Report

VOCATIONAL TRAINING REPORT
29/6/2011 30/7/2011
NTPC, Badarpur
Aman Samaiyar XA1/EEE/009 1st Year, Electrical and Electronics Engineering Delhi Technological University (formally Delhi College of Engineering)
ACKNOWLEDGEMENT
After completing the 1 month of industrial training at NTPC, Badarpur, I would like to thank the concerned engineers of company for their continuous support and step by step guidance.
I would like to pay my obligation to Mr.G.D. SHARMA, Employee Development Center, for his valuable suggestions, he gave before commencement of the training & made me familiar with the HODs of all departments , which guided me on the way of better learning. I would like to pay my special gratitude to Mr.S.P.VASHIST(DGM) sir of EMD-I department for allowing me to learn under his highly experienced persona & providing me in-depth Technical Specification of the electrical machinery. I am thankful to all HODs, Mr.S.K.MARWAH(DGM EMD II) for guiding me to understand turbogenerators, batteries, switch yards etc and Mr.SHYAMAL BHATTACHARYA(DGM C&I) for guiding me to understand the control and instrumentation and other parts of power plants during project.
- Aman Samaiyar
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TRAINING AT BTPS
I was appointed to do one-month training at this esteemed organization from 29th June to 30th July 2011. In these 34 days I was assigned to visit various division of the plant which were Electrical Maintenance Department I Electrical Maintenance Department II Control and Instrumentation This one-month training was a very educational adventure for me. It was really amazing to see the plant by yourself and learn how electricity, which is one of our daily requirements of life, is produced. This report has been made by self-experience at BTPS. The material in this report has been gathered from my textbooks, senior student report, and trainer manual provided by training department. The specification & principles are at learned by me from the employee of each division of BTPS.
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ABOUT THE COMPANY

N AT I O N A L T H E RM A L P O W E R C O RP O R AT I O N
NTPC Limited (formerly National Thermal Power Corporation) is the largest state-owned power generating company in India. Forbes Global 2000 for 2010 ranked it 341th in the world. It is an Indian public sector company listed on the Bombay Stock Exchange although at present the Government of India holds 84.5% (after divestment the stake by Indian government on 19th October, 2009) of its equity. With a current generating capacity of 34894 MW, NTPC has embarked on plans to become a 75,000 MW company by 2017. It was founded on November 7, 1975. NTPC's core business is engineering, construction and operation of power generating plants and providing consultancy to power utilities in India and abroad. The total installed capacity of the company is 34894 MW (including JVs) with 15 coal based and 7 gas based stations, located across the country. In addition under JVs, 5 stations are coal based & another station uses naphtha/LNG as fuel. By 2017, the power generation portfolio is expected to have a diversified fuel mix with coal based capacity of around 27,535 MW, 3,955 MW through gas, 1,328 MW through Hydro generation, about 000 MW from nuclear sources and around 1000 MW from Renewable Energy Sources (RES). NTPC has adopted a multi-pronged growth strategy which includes capacity addition through green field projects, expansion of existing stations, joint ventures, subsidiaries and takeover of stations. NTPC has been operating its plants at high efficiency levels. Although the company has 18.79% of the total national capacity it contributes 28.60% of total power generation due to its focus on high efficiency. NTPCs share at 31 Mar 2001 of the total installed capacity of the country was 24.51% and it generated 29.68% of the power of the country in 2008 09. Every fourth home in India is lit by NTPC. As
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at 31 Mar 2011 NTPC's share of the country's total installed capacity is 17.75% and it generated 27.4% of the power generation of the country in 201011. NTPC is lighting every third bulb in India. 170.88BU of electricity was produced by its stations in the financial year 20052006. The Net Profit after Tax on March 31, 2006 was INR 58,202 million. Net Profit after Tax for the quarter ended June 30, 2006 was INR 15528 million, which is 18.65% more than for the same quarter in the previous financial year. 2005). Pursuant to a special resolution passed by the Shareholders at the Companys Annual General Meeting on September 23, 2005 and the approval of the Central Government under section 21 of the Companies Act, 1956, the name of the Company "National Thermal Power Corporation Limited" has been changed to "NTPC Limited" with effect from October 28, 2005. The primary reason for this is the company's foray into hydro and nuclear based power generation along with backward integration by coal mining. (NTPC) is in the 138th position in Fortune 500 in 2009. 10 Indian companies make it to FT's top 500.
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POWER GENERATION AT BTPS
Stage
Unit No.
Installed Capacity(MW)
Date of Commissioning
Status
First
95
July 1973
Running
First
95
August 1974
Running
First
95
March 1975
Running
Second
210
December 1978
Running
Second
210
December 1981
Running
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THERMAL POWER PLANTS

A thermal power station is a power plant in which the prime mover is steam driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed in a condenser and recycled to where it was heated; this is known as a Rankine cycle. The greatest variation in the design of thermal power stations is due to the different fuel NTPC Vindhyanagar sources. Some prefer to use the term energy center because such facilities convert forms of heat energy into electricity. Some thermal power plants also deliver heat energy for industrial purposes, for district heating, or for desalination of water as well as delivering electrical power. A large part of human CO2 emissions comes from fossil fueled thermal power plants; efforts to reduce these outputs are various and widespread.
INTRODUCTORY OVERVIEW | ONE

Almost all coal, nuclear, geothermal, solar, thermal, electric and waste incineration plants, as well as many natural gas power plants are thermal. Natural gas is frequently combusted in gas turbines as well as boilers. The waste heat from a gas turbine can be used to raise steam, in a combined cycle plant that improves overall efficiency. Power plants burning coal, fuel oil, or natural gas are often called fossil-fuel power plants. Some biomass-fueled thermal power plants have appeared also. Non-nuclear thermal power plants, particularly fossil-fueled plants, which do not use co-generation, are sometimes referred to as conventional power plants. Commercial electric utility power stations are usually constructed on a large scale and designed for continuous operation. Electric power plants typically use three-phase electrical generators to produce alternating current (AC) electric power at a frequency of 50 Hz or 60 Hz. Large companies or institutions may have their own power plants to supply heating or electricity to their facilities, especially if steam is created anyway for other purposes. Steam-driven power plants have been used in various large ships, but are now usually used in large naval ships. Shipboard power plants usually directly couple the turbine to the ship's propellers through gearboxes. Power plants in such ships also provide steam to smaller turbines driving electric generators to supply electricity. Shipboard steam power plants can be either fossil fuel or nuclear. Nuclear marine propulsion is, with few
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exceptions, used only in naval vessels. There have been perhaps about a dozen turboelectric ships in which a steam-driven turbine drives an electric generator which powers an electric motor for propulsion. Combined heat and power (CH&P) plants, often called co-generation plants, produce both electric power and heat for process heat, space heating, or process heat. Steam and hot water lose energy when piped over substantial distance, so carrying heat energy by steam or hot water is often only worthwhile within a local area, such as a ship, industrial plant, or district heating of nearby buildings.
HISTORY | TWO
Reciprocating steam engines have been used for mechanical power sources since the 18th Century, with notable improvements being made by James Watt. The very first commercial central electrical generating stations in the Pearl Street Station, New York and the Holborn Viaduct power station, London, in 1882, also used reciprocating steam engines. The development of the steam turbine allowed larger and more efficient central generating stations to be built. By 1892 it was considered as an alternative to reciprocating engines. Turbines offered higher speeds, more compact machinery, and stable speed regulation allowing for parallel synchronous operation of generators on a common bus. Turbines entirely replaced reciprocating engines in large central stations after about 1905. The largest reciprocating engine-generator sets ever built were completed in 1901 for the Manhattan Elevated Railway. Each of seventeen units weighed about 500 tons and was rated 6000 kilowatts; a contemporary turbine-set of similar rating would have weighed about 20% as much.
EFFICIENCY | THREE
The energy efficiency of a conventional thermal power station, considered as salable energy as a percent of the heating value of the fuel consumed, is typically 33% to 48%. This efficiency is limited as all heat engines are governed by the laws of thermodynamics. The rest of the energy must leave the plant in the form of heat. This waste heat can go through a condenser and be disposed of with cooling water or in cooling towers. If the waste heat is instead utilized for district heating, it is called co-generation. An important class of thermal power station are associated with desalination facilities; these are typically found in desert countries with large supplies of natural gas and in these plants, freshwater production and electricity are equally important co-products. A Rankine cycle with a two-stage steam turbine and a single feed water heater.
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A Rankine cycle with a two-stage steam turbine and a single feed water heater. Page 8
Since the efficiency of the plant is fundamentally limited by the ratio of the absolute temperatures of the steam at turbine input and output, efficiency improvements require use of higher temperature, and therefore higher pressure, steam. Historically, other working fluids such as mercury have been used in a mercury vapor turbine power plant, since these can attain higher temperatures than water at lower working pressures. However, the obvious hazards of toxicity, high cost, and poor heat transfer properties, have ruled out mercury as a working fluid. Above the critical point for water of 705 F (374 C) and 3212 psi (22.06 MPa), there is no phase transition from water to steam, but only a gradual decrease in density. Boiling does not occur and it is not possible to remove impurities via steam separation. In this case a super critical steam plant is required to utilize the increased thermodynamic efficiency by operating at higher temperatures. These plants, also called once-through plants because boiler water does not circulate multiple times, require additional water purification steps to ensure that any impurities picked up during the cycle will be removed. This purification takes the form of high pressure ion exchange units called condensate polishers between the steam condenser and the feed water heaters. Sub-critical fossil fuel power plants can achieve 3640% efficiency. Super critical designs have efficiencies in the low to mid 40% range, with new "ultra critical" designs using pressures of 4400 psi (30.3 MPa) and dual stage reheat reaching about 48% efficiency. Current nuclear power plants operate below the temperatures and pressures that coalfired plants do. This limits their thermodynamic efficiency to 3032%. Some advanced reactor designs being studied, such as the Very high temperature reactor, advanced gascooled reactor and Super critical water reactor, would operate at temperatures and pressures similar to current coal plants, producing comparable thermodynamic efficiency.
COST OF ELECTRICITY | FOUR

The direct cost of electric energy produced by a thermal power station is the result of cost of fuel, capital cost for the plant, operator labour, maintenance, and such factors as ash handling and disposal. Indirect, social or environmental costs such as the economic value of environmental impacts, or environmental and health effects of the complete fuel cycle and plant decommissioning, are not usually assigned to generation costs for thermal stations in utility practice, but may form part of an environmental impact assessment.
BOILER AND STEAM CYCLE | FIVE

In fossil-fueled power plants, steam generator refers to a furnace that burns the fossil fuel to boil water to generate steam.
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In the nuclear plant field, steam generator refers to a specific type of large heat exchanger used in a pressurized water reactor (PWR) to thermally connect the primary (reactor plant) and secondary (steam plant) systems, which generates steam. In a nuclear reactor called a boiling water reactor (BWR), water is boiled to generate steam directly in the reactor itself and there are no units called steam generators. In some industrial settings, there can also be steam-producing heat exchangers called heat recovery steam generators (HRSG) which utilize heat from some industrial process. The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. Geothermal plants need no boiler since they use naturally occurring steam sources. Heat exchangers may be used where the geothermal steam is very corrosive or contains excessive suspended solids. A fossil fuel steam generator includes an economizer, a steam drum, and the furnace with its steam generating tubes and super heater coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include: forced draft (FD) fan, Air Preheater (AP), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or baghouse) and the flue gas stack.
Steam Boiler
Feed water heating and deaeration | One

The feed water used in the steam boiler is a means of transferring heat energy from the burning fuel to the mechanical energy of the spinning steam turbine. The total feed water consists of recirculated condensate water and purified makeup water. Because the metallic materials it contacts are subject to corrosion at high temperatures and pressures, the makeup water is highly purified before use. A system of water softeners and ion exchange demineralizers produces water so pure that it coincidentally becomes an electrical insulator, with conductivity in the range of 0.31.0 microsiemens per centimeter. The makeup water in a 500 MWe plant amounts to perhaps 20 US gallons per minute (1.25 L/s) to offset the small losses from steam leaks in the system.
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The feed water cycle begins with condensate water being pumped out of the condenser after traveling through the steam turbines. The condensate flow rate at full load in a 500 MW plant is about 6,000 US gallons per minute (400 L/s). The water flows through a series of six or seven intermediate feed water heaters, heated up at each point with steam extracted from an appropriate duct on the turbines and gaining temperature at each stage. Typically, the condensate plus the makeup water then flows through a deaerator that removes dissolved air from the water, further purifying and reducing its corrosiveness. The water may be dosed following this point with hydrazine, a chemical Diagram of boiler feed water deaerator (with vertical, domed aeration section and horizontal water storage that removes the remaining oxygen in the section water to below 5 parts per billion (ppb).[vague] It is also dosed with pH control agents such as ammonia or morpholine to keep the residual acidity low and thus non-corrosive.
Boiler Operation | Two

Once water inside the boiler or steam generator, the process of adding the latent heat of vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical reaction of burning some type of fuel. The water enters the boiler through a section in the convection pass called the economizer. From the economizer it passes to the steam drum. Once the water enters the steam drum it goes down to the lower inlet water wall headers. From the inlet headers the water rises through the water walls and is eventually turned into steam due to the heat being generated by the burners located on the front and rear water walls (typically). As the water is turned into steam/vapor in the water walls, the steam/vapor once again enters the steam drum. The steam/vapor is passed through a series of steam and water separators and then dryers inside the steam drum. The steam separators and dryers remove water droplets from the steam and the cycle through the water walls is repeated. This process is known as natural circulation. The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot blowers, water lancing and observation ports (in the furnace walls) for observation of the furnace interior. Furnace explosions due to any accumulation of combustible gases after a
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trip-out are avoided by flushing out such gases from the combustion zone before igniting the coal. The steam drum (as well as the super heater coils and headers) have air vents and drains needed for initial start up. The steam drum has internal devices that removes moisture from the wet steam entering the drum from the steam generating tubes. The dry steam then flows into the super heater coils.
Boiler Furnace and Steam Drum | Three

Once water inside the boiler or steam generator, the process of adding the latent heat of vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical reaction of burning some type of fuel. The water enters the boiler through a section in the convection pass called the economizer. From the economizer it passes to the steam drum. Once the water enters the steam drum it goes down to the lower inlet water wall headers. From the inlet headers the water rises through the water walls and is eventually turned into steam due to the heat being generated by the burners located on the front and rear water walls (typically). As the water is turned into steam/vapor in the water walls, the steam/vapor once again enters the steam drum. The steam/vapor is passed through a series of steam and water separators and then dryers inside the steam drum. The steam separators and dryers remove water droplets from the steam and the cycle through the water walls is repeated. This process is known as natural circulation. The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot blowers, water lancing and observation ports (in the furnace walls) for observation of the furnace interior. Furnace explosions due to any accumulation of combustible gases after a trip-out are avoided by flushing out such gases from the combustion zone before igniting the coal. The steam drum (as well as the super heater coils and headers) have air vents and drains needed for initial start up. The steam drum has internal devices that removes moisture from the wet steam entering the drum from the steam generating tubes. The dry steam then flows into the super heater coils.
Super Heater | Four

Fossil fuel power plants can have a super heater and/or re-heater section in the steam generating furnace. In a fossil fuel plant, after the steam is conditioned by the drying equipment inside the steam drum, it is piped from the upper drum area into tubes inside an area of the furnace known as the super heater, which has an elaborate set up of
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tubing where the steam vapor picks up more energy from hot flue gases outside the tubing and its temperature is now superheated above the saturation temperature. The superheated steam is then piped through the main steam lines to the valves before the high pressure turbine. Nuclear-powered steam plants do not have such sections but produce steam at essentially saturated conditions. Experimental nuclear plants were equipped with fossil-fired super heaters in an attempt to improve overall plant operating cost.
Steam Condensing | Five

The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be pumped. If the condenser can be made cooler, the pressure of the exhaust steam is reduced and efficiency of the cycle increases. The surface condenser is a shell and tube heat exchanger in which cooling water is circulated through the tubes. The exhaust steam from the low pressure turbine enters the shell where it is cooled and converted to condensate (water) by flowing over the tubes as shown in the adjacent diagram. Such condensers use steam ejectors or rotary motor-driven exhausters for continuous removal of air and gases from the steam side to maintain vacuum. For best efficiency, the temperature in the condenser must be kept as low as practical in order to achieve the lowest possible pressure in the condensing steam. Since the condenser temperature can almost always be kept significantly below 100 C where the vapor pressure of water is much less than atmospheric pressure, the condenser generally works under vacuum. Thus leaks of non-condensible air into the closed loop must be prevented. Typically the cooling water causes the steam to condense at a temperature of about 35 C (95 F) and that creates an absolute pressure in the condenser of about 27 kPa (Template:Convert/in Hg), i.e. a vacuum of about 95 kPa (Template:Convert/in Hg) relative to atmospheric pressure. The large decrease in volume that occurs when water vapor condenses to liquid creates the low vacuum that helps pull steam through and increase the efficiency of the turbines. The limiting factor is the temperature of the cooling water and that, in turn, is limited by the prevailing average climatic conditions at the power plant's location (it may be possible to lower the temperature beyond the turbine limits during winter, causing excessive condensation in the turbine). Plants operating in hot climates may have to reduce output if their source of condenser cooling water becomes warmer; unfortunately this usually coincides with periods of high electrical demand for air conditioning.
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The condenser generally uses either circulating cooling water from a cooling tower to reject waste heat to the atmosphere, or once-through water from a river, lake or ocean. The heat absorbed by the circulating cooling water in the condenser tubes must also be removed to maintain the ability of the water to cool as it circulates. This is done by pumping the warm water from the condenser through either natural draft, forced draft or induced draft cooling towers (as seen in the image to the right) that reduce the temperature of the water by evaporation, by about 11 to 17 C (20 to 30 F)expelling waste heat to the atmosphere. The circulation flow rate of the cooling water in a 500 MW unit is about 14.2 m/s (500 ft/s or 225,000 US gal/min) at full load. The condenser tubes are made of brass or stainless steel to Diagram of a typical water-cooled surface condenser resist corrosion from either side. Nevertheless they may become internally fouled during operation by bacteria or algae in the cooling water or by mineral scaling, all of which inhibit heat transfer and reduce thermodynamic efficiency. Many plants include an automatic cleaning system that circulates sponge rubber balls through the tubes to scrub them clean without the need to take the system off-line. The cooling water used to condense the steam in the condenser returns to its source without having been changed other than having been warmed. If the water returns to a local water body (rather than a circulating cooling tower), it is tempered with cool 'raw' water to prevent thermal shock when discharged into that body of water. Another form of condensing system is the air-cooled condenser. The process is similar to that of a radiator and fan. Exhaust heat from the low pressure section of a steam turbine runs through the condensing tubes, the tubes are usually finned and ambient air is pushed through the fins with the help of a large fan. The steam condenses to water to be reused in the water-steam cycle. Air-cooled condensers typically operate at a higher temperature than water cooled versions. While saving water, the efficiency of the cycle is reduced (resulting in more carbon dioxide per megawatt of electricity).
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From the bottom of the condenser, powerful condensate pumps recycle the condensed steam (water) back to the water/steam cycle.
Re Heater | Six
Power plant furnaces may have a re heater section containing tubes heated by hot flue gases outside the tubes. Exhaust steam from the high pressure turbine is rerouted to go inside the re heater tubes to pickup more energy to go drive intermediate or lower pressure turbines.
Air Path | Seven

External fans are provided to give sufficient air for combustion. The forced draft fan takes air from the atmosphere and, first warming it in the air preheater for better combustion, injects it via the air nozzles on the furnace wall. The induced draft fan assists the FD fan by drawing out combustible gases from the furnace, maintaining a slightly negative pressure in the furnace to avoid backfiring through any opening.
STEAM TURBINE GENERATOR | SIX

The turbine generator consists of a series of steam turbines interconnected to each other and a generator on a common shaft. There is a high pressure turbine at one end, followed by an intermediate pressure turbine, two low pressure turbines, and the generator. As steam moves through the system and loses pressure and thermal energy it expands in volume, requiring increasing diameter and longer blades at each succeeding stage to extract the remaining energy. The entire rotating mass may be over 200 metric tons and 100 feet (30 m) long. It is so heavy that it must be kept turning slowly even when shut down (at 3 rpm) so that the shaft will not bow even slightly and become unbalanced. This is so important that it is one of only five functions of blackout emergency power batteries on site. Other functions are emergency lighting, communication, station alarms and turbogenerator lube oil. Superheated steam from the boiler is delivered through 1416-inch (360410 mm) diameter piping to the high pressure turbine where it falls in pressure to 600 psi (4.1 MPa) and to 600 F (320 C) in temperature through the stage. It exits via 2426-inch (610 660 mm) diameter cold reheat lines and passes back into the boiler where the steam is reheated in special reheat pendant tubes back to 1,000 F (500 C). The hot reheat steam is conducted to the intermediate pressure turbine where it falls in both temperature and pressure and exits directly to the long-bladed low pressure turbines and finally exits to the condenser.
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The generator, 30 feet (9 m) long and 12 feet (3.7 m) in diameter, contains a stationary stator and a spinning rotor, each containing miles of heavy copper conductor - no permanent magnets here. In operation it generates up to 21,000 amperes at 24,000 volts AC (504 MWe) as it spins at either 3,000 or 3,600 rpm, synchronized to the power grid. The rotor spins in a sealed chamber cooled with hydrogen gas, selected because it has the highest known heat transfer coefficient of any gas and for its low viscosity which reduces windage losses. This system requires special handling during startup, with air in the chamber first displaced by carbon dioxide before filling with hydrogen. This ensures that the highly explosive hydrogen oxygen environment is not created. The power grid frequency is 60 Hz across North America and 50 Hz in Europe, Oceania, Asia (Korea and parts of Japan are notable exceptions) and parts of Africa. The electricity flows to a distribution yard where transformers step the Rotor of a modern steam turbine, used in a power station voltage up to 115, 230, 500 or 765 kV AC as needed for transmission to its destination. The steam turbine-driven generators have auxiliary systems enabling them to work satisfactorily and safely. The steam turbine generator being rotating equipment generally has a heavy, large diameter shaft. The shaft therefore requires not only supports but also has to be kept in position while running. To minimize the frictional resistance to the rotation, the shaft has a number of bearings. The bearing shells, in which the shaft rotates, are lined with a low friction material like Babbitt metal. Oil lubrication is provided to further reduce the friction between shaft and bearing surface and to limit the heat generated.
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ELECTRICAL MAINTAINANCE DEPARTMENT I

I was trained under the electrical maintenance department 1 from 29th June to 9th July. This department maintains the basic electrical section of the industry. Following things came under this section of my training LT/HT Motors. Turbine and boiler side LT/HT Switchgear Coal Handling Plant/New coal Handling Plant(CHP/NCHP) Electrical
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L. T. / H. T. MOTORS
TURBINE & BOILER SIDE MOTORS
Both high tension and low tension motors are installed in the power plant.
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For Unit 1, 2, 3 Used in Quantity
I.D. Fans
F.D. Fans
P.A. Fans
Mill Fans
Ball Mill Fans
RC Feeders
Slag Crusher
DM makeup pump
PC Feeders
Worm Conveyor
Furnikets
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For Unit 3, 4 Used in Quantity
I.D. Fan
F.D. Fan
P.A. Fan
Bowl Mills
RC Feeders
Clinker Grinder
Scrapper
Seal Air Fans
Hydrazine and Phosphorous Dozing
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L. T. / H. T. SWITCHGEAR
It makes or breaks an electrical circuit.
Isolation | One
A device which breaks an electrical circuit when circuit is switched on to no load. Isolation is normally used in various ways for purpose of isolating a certain portion when required for maintenance.
Switching Isolation | Two

It is capable of doing things like interrupting transformer magnetized current, interrupting line charging current and even perform load transfer switching. The main application of switching isolation is in connection with transformer feeders as unit makes it possible to switch out one transformer while other is still on load.
Circuit Breakers | Three

One which can make or break the circuit on load and even on faults is referred to as circuit Electrical Switchgear breakers. This equipment is the most important and is heavy duty equipment mainly utilized for protection of various circuits and operations on load. Normally circuit breakers installed are accompanied by isolators.
Load Break Switches | Four

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

Devices which are used normally to earth a particular system, to avoid any accident happening due to induction on account of live adjoining circuits. These equipment do not handle any appreciable current at all. Apart from this equipment there are a number of relays etc. which are used in switchgear.
LOW TENSION SWITCHGEAR | ONE

It is classified in following ways:-
Main Switch | One

Main switch is control equipment which controls or disconnects the main supply. The main switch for 3 phase supply is available for tha range 32A, 63A, 100A, 200Q, 300A at 500V grade.
Fuses | Two
With Avery high generating capacity of the modern power stations extremely heavy carnets would flow in the fault and the fuse clearing the fault would be required to withstand extremely heavy stress in process. It is used for supplying power to auxiliaries with backup fuse protection. Rotary switch up to 25A. With fuses, quick break, quick make and double break switch fuses for 63A and 100A, switch fuses for 200A, 400A, 600A, 800A and 1000A are used.
Contractors | Three
AC Contractors are 3 poles suitable for D.O.L Starting of motors and protecting the connected motors.
Overload Relay | Four

For overload protection, thermal over relay are best suited for this purpose. They operate due to the action of heat generated by passage of current through relay element.
Air Circuit Breakers | Five

It is seen that use of oil in circuit breaker may cause a fire. So in all circuits breakers at large capacity air at high pressure is used which is maximum at the time of quick tripping of contacts. This reduces the possibility of sparking. The pressure may vary from 50-60 kg/cm^2 for high and medium capacity circuit breakers.
HIGH TENSION SWITCHGEAR | TWO

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Classified in following ways
Minimum Oil Circuit Breaker | One

These use oil as quenching medium. It comprises of simple dead tank row pursuing projection from it. The moving contracts are carried on an iron arm lifted by a long insulating tension rod and are closed simultaneously pneumatic operating mechanism by means of tensions but throw off spring to be provided at mouth of the control the main current within the controlled device. Type HKH 12/1000c Rated Voltage 66 KV Normal Current 1250A Frequency 5Hz Breaking Capacity
3.4+ KA Symmetrical 3.4+ KA Asymmetrical 360 MVA Symmetrical
Operating Coils
CC 220V/DC FC 220V/DC
Motor Voltage 220V/DC
Air Circuit Breaker | Two

In this the compressed air pressure around 15 kg per cm2 is used for extinction of arc caused by flow of air around the moving circuit. The breaker is closed by applying pressure at lower opening and opened by applying pressure at upper opening. When contacts operate, the cold air rushes around the movable contacts and blown the arc. It has the following advantages over OCB : Fire hazard due to oil are eliminated. Operation takes place quickly. There is less burning of contacts since the duration is short and consistent.
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Facility for frequent operation since the cooling medium is replaced constantly. Rated Voltage 6.6 KV Current 630 A Auxiliary Current 220V/DC
SF6 Circuit Breaker | Three

This type of circuit breaker is of construction to dead tank bulk oil to circuit breaker but the principle of current interruption is similar o that of air blast circuit breaker. It simply employs the arc extinguishing medium namely SF6. the performance of gas . When it is broken down under an electrical stress. It will quickly reconstitute itself. Circuit Breaker HPA Standard 1 EC 56 Rated Voltage 12 KV Insulation Level 28/75 KV Rated Frequency 50 Hz Breaking Circuit 40 KA Rated Current 1600 KA Making Capacity 110 KA Rated Short Time Current 1/3 sec 40 A Mass Approximation 185 Kg Auxiliary Voltage
Closing Coil 220V/DC Opening Coil 220V/DC
Motor 220V/DC SF6 Pressure at 20 Degree Celsius 0.25 Kg SF6 Gas Per Pole 0.25 Kg
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Vacuum Circuit Breaker | Four

It works on the principle that vacuum is used to save the purpose of insulation and it implies that pr. Of gas at which breakdown voltage independent of pressure. It regards of insulation and strength, vacuum is superior dielectric medium and is better that all other medium except air and sulphur which are generally used at high pressure. Rated Frequency 50 Hz Rated Making Current 10 Peak KA Rated Voltage 12 KV Supply Voltage Closing 220V/DC Rated Current - 1250 A Supply Voltage Tripping 220V/DC Insulation Level IMP 75 KVP Rated Short Time Current 3sec 40 KA Weight of Breaker 8Kg
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C. H. P. / N. C. H. P.
C O L D H A N D L I N G P L A N T / N E W C OA L H A N D L I N G P L A N T
COAL HANDLING PLANT | ONE

The old coal handling plant caters to the need of units 2,3,4,5 and 1 whereas the latter supplies coal to units 4 and V.O.C.H.P. supplies coal to second and third stages in the advent coal to usable form to (crushed) form its raw form and send it to bunkers, from where it is send to furnace. Major components
Wagon Tippler | One

Wagons from the coal yard come to the tippler and are emptied here. The process is performed by a slip ring motor of rating: 55 KW, 415V, 1480 Coal Handling Plant RPM. This motor turns the wagon by 135 degrees and coal falls directly on the conveyor through vibrators. Tippler has raised lower system which enables is to switch off motor when required till is wagon back to its original position. It is titled by weight balancing principle. The motor lowers the hanging balancing weights, which in turn tilts the conveyor. Estimate of the weight of the conveyor is made through hydraulic weighing machine.
Conveyor | Two
There are 14 conveyors in the plant. They are numbered so that their function can be easily demarcated. Conveyors are made of rubber and more with a speed of 250300m/min. Motors employed for conveyors has a capacity of 150 HP. Conveyors have a capacity of carrying coal at the rate of 400 tons per hour. Few conveyors are double belt, this is done for imp. Conveyors so that if a belt develops any problem the process is not stalled. The conveyor belt has a switch after every 25-30 m on both sides so stop the belt in case of emergency. The conveyors are 1m wide, 3 cm thick and made of chemically treated vulcanized rubber. The max angular elevation of conveyor is designed such as never to exceed half of the angle of response and comes out to be around 20 degrees.
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Zero Speed Switch | Three

It is safety device for motors, i.e., if belt is not moving and the motor is on the motor may burn. So to protect this switch checks the speed of the belt and switches off the motor when speed is zero.
Metal Separators | Four

As the belt takes coal to the crusher, No metal pieces should go along with coal. To achieve this objective, we use metal separators. When coal is dropped to the crusher hoots, the separator drops metal pieces ahead of coal. It has a magnet and a belt and the belt is moving, the pieces are thrown away. The capacity of this device is around 50 kg. .The CHP is supposed to transfer 600 tons of coal/hr, but practically only 300-400 tons coal is transfer.
Crusher | Five
Both the plants use TATA crushers powered by BHEL. Motors. The crusher is of ring type and motor ratings are 400 HP, 606 KV. Crusher is designed to crush the pieces to 20 mm size i.e. practically considered as the optimum size of transfer via conveyor.
Rotatory Breaker | Six

OCHP employs mesh type of filters and allows particles of 20mm size to go directly to RC bunker, larger particles are sent to crushes. This leads to frequent clogging. NCHP uses a technique that crushes the larger of harder substance like metal impurities easing the load on the magnetic separators.
Crusher House
MILLING SYSTEM | TWO

RC Bunker | One
Raw coal is fed directly to these bunkers. These are 3 in no. per boiler. 4 & tons of coal are fed in 1 hr. the depth of bunkers is 10m.
RC Feeder | Two
It transports pre crust coal from raw coal bunker to mill. The quantity of raw coal fed in mill can be controlled by speed control of aviator drive controlling damper and aviator change.
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Ball Mill | Three

The ball mill crushes the raw coal to a certain height and then allows it to fall down. Due to impact of ball on coal and attraction as per the particles move over each other as well as over the Armor lines, the coal gets crushed. Large particles are broken by impact and full grinding is done by attraction. The Drying and grinding option takes place simultaneously inside the mill.
Classifier | Four
It is an equipment which serves separation of fine pulverized coal particles medium from coarse medium. The pulverized coal along with the carrying medium strikes the impact plate through the lower part. Large particles are then transferred to the ball mill.
Cyclone Separators | Five

It separates the pulverized coal from carrying medium. The mixture of pulverized coal vapour caters the cyclone separators.
The Turniket | Six

It serves to transport pulverized coal from cyclone separators to pulverized coal bunker or to worm conveyors. There are 4 turnikets per boiler.
Worm Conveyor | Seven

It is equipment used to distribute the pulverized coal from bunker of one system to bunker of other system. It can be operated in both directions.
Mill Fans | Eight

It is of three types. Six in all are in running condition all the time. ID Fans | One Located between electrostatic precipitators and chimney. Type Radial Speed 1490 rpm Rating 300 KW Voltage 6.6 KV Lubrication by Oil
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FD Fans | Two Designed to handle secondary air for boiler. 2 in number and provide ignition of coal. Type axial Speed 990rpm Rating 440 KW Voltage 6.6 KV Primary Air Fans | Three Designed for handling the atmospheric air up to 50 degrees Celsius, 2 in number. And they transfer the powered coal to burners to firing. Type Double Suction Radial Rating 300 KW Voltage 6.6 KV Lubrication by Oil Type of Operation Continuous
Bowl Mill | Nine

One of the most advanced designs of coal pulverizes presently manufactured. Motor Specification Squirrel Caged Induction Motor Rating 340 KW Voltage 6600 KV Current 41.7 A Speed 980 rpm Frequency 50Hz No load current 15-16 A
NEW COAL HANDLING PLANT | THREE

WAGON TIPPLER
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Motor specification Horse power Voltage Speed Frequency Current Rating -
75 HP 415, 3 phase 1480 rpm 50 Hz 102 A
COAL FEED TO PLANT Feed Motor Specification Horse Power 15 HP Voltage 415V, 3 phase Speed 1480 rpm Frequency 50Hz CONVEYORS 10A, 10B 11A, 11B 12A, 12B 13A, 13B 14A, 14B 15A, 15B 16A, 16B 17A, 17B 18A, 18B TRANSFER POINT 6 BREAKER HOUSE REJECTION HOUSE RECLAIM HOUSE TRANSFER POINT 7 CRUSHER HOUSE EXIT
The coal arrives in wagons via railways and is tippled by the wagon tipplers into the hoppers. If coal is oversized (>400 mm sq) then it is broken manually so that it passes the hopper mesh. From the hopper mesh it is taken to the transfer point TP6
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by conveyor 12A ,12B which takes the coal to the breaker house , which renders the coal size to be 100mm sq. the stones which are not able to pass through the 100mm sq of hammer are rejected via conveyors 18A,18B to the rejection house . Extra coal is to sent to the reclaim hopper via conveyor 16. From breaker house coal is taken to the TP7 via Conveyor 13A, 13B. Conveyor 17A, 17B also supplies coal from reclaim hopper, From TP7 coal is taken by conveyors 14A, 14B to crusher house whose function is to render the size of coal to 20mm sq. now the conveyor labors are present whose function is to recognize and remove any stones moving in the conveyors . In crusher before it enters the crusher. After being crushed, if any metal is still present it is taken care of by metal detectors employed in conveyor 10.
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ELECTRICAL MAINTAINENCE DEPARTMENT II

I was trained under the electrical maintenance department 2 from 9th July to 18th July. This department maintains the basic electrical section of the industry. Following things came under this section of my training Generator and Transformer Switchyard Lightening
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GENERATOR AND AUXILIARIES

The transformation of mechanical energy into electrical energy is carried out by the Generator. This Chapter seeks to provide basic understanding about the working principles and development of Generator.
WORKING PRINCIPLE | ONE

The A.C. Generator or alternator is based upon the principle of electromagnetic induction and consists generally of a stationary part called stator and a rotating part called rotor. The stator housed the armature windings. The rotor houses the field windings. D.C. voltage is applied to the field windings through slip rings. When the rotor is rotated, the lines of magnetic flux (viz magnetic field) cut through the stator windings. This induces an electromagnetic force (e.m.f.) in the stator windings. The magnitude of this e.m.f. is given by the following expression. E 0 F N F = 4.44 /O FN volts = Strength of magnetic field in Webers = Frequency in cycles per second or hertz = Number of turns in a coil of stator winding = Frequency = Pn/120, where P = nos. of plates, n = revolutions per second of rotor
From the expression it is clear that for the same frequency, number of poles increases with decrease in speed and vice versa. Therefore, low speed hydro turbine drives generators have 14 to 20 poles where as high speed steam turbine driven generators have generally 2 poles. Pole rotors are used in low speed generators, because the cost advantage as well as easier, construction.
DEVELOPMENT | TWO
The first A.C. Generator concept was enunciated by Michael Faraday in 1831. In 1889 Sir Charles A. Parsons developed the first AC turbo-generator. Although slow speed AC generators have been built for some time, it was not long before that the high-speed generators made its impact.
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Development contained until, in 1922, the increased use of solid forgings and improved techniques permitted an increase in generator rating to 20MW at 300rpm. Up to the out break of second world war, in 1939, most large generator;- were of the order of 30 to 50 MW at 3000 rpm. During the war, the development and installation of power plants was delayed and in order to catch up with the delay in plant installation, a large number of 30 MW and 60 MW at 3000 rpm units were constructed during the years immediately following the war. The changes in design in this period were relatively small. In any development programme the. Costs of material and labour involved in manufacturing and erection must be a basic consideration. Coupled very closely with these considerations is the restriction is size and weight imposed Steam Turbo Generator by transport limitations. Development of suitable insulating materials for large turbo-generators is one of the most important tasks and need continues watch as size and ratings of machines increase. The present trend is the use only class "B" and higher grade materials and extensive work has gone into compositions of mica; glass and asbestos with appropriate bonding material. An insulation to meet the stresses in generator slots must follow very closely the thermal expansion of the insulated conductor without cracking or any plastic deformation. Insulation for rotor is subjected to lower dielectric stress but must withstand high dynamic stresses and the newly developed epoxy resins, glass and/or asbestos molded in resin and other synthetic resins are finding wide applications.
GENERATOR COMPONENT | THREE

Rotor | One
The electrical rotor is the most difficult part of the generator to design. It revolves in most modern generators at a speed of 3,000 revolutions per minute. The problem of guaranteeing the dynamic strength and operating stability of such a rotor is complicated by the fact that a massive non-uniform shaft subjected to a multiplicity of differential stresses must operate in oil lubricated sleeve bearings supported by a structure mounted on foundations all of which possess complex dynamic be behavior peculiar to
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themselves. It is also an electromagnet and to give it the necessary magnetic strength the windings must carry a fairly high current. The passage of the current through the windings generates heat but the temperature must not be allowed to become so high, otherwise difficulties will be experienced with insulation. To keep the temperature down, the cross section of the conductor could not be increased but this would introduce another problems. In order to make room for the large conductors, body and this would cause mechanical weakness. The problem is really to get the maximum amount of copper into the windings without reducing the mechanical strength. With good design and great care in construction this can be achieved. The rotor is a cast steel ingot, and it is further forged and machined. Very often a hole is bored through the centre of the rotor axially from one end of the other for inspection. Slots are then machined for windings and ventilation.
Rotor Winding | Two

Silver bearing copper is used for the winding with mica as the insulation between conductors. A mechanically strong insulator such as micanite is used for lining the slots. Later designs of windings for large rotor incorporate combination of hollow conductors with slots or holes arranged to provide for circulation of the cooling gas through the actual conductors. When rotating at high speed. Centrifugal force tries to lift the windings out of the slots and they are contained by wedges. The end rings are secured to a turned recess in the rotor body, by shrinking or screwing and supported at the other end by fittings carried by the rotor body. The two ends of windings are connected to slip rings, usually made of forged steel, and mounted on insulated sleeves.
Rotor Balancing | Three

When completed the rotor must be tested for mechanical balance, which means that a check is made to see if it will run up to normal speed without vibration. To do this it would have to be uniform about its central axis and it is most unlikely that this will be so to the degree necessary for perfect balance. Arrangements are therefore made in all designs to fix adjustable balance weights around the circumference at each end.
Stator | Three
Stator frame: The stator is the heaviest load to be transported. The major part of this load is the stator core. This comprises an inner frame and outer frame. The outer frame is a rigid fabricated structure of welded steel plates, within this shell is a fixed cage of girder built circular and axial ribs. The ribs divide the yoke in the compartments through which hydrogen flows into radial ducts in the stator core and circulate through the gas coolers housed in the frame. The inner cage is usually fixed in to the yoke by an arrangement of springs to dampen the double frequency vibrations inherent in 2 pole generators. The end
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shields of hydrogen cooled generators must be strong enough to carry shaft seals. In large generators the frame is constructed as two separate parts. The fabricated inner cage is inserted in the outer frame after the stator core has been constructed and the winding completed. Stator core: The stator core is built up from a large number of 'punching" or sections of thin steel plates. The use of cold rolled grain-oriented steel can contribute to reduction in the weight of stator core for two main reasons: There is an increase in core stacking factor with improvement in lamination cold rolling and in cold buildings techniques. The advantage can be taken of the high magnetic permeance of grainoriented steels of work the stator core at comparatively high magnetic saturation without fear or excessive iron loss of two heavy a demand for excitation ampere turns from the generator rotor.
Stator Winding | Four

Each stator conductor must be capable of carrying the rated current without overheating. The insulation must be sufficient to prevent leakage currents flowing between the phases to earth. Windings for the stator are made up from copper strips wound with insulated tape which is impregnated with varnish, dried under vacuum and hot pressed to form a solid insulation bar. These bars are then place in the stator slots and held in with wedges to form the complete winding which is connected together at each end of the core forming the end turns. These end turns are rigidly braced and packed with blocks of insulation material to withstand the heavy forces which might result from a short circuit or other fault conditions. The generator terminals are usually arranged below the stator. On recent generators (210 MW) the windings are made up from copper tubes instead of strips through which water is circulated for cooling purposes. The water is fed to the windings through plastic tubes.
GENERATOR COOLING SYSTEM | FOUR

Rotor Cooling System | One
The rotor is cooled by means of gap pick-up cooling, wherein the hydrogen gas in the air gap is sucked through the scoops on the rotor wedges and is directed to flow along the ventilating canals milled on the sides of the rotor coil, to the bottom of the slot where it takes a turn and comes out on the similar canal milled on the other side of the rotor coil to the hot zone of the rotor. Due to the rotation of the rotor, a positive suction as well as discharge is created due to which a certain quantity of gas flows and cools the rotor. This method of cooling gives uniform distribution of temperature. Also, this method has an
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inherent advantage of eliminating the deformation of copper due to varying temperatures.
Hydrogen Cooling System | Two

Hydrogen is used as a cooling medium in large capacity generator in view of its high heat carrying capacity and low density. But in view of its forming an explosive mixture with oxygen, proper arrangement for filling, purging and maintaining its purity inside the generator have to be made. Also, in order to prevent escape of hydrogen from the generator casing, shaft sealing system is used to provide oil sealing. The hydrogen cooling system mainly comprises of a gas control stand, a drier, an liquid level indicator, hydrogen control panel, gas purity measuring and indicating instruments. The system is capable performing the following functions Filling in and purging of hydrogen safely without bringing in contact with air. Maintaining the gas pressure inside the machine at the desired value at all the times. Provide indication to the operator about the condition of the gas inside the machine i.e. its pressure, temperature and purity. Continuous circulation of gas inside the machine through a drier in order to remove any water vapour that may be present in it. Indication of liquid level in the generator and alarm in case of high level.
Stator Cooling System | Three

The stator winding is cooled by distillate which is fed from one end of the machine by Teflon tube and flows through the upper bar and returns back through the lower bar of another slot. Turbo generators require water cooling arrangement over and above the usual hydrogen cooling arrangement. The stator winding is cooled in this system by circulating demineralized water (DM water) through hollow conductors. The cooling water used for cooling stator winding calls for the use of very high quality of cooling water. For this purpose DM water of proper specific resistance is Air inlets for cooling selected. Generator is to be loaded within a very short period if the specific resistance of the cooling DM water goes beyond certain preset
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values. The system is designed to maintain a constant rate of cooling water flow to the stator winding at a nominal inlet water temperature of 40 deg C.
RATING OF GENERATORS IN NTPC | FIVE

95 MW Generator | One
Manufacture by Bharat heavy electrical Limited (BHEL). Capacity Voltage Speed Hydrogen Power Factor Stator Current Frequency Stator wdg conn 117500 KVA 10500V 3000 rpm 2.5 Kg/cm2 0.85 (lagging) 6475 A 50 Hz 3 phase
210 MW Generator | Two

Manufacture by Bharat heavy electrical Limited (BHEL). Capacity Voltage (stator) Current (stator) Voltage (rotor) Current (rotor) Speed Power Factor Frequency Hydrogen Stator wdg conn Insulation Class 247000 KVA 15750 V 9050 A 310 V 2600 A 3000 rpm 0.85 50 Hz 3.5 Kg/cm2 3 phase stator connection B
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TRANSFORMER
A transformer is a device that transfers electrical energy from one circuit to another by magnetic coupling with out requiring relative motion between its parts. It usually comprises two or more coupled windings, and in most cases, a core to concentrate magnetic flux. An alternating voltage applied to one winding creates a time-varying magnetic flux in the core, which includes a voltage in the other windings. Varying the relative number of turns between primary and secondary windings determines the ratio of the input and output voltages, thus transforming the voltage by stepping it up or down between circuits. By transforming electrical power to a high-voltage,_low-current form and back again, the transformer greatly reduces energy losses and so enables the economic transmission of power over long distances. It has thus shape the electricity supply industry, permitting generation to be located remotely from point of demand. All but a fraction of the worlds electrical power has passed trough a series of transformer by the time it reaches the consumer.
BASIC PRINCIPLES | ONE

The principles of the transformer are illustrated by consideration of a hypothetical ideal transformer consisting of two windings of zero resistance around a core of negligible reluctance. A voltage applied to the primary winding causes a current, which develops a
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magneto motive force (MMF) in the core. The current required to create the MMF is termed the magnetizing current; in the ideal transformer it is considered to be negligible, although its presence is still required to drive flux around the magnetic circuit of the core. An electromotive force (MMF) is induced across each winding, an effect known as mutual inductance. In accordance with faradays law of induction, the EMFs are proportional to the rate of change of flux. The primary EMF, acting as it does in opposition to the primary voltage, is sometimes termed the back EMF.
ENERGY LOSSES | TWO

An ideal transformer would have no energy losses and would have no energy losses, and would therefore be 100% efficient. Despite the transformer being amongst the most efficient of electrical machines with ex the most efficient of electrical machines with experimental models using superconducting windings achieving efficiency of 99.85%, energy is dissipated in the windings, core, and surrounding structures. Larger transformers are generally more efficient, and those rated for electricity distribution usually perform better than 95%. A small transformer such as plug-in power brick used for low-power consumer electronics may be less than 85% efficient. Transformer losses are attributable to several causes and may be differentiated between those originated in the windings, sometimes termed copper loss, and those arising from the magnetic circuit, sometimes termed iron loss. The losses vary with load current, and may furthermore be expressed as no load or full load loss, or at an intermediate loading. Winding resistance dominates load losses contribute to over 99% of the no-load loss can be significant, meaning that even an idle transformer constitutes a drain on an electrical supply, and lending impetus to development of low-loss transformers. Losses in the transformer arise from:
Winding resistance | One

Current flowing through the windings causes resistive heating of the conductors. At higher frequencies, skin effect and proximity effect create additional winding resistance and losses.
Hysteresis losses | Two

Each time the magnetic field is reversed, a small amount of energy is lost due to hysteresis within the core. For a given core material, the loss is proportional to the frequency, and is a function of the peak flux density to which it is subjected.
Eddy current | Three

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Ferromagnetic materials are also good conductors, and a solid core made from such a material also constitutes a single short-circuited turn trough out its entire length. Eddy currents therefore circulate with in a core in a plane normal to the flux, and are responsible for resistive heating of the core material. The eddy current loss is a complex function of the square of supply frequency and inverse square of the material thickness.
Magnetostriction | Four
Magnetic flux in a ferromagnetic material, such as the core, causes it to physically expand and contract slightly with each cycle of the magnetic field, an effect known as magnetostriction. This produces the buzzing sound commonly associated with transformers, and in turn causes losses due to frictional heating in susceptible cores.
Mechanical losses | Five

In addition to magnetostriction, the Power Transformer alternating magnetic field causes fluctuating electromagnetic field between primary and secondary windings. These incite vibration with in near by metal work, adding to the buzzing noise, and consuming a small amount of power.
Stray losses | Six

Leakage inductance is by itself loss less, since energy supplied to its magnetic fields is returned to the supply with the next half-cycle. However, any leakage flux that intercepts nearby conductive material such as the transformers support structure will give rise to eddy currents and be converted to heat.
COOLING SYSTEMS | THREE

Large power transformers may be equipped with cooling fans, oil pumps or water-cooler heat exchangers design to remove heat. Power used to operate the cooling system is typically considered part of the losses of the transformer.
RATING | FOUR
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Manufactured by Bharat heavy electrical limited. No Load Voltage (hv) Line Current Temperature Rise Oil Quantity Weight of Oil Total Weight Core and Winding Phase Frequency 229 KV 315.2 A 45 deg Celsius 40180 L 34985 Kg 147725 Kg 84325 Kg 3 50 Hz
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220 KV SWITCHYARD
BUS BARS | ONE
The arrangement in the 220kV switchyard comprises of a 220kV double bus bar system, with a bus coupler and a bypass bus. With this arrangement it is possible to take out any one breaker for maintenance without interruption of supply. In the eventuality of a bus bar or a circuit breaker fault the period for which supply is interrupted is the time taken to transfer the feeders from the faulty bus to the healthy one or replacing the faulty circuit breaker by the bypass breaker. It is only in the case of a line fault that supply cannot be restored to the feeder until the fault is rectified. For maintenance of a particular bus all feeders connected to the bus requiring the maintenance shall be transferred to the Switchyard other bus by closing one bus isolator and opening the other. The bus coupler shall be tripped and the earthing switch closed. After the maintenance work is over, the earthing switch must be opened before the respective bus bar is energized. For maintenance of the by-pass bus, it should be ensured that by-pass breaker is open and all the bypass isolators of various bays are open.
220 KV CIRCUIT BREAKER | TWO

There are two types of 220kV breakers being used in BTPS switchyard: Air blast circuit breaker SF6 circuit breaker
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These breakers operate with sequential isolators and suitable for three-phase autoreclosing facility. These breakers can be operated from the switch yard control board. In case of failure, emergency manual handles are provided in the control kiosk.
Feeder breaker | One

When it is required to maintain either a line or a generator or a transformer breaker, the feeder is transferred to the by-pass breaker. The earthing switches on isolators must be earthed before maintaining the breaker.
By-pass breaker | Two

The main purpose of the bypass breaker is to facilitate maintenance/repair of other 220 kV breakers without the necessity of tripping out the associated circuit.
Bus coupler breaker | Three

The two bus bars can be kept coupled through bus couplers. The by pass breaker cannot act as a substitute for bus coupler breaker when the bus coupler breaker is being maintained. If buses I and II are paralleled by means of bus coupler and by pass breaker then in order to maintain the bus coupler breaker all feeders must be transferred to one bus depending upon the prevalent load.
RATINGS OF CIRCUIT BREAKERS | THREE

Air Blast Circuit Breaker | BHEL
Volts Amperes Breaking Capacity
Symmetrical Equivalent -
220 KV 1200 A
26.31 KA 10000 MVA 32.1 KA
Asymmetrical -
Making Capacity Short Circuit Time Closing Coil Voltage Tripping Coil Voltage Working Pressure

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peak 67.1 KA 3 sec 26.3 KA 220 V DC 220 V DC
Max Min
28.1 Kg/cm2-g 26.0 Kg/cm2-g
Lockout Pressure
21.1 Kg/cm2-g
Air Blast Circuit Breaker | ABB

Volts Amperes Breaking Capacity

245 KV 1200 A
Symmetrical Asymmetrical -
31.5 KA 38.4 KA
Short Circuit Time Closing Coil Voltage Tripling Coil Voltage RIL at 50 Hz VI Impulse U Switching Impulse Mass Working Pressure
3 sec 31.5 KA 220 V DC 220 V DC 480 KV 1.2/50 s 1050 KV per sec first pole to clear 1.3 1830 Kg Max 27.31 kg/cm2-g
Air Blast Circuit Breaker | BHEL

Volts 245 KV Amperes 2000 A Short Circuit Time 3 sec 26.3 KA Closing Coil Voltage 220 V DC Tripping Coil Voltage 220 V DC Working Gas Pressure 6.1 Kg/cm2-g at 20OC Rated Frequency and Voltage for auxiliary 415 AC 50 Hz Total Weight of Gas 3900 Kg Rated operating scheme O-0.3sec-CO-3 min.-CO Rated lightening impulse withstands voltage 1050 KVp Rated short circuit breaking current 40 KA Rated operating pressure 15 kg/cm2-g First pole to clear factor 1.3 Rated duration of short circuit current 40 kA for 3 sec Rated line charging breaking current 125 A Gas weight 21 Kg
ISOLATORS | FOUR
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These are single break, single pole isolators supplied by M/s. Hvelm limited, Madras. These are pneumatically operated at a pressure of 15 kg/cm2. These isolators and earthing switches are interlocked with each other and with the circuit breakers to prevent mal-operation. No interlocking arrangements are provided for the bus earthing switches.
Main Bus Isolators | One

To maintain the main bus isolators the corresponding bus has to be shut down by transferring loads to other bus, bus earthed and circuit breaker and isolator opened, after transferring the requisite feeder on to the bypass breaker and the earthing switches are closed.
Bypass Isolator | Two

To maintain the by-pass isolators the bypass bus has to be shut down, isolators opened and the earthing switches are closed.
Feeder Isolators | Three

When the feeder is working on bus I or Outdoor Isolator Switch bus II, the earthing switches on both sides of the isolator are closed after opening the breaker and isolators and shutting down the feeder.
PT Isolators | Four
The corresponding bus must be shut down and earthing switches on the isolator closed for maintenance.
PNEUMATIC SYSTEM | FIVE

This system consists of seven compressors with one spare air compressor. All the seven compressors are connected to two wet air cylinders, which are coupled to each other. This wet air is dried through an air drier and fed into six dry cylinders divided into a two groups each having three dry cylinders. The dry air through these two groups is passed through two separate air drier for further dryness of air up to a dew point of C. The dried air from these two dryers is fed into two separate dry cylinders which feed dry air into pressure reducers. From these pressure reducers the pressurized dry air is supplied to air blast circuit breakers. High pressure and low-pressure alarms are arranged on the pressure gauges and any mal-operation noticed must be rectified immediately.
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POWER LINE COMMUNICATION EQUIPMENT | SIX

To maintain the power line carrier communication equipment like wave trap or coupling capacitor the conditions would be same as those of maintaining the concerned feeder isolator. Depending upon whether inter-circuit coupling or phase to ground coupling is used either both the circuits or the single circuit must be shut down along with the feeder isolator.
220KV CURRENT TRANSFORMERS | SEVEN

The 220kV single phase 4 core current transformers supplied by Hindustan Brown Broveri Ltd. (Baroda). The transformation ratio 1200-600/1/1/1/1 amps are used in Tie in transformer, generator and transmission line bays and bus coupler bay. The secondary windings of these CTs are connected to protection and measurement circuits.
220KV POTENTIAL TRANSFORMERS | EIGHT

These single phase potential transformers supplied by HE(I) Ltd., Bhopal are connected to 220kV buses. These are required for measurement and protection purposes. The main PTs are of ratio 22000/53/110/53 volts and the auxiliary PTs are of ratio 62.5/63.5 volts. The auxiliary PTs will operate in conjunction with the main PT to provide one more secondary winding. Consequent by the combined set of main and auxiliary PTs will provide to secondary winding each of 110/53 voltage ratings.
LIGHTING ARRESTORS | NINE

These have been supplied by M/s. W.S. insulators of India Ltd. (Madras). These are installed for protection of transformers and other electrical equipments against voltage surges. One set of lighting arrestors have been provided on each power transformers, tie in transformers and to the bus PTs. The 195kV, 10000 amps single pole heavy duty station class SVS type self supporting L.A. comprises of one metal top and metal base, having mobile arc, pressure relief and a transfer device. The mobile arc gap assembly consists of a permanent ceramic ring magnet, radially magnetized, m series with air gap. Thus it provides a constant magnetic field in the air gap which is always preset at full strength regardless of the current of the discharge, when lighting wave discharges through it, the spark discharge takes place in the annular space, causing an arc at right angles to the magnetic field. This field forces the arc to spin around the gap electrode surfaces. Pressure relief device is provided to take care of the gas formed at the time of short circuit when the arrestor is damaged. When
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the diaphragm bursts due to a gas pressure, the ionized gases come out and are vented through the exhaust ports. The gas from the top of the unit is deflected downward and that from the bottom is deflected upward. The gas steams meet and transfer the fault current is from inside the arrestor to the outside in less than half cycle of fault current.
220KV LINES | TEN

all the feeders from the 220 kV bus bars are shown in the diagram on the previous page. All the metering and protection should normally be connected only to the bus VT supplies. However when necessary CVTs can be used for metering and protection. Bus - 1 Gen Tr - 1 Gen Tr - 3 Gen Tr - 5 IP Line II Mehrauli Line I Ballabgarh Line I Alwar Line Okhla Line I Stn Tr - 1 Stn Tr - 3 Bus - 2 Gen Tr - 2 Gen Tr - 4 IP Line I Mehrauli Line II Ballabgarh Line II Noida Line Okhla Line II Stn Tr 2 Bus Coupler By Pass Bay
SYNCHRONISING | ELEVEN
Synchronizing facility with check feature has been provided for all 220KV breakers. Whenever a breaker is proposed to be closed, its synchronizing switch should be unlocked and synchronizing check relay by pass switch is in circuit position. It is ensured that voltage and frequency of the incoming and running supplies are nearly same, and the red out of synchronism lamp is not continuously on. After the breaker has been closed, its synchronizing switch should be returned to off position and locked.
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Synchronizing check relay SKE prevents closing of a breaker when incoming and running supplies are out of synchronism. This relay has to be bypassed when closing a breaker one side of, which is dead.
ANNUNCIATION SYSTEM | TWELVE

All breaker tripped alarms have been classed as emergency alarms. Whenever a breaker trips, the breaker tripped facia/flashes and a separate buzzer sounds to draw immediate attention of operator to tripping of a breaker. Whenever an alarm initiating contact closes, the corresponding facia of that alarm starts flashing. Simultaneously, the bell /buzzer starts ringing. Ringing of buzzer stops automatically after a preset time. Flashing continues unit accepts push button pressed, whereupon facia becomes steadily lighted if the initiating contact is still closed. Facial lamps should be tested for operation regularly by pressing lamp test button, provided separately for each control panel.
PROTECTION AND RELAYS USED IN MAIN CIRCUIT BOARD | THIRTEEN

High Speed Biased Differential Relay | One
The DMH type relay provides high speed biased differential protection for two or three winding transformers. The relay is immune to high inrush current and has a high degree of stability against through faults. It requires a max of two cycles operating time for current above twice relay rated current. Instantaneous over current protection clears heavy internal faults immediately. This relay is available in two forms. Firstly for use with time Cts, the ratios of line
Relay Wiring Schematics which are matched to the load current to give zero differential current under normal working conditions. Secondly with tapped interposing transformers for use with standard line current transformers of any ratio.
Directional inverse time overcurrent and ear th fault relays | Two
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The CDD type relays are applied for directional or earth fault protection of ring mains, parallel transformers or parallel feeders with the time graded principle. It is induction disc type relay with induction cup used to add directional feature.
Instantaneous voltage relay | Three

The type VAG relay is an instantaneous protection against abnormal voltage conditions such as over voltage, under voltage or no voltage in AC and DC circuits and for definite time operation when used with a timer. It is an attracted armature type relay.
Auxiliary relays | Four

The VAA/CAA type auxiliary relays are applied for control alarm, indication and other auxiliary duties in AC or DC systems. CAA is a current operated and VAA is a voltage operated relay.. it is attracted armature type.
High speed tripping relays | Five

This VAJH type relay is employed with a high speed tripping duties where a number of simultaneous switching operations are required. This is a fast operating multi contact attracted armature relay.
Definite time delay relay | Six

This VAT type relay is used in auto reclosing and control schemes and to provide a definite time feature for instantaneous protective relay. It is an Electro mechanical definite time relay. It has two pair of contacts. The shorter time setting is provided by a passing contact and longer time setting by the final contact.
Trip circuit supervision relay | Seven

This VAX relay is applied for after closing or continuous supervision of the trip circuit of circuit breakers. They detect the following conditions Failure of trip relay Open circuit of trip coil Failure of mechanism to complete the tripping operation
Instantaneous over current and ear th fault relay | Eight

An instantaneous phase or earth fault protection and for definite time operation when used with a timer. It is a CAG 12/12G standard attracted armature relay with adjustable settings. It may be a single pole or triple pole relay.
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Inverse time over current and ear th fault relay | Nine

This CDG 11-type relay is applied for selective phase and earth fault protection in time graded systems for AC machines. Transformers, feeders etc. this is a non-directional relay with a definite minimum time which has an adjustable inverse time/current characteristics. It may be a single pole or triple pole relay.
Fuse failure relay | Ten

This VAP type relay is used to detect the failure or inadvertent removal of voltage transformer sec. fuses and to prevent incorrect tripping of circuit breaker. It is three units, instantaneous attracted armature type relay the coil of each unit connected across one of the VTs. The secondary fuses under healthy conditions, the coil is SC by fuses and cant be energized. But one or more fuses blow the coil is energized and relay operates.
Instantaneous high stability circulating current relay | Eleven

It is used to serve the following three purposes Differential protection of Ac machines , reactors auto transformers and bus bars. Balanced and restricted earth fault protection of generator of generator and transformer windings. Transverse differential protection of generators and parallel feeders. This CAG type relay is a standard attracted armature relay. In circulating current protection schemes, the sudden and often asymmetrical growth of the system current during external fault conditions can cause the protection current transformers to go into saturation, resulting in high unbalance current to insure stability under these conditions. The modern practice is to use a voltage operated high impedance relay, set to operate at a voltage slightly higher than that developed by CT under max fault conditions. Hence this type of relay is used with a stabilizing resistor.
Local breaker back up relay | Twelve

This is a CTIG type three phase or two phase earth fault instantaneous over current unit intended for use with a time delay unit to give back up protection in the event of a circuit breaker failure.
Poly-phase directional relay | Thir teen

The PGD relay is a high speed induction cup unit used to give directional properties to three phase IDMT over-current relays, for the protection of parallel feeders, inter
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connected networks and parallel transformers against phase to phase and three phase faults. Owing to low sensitivity on phase to earth faults the relay is used with discretion on solidly earthed systems.
Auto reclose relay | Four teen

Five types of auto reclose relays are available VAR21 Giving one reclosure. The dead time and reclaim time are adjustable form 5 to 25 secs. If the circuit breaker reopens during reclaim time, it remains open and locked out. VAR41B Is a single shot scheme for air blast circuit breakers. Reclaim time is fixed at between 15 to 20 secs. Dead time adjustment is from 0.1 to 1.0 sec of which first 300 millisec will be circuit breaker opening time. VAR42 Giving four reclosure. It is precision timed from 0 to 60 sec. it can be set for max four enclosures at min intervals of 10 sec and instantaneous protection can be suppressed after the first reclosure so that persistent faults are referred to time graded protection. VAR 71 Giving single shot medium speed reclosure with alarm and lockout for circuit breaker. This allows up to 10 faults clearance before initiating an alarm. The alarm is followed by lockout if selected no. of faults clearances exceed. If the circuit breaker reopens during reclaim time, it remains open and locked out. It offers delay in reclosing sequence. Instantaneous lockout on low current earth fault and suppressing instantaneous protection during reclamation time. VAR 81 Is a single shot high-speed reclosure with alarm and lockout for circuit breaker This allows up to 10 faults clearance before initiating an alarm.
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CONTROL AND INSTRUMENTATION

I was trained under the control and instrumentation department from 18th July to 27th July. This division basically calibrates various instruments and takes care of any faults occur in any of the auxiliaries in the plant. 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. Instrumentation can be well defined as a technology of using instruments to measure and control the physical and chemical properties of a material.
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LABS
Control and instrumentation has following labs Manometry Lab Protection and Interlocks Lab Automation Lab Electronics Lab Water Treatment Plant Furnace Safety and Supervisory System Lab
MANOMETRY LAB | ONE

Transmitters- Transmitter 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 conditioned 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 transmitters is mounted below main process piping and for gas measurement transmitter is placed above pipe. Manometer- Its a tube which is bent, in U shape. It is filled with a liquid. This device corresponds to a difference in pressure across the two limbs. Bourden Pressure Gauge- Its an oval section tube. Its one end is fixed. It is provided with a pointer to indicate the pressure on a calibrated scale. It is of two types : (a) Spiral type : for low pressure measurement and (b) Helical type : for high pressure measurement.
PROTECTION AND INTERLOCK LAB | TWO

Interlocking- It is basically interconnecting two or more equipments so that if one equipments fails other one can perform the tasks. This type of interdependence is also created so that equipments connected together are started and shut down in the specific sequence to avoid damage. For protection of equipments tripping are provided for all the equipments. Tripping can be considered as the series of instructions
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connected through OR GATE. When the main equipments of this lab are relay and circuit breakers. Some of the instrument uses for protection are: 1. RELAY It is a protective device. It can detect wrong condition in electrical circuits by constantly measuring the electrical quantities flowing under normal and faulty conditions. Some of the electrical quantities are voltage, current, phase angle and velocity. 2. FUSES It is a short piece of metal inserted in the circuit, which melts when heavy current flows through it and thus breaks the circuit. Usually silver is used as a fuse material because: a) The coefficient of expansion of silver is very small. As a result no critical fatigue occurs and thus the continuous full capacity normal current ratings are assured for the long time. b) The conductivity of the silver is unimpaired by the surges of the current that produces temperatures just near the melting point. c) Silver fusible elements can be raised from normal operating temperature to vaporization quicker than any other material because of its comparatively low specific heat. Miniature Circuit Breaker- They are used with combination of the control circuits to. a) Enable the staring of plant and distributors. b) Protect the circuit in case of a fault. In consists of current carrying contacts, one movable and other fixed. When a fault occurs the contacts separate and are is stuck between them. There are three types of MANUAL TRIP - THERMAL TRIP - SHORT CIRCUIT TRIP. Protection and Interlock System- 1. HIGH TENSION CONTROL CIRCUIT For high tension system the control system are excited by separate D.C supply. For starting the circuit conditions should be in series with the starting coil of the equipment to energize it. Because if even a single condition Thermal Trip Circuit Breaker is not true then system will not start. 2. LOW TENSION CONTROL CIRCUIT For low tension system the control circuits are directly excited from the 0.415 KV A.C supply. The same circuit achieves both excitation and tripping. Hence the tripping coil is provided for emergency tripping if the interconnection fails.
AUTOMATION LAB | THREE

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) Management Information System. But this lab universally applies the pressure measuring
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instruments as the controlling force. However, the relays are also provided but they are used only for protection and interlocks.
PYROMETRY LAB | FOUR

Liquid in glass thermometer - Mercury in the glass thermometer boils at 340 degree Celsius which limits the range of temperature that can be measured. It is L shaped thermometer which is designed to reach all inaccessible places. Ultra violet censor- This device is used in furnace and it measures the intensity of ultra violet rays there and according to the wave generated which directly indicates the temperature in the furnace. Thermocouples - This device is based on SEEBACK and PELTIER effect. It comprises of two junctions at different 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 temperature detector) - It performs the function of thermocouple basically but the difference is of a resistance. In this due to the change in the resistance the temperature difference is measured. In this lab, also the measuring devices can be calibrated in the oil bath or just boiling water (for low range devices) and in small furnace (for high range devices).
FURNACE SAFETY AND SUPERVISORY SYSTEM LAB |FIVE

This lab has the responsibility of starting fire in the furnace to enable the burning of coal. For first stage coal burners are in the front and rear of the furnace and for the second and third stage corner firing is employed. Unburnt coal is removed using forced draft or induced draft fan. The temperature inside the boiler is 1100 degree Celsius and its height is 18 to 40 m. It is made up of mild steel. An ultra violet sensor is employed in furnace to measure 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 pipes fed from forced draft fans. In first stage indirect firing is employed that is feeder mills are not fed directly from coal but are fed from three feeders but are fed from pulverized coalbunkers. The furnace can operate on the minimum feed from three feeders but under not circumstances should any one be left out under operation, to prevent creation of pressure different with in the furnace, which threatens to blast it.
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ELECTRONICS LAB | SIX

This lab undertakes the calibration and testing of various cards. It houses various types of analytical instruments like oscilloscopes, integrated circuits, cards auto analyzers etc. Various 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 magnetic portion.
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CONTROL SYSTEM STRUCTURE

The primary requirement to be fulfilled by any control system architecture is that it be capable of being organized and implemented on true process-oriented lines. In other words, the control system structure should map on to the hierarchy process structure. BHELs PROCONTROL P, a microprocessor based intelligent remote multiplexing system, meets this requirement completely.
SYSTEM OVERVIEW | ONE

The control and automation system used here is a micro based intelligent multiplexing system. This system, designed on a modular basis, allows to tighten the scope of control hardware to the particular control strategy and operating requirements of the process Regardless of the type and extent of process to control provides system uniformity and integrity for Signal conditioning and transmission Modulating controls
CONTROL AND MONITORING MECHANISMS | TWO

There are basically two types of Problems faced in a Power Plant. Metallurgical Mechanical Mechanical Problem can be related to Turbines that is the max speed permissible for a turbine is 3000 rpm, so speed should be monitored and maintained at that level Metallurgical Problem can be view as the max Inlet Temperature for Turbile is 1060 oC so temperature should be below the limit. Monitoring of all the parameters is necessary for the safety of both Employees Machines So the Parameters to be monitored are Speed
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Temperature Current Voltage Pressure Eccentricity Flow of Gases Vacuum Pressure Valves Level Vibration
PRESSURE MONITORING | THREE

Pressure can be monitored by three types of basic mechanisms Switches Gauges Transmitter type For gauges we use Bourden tubes : The Bourdon Tube is a non liquid pressure measurement device. It is widely used in applications where inexpensive static pressure measurements are needed. A typical Bourdon tube contains a curved tube that is open to external pressure input on one end and is coupled mechanically to an indicating needle on the other end, as shown schematically below. For Switches pressure switches are used and they can be used for digital means of Typical Bourdon Tube Pressure Gage monitoring as switch being ON is referred as high and being OFF is as low. All the monitored data is converted to either Current or Voltage parameter.
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The Plant standard for current and voltage are as under Voltage : 0 10 Volts range Current : 4 20 milliAmperes We use 4mA as the lower value so as to check for disturbances and wire breaks. Accuracy of such systems is very high . ACCURACY : + - 0.1 % The whole system used is SCADA based. Programmable Logic Circuits ( PLCs) are used in the process as they are the heard of Instrumentation.
TEMPERATURE MONITORING | FOUR

We can use Thermocouples or RTDs for temperature monitoring. Normally RTDs are used for low temperatures. Thermocouple selection depends upon two factors Temperature Range Accuracy Required Normally used Thermocouple is K Type Thermocouple - Chromel (Nickel-Chromium Alloy) / Alumel (Nickel-Aluminium Alloy) This is the most commonly used general purpose thermocouple. It is inexpensive and, owing to its popularity, available in a wide variety of probes. They are available in the 200 C to +1200 C range. Sensitivity is approximately 41 V/C. RTDs are also used but not in protection systems due to vibrational errors. We pass a constant current through the RTD. So that if R changes then the Voltage also changes. RTDs used in Industries are Pt100 and Pt1000. Pt100 : 00C 100 ( 1 = 2.50C ) Pt1000 : 00C - 1000 Pt1000 is used for higher accuracy.
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The gauges used for Temperature measurements are mercury filled Temperature gauges. For Analog medium thermocouples are used. And for Digital medium Switches are used which are basically mercury switches.
FLOW MEASUREMENT | FIVE

Flow measurement does not signify much and is measured just for metering purposes and for monitoring the processes.
Rotameters | One
A Rotameter is a device that measures the flow rate of liquid or gas in a closed tube. It is occasionally misspelled as 'rotometer'. It belongs to a class of meters called variable area meters, which measure flow rate by allowing the cross sectional area the fluid travels through to vary, causing some measurable effect. A rotameter consists of a tapered tube, typically made of glass, with a float inside that is pushed up by flow and pulled down by gravity. At a higher flow rate more area (between the float and the tube) is needed to accommodate the flow, so the float rises. Floats are made in many different shapes, with spheres and spherical ellipses being the most common. The float is shaped so that it rotates axially as the fluid passes. This allows you to tell if the float is stuck since it will only rotate if it is not. For Digital measurements Flap system is used. For Analog measurements we can use the following methods Flowmeters Venurimeters / Orifice meters Turbines Massflow meters ( oil level ) Ultrasonic Flow meters Magnetic Flow meter (water level) Selection of flow meter depends upon the purpose , accuracy and liquid to be measured so different types of meters used. Turbine type are the simplest of all. They work on the principle that on each rotation of the turbine a pulse is generated and that pulse is counted to get the flow rate.
Venturimeters | Two
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Referring to the diagram, using Bernoulli's equation in the special case of incompressible fluids (such as the approximation of a water jet), the theoretical pressure drop at the constriction would be given by (/2)(v22 - v12). And we know that rate of flow is given by Flow = k (D.P) Where DP is Differential Presure or the Pressure Drop.
Venturimeter
CONTROL VALVES | SIX

A valve is a device that regulates the flow of substances (either gases, fluidized solids, slurries, or liquids) by opening, closing, or partially obstructing various passageways. Valves are technically pipe fittings, but usually are discussed separately. Valves are used in a variety of applications including industrial, military, commercial, residential, transportation. Plumbing valves are the most obvious in everyday life, but many more are used. Some valves are driven by pressure only, they are mainly used for safety purposes in steam engines and domestic heating or cooking appliances. Others are used in a controlled way, like in Otto cycle engines driven by a camshaft, where they play a major role in engine cycle control. Many valves 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 positions, the valve is called a quarterturn valve. Butterfly valves, ball valves, and plug valves are often quarter-turn valves. Valves can also be controlled by devices called actuators attached to the stem. They can be electromechanical actuators such as an electric motor or solenoid, pneumatic actuators which are controlled by air pressure, or hydraulic actuators which are controlled by the pressure of a liquid such as oil or water. So there are basically three types of valves that are used in power industries besides the handle valves. They are Pneumatic Valves they are air or gas controlled which is compressed to turn or move them. Hydraulic valves they utilize oil in place of Air as oil has better compression. Motorized valves these valves are controlled by electric motors.
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FURNACE SAFEGUARD SUPERVISORY SYSTEM | SEVEN

FSSS is also called as Burner Management System (BMS). It is a microprocessor based programmable logic controller of proven design incorporating all protection facilities required for such system. Main objective of FSSS is to ensure safety of the boiler. The 95 MW boilers are indirect type boilers. Fire takes place in front and in rear side. Thats why its called front and rear type boiler. The 210 MW boilers are direct type boilers (which means that HSD is in direct contact with coal) firing takes place from the corner. Thus it is also known as corner type boiler.
Igniter System | One

Igniter system is an automatic system, it takes the charge from 110kv and this spark is brought in front of the oil guns, which spray aerated HSD on the coal for coal combustion. There is a 5 minute delay cycle before igniting, this is to evacuate or burn the HSD. This method is known as PURGING.
Pressure Switch | Two

Pressure switches are the devices that make or break a circuit. When pressure is applied , the switch under the switch gets pressed which is attached to a relay that makes or break the circuit. Time delay can also be included in sensing the pressure with the help of pressure valves. Examples of pressure valves Manual valves (tap) Motorized valves (actuator) works on motor action Pneumatic valve (actuator) _ works due to pressure of compressed air Hydraulic valve
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CONCLUSION
The training was organized by NTPC Badarpur training department from 29th June to 28th July 2011 in following departments EMD I EMD II C&I I am thankful to all the operational and maintenance staff of BTPS. Without their cooperation the training would not be successful. Report Submitted.
Aman Samaiyar 1st Year Student Electrical and Electronics Engineering Delhi Technological University (formally Delhi College of Engineering)
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VOCATIONAL TRAINING REPORT

VOCATIONAL TRAINING REPORT

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ABOUT THE COMPANY

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POWER GENERATION AT BTPS

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THERMAL POWER PLANTS

INTRODUCTORY OVERVIEW | ONE

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COST OF ELECTRICITY | FOUR

BOILER AND STEAM CYCLE | FIVE

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Feed water heating and deaeration | One

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Boiler Operation | Two

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Boiler Furnace and Steam Drum | Three

Super Heater | Four

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Steam Condensing | Five

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Air Path | Seven

STEAM TURBINE GENERATOR | SIX

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ELECTRICAL MAINTAINANCE DEPARTMENT I

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For Unit 1, 2, 3 Used in Quantity

Ball Mill Fans

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For Unit 3, 4 Used in Quantity

Seal Air Fans

Hydrazine and Phosphorous Dozing

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Switching Isolation | Two

Circuit Breakers | Three

Load Break Switches | Four

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Ear th Switches | Five

LOW TENSION SWITCHGEAR | ONE

Main Switch | One

Overload Relay | Four

Air Circuit Breakers | Five

HIGH TENSION SWITCHGEAR | TWO

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Classified in following ways

Minimum Oil Circuit Breaker | One

Motor Voltage 220V/DC

Air Circuit Breaker | Two

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SF6 Circuit Breaker | Three

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Vacuum Circuit Breaker | Four

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COAL HANDLING PLANT | ONE

Wagon Tippler | One