BADARPUR

THERMAL POWER
STATION

SUMMER TRAINING
REPORT
2012

NTPC LIMITED

Training at BTPS
I was appointed to do 6 week training at this esteemed organization from
11th June to 21st July, 2012. I was assigned to visit various division of the
plant, which were:

Electrical Maintenance Department I (EMD-I)

Electrical Maintenance Department II (EMD-II)
Control and Instrumentation Department (C&I)

These 6 weeks training was a very educational adventure for me. It was
really amazing to see the plant by yourself and learn how electricity, which is
one of our daily requirements of life, is produced. This report has been made
by my experience at BTPS. The material in this report has been gathered
from my textbook, senior student reports and trainers manuals and power
journals provided by training department. The specification and principles
are as learned by me from the employees of each division of BTPS.

Anubhav Ghosh

INDEX
ABOUT NTPC
2) STRATEGIES
3) JOURNEY OF NTPC
4) ABOUT BTPS
5) OPERATION OF POWER PLANT
6) PARTS OF A POWER PLANT
7) VARIOUS CYCLES AT POWER STATION
8) ELECTRICAL MAINTENANCE DEPARTMENT9) ELECTRICAL MAINETNANCE DEPARTMENT-II
10) CONTROL AND INSTRUMENTATION
1)

ABOUT NTPC
Indias largest power company, NTPC was set up in
1975 to accelerate power development in India.
NTPC became a Maharatna company in May, 2010,
one of the only four companies to be awarded this
status.
The total installed capacity of the company is 39,174
MW (including JVs) with 16 coal based and 7 gas based
stations, located across the country.
In addition under JVs, 7 stations are coal based &
another station uses naptha/LNG as fuel.
The company has set a target to have an installed
power generating capacity of 1,28,000 MW by the year
2032.

Strategies of NTPC

JOURNEY OF NTPC

About BTPS
BADARPUR

THERMAL POWER STATION was established on1973 and it was

the part of Central Government.
On 01/04/1978 is was given to NTPC.
Since then operating performance of NTPC has been considerably above the
national average.
Badarpur thermal power station started with a single 95 mw unit.
There were 2 more units (95 MWeach) installed in next 2consecutive years.
Nowit hastotalfive units with total capacity of 720MW. Ownership of BTPS
was transferred to NTPC with effect from 01.06.2006
The power is supplied to a 220 KV network that is a part ofthe northern grid.
The ten circuits through which the power is evacuated from the plant are:
1. Mehrauli
2. Okhla
3. Ballabgarh
4. Indraprastha
5. UP (Noida)
6. Jaipur

Given below arethe details ofunit with the

year theyreinstalled

OPERATION OF A POWER PLANT

Basic Principle
As per FARADAYs Law-Whenever the amount of magnetic flux linked with a
circuit changes, an EMF is produced in the circuit. Generator works on the
principle of producing electricity. To change the flux in the generator turbine is
moved in agreat speed with steam.
To produce steam, water is heated in the boilers by burning the coal.
In a Badarpur Thermal Power Station, steam is produced and used tospin a
turbine that operatesa generator.
Water is heated, turns into steam and spins asteam turbine which drives an
electrical generator.
After it passes through the turbine, the steam is condensed in acondenser.
The electricity generated at the plant is sent to consumers through highvoltage power lines
The Badarpur Thermal Power Plant hasSteam Turbine-Driven Generators
which hasa collective capacity of 705MW.
The fuel being used is Coal which is supplied from the Jharia Coal Field in
Jharkhand.
Water supply is given from the Agra Canal.

Basic Steps of Electricity Generation

The

basic steps in the generation of

electricity from coal involves following
steps:

Coal to steam
Steam to mechanical power
Mechanical power to electrical power

PARTS OF A POWER PLANT

1. Cooling tower
2. Cooling water pump
3. Transmission line (3-phase)
4. Unit transformer (3-phase)
5. Electric generator (3-phase)
6. Low pressure turbine
7. Condensate extraction pump
8. Condenser
9. Intermediate pressure turbine
10. Steam governor valve
11. High pressure turbine
12. Deaerator
13. Feed heater
14. Coal conveyor
15. Coal hopper
16. Pulverised fuel mill
17. Boiler drum
18. Ash hopper
19. Super heater
20. Forced draught fan
21. Reheater
22. Air intake
23. Economiser
24. Air preheater
25. Precipitator
26. Induced draught fan
27. Flue Gas

VARIOUS CYCLES AT POWER STATION

PRIMARY

AIR CYCLE
SECONDARY AIR CYCLE
COAL CYLCE
ELECTRICITY CYCLE
FLUE GAS CYCLE
CONDENSATE CYCLE
FEED WATER CYCLE
STEAM CYCLE

ELECTRICAL MAINTENANCE DEPARTMENT I

(EMD-I)

It includes:

Motors
High Tension/Low Tension Switchgear
Coal handling plant

MOTORS
AC MOTORS
Squirrel

cage motor
Wound motor
Slip ring induction motor

In modern thermal power plant three phase squirrel cage induction motors are used but sometime double wound
motor is used when we need high starting torque e.g. in ball mill.

THREE PHASE INDUCTION MOTOR

Ns

(speed) =120f/p
can handle concentrated single layer winding, with each coil occupying one stator slot
The most common type of winding are:
Stator

DISTRIBUTED

WINDING :
This type of winding is distributed over a number of slots.

DOUBLE

LAYER WINDING :
Each stator slot contains sides of two different coils.
SQUIRREL CAGE INDUCTION MOTOR
Squirrel

cage and wound cage have same mode of operation. Rotor conductors cut the rotating stator magnetic
field. an emf is induced across the rotor winding, current flows, arotor magnetic field is produced which interacts
with thestator field causing a turning motion. The rotor does not rotate at synchronous speed, its speed varies with
applied load. The slip speed being just enough to enable sufficient induced rotor current to produce the power
dissipated by the motor load and motorlosses.

BEARINGS AND LUBRICATIONS

A good bearing is needed for trouble free operation of motor. Since it is very costly part of
the motor, due care has tobe taken by checking it at regular intervals. So lubricating plays
an important role.Two types oflubricating are widely used

Oil lubrication
Grease lubrication
Insulation

INSULATION
Winding isan essentialpart so itshould be insulated. Following types ofinsulation are widely
used
INSTRUMENTS SEEN
MICROMETER
This instrument is used for measuring inside as well as outside diameter of bearing.
MEGGAR
This instrument is used for measuring insulation resistance.
VIBRATION TESTER
It measures the vibration of the motor. It is measured in three dimensions-axial, vertical and
horizontal.

SWITCH GEAR
Switchgear is one that makes or breaks the electrical circuit.
It is a switching device that opens & closes a circuit that defined as apparatus used for
switching, Lon rolling & protecting the electrical circuit & equipments.
The switchgear equipment is essentially concerned with switching & interrupting
currents either under normal or abnormal operating conditions.
The tubular switch with ordinary fuse is simplest form of switchgear & is used
tocontrol & protect& other equipments in homes, offices etc.
For circuits of higher ratings, a High Rupturing Capacity (H.R.C) fuse in condition with a
switch mayserve the purpose of controlling & protecting the circuit.
However such switchgear cannot be used profitably on high voltage system (3.3 KV)
for 2 reasons.

Firstly, when a fuse blows, it takes some time to replace it & consequently there is
interruption ofservice to customer.
Secondly, the fusecannot successfully interrupt large currents that resultfrom theHigh
Voltage System.

In order tointerrupt heavy fault currents, automatic circuit breakers are used.
There are very few types of circuit breakers in B.P.T.S they are VCB, OCB, and SF6 gas
circuit breaker.
The most expensive circuit breaker is theSF6 type dueto gas.
There are various companies which manufacture these circuit breakers: VOLTAS, JYOTI,
and KIRLOSKAR.
Switchgear includes switches, fuses, circuit breakers, relays & other equipments.
In low tension switch gear thermal over load relays are used whereas in high tension 5
different types of relays are used.

THE EQUIPMENTS THAT NORMALLY FALL IN THIS

CATEGORY ARE:ISOLATOR

Isolator cannot operate unless breaker is open

Bus 1 and bus 2isolators cannot be closed simultaneously
The interlock can be bypass in the event of closing of bus coupler breaker.
No isolator can operate when the corresponding earth switch is on

SWITCHING ISOLATOR

Switching isolatoris capable of:

Interrupting

charging current
transformermagnetizing current
Load transformer switching. Its main application isin connection with the transformer feeder as theunit makes it
possible to switch gear one transformer while the other is still on load.
Interrupting

CIRCUIT BREAKER

One which can make or break the circuit on load and even on faults is referred to as circuit breakers. This
equipment is the most important and is heavy duty equipment mainly utilized for protection ofvarious circuits
and operations on load. Normally circuit breakers installed are accompanied by isolators.

LOAD BREAK SWITCHES

These are those interrupting devices which can make or break circuits. These are normally on same circuit,
which are backed by circuit breakers

EARTH SWITCHES

Devices which are used normally to eartha particular system, toavoid any accident happening due to induction
on account of live adjoining circuits. These equipments do not handle any appreciable current at all. Apart from
thisequipment there are a number of relays etc.which are used in switchgear.

Low Tension SWITCHGEAR

MAIN SWITCH
Main switch is control equipment which controls or disconnects the main supply. The main switch for
3 phase supply is available for the range 32A, 63A, 100A, 200Q, 300A at500V grade.

FUSES
With Avery high generating capacity of the modern powerstations extremely heavy carnets would
flow in the faultand the fuse clearing the fault wouldbe required to withstand extremely heavy
stress in process. It is used for supplying power to auxiliaries with backup fuse protection.
Withfuses, quick break, quick make and double break switch fuses for 63A and 100A, switch fuses
for 200A,400A, 600A, 800A and 1000A are used.

CONTACTORS
AC Contractors are 3 poles suitable for D.O.LStarting of motors and protecting the connected
motors.
OVERLOAD RELAY
For overload protection, thermal overload relay are best suited for this purpose. They operate due
to theaction of heat generated by passage of current through relay element.
AIR CIRCUITBREAKERS
It is seen that use of oil in circuit breaker may cause a fire.So in allcircuits breakers atlarge
capacity air at high pressure is used which is maximum at the time of quick tripping of contacts.
This reduces the possibility of sparking. The pressure may vary from 50-60kg/cm^2 for high and
medium capacity circuit breakers.

Contactors used in ntpc

Thermal overload relay

HT SWITCHGEAR
MINIMUM OIL CIRCUIT BREAKER
These use oil as quenching medium.
AIR CIRCUIT BREAKER
In this the compressed air pressure around 15 kg per cm^2 is used for
extinction of arc caused by flow of air around the moving circuit . The breaker
is closed by applying pressure at lower opening and openedby applying
pressure at upper opening. When contacts operate, the coldair rushes around
the movable contacts and blown the arc
SF6 CIRCUIT BREAKER
The principle of current interruption is similar to that of air blast
circuitbreaker. It simply employs the arc extinguishing medium namely SF6.
When it isbroken down under an electrical stress, it will quickly reconstitute
itself.
VACUUM CIRCUIT BREAKER
It works on the principle that vacuum is used to save the purpose of insulation
and. In regards of insulation and strength, vacuum is superiordielectric
medium and is better thatall other medium except air andsulphur which are
generally used at high pressure.

AIR CIRCUIT
BREAKERS

OIL CIRCUIT
BREAKERS

SF6 CIRCUIT
BREAKERS

COAL HANDLING PLANT (CHP)

The coal handling plant consists of two
plants:

Old Coal Handling Plant (OCHP)

New Coal Handling Plant (NCHP)

The

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

NCHP supplies coal to Unit- IV and V.

COAL SUPPLIED AT BTPS

Coal is suppliedto BTPS by Jharia coal mines.

COAL CYCLE

The main constituents of CHP plant are:

WAGON TIPPLER
Wagon from coal yard come tothe tippler and emptied here. There are2 wagon tipplers in the OCHP.
CONVEYER

Conveyer belts are used in the OCHP to transfer coal from one place to other asrequired in a
convenient & safe way.
ZERO

SPEED SWITCH

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

DETECTOR

As the conveyer belt take coal from wagon to crusher house, no metal piece should go along with
coal. To achieve this objective, metal detectors & separators are used.
CRUSHER

HOUSE

Both the plants i.e. OCHP & NCHP use TATA crusher powered by BHEL motor. Crusher is designed to
crush the pieces to 20 mm size i.e. practically considered as the optimum size for transfer via
conveyer.
ROTARY

BREAKER

If any large piece of metal of any hard substances like metal impurities comes in the conveyer belt
which cause load on the metal separator, then the rotary breaker rejects them reducing the load on
the metal detector.
PULL

GUARD SWITCH
are the switches which are installed at every 10m gap in a conveyer belt to ensure the
safety of motors running the conveyer belts. If at any time some accident happens or
coaljumps from belt and startscollecting at a place, then the switch can be used.

These

SEQUENTIAL OPERATION OF OCHP

Unloading the coal
Crushing &storage.
Conveying to boiler bunkers.

Coal arrives to plant via road, rail, sea,and river orcanal route from collieries.
Most of it arrives by rail route only in railway wagons. Coal requirement by this
plant is approximately 10,500metric ton/day.
This coal is tippled into hoppers. If the coal isoversized (400 mm sq), thenit is
broken manually so that it passes the hopper mesh where through elliptic feeder
it is put into vibrators & then to conveyor belt 1A & 1B.
The coal through conveyor belts 1A & 1B goesto the crusher house. Also the
extra coal is sent tostockyard through these belts.
In the crusher house the small size coal pieces goes directly to the belt 2A & 2B
whereas the big size coal pieces are crushed in the crusher & then given to the
belts 2A & 2B.
The crushed coal is taken to the bunker house via the conveyor belts 3A & 3B
where it can be used for further operations.

OCHP

SEQUENTIAL OPERATION OF NCHP

Coal arrives in wagons andtipples into hoppers.
if the coal is oversized (400mm sq),then it is brokenmanually
so that it passes through the hopper mesh.
From hopper it is taken to TP-6 12A & 12B.
Conveyors 12A & 12B take the coal to the breaker house which
renders the coal size to be 100 mm sq.
Metal separator & metal detector are installed in conveyor belts
14A/B & 15A/B respectively to remove the metal impurities
Stones which are not able to pass through the100mm sq
meshof hammer are rejected via 18A & 18Bto the rejection
house.
Extra coal is sent to thereclaim hopper via conveyor 16A & 16B.
From TP-7, coal is taken by conveyor 14A & 14B tothe crusher
house whose function is to render size of the coal to 20mm sq.

NCHP

ELECTRICAL MAINTENANCE
DEPARTMENT II (EMD-II)
It includes:
Generators
Transformers
Switch yard

GENERATORS
The generator works on theprinciple of
electromagnetic induction. There are two components
stator and rotor. The rotor is themoving part and
thestator is the stationary part. The rotor, which has
a field winding, is given aexcitation through a set
of3000rpm to give the required frequency of HZ. The
rotor is cooled by Hydrogen gas, which is locally
manufactured by the plant and hashigh heat carrying
capacity of low density. If oxygen and hydrogen get
mixed then they will form very high explosive and to
prevent their combining in any way there is seal oil
system. The stator cooling is done by de-mineralized
(DM) water through hollow conductors. Water is fed
by one end by Teflon tube. A boiler and a turbine are
coupled to electric generators. Steam from the boiler
isfed to the turbine through the connecting pipe.
Steam drivesthe turbine rotor. Theturbine rotor
drives thegenerator rotor which turns the
electromagnet within the coil ofwire conductors.
Carbon dioxide is provided from the top and oil
isprovided from bottom to the generator. With the
help of carbon dioxide the oil is drained out to the oil
tank.

RATINGS OF THE GENERATORS USED

Turbo generator 100MW
TURBO GENERATOR 210 MW

The 100 MW generator generates 10.75 KV and 210 MW

generates 15.75 KV. The voltage is stepped up to 220 KV
with the help of generator transformer and is connected
to the grid.
The voltage is stepped down to 6.6 KV with the help of
UNIT AUXILLARY TRANSFORMER (UAT) and this voltage is
used to drive theHT motors. The voltage is further
stepped down to415 V and then to 220 V and this
voltage is used to drive Lt Motors.

TURBO GENERATOR 100MW

MAKE BHEL,Haridwar
CAPACITY 117,500KVA
POWER 100,000KW
STATORVOLTAGE 10,500V
STATORCURRENT 6475A
SPEED 5000rpm
POWERFACTOR 0.85
FREQUENCY 50HZ
EXCITATION 280V

TURBO GENERATOR 210MW

MAKE BHEL,Haridwar
CAPACITY 247,000KVA
POWER 210,000KW
STATORVOLTAGE 15,750V
STATORCURRENT 9050A
SPEED 5000rpm
POWERFACTOR 0.85
FREQUENCY 50HZ
EXCITATION 310V
GASPRESSURE 3.5kg/cm

TRANSFORMERS
It is a static machine whichincreases or
decreases the AC voltage withoutchanging the
frequency of the supply.
It is a device that:

Transfer electric power from one circuit

toanother.
It accomplishes this by electromagnetic induction.
In this the two electriccircuits are in mutual
inductive influence of each other.

WORKING

PRINCIPLE:

It workson FARADAYSLAW OFELECTROMAGNETIC

INDUCTION(self ormutual induction depending on
the type of transformer).

COOLING OFTRANSFORMERS
OFLARGEMVA

As size of transformer becomes large, the rate of the oil circulating becomes insufficient to dissipate
all the heat produced & artificial means of increasing the circulation by electric pumps. In very large
transformers, special coolers withwater circulation may have to be employed.

TYPES OF COOLING:

Air cooling
Air Natural (AN)
Air Forced (AF)

Oil immersed cooling

Oil Natural Air Natural (ONAN)

Oil Natural Air Forced (ONAF)
Oil Forced Air Natural (OFAN)
Oil Forced Air Forced (OFAF)

Oil immersed Water cooling

Oil Natural Water Forced (ONWF)

Oil Forced Water Forced (OFWF)

MAIN PARTS OF TRANSFORMER

Secondary Winding
2. Primary Winding.
3. Oil Level
4. Conservator
5. Breather
6. Drain Cock
7. Cooling Tubes.
8. Transformer Oil.
9. Earth Point
10. Explosion Vent
11. Temperature Gauge.
12. Buchholz Relay
13. Secondary Terminal
14. Primary Terminal
1.

GENERATOR TRANSFORMER
(125MVA UNIT-I & UNIT-III)
RATING

125MVA
TYPEOFCOOLING
OFB
TEMPOFOIL
45^C
TEMP WINDING 60^C
KV(noload) HV-233KVA
LV-10.5 KVA
LINEAMPERES HV-310A
LV-6880
PHASE THREE
FREQUENCY
50HZ
IMPEDANCEVOLTAGE 15%
VECTORGROUP
YDELTA
INSULATIONLEVEL HV-900KV
LV-Neutral-38
COREANDWINDINGWEIGHT
110500Kg
WEIGHTOFOIL37200Kg
TOTALWEIGHT 188500Kg
OILQUANTITY 43900lit

GENERATOR TRANSFORMER
(166 MVA UNIT-IV)
RATING

240MVA
TYPEOFCOOLING ON/OB/OFB
TEMPOFOIL 45C
TEMPWINDING 60C
VOLTSATNOLOAD HV-236000
LV-A5750
LINEAMPERES
HV-587A
LV-8798
PHASE
THREE
FREQUENCY
50HZ
IMPEDANCEVOLTAGE 15.55%
VECTORGROUP YDELTA
COREANDWINDINGWEIGHT138800Kg
WEIGHTOFOIL
37850Kg
TOTALWEIGHT
234000Kg
OILQUANTITY 42500lit
GUARANTEEDMAXTEMP 45C
DIVISION
KERELA
YEAR 1977

UNIT AUXILIARY TRANSFORMER (UAT)

Unit I & V- 12.5 MVA

The UAT draws its input from themain bus-ducts. The total KVA capacity of
UAT required can be determined by assuming 0.85 powerfactor & 90%
efficiency for total auxiliary motor load. It is safe & desirable to provide
about 20% excess capacity then circulated to provide for miscellaneous
auxiliaries & possible increase in auxiliary.

STATION TRANSFORMER
It is required to feed power to the auxiliaries during startups. This
transformer is normally rated for initial auxiliary load requirements ofthe
unit in typical cases; this load is of the order of 60% ofthe load at full
generating capacity. It is provided with on load tap change to cater to the
fluctuating voltage of the grid.

NEUTRAL GROUNDED TRANSFORMER

This transformer is connected with supply coming out ofUAT in stage-2.
This is used to ground the excess voltage if occurs in the secondary of UAT
in spite of rated voltage.

SWITCH YARD
As we know that electrical energy cant be stored like cells, so what we generate should be
consumed instantaneously. But as the load is not constants therefore we generate electricity
according to need i.e. the generation depends upon load. The yard is the places from where the
electricity is send outside. It has bothoutdoor andindoor equipments.

OUTDOOR EQUIPMENTS
BUS BAR.
LIGHTENING ARRESTER
WAVE TRAP
BREAKER
CAPACITATIVE VOLTAGE TRANSFORMER
EARTHING ROD
CURRENT TRANSFORMER.
POTENTIAL TRANSFORMER
LIGHTENING MASK

INDOOR EQUIPMENTS
RELAYS.
CONTROL PANELS
CIRCUIT BREAKERS

BUS BAR
Bus bars generally are of high conductive aluminum conforming to IS-5082 or copper
ofadequate cross section. Bus bar located in air insulated enclosures & segregated from all
other components .Bus bar is preferably cover with polyurethane.

BY PASS BUS
This bus is a backup bus which comes handy when any of the buses become faulty. When
any operation bus has fault, this bus is brought into circuit and then faulty line is removed
there by restoring healthy power line.
LIGHTENING ARRESTOR
It saves the transformer and reactor from over voltage and over currents. It grounds the
overload if there is fault on the line and it prevents the generator transformer.

WAVE TRAP
WAVETRAP is connected in series with thepower (transmission) line. It blocks the high
frequency carrier waves (24 KHz to 500 KHz) and let power waves (50 Hz - 60 Hz) to passthrough.
BREAKER
Circuit breaker is an arrangement by which we can break the circuit or flow of current. A
circuit breaker in station serves the same purpose as switch but it has many added and
complex features. The basic construction of any circuit breaker requires the separation of
contact in an insulating fluid thatservers two functions:

extinguishes the arc drawn between the contacts when circuit breaker opens.
It provides adequate insulation between the contacts and from each contact to earth.

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

CURRENT TRANSFORMER
It is essentially a step up transformer which step down the current to a known ratio. Itis a type of
instrument transformer designed to provide acurrent in itssecondary winding proportional to the
alternating current flowing inits primary.
POTENTIAL TRANSFORMER
It is essentially a step down transformer and it step downs the voltage to a known ratio.

RELAYS
Relay is a sensing device that makes your circuit ON or OFF.They detect the abnormal conditions in the
electrical circuits by continuously measuring the electrical quantities, which are different under normal
and faulty conditions, like current, voltage frequency. Having detected the fault the relay operates to
complete the trip circuit, which results in the opening of the circuit breakers anddisconnect the
faultycircuit.
There are different types of relays:
Current relay
Potential relay
Electromagnetic relay
Numerical relay etc.

AIR BREAK EARTHING SWITCH

The work of this equipment comes into picture when we want to shut down the supply for maintenance
purpose. This help toneutralize the system from induced voltage fromextra high voltage. This induced
power is up to2KV in case of400 KV lines.

CONTROL & INSTRUMENTATION

INTRODUCTION
C&I

LABS
CONTROL & MONITORING MECHENISM
PRESSURE MONITORING
TEMPERATURE MONITORING
FLOW MEASUREMENT
CONTROL VALVES

INTRODUCTION
This division basically calibrates various instruments and takes
care of any faults occurin any ofthe auxiliaries in the plant.
Instrumentation can bewell defined as atechnology of
using instruments to measure and control the physical
and chemical properties of a material.
C&I LABS
Control and Instrumentation Department has following labs:

Manometry Lab.
Protection and Interlocks Lab.
Automation Lab.
Electronics Lab.
Water Treatment Plant.
Furnaces Safety Supervisory System Lab

THANKU