Summer Training Report: Badarpur Thermal Power Station (A Unit of NTPC)

BTPS
SUMMER TRAINING REPORT
NAME-MANSI TIWARI
BRANCH-ELECTRICALS
COLLEGE-APEEJAY
COLLEGE OF
ENGINEERING,SOHNA
BADARPUR GURGAON
THERMAL ROLL NO-072023
POWER SEMESTER-
STATION IVTHTTHTHTHGTH
(A UNIT OF
NTPC)
SUMMER TRAINING REPORT BTPS
CERTIFICATE
This is to certify that MANSI TIWARI student of bachelor of

Technology, Electricals, 3rd Year, APEEJAY COLLEGE OF ENGINEERING
(SOHNA,GURGAON) has successfully completed her 34 days industrial
Training at Badarpur Thermal Power Station, New Delhi from 29th June to 1st
August 2009. She has completed the whole training as per the training
report submitted by her.
Training Incharge
BTPS/NTPC,
Badarpur,
New Delhi
Page 2
Page 3
ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey

my thanks for permitting me to complete my training here.
I extend my heartfelt thanks to Ms. Rachna Singh Bahal for providing

me this opportunity to be a part of this esteemed organization.
I’m extremely grateful to all the technical staff of BTPS / NTPC for their
co-operation and guidance that has helped me a lot during the course of
training. I have learnt a lot working under them and I will always be
indebted to them for this value addition in me.
I would also like to thank the training incharge of APEEJAY COLLEGE

OF ENGINEERING(SOHNA,GURGAON) and all the faculty members of
electrical department for their effort of constant co-operation, which have
been a significant factor in the accomplishment of my industrial training.
MANSI TIWARI
APEEJAAY COLLEGE
OF ENGINEERING
SOHNA,GUR
GAON
Page 4
ABOUT NTPC
NTPC Limited today is one of the largest companies in India in terms of
Market Capitalization and the single largest player in power sector, catering
to approximately 30% of country's power needs.
Set up in 1975 by Government of India, today it is a Navratna PSU with

a strong workforce of 24,447 power professionals and an annual turnover of
Rs.28, 750.7 Crores.
The Company has 14 coal based and 7 gas based power plants across
India with a total installed capacity of 26,404 MW. Several new projects are
underway as the company has ambitious plans of achieving 75,000 MW
installed capacity by 2017.
NTPC Limited is the largest power generating company of India. A public

sector company, it was incorporated in the year 1975 to accelerate power
development in the country as a wholly owned company of the Government
of India. At present, Government of India holds 89.5% of the total equity
shares of the company and the balance 10.5% is held by FIIs, Domestic
Banks, Public and others. Within a span of 33 years, NTPC has emerged as a
truly national power company, with power generating facilities in all the
major regions of the country.
Page 5
NTPC's core business is engineering, construction and operation of power

generating plants. It also provides consultancy in the area of power plant
constructions and power generation to companies in India and abroad.
Major Achievements of NTPC:

1) Largest thermal power generating company of India.
2) Sixth largest thermal power generator in the world.
3) Second most efficient utility in terms of capacity utilization.
4) One of the nine PSUs to be awarded by the status of Navratna.
Page 6
ABOUT BTPS
Badarpur thermal power station started working in 1973 with a single
95MW 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 GOI’s Gazette Notification.
Given below are the details of unit with the year they are installed.
Page 7
Address: Badarpur, New Delhi – 110 044

Telephone: (STD-011) – 26949523
Fax: 26949532
Installed Capacity 720 MW
Derated Capacity 705 MW
Location New Delhi
Coal Source Jharia Coal Fields
Water Source Agra Canal
Beneficiary States Delhi
Unit Sizes 3X95 MW
2X210 MW
Units Commissioned Unit I- 95 MW - July 1973
Unit II- 95 MW August 1974
Unit III- 95 MW March 1975
Unit IV - 210 MW December 1978
Unit V - 210 MW - December 1981
Transfer of BTPS to NTPC Ownership of BTPS was transferred to NTPC
with effect from 01.06.2006 through GOI’s
Gazette Notification
Training at BTPS
I was appointed to do 5 weeks training at this esteemed organization
from 29th June to 1ST August 2009. I was assigned to visit various division of
the plant, which were:
• Control & Instrumentation (C & I)
Page 8
• Electrical Maintenance Department - 1 (EMD-1)

• Electrical Maintenance Department -2 (EMD-2)
This 5 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,
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.
MANSI TIWARI
Page 9
THERMAL POWER PLANT

Thermal power plant converts the heal energy of coal to electrical
energy. Coal is burnt in a boiler, which converts water into steam. The
expansions of steam in turbine produces mechanical power, which drives
the generator or the alternator.
GENERAL STRUCTURE OF BTPS(750MW CAPACITY) :
Page
10
Schematic arrangement of steam power

station
1. Coal and ash handling arrangement.
2. Steam generating plant.
3. Steam turbine.
4. Alternator.
5. Feed water.
6. Cooling arrangement.
Coal and ash handling plant :-

The coal is transported to the power station by road or rail and is
stored in the coal storage plant. Storage of coal is primarily a matter of
protection against coal strikes, failure of transportation system and
general coal shortages. Form the coal storage plant, coal is delivered to
the coal handling plant(CHP) where it is pulverized (i.e., crushed into
small pieces) in order to increase its surface exposure, thus promoting
rapid combustion without using large quantity of excess air. The main
aim of CHP is to maintain the level of coal in the bunkers for smooth
supply of coal to the boilers. The working conditions in CHP are dusty,
dirty and often wet.
The pulverized coal is fed to the boiler by bell conveyors. The coal
is burnt in the boiler and the ash produced after the complete combustion
of coal is removed to the ash handling plant and then delivered to the ash
storage plant for disposal. The removal of the ash from the boiler furnace
is necessary for proper burning of coal.
It is worthwhile to give a passing reference to the amount of coal burnt
and ash produced in a modern thermal power station. A 100 MW station
operating at 5Q/
load factor may burn about 20,000 tons of coal per month and ash
produced may be to the tune of IO% to 5% of coal fired i.e., 2,000 to
3,000 tons. In fact, in a thermal station, about 50% to 60% of the total
operating cost consists of fuel purchasing and its handling.
Page
11
Following is the systematic diagram of the coal handling

plant :
Page
12
Page
13
CRUSHERS:-
In CHP crusher works on the principle of combination of impact and attrition
crushing. In this type of crushing first coal breaks due to impact crushing
and further it is scrubbed between two hard surfaces to get desired coal
size. Some crushers work only on the principle of impact crushing. Generally
these crushers are used before final crushers. The output size of coal affects
the performance of CHP. The two hard surfaces of crusher are crucial parts.
One of these is known as grinding plate and the other as rings, hammers
etc. The link between crusher rotor and driver assembly is also crucial, as its
failure will stop the crushing process.
WAGON TIPPLERS: -
In CHP generally there are two types of wagon tippler. They are known as
rota type and rotary type. The main difference between these tipplers is
that rotary type tippler has floating barrel and rota type tippler turns
between two bearings. The drive linkages undergo cyclic loading and failure
of these linkage stop the equipment operation, due to this unloading of coal
cars affects, which drops the performance of CHP.
BUNKER - FEEDING CONVEYORS: -

CHP has number of conveyors but bunker-feeding conveyors play a vital
role. The main aim of each CHP is to maintain bunker levels for smooth coal
supply to boilers. As these conveyors feed the bunker their performance
affects CHP performance. The drive linkages consists of gearbox and
couplings. Failure of any part of the linkage will stop operation of feeding
bunker level. So these parts are crucial parts of bunker feeding conveyors.
The conveyor pulleys are also crucial parts.
Page
14
FEEDERS: -
The performance of feeders affects the efficiency of CHP. The feeders used
in CHP are Apron Feeder, Vibrating Feeders, Roller Screens and Vibrating
Screen Feeders etc. Generally vibrating feeders used, are of
electromagnetic type. The springs, coils and suspension rods are the crucial
parts. Weak coil springs that are not generating sufficient accelerating
forces can also cause low speed and reduce the performance. In vibrating
screen feeder have crucial part like beam and its members, drive linkages
etc. Apron Feeders is sturdy machine, the crucial parts are fans, chain and
rollers. The roller screens have crucial parts in drive linkages
Steam generating plant:-

The steam generating plant consists of boiler for the production of steam
and other auxiliary equipment for the utilization of flue gases.
a) Boiler:-
The heat of combustion of coal in the boiler is utilized to

convert
water into steam at high temperature and pressure. The flue gases from
the
boiler make their journey through super-heater, Economizer, air pre-
heater
and are finally exhausted to atmosphere through the chimney.
b) Super-heater :-
The steam produced in the boiler is wet and is passed through a

super-heater where it is dried and superheated (i.e., steam temperature
is increased above that of boiling point of water) by the flue gases on
their way
to chimney. Superheating provides two principle benefits. Firstly, the
overall
efficiency is increased. Secondly, too much condensation in the last
stages of
Page
15
turbine (which would cause blade corrosion) is avoided. The superheated

steam from the super-heater is fed to steam turbine through the main
valve.
c) Economizer:-
An economizer is essentially a feed water heater and derives

heat from the flue gases for this purpose. The feed water is fed to the
economizer before supplying to the boiler. The economizer extracts a
part of heat of flue gases to increase the feed water temperature.
d) Air-preheater.-
An air-pre heater increases the temperature of the air supplied for

coal burning by deriving heat from flue gases. Air is drawn from the
atmosphere by a forced draught fan and is passed through air-pre heater
before supplying to the boiler furnace. The air pre heater extracts heat
from flue gases and increases the temperature of air used for coal
combustion. The principal benefits of preheating the air are increased
thermal efficiency and increased steam capacity per square meter of
boiler surface.
Steam turbine:-
The dry and superheated steam from the super heater is fed to
the steam turbine through main valve. The heat energy of steam when
passing over the
blades of turbine is converted into mechanical energy. After giving heat
energy to the
turbine, the steam is exhausted to the condenser which condenses the
exhausted steam by means of cold water circulation.
Alternator:-
The steam turbine is coupled to an alternator. The alternator
converts mechanical energy of turbine into electrical energy. The
electrical output from the
alternator is delivered to the bus bars through transformer, circuit
breakers and isolators.
Page
16
Feed water:-
The condensate from the condenser is used as feed water to the
boiler.
Some water may be lost in the cycle which is suitably made up from
external source. The feed water on its way to the boiler is heated by
water heaters and economizer. This helps in raising the overall efficiency
of the plant.
Cooling arrangement:-
In order to improve the efficiency of the plant, the steam
exhausted from the turbine is condensed by means of a condenser.
Water is drawn from a natural source of supply such as a river, canal or
lake and is circulated through the
condenser. The circulating water takes up the heat of the exhausted
steam and itself
becomes hot. This hot water coming out from the condenser is
discharged at a suitable
location down the river. In case the availability of water from the source
of supply is not assured throughout the year, cooling towers are used.
During the scarcity of water in the river, hot water from the condenser is
passed on to the cooling towers where it is cooled. The cold water from
the cooling tower is reused in the condenser.
NCHP feeds unit 4 and 5 (each of 210 MW capacity). It consists of double
stream of conveyors of capacity 600 metric tones/hour. Except for
stacking conveyors of 600mtph which is a single one wagon Tippler, four
vibrating feeders of 300mtph each below the wagon tippler, two rotatry
breakers of 600mtph each in secondary crusher house, one telescopic
chute for stacking, two sets of reclaim hoppers, necessary transfer points
and new rail tracks for the wagon tippler are provided. The wagon tippler
is provided with integral weight bridge for recording the gross and true
weight of the wagon and is located beyond the old marshalling yard, due
to space Limitation only one wagon tippler is provided. Car pullers are
used for placing the loaded wagon on the wagon tippler and removing the
empty wagon.
Page
17
Page
18
Page
19
CONTROL & INSTRUMENTATION
This division basically calibrates various instruments and takes

care of any fault that occurs in any of the auxiliaries in the plant. It has
the following Labs.
1. MANOMETRY LAB.
2. PYROMETRY LAB.
3. AUTOMATION LAB.
4. PROTECTION & INTERLOCKING LAB.
5. TURBO SUPERVISORY INSTRUMENT LAB.
6. FURANCE SAFETY SUPERVISORY SYSTEM.
7. ELECTRONICS TEST LAB.
This department is the brain of the plant because from relays to

transmitters followed by the electronic computation chipsets and
recorders and lastly the controlling circuitry, all fall under their
responsibility.
Page
20
MANOMETRY LAB
Various instruments used in this lab are:-
1. MANOMETER:-
It is a tube, which is bent, in the U shape. It is filled with a liquid. This device
corresponds to a difference in the pressure across the two limbs.
2. BOURDON PRESSURE GUAGE:-
It is an oval section of tube. Its one end is fixed. It is provided

with a pointer to indicate the pressure on a calibrated scale. It is of two
types.
a. Spiral type-: It is used for measuring low pressure. It is more sensitive

and is used where compactness is necessary.
b. Helical type-: It is used for measuring high pressure. It is most sensitive

and compact. Pointer may be mounted direct on end of helix which
rotates, thus eliminating backlash error and lost motion.
Page
21
PYROMETRY LAB
This lab consists of various temperature measuring instruments.
LIQUID IN GLASS THERMOMETER:-
Mercury in the glass thermometer boils at 340 degree Celsius

which limits the range of temperature that can be measured it is an L
shaped thermometer, which is designed to reach all inaccessible places.
1. The Bi-Metallic Strip:-
Bi-metal strips are composed of two metals, as the name implies,

it is the one whose coefficients of linear expansion are dissimilar. These
two metal plates are welded together as a sandwich. When heated, both
metals expand, but the metal with greatest coefficient of linear expansion
will expand more causing the sandwich to curl up or down depending on
the position of this metal. (Refer Fig.).
2. ULTRA VOILET CENSOR:-
This device is used in furnace and it measures the intensity of

ultraviolet rays present and according to the wave generated, a signal of
the order of same is generated, which directly indicates the temperature
in the furnace. This lab also has the responsibility of calibrating various
instruments. Depending on the range of the device, the method to
calibrate the device is adopted. The low range measuring devices are
calibrated in the oil bath or just by using boiling water. The high
temperature measuring device is calibrated in the small furnace.
Page
22
AUTOMATION LAB
This lab deals in automating the existing equipment system,
and feeding routes. Earlier, the old technology dealt with only data
acquisition system and was known as primary. The modern technology or
the secondary system is coupled with management information system. But
this lab universally applies the pressure measuring instrument as the
controlling force. Suppose, if in a motor the fall in pressure of lubricating oil
directly implies to the heating of the machine then similarly fall in water
pressure in the water pipe line implies overload or short circuit of the feed
or circulating pump motors. However, the relays provided, are used only
for the protection and interlocking. Once the measure is common, the
pressure control circuit can easily be designed with single chip having
multiple applications. Another point is the universality of the supply, the
laws of the electronics state that it can be anywhere between 12 V and 35V.
At the plant all control instruments are excited by 24V DC supply (0.5-2OA).
PROTECTION AND INTERLOCK LAB

There are two kinds of protection system based on the voltage level at
which they operate. These are discussed below:-
a) HIGH TENSION CONTROL CIRCUIT:-
For high-tension system the control system is excited by separate DC

supply. For starting the circuit, condition should be in series with the
starting coil of the equipment to energize it. The tripper is a coil, which de-
energizes the start coil so that the equipment stops. The tripper derives
signal from the tripping coil of the high tension tripping system. It should be
noted that for tripping all the conditions should be in parallel.
b) LOW TENSION CONTROL CIRCUIT: -
For low-tension circuits the control circuits are directly excited from
the 0.415KV AC supply. The same circuit achieves both excitation and
tripping. Here the tripping coil is provided for emergency tripping if the
Page
23
interconnection fails. This system is more prone to failure as it is excited

from 415V of AC.
INTERLOCKING: -
It is basically interconnecting two or more equipment so that if one

equipment fails other can perform the task. This type of interdependence is
also created so that all the equipment connected together are started and
shutdown in specific sequence to avoid damage. For protection of
equipments tripping are provided for all the equipments. Tripping can be
considered as the series of the instruction connected through OR gate.
When a fault occurs and any one of the tripping is, satisfied a signal is sent
to the relay, which trips the circuit. The main equipment of this lab are
relays and circuit breakers. Some of the instruments used for protection
are:-
1. RELAY: -
It is a protective device. It can detect wrong condition in electrical

circuit by constantly measuring the electrical quantities flowing under
normal & faulty condition. Some of the electrical quantities are voltage,
current, phase angle and Velocity. After detecting the fault, the relay
operates to complete the trip circuit, which results in the break up of circuit
caused due to circuit breakers, and disconnects the faulty circuit. Two
types of relays used in this lab are given below.
a) Current Relay: - It gets energized when the rated amount of

current flows through it. It is always connected in series.
b) Potential Relay: - It gets energized by voltage and has copper

winding as the coil. It is always connected in parallel.
2. FUSE: -
It is a short piece of metal inserted in the circuit, which melts if heavy current
flows through it and thus breaks the circuit. Usually sliver is used as a fuse material
because:-
Page
24
a) The expansion coefficient of sliver is very small. As a result, no critical fatigue

occurs and thus the continuous full capacity normal current rating is assured for
the long time.
b) The conductivity of the silver is unimpaired by the surges of the current that
produces temperatures just near the melting point.
c) Silver fusible elements can be raised from normal operating temperature to
vaporization much quicker than any other.
3. MINIATURE CIRCUIT BREAKERS: -
They consist of current carrying contacts, one is movable and the other is fixed.
When a fault occurs, the contacts separate and an arc is struck between them. They are
used with combination of the control circuit to:-
a) Enable the starting of plant and distributors.

b) Protect the circuit in case of a fault.
The miniature circuit breakers that are used, employ three tripping mechanism as given
below:-
a) Manual Trip: - Manual trip implies that the miniature current breaker can be
operated as an electrical switch.
b) Thermal trip: - Thermal trip is the hi-metallic tripper when the circuit draws the
excess current, the contact between the two metals breakers rises due to
temperature.
c) Short Circuit Trip:-The short circuit or dec. Mag. Trip works in the case of short
circuit as the short circuit current is many times the rated current, it is allowed to
flow through coil with movable aluminum core attached to the tripping spring. This
on being energized with sufficiently large current pulls the core, which in turn
releases the spring.
Page
25
FURANCE SAFETY SUPERVISORY SYSTEM

LAB
This lab has the responsibility of starting the fire in the furnace
to enable the burning of coal. For first stage coal burners are in the front
and rear of the furnace and for the second and third stage corner firing is
employed. Unburnt coal is removed using forced draft fan. The temperature
inside the boiler is 1100 degree Celsius and its height is 18 to 40m. It is
made up of mild steel. An ultra violet sensor is employed in the furnace to
measure the intensity of the ultra violet rays inside the furnace and
according to it, signal in the same order of same mV is generated, which
directly indicates the temperature of the furnace.
For firing the furnace a 10 KV spark plug is operated for 10

seconds over a spray of diesel fuel and pre- heated air along each of the
feeder mills. The furnace has six feeder mills each separated by warm air
pipes fed from forced draft fans. In first stage indirect firing is employed
that is feeder mills are not fed directly from coal but are fed from pulverized
coal from bunkers. The furnace can operate on the minimum feed from
three feeders but under no circumstances should any one of the
intermediate mills be left out under operation, to prevent creation of
pressure difference with in the furnace, which theaters to blast it.
Page
26
TURBO SUPERVISORY INSTRUMENTS

LAB
This lab takes of all the instruments, which are part of the turbo
supervisory system to allow safe and proper operation of the turbine. Some
of the turbine parameters that have to be monitored are as follows:-
a) TURBINE SPEED:-
The speed of the turbine is to be kept constant so that the

frequency of the generated electricity is close to 50 Hz. The indicator
of the speed gives us a remote indication of the speed when barring
gear rotates the rotor. It gives a local and remote digital indication of
the turbine speed, which in turn is given by the photoelectric pick up
system. There is a white dot on the turbines, which reflect the light
given by the photoelectric pick up device. The rate at which light is
sensed is use to calculate the speed of turbine. There is indicator,
which also set up alarm signal at 10% and 16% over speed.
b) AXIAL SHIFT OF ROTOR: -
During the rotation of the turbine at high speeds where there is

the wearing down of bearing, there is axial shift. Depending on the
bearing which have become worn, thrust collar is given with respect to
working pads, if this parameter is not monitored properly, then severe
bubbling and mechanical interfaces can take place. The position of the
thrust collar is taken by detector, which has two elements. There is
variable type transducer and a bridge configuration.
c) SHAFT ECCENTRICITY: -
Eccentricity is the deviation of the mass centre from the

geometrical centre of the bearing case. It usually occurs in the rotor
when there is a shut down. If it becomes large, then there will be a
variation, which can be dangerous. To measure the eccentricity a
Page
27
passive and active magnetic reluctance type transducer in combination

with bridge circuit in balance condition is used. In this case tolerance is
of the order of 10 to 500 microns.
d) BEARING VIBRATIONS:-
This vibration is to and fro motion of the machine under the

influence of oscillatory force caused by unbalanced masses in the
rotating system. This is one of the most vital parameter of the turbine
and it has to be monitored continuously.
Page
28
EMD-I
The EMD-I section in BTPS is engaged in maintenance of motors and
switchgears.
MOTORS:-
Motors play a very important role in the operation of a power plant as

most devices are run by it. The objective of this Chapter is to give an insight
into the fundamentals of motor operation and starting .Motor are of various
types. There are DC as well as AC motors. Both are used at different places
according to the work required. These are further classified according to
their construction.
DC Motor Classification:-
> Series motor
> Shunt motor
> Compound motor
AC Motor Classification:-
> Squirrel cage motor
> Wound motor
> Slip ring induction motor
In a modern thermal power plant normally a three-phase squirrel cage

Induction motor is used but some times a double wound motor is also used
when we need a high starting torque e.g. in ball mills.
THREE PHASE INDUCTION MOTOR:-
In a three phase induction motor, stator is connected to a three phase

supply which produces a rotating magnetic field. Speed of rotation is
proportional to main frequency and inversely proportional to the number of
pairs of poles. N sync - 60 x supply frequency Pairs of poles. Stator can have
concentric single layer windings with each coil side occupying one stator
Page
29
slot. In practice many types of stator winding may be encountered. Two of

the most common types are illustrated in Fig. 58.A three phase Induction
motor stator connected a 3 phase supply produces a rotating magnetic field
whose speed is given by :-
Ns=120*f/p
STATOR :-
Stator can have concentric single layer winding with each coil side
occupying one stator slot. Two most common types of windings are.
(1) Distributed winding: - This type of winding is distributed over a

number of slots.
(2) Double layer winding:- Each stator slot contains sides of two
separate coils.
 BEARING AND LUBRICATION:-
A good bearing is needed for trouble free operation of the motor.

Since it is a very costly part of motor, a lot of care has to be taken by
checking it at regular intervals. Damaged bearing may severally affect a
motor, so lubrication plays important role. Two types of lubrication are used.
(1) Oil Lubrication
(2) Grease lubrication
INSULATION:-
Page
30
Since winding play an important role in the operation of a motor. It has to

be properly insulated from being short circuited and causing unnecessary
damage. Previously class B insulation was being used but now better class F
insulator is used.
TYPES OF INSULATION
TYPES OF TEMPRATURE
INSULATION WITHSTANDING CAPACITY
(0 C)
Y 90
A 105
E 120
B 130
F 155
H 180
C <180
 ROTOR:-
There are two types of rotors used in three phase induction motors
as given below.
1) Squirrel Cage.
2) Wound Rotor Motors:
Squirrel cage and wound rotor motors have the same basic mode
of operation. Rotor inductors cut the rotating stator magnetic field, an e.m.f.
is induced across rotor windings, 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 the
applied load. The slip speed is just enough to enable sufficient induced rotor
current to produce the power dissipated by motor load and motor losses.
Page
31
The torque at any speed can be made maximum by arranging it for the
ideal situation to be achieved. The induction motor has poor efficiency and
power factor (mainly inductive reactance). On full load a typical efficiency of
85% and power factor of 0.8 can be achieved. Fig. 59 shows a simplified
squirrel cage motor.
SYNCHRONOUS MOTORS:-
Conventional three phase stator, speed of rotation is dependant

on the number of pairs of stator poles. Rotor winding is D.C. excited or of
variable reluctance. True synchronous motor is not self starting. Squirrel
cage or wound motor is required to accelerate it to a synchronous speed.
Rotor 'pulls in' and rotates with stator field. On load, the rotor has a 'load
angle' with respect to the rotating magnetic field. The speed of the rotor is
constant over the load range of the motor. As the load increases, load angle
increases and power drawn from the supply increases. When on excessive
overload, rotor 'pulls out' of synchronism. When operating at synchronous
speed the power factor of the motor can be changed by varying the degree
of excitation. A conventional cylindrical wound rotor is as shown in figure
60.
MOTOR STARTING:-
The methods employed in starting a motor are extremely varying,

depending upon size, type, starting repetition and environment etc.
Page
32
Probably the simplest and most common method is to connect the supply
directly to the motor and allow it to accelerate normally to its running
speed. This method is referred to as Direct-on-line Starting (D-O-L).
 Direct-On-Line Starting:
The choice of this method may depend upon a number of

conditions. If for example the load has high inertia, then D.O.L. would not be
ideal because the prolonged starting current could be six times the normal
running current. This in turn (assuming that the switch used could carry this
large current) would put an excessive "drain" upon the supply system. In
fact, for large horse power motors the supply authorities will not usually
permit D.O.L starting. D.O.L. staring is however used extensively in modern
power stations one reason being that it is less expensive than other
methods. Excessive current surge is more tolerable in power stations than
on consumer premises.
 Direct -On Line-Starters: -
The simplest electric motor drive consists of a squirrel-cage motor

switched direct-on-line, and an associated automatic motor starter consists
basically of a contactor to connect the motor to the supply and an overload
relay to prevent over-heating of the motor.
 Reduced Voltage Methods:-
When it is necessary to limit the starting current drawn by a

motor, reduced voltage starting methods may be considered. The methods
available are star/Delta, Auto-transformer, and primary resistance. Of these,
Star/ Delta is by far the most common. It must be remembered however,
that reduced voltage also means reduced torque, and in the case of
star/delta starting, the initial torque is only one third of that available with
D-O-L starting. This is adequate for most drives.
 Star/Delta starters:-
Page
33
This method involves starting the motor from rest, with the stator
windings connected in star configuration. In this condition the effective
voltage across each winding is 1/3 of the line voltage, or 59%. The current
and torque are reduced to 33% of the values obtained if the motor was
started D-O-L. After a period of acceleration the supply is removed from the
motor, and by a suitable switching process the windings are connected in

delta configuration. Before the motor has chance to deaccelerate, the
supply is re-established with full voltage across each winding. Some
deacceleration does takes place in practice, and mechanical shock is
introduced to the drive on re-connection at full voltage. This would not be
practical on large units but can be accepted on many small and medium
drives. (Refer Fig-61).
 Auto-Transformer Starters:-
In its simple form the motor is initially started at reduced voltage

by connections to a tapped auto-transformer. The transformer is usually
provided with three sets of tapping which allow site adjustments to suit
most applications. Typical values are 50%, 65%, and 80%. Because the
transformer is short rated, the number of starts is usually limited to five per
Page
34
hour. The method involves disconnection of the motor from supplies before
reconnection is made at full line voltage. Connections are arranged as
shown below (Fig. 63).
The switching sequence is as follows:
o Contactor I closes to connect motor to autotransformer tapping. When

motor has achieved suitable speed, contactor I opens .
o Immediately following this, contactor II closes to connect the motor to

full line voltage.
Due to the open circuit transition from starting to running position, it is

possible to obtain transient currents between twenty to thirty times. When
making the running connection, the heaviest transients occur when the
starter is on the high tap position (80%). An improved method of starting
without open transition is described next.
Page
35
 Induction Regulators:-
It is worth a consideration that induction regulators, whilst being,

primarily, speed controllers, can be used to provide a smooth voltage
variation 1 from about 60% to full voltage, ensuring a smooth and gradual
start without transients. The frequency of starts is limited and the devices
are very expensive for ordinary staring purposes. It is not proposed to
discuss them at this stage but they will be dealt with in further text under
"motor speed control"
 D.C. Starters:-
As a general case a D.C. Starter consists of a variable resistance place

in series with the motor armature, which is gradually reduced to zero as the
speed rises. As the motor accelerates a back e.m.f. is produced which limits
the current so that at running speed the motor requires no external
resistance (Refer Fig. 64-A). The value of resistance is usually varied in
small steps by a manually operated wiper arm, When the "Full on" position
is reached an electromagnet attracts the arm and holds it against spring
tension. This is known as the hold in coil and if the supply fails or drops
below a certain value, the magnetic field is insufficient to hold the arm,
which returns to the "off" position
Page
36
Page
37
INDUSTRIAL MOTORS:-
There are various types and sizes of motors used in a power

station. These are used for various purposes as prime movers. Apart from
the simple motors used in different areas, there are HT Motors used in
conjunction with various heavy-duty equipments. These are FD, ID, PA and
other fans, Boiler Feed pumps, CW pumps etc. These motors have certain
special features like cooling, auto starting, interlocks and controls. Critical
auxiliaries have stand-by's driven by DC motors, speed control, wherever
required it is achieved using either hydraulic couplings, eddy current
couplings or double frequency power controllers.
FAILURE OF MOTORS & CAUSES:-
Number of motor failures have taken place due to:-
1) High number of starts in an hour.
2) Incorrect setting of thermal overload relays/other motor

predictive relays.
3) The use of incorrect fuses.
4) The failure to switch on the space heaters when the motors are
made off (cooling two motors especially).
5) Incorrect oil levels in fluid couplings.
6) Non calibration of protective relays as pre schedules.
MAIN MOTOR USED IN THE BOILER AND OFF-SIDE AREA:-

(1) ID FAN
(2) FU FAN
(3) PA FAN
(4) MILL FAN
(5) BALL MILL FAN
Page
38
(6) RC FEEDER
(7) SLAG CRUSHER
(8) LUBRICATING OIL PUMP
(9) PC FEEDERS
(10) BOWL MILL FAN
TECHNICAL SPECIFICATION OF MOTORS

Boiler feed pump motor (100 MW unit)
MAIN MOTOR SPECIFICATIONS VALUES
KW 1600
TYPE ATP-1600/66007
MAKERS NUMBER 300613/X-12
RPM 2980
RATING CONTINUOUS
FREQUENCY 50Hz
EFFICIENCY 95.6%
STATOR STAR CONNECTION
KV 6.6KV
AMPERE 103
EFFICIENCY 95.3
POWER FACTOR 0.9
YEAR 1971
Boiler feed pump motor (210 MW unit)

KW 400 kw
RPM 1483
RATING CONTINUOUS
FREQUENCY 50Hz
KV 6.6KV
AMPERE 421 A
EFFICIENCY 95.3%
POWER FACTOR 0.85
PEAK LOAD 200%
TYPE OF BEARING SLEEVE
Page
39
CONDENSER WATER PUMP MOTOR

RPM 424
RATING CONTINUOUS
FREQUENCY 50Hz
EFFICIENCY 92.8%
KV 6.6KV
AMPERE 79 A
POWER FACTOR 0.80
Page
40
Page
41
EMD-II
The ELECTRICAL MAINTENANCE DEPARTMENT -2 (EMD-2) is engaged in
maintenance of Generators, Transformers and Switchyard.
GENERATOR
The transformation of mechanical energy into electrical energy is
carried out by the Generator. This Chapter seeks to provide basic
understanding about the working principles and development of Generator.
HISTORY :-
The first A.C. Generator concept was enunciated by Michael

Faraday in 1831. In 1889 Sir Charles A. Parsons developed the first AC
turbo-generator. Although slow speed AC generators have been built for
some time, it was not long before that the high-speed generators made its
impact. Development contained until, in 1922, the increased use of solid
Page
42
forgings and improved techniques permitted an increase in generator rating

to 20MW at 3000rpm. Up to the out break of Second World War, in 1939,
most large generators were of the order of 30 to 50 MW at 3000 rpm.
During the war, the development and installation of power plants was
delayed and in order to catch up with the delay in plant installation, a large
number of 30 MW and 60 MW at 3000 rpm units were constructed during
the years immediately following the war.
The first-cooled generator, a 60MW machine, was installed in UK

in 1949. This was a conventionally cooled generator wherein hydrogen
replaced air as cooling medium. In 1955 the first 100MW generators were
commissioned and from the same design followed the 120 M W machines
which came into service from 1958. The 200 MW generators were installed
in 1959. The advantages of direct cooling were further emphasized when
hydrogen was superseded by the use of water for cooling the stator
windings, and ratings of generators rapidly increased from 275 MW to 500
MW. The next decisive stage must be the development of single shaft
generators in output range 750-1000 MW.
Page
43
WORKING PRINCIPLE
The A.C. Generator or alternator is based upon the principle of

electromagnetic induction and consists generally of a stationary part called
stator and a rotating part called rotor. The stator housed the armature
windings. The rotor houses the field windings. D.C. voltage is applied to the
field windings through slip rings. When the rotor is rotated, the lines of
magnetic flux (via magnetic field) cut through the stator windings. This
induces an electromagnetic force (e.m.f.) in the stator windings. The
magnitude of this e.m.f. is given by the following expression.
E = 4.44 / Ø F N volts
Where Ø = Strength of magnetic field in Weber’s.
F = Frequency in cycles per second or Hertz.
N = Number of turns in a coil of stator

winding
And Frequency F = P n/120
Where P = Number of poles
n = revolutions per second of

rotor.
From the expression it is clear that for the same frequency, number of poles
increases with decrease in speed and vice versa. Therefore, low speed
hydro turbine drives generators having 14 to 20 poles where as high speed
steam turbine driven generators have generally 2 poles. Pole rotors are
used in low speed generators, because the cost advantage as well as easier
construction.
CONSTRUCTION
Generator can be divided into three parts in constructional point of view:
1. Stator
Page
44
2. Rotor
3. Generator Cooling System
1) STATOR
a) Stator Frame
A grid frame is required to arrest forces and torques aroused

during operation and give mechanical support. It comprises of an inner
frame and outer frame. The outer frame is a rigid structure of welded steel
plates, within this shell is a fixed case of grider built circular and axial ribs.
The ribs divide yoke in the components through which hydrogen flows for
cooling. The inner cage is fixed into yoke by an arrangement of springs.
b) Stator core
Stator core is built up of large no. of laminations of thin CRG0

steel to contribute the reduction in weight. Each lamination segment is
0.5mm thick steel with varnish on both the sides. To obtain maximum
compression and elimination under setting during the operation, the
laminations are hydraulically compressed and heated during the stacking
procedure and the complete stack is kept under pressure locate in the
frame by the means of clamping bolt and pressure plate. The use of cold
rolled grain-oriented steel can contribute to reduction in the weight of stator
core for two main reasons:
I. There is an increase in core stacking factor with

improvement in lamination cold rolling and in cold buildings
techniques.
II. The advantage can be taken of the high magnetic

permeance of grain-oriented steels of work the stator core at
comparatively high magnetic saturation without fear or
excessive iron loss of two heavy a demand for excitation
ampere turns from the generator rotor.
c) Stator windings
Page
45
The three-phase stator winding is a fractional pitch two layer

type. These are made up of copper tubes wound with insulated type, which
is impregnated with varnish, dried under vacuum and hot pressed. Water is
fed into the windings (copper tubes) for cooling purposes. Water is fed to
the windings through the plastic (Teflon) tubes. There is a 54° transposition
in the lot portion. In the end-winding portion no transposition is there
instead windings are short circuit. Two flexible core suspensions are located
directly adjacent to the point where the frame is supported on foundation.
The spring takes care of forces due to weight and short circuit.
2) ROTOR
The electrical rotor is the most difficult part of the generator to

design. It revolves in most modern generators at a speed of 3,000
revolutions per minute. It is also an electromagnet and to give it the
necessary magnetic strength the windings must carry a fairly high current.
The passage of the current through the windings generates heat but the
temperature must not be allowed to become so high, otherwise difficulties
will be experienced with insulation. The rotor shaft is made of high quality
heat-treated steel forged from a vacuum cast steel ingot and it is further
forged and machined. Very often a hole is bored through the centre of the
rotor axially from one end of the other for inspection. Slots are then
machined for windings and ventilation.
a) Rotor winding
Silver bearing, de-oxidized copper is used for the windings with

mica as the insulation between the conductors. Hollow conductors with slots
or holes arranged for circulation of the cooling gas through the actual
conductors. An axial flow time located in the turbine and the shaft journal
circulates the cooling gas. At high speed, centrifugal force tries to lift the
winding out of the slots, and hence these contained by wedges. The two
ends of windings are connected to the slip rings, made of forged steel, and
mounted on insulated sleeves.
b) Rotor balancing
When completed the rotor must be tested for mechanical

balance, which means that a check is made to see if it will run up to normal
Page
46
speed without vibration. To do this it would have to be uniform about its

central axis and it is most unlikely that this will be so to the degree
necessary for perfect balance. Arrangements are therefore made in all
designs to fix adjustable balance weights around the circumference at each
end.
3) GENERTOR COOLING SYSTEM
The 210MW generator is provided with an efficient cooling system

to avoid excessive heating and wear and tear of components during
operation.
a) Rotor cooling system
The rotor is cooled by means of gap pickup cooling; wherein the

hydrogen gas in the air gap is sucked through the scoops on the rotor
wedges and directed to flow along the ventilating canals mild on the hot
zone of the rotor. This method not only gives uniform distribution of
temperature but also eliminates the deformation of copper due to high
temperatures. Hydrogen is used as cooling medium because of its high heat
carrying capacity and low density. But in view of its forming an explosive
mixture with oxygen, proper arrangement for filling, purging and
maintaining its purity inside the generator have to be made. Also, in order
to prevent escape of hydrogen forming the generator casing, shaft-system
sealing is used to provide oil sealing.
b) Stator cooling system:-
The stator winding is cooled by distillate, which is fed from

one end of the machine by Teflon tube and flows through the upper bar and
returns back through the lower end of the other slot. The stator winding is
cooled by circulating the dematerialized water (DM water) used for the
cooling of the stator winding calls for the use of very high quality of cooling
water. For this purpose DM water of specific resistance is selected. The
system is designed to maintain a constant rate of cooling water flow to the
stator winding at a normal inlet water temperature of 40°C.
4) GENERATOR SEALING SYSTEM
Page
47
Sealings are employed to prevent leakage of hydrogen from the

stator at the point of rotor exit. A continuous film between the rotor collar
and seal liner is maintained by the means of oil at a pressure, which is
about O.5 atm above the casing of hydrogen gas pressure. The thrust pad
provides a positive maintenance of the oil film thickness.
SEAL OIL SYSTEM

This system follows the following path:
a. Main Oil Tank

b. Main Oil Pump
c. Seal Oil Cooler
d. Seal Oil Filter
e. Damper Tank
f. DPR (Differential Pressure Regulator)
g. Hydrogen Seal
h. Seal Oil Fans
i. Main Oil Tank
This system has two more pumps:
a. AC Seal Oil Pump

b. DC Seal Oil Pump
The pressure of seal is 4.2kg per sq Cm. while the pressure of hydrogen is
3.5 kg per sq. cm. The purpose of this system is to provide seal to the
hydrogen used for cooling of stator. If the seal breaks, the system also
breaks down.
• MOT(main oil tank):-
It contains 28000ltrs of turbine oil. It supplies oil to all bearings and

seal.
• MOP(main oil pump):-
It takes from the main oil tank and supplies further.
Page
48
• Seal oil cooler:-
It contains clarified water and distilled mineral water. The outer

covering area is called housing. It covers an assembly of about 200 tubes
assembled on plates. Air gaps are found between the tubes (25mm above,
below and on each side of each tube).These gaps are filled using hydrogen
which cools the stator.
• Seal oil filters:-
These are rounded mesh like structures kept over each other. There
are about 34 filters present.
• Damper tank:-
It is kept at 14mtrs of height above the ground. If MOP fails A/C or D/C
pump works and if these fail then damper pump comes into action.
Here the hydrogen pressure is .7% to .9% less than the oil pressure
because if the hydrogen pressure increases, the seal would break
down.
• DPR(differential pressure regulator):-
The function of DPR is to regulate the pressure of the oil and balance
it. Whenever main oil pump fails, the AC seal oil pumps starts
automatically .DC seal pump fails but it can supply the oil up to an hour. The
generator is kept at a height of 8meters so that oil is supplied by pressure.
5) BEARINGS
Bearings are lubricated type bearings. Ring oiling is

supplemented by recirculation of externally cooled oil. An emergency supply
of oil is also maintained as a standby for failure of main supply.
6) EXCITATION SYSTEM
The excitation currents for typical 500 MW generators range from

3700 to 5100 amps and sliding electric contracts and components need
frequent attention and maintenance due to heating caused by brush friction
and brush losses. The electric power generators require direct current
excited magnet for its field system. The excitation field system should be
Page
49
reliable, stable in operation and must respond quickly to excitation current

requirements. The field excitation system is employed is static excitation
system. The voltage and current ratings are 310 V & and 2600 amp dc. The
excitation is controlled by automatic voltage regulator (AVR). The start up
power is taken using the station battery to provide initial alternator field
current.
a) High Frequency Excitation
The high frequency excitation system, adopted in 200/210 MW TG

is based on the principle of separate excitation with the help of a 500 C/S
A/C main and 400 C/S pilot exciter in conjunction with the static rectifying
unit. Both the exciters are directly mounted on the TG and four field
windings on the stator. There is no winding on the rotor to enhance its
reliability and maintenance. The pilot exciter (PEX) is a permanent magnet
type and serves as a source of stable supply to the power magnetic
amplifiers of AVR and the manual excitation of flux at various operational
conditions. The rectifying unit is water cooled, three phase static converter,
which rectifies the HFEX output and free the turbo-generator fields. The
main exciter HFEX is an inductor type generator which has three phase AC
winding.
ELECTRICAL SPECIFICATIONS OF
GENERATOR
RATING TURBO GENERATORS ONE,TWO AND THREE (95 MW each)

Power KW 95000 KW
Capacity 1175000 KV
Voltage 10500 V
Speed 6000 Rpm
Hydrogen 2.5 Kg/Cm2 (Gauge)
Page
50
Stator Winding Connection Star-Star
Phase 3
Year 1972
Power Factor 0.85(Lag)
Stator Current 6475 A
Frequency 50 Hz
Cooling Hydrogen
Maker BHEL(Haridwar)
Page
51
Rating Of Turbo Generators Four And Five [Units TG4 and TG5] (210MW
each)
Generator --
KVA Rating 247000kva
KW Rating 210000kw
Voltage 15750 V- Stator
310 V - Rotor
Amperes 9050 A- Stator
2600 A - Rotor
Rated Power Factor 0.85 Lag
Phases 3
Connection Star-Star
Coolant Water And Hydrogen
Gas Pressure 3.5 Kg/Cm3
Insulation Class B
Type Thw-210-2
Maker & Year BHEL (Haridwar) 1986-87
Rated Speed 3000 Rpm
Rated Frequency 50 C/S
Phase Connection Double Star
Rotor Cooling
A) H2 Pressure 3.5kg/Cm2
B) Purity 97%
C) Gas Volume 66 M3
Stator Cooling
A) Water Pressure 3.5 Kg/Cm2

B) Qty Of Water 130 M3/Hr
Generator Seal Oil System
Sealing Data:
A) Seal Oil Pressure 4.1 To 4.4 Kg/Cm2
B) Quantity 80 Lt/Min
C) Type Radial Flow, Double Chamber Thrust Type
AC Seal Oil Pump
A) Type Multistage Vertical Split Centrifugal Type
B) Capacity 3.34 Lit/Se At 12kg/Cm2
DC Seal Oil Pump
A) Type Multistage Vertical Split Centrifugal Type
B) Capacity 4.16 Liters At 12 Kg/Cm2
Resistance Of Stator Winding/Phase At 20 0.00 155 Ohm
Degrees
Resistance Of Rotor Winding/Phase At 20 0.08% Ohm
Page
52
Degrees
Capacitance Of Stator Winding In Hot 0.6 Micro Farad
Position
Line Charge Capacity 75 MVAR
Basic Impulse Insulation Level Between 49000 V
Turns
Basic Impulse Insulation Level Wrt. Body 49000 V
Generator Excitation Data
Ratio Of Cooling Voltage To The Excitation 2.0

Voltage
Ratio Of Field Current To The Nominal 1.6
Current
Duration Of Field Forcing 60 Sec.
Response Time 100 Sec.
Short Circuit Current
Sub-Transient Current On The Three Phase 10 PU

Short Circuit
Transient Current In Three Phase Short 3.3 PU
Circuit
Steady State Current In Three Phase Short 1.4 PU
Circuit
Resistance
Direct Axis Sub Transient Resistance 0.2 14 PU

Zero Sequence Reactance 0.105 PU
Negative Phase Sequence Reactance 0.26 PU
Temperature
Maximum Temperature Of Stator Core 105 Degrees

Maximum Temperature Of Stator Winding 115 Degrees
Permissible Rise Of Temperature Rise Of 71 Degrees
Rotor
Maximum Temperature Of Hot Gas 75 Degrees
Maximum Stator Winding Temperature 75 Degrees
Page
53
SWITCHYARD AND TRANSMISSION

EQUIPMENTS
The switchyard links the generating station to the supply grid and
constitutes the efficient switching arrangement so that it provides control
over power flow from generating station to the grid and grid to station as
required. The switchgear is basically switching network to the switch and
the power from the generator to the grid via common bus connecting all the
generators in parallel.
In BTPS switchyard is placed and installed in straight to

transformer in MCBR. The switchyard is installed at the starting of BTPS
gate. The switchyards not only controls the incoming but also feeds the
outgoing feeder there are various equipments installed in the switchyard in
order to protect the switchyard from voltage surge.
The various components of switchyard are listed below:
• Transformer
• Isolators
• Circuit Breakers
• Lightening Arrestors
• Current Transformer
• Potential Transformer
• Earth Switches
• Bus Bars and Clamp Fittings
Page
54
• Supporting Structures for Hanging Buses
• Control Relay Panel
• Fire Fighting equipments
• Power Cables and Control Cables
TRANSFORMERS
Transformers are used to step up or step down the voltage levels.

The main transformers in concern with switchyard are:
a) Switchyard Service Transformer
It supplies the auxiliary load for switchyard i.e. AC. Systems,

lighting etc.
b) Generator transformers
It steps up the generated voltage level of 16.5KV to 220KV.
c) Station transformers
It is used for supplying the station auxiliary load and start up for
power station via ICTs.
d) Interconnecting transformers
These are single-phase auto transformer and supply three-phase

power to the grid in a group of three. The ICT steps up 220KV voltage to
400KV voltage before feeding the grid.
ISOLATORS
An isolator is one, which can break an electric circuit when the

circuit is to be switched on load. These are normally used in various circuits
for the purposes of isolating a certain portion when required for
maintenance etc. Switching isolators are capable of interrupting transformer
magnetized currents, interrupting line charging current, load transfer
switching. Its main application is in connection with transformer feeder as
this makes it possible to switch out one transformer while the other one is
still on load.
Page
55
CIRCUIT BREAKERS
A circuit breaker is one, which can make and break the circuit on
load and even on faults. The equipment is most important and is heavy-duty
equipment mainly utilized for the protection of the various circuits and
operation at load. Normally isolators accomplish circuit breakers. Main types
of circuit breakers are:
• Minimum oil CB
• Bulk Oil CB
• Air Blast CB
• SF6 Gas CB
For 220KV switchyard, SF6 type CB has been employed and

400KV switchyard air blast and SF6 CBs have been employed.
Page
56
LIGHTENING ARRESTORS
LA’s are provided at the terminals of the transformer for

protection against lightening or any surges developing in the system. The
station shielding against direct lightening stoke is provided through earth
wires located at structures’ peaks.
CURRENT TRANSFORMER
The CTs used are single-phase oil immersed type. The secondary
current is generally 1A, but also 5A in certain cases.
POTENTIAL TRANSFORMER
Since we are dealing with voltages 220KV and above, capacitor

voltage transformers (CVT, a type of Fr) are used. The secondary voltage is
110/3 volts.
CTs and PTs are mainly used for three advantages:
• Metering
• Protection
• Controlling
EARTH SWITCHES
Earth switches in the switchyard are the simple mechanically

operated switches. The purpose of these is to earth the bus if required for
the purpose of eliminating induced voltage in a particular bay on account of
parallel running live conductors. These are always accompanied by an
auxiliary switch to provide interlock and indication contact.
THE BUS BAR ARRANGEMENT
For 220 KV and 400KV switchyard different bus bar arrangements have
been adopted. The type of arrangements to be adopted depends upon the
Page
57
reliability of supply from the substation. For 220KV switchyard, two main
and one transfer bus arrangement has been provided whereas for 400KV
switchyard, 1½ bus bar arrangement has been provided.
Page
58
a) Two main and one transfer bus arrangement
In this arrangement there are two main buses and one transfer
bus. The main buses are so named because they are provided with main
elaborate protection and other things and normally load is taken through
them. Whenever hilt occurs, the load can interchange the loads through
bus couplers. Under fault conditions the fault circuit can be disconnected
and repair and maintenance can be done when required. This is done from
the reliability point of view, because it is necessary to insure proper
transmission of power from generator to the grid.
b) 1½ Bus Bar Arrangement
This type of bus arrangement has been adopted for 400KV

switchyard. This arrangement is more reliable and costly than the previous
one as it has more circuit breakers and isolators for given feeders. By using
this type of arrangement, even if there is a case of failure of both buses,
power can be returned from line 1 to2 or vice versa without affecting the
rest of the system.
BUS BARS SUPPORTING STRUCTURES
The bus bar supporting structures used for hanging bus bars are
generally of steel lattice type.
CONTROLLING RELAYS
These panels consist of a no. of various types of relays installed

for Protection against over currents, over voltages, earth faults etc. As soon
as these receive an indication of some fault from CT, PT etc, these relays
trip concerned circuits, with or without time lag (as designed), Hence saving
the system from damage.
FIRE FIGHTNING EQUIPMENT
Soap pits are provided in respect of all the transformers where

the quantity of oil exceeds 2000 LTR. Besides, supportable type of fire
fighting equipment such as dry powder type, chemical foam type are also
provided in adequate quantities for protection of electrical equipments.
Page
59
Automatic types of emulsifier system (using water) have also been used for
the protection of equipment against fire.
Page
60
CONTROL ROOM
The control room building for a sub-station includes the panels,

PLCC equipment, & battery etc. The control room can be truly said to be the
heating of a sub-station, where the people concerned continuously monitor
the working conditions of equipment/system for its proper functioning.
Malfunctioning of any equipment can be immediately brought to notice the
person operating in the control room by the means of certain indications on
the panel and the fault can be easily eliminated without much damage or
tripped automatically or manually from the control room itself.
POWER CABLES AND CONTROL CABLES
The control cables are armored type and are laid in trenches
covered with RCC covers. These trenches are also housing the power
cables.
TRANSMISSION LINE EQUIPMENT
Transmission lines are required for transmitting power form generating

stations to the load centers. The important components of the transmission
lines are:
1) Conductor and accessories
2) Insulators and hardware
3) Supporting structure and accessories
4) Earth wire and accessories
The optimum voltage is determined purely from techno economic

considerations. The voltage standardized for the transmission line in the
country are 66KV, 132KV, 220KV and 400KV. The optimum power and
distance over which these voltages an adopted an as given below :
Page
61
The permissible voltages regulations are + 6 to –9 %( for HV lines and + 12

½% for EHV lines).
1) Conductors & Accessories
The lines may be single circuit or double circuit either in vertical

or horizontal configurations. A double circuit line carries double the power
than that of a single circuit line. The conductors used for the transmission
lines are aluminum conductors steel reinforced, conforming to IS-398. The
size standardized for the transmission lines are
• 'Dog' ACSR (0.1 sq inch copper equivalent ) for 66KV line
• 'Panther' ACSR (0.2 sq inch copper equivalent) for 132 KV line
• 'zebra' ACSR ( 0.4 sq inch copper equivalent) for 220KV line and
• Twin 'Moose' ACSR (2 x 0.5 sq inch copper equivalent) for 400 KV

lines.
All aluminum conductors are used at 11 KV and lower voltage

lines For 33 KV lines ACSR conductors are used.
2) Insulator & Hardware
The steel structures support these conductors attached through

insulator strings. The string consists of a number of hard wares namely
suspension tension clamps, socket clevis, ball clevis, anchor shackles, etc,
under standard atmospheric conditions.
Line No. of discs Electromechanical strength of the

Page
62
voltage insulators discs insulator

66KV 5 to 6 5000 Kg
132 KV 9 to 10 7500 kg
220 KV 13 to 14 11500 kg
400 KV 21 to 22 16500 kg
3) Supporting Structure & Accessories
The Supporting structures are normally of bolted steel lattice

type. Angle sections are bolted together to form a square base lattice
structure. The structures are provided with cross arms through which
insulator strings are hung for supporting the conductors. The base of these
towers may vary from 2.5 meters to 6 meters. The maximum distance from
the ground is normally maintained in accordance with the stipulations made
in the Indian Electricity Rules. These clearances are as follows:
The super structures are placed at an interval called the span

length the maximum span in a line is influence by:-
(i) strength and size of conductor,
(ii) height and strength of the structure,
(iii) wind pressure,
(iv) maximum temperature and
(v) spacing and circuit configuration.
These structures are used for the straight run as well as for the
points where the line deviates from the straight run. Span lengths and
phase to phase distances of lines are given as under
Page
63
Line span length phase to phase distance

voltage
66KV 250 m 2m
132 KV 330 m 4m
220 KV 350 m 5m
400 KV 400 m 7.8 m
The structures used in deviation points are called. Angle towers.

Experience has shown that 4 types of deviations viz
• up to 2°,
• from 2° to 15°,
• from 15° to 30° ,
• From 30° to 60°.
The structures are designed for the maximum wind loadings

occurring in that region and also for the maximum and minimum
temperatures in that region. The design loadings and the permissible
loadings for those structures are covered in the Indian standard IS 802-
1973.
4) Earth wires & Accessories
Earth wire is provided for giving protection to the transmission

line against lightning strikes. These wires are supported in such a manner
as to provide a shield angle of 30° to the conductors for 400KV lines, 2
ground wires are used with reduced shield angle of 20°. These earth wires
are of galvanized stranded steel, high tensile steel quality. Earth wire is
connected to the tower steel. The tower footings are further earthed
thorough a suitable earthing arrangement.
Failures and causes of Bus faults in switchyard :-
Failures and causes of Bus faults in switchyard have taken place due
to:-
• Loose contact in isolators.
Page
64
• While bus switching of feeders.
• Attributable to improper setting or auxiliary contacts or isolates.
• Loose sheets from boiler roof and other high rise structures near
to switchyard flying in dust storm and land on the live posts in the
switchyard.
An uncleared fault on a live bus is quite serious as it has potential to cause

grid collapse and in order to avoid such an occurrence, in addition to
following proper and adequate maintenance practices, it is essential not to
bypass the bus bar protection.
Page
65
Page
66
TRANSFORMERS
Transformer is a static (or stationary) piece of apparatus by means of which
electric power in one circuit is transformed to electric power of the same
frequency in another circuit. It can raise or lower the voltage in a circuit but
with a corresponding decrease or increase in current. This Chapter deals
with the basic theory, constructional features and types of major
transformers found in a power station. In its simplest form, it consists of two
inductive coils, which are electrically separated by magnetically linked
through a path of low reluctance as shown in Fig 53. The two coils possess
high mutual inductance. If one coil is connected to a source of alternating
voltage, an alternating flux is set up in the laminated core and it produces
mutually induced e.m.f. If the second coil circuit is closed, a current flows in
it and so electrical energy is transferred from the first coil to the second coil.
The first coil, in which electric energy is fed from the a.c supply mains, is
called primary winding, while the second coil is known as secondary
winding. The necessity of the transformer arises when voltages are required
to be changed. For example, the generated voltage of the alternators will be
around 15 KV.
Page
67
MAJOR TRANSFORMER IN THE POWER STATION
a) GENERATOR TRANSFORMER
The generator is connected to this transformer by means of

isolated bars. This transformer is used to step up the generating voltage of
16.5 KV to 200 KV. There is one GT per unit. It provides with off load tap
changer on high voltage side. This transformer has elaborate cooling system
consisting of number of oil pumps and cooling fans apart from various
accessories.
SPECIFICATIONS:-
Make BHEL
Cooling OFAF
Rating HV 270 MVA
LV 27OMVA
No Load Voltage HV 235 KV

LV 16.5KV
Line Current HV 664.12 A

LV 9458.75 A
Temperature rise oil 50°C
Temperature rise winding 55°C

Phases 3
Frequency 50 Hz
Connection Symbol STAR - DELTA
Impedance volts 270 MVA
Normal tap% 13.75%
Page
68
STATION TRANSFORMERS
There are two station transformers in the power station that draw
the power from the grid via 220 KV bus. Station transformer is a three
winding transformer having two LV winding and one HV winding of voltages
6.6 KV and 220KV respectively. From the station transformer four
switchgears are fed. It is required to feed power to the auxiliaries during
start-ups. It is also provided with on load tap changer to cater high
fluctuating voltages of the grid.
SPECIFICATIONS:-
Make NGEF
Cooling ONAN/ONAF/OFAF
Rated voltage HV 220 KV
LV1 6.6KV
LV 2 6.6KV
Rating HV 55 MVA
LV1 22.5 MVA
LV2 22.5 MVA
Rated current HV 144.3 A

LV1 230A
LV2 230A
Temperature rise oil 50°C

Phases 3
Frequency 50 Hz
Page
69
UNIT AUXILARY TRANSFORMER
The UAT draws its input from main bus-duct connecting generator
of the GT. There are two UAT per unit. It is used to step down the voltage
level from 16.5 KV to 6.6 KV and gives supply to the unit auxiliary
switchgear. The on load/off load Tap changer have been provided for
operational requirements.
SPECIFICATIONS
Make BHEL
Cooling ONAF / ONAN
Rating ONAF 1600 KVA
ONAN 1250 KVA
No Load Voltage HV 16.5 KV

LV 6.6KV
Line Current HV LV
ONAF 559.8 A 1338.8 A
ONAN 437.3 A 1045.9 A
Max. Ambient Temp. 50°C

Phases 3
Frequency 50 Hz
Symmetrical SC current 14.3 x I Amps
Impedance volts 270 MVA
Normal tap% 13.75%
Page
70
TEST FOR TRANSFORMERS
• OIL TEST
The oil test is performed at 33 KV and oil if filled in the container

and 33KV is given to two electrodes. When at 33 KV sparking takes place
and oil extinguishes the spark, oil gets black. If the oil quenches the arc
and does not get black, it suites for transformer.
• INSULATION TEST
The test is performed to cheek the insulation of the transformer

and done by megger. These tests are done between
a) High voltage to earth
b) Low voltage to earth
c) High voltage to low voltage firstly of 15 sec. And then 60 sec. And
then for 600 sec.
• NO LOAD TEST
This test is done in order to determine the no load or core loss

and no-load 10. In this secondary or load side is disconnected.
PROTECTION OF TRANSFORMERS
Buchholz relay is a gas actuated relay installed in oil immersed

transformers for protection against all kinds of faults. It is mainly installed in
the pipe connecting the conservator to the main tank. It is used for
transformers more than 750 KVA.
• Operation
In case of fault within the transformer the heat due to fault

1)
causes the decomposition of the same transformer oil in the main tank. The
product of decomposition contains more than 70% of hydrogen. It gets
trapped in upper part of relay chamber. When the gas accumulates it exerts
Page
71
sufficient pressure on the float to cause it to tilt and close the contact of
mercury switch attached thus completing the alarm circuit to sound the
alarm.
2) If
a series fault occurs then an enormous amount of gas is
generated in the tank. The oil in the tank rushes towards conservator via
the Buchholz relay and in doing so tilts the flap to close the contact of
mercury switch. This completes the trip circuit to open the circuit breaker.
Page
72

Summer Training Report: Badarpur Thermal Power Station (A Unit of NTPC)

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Summer Training Report: Badarpur Thermal Power Station (A Unit of NTPC)

Uploaded by

Copyright:

Available Formats

BTPS

SUMMER TRAINING REPORT

This is to certify that MANSI TIWARI student of bachelor of

With profound respect and gratitude, I take the opportunity to convey

I extend my heartfelt thanks to Ms. Rachna Singh Bahal for providing

I would also like to thank the training incharge of APEEJAY COLLEGE

Set up in 1975 by Government of India, today it is a Navratna PSU with

NTPC Limited is the largest power generating company of India. A public

NTPC's core business is engineering, construction and operation of power

Major Achievements of NTPC:

2) Sixth largest thermal power generator in the world.

3) Second most efficient utility in terms of capacity utilization.

4) One of the nine PSUs to be awarded by the status of Navratna.

Address: Badarpur, New Delhi – 110 044

• Electrical Maintenance Department - 1 (EMD-1)

THERMAL POWER PLANT

GENERAL STRUCTURE OF BTPS(750MW CAPACITY) :

Schematic arrangement of steam power

2. Steam generating plant.

Coal and ash handling plant :-

Following is the systematic diagram of the coal handling

BUNKER - FEEDING CONVEYORS: -

Steam generating plant:-

The heat of combustion of coal in the boiler is utilized to

The steam produced in the boiler is wet and is passed through a

turbine (which would cause blade corrosion) is avoided. The superheated

An economizer is essentially a feed water heater and derives

An air-pre heater increases the temperature of the air supplied for

CONTROL & INSTRUMENTATION

This division basically calibrates various instruments and takes

4. PROTECTION & INTERLOCKING LAB.

5. TURBO SUPERVISORY INSTRUMENT LAB.

6. FURANCE SAFETY SUPERVISORY SYSTEM.

7. ELECTRONICS TEST LAB.

This department is the brain of the plant because from relays to

2. BOURDON PRESSURE GUAGE:-

It is an oval section of tube. Its one end is fixed. It is provided

a. Spiral type-: It is used for measuring low pressure. It is more sensitive

b. Helical type-: It is used for measuring high pressure. It is most sensitive

LIQUID IN GLASS THERMOMETER:-

Mercury in the glass thermometer boils at 340 degree Celsius

1. The Bi-Metallic Strip:-

Bi-metal strips are composed of two metals, as the name implies,

2. ULTRA VOILET CENSOR:-

This device is used in furnace and it measures the intensity of

PROTECTION AND INTERLOCK LAB

a) HIGH TENSION CONTROL CIRCUIT:-

For high-tension system the control system is excited by separate DC

b) LOW TENSION CONTROL CIRCUIT: -

interconnection fails. This system is more prone to failure as it is excited

It is basically interconnecting two or more equipment so that if one

It is a protective device. It can detect wrong condition in electrical

a) Current Relay: - It gets energized when the rated amount of

b) Potential Relay: - It gets energized by voltage and has copper

a) The expansion coefficient of sliver is very small. As a result, no critical fatigue

3. MINIATURE CIRCUIT BREAKERS: -

a) Enable the starting of plant and distributors.

FURANCE SAFETY SUPERVISORY SYSTEM

For firing the furnace a 10 KV spark plug is operated for 10

TURBO SUPERVISORY INSTRUMENTS

The speed of the turbine is to be kept constant so that the

b) AXIAL SHIFT OF ROTOR: -