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Ntpc badarpur summer training
1. BADARPUR THERMAL
POWER STATION
SUMMER TRAINING
REPORT
2012
NTPC LIMITED
2. Training at BTPS
I was appointed to do 6 week training at this esteemed
organization from 11th June to 21st July, 2012. I was assigned to visit
various division of the plant, which were:
Electrical Maintenance Department I (EMD-I)
Electrical Maintenance Department II (EMD-II)
Control and Instrumentation Department (C&I)
These 6 weeks 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 my experience at BTPS.
The material in this report has been gathered from my
textbook, senior student reports and trainers manuals and power
journals provided by training department. The specification and
principles are as learned by me from the employees of each
division of BTPS.
Anubhav Ghosh
3. INDEX
1) ABOUT NTPC
2) STRATEGIES
3) JOURNEY OF NTPC
4) ABOUT BTPS
5) OPERATION OF POWER PLANT
6) PARTS OF A POWER PLANT
7) VARIOUS CYCLES AT POWER STATION
8) ELECTRICAL MAINTENANCE DEPARTMENT-
9) ELECTRICAL MAINETNANCE DEPARTMENT-II
10) CONTROL AND INSTRUMENTATION
4. ABOUT NTPC
India’s largest power company, NTPC was set up
in 1975 to accelerate power development in
India.
NTPC became a Maharatna company in
May, 2010, one of the only four companies to be
awarded this status.
The total installed capacity of the company is
39,174 MW (including JVs) with 16 coal based and
7 gas based stations, located across the country.
In addition under JVs, 7 stations are coal based &
another station uses naptha/LNG as fuel.
The company has set a target to have an installed
power generating capacity of 1,28,000 MW by
the year 2032.
7. About BTPS
BADARPUR THERMAL POWER STATION was established on 1973 and it was the
part of Central Government.
On 01/04/1978 is was given to NTPC.
Since then operating performance of NTPC has been considerably above
the national average.
Badarpur thermal power station started with a single 95 mw unit.
There were 2 more units (95 MW each) installed in next 2 consecutive years.
Now it has total five units with total capacity of 720 MW. Ownership of BTPS
was transferred to NTPC with effect from 01.06.2006
The power is supplied to a 220 KV network that is a part of the northern grid.
The ten circuits through which the power is evacuated from the plant are:
1. Mehrauli
2. Okhla
3. Ballabgarh
4. Indraprastha
5. UP (Noida)
6. Jaipur
8. Given below are the details of unit with the year
they’re installed
9. OPERATION OF A POWER PLANT
Basic Principle
As per FARADAY’s Law-“Whenever the amount of magnetic flux linked
with a circuit changes, an EMF is produced in the circuit. Generator works
on the principle of producing electricity. To change the flux in the
generator turbine is moved in a great speed with steam.”
To produce steam, water is heated in the boilers by burning the coal.
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.
The electricity 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.
10. Basic Steps of Electricity Generation
Thebasic steps in the generation of electricity
from coal involves following steps:
Coal to steam
Steam to mechanical power
Mechanical power to electrical power
11. PARTS OF A POWER PLANT
1. Cooling tower
2. Cooling water pump
3. Transmission line (3-phase)
4. Unit transformer (3-phase)
5. Electric generator (3-phase)
6. Low pressure turbine
7. Condensate extraction pump
8. Condenser
9. Intermediate pressure turbine
10. Steam governor valve
11. High pressure turbine
12. Deaerator
13. Feed heater
14. Coal conveyor
15. Coal hopper
16. Pulverised fuel mill
17. Boiler drum
18. Ash hopper
19. Super heater
20. Forced draught fan
21. Reheater
22. Air intake
23. Economiser
24. Air preheater
25. Precipitator
26. Induced draught fan
27. Flue Gas
12. VARIOUS CYCLES AT POWER STATION
PRIMARY AIR CYCLE
SECONDARY AIR CYCLE
COAL CYLCE
ELECTRICITY CYCLE
FLUE GAS CYCLE
CONDENSATE CYCLE
FEED WATER CYCLE
STEAM CYCLE
14. MOTORS
AC MOTORS
Squirrel cage motor
Wound motor
Slip ring induction motor
In modern thermal power plant three phase squirrel cage induction motors are used but sometime
double wound motor is used when we need high starting torque e.g. in ball mill.
THREE PHASE INDUCTION MOTOR
Ns (speed) =120f/p
Stator can handle concentrated single layer winding, with each coil occupying one stator slot
The most common type of winding are:
DISTRIBUTED WINDING :
This type of winding is distributed over a number of slots.
DOUBLE LAYER WINDING :
Each stator slot contains sides of two different coils.
SQUIRREL CAGE INDUCTION MOTOR
Squirrel cage and wound cage have same mode of operation. Rotor conductors cut the rotating
stator magnetic field. an emf is induced across the rotor winding, current flows, a rotor magnetic field
is produced which interacts with the stator field causing a turning motion. The rotor does not rotate
at synchronous speed, its speed varies with applied load. The slip speed being just enough to enable
sufficient induced rotor current to produce the power dissipated by the motor load and motor losses.
15. BEARINGS AND LUBRICATIONS
A good bearing is needed for trouble free operation of motor. Since it is very costly part
of the motor, due care has to be taken by checking it at regular intervals. So lubricating
plays an important role. Two types of lubricating are widely used
Oil lubrication
Grease lubrication
Insulation
INSULATION
Winding is an essential part so it should be insulated. Following types of insulation are
widely used
INSTRUMENTS SEEN
MICROMETER
This instrument is used for measuring inside as well as outside diameter of bearing.
MEGGAR
This instrument is used for measuring insulation resistance.
VIBRATION TESTER
It measures the vibration of the motor. It is measured in three dimensions-axial, vertical
and horizontal.
16. SWITCH GEAR
Switchgear is one that makes or breaks the electrical circuit.
It is a switching device that opens & closes a circuit that defined as apparatus used
for switching, Lon rolling & protecting the electrical circuit & equipments.
The switchgear equipment is essentially concerned with switching & interrupting
currents either under normal or abnormal operating conditions.
The tubular switch with ordinary fuse is simplest form of switchgear & is used to control
& protect& other equipments in homes, offices etc.
For circuits of higher ratings, a High Rupturing Capacity (H.R.C) fuse in condition with
a switch may serve the purpose of controlling & protecting the circuit.
However such switchgear cannot be used profitably on high voltage system (3.3 KV)
for 2 reasons.
Firstly, when a fuse blows, it takes some time to replace it & consequently there is
interruption of service to customer.
Secondly, the fuse cannot successfully interrupt large currents that result from the High
Voltage System.
In order to interrupt heavy fault currents, automatic circuit breakers are used.
There are very few types of circuit breakers in B.P.T.S they are VCB, OCB, and SF6 gas
circuit breaker.
The most expensive circuit breaker is the SF6 type due to gas.
There are various companies which manufacture these circuit breakers:
VOLTAS, JYOTI, and KIRLOSKAR.
Switchgear includes switches, fuses, circuit breakers, relays & other equipments.
In low tension switch gear thermal over load relays are used whereas in high tension 5
different types of relays are used.
17. THE EQUIPMENTS THAT NORMALLY FALL IN THIS
CATEGORY ARE:-
ISOLATOR
Isolator cannot operate unless breaker is open
Bus 1 and bus 2 isolators cannot be closed simultaneously
The interlock can be bypass in the event of closing of bus coupler breaker.
No isolator can operate when the corresponding earth switch is on
SWITCHING ISOLATOR
Switching isolator is capable of:
Interrupting charging current
Interrupting transformer magnetizing current
Load transformer switching. Its main application is in connection with the transformer feeder as the unit
makes it possible to switch gear one transformer while the other is still on load.
CIRCUIT BREAKER
One which can make or break the circuit on load and even on faults is referred to as circuit
breakers. This equipment is the most important and is heavy duty equipment mainly utilized for
protection of various circuits and operations on load. Normally circuit breakers installed are
accompanied by isolators.
LOAD BREAK SWITCHES
These are those interrupting devices which can make or break circuits. These are normally on same
circuit, which are backed by circuit breakers
EARTH SWITCHES
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 equipments do not handle any
appreciable current at all. Apart from this equipment there are a number of relays etc. which are
used in switchgear.
18. Low Tension SWITCHGEAR
MAIN SWITCH
Main switch is control equipment which controls or disconnects the main supply. The main
switch for 3 phase supply is available for the range 32A, 63A, 100A, 200Q, 300A at 500V
grade.
FUSES
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. 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.
CONTACTORS
AC Contractors are 3 poles suitable for D.O.L Starting of motors and protecting the
connected motors.
OVERLOAD RELAY
For overload protection, thermal overload 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
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 50-60kg/cm^2
for high and medium capacity circuit breakers.
20. HT SWITCHGEAR
MINIMUM OIL CIRCUIT BREAKER
These use oil as quenching medium.
AIR CIRCUIT BREAKER
In this the compressed air pressure around 15 kg per cm^2 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
SF6 CIRCUIT BREAKER
The principle of current interruption is similar to that of air blast
circuit breaker. It simply employs the arc extinguishing medium namely
SF6. When it is broken down under an electrical stress, it will quickly
reconstitute itself.
VACUUM CIRCUIT BREAKER
It works on the principle that vacuum is used to save the purpose of
insulation and. In 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.
21. AIR CIRCUIT
BREAKERS
OIL CIRCUIT
BREAKERS SF6 CIRCUIT
BREAKERS
22. COAL HANDLING PLANT (CHP)
The coal handling plant consists of two plants:
Old Coal Handling Plant (OCHP)
New Coal Handling Plant (NCHP)
TheOCHP supplies coal to Unit- I, II, III &
NCHP supplies coal to Unit- IV and V.
COAL SUPPLIED AT BTPS
Coal is supplied to BTPS by Jharia coal mines.
24. The main constituents of CHP plant are:-
WAGON TIPPLER
Wagon from coal yard come to the tippler and emptied here. There are 2 wagon tipplers in
the OCHP.
CONVEYER
Conveyer belts are used in the OCHP to transfer coal from one place to other as required in
a convenient & safe way.
ZERO SPEED SWITCH
It is used as a safety device for the motor i.e. if the belt is not moving & the motor is
ON, then it burns to save the motor. This switch checks the speed of the belt & switches off
the motor when speed is zero.
METAL DETECTOR
As the conveyer belt take coal from wagon to crusher house, no metal piece should go
along with coal. To achieve this objective, metal detectors & separators are used.
CRUSHER HOUSE
Both the plants i.e. OCHP & NCHP use TATA crusher powered by BHEL motor. Crusher is
designed to crush the pieces to 20 mm size i.e. practically considered as the optimum size
for transfer via conveyer.
ROTARY BREAKER
If any large piece of metal of any hard substances like metal impurities comes in the
conveyer belt which cause load on the metal separator, then the rotary breaker rejects
them reducing the load on the metal detector.
PULL GUARD SWITCH
These are the switches which are installed at every 10m gap in a conveyer belt to
ensure the safety of motors running the conveyer belts. If at any time some accident
happens or coal jumps from belt and starts collecting at a place, then the switch
can be used.
25. SEQUENTIAL OPERATION OF OCHP
Unloading the coal
Crushing & storage.
Conveying to boiler bunkers.
Coal arrives to plant via road, rail, sea, and river or canal route from
collieries. Most of it arrives by rail route only in railway wagons. Coal
requirement by this plant is approximately 10,500 metric ton/day.
This coal is tippled into hoppers. If the coal is oversized (400 mm
sq), then it is broken manually so that it passes the hopper mesh where
through elliptic feeder it is put into vibrators & then to conveyor belt 1A &
1B.
The coal through conveyor belts 1A & 1B goes to the crusher house. Also
the extra coal is sent to stockyard through these belts.
In the crusher house the small size coal pieces goes directly to the belt 2A
& 2B whereas the big size coal pieces are crushed in the crusher & then
given to the belts 2A & 2B.
The crushed coal is taken to the bunker house via the conveyor belts 3A
& 3B where it can be used for further operations.
27. SEQUENTIAL OPERATION OF NCHP
Coal arrives in wagons and tipples into hoppers.
if the coal is oversized (400mm sq), then it is broken manually so
that it passes through the hopper mesh.
From hopper it is taken to TP-6 12A & 12B.
Conveyors 12A & 12B take the coal to the breaker house which
renders the coal size to be 100 mm sq.
Metal separator & metal detector are installed in conveyor belts
14A/B & 15A/B respectively to remove the metal impurities
Stones which are not able to pass through the 100mm sq mesh of
hammer are rejected via 18A & 18B to the rejection house.
Extra coal is sent to the reclaim hopper via conveyor 16A & 16B.
From TP-7, coal is taken by conveyor 14A & 14B to the crusher
house whose function is to render size of the coal to 20mm sq.
30. GENERATORS
The generator works on the principle of
electromagnetic induction. There are two
components stator and rotor. The rotor is
the moving part and the stator is the stationary
part. The rotor, which has a field winding, is
given a excitation through a set of 3000rpm to
give the required frequency of HZ. The rotor is
cooled by Hydrogen gas, which is locally
manufactured by the plant and has high heat
carrying capacity of low density. If oxygen and
hydrogen get mixed then they will form very
high explosive and to prevent their combining in
any way there is seal oil system. The stator
cooling is done by de-mineralized (DM) water
through hollow conductors. Water is fed by one
end by Teflon tube. A boiler and a turbine are
coupled to electric generators. Steam from the
boiler is fed to the turbine through the
connecting pipe. Steam drives the turbine rotor.
The turbine rotor drives the generator rotor
which turns the electromagnet within the coil
of wire conductors.
Carbon dioxide is provided from the top and oil
is provided from bottom to the generator. With
the help of carbon dioxide the oil is drained out
to the oil tank.
31. RATINGS OF THE GENERATORS USED
Turbo generator 100MW
TURBO GENERATOR 210 MW
The 100 MW generator generates 10.75 KV and
210 MW generates 15.75 KV. The voltage is
stepped up to 220 KV with the help of generator
transformer and is connected to the grid.
The voltage is stepped down to 6.6 KV with the
help of UNIT AUXILLARY TRANSFORMER (UAT) and
this voltage is used to drive the HT motors. The
voltage is further stepped down to 415 V and then
to 220 V and this voltage is used to drive Lt Motors.
32. TURBO GENERATOR 100MW
MAKE BHEL, Haridwar
CAPACITY 117,500 KVA
POWER 100,000 KW
STATOR VOLTAGE 10,500 V
STATOR CURRENT 6475 A
SPEED 5000rpm
POWER FACTOR 0.85
FREQUENCY 50 HZ
EXCITATION 280 V
33. TURBO GENERATOR 210MW
MAKE BHEL, Haridwar
CAPACITY 247,000 KVA
POWER 210,000 KW
STATOR VOLTAGE 15,750 V
STATOR CURRENT 9050 A
SPEED 5000 rpm
POWER FACTOR 0.85
FREQUENCY 50 HZ
EXCITATION 310 V
GAS PRESSURE 3.5 kg/cm
34. TRANSFORMERS
It is a static machine which increases or
decreases the AC voltage without changing
the frequency of the supply.
It is a device that:
Transfer electric power from one circuit
to another.
It accomplishes this by electromagnetic
induction.
In this the two electric circuits are in mutual
inductive influence of each other.
WORKING PRINCIPLE:
It works on FARADAY’S LAW
OF ELECTROMAGNETIC INDUCTION (self
or mutual induction depending on the type of
transformer).
35. COOLING OF TRANSFORMERS
OF LARGE MVA
As size of transformer becomes large, the rate of the oil circulating becomes insufficient to
dissipate all the heat produced & artificial means of increasing the circulation by electric
pumps. In very large transformers, special coolers with water circulation may have to be
employed.
TYPES OF COOLING:
Air cooling
Air Natural (AN)
Air Forced (AF)
Oil immersed cooling
Oil Natural Air Natural (ONAN)
Oil Natural Air Forced (ONAF)
Oil Forced Air Natural (OFAN)
Oil Forced Air Forced (OFAF)
Oil immersed Water cooling
Oil Natural Water Forced (ONWF)
Oil Forced Water Forced (OFWF)
36. MAIN PARTS OF TRANSFORMER
1. Secondary Winding
2. Primary Winding.
3. Oil Level
4. Conservator
5. Breather
6. Drain Cock
7. Cooling Tubes.
8. Transformer Oil.
9. Earth Point
10. Explosion Vent
11. Temperature Gauge.
12. Buchholz Relay
13. Secondary Terminal
14. Primary Terminal
37. GENERATOR TRANSFORMER
(125MVA UNIT-I & UNIT-III)
RATING 125MVA
TYPE OF COOLING OFB
TEMP OF OIL 45^C
TEMP WINDING 60^C
KV (no load) HV-233 KVA
LV-10.5 KVA
LINE AMPERES HV-310 A
LV-6880
PHASE THREE
FREQUENCY 50 HZ
IMPEDANCE VOLTAGE 15%
VECTOR GROUP Y DELTA
INSULATION LEVEL HV-900 KV
LV-Neutral-38
CORE AND WINDING WEIGHT 110500 Kg
WEIGHT OF OIL 37200 Kg
TOTAL WEIGHT 188500 Kg
OIL QUANTITY 43900 lit
38. GENERATOR TRANSFORMER
(166 MVA UNIT-IV)
RATING 240MVA
TYPE OF COOLING ON/OB/OFB
TEMP OF OIL 45 C
TEMP WINDING 60 C
VOLTS AT NO LOAD HV-236000
LV-A5750
LINE AMPERES HV-587 A
LV-8798
PHASE THREE
FREQUENCY 50 HZ
IMPEDANCE VOLTAGE 15.55%
VECTOR GROUP Y DELTA
CORE AND WINDING WEIGHT 138800 Kg
WEIGHT OF OIL 37850 Kg
TOTAL WEIGHT 234000 Kg
OIL QUANTITY 42500 lit
GUARANTEED MAX TEMP 45 C
DIVISION KERELA
YEAR 1977
39. UNIT AUXILIARY TRANSFORMER (UAT)
Unit I & V- 12.5 MVA
The UAT draws its input from the main bus-ducts. The total KVA
capacity of UAT required can be determined by assuming 0.85
power factor & 90% efficiency for total auxiliary motor load. It is
safe & desirable to provide about 20% excess capacity then
circulated to provide for miscellaneous auxiliaries & possible
increase in auxiliary.
STATION TRANSFORMER
It is required to feed power to the auxiliaries during startups. This
transformer is normally rated for initial auxiliary load requirements
of the unit in typical cases; this load is of the order of 60% of the
load at full generating capacity. It is provided with on load tap
change to cater to the fluctuating voltage of the grid.
NEUTRAL GROUNDED TRANSFORMER
This transformer is connected with supply coming out of UAT in
stage-2. This is used to ground the excess voltage if occurs in the
secondary of UAT in spite of rated voltage.
40. SWITCH YARD
As we know that electrical energy can’t be stored like cells, so what we generate should be consumed
instantaneously. But as the load is not constants therefore we generate electricity according to need i.e.
the generation depends upon load. The yard is the places from where the electricity is send outside. It
has both outdoor and indoor equipments.
OUTDOOR EQUIPMENTS
BUS BAR.
LIGHTENING ARRESTER
WAVE TRAP
BREAKER
CAPACITATIVE VOLTAGE TRANSFORMER
EARTHING ROD
CURRENT TRANSFORMER.
POTENTIAL TRANSFORMER
LIGHTENING MASK
INDOOR EQUIPMENTS
RELAYS.
CONTROL PANELS
CIRCUIT BREAKERS
41. BUS BAR
Bus bars generally are of high conductive aluminum conforming to IS-5082 or copper
of adequate cross section. Bus bar located in air insulated enclosures & segregated from all
other components .Bus bar is preferably cover with polyurethane.
BY PASS BUS
This bus is a backup bus which comes handy when any of the buses become faulty. When
any operation bus has fault, this bus is brought into circuit and then faulty line is removed there
by restoring healthy power line.
LIGHTENING ARRESTOR
It saves the transformer and reactor from over voltage and over currents. It grounds the
overload if there is fault on the line and it prevents the generator transformer.
WAVE TRAP
WAVETRAP is connected in series with the power (transmission) line. It blocks the high
frequency carrier waves (24 KHz to 500 KHz) and let power waves (50 Hz - 60 Hz) to pass-
through.
BREAKER
Circuit breaker is an arrangement by which we can break the circuit or flow of current. A
circuit breaker in station serves the same purpose as switch but it has many added and
complex features. The basic construction of any circuit breaker requires the separation of
contact in an insulating fluid that servers two functions:
extinguishes the arc drawn between the contacts when circuit breaker opens.
It provides adequate insulation between the contacts and from each contact to earth.
42. EARTHING ROD
Normally un-galvanized mild steel flats are used for earthling. Separate earthing electrodes
are provided to earth the lightening arrestor whereas the other equipments are earthed by
connecting their earth leads to the rid/ser of the ground mar.
CURRENT TRANSFORMER
It is essentially a step up transformer which step down the current to a known ratio. It is a type
of instrument transformer designed to provide a current in its secondary winding proportional
to the alternating current flowing in its primary.
POTENTIAL TRANSFORMER
It is essentially a step down transformer and it step downs the voltage to a known ratio.
RELAYS
Relay is a sensing device that makes your circuit ON or OFF. They detect the abnormal
conditions in the electrical circuits by continuously measuring the electrical quantities, which
are different under normal and faulty conditions, like current, voltage frequency. Having
detected the fault the relay operates to complete the trip circuit, which results in the opening
of the circuit breakers and disconnect the faulty circuit.
There are different types of relays:
Current relay
Potential relay
Electromagnetic relay
Numerical relay etc.
AIR BREAK EARTHING SWITCH
The work of this equipment comes into picture when we want to shut down the supply for
maintenance purpose. This help to neutralize the system from induced voltage from extra high
voltage. This induced power is up to 2KV in case of 400 KV lines.
43. CONTROL & INSTRUMENTATION
INTRODUCTION
C&I LABS
CONTROL & MONITORING MECHENISM
PRESSURE MONITORING
TEMPERATURE MONITORING
FLOW MEASUREMENT
CONTROL VALVES
44. INTRODUCTION
This division basically calibrates various instruments and takes
care of any faults occur in any of the auxiliaries in the plant.
“Instrumentation can be well defined as a technology of
using instruments to measure and control the physical and
chemical properties of a material.”
C&I LABS
Control and Instrumentation Department has following labs:
Manometry Lab.
Protection and Interlocks Lab.
Automation Lab.
Electronics Lab.
Water Treatment Plant.
Furnaces Safety Supervisory System Lab