, however, a large number of modifications and improvements have been made so as to affect economy and improve the thermal efficiency of the plant. The entire arrangement of a thermal power plant may be divided into four main circuits namely: 1. fuel and ash circuit 2. air and flue gas circuit 3. feed water and steam circuit 4. cooling water circuit A schematic diagram of a thermal power plant is shown below:

(Schematic Diagram of a Thermal Power Plant)

A general layout of a thermal power plant is shown below:

(General Layout of a Thermal Power Plant)

Detailed description of the operation of a thermal power plant: Coal is conveyed (14) from an external stack and ground to a very fine powder by large metal spheres in the pulverised fuel mill (16). There it is mixed with preheated air (24) driven by the forced draught fan (20). The hot air-fuel mixture is forced at high pressure into the boiler where it rapidly ignites. Water of a high purity flows vertically up the tubelined walls of the boiler, where it turns into steam, and is passed to the boiler drum, where steam is separated from any remaining water. The steam passes through a manifold in the

roof of the drum into the super heater (19) where its temperature and pressure increase rapidly to around 200 bar and 540C, sufficient to make the tube walls glow a dull red. The steam is piped to the high pressure turbine (11), the first of a three-stage turbine process. A steam governor valve (10) allows for manual control of the turbine. The steam is exhausted from the high pressure turbine, and reduced in both pressure and temperature, is returned to the boiler reheater (21). The reheated steam is then passed to the intermediate pressure turbine (9), and from there passed directly to the low pressure turbine set (6). The exiting steam, now a little above its boiling point, is brought into thermal contact with cold water (pumped in from the Cooling tower) in the condenser (8), where it condenses rapidly back into water, creating near vacuum-like conditions inside the condenser chest. The condensed water is then passed by a feed pump (7) through a deaerator (12), and pre-warmed, first in a feed heater (13) powered by steam drawn from the high pressure set, and then in the economiser (23), before being returned to the boiler drum. The cooling water from the condenser is sprayed inside a cooling tower (1), creating a highly visible plume of water vapour, before being pumped back to the condenser (8) in cooling water cycle. The three turbine sets are sometimes coupled on the same shaft as the three-phase electrical generator (5) which generates an intermediate level voltage (typically 20-25 kV). This is stepped up by the unit transformer (4) to a voltage more suitable for transmission (typically 250-500 kV) and is sent out onto the three-phase transmission system (3). Exhaust gas from the boiler is drawn by the induced draft fan (26) through an electrostatic precipitator (25) and is then vented through the chimney stack (27).

ELECTRICAL MAINTENANCE DIVISION I (EMD-I)

In BTPS, I was assigned EMD-I from 21st May 2012 to 9th June 2012. This division includes the following 4 sections: 1. New Coal Handling Plant (NCHP) 2. Electrostatic Precipitator (EP) 3. Motor Workshops 4. Switchgear A detailed description of the above sections is given below: NEW COAL HANDLING PLANT (NCHP) ~ The schematic diagram of NCHP is shown below:

(Schematic diagram of NCHP, BTPS)

BTPS receives coal from the Jharia coal fields. The coal requirement of BTPS is 13-14 metric tonnes per day. The received coal has the following specifications:
Moisture ~ less than 3 % Ash content ~ 25-30 % Volatile material ~ 17-19 % Calorific value ~ 4500-5300 kcal/kg

(Coal Handling Division, BTPS) The major constituents of NCHP are as follows: 1. Wagon Tippler: The coal arrives in wagons via railways and is tippled by the wagon tippler into the coal hoppers. The wagon tippler employs a slip-ring induction motor for providing the necessary torque. Motor specifications: 3-phase, star-connected, 6.6 KV, 200 KW, 1400 rpm. 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 TP-6 via conveyors 11A, 11B.

(Wagon Tippler, BTPS) 2. Breaker House: Coal from TP6 is taken to the breaker house by the conveyors 12A, 12B. The breaker house has rotary breakers which render the size of the coal to 100 mm. Larger pieces of stones or other impurities left are rejected via conveyors 18A, 18B to the reject bin house. Required amount of coal is being taken to transfer point TP-7 via conveyors 13A, 13B and the extra coal is taken to the reclaim hopper via conveyors 16A, 16B. Conveyors 17A, 17B are used to transport the coal from the reclaim hopper to TP-7.

(Coal Storage Area, BTPS) 3. Crusher House: Coal from TP-7 is taken to the crusher house via conveyors 14A, 14B. In the crusher house, the size of coal is reduced to 20 mm. This coal is then taken to transfer point TP-8 via conveyors 15A, 15B and is finally exited from conveyors 10A, 10B. Any metal impurities present are removed using metal separators employed in conveyors 10A, 10B.

4. Pulveriser: BTPS employs bowl mill pulveriser. The arrangement consists of 2 stationary rollers and a power driven bowl in which pulverization takes place as the coal passes through the sides of the rollers and the bowl. A primary air induced draught fan draws a stream of heated air through the mill carrying the pulverized coal into a stationary classifier at the top of the pulveriser. The classifier separates the pulverized coal from the coarse one. Pulverised coal is finally transferred to the pulverised coal bunkers from where they are taken to the coal burners.

(Storage Yard for Crushed Coal, BTPS)

ELECTROSTATIC PRECIPITATOR (EP) ~ An electrostatic precipitator is a large, industrial emission-control unit. It is designed to trap and remove dust particles from the exhaust gas stream of an industrial process. The particle-laden flue gas from the boiler flows through the ESP before it enters the environment. The ESP works as a cleaning device, using electrical forces to separate the dust particles from the flue gas. A typical ESP consists of an inlet diffuser known as an inlet evase, a rectangular collection chamber, and an outlet convergent duct known as an outlet evase. Perforated plates are placed inside the inlet and the outlet evase for the purpose of flow distribution. Inside the collection chamber there are a number of discharge electrodes (DEs) and collection electrodes (CEs). A set of discharge electrodes is suspended vertically between two collection electrodes in a typical wire-plate ESP channel. While the flue gas flows through the collection area, electrostatic precipitators accomplish particle separation through the use of an electric field in the following three steps. The electrical field does the following:

 Imparts a positive or negative charge to the particles by means of discharge electrodes. Attracts the charged particles to oppositely charged collection electrodes. Removes the collected particles by vibrating or rapping the collection electrodes. Description of major equipments in EP:

1) Discharge/Emitting Electrodes - Discharge electrodes emit charging current and provide voltage that generates an electrical field between the discharge electrodes and the collecting plates. The electrical field forces dust particles in the gas stream to migrate toward the collecting plates. The particles then precipitate onto the collecting plates. Common types of discharge electrodes include:

Straight round wires Twisted wire pairs

Barbed discharge wires Rigid masts Rigid frames Rigid spiked pipes Spiral wires Discharge electrodes are typically supported from the upper discharge frame and are frame is in turn supported from the roof of the precipitator casing. High-voltage insulators are incorporated into the support system. In weighted wire systems, the discharge electrodes are held taut by weights at the lower end of the wires.

held in alignment between the upper and lower discharge frames. The upper discharge

2) Collecting Plates - Collecting plates are designed to receive and retain the precipitated particles until they are intentionally removed into the hopper. Collecting plates are also part of the electrical power circuit of the precipitator. These collecting plate functions are incorporated into the precipitator design. Plate baffles shield the precipitated particles from the gas flow while smooth surfaces provide for high operating voltage. within the precipitator. Collecting plates are suspended from the precipitator casing and form the gas passages 3) Rapping System - Rappers are time-controlled systems provided for removing dust from the collecting plates and the discharge electrodes as well as for gas distribution devices (optional) and for hopper walls (optional). Rapping systems may be actuated by electrical or pneumatic power, or by mechanical means. Tumbling hammers may also be used to dislodge ash. Rapping methods include:

Electric vibrators

Electric solenoid piston drop rappers Pneumatic vibrating rappers Tumbling hammers

Sonic horns (do not require transmission assemblies) possible of accumulated particulate. The rapping system for the discharge electrodes should be operated on a continuous schedule with repeat times in the 2 - 4 minute range, depending on the size and inlet particulate loading of the precipitator.

a) Discharge Electrode Rapping: In general, discharge electrodes should be kept as free as

b) Collecting Plate Rapping: Collecting plate rapping must remove the bulk of the precipitated dust. The collecting plates are supported from anvil beams or directly with system is directed into the beams located at the leading and/or trailing edge of the collecting plates. For direct casing support, the impact is directed into the rapper beams located at or near the centre of the top of the collecting plates. The first electrical field generally collects about 60-80% of the inlet dust load. The first field plates should be rapped often enough so that their precipitated layer of particulate is about 3/8-1/2" thick. There is no advantage in rapping more often since the precipitated dust has not yet agglomerated to a sheet which requires a minimum layer thickness. Sheet formation is essential to make the dust drop into the precipitator hopper deterioration of the electrical power input by adding an additional resistance into the power circuit. Once an optimum rapping cycle has been found for the first electrical field (which may vary across the face of a large precipitator), the optimum rapping cycles for the downstream electrical fields can be established. The collecting plate rapping system of the first field has a repeat time T equal to the time it takes to build a 3/8-1/2"layer on the collecting plates. The plates in the second field should have a repeat time of about 5T, and the plates in the third field should have a repeat time of 25T. Ideally, these repeat times yield a deposited layer of 3/8-1/2" for the plates in all three fields. Adjustment may be required for factors such as dust resistivity, dust layer cohesiveness, gas temperature effects, electrical field height and length, and the collecting area served by one rapper. c) Gas Distribution Plate and Hopper Wall Rapping: The gas distribution plates should also be kept free of excessive particulate build-up and may require rapping on a continuous base with a cycle time in the 10-20 minute range, depending on the inlet particulate loading of the precipitator and the nature of the particulate. Gas distribution plates in the outlet of the precipitator may be rapped less often (every 30-60 minutes). d) Improving Rapping System Performance: All precipitator rapping systems allow adjustment of rapping frequency, normally starting with the highest frequency (the least time between raps), progressing to the lowest frequency. The times that are actually available may be limited. Rapping systems with pneumatic or electric actuators allow variations of the rapping intensity. Pneumatic or electric vibrators allow adjustments of without re-entrainment into the gas stream. Rapping less frequently typically results in a hooks from the precipitator casing. With anvil beam support, the impact of the rapping

the rapping time. State-of-the-art rapper controls allow selection of rapping sequences, selection of individual rappers, and provide anti-coincidence schemes which allow only one rapper to operate at a given time. Rapping systems can be optimized for top precipitator performance using precipitator power input and stack opacity as criteria. Optimization of the rapping system starts with the discharge electrode rapping system operating on its own time schedule, for example with repeat times of 2-4 minutes. The rapping system for the gas distribution screens in the inlet and outlet of the precipitator the outlet screens. The only rapping system requiring optimization is the collecting plate rapping system. The optimization should start with the Collecting Plate Rapping Schedule determined until the electrical power input of the inlet field remains constant. Next, the rapping inputs remain constant. If the stack opacity trace shows rapping spikes, the rapping intensity should be reduced while observing the electrical power input of the precipitator. The adjustment of the rapping system for optimum precipitator performance is a slow 4) Hoppers - Precipitator hoppers are designed to completely discharge dust load on demand. Typically, precipitator hoppers are rectangular in cross-section with sides of at least 60-degree slope. These hoppers are insulated from the neck above the discharge of the hopper wall may be heated. Discharge diameters are generally 8"-12". flange with the insulation covering the entire hopper area. In addition, the lower 1/4-1/3 a) Insulation: Insulation provides protection for facility personnel as well as working to retain as much hopper wall temperature as possible. Hopper wall temperature retention discourages condensation on the inside of the hopper. Heaters are added to ensure hot metal surfaces immediately above the fly ash discharge. b) Facilitating hopper discharge: Hopper discharge problems are caused by compaction of the fly ash in the hopper. Compaction characteristics are affected by moisture content, particle size and shape, head of material, and vibration. The flow of fly ash out of the hopper can be facilitated by the use of external vibrators. These can operate on the outside wall of the hopper or on an internal hopper baffle. c) Hopper fluidizers: Hopper fluidizers have a membrane that permits air flow to the fly ash directly above. This air flow fills the voids between the fly ash particles at a slight pressure, changes the repose angle of the particles, and promotes gravity flow. d) Ash handling system: The fly ash handling system evacuates the fly ash from the hoppers, and transports the fly ash to reprocessing or to disposal. The ash handling system should above. Next, the rapping frequency of the inlet field should be increased or decreased frequency of the other fields should be adjusted in sequence until their electrical power should then be operated with repeat times of 2-3 minutes for the inlet and 2-3 hours for

process. It requires a substantial amount of time for stabilization after each adjustment.

be designed and operated to remove the collected fly ash from the hoppers without causing re-entrainment into the gas flow through the precipitator. The design of the ash handling system should allow for flexibility of scheduling the hopper discharges according to the fly ash being collected in these hoppers. Either the precipitator hopper or the feeder hopper is used for temporarily storing material prior to discharge. Three types of handling systems are in use:

Negative pressure or vacuum system: Connects to the hopper by a simple discharge valve Positive pressure dilute phase system: Uses an airlock-type feeder; the feeder is separated from the hopper by an inlet gate and from the conveying line by a discharge gate

Positive pressure dense phase system: Connects to the hopper with an airlock type feeder.

(Ash Handling Plant, BTPS) EPs of Units I, II and III are identical. EP of either Unit has: 2 passes Pass A and Pass B 16 control panels 16 rectifier transformers 26 rapping motors (8 collecting motors, 16 emitting motors and 2 GD motors) 16 hoppers EPs of Units IV and V are identical. EP of either Unit has: 4 passes Pass A, Pass B, Pass C and Pass D 20 control panels 20 rectifier transformers 40 hoppers 40 rapping motors (20 collecting motors and 20 emitting motors)

MOTOR WORKSHOPS ~ An electric motor is an electromechanical energy conversion device which transfers electrical energy from one circuit to another via magnetic medium and delivers the output in the form of mechanical energy. There are primarily two types of motors, namely, ac motors and dc motors. In BTPS, only ac motors are employed. Hence, the discussion will be restricted to ac motors only. Types of ac motors: 1. Synchronous motors - Synchronous motors are mainly classified as 1-phase and 3-phase motors. 1-phase SMs are constant speed machines of small ratings. They are singly excited machines and dont require any dc field excitation. 1-phase SMs include reluctance motors, sub-synchronous motors and hysteresis motors. A 3-phase SM has a 3-phase winding on stator (armature winding) and distributed dc winding on rotor (field winding). Its not a self-starting motor and must be started by some auxiliary means. Most popular methods of starting a 3-phase SM are (i) induction motor starting, and (ii) auxiliary motor starting. A SM always runs at a constant speed, called synchronous speed irrespective of the load. An over-excited SM used to supply lagging kVAr to loads for improving the pf of supply system is called a synchronous condenser.

(3-phase synchronous motor) 2. Induction motor Induction motors are mainly classified as 3-phase and 1-phase motors. A 1-phase IM has two windings on the stator, namely main winding and auxiliary winding. Its not a self-starting motor and must be started by some auxiliary means. Most popular methods include (i) resistance split-phase starting (ii) capacitor-start starting (iii) capacitor-start capacitor-run starting (iv) capacitor-run starting (v) shaded-pole starting (vi) reluctance motor starting (vii) repulsion motor starting.

A 3-phase IM has 3-phase windings on stator (carries armature winding) as well as rotor (carries field winding). When the stator is energised from a balanced 3-phase supply, a rotating magnetic field is produced. This rotating magnetic field interacts with the rotor windings to induce balanced 3-phase emfs in the rotor windings. Since the rotor winding is short-circuited, balanced 3-phase currents circulate in the rotor windings. The rotor currents in turn produce a rotating magnetic field which interacts with the stator magnetic field to produce an electromagnetic torque which sets the rotor in motion. The speed at which the magnetic fields rotate is called synchronous speed and the motor always runs at a speed below the synchronous speed. In this way, we see that a 3-phase IM is a self-starting motor. There are two types of 3-phase IMs, namely (i) squirrel-cage IM, and (ii) slip-ring IM.

(Squirrel-cage Induction Motor)

(Slip-ring Induction Motor)

LT Motor Workshop Motors with voltage rating in the range of 415-440 V are called LT motors. They are used in conveyors, pumps, etc. In BTPS, all the motors in the LT motor workshop are squirrel-cage IMs. Specifications of a LT motor in BTPS: Manufacturer BHEL Frame LE 200 Stator Delta connected Voltage rating 415 V Current rating 21 A Power 18.5 kW Speed 2950 rpm Ambient temperature 50 C

HT Motor Workshop Motors with voltage rating of 6.6 kV and above are classified as HT motors. They are used in the main plant; for instance, ID and FD fan motors, etc. In BTPS, all the motors in the HT motor workshop are squirrel-cage IMs. Specifications of a HT motor of ID fan in BTPS: Manufacturer BHEL Stator Star connected Voltage rating 6.6 kV Power 1300 kW Speed 990 rpm Peak load 240% FLT Temperature rise at rated load 50 C Insulation Class F Current rating 138 A

SWITCHGEAR ~ In power supply system, to ensure maximum continuity of supply and protection of the system during faults means must be provided to switch on or off generators, transmission lines, distributors and other equipments under both normal and abnormal conditions. This is achieved by an apparatus called switchgear. Switchgear essentially consists of switching and protecting devices such as switches, fuses, circuit breakers, relays etc. The apparatus used for switching, controlling and protecting the electrical circuits and equipments is known as SWITCHGEAR. Switchgear Equipments: Switches A switch is used in an electric circuit as a device for making or breaking the electric circuit in a convenient way i.e. by the simple motion of a knob or handle to connect together or disconnect two terminals to which wires or cables are connected. a) Air Switches Contacts are opened in air. These are of two types-: 1) Air break switches Equipped with arcing horns (pieces of metal between which the arc resulting from opening a circuit carrying current is allowed to form) As the switch opens, these horns are spread farther and farther apart and the arc is lengthened until is finally broken.

2) Isolators Isolators (or disconnect switches) arent equipped with arc quenching devices and therefore not used to open circuits carrying current. An isolator isolates one portion of the circuit from another and is not intended to be opened while current is flowing. Isolators must not be opened until the circuit is interrupted by some other means. While closing a circuit the isolator is closed first then the circuit breaker. b) Oil Switches Contacts are opened in oil. The switch is normally operated from a handle on the outside of the case/ tank containing oil. As the switch opens the arc formed between the blade and contact is quenched by the oil. c) Load Interrupter Switches These switches are designed and used to close and open high voltage circuits under normal working conditions (at normal load). The arc extinguishing device of the load interrupter is made in the form of a split, moulded plastic chute fitted with organic glass inserts. This chute surrounds the moving knife of the arc extinguishing system. The stationary acting contact is located in the lower part of the chute. When the switch is opened the working contacts between which the arc is drawn separate. Acted upon the high temperature of the arc, the walls of the organic material inserts generate gases (mainly H2) which create a longitudinal blast serving to extinguish the arc. Lever arm manually operating mechanisms are employed for closing and opening the load interrupter switches. Protective relays It is an electrical device interposed between the main circuit and the Circuit breaker in such a manner that any abnormality in the circuit acts on the relay, which in turn, if the abnormality is of a dangerous character, causes the breaker to open and to isolate the faulty element. Functional elements: 1. Sensing element - Responds to change in actuating quantity, the current in a protected system in case of over-current relay. 2. Comparing element - Serves to compare the action of the actuating quantity on the relay with a pre-selected relay setting. 3. Control element - Accomplishes a sudden change in the control quantity such as closing of the operative current circuit. Three main circuits: 1. Primary winding of CT connected in services with the main circuit to be protected. 2. Secondary winding of CT and the relay operating winding. 3. Tripping circuit.

(Thermal Overload Relay) Circuit Breakers A circuit breaker is a mechanical device designed to close or open contact members, thus closing or opening an electrical circuit under normal or abnormal conditions. It is so designed that it can be operated manually under normal conditions and automatically under fault conditions. An automatic circuit breaker is equipped with a trip coil connected to a relay or other means, designed to open or break automatically under abnormal conditions, such as over-current. Types of circuit breakers: 1) Air-Break Circuit Breakers Air-break circuit breakers are quite suitable for high current interruption at low voltage. In this type of a circuit breaker, air at atmospheric pressure is used as an arc extinguishing medium. In air-break circuit breakers, the principle of high resistance is employed for arc interruption. Air-break circuit breakers are available in the voltage range 400 to 12 kV. 2) Air-Blast Circuit Breakers In air blast circuit breakers, compressed air at a pressure of 20-30 kg/cm2 is employed as an arc quenching medium. Air blast circuit breakers are suitable for operating voltage of 132kV and above. They have also been used in 11 kV 33 kV range for certain applications. At present, SF6 circuit breakers are preferred for 132 kV and above. 3) Bulk Oil and Minimum Oil Circuit Breakers In bulk oil circuit breakers, oil performs two functions. It acts as an arc extinguishing medium and it also serves as insulation between the live terminals and earth. The tank of a bulk oil circuit breaker is earthed. Its main drawback is that it requires a huge amount of oil at higher voltages. Due to this very reason it is not used at higher voltages. A minimum oil circuit breaker does not

employ a steel tank. Its container is made of porcelain or other insulating material. This type of a circuit breaker consists of two sections, namely an upper chamber and a lower chamber. The upper chamber contains an arc control device, fixed and a moving contact. The lower chamber acts as an insulating support and it contains the operating mechanism. These two chambers are filled with oil but they are physically separated from each other. Minimum oil circuit breakers are available in the voltage range 3.3kV to 420kV.

(Oil Circuit Breaker) 4) SF6 Circuit Breakers- In SF6 circuit breakers, SF6 is used as an arc quenching medium. In SF6 circuit breakers, the SF6 gas is blown axially along the arc during the arcing period. The gas removes the heat from the arc by axial convection and radial dissipation. As a result of this, the diameter of the arc is reduced during the decreasing node of the current wave. The arc diameter becomes very small at current zero. In order to extinguish the arc, the turbulent flow of the gas is introduced. SF6 circuit breakers are manufactured in the voltage range of 3.3 kV to 765 kV. However, they are preferred for voltages of 132 kV and above.

(SF6 Circuit Breaker) 5) Vacuum Circuit Breakers- In vacuum, the mean free path of gas molecules increases. So, an electron avalanche due to multiple collisions cant form. In vacuum, arc electrons dont come from the medium in which the arc is drawn but they come they come from the electrodes due to the evaporation of their surface material. In ac, when the current decreases, vapour emission decreases. Near current zero, the rate of vapour emission tends to zero. Immediately after current zero, the remaining vapour condenses and the dielectric strength increases rapidly. Vacuum circuit breakers have now become popular for voltage ratings upto 36 kV. Lightning Arresters It is a surge diverter and is used for the protection of power system against the high voltage surges. It is connected between the line and earth and so diverts the incoming high voltage wave to the earth. Lightning arresters act as safety valves designed to discharge electric surges resulting from lightning strokes, switching or other disturbances which would otherwise flash-over insulators or puncture insulation, resulting in a line outage and possible failure of equipment.

ELECTRICAL MAINTENANCE DIVISION II (EMD-II)

In BTPS, I was assigned EMD-II from 10th June 2012 to 30th June 2012. This division includes the following 3 sections: 1. Generator Overview 2. Generator Excitation and Protection 3. Transformer & Switchyard A detailed description of the above sections is given below: GENERATOR OVERVIEW ~ A generator is an electromechanical device which converts mechanical energy into electrical energy. Depending upon the type of power generated, generators are mainly classified as DC generators and AC generators. Since thermal power stations employ AC generators; therefore, our discussion will be restricted to AC generators only. Synchronous generators (alternators) are commercially employed for the purpose of power generation. Alternators have mainly two major parts, namely stator and rotor. The stationary part of the alternator is called stator whereas the rotating part is called rotor. The stator carries the armature winding whereas the rotor carries the field winding. The field winding is excited from a DC source. When the rotor is driven by a prime-mover, the field poles on the rotor rotate at a speed called synchronous speed. The synchronously rotating magnetic field links with the armature winding and induces emf in it. In this way, ac power is generated. There are two types of alternators, namely, hydro-generators and turbogenerators. Hydro-generators have salient-pole rotor construction whereas turbogenerators have cylindrical-rotor construction. Hydro-generators are used in hydro power plants, while, turbo-generators are used in thermal power plants. Hence, our discussion will be restricted to turbo-generators. Characteristics of a turbo generator are: a) Rotor in the form of smooth cylinder having no physical poles projecting out.

b) Field winding is distributed in rotor slots. c) Uniform air-gap between stator and rotor, neglecting the slot openings. d) Works at relatively higher speeds as compared to hydro generators. In BTPS, there are 5 generating units; 3 of 210 MW each and 2 of 95 MW each. The specifications of the alternators are given below: ALTERNATOR (95 MW) Manufacturer BHEL Phase connection Y-connected Rated stator current 6475 A Rated power factor 0.85 (lagging) Excitation current 1860 A Slip-ring voltage 210 V Rated speed 3000 rpm Rated frequency 50 Hz Coolants Water(stator) and Hydrogen(rotor) Efficiency 98.4 % Direction of rotation viewed Counter-clockwise Rated terminal voltage 10.5 kV

(95 MW Generator, BTPS) ALTERNATOR (210 MW) Manufacturer BHEL

Phase connection Y-connected Rated terminal voltage 15.75 kV Rated stator current 9050 A

 Rated power factor 0.85 (lagging) Excitation current 2600 A Slip-ring voltage 310 V Rated speed 3000 rpm Rated frequency 50 Hz Efficiency 98.4 % Coolant Water(stator) and Hydrogen(rotor) Direction of rotation viewed Counter-clockwise

(210 MW Generator, BTPS)

GENERATOR EXCITATION & PROTECTION ~ Excitation of Alternators: There are various schemes for providing dc excitation to the field windings. Major excitation systems include DC EXCITERS, STATIC EXCITATION and BRUSHLESS EXCITATION. In BTPS, static excitation is used for providing dc excitation to the field windings. Static Excitation: In this method, the excitation power for the main alternator field is drawn from the output terminals of the main 3-phase alternator. For this purpose, a 3-phase transformer steps down the alternator voltage to the desired value. This 3-phase voltage is fed to the 3-phase full-converter bridge using thyristors. The firing angle of these thyristors id controlled by means of a regulator which picks up the signal from alternator terminals through potential transformer and current transformer. The controlled power output from thyristors unit is delivered to the field winding of main alternator through brushes and slip-rings. For

initiating the process of static excitation, first of all, field winding is switched on to the station battery bank to establish the field current in alternator. The alternator speed is adjusted to rated speed. After the output voltage from alternator has build up sufficiently, the alternator field winding is disconnected from battery bank and is switched on to the thyristors bridge output. Protection of Alternators: A generator is the most important and costly equipment in a power system. As it is accompanied by prime-mover, excitation system, voltage regulator, cooling system, etc., its protection becomes very complex and elaborate. It is subjected to more types of troubles than any other equipment. A modern generating set is generally provided with the following protective schemes. Stator Protection: a) Percentage Differential Protection: It is used for the protection of generators above 1 MW. It protects against winding faults, i.e. phase to phase and phase to ground faults. In the operating coil, the current sent by the upper CT is cancelled by the current sent by the lower CT and the relay does not operate. For an internal fault, the polarity of the secondary voltage of the upper CT is reversed. Now the operating coil carries the sum of the currents sent by the upper CT and the lower CT and it operates and trips the circuit breaker. b) Protection against Stator Interturn Faults: Longitudinal percentage differential protection does not detect stator interturn faults. A transverse percentage differential protection is employed for the protection of the generator against stator interturn faults. This type of protection is used for generators having parallel windings separately brought out to the terminals. c) Stator-overheating Protection: Overheating of the stator may be caused by the failure of the cooling system, overloading or core faults like short-circuited laminations and failure of core bolt insulation. Modern generators employ two methods to detect overheating both being used in large generators (above 2 MW). In one method, the inlet and outlet temperatures of the cooling medium which may be hydrogen/water are compared for detecting overheating. In the other method, the temperature sensing elements is embedded in the stator slots to sense the temperature. When the

temperature exceeds a certain preset maximum temperature limit, the relay sounds an alarm. Rotor Protection: a) Field Ground-fault Protection In rotor earth protection, a DC voltage is impressed between the field circuit and earth through a polarised moving iron relay. It is not necessary to trip the machine when a single field earth fault occurs. Usually an alarm is sounded. Then immediate steps are taken to transfer the load from the faulty generator and to shut it down as quickly as possible to avoid further problems. b) Loss of Excitation Field failure may be caused by the failure of excitation or maloperation of a faulty field breaker. A protective scheme employing offset mho or directional impedance relay is recommended for large modern generators. When a generator loses its excitation, the locus of the equivalent generator impedance moves from the first quadrant, irrespective of initial conditions. This type of locus is not traced in any other conditions. The relay trips the field breaker and the generator is disconnected from the system. Miscellaneous: a) Overvoltage Protection Overvoltage may be caused by a defective voltage regulator or it may occur due to sudden loss of electrical load on generators. In thermal power plants, it is possible to bypass the steam before the speed reaches a limit above which a dangerous overvoltage can be produced. Moreover, the use of automatic voltage regulators helps in controlling the overvoltage due to overspeed. b) Overspeed Protection A turbo-generator is provided with a mechanical overspeed device. The speed governor normally controls its speed. It is designed to prevent any speed rise even with a 100 % load rejection. An emergency centrifugal overspeed device is also incorporated to trip emergency steam valves when the speed exceeds 110 %.

TRANSFORMER & SWITCHYARD ~ Transformer: A transformer is an electromagnetic device which transfers electrical energy from one electrical circuit to another electrical circuit via magnetic medium. The electrical circuit which receives energy from the supply mains is called primary winding and the other circuit which delivers electric energy to the load is called the secondary winding.

There are two general types of transformers, the core type and the shell type. In the core type, the windings surround a considerable part of steel core. In the shell type, the steel core surrounds a major part of the windings. For a given output and voltage rating, core-type transformer requires less iron but more conductor material as compared to a shell-type transformer. For transmission and distribution purposes, two major types of transformers are used, namely, power transformers and distribution transformers.

(Core-type and Shell-type Transformers) Power Transformers: Power transformers are used at the sending and receiving ends of a long, high-voltage power transmission line for stepping up or stepping down the voltage. These transformers are manipulated to operate almost always at or near their rated capacity (kVA rating). Therefore, power transformers are disconnected during light load periods. In view of this, a power transformer is designed to have maximum efficiency at or near its full load (rated) kVA. POWER TRANSFORMER (125 MVA) Manufacturer BHEL

Rated voltage (HV) 233 kV Rated voltage (LV) 10.5 kV Rated current (HV) 0.536 kA Rated current (LV) 11.9 kA Oil quantity 40180 litres Weight of oil 34985 kg Weight of core and winding 84325 kg Total weight of transformer 147725 kg

(Power Transformer, BTPS) Distribution Transformers: Distribution transformers are those which change the voltage to a level suitable for utilisation purposes at the consumers premises. The load on a distribution transformer varies over a wide range during a 24 hour day. The primary of distribution transformers is always energised and, therefore, the core loss takes place continuously. In view of this, the distribution transformers are designed to have very low value of core loss.

(Distribution Transformer) Transformer Oil: Transformer oil is usually a highly-refined mineral oil that is stable at high temperatures and has excellent electrical insulating properties. It is used in oil-filled transformers, some types of high voltage capacitors, fluorescent lamp ballasts, and some types of high voltage switches and circuit breakers. Its functions are to insulate, suppress insulation between internal live parts, transformer oil must remain stable at high corona and arcing, and to serve as a coolant. Because it also provides part of the electrical temperatures for an extended period. To improve cooling of large power transformers, the oil-filled tank may have external radiators through which the oil circulates by natural

convection. Very large or high-power transformers may also have cooling fans, oil pumps, and even oil-to-water heat exchangers. Large, high voltage transformers undergo prolonged drying processes, using electrical selfheating, the application of a vacuum, or both to ensure that the transformer is completely free of water vapour before the cooling oil is introduced. This helps prevent corona formation and subsequent electrical breakdown under load. Oil filled transformers with a conservator tend to be equipped with Buchholz relays. These are safety devices that detect the build up of gases (such as acetylene) inside the transformer (a side effect of corona or an electric arc in the windings) and switch off the transformer. Transformers without conservators are usually equipped with sudden pressure relays which perform a similar function as the Buchholz relay. Well into the 1970s, polychlorinated biphenyls (PCBs) were often used as a dielectric fluid since they are not flammable. They are toxic, and under incomplete combustion, can form highly toxic products such as furan.

Today, non-toxic, stable silicon-based or fluorinated hydrocarbons are used, where the vault. Combustion-resistant vegetable oil-based dielectric coolants and synthetic

added expense of a fire-resistant liquid offsets additional building cost for a transformer pentaerythritol tetra fatty acid (C7, C8) esters are also becoming increasingly common as alternatives to naphthenic mineral oil. Esters are non-toxic to aquatic life, readily biodegradable, and have a lower volatility and a higher flash point than mineral oil. Switchyard: A switchyard is a junction which connects a generating station to its nearest grid. BTPS has a 220 kV switchyard. 220 kV Switchyard of BTPS has the following Main bus1 Main bus2 Auxiliary bus 5 power transformers 4 station transformers 1 bus coupler 1 bypass Unit auxiliary transformers

 SF6 circuit breakers Current transformers Isolators Surge arrestors CVTs (capacitance voltage transformers) Wave trap 10 outgoing feeders: 1) Sarita Vihar line 1 2) Sarita Vihar line 2 3) Okhla line 1 4) Okhla line 2 5) Mehrauli line 1 6) Mehrauli line 2 7) Ballabhgarh line 1 8) Ballabhgarh line 2 9) Noida line 10) Alwar line

(Switchyard, BTPS)

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