ABOUT NTPC

I ndia s lar gest power company, NTPC was set up in 1975 to accelerate power

development in India. NTPC is emerging as a diversified po wer major with pr esence

in
the entir e value chain of the po wer generation business. Apart from power generatio
n,
which is th e mainstay of th e company, NTPC has already ventured into con sultancy,

power trading, ash utilization and coal mining. NTPC rank edin341
the 2010st , Forbes

Glo bal 2000 ranking of the World s biggest co mpanies. NTPC became a
Maharatna
company in May, 2010 , one o f the only four co mpanies to be awarded this status.

Th e total installed capacity of the company is 39,174 MW (in cluding JVs) with 16
coal
based and 7 gas based stations, located acr oss the country. In addition under JVs, 7

stations are coal based & another station u ses naptha/LNG as fuel. The company has
set
a target to have an installed power generating capacity of 1,28,000 MW by the year
2032.
The capacity will have a diversified fuel mix comprising 5 6% coal, 16% Gas, 11%

Nuclear and 17% Renewable Energy Sou rces(RES) including hydro. By 2032, nonfossil
fuel based g eneration capacity shall make u p nearly 28 % o f NTPC s por tfolio.

NTPC has been operating its plants at high efficiency levels. Althou gh the company
has
17.75% of the total national capacity, it contr ibutes 27.40% of total p ower generation
due to its focus on high efficiency.
1

In October 20 04, NTPC launched its I nitial Public Offering (IPO)

consisting of 5.25% as
fresh issu e and 5.25% as offer for sale by Gov ernment of India. NTPC
thus became a
listed company in Novemb er 2 004 with the Gover nment holding 89 .5
% of the equity
share capital. In Februar y 201 0, the Sharehold ing of Go vernment of
India was reduced
from 89.5% to 84 .5 % thr ough Further Pu blic Offer . The rest is held by
Institutional
Investors and the Public.

Strategies of NTPC

Technological Initiativ es

Introduction of steam generator s (boilers) of the size of 800 MW.

Integ rated Gasification Combined Cycle (IGC C) Techn ology.

Launch of Ener gy Techn ology Centre -A new initiative for dev elopment
of technologies with focu s on fundamental R&D.
The company sets aside up to 0.5% of the profits for R&D.
Roadmap developed for ad opting Clean Development.
Mechanism to help get / ear n Cer
3 tified Emission R eduction.

Corporate Socia l Responsibilit y

As a respon sib le cor porate citizen NTPC has taken up nu mber of CSR
initiatives.
NTPC Foundation formed to address Social issues at national level
NTPC has framed C or porate So cial R esponsibility Guidelines
committing up
to0.5% of net profit annually for Commu nity Welfare.
The welfare of pr oject affected persons and the local p opu lation
around
NTPC pr ojects are taken care of throu gh well drawn Rehabilitation and
Resettlement policies.
The company has also taken up distributed generation for remote rural
areas
Partnering government in various initiatives
Consultant role to modernize and improvise several plants across the
country.
Disseminate technologies to other players in the sector.

Consultant role Partn ership in Ex cellence Programme for impr ovemen

t of
PLF of 15 Po wer Stations of SEBs.
Rural Electrification work under Rajiv Gandhi Gar min Vidyutikaran .

Env ironment management

All stations of NTPC are ISO 14001 certified.
Various groups to care of environmental issues.
The Environment Management Group.
Ash tilization Division.
Afforestation Group.
Centr e for Power Efficiency & Envir onment Protection.
Group on Clean Development Mechanism.
NTPC is the seco nd largest owner of trees in the cou ntry after the
For est departmen t
4

Vision

To be th e world s largest and b est power producer, powering India s

growth.

Mission
Develop and pr ovide reliable power, related p ro ducts and services at
competitive
prices, integratin g multiple energy sour ces with in novative and ecofriendly
technolog ies and con tribute to society.

Core Values BE COMMITTED

Business Ethics

Environmentally & Economically Sustainable

Customer Focu s

Organizational & Professional Prid e

Mutual R espect & Trust

Motivating Self & others

Innovation & Speed

Total Quality for Excellence

T
E
D

Transparent & Respected Organization

Enter prising
Devoted

JOURNEY OF NTPC

NTPC Environment Policy

NTPC is committed to the enviro nment, generating po wer at minimal

envir onmental cost
and preser ving the ecolog y in the vicinity of the plants. NTPC has under
taken massive a
forestation in the vicinity of its plants. Plantations have incr eased forest
area and reduced
barren land. The massive a forestation by NTPC in and around its
Ramagun dam Power
station (2600 MW) have contributed redu cing the temperature in the ar
eas by about 3 c.
NTPC has also taken proactive steps for ash utilization. In 1991, it set up
Ash Utilization
Division A

"Centre for Po wer Efficiency and Environment Protection- CENPEhas been

E"
estab lished in NTPC with the assistance of United States Agency for
International
Develo pment- USAID. CENPEEP is efficiency oriented, eco-friendly
and eco-nurtu ring
initiative - a symbol of NTPC's concern towards enviro nmental protection
and co ntinued
commitment to su stainable power d evelop ment in India. As a
responsible corporate
citizen, NTPC is making constant efforts to improve the socio -economic
status of
the people affected by its pr ojects. Through its Rehabilitation and R
esettlement
programmes, the company endeavor s to improve the overall socio econ
omic status
Project Affected Person s. NTPC was among the first Public Sector Enter
prises to enter
into a Memorandu m of Understanding-MOU with the Gover nment in
1987-88. NTPC
has been placed under th e 'Excellent category' (the best category) every
year since the
MOU system became operative. Harmony between man and envir on
ment is the essence
of healthy life and gr owth. Therefor e, maintenance of ecolog ical
balance and a pristine
envir onment has been of utmost impo rtance to NTPC. It has been tak ing
variou s measures discussed below for mitigation of environment
pollution due to power
generation.
NTPC is the second largest owner of trees in the country after the
Forest department.
7

As early as in November 1995, NTPC br ou ght out a compreh ensive

document entitled
"NTPC Environment Policy and E nvironment Management System
". Amongst the
guiding prin ciples adopted in the docu ment is compan y s proactive
approach to
envir onment, optimum utilization of equipment, ad option of latest
technologies and
continual environment improvement. The policy also envisag es efficient
utilization of
resources, thereby minimizing waste, maximizing ash utilizatio n and pr
oviding green belt
all around the plant for maintaining ecological balance.

Env ironment Management, Occupatio nal Health and Safety

Systems:
NTPC has actively gon e for adoption of best international practices on
en vironment,
occu pational health and safety areas. The organization has pur sued the
Envir onmental
Management System (EMS) ISO 14001 and the Occupational Health and
Safety
Assessment System OHSAS 18001 at its different establishments. As a
result of pursu ing
these p ractices, all NTPC power stations have been certified for I SO 1
4001 & OHSAS
18001 by reputed national and internatio nal C ertifying Agencies.

Pollution Control systems:

While deciding the appropriate tech nology for its projects, NTPC
integrates many
envir onmental provisio ns into the plant design. I n ord er to ensure that
NTPC complies
with all the stipulated environment norms, variou s state-of-the-art
pollution contr ol
systems / devices as discussed below have been installed to control air and
water
pollu tion.

Electrostatic Precipitators:
The ash left behind after combu stion of coal is arr ested in high efficien
cy Electrostatic
Precipitators (ESPs) and particulate emission is controlled well within th
e stipulated
norms. The ash collected in the ESPs is disposed to Ash Ponds in slurry
form.
8

Flue Gas Stacks:

Tall Flue Gas Stacks have been provided for wide dispersion of the
gaseous emissions
(SOX, NOX etc.) into the atmosphere.

Low-NOX Burners:
In gas based NTPC power stations, NOX emissions are controlled by
provision of Lo wNOX Burners ( Dry or wet type) an d in coal fired stations, by adopting
best combu stion
practices.

Neutralization Pits:
Neutralization pits have been provided in the Water Treatment Plant
(WTP) for pH
correction o f the Efflu ents before discharge into Effluent Treatment Plant
(ETP) for
further treatment and use.

Coal Settling Pits / Oil Sett ling Pits:

In these Pits, coal du st and oil ar e removed from the efflu ents
emanating from the Coal
Handlin g Plant (CHP) , coal yar d and Fu el Oil Hand ling areas before
discharge into ETP.
DE & DS Systems:
Dust Extraction (DE) and Du st Suppression (DS) systems have been
installed in all coal
fired power statio ns in NTPC to contain and extract the fugitive dust r
eleased in the Coal
Handlin g Plant (CHP) .

Cooling Towers:
Cooling Towers have been pr ovided for cooling the hot Cond enser
cooling water in
closed cycle, Condenser Cooling Water (CCW) Systems. This h elps in
redu ctio n in
ther mal po llution and conservatio n of fresh water.
9

Ash Dykes & Ash Disposal systems:

Ash ponds have been provided at all coal based station s except Dadri
where Dry Ash
Disposal Sy stem has been pr ovided. Ash Ponds have b een divided into
lag oon s an d
provided with garlanding arrangement for changeover of th e ash slu rr y
feed points for
even filling of the pond and for effective settlemen t of the ash particles.
Ash in slu rry for m is discharg ed into the lagoons where ash particles
get settled from the
slurry and clear effluent water is discharged from the ash pond. The
dischar ged effluents
conform to standards specified by CPCB and the same is regularly mon
itored.
At its Dadri Power Station, NTPC has set up a unique sy stem for dry ash
collection an d
disposal facility with Ash Mou nd formation. This has been envisaged
for the fir st time in
Asia which has resulted in progressiv e development of gr een belt
besides far less
requirement of lan d and less water requ irement as co mpared to the wet
ash disposal
system.

Ash Water Recycling System:

Further, in a number o f NTPC stations, as a proactive measure, Ash
Water Recycling
System ( AWRS) has been pr ovided. In the AWRS, the effluent from ash
pond is
cir culated back to the station for further ash sluicing to the ash pond.
This h elps in
savings of fresh water r equ irements for transportation o f ash from the
plant.
The ash water recycling system has alr eady been installed and is in
operation at
Ramagundam, Simhadri, Rihand, Talcher Kaniha, Talch er Thermal,
Kahalgaon, Korba
and Vindhyachal. The scheme has helped stations to save huge qu antity
of fresh water
required as mak e-up water for dispo sal of ash.

Dry Ash Extractio n System (DAES):

Dry ash has much higher utilization potential in ash-based products ( such
as bricks,
aerated
block
s,Vindhyachal,
concrete,
Portland
has
Farakk
beena,autoclaved
installed
Talcher Thermal,
atconcrete
Unchahar,
Korba,
Dadri,
Simhadri,
Ramagu
Talcherpozzolana
ndam,
Kaniha an d
cement, etc.)
. DAES,
Singrauli,
BTPS.
Kahalgaon
10

Liquid Waste Treatment Plants & Management System:

The ob jective of indu str ial liquid effluent treatment plant (ETP) is to
dischar ge lesser and
cleaner effluent from the power plants to meet en vironmental regu
lations. After pr imary
treatment at the source of their generation, the effluents are sent to th e
ETP for further
treatment. The composite liqu id efflu ent tr eatment plant has been
designed to treat all
liquid efflu ents which originate within the power station e.g. Water
Treatment Plant
(WTP), Condensate Polishing Unit (C PU) effluent, Coal Handlin g Plant
(CHP) effluent,
floor washings, service water drains etc. The scheme inv olves collection
of variou s
efflu ents and th eir appr opr iate treatment centrally and re-circulation of
th e treated
efflu ent for various plant uses.
NTPC has implemented such systems in a nu mber of its power statio
ns such as
Ramagundam, Simhadri, Kayamkulam, Singrauli, Rihand, Vindhyachal,
Ko rba, Jhanor
Gandhar, Faridabad, Farakk a, Kahalgaon and Talcher Kaniha. These
plants have helped
to con trol quality and quantity of th e effluen ts discharged fr om the
station s.
Sewage Treatment Plants & Facilities:
Sewage Treatment Plants (STPs) sewage treatment facilities have been pr
ov ided at all
NTPC station s to take care of Sewage Effluent from Plant and township
ar eas. In a
number of NTPC projects mod ern type STPs with Clarifloculator s,
Mechanical Agitators,
sludge drying b eds, Gas Collection Chambers etc. have been provided
to improve the
efflu ent quality. The effluent quality is monitor ed regularly an d treated
efflu ent
conforming to th e prescribed limit is discharged from the station. At
several stations
treated effluents of STPs are being used for horticu lture purpose.

11

ABOUT BTPS

BADARPUR THERMAL POWER STATION was established on 1973

and it was the
part of C entral Go vernment. On 0 1/04/19 78 is was given as No Loss
No Profit Plant of
NTPC. Since then operating perfo rmance of NTPC has been consid
erably above the
national average. The availability factor for coal station s has increased
fro m 85.03 % in
1997-98 to 90.09 % in 2006-07, which compares favorably with
international standards.
The PLF has increased fr om 75.2% in1997-98 to 8 9.4% du ring the
year 2006-07 which is
the highest since the inception of NTPC.
Badarpur thermal power station started with a single 95 mw u nit. There
were 2 more units
(95 MW each) installed in next 2 consecutive years. Now it has total five
units with total capacity of
720 MW. Ownership of BTPS was transferred to NTPC with effect from
01.06.2006 through
GOIs Gazette Notification .
The power is supplied to a 220 KV n etwork that is a part of the northern
grid. Th e ten
cir cuits thr oug h which the power is evacuated fr om the plant are:
1. Mehrauli
2. Okhla
3. Ballabgar h
4. Indraprastha
5. UP (Noida)
6. Jaipur

12

Given below are the details of unit with the year theyre installed.

13

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

14

OPERATION OF A POWER PLANT

Basic Principle

As per FAR ADAY s Law-Whenev er the amount of magnetic flux linked

with a circuit
changes, an EMF is pr odu ced in the circuit. Generator work s on the
principle of
producin g electricity. To chang e the flux in the generator tur bine is
mov ed in a great
speed with steam. To produce steam, water is heated in the boilers by
bur ning the coal.
In a Badarpu r Ther mal PowerStation, steam is produced and used to spin
a turbine that
operates a generator . Water is heated, tur ns into steam and spins a steam
tu rbine which
drives an electrical generator. After it passes through the turbine, the
steam is con densed
in a condenser; this is known as a Rankine cycle.
The electricity g enerated at the plant is sent to consumers through highvoltage power
lines The Badarpur Ther mal Power Plant has Steam Tu rbin e-Dr iven
Gen erator s which
has a co llective capacity of 705MW. The fu el being used is Coal which
is su pplied from
the Jharia Coal Field in Jharkhand. Water supply is given fro m the Agra
Canal.

15

Basic Steps of Electricity Generation

The basic steps in the generation of electricity from coal involves
following steps:
Coal to steam
Steam to mechanical power
Mechan ical power to electrical power

16

Coal to Electricity : Basics

17

18

19

PARTS OF A POWER PLANT

The va rio us parts are listed below:1. Cooling tower

2. Cooling water pump
3. Transmissio n line (3 -phase)
4. Unit transformer (3 -phase)
5. Electric generator (3 -phase)
6. Low pressur e turbine
7. Condensate extraction pu mp
8. Condenser
9. Inter
10.
11.
High
Steam
mediate
pressur
governor
pr
e turbin
essure
valveeturbine

20

12. Deaerator
13. Feed heater
14. Coal conveyor
15. Coal hop per
16. Pulverised fu el mill
17. Boiler dru m
18. Ash hopper
19. Super heater
20. For ced drau ght fan
21. Reheater
22. Air intake
23. Econo miser
24. Air preheater
25. Precipitator
26. Induced drau ght fan
27. Flue Gas

1. Cooling Tower
Cooling towers are heat removal devices used to transfer process waste
heat to the
atmosp here. Cooling towers may either u se the evaporation of water to r
emove process
heat and cool the workin g fluid to near the wet-bulb air temperature or
in the case of
closed circuit dry co oling to wer s rely solely on air to cool th e
working fluid to near the
dry-bulb air temperature. Common applications include cooling the cir
culating water
used in oil refineries, ch emical plants, power stations and build ing
cooling.
The towers vary in size fr om small roof-to p u nits to ver y large h yper
boloid structur es that
can b e up to 200 meters tall and 10 0 meters in diameter , or r ectangular
structures that can
be over 40 meters tall and 80 meters long. Smaller towers are normally
while
by
thery-built,
larger
evaporation
ones are
of some
con stru
o f the
ctedcooling
on site.water
Th e absorbed
in mechanical
heat is
forced
rejected
facto
to the or
-draft
atmosphere
induced
21

Draft tower s or in natural draft h yper bolic shaped cooling towers as

seen at most nuclear
power plants.

2. Cooling Water Pump

it pumps the water from the cooling tower which goes to the co ndenser.

3. Three phase transmission line

Three phase electric p ower is a common method of electric power tran
smissio n. It is a
type o f p olyphase system mainly used to power motors and many other
devices. A three
phase system u ses less con ductive material to transmit electric power
than equivalent
single phase, two phase, or dir ect current system at the same voltage. In
a three phase
system, thr ee circuits r each their instantaneous peak values at different
times.
Taking current in one conductor as the refer ence, the curr ents in the
other two are delayed
in time b y one-thir d and two-third of one cycle .This delay between
phases has the
effect of giving constant power transfer ov er each cycle of the current
and also makes it
possible to pro duce a rotating magnetic field in an electric motor. At the
power station, an
electric generator converts mechanical power into a set of electric curr
ents, one from each
electr omagnetic coil or winding of the gen erator.
The current are sinusoidal fu nctions of time, all at the same fr equ ency
but offset in time
to give differ ent phases. In a three phase system th e phases are spaced
equally, giving a
phase separation o f one-thir d of one cycle. Generators output at a
voltage that ranges
from hundred s of volts to 3 0,000 volts.

4. Unit transformer (3-phase)

At the power station , transformer s step-u p this voltage to one more
suitable for
transmission. After numer ou s furth er conversion s in the transmission
and distribution
network the power is finally transfor med to the standard mains voltage
hou
point
transformer
sehold
or it may
isvoltage).
ustill
sually
be three
star
The connected
power
phase. may
Where
with
already
thethe
step
have
standard
-down
beenmains
issplit
3 phase,
into
voltag
single
the
e
( i.e. the
phase at
output
being
the
ofthis
this
phase22

neutral voltage. Anoth er sy stem commonly seen in North America is to

have a delta
connected secondary with a center tap on on e of the wind ings supplying
the ground and
neutral.
This allows for 240 V thr ee phase as well as three differ ent single phase
voltages( 120 V
between two of the p hases and neutral , 208 V between the third phase
( or wild leg) and
neutral an d 240 V between any two phase) to be available fr om the
same supply.
5. Electrical generator
An Electrical generator is a device that conv erts kinetic energy to
electrical energ y,
generally u sing electromagnetic induction. The task of converting the
electrical energy
into mechanical energy is accomplished by using a motor . The source of
mechanical
ener gy maybe water fallin g through the turbine or steam turning a
turbine (as is the case
with thermal power plants). There are several classifications for moder n
steam turbines.
Steam turbin es are used in our entire major coal fired po wer stations to
drive th e
generators or alternators, which pr odu ce electricity. The turbines
themselves are driven
by steam generated in "boilers or "steam generators" as they are so
metimes called.
Electrical power stations use large steam tu rb ines driving electric
generators to produce
mo st (about 86 %) o f the world s electricity. These centralized stati ons
ar e of two types:
fossil fuel p ower plants and nuclear po wer p lants. Th e turbines used
for electric p ower
generation are most often dir ectly coupled to their-gen erator s .As the
generators mu st
rotate at constant synchronous speeds according to the frequency of the
electric power
system, the most common speeds are 3000 r/min for 50 Hz systems, an
d 3600 r/min for
60 Hz systems. Most large nuclear sets ro tate at half th ose speeds, and
have a 4-pole
generator rather than the more common 2-pole one.

6. Low Pressure Turbine

Ener gy in the steam after it leaves the b oiler is converted into rotational
passes
stages
convert
through
the
nsisting
theofturbine.
aenergy
stationary
The
of the
turbine
blade
steam
( normally
orinto
no zzle)
kinetic
consists
anden
a rergy
ootating
f several
andblad
dir ect
e.
energyco
as
it potential
stages
Stationary
the
flow
with
onto
blades
each
the
23

rotating blades. The r otating blades convert the kinetic ener gy into
impulse and reaction
forces, caused by pressur e drop, which results in the r otation of the
turbine shaft. The
turbine shaft is conn ected to a g enerator, which produces th e electrical
energ y.
Low Pr essure Turbine (LPT) consists of 4 x2 stages. After passing throu
gh I ntermediate
Pressure Turbine steam is passed through LPT which is made u p of two
parts- LPC
REAR & LPC FRONT. As water gets cooler here it gathers into a
HOTWELL placed in
lower parts of turbine.

7. Condensatio n E xtraction Pump

A Boiler feed water pump is a specific type of pump u sed to pu mp
water into a steam
boiler. The water may be freshly supplied or returning conden sation of th
e steam
produced by the boiler. These pu mps are nor mally high pressu re units
that use suction
from a condensate return system and can be of th e centrifugal pump typ
e or positive
displacement type.

Construction and operation:

Feed water pumps range in size up to many horsepower an d the electric
motor is usually
separated from the pump b ody by some form of mechanical couplin g.
Large indu strial
conden sate pumps may also serve as the feed water pu mp. In either case,
to force the
water into the boiler , the pump must generate sufficient pressure to o
vercome the steam
pressur e developed by the boiler. This is usually accomplish ed through
th e use of a
centrifugal pu mp. Feed water pump s usually run intermittently and are
controlled by a
float switch or other similar level-sensing d evice energizin g the pump
when it detects a
lowered liquid level in the boiler. So me pumps contain a two-stage
switch. As liquid
lowers to the trigg er point o f the fir st stage, the pump is activated. I f the
liqu id continues
to drop, (perhaps becau se the pump has failed, its su pply has been cut
off or exhausted, or
its discharge is blo cked) the second stage will be trigg ered. This stage
boiler
equip ment
may switch
off the( pr eventing the bo iler fr om running dry and o
verheating),
alarm,
or both.
trigger an
24

8. Condenser
The steam coming out from the Low Pressure Tu rbine (a little above its
boiling pump) is
brought into ther mal contact with cold water (pu mped in fro m the
cooling tower) in the
conden ser, where it condenses rapidly back into water, creating near
Vacuum-like
conditions inside the cond enser chest.

9. Intermediate Pressure Turbine

Inter mediate Pressure Tu rbine (IPT) consists of 11 stages. Wh en the
steam h as b een
passed through HPT it enter s into IPT. IPT has two ends named as
FRONT & REAR.
Steam enters throu gh front end and leaves from Rear end.

10. Steam Governor Valv e

Steam locomotives and the steam engines used on sh ips and stationary
applications such
as power plants also requir ed feed water pumps. In this situ atio n,
though, the pump was
often po wer ed using a small steam eng ine that ran using the steam
produced b y the boiler
a means had to b e provided, of course, to put the initial charge of water
into the boiler
(before steam po wer was available to operate the steam-powered feed
water pu mp).The
pump was often a positiv e displacement pump that had steam valves and
cylinders at one
end and feed water cylinders at the other end; no crank shaft was requ
ired. In thermal
plan ts, the primary purpose of su rface condenser is to condense the
exhaust steam from a
steam turbine to obtain maximu m efficiency and also to convert the
turbine exhaust
steam into pu re water so that it may be reused in the steam generator or
boiler as boiler
feed water. By co ndensing the exhaust steam of a tur bine at a pressure
below atmo spheric
pressur e, the steam pressure dr op between the inlet and exhau st o f the
turbine is
incr eased, which increases the amoun t heat available for conversion to
mechanical
power. Mo st of the heat liberated due to condensation of the exhaust
steam is carried
away by th e cooling mediu m (water or air) used by th e sur face
are
su
closing
chvalves
as in
temperature,
response
used within
topressure,
signals
industrial
received
floplants
w andfrom
and
liquid
elsewher
controllers
level by
e tothat
fuco
llycompares
ntrol
or partially
op a
condenser.
Control
valves
erating
opening
set
point
conditions
or to a
25

process variable whose value is provid ed by sensor s that monitor

changes in su ch
conditions. The op ening or closing of control valves is done by mean s
of electrical,
hydraulic or pneu matic systems.

11.High Pressure Turbine

Steam coming from Boiler dir ectly feeds into HPT at a temperature of
540C and at a
pressur e of 136 kg/cm2. Here it passes through 12 different stages due to
which its
temperature goes down to 329C and pressure as 27 kg/cm2. This line is
also called as
CRH COLD REHEAT LINE. I t is now passed to a REHEATER where
its temperatu re
rises to 540C an d called as HRH-HOT REHEATED LINE.

12. Deaerator
A Deaerator is a device for air removal and u sed to remove dissolved
gases (an alter nate
wou ld be th e use of water treatment chemicals) fro m boiler feed water
to make it non corrosive. A dearator typically inclu des a vertical domed d eaeration
section as th e
deaeration boiler feed water tank . A Steam generating boiler requires
that the circulatin g
steam, condensate, and feed water should b e devo id of disso lved
gases, particularly
corrosive ones and dissolved or suspended solids. The gases will give
rise to corrosion of
the metal. The solids will d eposit on the heating sur faces giving rise to
localized heating
and tu be ruptures due to overheating. Under some conditions it may give
rise to str ess
corrosion crackin g. Deaerator lev el an d pressure mu st be contro lled
b y adjusting control
valv es the level b y r egulating con densate flow and the pressure by
regulating steam flow.
If operated properly, most deaerator vendors will guarantee that oxygen
in the deaerated
wa ter will not exceed 7 ppb by weight (0.005 cm3/L)

13. Feed water heater

A Feed water heater is a power plant component used to pr e-heat water
steam
This
redu
generatin
generation
ces
gand
boiler.
operating
therPreheating
efore
costs
improves
andthe
also
feed
thehelps
thermo
water
to ravoid
dynamic
educes
ther
the
efficiency
mal
irrever
shock
delivered
to aplant
osibility
to
fthe
theboiler
system.
inv olved in
26

metal when the feed water is introduced back into the steam cycle. In a
steam p ower
(usu ally modelled as a modified Rankine cycle), feed water heater s
allow th e feed water
to be brou ght up to the saturation temperature very gradually. This
minimizes the
inev itab le irr eversibility associated with heat transfer to the workin g
fluid ( water).
14. Coal conveyor
Coal conveyors are belts which are used to transfer coal fr om its storage
place to Coal
Hop per. A belt conveyor co nsists of two pulleys, with a continuous loop
of material- the
convey or Belt that rotates about them. The pu lleys ar e powered,
moving the belt and
the material on the b elt forward.
Conveyor belts are extensively used to transp ort industrial and
agricultural material, such
as grain, coal, or es etc.

15. Coal Hopper

Coal Hopper s are the places which are u sed to feed coal to Fuel Mill. It
also has the
arrangemen t of entering Hot Air at 200C inside it which solves our two
purposes:1. If our Coal has moisture content then it dries it so that a proper combu
stion tak es p lace.
2. It raises the temperature of coal so that its temperature is more n ear to
its Ignite
Temperature so that combu stion is easy.

16. Pulverized Fuel Mill

A pulveriser is a device for grin ding coal for combustio n in a furnace
in a fossil fu el
power plant.

17. Boiler drum

Steam Drums are a r egular feature of water tube boilers. It is reser voir
of water/steam at
the top end of th e water tubes in the water -tube boiler. Th ey store th e
the
in
water/and
den
water
sities
tu
saturated
between
bes in
andact
hot
steam
as
and
ainto
phase
coldsteam
water
separator
drum.
helpsMade
for
in the
thefrom
accumulation
steam/water
hig h-gradeofsteel
the
steam
generated
mixture.
ho
(probably
tter The
- differ ence
27

stainless) and its work ing in volve temperature of 390C and pressure
well above 350psi
(2.4MPa). The separated steam is drawn ou t from the top section of th e
drum.
Saturated steam is drawn off the top of the d rum. The steam will re-enter
the fur nace in
through a super heater, while the saturated water at the bottom of steam
drum flows down
to the mud -drum /feed water drum by down comer tu bes accessories
include a safety
valv e, water level indicator and fuse plug.

18. Ash Hopper

A steam dru m is used in the company of a mud -dru m/feed water drum
which is located at
a lower level.
So that it acts as a sump for the slu dge or sediments which have a tenden
cy to accumulate
at the bottom.

19. Super Heater

A Super h eater is a device in a steam engine that heats the steam
generated by the boiler
again incr easing its thermal ener gy. Super heaters increase the efficiency
o f the steam
engine, and were wid ely adopted. Steam which has b een superheated is
log ically known
as sup erheated steam; non - superheated steam is called satu rated steam
or wet steam.
Super heaters were applied to steam locomotives in quantity from the
early 20 th centur y,
to most steam v ehicles, and also stationary steam engines includin g
power stations.
20. Force Draught Fan
External fans are provid ed to giv e su fficien t air for combustion. The
forced draught fan
takes air from the atmosphere and, war ms it in the air preheater for
better co mbustion,
injects it via the air nozzles on the furnace wall.

21. Reheater
Reheater is a heater which is used to raise th e temperature of steam
which
the
inter
h as
mediate
fallen fr
pressure
om turbine.
28

22. Air Int ake

Air is taken from the envir onment by an air intake tower which is fed to
the fu el.
23. Economizers
Econ omizer, or in th e UK economizer, are mechanical devices intended
to r edu ce energy
consumption, or to per for m anoth er u seful function like preheating a
fluid. The term
economizer is used for other pur poses as well-Boiler, power plant,
heating, ventilatin g
and air-conditioning . I n bo iler s, economizer ar e heat exchange devices
that heat fluids ,
usually water, up to but not normally beyond the boiling point of the
fluid. Economizers
are so named because th ey can make use of the enthalpy and improving
the boiler s
efficiency. They are devices fitted to a boiler which save energy by using
th e exhaust
gases from the boiler to preheat the cold water used to fill it (the feed
water). Modern day
boilers, such as those in cold fired power stations, are still fitted with
economizer which
is decedents of Green s original design. In this context there are tur bines
before it is
pumped to the boiler s. A common application of econ omizer in steam
power plants is to
capture th e waste heat from b oiler stack gases (flue gas) and tran sfer
thus it to the boiler
feed water thu s lowering the n eeded energy input , in turn reducing the
firing rates to
accomplish the rated boiler output . Economizer lo wer stack
temperatures which may
cause condensation of acidic combustion gases an d serious equipment
corrosion damage
if care is not taken in their design and material selection.

24. Air Preheater

Air preheater is a general ter m to describe any d evice design ed to heat
air before another
process (for example, combustio n in a boiler). The purpose of the air pr
eheater is to
reco ver the heat fro m the boiler flue gas which increases th e ther mal
efficiency of the
boiler by reducing the useful heat lost in the flu e gas. As a consequ ence,
the flu e gases
are also sent to the flue gas stack (or chimney) at a lower temperature
design
of th
e ducting and the flue gas stack. It also allows contr ol over
allowing
simplified
the temperature
gases
leaving theofstack.
29

25. Precipit ato r

An Electrostatic pr ecipitator (ESP) or electrostatic air cleaner is a
particulate d evice that
remo ves particles from a flowing gas (such as air) using the force of an
induced
electr ostatic charge. Electrostatic precipitators are highly efficient
filtration devices, and
can easily r emove fine particulate matter such as dust and smoke from
the air steam.
ESPs continue to be excellent devices for co ntrol of many industrial
particulate
emissions, including smoke from electricity-generating utilities (coal and
oil fired) , salt
cake collection from black liquor boilers in pump mills, and catalyst
collection from
fluidized bed catalytic cracker s fr om several hu ndr ed thousand ACFM
in the largest coalfired boiler applications. The original parallel plate-Weighted wire
design (described
above) has evolved as mor e efficient (an d ro bust) discharge
electrode designs, today
focus is on rigid discharge electrodes to which many sharpened spikes ar
e attached ,
max imizing cor ona production. Transformer rectifier systems apply
voltages of
50-100 Kilovolts at relatively high current densities. Moder n controls
minimize sparking
and prevent arcing, av oiding damage to the components. Automatic
rapping systems and
hopper evacuation systems remove the collected particulate matter while
on line allowing
ESPs to stay in operation for years at a time.

26. Induced Draught Fan

The induced draft fan assists the FD fan by drawing out combustible
gases from the
furnace, maintaining a slightly n egative pressur e in the furnace to avoid
backfiring
through any o pening. At th e furnace outlet and before the furnace gases
are han dled by
the ID fan, fine dust carried by the outlet gases is r emoved to avoid
atmo spheric
pollu tion. This is an enviro nmental limitation pr escribed by law, which
additionally
minimizes erosion of the ID fan.

27. Flue g as stack

A Fluare
which
gases
ecombustion
gas
pr odu
stackced
isproduct
when
a typecoal,
gases
of chimney,
oil,
called
natural
flue
a vertical
gas,
gases
wood
pipe,
are or
exhausted
channel
any other
or
tolarge
the
similar structure
outside
combustion
air. Flu e thr ough
30

device. Flue gas is u sually composed of car bon d ioxide (CO2) an d

water vapour as well
as nitr ogen and excess o xyg en remaining from the intake combu stion
air. It also contains
a small per centage of pollu tants such as par ticulates matter, carbon
mono o xide, nitrogen
oxides and sulp hur oxides. The flu e gas stacks are often quite tall, up to
4 00 meters (1300
feet) or more, so as to disper se the exhaust pollutants over a greater area
and ther eby
reduce the concentration of the pollutants to the levels required by
government's
envir onmental policies and r egulations. The flue gases ar e exhausted
from stoves, ovens,
fireplaces or other small sources within r esidential abodes, restaurants,
hotels through
other stacks which ar e r eferred to as chimneys.

31

VARIOUS CYCLES AT POWER STATION

PRIMARY AIR CYCLE

SECONDARY AIR CYC LE
COAL CYLCE
ELECTRICITY CYCLE
FLUE GAS CYC LE
CONDENSATE CYCLE
FEED WATER CYCLE
STEAM CYCLE

32

PRIMARY AIR CYCLE

P A FAN

APH

COLD AIR DUCT

SEAL AIR FAN

HOT AIR DUCT

PULVERISER

33

SECONDARY AIR CYCLE

W
I
IGNITER FANN
D

FD FAN

B
SCANNER AIR FAN
O
X

SC APH

SCANNER COOLING
APH

WIND BOX

BOILER

34

ELECTRICITY CYCLE

GENERATOR

UAT

UAT

To Auxiliaries

To Auxiliaries

MAIN TRANSFOR MER

SWITCH YAR D

OUTGOING FEEDER

35

CONDENSATE CYCLE
HOT WELL

CONDENSATE PUMPS

MAIN EJECTOR

GLAND STEAM COOLER WITH EJECTOR

LP HEATER 2

LP HEATER 3

LP HEATER 4

BOILER
DEAERATOR
36 FEED PUMP

FEED WATER CYCLE

BOILER FEED PUMP

HP HEATOR 5

HP HEATOR 6

HP HEATOR 7

FEED REGULATING STN

ECONOMISER

BOILER DR UM

DOWN COMERS

BOILER
UPRISERS
37 DR UM

STEAM CYCLE

BOILER DRUM

L.T.S.H.

FLATEN S.H.

FINAL S.H.

H P TURBINE

C.R.H.

H.R.H

I P TURBINE

L P TURBINE

CONDENSER
38

Coal Cycle

39

Flue Gas Cycle

40

ELECTRICAL MAINTENANCE DEPARTMENT

I (EMD-I)

Electrical maintenance d ivision 1

It include s:
Motors
High Tension/Low Tension Switchgear
Coal handling plant

I was assigned to do training in this division from 11

41

th

June to
June.
29th

MOTORS

Motors can be classified as AC and DC

.

AC MOTORS

1. Squirrel cage motor

2. Wound motor
3. Slip ring induction motor

In moder n thermal power plant thr ee phase squirr el cage indu ction
motors ar e u sed bu t
sometime double wound motor is used when we need high starting torque
e.g. in ball mill.
THREE PHASE INDUCTION MOTOR
Ns (speed) =120f/p
Stator can handle concentrated single layer winding, with each coil
occupying one stator slot
The most common type of winding are:

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

2. DOUBLE LAYER WINDING :

Each stator slot contains sides of two different coils.

SQUIRREL CAGE INDUCTION MOTOR

a rotor magnetic
Squirrel
rotating
stator
cage and
magn
field
wou
etic
is
ndfield.
prcage
oduan
have
ced
emf
which
same
is induced
mode
interacts
across
of operation.
withthetherotor
stator
Rotor
winding,
field
con
du rrent
cu
cau
ctor
singsflows,
acut
turning
the
42

motion. The r otor does not rotate at synchronous speed, its speed varies
with applied
load . The slip speed being just enough to enable sufficient induced rotor
current to produce the power
dissipated by the motor load and motor losses.

BEARINGS AND LUBRICATIONS

A good bearing is needed for trouble free operation of motor. Since it is
very costly part of the motor,
due care has to be tak en by checking it at r egular inter vals. So
lubricatin g plays an
important r ole. Two typ es of lubricatin g are widely used

1. Oil lubrication
2. Grease lubrication
3. Insulation

INSULATION
Winding is an essential part so it should be insulated. Following types of
insulation are widely u sed
TYPES OF INSULATION

CLASS TEMP UPTO W HICH THEY ARE EFFECTIVE

(DEGREE CENTIGRADE)

90

105

120

130

155

H
180
F class insulation
C
more
is generally
than 180 preferred. 43

MAIN MOTOR USED IN BOILER AND OFF SIDE

AREA
1. ID FAN( 2 PER UNIT)
It is located between EP and chimney used for creating induced draft in
the furnace.
2. PA FAN(2 PER UNIT)
It is used for handling atmospheric air up to temperature 50 degree
centigrade
3. FD FAN(2 PER UNIT)
It is used for handling secondary air for the boiler.

4. SCANNER FAN( 2 PER UNIT )

It is required for requisite air for scanner cooling.

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

INSTRUMENTS SEEN

1. MICROMETER
This instrument is used for measuring inside as well as outside diameter of
bearing.
2. MEGGAR
This instrument is used for measuring insulation resistance.
3. VIBRATION TESTER
It measures the vibration of the motor. It is measured in three dimensionsaxial, vertical and
horizontal.
44

SWITCH GEAR

INTRODUCTION
Switchgear is one that makes or breaks the electrical circuit. It is a
switching device that opens& closes a
cir cuit that d efined as apparatus u sed for switching, Lon r olling &
protecting the electrical
circuit & equipments. The switchgear equipment is essentially concerned
with switching & interrupting
currents either under normal or abnormal operating conditions. The tubu
lar switch with ordinar y
fuse is simplest form of switchgear & is used to control & protect& other
equipments in
homes, offices etc. For circuits of higher ratings, a High Rupturing
Capacity (H.R.C) fuse in
condition with a switch may serve the purpose of contr olling
&protecting the circuit. However
such switchgear cannot be used profitably on high voltage system (3.3
KV) for 2 reasons. Firstly, when a
fuse blows, it takes some time to replace it &con sequ ently there is
interruption of service to
customer. Secondly, the fuse cannot successfully interrupt large currents
that resu lt fr om
the High Voltage System. In order to interru pt heavy fault currents, au
tomatic circu it
breakers are used. There ar e very few types of circuit breakers in B.P.T.S
they are VCB, OCB, and
SF6 gas circuit breaker. The most expensive circuit breaker is th e SF6 ty
pe due to gas. There
are various companies which manufacture these circuit breakers:
VOLTAS, JYOTI, and
KIRLOSKAR. Switchgear includes switches, fuses, circuit breakers,
relays & other equipments

45

THE EQUIPMENTS THAT NORMALLY FALL IN THIS

CATEGORY ARE:1. ISOLATOR
An isolator is one that can break the electrical circuit when the circuit is to
be switched on no load.
These are u sed in various cir cuits for isolating the certain portio n
when r equired for
maintenance etc. An operating mechanism box normally installed at
ground level drives the isolator.
The box has an operating mechanism in addition to its contactor circuit
and auxiliary contacts may be
solenoid operated pneumatic three phase motor or DC motor transmitting
through a spur gear to
the torsion shaft of the isolator. Certain interlocks are also pro vided with
the isolator
These are
1. Isolator cannot operate unless breaker is open
2. Bus 1 and bus 2 isolator s cannot be closed simu ltaneously

3. The interlock can be bypass in the event of closing of bus coupler breaker.
4. No isolator can operate when the corresponding earth switch is on

2. SWITCHING ISOLATOR
Switching isolator is capable of:
1. Interrupting charging current
2. Interrup ting transfor mer magnetizin g current

Load
3. tran sformer switching. Its main application is in con nection with
th e
transformer feeder as the unit makes it possible to switch gear one
transformer
while the other is still on load.

3. CIRCUIT BREAKER
One which can make or break the circuit on load and even on faults is
referred to as circuit
breakers. This equipment is the most important and is heavy duty
protectio
of various
cir cuits
equipmentn mainly
utilized
for and operations on load. Normally circuit
installed are accompanied by isolators. 46
breakers

4. LOAD BREAK SWITCHES

These are those interrupting devices which can make or break circuits.
These are normally on same
circuit, which are backed by circuit breakers

5. EARTH SWITCHES
Devices which are u sed nor mally to earth a particular system, to avoid
any accident
happen ing due to induction on account of live adjoining circuits. These
equipments do not handle
any appr eciable current at all. Apart from this equipmen t there are a
number of r elays
etc. which are used in switchgear.

LT SWITCHGEAR
In LT switchgear there is no interlockin g. It is classified in following
way s:1. MAIN SWITCH
Main switch is control equipment which controls or disconnects the
main supp ly. The
main switch for 3 phase supply is available for the range 32A, 63A,
100A, 20 0Q,
300A at 500V grade.

2. FUSES
With Avery high generating capacity of the modern power stations extr
emely heavy
carn ets would flow in the fault and the fuse clearing the fault would be r
equired to
withstand extremely heavy stress in process. It is u sed for supplying
power to
au xiliaries with backup fuse protection . With fu ses, quick break , quick
make and
double break switch fu ses for 63A and 100A, switch fu ses for 200A,400
A, 600A,
800A and 1000A are u sed.
AC Contractors are 3 poles suitable for D.O.L Starting of motors and pr
3. CONTACTORS
otecting
connected
themotors.
47

4. OVERLOAD RELAY
For overload pr otection, thermal overload relay are best suited for this
purpose. They
operate due to the action of heat generated by passag e of current through
relay element.

5. AIR CIRCUIT BREAKERS

It is seen that u se of oil in circuit breaker may cau se a fire. So in all
circuits breakers
at large capacity air at high pressure is used which is maximum at the
tripping
of contacts. This reduces th e possibility of sparking. The pressu
time of quick
re may vary from
50-60kg/cm^2
fo r high and medium capacity circu
48 it breakers.

HT SWITCHGEAR
1. MINIMUM OIL CIRCUIT BREAKER
These u se oil as quen ching medium. It compr ises of simple dead tank
row pursuing
projectio n fro m it. The mo ving contracts are carried on an iron arm
lifted by a lo ng
insulating tension rod and are clo sed simultaneously pneu matic op
erating mechanism by
means of tensions but thr ow off spring to be provided at mouth of th e
control the main
current within the con trolled device.

Type-HKH 12 /1000c
Rated Voltage-66 KV
Nor mal Curr ent-1250A
Frequency-5 Hz
Break ing Capacity-3.4+ KA Symmetrical
3.4+KA Asymmetrical
360 MVA Symmetrical
Motor Voltag e-220 V/DC

49

2. AIR CIRCUIT BREAKER

In this the compr essed air pressure ar oun d 15 kg per cm^2 is used for
extinction of arc
caused by flow of air arou nd the moving cir cuit . The breaker is
closed by applying
pressur e at lower opening and opened by applyin g pr essure at upper
opening. When
contacts operate, the cold air ru shes ar ound the movable contacts and
blown the ar c:
It has th e follo win g advantages over OCB:i.

Fire hazard due to oil are eliminated.

ii.

Operation takes place quickly.

iii.
iv.

Ther e is less burning of co ntacts since the duration is short and

consistent.
Facility for frequent operation since the cooling medium is r eplaced
constantly.
Rated Voltage-6.6 KV
Current-630
A
Au
xiliary current-220
V/DC

50

3. SF6 CIRCUIT BREAKER

This type of circuit breaker is of construction to d ead tank bulk oil to

circuit breaker but
the princip le of cu rrent interruption is similar to that of air blast cir cuit
br eak er. It simply
emp loys the ar c extinguishing medium namely SF6. When it is brok en
down u nder an
electrical stress, it will quick ly recon stitute itself.

Circuit Breakers-HPA
Standard -1 EC 56
Rated Voltage-12 KV
Insu lation Lev el-28/75 KV
Rated Frequency-50 Hz
Break ing Current-40 KA
Rated Current-1600
A KA
Making
Capacity-110

51

4. VACUUM CIRCUIT BREAKER

It works on the principle that vacu um is used to save the purpose of
insulation and. In
regards of in sulatio n and strength, vacuum is super ior dielectric mediu
m and is better
that all other mediu m except air and sulphur which are generally used at
h igh pressur e.
Rated frequency-50 Hz
Rated mak ing Current-10 Peak KA
Rated Voltage-12 KV
Supply Voltag e Clo sing-220 V/DC

52

COAL HANDLING PLANT (CHP)

The coal handling plant consists of two plants:

Old Coal Handling Plant (OCHP)
New C oal Handling Plant (NCHP)

The OCHP supplies coal to Unit- I, II, I II &

NCHP su pplies coal to Unit- IV and V.

COAL SUPPLIED AT BTPS

Coal is supplied to BTPS by Jharia coal mines. It is non-co oking coal
and has following
specifications:Moisture- less than 8%
Volatile matter-17% to 19%
Ash- 35% - 40%
Calorific Value- 4500 to 5300 Kcal/kg

Coal is r eceived in railway box racks containing 20 - 42 wago ns in each

rack.
Capacity of each box wagon is about 55 ton.
These wag ons ar e placed on 2 wagon tippler in OCHP & one wagon
tippler in
NCHP, in total 3, capacity 80 ton each.

53

COAL CYCLE

54

OLD COAL HANDLING PLANT (OCHP)

KEY DIAGRAM

55

The main constituents of OCHP plant are:-

WAGON TIPPLER
Wagon fro m coal yard come to the tippler and emptied here. Th ere ar e
2 wagon tipplers
in the OCHP. The tippler is tilted to about 137- 141 so that coal from
the wagon is
emp tied into the hopper. Elliptics feeder is used in OCHP. Total 8
feeders are u sed, 4 in
each hopper.
Slip Ring I nductio n Moto r is u sed to operate a wagon tippler. This type
of IM is used in
the tippler because of its high resistance, lo w speed & high torque
characteristics. The
rating of the motor used is:
o

Power 55 Kw

Voltage 415V

Current 102A

Speed 1480 rpm

Phase 3

Frequency 5 0Hz

Three types of wagon tippler s ar e used:a) ROTASIDE: - It is used for open type wagon s in which each wago n
carries around 5056 tons of coal. The wag on is tilted by 150 to put the coal in the u
nloading ho pper.
b) ROTARY: - In this case the unloading hopp er is placed dir ectly u
nder the tippler table.
This is also u sed to tilt the wagon tippler to 180.
c) ROCKING TYPE: - It is u sed for close type wagons. In this hopper
s is placed by the
side of end ro cking is provided to facilitate unloading of coal at corner s
of the wagon.
56

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

ZERO SPEED SWITCH

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

METAL DETECTOR
As the conveyer belt tak e coal from wagon to crusher house, no metal
piece should go
alon g with coal. To achiev e this objective, metal detecto rs & separator
s are used. In the
OCHP, these MD s are installed in the convey er belts 2A & 2 B.

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

ROTARY BREAKER
If any large piece of metal of any hard substances like metal impurities
comes in the conveyer belt which
cause load on the metal separator, then the rotary breaker rejects them
reducing the load on the metal
detector.
57

STACKER-CUM-RECLAIMER
It is used for stacking & reclaiming the coal fr om the stockyard in case
of un availability
of wagons fr om coal mines.

PLOUGH FEEDER
These plough feeders are generally installed under slot bunkers or
hoppers. These are used top lough the
coal to the belt from th e coal fed from sto ckyard. These feeders u sed in
this power station
are generally of rotary type.

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

PULL GUARD SWITCH

These are the switches which are installed at every 10m gap in a conveyer
belt to ensure the safety of
motors running the co nveyer belts. If at any time some accident happens
or coal ju mps
from belt and starts collecting at a place, this switch can be moved to
NO(normally open)
position fr om NC (nor mally closed) p osition to stop conveyor belt
from moving. At this
time the problem can be corrected & then again the switch can be moved
to NC (normally closed)
position fo r nor mal working again.

INTERLOCKS:The CHP is normally spread over a wide area with centralized control r
oom. Elaborate
scheme is therefore provided. If due to any emergency either the conveyor
belt or the motor has to be
stopped, due to this in terlocking all th e other motors connected to it will
au tomatically
stop &will not work till signal is given fr om the control room.
58

The control & protection scheme nor mally includes: -

A hoo ter system to warn that the plant is going to be started. The plant
can be
started only after a definite time after the hooter is energ ized.
Sequential starting of conveyor system and tripping of all proceeding
system if
any equipment in the chain is tripped.
Tripping of convey or from speed switch for pr otection against belt
slippage.
SEQUENTIAL OPERATION OF OCHP: -

I.

Unloading the coal

II.

Crushing & storage.

III.

Conveying to boiler bunkers.

a) Coal arriv es to plant via r oad, rail, sea, an d river or canal r oute from
collieries.
Most of it arrives by rail route only in railway wagons. Coal requirement
by this plant is
approximately 10,500 metric ton/day.

b) This coal is tippled into hoppers. If the coal is over sized (400 mm sq),
then it is
broken manually so that it passes the hopper mesh where through elliptic
feeder it is put into
vibrators & then to conveyor belt 1A & 1B.
c) The coal through con veyor belts 1A & 1B goes to the crusher house.
Also the
extra coal is sent to stockyard th rou gh these belts.

d) In the crusher house the small size coal pieces goes directly to the belt
2A & 2B whereas the
big size coal pieces are crushed in the crusher & then given to the belts 2A
& 2B.

e) The crushed coal is taken to the bunker house via the conveyor belts 3A
& 3B where it can be
used for further operations.
59

NEW COAL HNDLING PLANT (NCHP)

KEY DIAGRAM

60

The main constituents of NCHP plant are:Most of the con stituen ts of the NCHP ar e the same as that of OCHP.

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

61

COAL FEEDER TO THE PLANT

Vibro feeders are installed below the hopper which helps in putting the
coal to the conveyor belts. There
are 2 conveyor belts & 3 vib ro feeder per plan t, so in total there ar e 6
vibrofeeders.
Given below are the feeder motor specifications:
Po wer 1 5HP
Voltage 415V
Speed 1450rpm

CONVEYOR TURNING POINT-6BREAKER HOUSE

This hou se is requ ired to r ender the coal size to 100mm sq. A 415W LT
motor is used
in the break er house.
REJECTION HOUSE
The coal comes to breaker house via conveyor belts 12A & 12B. Now in
the breaker house the huge
stones & metal impurities are separated & sent to reject bin hou se
through belts 18A
&18B.
RECLAIM HOPPER
It is the stockyar d in which coal is stored for emer gency purposes. Ar
oun d 3 lakh ton of
coal can be stored in it
TURNING POINT 7
CRUSHER HOUSE
To ensure that the coal is of unifor m size it is passed thr ough crusher.
The crusher is of ring
type. Has a motor rating of 400HP, 606KV. It is design ed to cru sh the
pieces to 20mm size
EXIT

62

SEQUENTIAL OPERATION OF NCHP:-

a) Coal arriv es in wagons and tipples into hopp ers.

b) if the coal is oversized (400mm sq), then it is brok en manually so that
it passes through
the ho pper mesh.
c) From hopper it is taken to TP-6 12A & 12B.
d) Conveyors 12A & 12B take the coal to the breaker house which renders
the coal size to be 100 mm
sq.
e) Metal separator & metal detector are installed in conveyor belts 14A/B
& 15A/B respectively to
remove the metal impurities
.f) Stones which are not able to pass through the 100mm sq mesh of
hammer are rejected
via 18A & 18B to the r ejection hou se.
g) Extra coal is sent to the reclaim hopper via conv eyor 16A & 16B.
h)Fr om TP-7, coal is tak en by convey or 14A & 14B to the crusher
house whose function
is to ren der size of the coal to 20mm sq.
SPECIFICATIONS OF MOTORS USED IN NCHP:I.

Crusher: - BHEL ILAT/12B HD/02, 736rpm, 550 Kw, 66 00V.

II.

Wagon Tippler: - 5D315l, 98Kw slip ring motor.

III.

Conveyors: 1)11A/B, 12A/B: - 125Kw, 3 15m, 1485rpm.

2)13A/B: - 55Kw, 250m, 1480rpm.
3)14A/B, 15A/B: - 150Kw, 3 55m, 1485rpm.

IV.

4)16A/B,
5)18A/B:
Rotar
y Br17A/B:
- eaker:
37Kw,--225m,
110Kw,
110Kw,
1470rpm.
315m,
3 15m,11485rpm.
485rpm
63

V.

Belt Feeder: - 15Kw, 180 L, 1445rpm

VI.

Reversib le Belt Feeder: - 18.7Kw, 200L, 1485rp

VII .

VF 1 -6: - 7.5 Kw, 160m, 1485rpm

VIII .

VF 7 -8: - 15 Kw, 180L, 14 85rpm

IX.

VF 9 -12: - 1 1Kw,160L, 1485 rpm

X.

WSP Cru sher House: - 1 5Kw, 160m, 40 00rpm

XI.

WSP Br eaker House: - 7 .5 Kw, 132m, 1865 rpm

XII .

Metal Separator: - 5 KV, 13 2m, 1410rpm

XIII .

Spray Precipitator: - 18.5Kw, 200L, 3000rpm

SAFETY DEVICES FOR BELT CONVEYORS

Sometimes the belt is wet due to any reason, so it may not run due to
reduced friction. A
switch senses this and p revents the belt from choking.
Sometime any accident may occur which r equires the belt to stop, the pull
cords are
pulled to stop the conveyor. This system starts again only when the pu ll
cor ds are rest.
Ther e is a push button in the control room from where the b elt can be
stopped in case
of emergency stoppage. Other equipments are pulley . Pulleys are made
of mild steel,
rubber logging is provided to incr ease the friction factor b etween the
pulley and belt.

MILLING SYSTEM

1. RC BUNKER
Raw coal is fed directly to these bunkers. These are 3 in no. per boiler. 4
& tons of coal
are fed in 1 hr. the depth of bu nk ers is 10m.
64

2. RC FEEDER

It transports pr e-cru st coal from raw coal bu nk er to mill. The quantity

of raw coal
fed in mill can be contr olled by speed contr ol of aviator drive contr
olling damper
and aviator change

3. BALL MILL :

The ball mill crushes the raw coal to a certain heigh t and then allows it
to fall
down. Due to impact of ball on coal and attraction as per the particles
move over
each other as well as over the Armor lines, the coal gets crushed. Large
par ticles
are brok en by impact and full gr inding is done by attraction. Th e Drying
and
grinding option takes place simultaneously inside the mill. In ball mill
coal is
converted to powder ed form and du e to pneu matic action the powdered
fo rm of
coal is transferr ed upwards.

4. CLASSIFIER:
It is equ ipment which serves separation of fine pulv erized coal particles
med ium from
coar se mediu m. The pulverized coal along with the carr ying medium
strik es the
impact plate through the lower part. Lar ge particles are then transferr ed
to the ball mill.
5. MILL FAN
From ball mill the powdered coal is sucked through mill fan.

6. CYCLONE SEPARATORS
It separates the pulver ized coal fr om carr ying medium. Th e mix ture
of pulverized coal
vapour caters the cyclone separators tangentially in the u pp er part of the
separator. Due
to decrease in the velocity the centrifugal action, the pulver ized coal
separated from the
vapour &falls down to the lower epical part.
65

7. THE TURNIGATE
It serves to transport pulverized coal from cyclone separator s to
pulverized coal bunker or
to worm con veyors. There are 4 tur nigates p er boiler.

8. WORM CONVEYOR
It is equ ipment used to distribute the pulv erized coal from bunker of one
system to
bunker of other sy stem. It can be op erated in both directions

66

ELECTRICAL MAINTENANCE DEPARTMENT II

(EMD-II)
Electrical maintenance d ivision 2
It include s:
Generators
Transformers
Switch yard

I was assigned to do training in this division from 2

67

nd

July to July.
13 th

GENERATORS

The generator work s on the principle of electromagnetic indu ction.

There are two
compon ents stator and rotor. The rotor is the moving part and the stator
is the statio nary
part. The rotor , which has a field winding , is given a excitation through
a set of 3000rpm
to give the required frequency of HZ. The rotor is cooled by Hydrogen
gas, which is locally
manu factur ed by the plant and has high heat carrying capacity of low
density. If oxygen
and hydrogen get mixed then they will form very high explosive and to
prevent their combining in any
way there is seal oil system. The stator cooling is done by de-mineralized
(DM) water through hollow
conductors. Water is fed by one end by Teflon tube. A boiler and a turbine
are cou pled to electric
generators. Steam from the boiler is fed to the tur bine thr ough the
connecting pipe. Steam
drives the turbin e rotor. The turbine rotor drives the generator r otor
which tu rns the
electr omagnet within the coil of wire conductor s.
Carbon dioxide is provided from the top and oil is provided from bottom
to
thethe
generator.
With
Hydr
Lube
help oogen
ofilcarbon
isgas
u sed
isdioxide
used
to cool
tothe
the
cool
oil
bearings.
down
is drained
the r out
otor.to the oil tank.
68

DM water is used to cool the stator.

Seal oil is used to pr event hydro gen leakage
Seal oil coolers are p resent to cool the seal oil
Hydr ogen dryer ar e used wh ich removes the moisture fr om hydrogen
gas and then
is supplied to the generator.

Clarified water in cooling tower is used to cool down the hydrog en gas.

RATINGS OF THE GENERATORS USED

Turbo generator 1 00MW

TURBO GENERATOR 210 MW

The 100 MW generator generates 10.75 KV and 210 MW generates 15.75

KV. The
voltage is stepped up to 220 KV with the help of generator transformer
and is connected to the grid.
The voltage is stepped down to 6.6 KV with the help of UNIT
AUXILLARY TRANSFORMER
(UAT) an d this voltage is used to drive the HT motors. The voltage is
further stepped
down to 415 V and th en to 220 V and this voltag e is u sed to driv e Lt
Motors.

69

TURBO GENERATOR 100MW

MAKE

BHEL, Haridwar

CAPACITY
POWER

117 ,5 00 KVA
100 ,0 00 KW

STATOR VOLTAGE 10,50 0 V

STATOR C URRENT 6475 A
SP EED

5 0 0 0 rp m

POWER FACTOR
FR EQ UEN CY
EXCITATION

0.85
50 HZ

280 V

TURBO GENERATOR 210MW

MAKE

BHEL, Haridwar

CAPACITY
POWER

247 ,0 00 KVA
210 ,0 00 KW

STATOR VOLTAGE 15,75 0 V

STATOR C URRENT 9050 A
SPEED

5000 rpm

POWER FACTOR
FREQUENCY

0.85

50 HZ

EXCITATION
V70kg/cm
GAS PRESSURE3103.5

TRANSFORMERS

INTRODUCTION
It is a static machine which incr eases or decr eases the AC voltage
without
changing
the
frequency
of the supply.
It is a device that:
Transfer electric power from one circu it to another .
It accomp lishes this by electromagn etic induction.
In this the two electric circuits are in mutual inductive influence of each
other.
WORKING PRINCIPLE:
It works on FAR ADAY S LAW OF ELECTROMAGNETIC
INDUCTION
(self n dependin g on the type of transformer).
or mutual inductio

71

MAIN PARTS
CONSERVATOR
It is used generally to con ser ve the insulating property of the oil from
deterioration&
protect the transformer against failure on account of bad quality of oil.
SILICAGEL DEHYDRATING BREATHER
It is used to prevent entry of moisture inside the transformer tank. The
breather
consists of silica gel.
GAS OPERATED RELAY (BUCHHOLZ RELAY)
It is a gas actuated relay u sed for pro tecting oil immersed transfor mer
against
types ofallfau lts. It indicates presence of gases in case of some minor fault
&
outtake
the transformer out of circuit in case of serious fault.
BUSHINGS
It is made from highly in sulatin g material to insulate & to bring ou t
thethe
terminals
of
transformer fr om the container. The bushings are of 3 typ es:
a. Por celain bushings used for lo w voltage transfor mer
b. Oil filled bu shin gs used for voltage up to 33KV.
c. Condensed type bushings u sed for voltage abov e 3 3KV.
OIL GUAGE
Ever y transformer with an oil guage to indicate the oil level. The oil
guage
may
be the alar m contacts which gave an alar m the oil level has
provided
with
dr
oppedper missible height due to oil leak etc.
beyond
TAPPINGS
The transformer are u sually provided with few tappings on secondary
side output
so
that
v oltage can be varied for con stant input voltage.
RADIATORS
It increases the sur face area of the tank & mor e heat is thus radiated in
less time.
Device wh ich in dicates the temperature of winding of transfor mer &
WINDINGS
INDICATOR
(OIL GUAGE)
possible
to
the
transformer
damage TEMPERATURE
due to o overload can
be 72
p revented.

CONSTRUCTIONAL FEATURES:

3 phase transfor mer is constructed in the core type construction

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

CLASSIFICATION:
(I)

ACCORDING TO THE CORE:

a) Core type transformer

b) shell type transformer
c) Berry type transformer
(II)

ACCORDING TO PHASES:

a) 1phase transfo rmer

b) 3phase transfo rmer
(III)

ACCORDING TO THE PURPOSE FOR WHICH USED

:
a)
b)
c)
d)
e)

Distribution transformer
Transmission transformer
Generator tran sformer
Station transformer
Unit Auxiliary transfor mer ( UAT)

73

COOLING OF TRANSFORMERS OF LARGE MVA:

As size of tran sformer beco mes large, the rate of the oil cir culating
becomes
insufficient
to dissipate
all the heat produced & artificial means of increasin g the
circulatio
n bys. In very large transformer s, special cooler s with water
electric pump
circulation
have to be may
employed.
TYPES OF COOLING:
Air cooling
1. Air Natural (AN)
2. Air For ced ( AF)
Oil immersed cooling
1.
2.
3.
4.

Oil Natural Air Natural (ONAN)

Oil Natural Air Forced (ONAF)
Oil Forced Air Natural (OFAN)
Oil Forced Air Forced (OFAF)

Oil immersed Water cooling

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

MAIN PARTS OF TRANSFORMER

i.

Secondar y Winding

ii.

Primary Winding .

iii.

Oil Level

iv.

Conservator

v.

Breather

vi.
vii.
viii.

Drain Cock
Cooling
Transformer
Tubes.
Oil.

74

ix.

Earth Point

x.

Explosion Vent

xi.

Temperature Gauge.

xii.

Buchholz Relay

xiii.

Secondar y Terminal

xiv.

Primary Terminal

GENERATOR TRANSFORMER (125MVA UNIT-I &

UNIT-III)
RATING

125 MVA

TYPE OF COOLING
TEMP OF OIL

OFB

45^C

TEMP WINDING
KV (no load)

60^C
HV-233 KVA
LV-10.5 KVA

LINE AMPERES

HV-310 A
LV-6880

PHASE

THREE

FREQUENCY

50 HZ

IMPEDANCE VOLTAGE
VECTOR GROUP

15%

Y DELTA

INSULATION LEVEL

HV-900 KV
LV-Neutral-38

CORE AND WINDING WEIGHT

WEIGHT OF OIL

372 00 Kg

TOTAL WEIGHT

188 500 Kg

OIL QUANTITY

439 00 lit
75

110 500 Kg

GENERATOR TRANSFORMER (166 MVA UNIT-IV)

RATING

240 MVA

TYPE OF COOLING

ON/OB/OFB

TEMP OF OIL
TEMP WINDING
VOLTS AT NO LOAD

HV-236000
LV-A57 50

LINE AMPERES

HV-587 A
LV-8798

PHASE

THREE

FREQUENCY

50 HZ

IMPEDANCE VOLTAGE
VECTOR GROUP

15.55 %

Y DELTA

CORE AND WINDING WEIGHT

WEIGHT OF OIL

378 50 Kg

TOTAL WEIGHT

234 000 Kg

OIL QUANTITY

425 00 lit

GUARANTEED MAX TEMP

DIVISION

KERELA

YEAR 1977

76

138 800 Kg

UNIT AUXILIARY TRANSFORMER (UAT)

Unit I & V- 12.5 MVA

The UAT draws its input from the main bus-ducts. The total KVA
capacity of UAT
required can be determin ed by assu ming 0.85 power factor & 90 %
efficiency for total
au xiliary motor load. It is safe & desirable to pr ovide about 20% excess
capacity then
cir culated to pro vide for miscellaneou s au xiliaries & p ossible incr ease
in auxiliary.

STATION TRANSFORMER
It is requ ired to feed power to the au xiliaries during startup s. This
transfo rmer is normally
rated for initial auxiliar y load requirements of the u nit in typical cases;
this load is of the
order of 60% of the load at full generating capacity. It is provided with
on load tap
change to cater to the fluctuating vo ltag e of the gr id.

NEUTRAL GROUNDED TRANSFORMER

This transfor mer is co nnected with supply coming out of UAT in stage2. This is used to
ground the excess voltage if occurs in the secondary of UAT in spite of
rated voltage.

77

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

OUTDOOR EQUIPMENTS
i.

BUS BAR.

ii.

LIGHTENING ARRESTER

iii.

WAVE TRAP

iv.

BREAKER

v.

CAPACITATIVE VOLTAGE TRANSFORMER

vi.

EARTHING ROD

vii.

CURRENT TRANSFORMER.

viii.

POTENTIAL TRANSFORMER

ix.

LIGHTENING MASK

INDOOR EQUIPMENTS
i.

RELAYS.

ii. CONTROL PANELS

iii. CIRCUIT BREAKERS

78

BUS BAR

Bus bars generally ar e of high condu ctiv e aluminum conforming to IS5082 or

copper of adequate cross section .Bus bar located in air insulated
enclosures & segregated
from all other components .Bus bar is preferably cover with polyurethane.

BY PASS BUS

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

LIGHTENING ARRESTOR

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

Power line carrier communication (PLCC) is mainly used for

telecommunication,
tele-protection and tele-monitoring between electrical substations thr ough
power
lines at high voltages, such as 110 kV, 220 kV, and 400 kV. PLCC
integrates the
transmission of commu nication signal and 50/60 Hz power signal
through the
same electric power cable. The major benefit is the union of two importan
t
applications in a single system. WAVETRAP is connected in series with
the power (tran smission) line. It blocks the high frequency carr ier
waves (24 KHz
to 500 KHz) and let power waves (50 Hz - 60 Hz) to pass-thr ou gh.
79

BREAKER

Circuit breaker is an arrangement by which we can break the circuit or

flow of current. A circuit
breaker in station serves the same purpose as switch but it has many added
and complex
features. The basic constructio n of any cir cuit br eaker requires the
separation of
contact in an insulatin g fluid that server s two functions:

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

CAPACITATIVE VOLTAGE TRANSFORMER

A capacito r voltage transformer (CVT) is a transfo rmer used in power
sy stems to
step -down extra high voltage signals and provide lo w voltage signals
either for
measur emen t or to operate a protective relay. It is located in the last in
the switchyard as it
increases the ground resistance. Finally the voltage from CVT in the
switchyard is
sent out fr om the station through transmission lines.

EARTHING ROD

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

CURRENT TRANSFORMER
It is essentially a step up transformer which step down the current to a k
nown
ratio. It is a type of instru ment tran sformer designed to pr ovide a
its
secondary
winding proportional to the alternating curr ent flo wing in
current
in
primary.
its
80

POTENTIAL TRANSFORMER

It is essentially a step down transformer and it step downs the voltage to a

known ratio.
RELAYS
Relay is a sensing d evice that makes your circuit ON or OFF. They
detect the
abnormal conditions in the electrical circuits by continuously measuring
the electrical quantities,
which are different under normal and faulty conditions, like current,
voltage frequency. Having
detected the fault the relay operates to complete the trip circuit, which
results in the opening of
the circuit breakers and disconnect the faulty circuit.
There are different types of relays:
i.

Current relay

ii. Potential relay

iii. Electromagnetic relay
iv. Numerical relay etc.

AIR BREAK EARTHING SWITCH

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

ELECTROSTATIC PRECIPITATOR
An electrostatic pr ecipitator ( ESP) or electrostatic air cleaner

is a par ticulate collection device that r emoves particles from a flowing

gas (such
as air) using the force of an induced electrostatic charge. Electrostatic
precipitators
of gases through
are highly
the device,
efficient
and filtration
can easily
devices
remove
thatfine
minimally
particulate
impede
the
matter
dust
flow
and
such
smoke
as fr om th e air stream. 81

In contrast to wet scru bb ers which apply energy directly to the flowing
fluid
med ium, an ESP applies energy only to the particu late matter being
collected and
ther efore is very efficient in its consump tion of energy (in the form of

electricity).The most basic p recipitator contains a row of thin vertical wir

es, and
followed by a stack of large flat metal plates oriented vertically, with
the plates
typically spaced about 1 cm to18 cm apar t, depending on the application.
The air
or gas stream flows horizontally through th e spaces between the wir es,
and then
passes through the stack of plates. A negative voltage of several
thousand vo lts is
applied between wire and plate. If the applied voltage is high enough an
electric
(corona) discharge ionizes the gas arou nd the electrodes. Negative ions
flow to
the plates and char ge the gas-flow particles.

The ionized particles, following the negative electric field created by the
power
su pply, move to the gr ounded plates. Particles build up on the collection
plates
and form a lay er. The layer do es not collapse, thanks to electr ostatic
pressure
(given fro m layer resistivity, electric field, and curren t flowing in the
collected
layer).

82

CONTROL & INSTRUMENTATION

INTRODUCTION
C&I LABS
CONTROL & MONITORING MECHENISM
PRESSURE MONITORING
TEMPERATURE MONITORING
FLOW MEASUREMENT
CONTROL VALVES

INTRODUCTION
This division basically calibrates various instruments and takes car e of
any faults occur in
any of th e auxiliar ies in the plan t.
Instrumentation can be well defined as a technology of using
instruments to
measure and control the physical and chemical properties of a
material.
C&I L ABS
Control and Instrumentation Department has following labs:

Manometry Lab.
Protection and I nterlocks Lab.
Automation Lab.
Electronics Lab.
Water Treatment
Furnaces
Safety Supervisory
Plant.
System Lab83

OPERATION AND MAINTAINANCE

Control and Instrumentation Department has following Contr ol Units:

1. Unit Contr ol Board2.

2. Main Control Board3.
3. Analog & Digital Signal C ontrol4.
4. Current Signal Control

This department is the brain of the plant because from the relays to
transmitters followed by the
electronic computation chipsets and recorders and lastly the controlling
circuitry, all fall under this.
A View of Control Room at BTPS

84

1. MANOMETRY L AB

TRANSMITTERS
It is used for pressure measurements of gases and liquids, its working
principle is that the
input pressure is converted into electrostatic capacitance and from there it
is condition ed
and amplified. It gives an output of 4-20 ma DC. It can be mounted on a
pipe or a wall.
For liquid or steam measurement tran smitter s is mounted b elow main
process piping and
for gas measur emen t transmitter is placed abov e pipe.
MANOMETER
It s a tub e which is bent, in U shape. It is filled with a liquid. This device
corresponds to a
differ ence in pressur e acro ss the two limbs.
BOURDEN PR ESSURE GAUGE
It s an oval section tube. Its one end is fixed. It is provided with a pointer
to indicate th e
pressur e on a calibrated scale. It is of 2 types :

(a) Spiral type: for Low pressur e measu rement.

(b) Helical Type: for High pressure measurement. While selectin g
Pressure Gauge these
parameters should k eep in mind 1. Accuracy
2. Safety
3. Utility
4. Price

ACCURACY
Higher Accuracy implies Larger Dial Size for accu racy of small and
readable pr essure
scale incr ements.
While be
should
selecting
ch emically
Pr essure
compatible
Gau ge with
it should
the environment
consider thateither
Gauge
in C
side
onstru
or
SAFETY
ction
outside
Material
it.
85

UTILITY
It should keep it mind that rang e of the Gauge should be according to
our need else
Overpressur e Failu re may occur resulting in damage of Gauge.
PRICE
Lager the Gauge s Dial size larger would be our price. Better Gauge s C
onstruction
material also increases the co st. So they must be chosen according to our
need.

2. PROTECTION AND INTERLOCKING

INTERLOCKING
It is basically interconnecting two or more equipmen ts so that if one
equipment fails oth er
one can per form the task s. This type of in terdependence is also created
so
that equip ments con nected together ar e started and shut down in the
specific sequence to
avoid damage. For pr otection of equipmen ts tripping are provided for
all the equipments.
Tripping can be consider ed as the series of instructions connected
through OR GATE,
which trips the circuit. The main equipments of this lab are r elay and cir
cuit breaker s.
Some of the instrument uses for protection are:
RELAY
It is a pr otective device. It can detect wrong con ditio n in electrical cir
cuits by con stantly
measur ing the electrical quantities flowing under normal and fau lty co
nditions. Some
of the electrical quantities ar e voltage, curr ent, phase angle and velocity.
2. FUSES it is a
shor t piece of metal inserted in the cir cuit, which melts when heavy
current flows through
it and thus breaks th e circuit.
Usually silver is used as a fuse mater ial becau se:
The coefficien
fatigue
occurs and
t ofthus
expansion
the continu
of silver
ou sisfull
vercapacity
y small.normal
As a result
current
no
a. ratings
assu redare
critical
for the long time.
86

b.
The conductivity of the silver is unimpaired by the surges of the current
that
produces temperatures ju st near the meltin g point

c. Silv er fu sible elements can be raised fr om normal operating

temperature to
vaporization quick er than any other material because of its comparatively
low
specific heat.

Miniat ure Circuit Breaker

They are used with combination of the co ntrol circuits to.

a) Enab le the staring of plant and distribu tors.

b) Protect the circu it in case of a fault. In consists of current carrying
contacts, one
movable and other fix ed. When a fault occur s the contacts separate and
are is
stuck between them.
Ther e are three types of trips.
I.

MANUAL TRIP

II.

THERMAL TRIP

III.

SHORT CIRCUIT TRIP

Protection and Interlock System1) HIGH TENSION CONTROL CIRCUIT for high tension system the
control
system is excited by separate D.C su pply. For starting the circuit
conditions
should be in series with the starting coil of th e equipment to energize it.
Because
if even a single condition is not true then system will not start.
2) LOW TENSION CONTROL CIRC UIT For low tension system th e
control
cir cuits ar e directly excited from the 0.415 KV A.C supply.
The sa me circuit achieves both excitation and tripping. Hence the
tripping coil is
provided for emerg ency tripping if the intercon nection fails.
87

3. AUTOMATION LAB
This lab deals in automating the existing equipment and feeding routes.
Earlier, the old
technology dealt with only (DAS) Data Acquisition System and came to
be known
as primary systems. The modern technology or the secondary systems are
coupled with
(MIS) Manag ement Information System. But this lab univ ersally applies
the pressure
measur ing instruments as the controlling force. However, the relays are
also provided
but they are used on ly for protectio n and interlock s.

4. PYROMETRY LAB

LIQUID IN GLASS THERMOMETER

Mercury in the glass thermometer boils at 340 C which limits the range
of temperatur e
that can be measur ed. It is L shaped thermometer which is d esigned to r
each all
inaccessible places.
ULTRA VIOLET CENSORThis device is u sed in furnace and it measur es the intensity of ultra
violet rays th ere and
according to the wave g enerated which directly indicates the
temperature in the furnace.
THERMOCOUPLES
This device is based on SEEBACK and PELTIER effect. It comprises of
two ju nctions at
differ ent temperature. Then the emf is induced in the circuit due to the
flow of electrons.
This is an important part in the plant.
RTD (RESISTANCE TEMPERATUR E DETECTOR)
It per for ms the function of thermocou ple basically but the differ ence is
of a resistance. In
this due to the change in the r esistance the temperatu re difference is
lab,
also theIn measuring
devices can be calibrated in the oil bath or ju st
measured.
this
boiling
.(for
lowwater
range devices) and in small furnace (for88high range devices)

5. FURNACE SAFETY AND SUPERVISORY SYSTEM LAB

This lab has the respon sibility of starting fire in the furnace to enable the
burning of coal.
For first stage coal bu rn ers are in the front and rear of the furnace an d
for the second and
thir d stage corn er firing is employ ed. Unbu rn t coal is removed using
forced draft or
induced draft fan. The temperatur e inside the boiler is 110 0C and its
heights 18 to 40 m.
It is made up of mild steel. An ultra violet sensor is employed in fur nace
to measur e the
intensity of ultra violet rays inside the furnace and according to it a signal
in the same
order of same mV is generated which directly indicates the temperature
of the furnace.
For firing the furnace a 10 KV spark plug is operated for ten seconds
over a spray
of diesel fuel and pre-heater air along each of the feeder -mills. The
furnace has six feeder
mills each separated by warm air pip es fed from forced draft fans. In
first stage indir ect
firin g is employed that is feeder mills are no t fed dir ectly from coal but
are fed fr om three
feed ers but are fed from pulverized coalbunkers. The fur nace can
operate on the
minimum feed from three feeder s but un der no cir cumstan ces should
anyone be left
out under op eration, to Preven t creation of p ressure different with in
the furn ace, which
threaten s to blast it.

6. ELECTRONICS LAB
This lab undertakes the calibration and testing of various cards. It houses
var ious types of
analytical instruments like oscillosco pes, integrated circu its, cards auto
analyzer s etc.
Variou s processes undertaken in this lab are:
1. Transmitter converts mV to mA.
2. Auto analyzer purifies the sample before it is sent to electrodes. It
extracts the
mag netic portion.

ANNUNCIATIN CARDS
They
if
parameter
are used
goes
to keep
beyo any
nd limit.
parameter
It has alike
switchin
temperatu
g transistor
re etc. within
connected
limits.
to
It gets
relay
in
alerting
that
a signal
helps
the UCB.
89

CONTROL & MONITORING MECHANISMS

Ther e are basically two types of Problems faced in a Power Plant

1. Metallurgical
2. Mechanical

Mechan ical Pr oblem can be related to Turbines that is the max speed
permissible for a
turbine is3000 rpm so speed should be monitored and maintained at that
level.
Metallurgical Problem can be view as the max Inlet Temperature for
Turbine is 1060
C so temperatur e should be below the limit. Mon itoring of all the
parameter s is necessary
for the safety of both :
1. Emp loyees
2. Machines
So the Parameters to be monitored are:
1. Speed
2. Temperat ure
3. Current
4. Voltage
5. Pressure
6. Eccentricity
7. Flo w of Gases
8. Vacuum Pressure
9. Valves
10. Level
11. Vibration
90

PRESSURE MONITORING

Pressure can be monitor ed by three types of basic mechanisms

1. Switches
2. Gauges
3. Transmitter type

For gauges we use Bourdon tubes. Th e Bourdon Tu be is a non-liquid

pressure
measur ement device. It is widely u sed in applications wh ere
inexpensive static pr essure
measur ements are needed. A typical Bour do n tube contains a curved tu
be that is open
to external pressur e input on one end and is coupled mechanically to an
indicating needle
on the other end, as shows sch ematically below.

Typical Bourdon Tube Pressu re Gages

For Switches pressu re switches are used and they can be used for digital
means of
monitoring as switch being ON is r eferred as high and being OFF is as
All
lo w.the monitored data is conv erted to either Curren t or Voltage
parameter.
91

The Plant standard for current and voltage are as under

Voltage : 0 10 Volts range
Current : 4 20 milli-Amperes

We use 4 mA as the lo wer value so as to check for disturbances and

wire breaks.
Accuracy of su ch systems is very high.

ACCURACY: 0.1 %
Programmable Logic Circuits (PLCs) ar e used in the process as they are
the hear t
of Instrumentation.

92

TEMPERATURE MONITORING

We can use Thermocouples or RTDs for temp eratur e monitoring.

Normally RTDs are
used for lo w temperatures.
Ther mocouple selectio n depends upon two factors:
1. Temperature Range
2. Accuracy Requir ed
Nor mally used Ther mocouple is

K Type Thermocouple:

In this we use Chromel (Nick el-Chromium Alloy) / Alumel (NickelAluminium Allo y) as

two metals. This is the most commonly used gen eral purpose thermocou
ple. It is
inex pensive and, owing to its popularity, available in a wide variety of
probes. They are
available in the-2 00C to +1200C range. Sensitivity is approximately
41 V/C.
RTDs are also u sed but not in pr otection systems due to vibrational
errors.
We pass a constant current through the RTD. So that if R changes then
the Voltage also
changes
RTDs u sed in Industries ar e Pt

100

And Pt

1000

Pt 100 : 0C 100 O ( 1 O = 2.5 0C )

Pt 1000 : 0C - 1000O
Pt1000 is used for higher accu racy.
The gauges used for Temperature measurements are mercu ry filled
Temperature
gauges.
For
Analog med
ium thermocou ples are u sed and for Digital medium
Switches
which
areare
basically
u sed mercur y switches.
93

FLOW MEASUREMENT

Flow measurement does not signify mu ch and is measured just for

metering purpo ses and
for monitoring the processes

ROTAMETERS:
A Rotameter is a device that measures the flow rate of liquid or gas in a
closed tube. It is
occasionally misspelled as 'R otometer'.
It belongs to a class of meters called variable area meters, which
measure flo w rate
by allowing the cross sectional area the fluid travels throu gh to vary,
causing some
measurable effect. A r otameter consists of a tapered tu be, typically
made of glass, with a
float inside that is pu shed up by flow and pulled down by gravity. At a
higher flow rate
more area (b etween the float and the tu be) is need ed to accommodate
the flow, so the
float rises. Floats ar e mad e in many differ ent shapes, with spher es and
spherical ellipses
bein g the most common. The float is shaped so that it rotates axially as
the fluid passes.
This allo ws you to tell if the float is stuck since it will only rotate if it is
not.
For Digital measur ements Flap system is used.
For Analog measurements we can use the following methods :
1. Flo w meters
2. Venturimeters / Orifice meters
3. Turbines
4. Mass flow meters(oil level)
5. Ultrasonic Flow meters
6.
Magnetic
(waters upon
lev elthe
) purpose, accuracy and liquid
Selectio
n of Flow
flow meter
meter depend
to be measured
differ
ent types of
someters u sed.
94

TURBINE TYPE:
They are simplest of all. They work on the principle that on each rotation
of the turbine a
pulse is gen erated and that pulse is counted to get the flow rate.

VENTURI METERS :

Referring to the diagram, using Ber noulli's equ ation in th e special case
of incompressible
fluids (such as the approximation of a water jet), and the theor etical pr
essure dr op at the
constriction would be given by ( /2)(v 2 2 - v1 2 ).
And we know that rate of flow is given by:
Flow = k v (D.P)
Wher e DP is Differ ential Pressu re or the Pressure Drop.

95

CONTROL VALVES

A valve is a device that

regulates the flow of subst

(either
ances
gases, fluidized solids,

slurries, or liquids) by openin g, closing, or par tially obstructing various

passageways.
Valves ar e technically pipe fittings, but u sually are discussed separately.
Valves are
used in a variety of applications including indu strial, military ,
commercial, residential,
transportatio n. Plumbing valves are the most obv ious in everyday life,
but many more are
used.
Some valves are d riven by pressure only, they are mainly used for safety
purposes in
steam engines and domestic heating or cooking appliances. Others are u
sed in
a controlled way, lik e in Otto cycle engines dr iven by a camshaft, where
they play a
major role in engine cycle con trol.

Many valv es are controlled manually with a handle attached to the valve
stem. If the
handle is turned a quarter of a full turn (90 ) between operating po
sitions, the valve
is called a quarter-turn valve. Butterfly valves, ball valves, and plu g
valves are often
quarter-turn valves. Valves can also be controlled by devices called
actuator s attached to
the stem. They can be electromechanical actuators such as an electr ic
mo tor or solenoid,
pneumatic actuators which are contr olled by air pressure,
hydraulic
or
actuators
which
are controlled by the pressu re of a liquid such as oil or water. So there ar
e basically three
types of valves that are used in power industries besides the handle
valves.
They are :
PNEUMATIC VALVES They are air or gas con trolled which is
compressed to turn or
move them
HYDRAULIC VALVES They utilize oil in place of Air as oil has
better compr essio n
MOTORISED VALVES These valves are controlled
by electric motors
96

FURNACE SAFEGUARD SUPERVISORY SYSTEM

FSSS is also called as Bur ner Management System (BMS). It is a

microprocessor Based
programmable logic contr oller of pr oven design incorporating all
protection facilities
required for such system. Main objective of FSSS is to ensur e safety of
the b oiler.
The 95 MW boiler s ar e indir ect type boilers. Fire takes place in fr ont
and in rear side.
That s why it s called front and rear type boiler.
The 210 MW boilers ar e direct type boilers ( which means that HSD is in
direct con tact
with coal) firing tak es p lace from th e corner. Thus it is also known as
cor ner type boiler.
IGNITER SYSTEM
Igniter system is an automatic system, it takes the charge from 110kv and
this spark is
brought in fr ont of the oil guns, which spray aerated HSD on the coal for
coal
combu stion. Ther e is a 5 minute d elay cycle before igniting, this is to
evacu ate or burn
the HSD. This method is known as PURGING.
PRESSURE SWITCH
Pressure switches are the devices that make or break a circuit. When p
ressure is applied,
the switch under the switch gets pressed which is attached to a r elay
that makes or break
the circuit.
Time delay can also be included in sensing the pressu re with the help of
pressure valves.
Examples of pressure valves:
1. Manual valves (tap)
2. Motorized valves (actuator) works on motor action
3. Pneumatic valve (actu ator) - works due to pressure of compressed air
4. Hydraulic valv e
97

REFERNCES

98

APPENDIX

NTPC COURSE MATERIAL FOR TRAINEES

99