BTPS

SUMMER TRAINING REPORT

Submitted by:

BADARPUR THERMAL POWER STATION (A UNIT OF NTPC)

ANKUR YADAV
B.TECH (MECHANICAL ENGG.) LAXMI DEVI INSTITUTE OF ENGINEERING& TECHNOLOGY ALWAR,RAJASTHAN. CONTENTS

Certificate Acknowledgement
Training at BTPS 1. Introduction 2. 3. NTPC Badarpur Thermal Power Station

Operation Electrical Maintenance Division-I HT/LT Switch Gear HT/LT Motors, Turbine & Boilers Side CHP/NCHP

4.

Electrical Maintenance Division-II Generator Transformer & Switchyard Protection Lighting EP

CERTIFICATE

This is to certify that Ankur Yadav, student of bachelor of Technology, mechanical, 3rd Year, LIET,Alwar,Rajasthan has successfully completed his industrial Training at Badarpur Thermal Power Corporation, New Delhi for 25 days from 4 th of July to 29th July 2011. He has completed the whole training as per the training report submitted by him.

Training Incharge BTPS/NTPC, Badarpur, New Delhi

ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training here. I do extend my heartfelt thanks to Ms. Rachna Singh for providing me this opportunity to be a part of this esteemed organisation. I am 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 of them for this value addition in me. I would also like to thank the training incharge and all the faculty members of our college, NPTI, Badarpur, for their effort of constant co- operation, which have been a significant factor in the accomplishment of my industrial training.

Ankur Yadav B.Tech (Mechanical Engg.)

Training at BTPS
I was appointed to do 25 Days training at this esteemed organization from 5th July to 29th July, 2011. I was assigned to visit various division of the plant, which were. Electrical Maintenance Department -1 (EMD- 1) Electrical Maintenance Department -2 (EMD- 2) These 25 Days training was a very educational adventure for me. It was really amazing to see the plant by yourself and learn how electricity, which is one of our daily requirements of life, is produced. This report has been made by my experience at BTPS. The material in this report has been gathered from my textbook, senior student reports and trainers manuals and power journals provided by training department. The specification and principles are as learned by me from the employees of each division of BTPS.

ANKUR YADAV

INTRODUCTION
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 is providing power at the cheapest average tariff in the country. With its experience and expertise in the power sector, NTPC is extending consultancy services to various organizations in the power business. NTPC has entered into a joint venture with Alstom, Germany for renovation and modernization of power

plants in India.

NTPC is committed to the environment, generating power at minimal environmental cost and preserving the ecology in the vicinity of the plants. It has undertaken massive afforestation in the vicinity of its plants. Plantations have

increased forest area and reduced barren land. The massive afforestation by NTPC in and around its Ramagundam Power station (2100 MW) has 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 to manage efficient use of the ash produced at its coal stations. This quality of ash produced is ideal for use in cement, concrete, cellular concrete, building material. A "Centre for Power Efficiency and Environment Protection (CENPEEP)" has been established in NTPC with the assistance of United States Agency for International Development. (USAID). Cenpeep is efficiency oriented, Eco-friendly and Econurturing 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 of Project Affected Persons. It was among the first Public Sector Enterprises to enter into a Memorandum of Understanding (MOU) with the Government in 1987-88. The development of power in the country was achieved through State Electricity Boards (SEBS) during the first three decades after independence. The outlay for power during viii-plan was Rs.34270 crores against Rs.393 crores during the first plan period. The outlay for power remained 19-20% during all plan periods out of total outlay. Vision: "To be one of the worlds largest and best power utilities, powering growth". India's

NTPC's vision for the new millennium is inspired by a glorious past, vibrant present and a brilliant future. Mission: 1) Make available reliable and quality power in increasingly large quantities at appropriate tariffs, and ensure timely realization of revenues. 2) Speedily plan and implement power projects, with contemporary technologies. 3) Implement strategic diversifications in the areas of R&M, Hydro, LNG and non-conventional and eco-friendly fuels and explore new areas like transmission, information technology etc.

ABOUT BTPS
Badarpur thermal power station started working in 1973 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 .Given below are the details of unit with the year they are installed.

Address: Telephone: Fax: Installed Capacity Derated Capacity Location Coal Source Water Source Beneficiary States Unit Sizes Units Commissioned

Badarpur, New Delhi 110 044 (STD-011) 26949523 26949532 720 MW 705 MW New Delhi Jharia Coal Fields Agra Canal Delhi 3X95 MW 2X210 MW Unit Unit Unit Unit Unit I- 95 MW - July 1973 II- 95 MW August 1974 III- 95 MW March 1975 IV - 210 MW December 1978 V - 210 MW - December 1981

OPERATION
ELECTRICITY FROM COAL
Coal from the coal wagons is unloaded with the help of wagon tipplers in the C.H.P. this coal is taken to the raw coal bunkers with the help of conveyor belts. Coal is then transported to bowl mills by coal feeders where it is pulverized and ground in the powered form. This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold mixture P.A fan. This fan takes atmospheric air, a part of which is sent to pre heaters while a part goes to the mill for temperature control. Atmospheric air from F.D fan in the air heaters and sent to the furnace as combustion air. Water from boiler feed pump passes through economizer and reaches the boiler drum . Water from the drum passes through the down comers and goes to the bottom ring header. Water from the bottom ring header is divided to all the four sides of the furnace. Due to heat density difference the water rises up in the water wall tubes. This steam and water mixture is again taken to the boiler drum where the steam is sent to super heaters for super heating. The super heaters are located inside the furnace and the steam is super heated (540 degree Celsius) and finally it goes to the turbine. Fuel gases from the furnace are extracted from the induced draft fan, which maintains balance draft in the furnace with F.D fan. These fuel gases heat energy to the various super heaters and finally through air pre heaters and goes to electrostatic precipitators where the ash particles are extracted. This ash is mixed with the water to from slurry is pumped to ash period.

The steam from boiler is conveyed to turbine through the steam pipes and through stop valve and control valve that automatically regulate the supply of steam to the turbine. Stop valves and controls valves are located in steam chest and governor driven from main turbine shaft operates the control valves the amount used. Steam from controlled valves enter high pressure cylinder of turbines, where it passes through the ring of blades fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on the disc secured in the turbine shaft. The second ring turns the shaft as a result of force of steam to the stationary and moving blades together. MAIN GENERATOR

Maximum continuous KVA rating Maximum continuous KW Rated terminal voltage Rated Stator current Rated Power Factor Excitation current at MCR Condition Slip-ring Voltage at MCR Condition Rated Speed Rated Frequency Short circuit ratio Efficiency at MCR Condition Direction of rotation viewed Phase Connection Number of terminals brought out

24700KVA 210000KW 15750V 9050 A 0.85 lag 2600 A 310 V 3000 rpm 50 Hz 0.49 98.4% Anti Clockwise Double Star 9( 6 neutral and 3 phase)

MAIN TURBINE DAT

Rated output of Turbine Rated speed of turbine Rated pressure of steam before emergency Stop valve rated live steam temperature

210 MW 3000 rpm 130 kg/cm^2 535 degree Celsius

Rated steam temperature after reheat at inlet 535 degree Celsius to receptor valve Steam flow at valve wide open condition 670 tons/hour

Rated quantity of circulating water through 27000 cm/hour condenser 1. For cooling water temperature (degree 24,27,30,33 Celsius) 1.Reheated steam pressure at inlet of 23,99,24,21,24,49,24 .82 68,645,652,662

interceptor valve in kg/cm^2 ABS 2.Steam flow required for 210 MW in ton/hour

3.Rated pressure at exhaust of LP turbine in 19.9,55.5,65.4,67.7 mm of Hg

THERMAL POWER PLANT

A Thermal Power Station comprises all of the equipment and a subsystem required to produce electricity by using a steam generating boiler fired with fossil fuels or befouls to drive an electrical generator. Some prefer to use the term ENERGY CENTER because such facilities convert forms of energy, like nuclear energy, gravitational potential energy or heat energy (derived from the combustion of fuel) into electrical energy. However, POWER PLANT is the most common term in the united state; While POWER STATION prevails in many Commonwealth countries and especially in the United Kingdom.Such power stations are most usually constructed on a very large scale and designed for continuous operation. 1. Cooling water pump 2. Three-phase transmission line 3. Step up transformer 4. Electrical Generator 5. Low pressure steam 6. Boiler feed water pump 7. Surface condenser 8. Intermediate pressure steam turbine 9. Steam control valve 10. High pressure steam turbine 11. Deaerator Feed water heater 12. Coal conveyor 13. Coal hopper 14. Coal pulverizer 15. boiler steam drum 16. Bottom ash hoper 17. Super heater 18. Forced draught(draft) fan 19. Reheater

20. Combustion air intake 21. Economizer 22. Air preheater 23. Precipitator 24. Induced draught(draft) fan 25. Fuel gas stack

The description of some of the components written above is described as follows:

1.Cooling towers
Cooling Towers are evaporative coolers used for cooling water or other working medium to near the ambivalent web-bulb air temperature. Cooling tower use evaporation of water to reject heat from processes such as cooling the circulating water used in oil refineries, Chemical plants, power plants and building cooling, for example. The tower 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 structure 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 primary use of large , industrial cooling tower system is to remove the heat absorbed in the circulating cooling water systems used in power plants , petroleum refineries, petrochemical and chemical plants, natural gas processing plants and other industrial facilities . 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.

2.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 conductor 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 one conductor as the reference, the other two current are delayed in time by one-third and two-third of one cycle of the electrical current. 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. 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 one cycle. Generators output at a voltage that ranges from hundreds of volts to 30,000 volts. 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 phase-neutral voltage. Another system commonly seen in North America is to have a delta connected secondary with a center 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 ( known as a wild leg) and neutral and 240 V between any two phase) to be available from the same supply.

3.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 may be a reciprocating or turbine steam engine, , water falling through the turbine are made in a variety of sizes ranging from small 1 hp (0.75 kW) units (rare) used as mechanical drives for pumps, compressors and other shaft driven equipment , to 2,000,000 hp(1,500,000 kW) turbines used to generate electricity. There are several classifications for modern steam turbines. Steam turbines are used in all of our major coal fired power stations to drive the generators or alternators, which produce electricity. The turbines themselves are driven by steam generated in Boilers or steam generators as they are sometimes called. Electrical power station use large stem turbines driving electric generators to produce most (about 86%) of the worlds electricity. 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 theirgenerators .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. 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 stage 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 into forces, caused by pressure drop, which results in the rotation of the turbine shaft. The turbine shaft is connected to a generator, which produces the electrical energy.

4.Boiler feed water 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 retuning 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. 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 is substantially increased. Some pumps contain a two-stage switch. As liquid lowers to the trigger point of the first stage, the pump is activated. I f 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.

5. Steam-powered pumps
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. 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.

6. Control valves
Control valves are valves used within industrial plants and elsewhere to control operating conditions such as temperature,pressure,flow,and liquid Level by fully 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

7. Deaerator
A Dearator 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 non-corrosive. 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 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. 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)

8. 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 irreversible involved in steam generation and therefore improves the thermodynamic efficiency of the system.[4] This reduces plant operating costs and also helps to avoid thermal shock to the boiler metal when the feed water is introduces back into the steam cycle. In a steam power (usually modeled as a modified Ranking cycle), feed water heaters allow the feed water to be brought up to the saturation temperature very gradually. This minimizes the inevitable irreversibilitys associated with heat transfer to the working fluid (water). 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.

9. Pulverizer
A pulverizer is a device for grinding coal for combustion in a furnace in a fossil fuel power plant.

10. Boiler Steam 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 hotter-water/and saturated steam into steam

drum. Made from high-grade steel (probably stainless) and its working involves temperatures 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. 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 the bottom.

11. 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 and decreasing the likelihood that it will condense inside the engine. 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 so stationary steam engines including power stations.

12. 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, and 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 a device fitted to a boiler which saves energy by using the exhaust gases from the boiler to preheat the cold water used the 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 they are turbines before it is pumped to the boilers. A common application of economizer is steam power plants is to capture the waste hit 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.

13. 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 fuel gas. As a consequence, the flue gases 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.

14. 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 coal-fired boiler application.

The original parallel plate-Weighted wire design (described above) has evolved as more efficient ( and robust) discharge electrode designs were developed, today focusing 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.

15. Fuel gas stack

A Fuel gas stack is a type of chimney, a vertical pipe, channel or similar structure through which combustion product gases called fuel gases are exhausted to the outside air. Fuel gases are produced when coal, oil, natural gas, wood or any other large combustion device. Fuel gas is usually composed of carbon dioxide (CO2) and water vapor 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 sulfur 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 aria and thereby reduce the concentration of the pollutants to the levels required by governmental environmental policies and regulations. When the fuel gases exhausted from stoves, ovens, fireplaces or to as chimneys. other small sources within residential abodes, restaurants , hotels or other stacks are referred

EMD I
Electrical Maintenance division I
I was assigned to do training in Electrical maintenance division I from 9th July 2011 to 15th July 2011. This two week - training in this division were divided as follows. HT/LT switchgear HT/LT Motors, Turbine &Boiler side CHP/NCHP Electrical EMD 1 is responsible for maintenance of: 1. Boiler side motors 2. Turbine side motors 3. Outside motors 4. Switchgear 5. A.C. MOTORS INTRODUCTION & PRINCIPLE OF OPERATION: As in a machine is simply an electric transformer whose magnetic circuit is separated by an air gap into two relative movable portions, one carrying the primary and other secondary winding; then the latter is short circuited or closed through external impedance. The electromagnetic forces corresponding to the power thus transferred across the air gap by induction produce relative motion between the primary and secondary structure.

1. Boiler side motors: For 1, units 1, 2, 3

1.1D Fans 2.F.D Fans 3.P.A.Fans 4.Mill Fans 5.Ball mill 2 in

no. 2 in no. 2 in no. 3 in no. 3 in no. 3 in no. 5 in no. 2 in no. 4 in no. 1 in no. 4 in no.

fans 6.RC feeders 7.Slag Crushers 8.DM Make up Pump 9.PC Feeders 10.Worm Conveyor 11.Furnikets

For stage units 1, 2, 3

1.I.D Fans 2.F.D Fans 3.P.A Fans 4.Bowl Mills 5.R.C Feeders 6.Clinker Grinder 2 2 2 6 in in in in no. no. no. no.

6 in no. 2 in no.

7.Scrapper 8.Seal Air Fans 9.Hydrazin e and Phosphorou s Dozing 1. COAL HANDLING PLANT (C.H.P) 2. NEW COAL HANDLING PLANT (N.C.H.P)

2 in no. 2 in no. 2 in no.

The old coal handling plant caters to the need of units 2,3,4,5 and 1 whereas the latter supplies coal to units 4 and V.O.C.H.P. supplies coal to second and third stages in the advent coal to usable form to (crushed) form its raw form and send it to bunkers, from where it is send to furnace. Major Components 1. Wagon Tippler: - Wagons from the coal yard come to the tippler and are emptied here. The process is performed by a slip ring motor of rating: 55 KW, 415V, 1480 RPM. This motor turns the wagon by 135 degrees and coal falls directly on the conveyor through vibrators. Tippler has raised lower system which enables is to switch off motor when required till is wagon back to its original position. It is titled by weight balancing principle. The motor lowers the hanging balancing weights, which in turn tilts the conveyor. Estimate of the weight of the conveyor is made through hydraulic weighing machine.

2. Conveyor: - There are 14 conveyors in the plant. They are

numbered so that their function can be easily demarcated. Conveyors are made of rubber and more with a speed of 250-300m/min. Motors employed for conveyors has a capacity of 150 HP. Conveyors have a capacity of carrying coal at the rate of 400 tons per hour. Few

conveyors are double belt, this is done for imp. Conveyors so that if a belt develops any problem the process is not stalled. The conveyor belt has a switch after every 25-30 m on both sides so stop the belt in case of emergency. The conveyors are 1m wide, 3 cm thick and made of chemically treated vulcanized rubber. The max angular elevation of conveyor is designed such as never to exceed half of the angle of response and comes out to be around 20 degrees.

3. Zero Speed Switch:-It is safety device for motors, i.e., if belt is

not moving and the motor is on the motor may burn. So to protect this switch checks the speed of the belt and switches off the motor when speed is zero.

4. Metal Separators: -

As the belt takes coal to the crusher, No

metal pieces should go along with coal. To achieve this objective, we use metal separators. When coal is dropped to the crusher hoots, the separator drops metal pieces ahead of coal. It has a magnet and a belt and the belt is moving, the pieces are thrown away. The capacity of this device is around 50 kg. .The CHP is supposed to transfer 600 tons of coal/hr, but practically only 300-400 tons coal is transfer

5. Crusher: - Both the plants use TATA crushers powered by BHEL.

Motors. The crusher is of ring type and motor ratings are 400 HP, 606 KV. Crusher is designed to crush the pieces to 20 mm size i.e. practically considered as the optimum size of transfer via conveyor. 6. Rotatory Breaker: - OCHP employs mesh type of filters and allows particles of 20mm size to go directly to RC bunker, larger particles are sent to crushes. This leads to frequent clogging. NCHP uses a technique that crushes the larger of harder substance like metal impurities easing the load on the magnetic separators.

MILLING SYSTEM
1. 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. 2. 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. 3. 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. 4. Classifier:It is an equipment which serves separation of fine

pulverized coal particles medium from coarse medium. The pulverized coal along with the carrying medium strikes the impact plate through the lower part. Large particles are then transferred to the ball mill. 5. Cyclone Separators: - It separates the pulverized coal from carrying medium. The mixture of pulverized coal vapour caters the cyclone separators.

6. The Tturniket: - It serves to transport pulverized coal from cyclone separators to pulverized coal bunker or to worm conveyors. There are 4 turnikets per boiler. 7. 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. 8. Mills Fans: - It is of 3 types: Six in all and are running condition all the time. (a) ID Fans: - Located between electrostatic precipitator and Type-radical Speed-1490 rpm Rating-300 KW Voltage-6.6 KV Lubrication-by oil (b) FD Fans: - Designed to handle secondary air for boiler. 2 in number and provide ignition of coal. Type-axial Speed-990 rpm Rating-440 KW Voltage-6.6 KV (c)Primary Air Fans: - Designed for handling the atmospheric air up to 50 degrees Celsius, 2 in number. And they transfer the powered coal to burners to firing.

chimney.

Type-Double suction radial Rating-300 KW Voltage-6.6 KV Lubrication-by oil Type of operation-continuous 9. Bowl Mill: - One of the most advanced designs of coal pulverizes presently manufactured. Motor specification squirrel cage induction motor Rating-340 KW Voltage-6600KV Curreen-41.7A Speed-980 rpm Frequency-50 Hz No-load current-15-16 A

NCHP
1. Wagon Tippler:Motor Specification (i) H.P (ii) Voltage (iii) Speed (iv) Frequency (v) Current rating 2. Coal feed to plant:Feeder motor specification (i) Horse power (ii) Voltage (iii) Speed (iv) Frequency 3. Conveyors:10A, 10B 11A, 11B 12A, 12B 13A, 13B 14A, 14B 15A, 15B 16A, 16B 17A, 17B 18A, 18B 4. Transfer Point 6 15 HP 415V,3 phase 1480 rpm 50 Hz 75 HP 415, 3 phase 1480 rpm 50 Hz 102 A

5. Breaker House 6. Rejection House 7. Reclaim House 8. Transfer Point 7 9. Crusher House 10. Exit The coal arrives in wagons via railways and is tippled by the wagon tipplers into the hoppers. If coal is oversized (>400 mm sq) then it is broken manually so that it passes the hopper mesh. From the hopper mesh it is taken to the transfer point TP6 by conveyor 12A ,12B which takes the coal to the breaker house , which renders the coal size to be 100mm sq. the stones which are not able to pass through the 100mm sq of hammer are rejected via conveyors 18A,18B to the rejection house . Extra coal is to sent to the reclaim hopper via conveyor 16. From breaker house coal is taken to the TP7 via Conveyor 13A, 13B. Conveyor 17A, 17B also supplies coal from reclaim hopper, From TP7 coal is taken by conveyors 14A, 14B to crusher house whose function is to render the size of coal to 20mm sq. now the conveyor labors are present whose function is to recognize and remove any stones moving in the conveyors . In crusher before it enters the crusher. After being crushed, if any metal is still present it is taken care of by metal detectors employed in conveyor 10.

SWITCH GEAR-It makes or breaks an electrical circuit.

1. Isolation: - A device which breaks an electrical circuit when circuit is switched on to no load. Isolation is normally used in various ways for purpose of isolating a certain portion when required for maintenance. 2. Switching Isolation: - It is capable of doing things like interrupting transformer magnetized current, interrupting line charging current and even perform load transfer switching. The main application of switching isolation is in connection with transformer feeders as unit makes it possible to switch out one transformer while other is still on load. 3. Circuit Breakers: - 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 4. 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. 5. 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.

LT Switchgear :

It is classified in following ways:-

1. Main Switch:- Main switch is control equipment which controls or disconnects the main supply. The main switch for 3 phase supply is available for tha range 32A, 63A, 100A, 200Q, 300A at 500V grade. 2. 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. Rotary switch up to 25A. With fuses, quick break, quick make and double break switch fuses for 63A and 100A, switch fuses for 200A, 400A, 600A, 800A and 1000A are used. 3. Contractors: - AC Contractors are 3 poles suitable for D.O.L Starting of motors and protecting the connected motors. 4. Overload Relay: - For overload protection, thermal over relay are best suited for this purpose. They operate due to the action of heat generated by passage of current through relay element. 5. Air Circuit Breakers: - It is seen that use of oil in circuit breaker may cause a fire. So in all circuits breakers at large capacity air at high pressure is used which is maximum at the time of quick tripping of contacts. This reduces the possibility of sparking. The pressure may vary from 50-60 kg/cm^2 for high and medium capacity circuit breakers.

HT SWITCH GEAR:1. 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. Type-HKH 12/1000c Rated Voltage-66 KV Normal Current-1250A Frequency-5Hz Breaking Capacity-3.4+KA Symmetrical 3.4+KA Asymmetrical 360 MVA Symmetrical Operating Coils-CC 220 V/DC FC 220V/DC Motor Voltage-220 V/DC

2. 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 3. 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 o that of air blast circuit breaker. It simply employs the arc extinguishing medium namely SF6. the performance of gas . When it is broken down under an electrical stress. It will quickly reconstitute itself Circuit 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 Rated Short Time Current 1/3s -40 A Mass Approximation-185 KG Auxiliary Voltage Closing Coil-220 V/DC Opening Coil-220 V/DC Motor-220 V/DC SF6 Pressure at 20 Degree Celsius-0.25 KG SF6 Gas Per pole-0.25 KG

4. Vacuum Circuit Breaker: - It works on the principle that vacuum is used to save the purpose of insulation and it implies that pr. of gas at which breakdown voltage independent of pressure. It regards of insulation and strength, vacuum is superior dielectric medium and is

better that all other medium except air and sulphur which are generally used at high pressure. Rated frequency-50 Hz Rated making Current-10 Peak KA Rated Voltage-12 KV Supply Voltage Closing-220 V/DC Rated Current-1250 A Supply Voltage Tripping-220 V/DC Insulation Level-IMP 75 KVP Rated Short Time Current-40 KA (3 SEC) Weight of Breaker-8 KG

EMD II
Electrical Maintenance division II
I was assigned to do training in Electrical maintenance division II from 15th July 2010 to 29th July 2011. This two week of training in this division were divided as follows.

Generator & Transformer Switchyard Protection Lighting

Generator and Auxiliaries

The transformation of mechanical energy into electrical energy is carried out by the Generator. 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 (viz magnetic field) cut through the stator windings. This induces an electromagnetic force (e.m.f.) in the stator windings. The magnitude of this e.m.f. is given by the following expression. E 0 F N F Where P n = 4.44 /O FN volts = = = = = = Strength of magnetic field in Webers. Frequency in cycles per second or Hertz. Number of turns in a coil of stator winding Frequency = Pn/120 Number of poles revolutions per second of rotor.

From the expression it is clear that for the same frequency, number of poles increases with decrease in speed and vice versa. Therefore, low speed hydro turbine drives generators have 14 to 20 poles where as high speed steam turbine driven generators have generally 2 poles. Pole rotors are used in low speed generators, because the cost advantage as well as easier construction.

Generator component
Rotor :
The electrical rotor is the most difficult part of the generator to design. The rotor multiplicity by behavior magnetic current become temperature would and maximum With this amount good through so down, introduce would of design It problem is of a peculiar strength the high, revolves of complicated differential structure to in most modern generators at a speed of 3,000 revolutions per minute. guaranteeing the dynamic strength and operating stability of such a by the fact that a massive non-uniform shaft subjected to a stresses must operate in oil lubricated sleeve bearings supported mounted on foundations all of which possess complex dynamic be themselves. It is also an electromagnet and to give it the necessary the windings must carry a fairly high current. The passage of the windings generates heat but the temperature must not be allowed to otherwise difficulties will be experienced with insulation. To keep the the cross section of the conductor could not be increased but this another problems. In order to make room for the large conductors, body cause mechanical weakness. The problem is really to get the copper into the windings without reducing the mechanical strength.

and great care in construction this can be achieved. The rotor is a cast steel ingot, and it is further forged and machined. Very often a hole is bored through the centre of the rotor axially from one end of the other for inspection. Slots are then machined for windings and ventilation. Rotor winding: Silver bearing copper is used for the winding with mica as the insulation between conductors. A mechanically strong insulator such as micanite is used for lining the slots. Later designs of windings for large rotor incorporate combination of hollow conductors with slots or holes arranged to provide for circulation of the cooling gas through the actual conductors. When rotating at high speed. Centrifugal force tries to lift the windings out of the slots and they are contained by wedges. The end rings are secured to a turned recess in the rotor body, by shrinking or screwing and supported at the other end by fittings carried by the rotor body. The two ends of windings are connected to slip rings, usually made of forged steel, and mounted on insulated sleeves.

Rotor balancing:
When completed the rotor must be tested for mechanical balance, which vibration. unlikely are means To that therefore do about its that this central axis and a speed it it is this most without check is made to see if it will run up to normal would have to be uniform

will be so to the degree necessary for perfect balance. Arrangements made in all designs to fix adjustable balance weights around the

circumference end.

at

each

Stator:
Stator frame: The stator is the heaviest load to be transported. The major part of this load is the stator core. This comprises an inner frame and outer frame. The outer frame is a rigid fabricated structure of welded steel plates, within this shell is a fixed cage of girder built circular and axial ribs. The ribs divide the yoke in the compartments through which hydrogen flows into radial ducts in the stator core and circulate through the gas coolers housed in the frame. The inner cage is usually fixed in to the yoke by an arrangement of springs to dampen the double frequency vibrations inherent in 2 pole generators. The end shields of hydrogen cooled generators must be strong enough to carry shaft seals. In large generators the frame is constructed as two separate parts. The fabricated inner cage is inserted in the outer frame after the stator core has been constructed and the winding completed. Stator core: The stator core is built up from a large number of 'punching" or sections of thin steel plates. The use of cold rolled grain-oriented steel can contribute to reduction in the weight of stator core for two main reasons: a)There is an increase in core stacking factor with improvement in lamination cold Rolling and in cold buildings techniques. b) 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. Stator Windings: Each stator conductor must be capable of carrying the rated current without overheating. The insulation must be sufficient to prevent leakage currents flowing between the phases to earth. Windings for the stator are made up from copper strips wound with insulated tape which is impregnated with varnish, dried under vacuum

and hot pressed to form a solid insulation bar. These bars are then place in the stator slots and held in with wedges to form the complete winding which is connected together at each end of the core forming the end turns. These end turns are rigidly braced and packed with blocks of insulation material to withstand the heavy forces which might result from a short circuit or other fault conditions. The generator terminals are usually arranged below the stator. On recent generators (210 MW) the windings are made up from copper tubes instead of strips through which water is circulated for cooling purposes. The water is fed to the windings through plastic tubes.

Generator Cooling System :

The 200/210 MW Generator is provided with an efficient cooling system to avoid excessive heating and consequent wear and tear of its main components during operation.

Rotor Cooling System

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

Hydrogen Cooling System

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

Stator Cooling System

The stator winding is cooled by distillate. Which is fed from one end of the machine by Teflon tube and flows through the upper bar and returns back through the lower bar of another slot? Turbo generators require water cooling arrangement over and above the usual hydrogen cooling arrangement. The stator winding is cooled in this system by circulating demineralised water (DM water) through hollow conductors. The cooling water used for cooling stator winding calls for the use of very high quality of cooling water. For this purpose DM water of proper specific resistance is selected. Generator is to be loaded within a very short period if the specific resistance of the cooling DM water goes beyond certain preset values. The system is designed to maintain a constant rate of cooling water flow to the stator winding at

a nominal inlet water temperature of 40 deg.C.

Rating of 95 MW Generator
Manufacture by Bharat heavy electrical Limited (BHEL) Capacity Voltage Speed Hydrogen Power factor Stator current Frequency Stator wdg connection - 117500 KVA - 10500V - 3000 rpm - 2.5 Kg/cm2 - 0.85 (lagging) 6475 A 50 Hz 3 phase

Rating of 210 MW Generator

Manufacture by Bharat heavy electrical Limited (BHEL)

Capacity Voltage (stator) Current (stator) Voltage (rotor) Current (rotor) Speed Power factor Frequency Hydrogen Stator wdg connection Insulation class

- 247000 KVA - 15750 V - 9050 A - 310 V - 2600 V - 3000 rpm - 0.85 - 50 Hz - 3.5 Kg/cm2 - 3 phase star connection -B

TRANFORMER

A transformer is a device that transfers electrical energy from one circuit to another by magnetic coupling with out requiring relative motion between its parts. It usually comprises two or more coupled windings, and in most cases, a core to concentrate magnetic flux. An alternating voltage applied to one winding creates a time-varying magnetic flux in the core, which includes a voltage in the other windings. Varying the relative number of turns between primary and secondary windings determines the ratio of the input and output voltages, thus transforming the voltage by stepping it up or down between circuits. By transforming electrical power to a highvoltage,_low-current form and back again, the transformer greatly reduces energy losses and so enables the economic transmission of power over long distances. It has thus shape the electricity supply industry, permitting generation to be located remotely from point of demand. All but a fraction of the worlds electrical power has passed trough a series of transformer by the time it reaches the consumer.

Rating of transformer
Manufactured by Bharat heavy electrical limited No load voltage (hv) No load Voltage (lv) Line current (hv) Line current (lv) Temp rise Oil quantity Weight of oil Total weight Core & winding Phase Frequency -3 - 50 Hz - 229 KV -10.5 KV - 315.2 A - 873.2 A - 45 Celsius -40180 lit -34985 Kg - 147725 Kg - 84325 Kg

LIGHTING
Lighting includes both artificial light sources such as lamps and natural illumination of interiors from daylight. Lighting represents a major component of energy consumption, accounting for a significant part of all energy consumed worldwide. Artificial lighting is most commonly provided today by electric lights, but gas lighting, candles or oil lamps were used in the past, and still are used in certain situations. Proper lighting can enhance task performance or aesthetics; while there can be energy wastage and adverse health effects of lighting

220 KV SWITCHYARD
BUS BARS: The arrangement in the 220kV switchyard comprises of a 220kV double bus bar system, with a bus coupler and a by pass bus. With this arrangement it is possible to take out any one breaker for maintenance without interruption of supply. In the eventuality of a bus bar or a circuit breaker fault the period for which supply is interrupted is the time taken to transfer the feeders from the faulty bus to the healthy one or replacing the faulty circuit breaker by the by-pass breaker. It is only in the case of a line fault that supply cannot be restored to the feeder until the fault is rectified. For maintenance of a particular bus all feeders connected to the bus requiring the maintenance shall be transferred to the other bus by closing one bus isolator and opening the other. The bus coupler shall be tripped and the earthing switch closed. After the maintenance work is over, the earthing switch must be opened before the respective bus bar is energized. For maintenance of the by-pass bus, it should be ensured that by-pass breaker is open and all the by pass isolators of various bays are open. 220KV CIRCUIT BREAKERS: There are two types of 220kV breakers being used in BTPS switchyard: Air blast ciruit breaker SF6 circuit breaker These breakers operate with sequential isolators and suitable for three-phase auto-reclosing facility. These breakers can be operated from the switch yard

control board. In case of failure, emergency manual handles are provided in the control kiosk. Feeder breaker: When it is required to maintain either a line or a generator or a transformer breaker, the feeder is transferred to the by-pass breaker. The earthing switches on isolators must be earthed before maintaining the breaker. By-pass breaker: the main purpose of the by pass breaker is to facilitate maintenance/repair of other 220 kV breakers without the necessity of tripping out the associated circuit. Bus coupler breaker: The two bus bars can be kept coupled through bus couplers. The by pass breaker cannot act as a substitute for bus coupler breaker when the bus coupler breaker is being maintained. If buses I and II are paralleled by means of bus coupler and by pass breaker then in order to maintain the bus coupler breaker all feeders must be transferred to one bus depending upon the prevalent load. RATINGS OF CIRCUIT BREAKERS: 1. AIR BLAST CIRCUIT BREAKER (BHEL) Volts: 220 kV Amperes: 1200A Breaking capacity: symmetrical 26.31 kA Equivalent 10000 MVA Asymmetrical 32.1 kA Making capacity: peak 67.1 kA Short circuit time: 3 sec. 26.3 kA Closing coil voltage: 220V DC Tripping coil voltage: 220V DC Working pressure: Max. 28.1 kg/cm2-g Min. 26.0 kg/cm2-g Lockout pressure: 21.1 kg/cm2-g 2. AIR BLAST CIRCUIT BREAKER (ABB) Volts: 245 kV Amperes: 1200A

Breaking capacity: symmetrical 31.5 kA Asymmetrical 38.4 kA Short circuit time: 3 sec. 31.5 kA Closing coil voltage: 220V DC Tripping coil voltage: 220V DC RIL at 50 Hz: 480 kV VI impulse: 1.2/50s 1050 kV per sec. U switching impulse: first pole to clear 1.3 Mass: 1830 Kg Working pressure: max. 27.31 kg/cm2-g

3. AIR BLAST CIRCUIT BREAKER (BHEL) Volts: 245 kV Amperes: 2000A Short circuit time: 3 sec. 26.3 kA Closing coil voltage: 220V DC Tripping coil voltage: 220V DC Working gas pressure: 6.1 kg/cm2-g at 200c Rated frequency and voltage for auxiliary: 415AC 50Hz Total weight of gas: 3900 Kg Rated operating scheme: O-0.3sec-CO-3 min.-CO Rated lightening impulse withstands voltage: 1050 kVp Rated short circuit breaking current: 40 kA Rated operating pressure: 15 kg/cm2-g First pole to clear factor: 1.3 Rated duration of short circuit current: 40 kA for 3 sec Rated line charging breaking current: 125 A Gas weight: 21 kg ISOLATORS: These are single break, single pole isolators supplied by M/s.

Hvelm limited, Madras. These are pneumatically operated at a pressure of 15 kg/cm2. These isolators and earthing switches are interlocked with each other and

with the circuit breakers to prevent mal-operation. No interlocking arrangements are provided for the bus earthing switches. Main bus isolators: to maintain the main bus isolators the corresponding bus has to be shut down by transferring loads to other bus, bus earthed and circuit breaker and isolator opened, after transferring the requisite feeder on to the by pass breaker and the earthing switches are closed. By pass isolator: to maintain the by-pass isolators the by-pass bus has to be shut down, isolators opened and the earthing switches are closed. Feeder isolators: when the feeder is working on bus I or bus II, the earthing switches on both sides of the isolator are closed after opening the breaker and isolators and shutting down the feeder. PT isolators: The corresponding bus must be shut down and earthing switches on the isolator closed for maintenance. PNEUMATIC SYSTEM: This system consists of seven compressors with one spare air compressor. All the seven compressors are connected to two wet air cylinders, which are coupled to each other. This wet air is dried through an air drier and fed into six dry cylinders divided into a two groups each having three dry cylinders. The dry air through these two groups is passed through two separate air drier for further dryness of air up to a dew point of -70 C. The dried air from these two dryers is fed into two separate dry cylinders which feed dry air into pressure reducers. From these pressure reducers the pressurized dry air is supplied to air blast circuit breakers. High pressure and low-pressure alarms are arranged on the pressure gauges and any mal-operation noticed must be rectified immediately. POWER LINE COMMUNICATION EQUIPMENT: To maintain the power line carrier communication equipment like wave trap or coupling capacitor the

conditions would be same as those of maintaining the concerned feeder isolator. Depending upon whether inter-circuit coupling or phase to ground coupling is used either both the circuits or the single circuit must be shut down along with the feeder isolator. 220KV CURRENT TRANSFORMERS: The 220kV single phase 4 core current transformers supplied by Hindustan Brown Broveri Ltd. (Baroda). The transformation ratio 1200-600/1/1/1/1 amps are used in Tie in transformer, generator and transmission line bays and bus coupler bay. The secondary windings of these CTs are connected to protection and measurement circuits. 220KV POTENTIAL TRANSFORMERS: These single phase potential

transformers supplied by HE(I) Ltd., Bhopal are connected to 220kV buses. These are required for measurement and protection purposes. The main PTs are of ratio 22000/53/110/53 volts and the auxiliary PTs are of ratio 62.5/63.5 volts. The auxiliary PTs will operate in conjunction with the main PT to provide one more secondary winding. Consequent by the combined set of main and auxiliary PTs will provide to secondary winding each of 110/53 voltage ratings. LIGHTING ARRESTORS: These have been supplied by M/s. W.S. insulators of India Ltd. (Madras). These are installed for protection of transformers and other electrical equipments against voltage surges. One set of lighting arrestors have been provided on each power transformers, tie in transformers and to the bus PTs. The 195kV, 10000 amps single pole heavy duty station class SVS type self supporting L.A. comprises of one metal top and metal base, having mobile arc, pressure relief and a transfer device. The mobile arc gap assembly consists of a permanent ceramic ring magnet, radially magnetized, m series with air gap. Thus it provides a constant magnetic field in the air gap which is always preset at full strength regardless of the current of the discharge, when lighting wave discharges through it, the spark discharge takes place in the annular space, causing an arc at right angles to the magnetic field. This field forces the arc to

spin around the gap electrode surfaces. Pressure relief device is provided to take care of the gas formed at the time of short circuit when the arrestor is damaged. When the diaphragm bursts due to a gas pressure, the ionized gases come out and are vented through the exhaust ports. The gas from the top of the unit is deflected downward and that from the bottom is deflected upward. The gas steams meet and transfer the fault current is from inside the arrestor to the outside in less than half cycle of fault current. 220KV LINES: all the feeders from the 220 kV bus bars are shown in the diagram on the previous page. All the metering and protection should normally be connected only to the bus VT supplies. However when necessary CVTs can be used for metering and protection.

Bus-1 1. Gen-Tr-1 2. Gen-Tr-3 3. Gen-Tr-5 4. IP line I 5. Mehrauli line I 6. Ballabgarh line I 7. Alwar line 8. Okhla line-1 9. Stn Tr-1 10. Stn Tr-3

Bus-2 1. Gen-Tr-2 2. Gen-Tr-4 3. IP line I 4. Mehrauli line II 5. Ballabgarh line II 6. Noida line 7. Okhla line-1I 8. Stn Tr-2 9. Bus coupler 10. By pass bay

SYNCHRONISING: synchronizing facility with check feature has been provided for all 220KV breakers. Whenever a breaker is proposed to be closed, its synchronizing switch should be unlocked and synchronizing check relay by pass switch is in circuit position. It is ensured that voltage and frequency of the incoming and running supplies are nearly same, and the red out of synchronism lamp is not continuously on. After the breaker has been closed, its synchronizing switch should be returned to off position and locked. Synchronizing check relay SKE prevents closing of a breaker when incoming and running supplies are out of synchronism. This relay has to be bypassed when closing a breaker one side of, which is dead. ANNUNCIATION SYSTEM: all breaker tripped alarms have been classed as emergency alarms. Whenever a breaker trips, the breaker tripped facia/flashes and a separate buzzer sounds to draw immediate attention of operator to tripping of a breaker. Whenever an alarm initiating contact closes, the corresponding facia of that alarm starts flashing. Simultaneously, the bell /buzzer starts ringing. Ringing of buzzer stops automatically after a preset time. Flashing continues unit accepts push button pressed, whereupon facia becomes steadily lighted if the initiating contact is still closed. Facial lamps should be tested for operation regularly by pressing lamp test button, provided separately for each control panel

PROTECTION AND RELAYS USED IN MAIN CIRCUIT BOARD

1. High speed biased differential relay: the DMH type relay provides high speed biased differential protection for two or three winding transformers. The relay is immune to high inrush current and has a high degree of stability against through faults. It requires a max of two cycles operating time for current above twice relay rated current. Instantaneous over current protection clears heavy internal faults immediately. This relay is available in two forms.

Firstly for use with time Cts, the ratios of line which are matched to the load current to give zero differential current under normal working conditions. Secondly with tapped interposing transformers for use with standard line current transformers of any ratio. 2. Directional inverse time over current and earth fault relays: the CDD type relays are applied for directional or earth fault protection of ring mains, parallel transformers or parallel feeders with the time graded principle. It is induction disc type relay with induction cup used to add directional feature. 3. Instantaneous voltage relay: the type VAG relay is an instantaneous protection against abnormal voltage conditions such as over voltage, under voltage or no voltage in AC and DC circuits and for definite time operation when used with a timer. It is an attracted armature type relay. 4. Auxiliary relays: the VAA/CAA type auxiliary relays are applied for control alarm, indication and other auxiliary duties in AC or DC systems. CAA is a current operated and VAA is a voltage operated relay.. it is attracted armature type. 5. High speed tripping relays: this VAJH type relay is employed with a high speed tripping duties where a number of simultaneous switching operations are required. This is a fast operating multi contact attracted armature relay. 6. Definite time delay relay: this VAT type relay is used in auto reclosing and control schemes and to provide a definite time feature for instantaneous protective relay. It is an Electro mechanical definite time relay. It has two pair of contacts. The shorter time setting is provided by a passing contact and longer time setting by the final contact.

7. Trip circuit supervision relay: this VAX relay is applied for after closing or continuous supervision of the trip circuit of circuit breakers. They detect the following conditions: a) Failure of trip relay b) Open circuit of trip coil c) Failure of mechanism to complete the tripping operation 8. Instantaneous over current and earth fault relay: an instantaneous phase or earth fault protection and for definite time operation when used with a timer. It is a CAG 12/12G standard attracted armature relay with adjustable settings. It may be a single pole or triple pole relay. 9. Inverse time over current and earth fault relay: this CDG 11-type relay is applied for selective phase and earth fault protection in time graded systems for AC machines. Transformers, feeders etc. this is a non-directional relay with a definite minimum time which has an adjustable inverse time/current characteristics. It may be a single pole or triple pole relay. 10. Fuse failure relay: this VAP type relay is used to detect the failure or

inadvertent removal of voltage transformer sec. fuses and to prevent incorrect tripping of circuit breaker. It is three units, instantaneous attracted armature type relay the coil of each unit connected across one of the VTs. The secondary fuses under healthy conditions, the coil is SC by fuses and cant be energized. But one or more fuses blow the coil is energized and relay operates. 11. Instantaneous high stability circulating current relay: it is used to

serve the following three purposes a) Differential protection of Ac machines , reactors auto transformers and bus bars b) Balanced and restricted earth fault protection of generator of generator and transformer windings c) Transverse differential protection of generators and parallel feeders.

This CAG type relay is a standard attracted armature relay. In circulating current protection schemes, the sudden and often asymmetrical growth of the system current during external fault conditions can cause the protection current transformers to go into saturation, resulting in high unbalance current to insure stability under these conditions.

The modern practice is to use a voltage operated high impedance relay, set to operate at a voltage slightly higher than that developed by CT under max fault conditions. Hence this type of relay is used with a stabilizing resistor.

12.

Local breaker back up relay: this is a CTIG type three phase or two

phase earth fault instantaneous over current unit intended for use with a time delay unit to give back up protection in the event of a circuit breaker failure. 13. Poly-phase directional relay: the PGD relay is a high speed induction

cup unit used to give directional properties to three phase IDMT over-current relays, for the protection of parallel feeders, inter connected networks and parallel transformers against phase to phase and three phase faults. Owing to low sensitivity on phase to earth faults the relay is used with discretion on solidly earthed systems.

14.

Auto reclose relay: five types of auto reclose relays are available

a) VAR21 giving one reclosure. The dead time and reclaim time are adjustable form 5 to 25 secs. If the circuit breaker reopens during reclaim time, it remains open and locked out. b) VAR41B is a single shot scheme for air blast circuit breakers. Reclaim time is fixed at between 15 to 20 secs. Dead time adjustment is from 0.1 to 1.0 sec of which first 300 millisec will be circuit breaker opening time.

c) VAR 42 giving four reclosure. It is precision timed from 0 to 60 sec. it can be set for max four enclosures at min intervals of 10 sec and instantaneous protection can be suppressed after the first reclosure so that persistent faults are referred to time graded protection. d) VAR 71 giving single shot medium speed reclosure with alarm and lockout for circuit breaker. This allows up to 10 faults clearance before initiating an alarm. The alarm is followed by lockout if selected no. of faults clearances exceed. If the circuit breaker reopens during reclaim time, it remains open and locked out. It offers delay in reclosing sequence. Instantaneous lockout on low current earth fault and suppressing instantaneous protection during reclamation time. e) Var81 is a single shot high-speed reclosure with alarm and lockout for circuit breaker This allows up to 10 faults clearance before initiating an alarm. REACTANCE DISTANCE SCHEME: this scheme consists of the following relays, XCG22-3 for phase to phase and 3 for phase to ground, YCG17, mho starting unit one in each place, VAT51 along with timing unit for zone 2 and 3, 86-X aux. tripping relay and 30G, H, and J for 1 st, 2nd and 3rd. Zone indication VAA51, CAG12 and VAA31. Theses schemes provide three zone phase and earth fault protection using reactance relays type XCG22 and also starting relays YCG17. They are applicable to important line sections where high values of arc resistance would otherwise effect the accuracy of measurement and where high speed tripping is essential. High-speed protection is provided for phase and earth faults on 80-90% of the line section and faults on the remaining section are cleared in second zone, time. The third zone provides backup protection after further time interval. Each mho starting unit Y3 and its auxiliary Y3 X is associated with one phase and operates for all faults involving this phase. Each reactance unit X is connected to measure phase or earth fault distance, but is prevented from operating by short circuit across the polarizing coils

LINE FAULT DETECTORS Y3

EARTH FAULT DETECTORS 64

ZONE TIMING 2

DETECTOR AUXILIARIES Y3X

RANGE EXTENSI ON 2X2X

EARTH FAULT REACTANCE UNITS X2

The principle of distance scheme is shown in the above block diagram

TRIPPING AND INDICATION 30

PHASE FAULT REACTANCE UNIT X1 Under the phase fault conditions, the Y3 X units unblock the appropriate X1 reactance units, which initiate tripping immediately for faults within their setting. Operation of the earth auxiliary relay 64 in conjunction with the Y3 X units selects the appropriate reactance units for measurement of earth faults. The reach of TRIP REINFORCING 86X reactance units is extended by the timer, 2 after successive intervals to cover

faults in zone 2 and 3. Discrimination is not affected by changing faults, for example a zone 2 earth fault which develops into a double phase to earth fault will be cleared correctly by the X1 (phase fault) units in zone 2 time. In the rare event of two faults occurring simultaneously at different points on the line; the scheme will measure to a distance approx. half way.