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INDUSTRIAL TRAINING REPORT

On

POWER PLANT OVERVIEW

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UNDERTAKEN AT NATIONAL THERMAL POWER CORPORATION LIMITED BADARPUR THERMAL POWER STATION BADARPUR, NEW DELHI UNDER GUIDANCE OF MR. ASHISH AGARWAL (23/5/2011 15/7/2011) Submitted in partial fulfillment of the requirement for the award of Degree of Bachelor of Technology In Electronics & Communication

SUBMITTED BY SHRUTI SANGER (08102261) ELECTRONICS AND COMMUNICATION ENGINEERING JAYPEE INSTITUE OF INFORMATION TECHNOLOGY UNIVERSITY, NOIDA

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CONTENTS
1. Introduction to the Company a. About the Company b. Vision c. Strategies 2. Introduction to the Project 3. Project Report a. Operation i. Introduction ii. Steam Boiler iii. Steam Turbine iv. Turbine Generator b. EMD I i. Coal Handling Plant ii. Motors iii. Switchgear iv. High Tension Switchgear v. Direct On Line Starter c. EMD II i. Generator ii. Protection iii. Transformer d. C&I i. MANOMETRY LAB ii. PROTECTION AND INTERLOCK LAB iii. AUTOMATION LAB iv. WATER TREATEMENT LAB

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v. FURNACE SAFETY SUPERVISORY SYSTEM(FSSS) vi. ELECTRONICS TEST LAB

4. Reference

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INTRODUCTION TO THE COMPANY

NTPC, the largest power Company in India, was setup in 1975 to accelerate power development in the country. It is among the worlds largest and most efficient power generation companies.

NTPC has installed capacity of 29,394 MW. It has 15 coal based power stations (23,395 MW), 7 gas based power stations (3,955 MW) and 4 power stations in Joint Ventures (1,794 MW). The company has power generating facilities in all major regions of the country. It plans to be a 75,000 MW company by 2017. NTPC has gone beyond the thermal power generation. It has diversified into hydro power, coal mining, power equipment manufacturing, oil & gas exploration, power trading & distribution. NTPC is now in the entire power value chain and is poised to become an Integrated Power Major. Recognizing its excellent performance and vast potential, Government of the India has identified NTPC as one of the jewels of Public Sector 'Navratnas'- a potential global giant. Inspired by its glorious past and vibrant present, NTPC is well on its way to realize its vision of being "A world class integrated power major, powering India's growth, with increasing global presence".

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VISION
A world class integrated power major, powering India's growth with increasing global presence. Mission Develop and provide reliable power related products and services at competitive prices, integrating multiple energy resources with innovative & Eco-friendly technologies and contribution to the society. Core Values - BCOMIT Business ethics Customer Focus Organizational & Professional Pride Mutual Respect & Trust Innovation & Speed Total Quality for Excellence

STRATEGIES
Technological Initiatives

Introduction of steam generators (boilers) of the size of 800 MW Integrated Gasification Combined Cycle (IGCC) Technology Launch of Energy Technology Center -A new initiative for development of technologies with focus on fundamental R&D

The company sets aside up to 0.5% of the profits for R&D Roadmap developed for adopting Clean Development

Corporate Social Responsibility As a responsible corporate citizen NTPC has taken up number of CSR initiatives NTPC Foundation formed to address Social issues at national level NTPC has framed Corporate Social Responsibility Guidelines committing up to 0.5% of net profit annually for Community Welfare Measures on perennial basis The welfare of project affected persons and the local population around NTPC projects are taken care of through well drawn Rehabilitation and Resettlement policies

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The company has also taken up distributed generation for remote rural areas

Environment Management All stations of NTPC are ISO 14001 certified Various groups to care of environmental issues The Environment Management Group Ash Utilization Division Afforestation Group Centre for Power Efficiency & Environment Protection Group on Clean Development Mechanism

NTPC is the second largest owner of trees in the country after the Forest department. Partnering government in various initiatives

Consultant role to modernize and improvise several plants across the country Disseminate technologies to other players in the sector Consultant role Partnership in Excellence Programme for improvement of PLF of 15 Power Stations of SEBs.

Rural Electrification work under Rajiv Gandhi Grameen Vidyutikaran Yojana

EVOLUTION
NTPC was set up in 1975 with 100% ownership by the Government of India. In the last 30 years, NTPC has grown into the largest power utility in India. In 1997, Government of India granted NTPC status of Navratna being one of the nine jewels of India, enhancing the powers to the Board of Directors. NTPC became a listed company with majority Government ownership of 89.5%. NTPC becomes third largest by Market Capitalization of listed companies. The company

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rechristened as NTPC Limited in line with its changing business portfolio and transforms itself from a thermal power utility to an integrated power utility. National Thermal Power Corporation is the largest power generation company in India. Forbes Global 2000 for 2008 ranked it 411th in the world. NTPC is the largest power utility in India, accounting for about 20% of Indias installed capacity.

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OPERATION

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In a Badarpur Thermal Power Station, steam is produced and used to spin a turbine that operates a generator. 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; this is known as a Rankine cycle. Shown here is a diagram of a conventional thermal power plant, which uses coal, oil, or natural gas as fuel to boil water to produce the steam. The electricity

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generated at the plant is sent to consumers through high-voltage power lines. The Badarpur Thermal Power Plant has Steam Turbine-Driven Generators which has a collective capacity of 705MW. The fuel being used is Coal which is supplied from the Jharia Coal Field in Jharkhand. Water supply is given from the Agra Canal. Sr No. 1 2 Capacity 210 95 No. of Generators 2 3 TOTAL Total capacity 420MW 285MW 705 MW

There are basically three main units of a thermal power plant: 1. Steam Generator or Boiler 2. Steam Turbine 3. Electric Generator Working of thermal power plant Coal is conveyed from an external stack and ground to a very fine powder by large metal spheres in the pulverised fuel mill . There it is mixed with preheated air driven by the forced draught fan . The hot air-fuel mixture is forced at high pressure into the boiler where it rapidly ignites. Water of a high purity flows vertically up the tube-lined walls of the boiler, where it turns into steam, and is passed to the boiler drum, where steam is separated from any remaining water. The steam passes through a manifold in the roof of the drum into the pendant superheater where its temperature and pressure increase rapidly to around 200 bar and 540C, sufficient to make the tube walls glow a dull red. The steam is piped to the high pressure turbine, the first of a three-stage turbine process. A steam governor valve allows for both manual control of the turbine and automatic set-point following. The steam is exhausted from the high pressure turbine, and reduced in both pressure and temperature, is returned to the boiler reheater . The reheated steam is then passed to the intermediate pressure turbine, and from there passed directly to the low pressure turbine set. The exiting steam, now a little above its boiling point, is brought into thermal contact with cold water (pumped in from the cooling tower) in the condensor, where it condenses rapidly back into water, creating near vacuum-like conditions inside the condensor chest. The condensed water is then passed by a feed pump through a deaerator , and prewarmed, first in a feed heater powered by steam drawn from the high pressure set, and then in the economiser, before being returned to the boiler drum. The cooling water from the condensor

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is sprayed inside a cooling tower, creating a highly visible plume of water vapor, before being pumped back to the condensor in cooling water cycle. The three turbine sets are sometimes coupled on the same shaft as the three-phase electrical generator which generates an intermediate level voltage (typically 20-25 kV). This is stepped up by the unit transforme to a voltage more suitable for transmission (typically 250-500 kV) and is sent out onto the three-phase transmission system. Exhaust gas from the boiler is drawn by the induced draft fan through an electrostatic precipitator and is then vented through the chimney stack .

STEAM GENERATOR OR BOILER

The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60 mm) in diameter. Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the center. The thermal radiation of the fireball heats the water that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the boiler is three to four times the throughput and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700 F (370 C) and 3,200 psi (22.1MPa). It is separated from the water inside a drum at the top of the furnace. The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to 1,000 F (540 C) to prepare it for the turbine. 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. The generator includes the economizer, the steam drum, the chemical dosing equipment, and the furnace with its steam generating tubes and the superheater 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 (APH), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or baghouse) and the flue gas stack.

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Boiler Furnace and Steam Drum 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 the down comers 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 the 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 tripout are avoided by

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flushing out such gases from the combustion zone before igniting the coal. The steam drum (as well as the superheater coils and headers) have air vents and drains needed for initial startup. The steam drum has an internal device that removes moisture from the wet steam entering the drum from the steam generating tubes. The dry steam then flows into the superheater coils.

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Fuel Preparation System In coal-fired power stations, the raw feed coal from the coal storage area is first crushed into small pieces and then conveyed to the coal feed hoppers at the boilers. The coal is next pulverized into a very fine powder. The pulverizers may be ball mills, rotating drum grinders, or other types of grinders. Fuel Firing System and Igniter System From the pulverized coal bin, coal is blown by hot air through the furnace coal burners at an angle which imparts a swirling motion to the powdered coal to enhance mixing of the coal powder with the incoming preheated combustion air and thus to enhance the combustion. To provide sufficient combustion temperature in the furnace before igniting the powdered coal, the furnace temperature is raised by first burning some light fuel oil or processed natural gas (by using auxiliary burners and igniters provide for that purpose). Air Path 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. At the furnace outlet, and before the furnace gases are handled by the ID fan, fine dust carried by the outlet gases is removed to avoid atmospheric pollution. This is an environmental limitation prescribed by law, and additionally minimizes erosion of the ID fan. Bottom Ash Collection and Disposal At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from the bottom of the furnace. This hopper is always filled with water to quench the ash and clinkers falling down from the furnace. Some arrangement is included to crush the clinkers and for conveying the crushed clinkers and bottom ash to a storage site.

STEAM TURBINES
Steam turbines are used in all of our major coal fired power stations to drive the generators or alternators, which produce electricity. The turbines themselves are driven by steam generated in

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'Boilers' or 'Steam Generators' as they are sometimes called. Energy in the steam after it leaves the boiler is converted into rotational energy as it passes through the turbine. The turbine normally consists of several stages with each stage consisting of a stationary blade (or nozzle) and a rotating blade. Stationary blades convert the potential energy of the steam (temperature and pressure) into kinetic energy (velocity) and direct the flow onto the rotating blades. The rotating blades convert the kinetic energy into forces, caused by pressure drop, which results in the rotation of the turbine shaft. The turbine shaft is connected to a generator, which produces the electrical energy. The rotational speed is 3000 rpm for Indian System (50 Hz) systems and 3600 for American (60 Hz) systems. In a typical larger power stations, the steam turbines are split into three separate stages, the first being the High Pressure (HP), the second the Intermediate Pressure (IP) and the third the Low Pressure (LP) stage, where high, intermediate and low describe the pressure of the steam. After the steam has passed through the HP stage, it is returned to the boiler to be re-heated to its original temperature although the pressure remains greatly reduced. The reheated steam then passes through the IP stage and finally to the LP stage of the turbine. Shaft Seals The shaft seal on a turbine rotor consist of a series of ridges and groves around the rotor and its housing which present a long, tortuous path for any steam leaking through the seal. The seal therefore does not prevent the steam from leaking, merely reduces the leakage to a minimum. The leaking steam is collected and returned to a low-pressure part of the steam circuit. Turning Gear Large steam turbines are equipped with "turning gear" to slowly rotate the turbines after they have been shut down and while they are cooling. This evens out the temperature distribution around the turbines and prevents bowing of the rotors. Vibration The balancing of the large rotating steam turbines is a critical component in ensuring the reliable operation of the plant. Most large steam turbines have sensors installed to measure the movement of the shafts in their bearings. This condition monitoring can identify many potential problems and allows the repair of the turbine to be planned before the problems become serious.

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ELECTRIC GENERATOR
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. Barring Gear (or Turning Gear) Barring gear is the term used for the mechanism provided for rotation of the turbine generator shaft at a very low speed (about one revolution per minute) after unit stoppages for any reason. Once the unit is "tripped" (i.e., the turbine steam inlet valve is closed), the turbine starts slowing or "coasting down". When it stops completely, there is a tendency for the turbine shaft to deflect or bend if allowed to remain in one position too long. This deflection is because the heat inside the turbine casing tends to concentrate in the top half of the casing, thus making the top half portion of the shaft hotter than the bottom half. The shaft therefore warps or bends by millionths of inches, only detectable by monitoring eccentricity meters. Condenser The surface condenser is a shell and tube heat exchanger in which cooling water is circulated through the tubes. The exhaust steam from the low pressure turbine enters the shell where it is cooled and converted to condensate (water) by flowing over the tubes as shown in the adjacent diagram. 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 100C where the vapor pressure of water is much less than atmospheric pressure, the condenser generally works under vacuum. Thus leaks of noncondensible air into the closed loop must be prevented. 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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Feedwater Heater A Rankine cycle with a two-stage steam turbine and a single feedwater heater. In the case of a conventional steam-electric power plant utilizing a drum boiler, the surface condenser removes the latent heat of vaporization from the steam as it changes states from vapour to liquid. The heat content (btu) in the steam is referred to as Enthalpy. The condensate pump then pumps the condensate water through a feedwater heater. The feedwater heating equipment then raises the temperature of the water by utilizing extraction steam from various stages of the turbine. Superheater As the steam is conditioned by the drying equipment inside the drum, it is piped from the upper drum area into an elaborate set up of tubing in different areas of the boiler. The areas known as superheater and reheater. The steam vapor picks up energy and its temperature is now superheated above the saturation temperature. The superheated steam is then piped through the main steam lines to the valves of the high pressure turbine. Deaerator A steam generating boiler requires that the boiler feed water should be devoid of air and other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the metal. Generally, power stations use a deaerator to provide for the removal of air and other dissolved gases from the boiler feedwater. A deaerator typically includes a vertical, domed deaeration section mounted on top of a horizontal cylindrical vessel which serves as the deaerated boiler feedwater storage tank. Monitoring and Alarm system Most of the power plants operational controls are automatic. However, at times, manual intervention may be required. Thus, the plant is provided with monitors and alarm systems that alert the plant operators when certain operating parameters are seriously deviating from their normal range.

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EMD-I COAL HANDLING PLANT Coal is delivered by highway truck, rail, barge or collier ship. Some plants are even built near coal mines and coal is delivered by conveyors. A large coal train called a "unit train" may be a kilometers (over a mile) long, containing 60 cars with 100 tons of coal in each one, for a total load of 6,000 tons. A large plant under full load requires at least one coal delivery this size every day. Plants may get as many as three to five trains a day, especially in "peak season", during the summer months when power consumption is high. A large thermal power plant such as the Badarpur Thermal Power Station, New Delhi stores several million tons of coal for use when there is no wagon supply. Modern unloaders use rotary dump devices, which eliminate problems with coal freezing in

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bottom dump cars. Coal is prepared for use by crushing the rough coal to pieces less than 2 inches (50 mm) in size. The coal is then transported from the storage yard to in-plant storage silos by rubberized conveyor belts at rates up to 4,000 tons/hour. ELECTRIC MOTORS An electric motor uses electrical energy to produce mechanical energy. The reverse process that of using mechanical energy to produce electrical energy is accomplished by a generator or dynamo. Traction motors used on locomotives and some electric and hybrid automobiles often performs both tasks if the vehicle is equipped with dynamic brakes. Categorization of Electric Motors The classic division of electric motors has been that of Direct Current (DC) types vs Alternating Current (AC) types. The ongoing trend toward electronic control further muddles the distinction, as modern drivers have moved the commutator out of the motor shell. For this new breed of motor, driver circuits are relied upon to generate sinusoidal AC drive currents, or some approximation of. The two best examples are: the brushless DC motor and the stepping motor, both being polyphase AC motors requiring external electronic control. There is a clearer distinction between a synchronous motor and asynchronous types. In the synchronous types, the rotor rotates in synchrony with the oscillating field or current (eg. permanent magnet motors). In contrast, an asynchronous motor is designed to slip; the most ubiquitous example being the common AC induction motor which must slip in order to generate torque. At Badarpur Thermal Power Station, New Delhi, mostly AC motors are employed for various purposes. We had to study the two types of AC Motors viz. Synchronous Motors and Induction Motor. The motors have been explained further. AC Motor An AC motor is an electric motor that is driven by an alternating current. It consists of two basic parts, an outside stationary stator having coils supplied with AC current to produce a rotating magnetic field, and an inside rotor attached to the output shaft that is given a torque by the rotating field. There are two types of AC motors, depending on the type of rotor used. The first is the synchronous motor, which rotates exactly at the supply frequency or a sub multiple of the supply frequency. The magnetic field on the rotor is either generated by current delivered through slip rings or a by a permanent magnet.

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The second type is the induction motor, which turns slightly slower than the supply frequency.The magnetic field on the rotor of this motor is created by an induced current. Synchronous Motor A synchronous electric motor is an AC motor distinguished by a rotor spinning with coils passing magnets at the same rate as the alternating current and resulting magnetic field which drives it. Another way of saying this is that it has zero slip under usual operating conditions. Contrast this with an induction motor, which must slip in order to produce torque. Sometimes a synchronous motor is used, not to drive a load, but to improve the power factor on the local grid it's connected to. It does this by providing reactive power to or consuming reactive power from the grid. In this case the synchronous motor is called a Synchronous condenser. Electrical power plants almost always use synchronous generators because it's very important to keep the frequency constant at which the generator is connected. Advantages Synchronous motors have the following advantages over non-synchronous motors: Speed is independent of the load, provided an adequate field current is applied. Accurate control in speed and position using open loop controls, eg. Stepper motors. They will hold their position when a DC current is applied to both the stator and the rotor windings. Their power factor can be adjusted to unity by using a proper field current relative to the load. Also, a "capacitive" power factor, (current phase leads voltage phase), can be obtained by increasing this current slightly, which can help achieve a better power factor correction for the whole installation.

Their construction allows for increased electrical efficiency when a low speed is required (as in ball mills and similar apparatus).

Induction Motor An induction motor (IM) is a type of asynchronous AC motor where power is supplied to the rotating device by means of electromagnetic induction. An electric motor converts electrical power to mechanical power in its rotor (rotating part). There are several ways to supply power to the rotor. In a DC motor this power is supplied to the armature directly from a DC source, while in an AC motor this power is induced in the rotating device. An induction motor is sometimes called a rotating transformer because the stator

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(stationary part) is essentially the primary side of the transformer and the rotor (rotating part) is the secondary side. Induction motors are widely used, especially polyphase induction motors, which are frequently used in industrial drives. Induction motors are now the preferred choice for industrial motors due to their rugged construction, lack of brushes (which are needed in most DC Motors) and thanks to modern power electronics the ability to control the speed of the motor. Construction The stator consists of wound 'poles' that carry the supply current that induces a magnetic field in the conductor. The number of 'poles' can vary between motor types but the poles are always in pairs (i.e. 2, 4, 6 etc). There are two types of rotor: 1. Squirrel-cage rotor 2. Slip ring rotor The most common rotor is a squirrel-cage rotor. It is made up of bars of either solid copper (most common) or aluminum that span the length of the rotor, and are connected through a ring at each end. The rotor bars in squirrel-cage induction motors are not straight, but have some skew to reduce noise and harmonics. The motor's phase type is one of two types: 1. Single-phase induction motor 2. 3-phase induction motor Principle of Operation The basic difference between an induction motor and a synchronous AC motor is that in the latter a current is supplied onto the rotor. This then creates a magnetic field which, through magnetic interaction, links to the rotating magnetic field in the stator which in turn causes the rotor to turn. It is called synchronous because at steady state the speed of the rotor is the same as the speed of the rotating magnetic field in the stator. By way of contrast, the induction motor does not have any direct supply onto the rotor; instead, a secondary current is induced in the rotor. To achieve this, stator windings are arranged around the rotor so that when energised with a polyphase supply they create a rotating magnetic field pattern which sweeps past the rotor. This changing magnetic field pattern can induce currents in the rotor conductors. These currents interact with the rotating magnetic field created by the stator and the rotor will turn.

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However, for these currents to be induced, the speed of the physical rotor and the speed of the rotating magnetic field in the stator must be different, or else the magnetic field will not be moving relative to the rotor conductors and no currents will be induced. If by some chance this happens, the rotor typically slows slightly until a current is re-induced and then the rotor continues as before. This difference between the speed of the rotor and speed of the rotating magnetic field in the stator is called slip. It has no unit and the ratio between the relative speed of the magnetic field as seen by the rotor to the speed of the rotating field. Due to this an induction motor is sometimes referred to as an asynchronous machine.

SWITCH GEARS
The working of the machine depends upon the working of long chain auxillaries. These auxillaries are fed through an efficient and reliable switch gear system. Thus switchgear is one that makes or breaks an electrical circuit. Equipments included in switchgear Isolators:- An isolator is one which can break an electrical circuit. When the circuit is to be switched on no load. They are used in various circuits. For isolating a part when required for maintenance. Switching isolators:- They are capable of interrupting transformer magnetizing currents, interrupting line charging current load transfer switching. Its main application is in connection with load transfer as the unit makes it possible to switch out one transformer while the other is still on load. Circuit breaker:- It is a one, which can make or break the circuit on load & even in faults.High voltage switchgear is any switchgear and switchgear assembly of rated voltage higher than 1000 volts.

HIGH VOLTAGE SWITCHGEAR

High voltage switchgear is any switchgear used to connect or to disconnect a part of a high voltage power system. These switchgears are essential elements for the protection and for a safety operating mode without interruption of a high voltage power system. This type of equipment is really important

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because it is directly linked to the quality of the electricity supply. The high voltage is a voltage above 1000 V for alternating current and above 1500 V for direct current. According to functions classification of switchgears are: Disconnectors and Earthing Switches High-Current Switching Mechanism Contactor Fuses Circuit Breaker

DIRECT ON LINE STARTER

A direct on line starter, often abbreviated DOL starter, is a widely-used starting method of electric motors. The term is used in electrical engineering and associated with electric motors. There are many types of motor starters, the simplest of which is the DOL starter. A motor starter is an electrical/electronic circuit composed of electro-mechanical and electronic devices which are employed to start and stop an electric motor. Regardless of the motor type (AC or DC), the types of starters differ depending on the method of starting the motor. A DOL starter connects the motor terminals directly to the power supply. Hence, the motor is subjected to the full voltage of the power supply. Consequently, high starting current flows through the motor. This type of starting is suitable for small motors below 5 hp (3.75 kW). Reduced-voltage starters are employed with motors above 5 hp. Although DOL motor starters are available for motors less than 150 kW on 400 V and for motors less than 1 MW on 6.6 kV. Supply reliability and reserve power generation dictates the use of reduced voltage or not. Major Components There are four major components of a Direct On Line Starter. They are given as follows: 1. Switch 2. Fuse 3. Conductor (Electromagnetic) 4. Thermal Overload Relay (Heat & Temperature)

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EMD II
GENERATORS
The basic function of the generator is to convert mechanical power, delivered from the shaft of the turbine, into electrical power. Therefore a generator is actually a rotating mechanical energy converter. The mechanical energy from the turbine is converted by means of a rotating magnetic field produced by direct current in the copper winding of the rotor or field, which generates three-phase alternating currents and voltages in the copper winding of the stator (armature). The stator winding is connected to terminals, which are in turn connected to the power system for delivery of the output power to the system. The class of generator under consideration is steam turbine-driven generators, commonly called turbo generators. These machines are generally used in nuclear and fossil fueled power plants, co-generation plants, and combustion turbine units. They range from relatively small machines of a few Megawatts (MW) to very large generators with ratings up to 1900 MW. The generators particular to this category are of the two- and four-pole design employing round-rotors, with rotational operating speeds of 3600 and 1800 rpm in North America, parts of Japan, and Asia (3000 and 1500 rpm in Europe, Africa, Australia, Asia, and South America). At Badarpur Thermal Power Station 3000 rpm, 50 Hz generators are used of capacities 210 MW and 95 MW. As the system load demands more active power from the generator, more steam (or fuel in a combustion turbine) needs to be admitted to the turbine to increase power output. Hence more energy is transmitted to the generator from the turbine, in the form of a torque. This torque is mechanical in nature, but electromagnetically coupled to the power system through the generator. The higher the power output, the higher the torque between turbine and generator.The power output of the generator generally follows the load demand from the system. Therefore the voltages and currents in the generator are continually changing based on the load demand. The generator design must be able to cope with large and fast load changes, which show up inside the machine as changes in mechanical forces and temperatures. The design must therefore incorporate electrical current-carrying materials (i.e., copper), magnetic flux-carrying materials (i.e., highly permeable steels), insulating materials (i.e., organic), structural members (i.e., steel and organic), and cooling media (i.e., gases and liquids), all working together under the operating conditions of a turbo generator.

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Since the turbo generator is a synchronous machine, it operates at one very specific speed to produce a constant system frequency of 50 Hz, depending on the frequency of the grid to which it is connected. As a synchronous machine, a turbine generator employs a steady magnetic flux passing radially across an air gap that exists between the rotor and the stator. (The term air gap is commonly used for air- and gas-cooled machines) STATOR The stator winding is made up of insulated copper conductor bars that are distributed around the inside diameter of the stator core, commonly called the stator bore, in equally spaced slots in the core to ensure symmetrical flux linkage with the field produced by the rotor. Each slot contains two conductor bars, one on top of the other. These are generally referred to as top and bottom bars. Top bars are the ones nearest the slot opening (just under the wedge) and the bottom bars are the ones at the slot bottom. The core area between slots is generally called a core tooth. The stator winding is then divided into three phases, which are almost always wye connected. Wye connection is done to allow a neural grounding point and for relay protection of the winding. The three phases are connected to create symmetry between them in the 360 degree arc of the stator bore. The distribution of the winding is done in such a way as to produce a 120 degree difference in voltage peaks from one phase to the other, hence the term three-phase voltage. Each of the three phases may have one or more parallel circuits within the phase. The parallels can be connected in series or parallel, or a combination of both if it is a four-pole generator. This will be discussed in the next section. The parallels in all of the phases are essentially equal on average, in their performance in the machine. Therefore, they each see equal voltage and current, magnitudes and phase angles, when averaged over one alternating cycle. ROTOR The rotor winding is installed in the slots machined in the forging main body and is distributed symmetrically around the rotor between the poles. The winding itself is made up of many turns of copper to form the entire series connected winding. All of the turns associated with a single slot are generally called a coil. The coils are wound into the winding slots in the forging, concentrically in corresponding positions on opposite sides of a pole. The series connection essentially creates a single multi-turn coil overall, that develops the total ampere-turns of the rotor (which is the total current flowing in the rotor winding times the total number of turns).

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There are numerous copper-winding designs employed in generator rotors, but all rotor windings function basically in the same way. They are configured differently for different methods of heat removal during operation. In addition almost all large turbo generators have directly cooled copper windings by air or hydrogen cooling gas. Cooling passages are provided within the conductors themselves to eliminate the temperature drop across the ground insulation and preserve the life of the insulation material. In an axially cooled winding, the gas passes through axial passages in the conductors, being fed from both ends, and exhausted to the air gap at the axial center of the rotor. In other designs, radial passages in the stack of conductors are fed from sub slots machined along the length of the rotor at the bottom of each slot. In the air gap pickup method, the cooling gas is picked up from the air gap, and cooling is accomplished over a relatively short length of the rotor, and then discharged back to the air gap. The cooling of the end-regions of the winding varies from design to design, as much as that of the slot section. In smaller turbine generators the indirect cooling method is used (similar to indirectly cooled stator windings), where the heat is removed by conduction through the ground insulation to the rotor body. The winding is held in place in the slots by wedges, in a similar manner as the stator windings. The difference is that the rotor winding loading on the wedges is far greater due to centrifugal forces at speed. The wedges therefore are subjected to a tremendous static load from these forces and bending stresses because of the rotation effects. The wedges in the rotor are not generally a tight fit in order to accommodate the axial thermal expansion of the rotor winding during operation. BEARINGS All turbo generators require bearings to rotate freely with minimal friction and vibration. The main rotor body must be supported by a bearing at each end of the generator for this purpose. In some cases where the rotor shaft is very long at the excitation end of the machine to accommodate the slip/collector rings, a steady bearing is installed outboard of the slipcollector rings. This ensures that the excitation end of the rotor shaft does not create a wobble that transmits through the shaft and stimulates excessive vibration in the overall generator rotor or the turbo generator line. AUXILIARY SYSTEMS All large generators require auxiliary systems to handle such things as lubricating oil for the

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rotor bearings, hydrogen cooling apparatus, hydrogen sealing oil, de-mineralized water for stator winding cooling, and excitation systems for field-current application. Not all generators require all these systems and the requirement depends on the size and nature of the machine. For instance, air cooled turbo generators do not require hydrogen for cooling and therefore no sealing oil as well. On the other hand, large generators with high outputs, generally above 400 MVA, have water-cooled stator windings, hydrogen for cooling the stator core and rotor, seal oil to contain the hydrogen cooling gas under high pressure, lubricating oil for the bearings, and of course, an excitation system for field current. There are five major auxiliary systems that may be used in a generator. They are given as follows: 1. Lubricating Oil System 2. Hydrogen Cooling System 3. Seal Oil System 4. Stator Cooling Water System 5. Excitation System

PROTECTION
The protection system of any modern electric power grid is the most crucial function in the system. Protection is a system because it comprises discrete devices (relays, communication means, etc.) and an algorithm that establishes a coordinated method of operation among the protective devices. This is termed coordination. Thus, for a protective system to operate correctly, both the settings of the individual relays and the coordination among them must be right. Wrong settings might result in no protection to the protected equipment and systems, and improper coordination might result in unwarranted loss of production. The key function of any protective system is to minimize the possibility of physical damage to equipment due to a fault anywhere in the system or from abnormal operation of the equipment (over speed, under voltage, etc.). However, the most critical function of any protective scheme is to safeguard those persons who operate the equipment that produces, transmits, and utilizes electricity. Protective systems are inherently different from other systems in a power plant (or for that matter any other place where electric power is present). They are called to operate seldom, and when they are, it is crucial they do so flawlessly. One problem that arises from protective systems being activated not often is that they are sometimes overlooked. This is a recipe for

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disaster. The most common reason for catastrophic failure of equipment in power systems is failure to operate or miss-operation of protective systems.

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TRANSFORMERS
Transformer is a static electronic device which is used for the transmission of electrical energy at constant frequency through magnetic coupling. Principle When voltage is applied to primary of the transformer, a magnetic flux sets up, the voltage is induced in primary winding by self induction. This flux also links with the secondary of the transformer & a voltage is induced in the secondary winding by mutual inductance. Construction Two types of constructions are mainly employed in the transformer construction. The transformer core is made of laminated silicon stell lamination to avoid eddy current & hysteresis losses. The core is made of E,L I stampingsa. Core type construction:-In this type the core is made of two vertical limbs & two

horizontal yokes. The primary winding is wounded over the yoke & the secondary winding is wounded over it. Two windings form a concentrated winding.

b. Shell type construction:- In shell type construction the core consists of three limbs & two

horizontal yokes. The LV & HV windings are placed alternately on the central limb & form sandwiched winding. It is not easy to dismantle shell type winding for repair and core type winding offers more natural cooling. INSULATION The winding is dipped into varnish to provide insulation. The transformer oil used for cooling also provide insulation for the winding. Two type of insulation are mainly employed:a. Major insulation b. Minor insulation

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Transformer Accessories- The following accessories are associated with the transformer a. OIL RESERVER b. BREATHER c. BUCHHOLTZ RELAY d. MARSHALLING BOX e. RADIATOR AND FAN

RATING OF GENERATOR TRANSFORMER Type of cooling Rating No load voltage No load voltage Temperature rise Temperature rise Phase Frequency Construction symbol Impedence voltage HV position/LV(max. tap) HV position/LV(min. tap) Weight Core & Winding Oil Total weight Oil quantity in liter 84325 Kg 34955 Kg 147725 Kg 40180 HV/LV HV LV Oil Winding OFAF 25MVA 29KV 0.5KV 50 C 60C 3 phase 50 Hz Y dl 16% + IS rise 41% + IS rise

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CONTROL AND INSTRUMENTATION

This division basically calibrates various instruments and table care of any faults that occur in any of the auxillaries in the plant. It has the following labs. Manometry lab Protection and interlocking lab Pyrometry lab Turbo supervisory instrument(TSI) lab Furnace safety supervisory instrument(FSSS) lab Electronics lab

This department is the brain of the plant because from relay to transmitter followed by the electronics computation chipsets and recorders and lastly the controlling circuitry,all fall under their responsibility.

MANOMETRY LAB
Various instruments used in this lab areTransmitter- it is used for pressure measurement of gas liquid. 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 to 20mA DC. Manometer- it is to be which is best in the U-shaped it is filled with liquid. This device corresponds to a difference in the pressure across the 2 limits. Bourdon pressure gauge- it is an oval section tube . its one end is fixed. It is provided with the pointer to indicate the pressure on a calibrated scale. It is of 2 types: Spiral type - it is used for low pressure measurement. Helical type - it is used for high pressure measurement.

PROTECTION AND INTERLOCKING LAB

INTERLOCKING It is basically interconnecting two or more equipments so that if equipment fails, other can performs the task. This type of inter dependence is also created, so that the equipments connected

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together are started and shut down in a specific sequence to avoid damage for protection of equipment tripping are provided for all the equipments. Tripping can be considered as the series of instructions connected through OR gate. When a fault occurs and one of the tripping is satisfied a signal is send to the relay,which trips the circuit. The main equipments of this lab are relay and circuit breakers. Some of the instruments used for the protection are:1. RELAY - It is protective device. It can detect wrong condition in electrical circuits. By

constant measuring the electrical quantities flowing under normal and faulty conditions. Some of the electrical quantities are voltage, cureent, phase angle and velocity. It is of 2 types:a. Current type relay b. Potential relay 2. FUSES - It is short piece of metal inserted in the circuit which melt when a heavy current

flow through it. Usually silver is used as fuse material. A. The coefficient of expansion of silver is very small B. The conductivity of silver is unimpaired by surge of the current that produces temperature near the map. C. It has low specific heat. PROTECTION AND INTERLOCKING SYSTEMS
1. High tension control circuit - for high tension systems, the control system are excited

by separate DC supply. Fo rthe starting, the circuit condition should be in series with the starting of equipment to energize it because if even a single condition is not true, then the sytem will not start.
2. Low tension control circuit - For this type of circuits, the control circuit are directly

excited by 0.415 kV AC supply. The same circuit achieves bothexcitation and tripping. Here the tripping coil is provided for emergency tripping if the interconnection is failed.

TURBINE SUPERVISORY INSTRUMENTATION LAB(TSI)

1. TURBINE SPEED- the speed of the turbine is to be kept constatnt so that frequency of the

generator electricity

is close to 50 Hz. The indicator of the speed gives us a remote

indication of the speed when barring gear rotates the rotor.

Page 34 of 35 2. AXIAL SHIFT- During the rotation of the turbine at high speeds where there is the wearing

down of bearing there is an axial shift. Depending on the bearings which have become worn the thrust collar is either on working pad or surge pad. The position of the thrust collar is given respect to working pads.
3. SHAFT ECCENTRICITY- Eccentricity is the deviation of the mass centre from the

geometrical centre of the bearing case. It usually occurs in the rotor where there is shut down. If it becomes large then there will be lot of vibration which can be dangerous. To measure the eccentricity a passive and the active magnetic reluctance type transducer in combination with bridge ckt.
4. BEARING VIBRATION- This is one of the most vital parameters of the turbine and it has

to be monitored vibration is the to and fro motion of the machine under the influence of oscillatory forces caused by unbalanced masses in the rotating system.

PYROMETRY LAB
This lab consists of various temperature measuring instruments. Various devices used are:1. LIQUID IN GLASS THERMOMETER- Mercury in glass thermometer boils at 340C

which limits the range of temperature that can be measured. It is an L shaped thermometer, which is designed to reach all inaccessible places.
2. 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 a signal of the order mV is generated which directly indicates the temperature in the furnace.
3. THERMOCOUPLE- It works on principle of seeback effect. Two different metals are

joined to form a junction and then change in temperature causes potential difference which can be measure through voltmeter and converted into corresponding temperature scale using transducers. BTPS uses nickel chrome thermocouple. It has a maximum range of 1600C. To measure the temperature inside boiler, these thermocouples are inserted into boiler, while on other end temperature is measured.

FURNACE SAFEGUARD SUPERVISORY SYSTEM(FSSS)

FSSS as a contrast to combustion control. It is an independent and discrete digital logic system specially meant for safety and protection during starting shut down, low load and emergency conditions. It does not take part in regular station, operation a sin the case with

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combustion, control which, sends out continuous analogous signal to maintain combustion rate at optimum value to match the demand of the boilers. FUNCTIONS OF FSSSThe furnace safeguard supervisory system has been designed to provide increased safety , reliability , flexibility and overall performances of the boiler. It consist the following:a.

Furnace purge supervision:-To interlock for scanner purge airflow drum level and all fuel.

b. Secondary air damper control :- To automatically maintain wind box furnace

differential, regulate air to the fuel compartment and control the secondary air dampers.
c. Igniter control supervision:- To interlock for igniter flame, furnace purge , ignition fuel

pressure and igniter tip value position.

d. Heavy oil control and supervision:- To remote and manual start/stop. It includes

interlocks for heavy oil pressure and temperature, oil gun value positions igniter, energy atomizing differential and local maintenance switches.
e. Mill and feed control and supervision:- which has automatic operation from a single

operator start/stop switch for each mill. Individual switches are also provided for the operator to control each mill.
f. Flame scanner intelligence and checking:- it includes automatic checking of each

scanner, scanner counting network and scanner cabinet.

g. Overall boiler flame failure protection:- which during light up and low load operations. h. Boiler trip protection:- which shut down all fuel in the following events

1. Both emergency trip buttons pushed 2. Loss of all fuel 3. Turbine trip 4. Air flow less than minimum preset value(during start-up only) 5. Tripping of FD or ID fans

REFERENCES

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