CHAPTER-1

INTRODUCTION OF NTPC
1.1 INTRODUCTION
NTPC Limited (Company) was incorporated in November 1975 with the objective to
plan and promote development of thermal power in the country. In May 1998, NTPC
diversified its objectives to include new business activities like development of hydro
power and power through nonconventional or renewable energy sources. As on 31 March
2010, NTPC with an installed power generating capacity of 28,902 mega watt (MW)
from 15 coal based thermal power stations and seven gas/liquid fuel based power stations
was the largest thermal power generating company of the country. NTPC contributed 28
per cent of the total electricity generation of the country as of 31 March 2010. NTPC is a
Government Company wherein Government of India holds 84.50 per cent of the total
equity.
In line with the objective of National Electricity Policy (February 2005) to increase
annual per capita consumption of electricity from the existing level of 631 units to 1,000
units, NTPC planned (April 2007) a Capacity Addition Programmed to become a
50,000MW Company by 2012. Since, NTPC had installed capacity of 27404 MW up to
31st March 2007, the Company planned to increase the capacity by 22,600 MW (83
percent) during next five years (2007-2012). However, due to non-fructification,
rescheduling or substitution, the Company revised (2007-08) its target downward to
22,430 MW to be achieved during 2007-2012. In order to achieve this target, NTPC
decided (2006-07) to adopt a multi-pronged growth strategy. A list of projects identified
for capacity addition during the above period is placed at Annexure-I based on type of
fuel to be used (i.e. Thermal, Hydro or Wind) and nature of project (i.e. Greenfield or
Expansion).
The Management stated (November 2010) that the capacity addition target of 22,430 MW was approved
neither by the Planning Commission nor by the Ministry of Power. Analysis should be done only against
the target for capacity addition of 17,760 MW fixed by Planning Commission for NTPC for 11th Plan.
We do not agree with the Management as the capacity addition target of 22,430 MW was set by the
1

Company itself as per the Corporate Plan. The Company had in fact identified projects to augment
capacity for 22,430 MW during 2007-12 and had also initiated action on these projects.
Of the target of 22,430 MW fixed involving 24 projects, the Company commissioned only five thermal
projects involving 4,220 MW (19 percent) till August 2010 of which Ratnagiri project was a revival
project. Further, out of above target, two projects involving 760 MW have not been so far (August 2010)
awarded. Out of balance 17,450 MW involving 17 projects, the size of Muzaffarpur Expansion project
was reduced by 110 MW. The Company anticipates achieving another 5,000 MW out of 17,340 MW on
firm basis by March 2012.
Thus, against the target of 22,430 MW, Company would be able to achieve only 9,220 MW resulting in a
shortfall of 13,210 MW (59 per cent). Analysis of progress made so far reveals that although the
Company anticipates to achieve additional 4,530 MW involving six projects on best effort basis,
commissioning of these projects appears to be difficult by March 2012 as present status of progress of
work is far from satisfactory.

1.2 INSTALLED CAPACITY $ GENERATION

Fig. 1.1 GROWTH OF NTPC

In October 2004, NTPC launched its Initial Public Offering (IPO) consisting of 5.25% as
fresh issue and 5.25% as offer for sale by Government of India. NTPC thus became a
listed company in November 2004 with the Government holding 89.5% of the equity
share capital. In February 2010, the Shareholding of Government of India was reduced

from 89.5% to 84.5% through Further Public Offer. The rest is held by Institutional
Investors and the Public.

Fig. 1.2 NTPC CONTRIBUTION IN GENERATION

1.3 STRATEGIES

Fig. 1.3 STRATEGIES

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1.3.1 TECHNOLOGICAL INITIATIVES

Introduction of steam generators (boilers) of the size of 800 MW.

Integrated Gasification Combined Cycle (IGCC) Technology.

Launch of Energy Technology Centre -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.

Mechanism to help get / earn Certified Emission Reduction.

1.3.2 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

to0.5% of net profit annually for Community Welfare.

The welfare of project affected persons and the local population around NTPC
projects are taken care of through well drawn Rehabilitation and Resettlement
policies.

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

1.3.3 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 Programmed for improvement of PLF

of 15 Power Stations of SEBs.

Rural Electrification work under Rajiv Gandhi Garmin Vidyutikaran.

1.3.4 ENVIRONMENT MANAGEMENT

All stations of NTPC are ISO 14001 certified.

Various groups to care of environmental issues.

The Environment Management Group.

Ash utilization Division.

A forestation 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

1.4 VISION
To be the worlds largest and best power producer, powering Indias growth.

1.5 MISSION
Develop and provide reliable power, related products and service at competitive prices,
integrating multiple energy sources with innovative and eco-friendly technologies and
contribute to society.

1.6 JOURNEY OF NTPC

Fig. 1.4 JOURNEY OF NTPC

CHAPTER-2
ABOUT BADARPUR THERMAL POER STATION
2.1 INTRODUCTION
BADARPUR THERMAL POWER STATION was established on 1973 and it was the
part of Central Government. On 01/04/1978 is given as No Loss No Profit Plant of
NTPC. Since then operating performance of NTPC has been considerably above the
national average. The availability factor for coal stations has increased from 85.03 % in
1997-98 to 90.09 % in 2006-07, which compares favorably with international standards.
The PLF has increased from 75.2%in1997-98 to 89.4% during the year 2006-07 which is
the highest since the inception of NTPC.
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 through GOIs Gazette Notification.
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
Given below are the details of unit with the year theyre installed.

Address

Badarpur,New Delhi-110044

Installed capacity

720MW

Derated capacity

705MW

Location

New Delhi

Coal Source

Jharia coal fields

Water Source

Agra Canal

Beneficiary states

Delhi

Unit sizes

3*95MW
2*210MW

Units commissioned

Unit 1-95MW July 1973

Unit 2-95MW August 1974
Unit 3-95MW March 1975
Unit 4-210MW December 1978
Unit 5-210MW December 1981

International assistance

Ownership of BTPS was transferred to

NTPC with
effect from 1-06-2006 GOIs Gazette
notification

Table 2.1 BTPS INFORMATION

2.2 STATION LOCATION

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

2.3 NTPC ENVIRONMENT POLICY

NTPC is committed to the environment, generating power at minimal environmental cost

and preserving the ecology in the vicinity of the plants. NTPC has undertaken massive a
forestation in the vicinity of its plants. Plantations have increased forest area and reduced
barren land. The massive a forestation by NTPC in and around its Ramagundam Power
station (2600 MW) have contributed reducing the temperature in the areas by about 3c.
NTPC has also taken proactive steps for ash utilization. In 1991, it set up Ash Utilization
Division A.
"Centre for Power Efficiency and Environment Protection- CENPEE" has been
established in NTPC with the assistance of United States Agency for International
Development- USAID. CENPEEP is efficiency oriented, eco-friendly and eco-nurturing
initiative - a symbol of NTPC's concern towards environmental protection and continued
commitment to sustainable power development in India. As a responsible corporate
citizen, NTPC is making constant efforts to improve the socio-economic status of the
people affected by its projects. Through its Rehabilitation and Resettlement programmes,
the company endeavors to improve the overall socio economic status Project Affected
Persons. NTPC was among the first Public Sector Enterprises to enter into a
Memorandum of Understanding-MOU with the Government in 1987-88. NTPC has been
placed under the 'Excellent category' (the best category) every year since the MOU
system became operative. Harmony between man and environment is the essence of
healthy life and growth. Therefore, maintenance of ecological balance and a pristine
environment has been of utmost importance to NTPC. It has been taking various
measures discussed below for mitigation of environment pollution due to power
generation.
NTPC is the second largest owner of trees in the country after the Forest department.
As early as in November 1995, NTPC brought out a comprehensive document entitled
"NTPC Environment Policy and Environment Management System". Amongst the
guiding principles adopted in the document is companys proactive approach to
environment, optimum utilization of equipment, adoption of latest technologies and
continual environment improvement. The policy also envisages efficient utilization of
resources, thereby minimizing waste, maximizing ash utilization and providing green belt
all around the plant for maintaining ecological balance.
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2.3.1 ENVIRONMENT MANAGEMENT, OCCUPATIONAL HEALTH AND

SAFETY SYSTEMS:
NTPC has actively gone for adoption of best international practices on environment,
occupational health and safety areas. The organization has pursued the Environmental
Management System (EMS) ISO 14001 and the Occupational Health and Safety
Assessment System OHSAS 18001 at its different establishments. As a result of pursuing
these practices, all NTPC power stations have been certified for ISO 14001 & OHSAS
18001 by reputed national and international Certifying Agencies
2.3.2 POLLUTION CONTROL SYSTEMS:
While deciding the appropriate technology for its projects, NTPC integrates many
environmental provisions into the plant design. In order to ensure that NTPC complies
with all the stipulated environment norms, various state-of-the-art pollution control
systems / devices as discussed below have been installed to control air and water
pollution.
2.3.3 ELECTROSTATIC PRECIPITATORS:
The ash left behind after combustion of coal is arrested in high efficiency Electrostatic
Precipitators (ESPs) and particulate emission is controlled well within the stipulated
norms. The ash collected in the ESPs is disposed to Ash Ponds in slurry form.
2.3.4 LIQUID WASTE TREATMENT PLANTS & MANAGEMENT SYSTEM:
The objective of industrial liquid effluent treatment plant (ETP) is to discharge lesser and
cleaner effluent from the power plants to meet environmental regulations. After primary
treatment at the source of their generation, the effluents are sent to the ETP for further
treatment. The composite liquid effluent treatment plant has been designed to treat all
liquid effluents which originate within the power station e.g. Water Treatment Plant
(WTP), Condensate Polishing Unit (CPU) effluent, Coal Handling Plant (CHP) effluent,
floor washings, service water drains etc.

10

CHAPTER-3
OPERATION OF A POWER PLANT

3.1 BASIC PRINCIPLE

As per FARADAYs 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 PowerStation, 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.
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.

3.2 BASIC STEPS OF ELECTRICITY GENERATION

The basic steps in the generation of electricity from coal involves following steps:

Coal to steam

Steam to mechanical power

Mechanical power to electrical power

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Fig. 3.1 THERMAL POWER PLANT

3.2.1 COAL TO ELECTRICITY:

Fig. 3.2 COAL TO ELECTRICITY

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Fig. 3.3 POWER PLANT CYCLE

3.3 FACTORS AFFECTING THERMAL CYCLE EFFICIENCY

Thermal cycle efficiency is affected by following

Initial stream pressure.

Initial stream temperature.

Whether reheat is used or not, and if used reheat pressure and temperature.

Condenser pressure.

3.4 PARTS OF A POWER PLANT

The various parts are listed below: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

13

Fig. 3.4 PARTS OF A POWER PLANT

10. STEAM GOVERNOR VALVE
11. HIGH PRESSURE TURBINE 21
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
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27. FLUE GAS

3.4.1 COOLING TOWER
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove process
heat and cool the working fluid to near the wet-bulb air temperature or in the case of
closed circuit dry cooling towers rely solely on air to cool the working fluid to near the
dry-bulb air temperature. Common applications include cooling the circulating water
used in oil refineries, chemical plants, power stations and building cooling. The towers
vary in size from small roof-top units to very large hyperboloid structures that can be up
to 200 meters tall and 100 meters in diameter, or rectangular structures that can be over
40 meters tall and 80 meters long. Smaller towers are normally factory-built, while larger
ones are constructed on site. The absorbed heat is rejected to the atmosphere by the
evaporation of some of the cooling water in mechanical forced-draft or induced Draft
towers or in natural draft hyperbolic shaped cooling towers as seen at most nuclear power
plants.
3.4.2 COOLING WATER PUMP
It pumps the water from the cooling tower which goes to the condenser.
3.4.3 THREE PHASE TRANSMISSION LINE
Three phase electric power is a common method of electric power transmission. It is a
type of polyphase system mainly used to power motors and many other devices. A three
phase system uses less conductive material to transmit electric power than equivalent
single phase, two phase, or direct current system at the same voltage. In a three phase
system, three circuits reach their instantaneous peak values at different times. Taking
current in one conductor as the reference, the currents in the other two are delayed in time
by one-third and two-third of one cycle .This delay between phases has the effect of
giving constant power transfer over each cycle of the current and also makes it possible
to produce a rotating magnetic field in an electric motor.

15

At the power station, an electric generator converts mechanical power into a set of
electric currents, one from each electromagnetic coil or winding of the generator. The
current are sinusoidal functions of time, all at the same frequency but offset in time to
give different phases. In a three phase system the phases are spaced equally, giving a
phase separation of one-third of one cycle. Generators output at a voltage that ranges
from hundreds of volts to 30,000 volts.
3.4.4 UNIT TRANSFORMER (3-PHASE)
At the power station, transformers step-up this voltage to one more suitable for
transmission. After numerous further conversions in the transmission and distribution
network the power is finally transformed to the standard mains voltage (i.e. the
household voltage). The power may already have been split into single phase at this
point or it may still be three phase. Where the step-down is 3 phase, the output of this
transformer is usually star connected with the standard mains voltage being the phaseneutral voltage. Another system commonly seen in North America is to have a delta
connected secondary with a centre tap on one of the windings supplying the ground and
neutral. This allows for 240 V three phase as well as three different single phase voltages(
120 V between two of the phases and neutral , 208 V between the third phase ( or wild
leg) and neutral and 240 V between any two phase) to be available from the same supply.
3.4.5 ELECTRICAL GENERATOR
An Electrical generator is a device that converts kinetic energy to electrical energy,
generally using electromagnetic induction. The task of converting the electrical energy
into mechanical energy is accomplished by using a motor. The source of mechanical
energy maybe water falling through the turbine or steam turning a turbine (as is the case
with thermal power plants). There are several classifications for modern steam turbines.
Steam turbines are used in our entire major coal fired power stations to drive the
generators or alternators, which produce electricity. The turbines themselves are driven
by steam generated in "boilers or "steam generators" as they are sometimes called.
Electrical power stations use large steam turbines driving electric generators to produce
most (about 86%) of the worlds electricity.
16

These centralized stations are of two types: fossil fuel power plants and nuclear power
plants. The turbines used for electric power generation are most often directly coupled to
their-generators .As the generators must rotate at constant synchronous speeds according
to the frequency of the electric power system, the most common speeds are 3000 r/min
for 50 Hz systems, and 3600 r/min for 60 Hz systems. Most large nuclear sets rotate at
half those speeds, and have a 4-pole generator rather than the more common 2-pole one.
3.4.6 LOW PRESSURE TURBINE
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
stages consisting of a stationary blade (or nozzle) and a rotating blade. Stationary blades
convert the potential energy of the steam into kinetic energy and direct the flow onto the
rotating blades. The rotating blades convert the kinetic energy into impulse and reaction
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. Low
Pressure Turbine (LPT) consists of 4x2 stages. After passing through Intermediate
Pressure Turbine steam is passed through LPT which is made up of two parts- LPC
REAR & LPC FRONT. As water gets cooler here it gathers into a HOTWELL placed in
lower parts of turbine.
3.4.7 CONDENSATION EXTRACTION PUMP
A Boiler feed water pump is a specific type of pump used to pump water into a steam
boiler. The water may be freshly supplied or returning condensation of the steam
produced by the boiler. These pumps are normally high pressure units that use suction
from a condensate return system and can be of the centrifugal pump type or positive
displacement type. Construction and operation: Feed water pumps range in size up to
many horsepower and the electric motor is usually separated from the pump body by
some form of mechanical coupling. Large industrial condensate pumps may also serve as
the feed water pump. In either case, to force the water into the boiler, the pump must
generate sufficient pressure to overcome the steam pressure developed by the boiler. This
is usually accomplished through the use of a centrifugal pump.
17

Feed water pumps usually run intermittently and are controlled by a float switch or other
similar level-sensing device energizing the pump when it detects a lowered liquid level in
the boiler. Some pumps contain a two-stage switch. As liquid lowers to the trigger point
of the first stage, the pump is activated. If the liquid continues to drop, (perhaps because
the pump has failed, its supply has been cut off or exhausted, or its discharge is blocked)
the second stage will be triggered. This stage may switch off the boiler equipment
(preventing the boiler from running dry and overheating), trigger an alarm, or both.
3.4.8 CONDENSER
The steam coming out from the Low Pressure Turbine (a little above its boiling pump) is
brought into thermal contact with cold water (pumped in from the cooling tower) in the
condenser, where it condenses rapidly back into water, creating near Vacuum-like
conditions inside the condenser chest.
3.4.9 INTERMEDIATE PRESSURE TURBINE
Intermediate Pressure Turbine (IPT) consists of 11 stages. When the steam has been
passed through HPT it enters into IPT. IPT has two ends named as FRONT & REAR.
Steam enters through front end and leaves from Rear end.
3.4.10 STEAM GOVERNOR VALVE
Steam locomotives and the steam engines used on ships and stationary applications such
as power plants also required feed water pumps. In this situation, though, the pump was
often powered using a small steam engine that ran using the steam produced by the boiler
a means had to be provided, of course, to put the initial charge of water into the boiler
(before steam power was available to operate the steam-powered feed water pump).The
pump was often a positive displacement pump that had steam valves and cylinders at one
end and feed water cylinders at the other end; no crankshaft was required. In thermal
plants, the primary purpose of surface condenser is to condense the exhaust steam from a
steam turbine to obtain maximum efficiency and also to convert the turbine exhaust
steam into pure water so that it may be reused in the steam generator or boiler as boiler
feed water.
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By condensing the exhaust steam of a turbine at a pressure below atmospheric pressure,

the steam pressure drop between the inlet and exhaust of the turbine is increased, which
increases the amount heat available for conversion to mechanical power. Most of the heat
liberated due to condensation of the exhaust steam is carried away by the cooling medium
(water or air) used by the surface condenser. Control valves are valves used within
industrial plants and elsewhere to control operating conditions such as temperature,
pressure, flow and liquid level by fully or partially opening or closing in response to
signals received from controllers that compares a set point to a process variable
whose value is provided by sensors that monitor changes in such conditions. The opening
or closing of control valves is done by means of electrical, hydraulic or pneumatic
systems.
3.4.11 HIGH PRESSURE TURBINE
Steam coming from Boiler directly feeds into HPT at a temperature of 540C and at a
pressure of 136 kg/cm2. Here it passes through 12 different stages due to which its
temperature goes down to 329C and pressure as 27 kg/cm2. This line is also called as
CRH COLD REHEAT LINE. It is now passed to a REHEATER where its temperature
rises to 540C and called as HRH-HOT REHEATED LINE.
3.4.12 DEAERATOR
A Deaerator is a device for air removal and used to remove dissolved gases (an alternate
would be the use of water treatment chemicals) from boiler feed water to make it
noncorrosive. A dearator typically includes a vertical domed deaeration section as the
deaeration boiler feed water tank. A Steam generating boiler requires that the circulating
steam, condensate, and feed water should be devoid of dissolved gases, particularly
corrosive ones and dissolved or suspended solids. The gases will give rise to corrosion of
the metal. The solids will deposit on the heating surfaces giving rise to localized heating
and tube ruptures due to overheating. Under some conditions it may give rise to stress
corrosion cracking. Deaerator level and pressure must be controlled by adjusting control
valves the level by regulating condensate flow and the pressure by regulating steam flow.

19

If operated properly, most deaerator vendors will guarantee that oxygen in the deaerated
water will not exceed 7 ppb by weight (0.005 cm3/L)
3.4.13 FEED WATER HEATER
A Feed water heater is a power plant component used to pre-heat water delivered to a
steam generating boiler. Preheating the feed water reduces the irreversibility involved in
steam generation and therefore improves the thermodynamic efficiency of the system.
This reduces plant operating costs and also helps to avoid thermal shock to the boiler
metal when the feed water is introduced back into the steam cycle. In a steam power
(usually modelled as a modified Rankin cycle), feed water heaters allow the feed water to
be brought up to the saturation temperature very gradually. This minimizes the inevitable
irreversibility associated with heat transfer to the working fluid (water).
3.4.14 COAL CONVEYOR
Coal conveyors are belts which are used to transfer coal from its storage place to Coal
Hopper. A belt conveyor consists of two pulleys, with a continuous loop of material- the
conveyor Belt that rotates about them. The pulleys are powered, moving the belt and
the material on the belt forward. Conveyor belts are extensively used to transport
industrial and agricultural material, such as grain, coal, ores etc.
3.4.15 COAL HOPPER
Coal Hoppers are the places which are used to feed coal to Fuel Mill. It also has the
arrangement of entering Hot Air at 200C inside it which solves our two purposes:1. If our Coal has moisture content then it dries it so that a proper combustion takes place.
2. It raises the temperature of coal so that its temperature is more near to its Ignite
Temperature so that combustion is easy.
3.4.16 PULVERIZED FUEL MILL
A pulveriser is a device for grinding coal for combustion in a furnace in a fossil fuel
power plant.

20

3.4.17 BOILER DRUM

Steam Drums are a regular feature of water tube boilers. It is reservoir of water/steam at
the top end of the water tubes in the water-tube boiler. They store the steam generated in
the water tubes and act as a phase separator for the steam/water mixture. The difference
in densities between hot and cold water helps in the accumulation of the hotterwater/and saturated steam into steam drum. Made from high-grade steel (probably
stainless) and its working involve temperature of 390C and pressure well above 350psi
(2.4MPa). The separated steam is drawn out from the top section of the drum. Saturated
steam is drawn off the top of the drum. The steam will re-enter the furnace in through a
super heater, while the saturated water at the bottom of steam drum flows down to the
mud-drum /feed water drum by down comer tubes accessories include a safety valve,
water level indicator and fuse plug.
3.4.18 ASH HOPPER
A steam drum is used in the company of a mud-drum/feed water drum which is located at
a lower level. So that it acts as a sump for the sludge or sediments which have a tendency
to accumulate at the bottom.
3.4.19 SUPER HEATER
A Super heater is a device in a steam engine that heats the steam generated by the boiler
again increasing its thermal energy. Super heaters increase the efficiency of the steam
engine, and were widely adopted. Steam which has been superheated is logically known
as superheated steam; non- superheated steam is called saturated steam or wet steam.
Super heaters were applied to steam locomotives in quantity from the early 20th century,
to most steam vehicles, and also stationary steam engines including power stations.
3.4.20 FORCE DRAUGHT FAN
External fans are provided to give sufficient air for combustion. The forced draught fan
takes air from the atmosphere and, warms it in the air preheater for better combustion,
injects it via the air nozzles on the furnace wall.
21

3.4.21 REHEATER
Reheater is a heater which is used to raise the temperature of steam which has fallen from
the intermediate pressure turbine.
3.4.22 AIR INTAKE
Air is taken from the environment by an air intake tower which is fed to the fuel.
3.4.23 ECONOMIZERS
Economizer, or in the UK economizer, are mechanical devices intended to reduce energy
consumption, or to perform another useful function like preheating a fluid. The term
economizer is used for other purposes as well-Boiler, power plant, heating, ventilating
and air-conditioning. In boilers, economizer are heat exchange devices that heat fluids ,
usually water, up to but not normally beyond the boiling point of the fluid. Economizers
are so named because they can make use of the enthalpy and improving the boilers
efficiency. They are devices fitted to a boiler which save energy by using the exhaust
gases from the boiler to preheat the cold water used to fill it (the feed water). Modern day
boilers, such as those in cold fired power stations, are still fitted with economizer which
is decedents of Greens original design. In this context there are turbines before it is
pumped to the boilers. A common application of economizer in steam power plants is to
capture the waste heat from boiler stack gases (flue gas) and transfer thus it to the boiler
feed water thus lowering the needed energy input , in turn reducing the firing rates to
accomplish the rated boiler output . Economizer lower stack temperatures which may
cause condensation of acidic combustion gases and serious equipment corrosion damage
if care is not taken in their design and material selection.
3.4.24 AIR PREHEATER
Air preheater is a general term to describe any device designed to heat air before another
process (for example, combustion in a boiler). The purpose of the air preheater is to
recover the heat from the boiler flue gas which increases the thermal efficiency of the
boiler by reducing the useful heat lost in the flue gas. As a consequence, the flue gases
22

are also sent to the flue gas stack (or chimney) at a lower temperature allowing simplified
design of the ducting and the flue gas stack. It also allows control over the temperature of
gases leaving the stack.
3.4.25 PRECIPITATOR
An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that
removes particles from a flowing gas (such as air) using the force of an induced
electrostatic charge. Electrostatic precipitators are highly efficient filtration devices, and
can easily remove fine particulate matter such as dust and smoke from the air steam.
ESPs continue to be excellent devices for control of many industrial particulate
emissions, including smoke from electricity-generating utilities (coal and oil fired), salt
cake collection from black liquor boilers in pump mills, and catalyst collection from
fluidized bed catalytic crackers from several hundred thousand ACFM in the largest coalfired boiler applications. The original parallel plate-Weighted wire design (described
above) has evolved as more efficient (and robust) discharge electrode designs, today
focus is on rigid discharge electrodes to which many sharpened spikes are attached ,
maximizing corona production. Transformer rectifier systems apply voltages of 50-100
Kilovolts at relatively high current densities. Modern controls minimize sparking and
prevent arcing, avoiding damage to the components. Automatic rapping systems and
hopper evacuation systems remove the collected particulate matter while on line allowing
ESPs to stay in operation for years at a time.
3.4.26 INDUCED DRAUGHT FAN
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, which additionally
minimizes erosion of the ID fan.

23

3.4.27 FLUE GAS STACK

A Flue gas stack is a type of chimney, a vertical pipe, channel or similar structure through
which combustion product gases called flue gases are exhausted to the outside air. Flue
gases are produced when coal, oil, natural gas, wood or any other large combustion 31
device. Flue gas is usually composed of carbon dioxide (CO2) and water vapour as well
as nitrogen and excess oxygen remaining from the intake combustion air. It also contains
a small percentage of pollutants such as particulates matter, carbon mono oxide, nitrogen
oxides and sulphur oxides. The flue gas stacks are often quite tall, up to 400 meters (1300
feet) or more, so as to disperse the exhaust pollutants over a greater area and thereby
reduce the concentration of the pollutants to the levels required by government's
environmental policies and regulations. The flue gases are exhausted from stoves, ovens,
fireplaces or other small sources within residential abodes, restaurants, hotels through
other stacks which are referred to as chimneys.

3.5 VARIOUS CYCLES AT POWER STATION

3.5.1 PRIMARY AIR CYCLE

Fig. 3.5 PRIMARY AIR CYCLE

24

3.5.2 SECONDARY AIR CYCLE

Fig. 3.6 SECONDARY AIR CYCLE

3.5.3 ELECTRICITY CYCLE

Fig. 3.7 ELECTRICITY CYCLE

25

3.5.4 CONDENSATE CYCLE

Fig. 3.8 CONDENSATE CYCLE

26

3.5.5 FEED WATER CYCLE

Fig. 3.9 FEED WATER CYCLE

27

3.5.6 STEAM CYCLE

Fig. 3.10 STEM CYCLE

28

3.5.7 COAL CYCLE

Fig. 3.11 COAL CYCLE

29

3.5.8 FLUE GAS CYCLE

3.12 FLUE GAS CYCLE

30

CHAPTER-4
ELECTRICAL MAINTENANCE DEPARTMENT I
4.1MOTORS
Motors can be classified as AC and DC .
4.1.1 AC MOTORS
1. Squirrel cage motor
2. Wound motor
3. 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.

4.1.2 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 motion. The
rotor does not rotate at synchronous speed, its speed varies with applied load.

31

The slip speed being just enough to enable sufficient induced rotor current to
produce the power dissipated by the motor load and motor losses.

4.1.3 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
1. Oil lubrication
2. Grease lubrication
3. Insulation
4.1.4 INSULATION
Winding is an essential part so it should be insulated. Following types of insulation are
widely used
TYPES OF INSULATION
CLASS
Y

TEMP UPTO WHICH THEY ARE

EFFECTIVE (DEGREE CENTIGRADE)
90

105

120

130

150

180

More than 180

Table 4.1 TYPE OF INSULATORS

F class insulation is generally preferred.

4.1.5 MAIN MOTOR USED IN BOILER AND OFF SIDE AREA
1. ID FAN( 2 PER UNIT)
It is located between EP and chimney used for creating induced draft in the
furnace.
32

2. PA FAN(2 PER UNIT)

It is used for handling atmospheric air up to temperature 50 degree centigrade
3. FD FAN(2 PER UNIT)
It is used for handling secondary air for the boiler.
4. SCANNER FAN( 2 PER UNIT )
It is required for requisite air for scanner cooling.
5. IGNITOR FAN
It supplies air for cooling of igniters.
4.1.6 INSTRUMENTS SEEN
1. MICROMETER
This instrument is used for measuring inside as well as outside diameter of
bearing.
2. MEGGAR
This instrument is used for measuring insulation resistance.
3. VIBRATION TESTER
It measures the vibration of the motor. It is measured in three dimensions-axial,
vertical and horizontal.

4.2 SWITCHGEAR
4.2.1 INTRODUCTION
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.
33

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.
4.2.2 EQUIPMENTS:

ISOLATOR: An isolator is one that can break the electrical circuit when the
circuit is to be switched on no load. These are used in various circuits for isolating
the certain portion when required for maintenance etc. An operating mechanism
box normally installed at ground level drives the isolator. The box has an
operating mechanism in addition to its contactor circuit and auxiliary contacts
may be solenoid operated pneumatic three phase motor or DC motor transmitting
through a spur gear to the torsion shaft of the isolator. Certain interlocks are also
provided with the isolator
These are
1. Isolator cannot operate unless breaker is open
2. Bus 1 and bus 2 isolators cannot be closed simultaneously
3. The interlock can be bypass in the event of closing of bus coupler breaker.
4. No isolator can operate when the corresponding earth switch is on

SWITCHING ISOLATOR
Switching isolator is capable of:

1. 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.
34

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.

4.2.3 LT SWITCHGEAR
In LT switchgear there is no interlocking. It is classified in following ways:

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.

35

CONTACTORS: AC Contractors are 3 poles suitable for D.O.L Starting of

motors and protecting the connected motors.

Fig. 4.1 CONTACTOR

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.

Fig. 4.2 OVERLOAD RELAY

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.

36

This reduces the possibility of sparking. The pressure may vary from 5060kg/cm^2 for high and medium capacity circuit breakers.

4.2.4 HT SWITCHGEAR

MINIMUM OIL CIRCUIT BREAKER: 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.

Fig. 4.3 OIL CIRCUIT BREAKER

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

37

Motor Voltage-220 V/DC

AIR CIRCUIT BREAKER

Fig. 4.4 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: It has the following advantages over OCB:i.

Fire hazard due to oil are eliminated.

ii.

Operation takes place quickly.

iii.

There is less burning of contacts since the duration is short and consistent.

iv.

Facility for frequent operation since the cooling medium is replaced

constantly.

Rated Voltage-6.6 KV

Current-630 A

Auxiliary current-220 V/DC

38

SF6 CIRCUIT BREAKER

Fig. 4.5 SF6 CIRCUIT BREAKER

This type of circuit breaker is of construction to dead tank bulk oil to circuit
breaker but 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.

Circuit Breakers-HPA

Standard-1 EC 56

Rated Voltage-12 KV

Insulation Level-28/75 KV

Rated Frequency-50 Hz

Breaking Current-40 KA

Rated Current-1600 A

Making Capacity-110 KA

39

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.

Rated frequency-50 Hz

Rated making Current-10 Peak KA

Rated Voltage-12 KV

Supply Voltage Closing-220 V/DC

4.3 COAL HANDLING PLANT

4.3.1 INTRODUCTION
The coal handling plant consists of two plants:

Old Coal Handling Plant (OCHP)

New Coal Handling Plant (NCHP)

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

NCHP supplies coal to Unit- IV and V.
4.3.2 COAL SUPPLIED AT BTPS
Coal is supplied to BTPS by Jharia coal mines. It is non-cooking coal and has following
specifications:

Moisture- less than 8%

Volatile matter-17% to 19%

Ash- 35% - 40%

Calorific Value- 4500 to 5300 Kcal/kg

Coal is received in railway box racks containing 20 - 42 wagons in each rack.

Capacity of each box wagon is about 55 ton.

These wagons are placed on 2 wagon tippler in OCHP & one wagon tippler in
NCHP, in total 3, capacity 80 ton each.

40

Fig. 4.6 COAL PLANT

4.3.3

OLD COAL HANDLING PLANT

Fig. 4.7 OLD COAL HANDLING PLANT

41

The main constituents of OCHP plant are:

WAGON TIPPLER :Wagon from coal yard come to the tippler and emptied
here. There are 2 wagon tipplers in the OCHP. The tippler is tilted to about 137141 so that coal from the wagon is emptied into the hopper. Elliptic feeder is
used in OCHP. Total 8 feeders are used, 4 in each hopper.
Slip Ring Induction Motor is used to operate a wagon tippler. This type of IM is
used in the tippler because of its high resistance, low speed & high torque
characteristics. The rating of the motor used is:

Power 55 KW

Voltage 415V

Current 102A

Speed 1480rpm

Phase 3

Frequency 50Hz

Three types of wagon tipplers are used:a) ROTASIDE: It is used for open type wagons in which each wagon carries around 50- 56 tons
of coal. The wagon is tilted by 150 to put the coal in the unloading hopper.
b) ROTARY: In this case the unloading hopper is placed directly under the tippler table. This is
also used to tilt the wagon tippler to 180.
c) ROCKING TYPE: It is used for close type wagons. In this hoppers is placed by the side of end
rocking is provided to facilitate unloading of coal at corners of the wagon.

CONVEYER: Conveyer belts are used in the OCHP to transfer coal from one
place to other as required in a convenient & safe way. All the belts are numbered
accordingly so that their function can be easily demarcated. These belts are made
of rubber & move with a speed of 250-300 m/min. Motor employed for the

42

conveyer has a capacity of 150 HP. These conveyers have a capacity of carrying
the coal at the rate of 400 ton/hr.

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

METAL DETECTOR: As the conveyer belt take coal from wagon to crusher
house, no metal piece should go along with coal. To achieve this objective, metal
detectors & separators are used. In the OCHP, these MDs are installed in the
conveyer belts 2A & 2B.

CRUSHER HOUSE: Both the plants i.e. OCHP & NCHP use TATA crusher
powered by BHEL motor. Crusher is of ring type and the motor is a HT motor of
rating 400HP & 6.6 KV. Crusher is designed to crush the pieces to 20 mm size i.e.
practically 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.

STACKER-CUM-RECLAIMER: It is used for stacking & reclaiming the coal

from the stockyard in case of unavailability of wagons from coal mines.

PLOUGH FEEDER: These plough feeders are generally installed under slot
bunkers or hoppers. These are used top laugh the coal to the belt from the coal fed
from stockyard. These feeders used in this power station are generally of rotary
type.

TRIPPERS: Trippers are provided in the conveyer to collect the material at

desired location on either side or along the conveyer with the help of chute/ducts
fitted with tripper itself. The motor in the tripper can make it move both in
forward and reverse direction.
43

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, this switch can be moved to NO(normally open) position
from NC (normally closed) position to stop conveyor belt from moving. At this
time the problem can be corrected & then again the switch can be moved to NC
(normally closed) position for normal working again.

INTERLOCKS: - The CHP is normally spread over a wide area with centralized
control room. Elaborate scheme is therefore provided. If due to any emergency
either the conveyor belt or the motor has to be stopped, due to this interlocking all
the other motors connected to it will automatically stop &will not work till signal
is given from the control room.
The control & protection scheme normally includes: -

A hooter system to warn that the plant is going to be started. The plant can be
started only after a definite time after the hooter is energized.

Sequential starting of conveyor system and tripping of all proceeding system if

any equipment in the chain is tripped.

Tripping of conveyor from speed switch for protection against belt slippage.

4.3.4 SEQUENTIAL OPERATION OF OCHP: I.

Unloading the coal

II.

Crushing & storage.

III.

Conveying to boiler bunkers.

a) 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.
b) 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

44

through elliptic feeder it is put into vibrators & then to conveyor belt 1A
& 1B
c) The coal through conveyor belts 1A & 1B goes to the crusher house. Also
the extra coal is sent to stockyard through these belts.
d) In the crusher house the small size coal pieces goes directly to the belt 2A
& 2B whereas the big size coal pieces are crushed in the crusher & then
given to the belts 2A & 2B.
e) The crushed coal is taken to the bunker house via the conveyor belts 3A
& 3B where it can be used for further operations.

4.4 NEW COAL HNDLING PLANT

Fig. 4.8 NEW COAL HANDLING PLANT

The main constituents of NCHP plant are:Most of the constituents of the NCHP are the same as that of OCHP.

45

4.4.1 WAGON TIPPLER

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

Fig. 4.9 WAGON TIPPLER

4.4.2 COAL FEEDER TO THE PLANT
Vibro feeders are installed below the hopper which helps in putting the coal to the
conveyor belts. There are 2 conveyor belts & 3 vibro feeder per plant, so in total there are
6 vibrofeeders.
Given below are the feeder motor specifications:

Power 15HP

Voltage 415V

Speed 1450rpm
46

4.4.3 CONVEYOR TURNING POINT-6BREAKER HOUSE

This house is required to render the coal size to 100mm sq. A 415W LT motor is used in
the breaker house.
4.4.4 REJECTION HOUSE
The coal comes to breaker house via conveyor belts 12A & 12B. Now in the breaker
house the huge stones & metal impurities are separated & sent to reject bin house through
belts 18A &18B.
4.4.5 RECLAIM HOPPER
It is the stockyard in which coal is stored for emergency purposes. Around 3 lakh ton of
coal can be stored in it.
4.4.6 TURNING POINT 7 CRUSHER HOUSE
To ensure that the coal is of uniform size it is passed through crusher. The crusher is of
ring type. Has a motor rating of 400HP, 606KV. It is designed to crush the pieces to
20mm size
4.4.7 SEQUENTIAL OPERATION OF NCHP:a) Coal arrives in wagons and tipples into hoppers.
b) if the coal is oversized (400mm sq), then it is broken manually so that it passes
through the hopper mesh.
c) From hopper it is taken to TP-6 12A & 12B. d) Conveyors 12A & 12B take the
coal to the breaker house which renders the coal size to be 100 mm sq.
d) Metal separator & metal detector are installed in conveyor belts 14A/B & 15A/B
respectively to remove the metal impurities.
e) Stones which are not able to pass through the 100mm sq mesh of hammer are
rejected via 18A & 18B to the rejection house.

47

f) Extra coal is sent to the reclaim hopper via conveyor 16A & 16B. h)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.

4.5 SPECIFICATIONS OF MOTORS USED IN NCHP:I.

Crusher: - BHEL ILAT/12B HD/02, 736rpm, 550Kw, 6600V.

II.

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

III.

Conveyors: 1)11A/B, 12A/B: - 125Kw, 315m, 1485rpm.

2)13A/B: - 55Kw, 250m, 1480rpm.
3)14A/B, 15A/B: - 150Kw, 355m, 1485rpm.
4)16A/B, 17A/B: - 110Kw, 315m, 1485rpm.
5)18A/B: - 37Kw, 225m, 1470rpm.

IV.

Rotary Breaker: - 110Kw, 315m, 1485rpm

V.

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

VI.

Reversible Belt Feeder: - 18.7Kw, 200L, 1485rp

VII.

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

VIII.

VF 7-8: - 15Kw, 180L, 1485rpm

IX.

VF 9-12: - 11Kw,160L, 1485rpm

X.

WSP Crusher House: - 15Kw, 160m, 4000rpm

XI.

WSP Breaker House: - 7.5Kw, 132m, 1865rpm

XII.

Metal Separator: - 5KV, 132m, 1410rpm

XIII.

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

4.5.1 SAFETY DEVICES FOR BELT CONVEYORS

Sometimes the belt is wet due to any reason, so it may not run due to reduced friction. A
switch senses this and prevents the belt from choking. Sometime any accident may occur
which requires the belt to stop, the pull cords are pulled to stop the conveyor. This system
starts again only when the pull cords are rest. There is a push button in the control room
from where the belt can be stopped in case of emergency stoppage.

48

Other equipments are pulley. Pulleys are made of mild steel, rubber logging is provided
to increase the friction factor between the pulley and belt.

4.6 MILLING SYSTEM

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

RC FEEDER: 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

BALL MILL: 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. In ball mill coal is converted to powdered form and due to pneumatic action
the powdered form of coal is transferred upwards.

CLASSIFIER: It is 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.

MILL FAN: From ball mill the powdered coal is sucked through mill fan

CYCLONE SEPARATORS: It separates the pulverized coal from carrying

medium. The mixture of pulverized coal vapour caters the cyclone separators
tangentially in the upper part of the separator. Due to decrease in the velocity the
centrifugal action, the pulverized coal separated from the vapour &falls down to
the lower epical part.

49

THE TURNIGATE: It serves to transport pulverized coal from cyclone

separators to pulverized coal bunker or to worm conveyors. There are 4 turnigates
per boiler.

WORM CONVEYOR: 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.

4.10 WORM CONVEYOR

50

CHAPTER-5
ELECTRICAL MAINTENANCE DEPARTMENT II
5.1GENERATOR
5.1.1

INTRODUCTION

Fig. 5.1 GENERATOR

There are two components:
1. Stator
2. 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 demineralized (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
51

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.

Hydrogen gas is used to cool down the rotor.

Lube oil is used to cool the bearings.

DM water is used to cool the stator.

Seal oil is used to prevent hydrogen leakage

Seal oil coolers are present to cool the seal oil

Hydrogen dryer are used which removes the moisture from hydrogen gas and
then is supplied to the generator.

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

5.1.2 RATINGS OF THE GENERATORS USED

Two types of generator 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.
5.1.3 BASIC PRINCIPLE
The generator works on the principle of electromagnetic induction.

52

5.1.3

TURBO GENERATOR 100MW

BHEL, Haridwar
MAKE
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

Table 5.1 GENERATOR 100MW

5.1.4 TURBO GENERATOR 210MW
BHEL, Haridwar
MAKE
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

5.2 kg/cm

Table 5.2 GENERATOR 210M

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5.2 TRANSFORMERS
5.2.1 INTRODUCTION

Fig. 5.2 TRANSFORMER

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

5.2.2 WORKING PRINCIPLE:

It works on FARADAYS LAW OF ELECTROMAGNETIC INDUCTION (self or
mutual induction depending on the type of transformer).
5.2.3 MAIN PARTS

CONSERVATOR: It is used generally to conserve the insulating property of the

oil from deterioration& protect the transformer against failure on account of bad
quality of oil.
54

SILICAGEL DEHYDRATING BREATHER: It is used to prevent entry of

moisture inside the transformer tank. The breather consists of silica gel.

GAS OPERATED RELAY (BUCHHOLZ RELAY): It is a gas actuated relay

used for protecting oil immersed transformer against all types of faults. It
indicates presence of gases in case of some minor fault & take out the transformer
out of circuit in case of serious fault.

BUSHINGS: It is made from highly insulating material to insulate & to bring out
the terminals of the transformer from the container. The bushings are of 3 types:
a. Porcelain bushings used for low voltage transformer b. Oil filled bushings used
for voltage up to 33KV. c. Condensed type bushings used for voltage above
33KV.

OIL GUAGE: Every transformer with an oil guage to indicate the oil level. The
oil guage may be provided with the alarm contacts which gave an alarm the oil
level has dropped beyond permissible height due to oil leak etc.

TAPPINGS: The transformers are usually provided with few tappings on

secondary side so that output voltage can be varied for constant input voltage.

RADIATORS: It increases the surface area of the tank & more heat is thus
radiated in less time.

WINDINGS TEMPERATURE INDICATOR (OIL GUAGE): Device which

indicates the temperature of winding of transformer & possible damage to the
transformer due too overload can be prevented.

5.2.4 CONSTRUCTIONAL FEATURES:

3 phase transformer is constructed in the core type construction.

For reducing losses a smaller thickness of lamination is used.

For the above reason it is also called cold-rolled steel instead hot-rolled steel is
used.
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High flux densities (1.4 to 1.7 Wb/sq m) are used in the core of power
transformer which carry load throughout.

For high voltage winding, disc type coils are used.

5.2.5 CLASSIFICATION:

ACCORDING TO THE CORE:

a) Core type transformer
b) Shell type transformer
c) Berry type transformer

ACCORDING TO PHASES:
a) 1phase transformer
b) 3phase transformer

ACCORDING TO THE PURPOSE FOR WHICH USED :

a) Distribution transformer
b) Transmission transformer
c) Generator transformer
d) Station transformer
e) Unit Auxiliary transformer (UAT)

5.2.6 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

1. Air Natural (AN)

2. Air Forced (AF)

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OIL IMMERSED COOLING

1. Oil Natural Air Natural (ONAN)

2. Oil Natural Air Forced (ONAF)
3. Oil Forced Air Natural (OFAN)
4. Oil Forced Air Forced (OFAF)

OIL IMMERSED WATER COOLING

1. Oil Natural Water Forced (ONWF)

2. Oil Forced Water Forced (OFWF)
5.2.7 MAIN PARTS OF TRANSFORMER
i.

Secondary Winding

ii.

Primary Winding.

iii.

Oil Level

iv.

Conservator

v.

Breather

vi.

Drain Cock

vii.

Cooling Tubes.

viii.

Transformer Oil.

ix.

Earth Point

x.

Explosion Vent

xi.

Temperature Gauge.

xii.

Buchholz Relay

xiii.

Secondary Terminal

xiv.

Primary Terminal

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5.2.8 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

Table 5.3 TRANSFORMER 125MVA

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5.2.9 GENERATOR TRANSFORMER (166 MVA UNIT-IV)

RATING

250MVA

TYPE OF COOLING

On/OB/OFB

TEMP OF OIL

45^C

TEMP WINDING

60^C

VOLTS AT NO LOAD

HV-236000
LV-15750

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

429500 lit

GUARANTEED MAX TEMP

45^C

DIVISION

KERELA

YEAR

1977

Table 5.4 TRANSFORMER 165MVA

59

5.2.10 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.
5.2.11 STATION TRANSFORMER
It is required to feed power to the auxiliaries during start-ups. 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.
5.2.12NEUTRAL 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.

5.3 SWITCH YARD

5.3.1 INTRODUCTION
As we know that electrical energy cant 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.
5.3.2 OUTDOOR EQUIPMENTS

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.

60

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. The practice is to install lightening arrestor
at the incoming terminal of the line. We have to use the lightning arrester both in
primary and secondary of transformer and in reactors. A meter is provided which
indicates the surface leakage and internal grading current of arrester.

WAVE TRAP: Power line carrier communication (PLCC) is mainly used for
telecommunication, tele-protection and tele-monitoring between electrical
substations through power lines at high voltages, such as 110 kV, 220 kV, and
400 kV. PLCC integrates the transmission of communication signal and 50/60 Hz
power signal through the same electric power cable. The major benefit is the
union of two important applications in a single system. 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 passthrough.

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.
.

61

CAPACITATIVE VOLTAGE TRANSFORMER: A capacitor voltage

transformer (CVT) is a transformer used in power systems to step-down extra
high voltage signals and provide low voltage signals either for measurement or to
operate a protective relay. It is located in the last in the switchyard as it increases
the ground resistance. Finally the voltage from CVT in the switchyard is sent out
from the station through transmission lines.

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

CURRENT TRANSFORMER: It is essentially a step up transformer which step

down the current to a 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.

5.3.3 INDOOR EQUIPMENTS

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.

62

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.

ELECTROSTATIC PRECIPITATOR: An electrostatic precipitator (ESP) or

electrostatic air cleaner is a particulate collection device that removes particles
from a flowing gas (such as air) using the force of an induced electrostatic charge.
Electrostatic precipitators are highly efficient filtration devices that minimally
impede the flow of gases through the device, and can easily remove fine
particulate matter such as dust and smoke from the air stream. 82 In contrast to
wet scrubbers which apply energy directly to the flowing fluid medium, an ESP
applies energy only to the particulate matter being collected and therefore is very
efficient in its consumption of energy (in the form of electricity). The most basic
precipitator contains a row of thin vertical wires, and followed by a stack of large
flat metal plates oriented vertically, with the plates typically spaced about 1 cm
to18 cm apart, depending on the application. The air or gas stream flows
horizontally through the spaces between the wires, and then passes through the
stack of plates. A negative voltage of several thousand volts is applied between
wire and plate. If the applied voltage is high enough an electric (corona) discharge
ionizes the gas around the electrodes. Negative ions flow to the plates and charge
the gas-flow particles. The ionized particles, following the negative electric field
created by the power supply, move to the grounded plates. Particles build up on
the collection plates and form a layer. The layer does not collapse, thanks to
electrostatic pressure (given from layer resistivity, electric field, and current
flowing in the collected layer).

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CONCLUSION

It was a wonderful experience, training in NATIONAL THERMAL POWER

CORPORATION, Badarpur plant.

There is great scope for engineers in the field of power generation.

Exposure to practical working conditions will be beneficial for our career.

64

BIBLIOGRAPHY

National Power Training Institute website.

NTPC.in.

NTPC Limited.

www. Telegraphindia.com.

BSE india.com.

MoneyControl.com.

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