PROJECT / TRAINING REPORT

( PROJECT / TRAINING SEMESTER JANUARY – JULY )

BTPS,NTPC BADARPUR ,NEW DELHI

DISSERTATION SUBMITTED TO

PANJAB UNIVERSITY, CHANDIGARH

SUBMITTED In Partial fulfillment of the

BACHELOR OF ENGINEERING (B.E)

SUBMITTED BY

ARVIND KUMAR NEGI

ROLL NO : SG – 9414

UNDER THE GUIDANCE OF

Mr. JASPAL SINGH Mr. SONIA SINGH

FACULTY COORDINATOR INDUSTRY COORDINATOR

AP EEE DEPARTMENT BTPS,NTPC BADARPUR

PUSSGRC HOSHIARPUR NEW DELHI 110044

INSTITUTE: PANJAB UNIVERSITY SSG REGIONAL CENTER HOSHIARPUR

1
 CERTIFICATE

This is to certify that the Internship Report is submitted by ARVIND KUMAR NEGI, SG9414
in partial fulfillment of the requirements of INTERNSHIP at NTPC Limited, BADARPUR as
part of degree of BACHELOR OF ENGINEERING in Electrical & Electronics Engineering of
PANJAB UNIVERSITY SSG REGIONAL CENTRE, HOSHIARPUR, session 2012-2013 is a
record of bonafide work carried out under our supervision and has not be submitted
anywhere else for any other purpose.

(Signature of student)

ARVIND KUMAR NEGI

3 JUNE 2013 SG-9414 , EEE 8TH SEM

Certified that the above statement made by the student is correct to the best of our
knowledge and belief.

Mr. JASPAL SINGH Ms. SONIA SINGH

FACULTY COORDINATOR INDUSTRY COORDINATOR

AP EEE DEPARTMENT BTPS,NTPC BADARPUR ,

PUSSGRC HOSHIARPUR NEW DELHI 110044

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 ACKNOWLEDGEMENT

It has been a great honor and privilege to undergo training at NTPC Limited, Badarpur,
Haryana, India. I am very grateful to Ms. RACHNA SINGH BHAL (DGM HR) & Ms. SONIA
SINGH (DEPUTY MANAGER O&M) for giving their valuable time and constructive
guidance in preparing the internship report for Internship. It would not have been
possible to complete this report in short period of time without their kind
encouragement and valuable guidance.

3 JUNE, 2013 ARVIND KUMAR NEGI

B.E.-8TH Sem(EEE)
2009-13 Batch

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 TABLE OF CONTENT

Table of Contents
CHAPTER-1........................................................................................................................................
COMPANY PROFILE............................................................................................................................
VISION AND MISSION........................................................................................................................
Core Values – BE COMMITTED..........................................................................................................
POWER GENERATION IN INDIA..........................................................................................................
EVOLUTION.......................................................................................................................................
STRATEGIES.......................................................................................................................................
NTPC HEADQUARTERS......................................................................................................................
NTPC PLANTS....................................................................................................................................
FUTURE GOALS..................................................................................................................................
POWER BURDEN...............................................................................................................................
ENVIRONMENT POLICY & ENVIRONMENT MANAGEMENT SYSTEM.................................................
NATIONAL ENVIRONMENT POLICY....................................................................................................
NTPC ENVIRONMENT POLICY............................................................................................................
ENVIRONMET MANAGEMENT, OCCUPATIONAL HEALTH and SAFETY SYSTEMS................................
POLLUTION CONTROL SYSTEMS........................................................................................................
UP GRADATION & RETROFITTING of POLLUTION CONTROL SYSTEMS...............................................
OVERALL POWER GENERATION.........................................................................................................
NTPC INTERNATIONAL CELL...............................................................................................................
CHAPTER-2........................................................................................................................................
ABOUT BADARPUR THERMAL POWER STATION................................................................................
BADARPUR THERMAL POWER STATION............................................................................................
FROM COAL TO ELECTRICITY PROCESS..............................................................................................
MAIN GENERATOR.............................................................................................................................
MAIN TURBINE DATA.........................................................................................................................
OPERATION.......................................................................................................................................
CHAPTER-3........................................................................................................................................
EMD- I...............................................................................................................................................
HT/LT MOTORS TURBINE & BOILER SIDE...........................................................................................
COAL HANDLING PLANT (C.H.P) & NEW COAL HANDLING PLANT (N.C.H.P)......................................

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CHAPTER-3........................................................................................................................................
EMD II................................................................................................................................................
Generator and Auxiliaries..................................................................................................................
Transformer.......................................................................................................................................
CHAPTER-4........................................................................................................................................
CONTROL AND INSTRUMENTATION..................................................................................................
INTRODUCTION.................................................................................................................................
OBJECTIVE........................................................................................................................................
MAIN OUTLINE..................................................................................................................................
BLOCK DIAGRAM...............................................................................................................................
DISCRIPTION OF BLOCK DIAGRAM....................................................................................................
CIRCUIT DISCRIPTION OF AUTO MODE..............................................................................................
CIRCUIT DIAGRAM FOR SET POINT....................................................................................................
CIRCUIT DIAGRAM FOR VARIABLE INPUT..........................................................................................
I-06R MINI CARD CIRCUIT DIAGRAM.................................................................................................
TRIGGER CIRCUIT..............................................................................................................................
ELECTRICAL ACTUATOR CIRCUIT........................................................................................................
DEXTILE, LIMIT SWITCH AND RELAY PIN DIAGRAM..........................................................................
COMPONENT DISCRIPTION...............................................................................................................
LIMIT SWITCH....................................................................................................................................
RELAY.................................................................................................................................................
CONTACTOR RELAY............................................................................................................................
7805 VOLTAGE REGULATOR IC...........................................................................................................
2N3055 TRANSISTOR.........................................................................................................................
LIGHT EMITTING DIODE....................................................................................................................
ZENER DIODE.....................................................................................................................................
POTENTIOMETER..............................................................................................................................
555 TIMER IC.....................................................................................................................................
CAPACITOR .......................................................................................................................................
RESISTOR……………………………………………………………………………………………………………………………………….
SINGLE PHASE AC MOTOR………………………………………………………………………………………………………..

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 CHAPTER-1

COMPANY PROFILE

NTPC Limited is the largest thermal power generating company of India. A public sector
company, it was incorporated in the year 1975 to accelerate power development in the
country as a wholly owned company of the Government of India. At present,
Government of India holds 89.5% of the total equity shares of the company and FIIs,
Domestic Banks, Public and others hold the balance 10.5%. Within a span of 31 years,
NTPC has emerged as a truly national power company, with power generating facilities in
all the major regions of the country.

VISION AND MISSION

Vision
“To be the world’s largest and best power producer, powering India’s growth.”

Mission
“Develop and provide reliable power, related products and services at competitive prices,
integrating multiple energy sources with innovative and eco-friendly technologies and contribute
to society.”

Core Values – BE COMMITTED

B Business Ethics
E Environmentally & Economically Sustainable
C Customer Focus
O Organizational & Professional Pride
M Mutual Respect & Trust
M Motivating Self & others
I Innovation & Speed
T Total Quality for Excellence
T Transparent & Respected Organization
E Enterprising
D Devoted

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 Figure 1: NTPC OPERATION GRAPH

POWER GENERATION IN INDIA

NTPC’s core business is engineering, construction and operation of power generating
plants. It also provides consultancy in the area of power plant constructions and power
generation to companies in India and abroad. As on date the installed capacity of NTPC is
27,904 MW through its 15 coal based (22,895 MW), 7 gas based (3,955 MW) and 4 Joint
Venture Projects (1,054 MW). NTPC acquired 50% equity of the SAIL Power Supply
Corporation Ltd. (SPSCL). This JV Company operates the captive power plants of
Durgapur (120 MW), Rourkela (120 MW) and Bhilai (74 MW). NTPC also has 28.33%
stake in Ratnagiri Gas & Power Private Limited (RGPPL) a joint venture company between
NTPC, GAIL, Indian Financial Institutions and Maharashtra SEB Co Ltd.

7
 Figure 2: TOTAL POWER GENERATION

NTPC has set new benchmarks for the power industry both in the area of power plant
construction and operations. Its providing power at the cheapest average tariff in the
country..

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

and preserving the ecology in the vicinity of the plants. NTPC has undertaken massive a
forestation in the vicinity of its plants. Plantations have increased forest area and
reduced barren land. The massive a forestation by NTPC in and around its Ramagundam
Power station (2600 MW) have contributed reducing the temperature in the areas by
about 3°c. NTPC has also taken proactive steps for ash utilization. In 1991, it set up Ash
Utilization Division

A "Centre for Power Efficiency and Environment Protection (CENPEEP)" has been
established in NTPC with the assistance of United States Agency for International
Development (USAID). Cenpeep is efficiency oriented, eco-friendly and eco-nurturing

8
initiative - a symbol of NTPC's concern towards environmental protection and continued
commitment to sustainable power development in India.

As a responsible corporate citizen, NTPC is making constant efforts to improve the socio-
economic status of the people affected by its projects. Through its Rehabilitation and
Resettlement programmes, the company endeavors to improve the overall socio
economic status Project Affected Persons.

NTPC was among the first Public Sector Enterprises to enter into a Memorandum of
Understanding (MOU) with the Government in 1987-88. NTPC has been placed under
the 'Excellent category' (the best category) every year since the MOU system became
operative.

Harmony between man and environment is the essence of healthy life and growth.
Therefore, maintenance of ecological balance and a pristine environment has been of
utmost importance to NTPC. It has been taking various measures discussed below for
mitigation of environment pollution due to power generation.

EVOLUTION

1975 NTPC was set up in 1975 in 100% by the ownership of Government

of India. In the last 30 years NTPC has grown into the largest power
utility in India.

In 1997, Government of India granted NTPC status of ‘Navratna’

1997
being one of the nine jewels of India, enhancing the powers to the
Board of directors.

9
 NTPC became a listed company with majority Government
2004
ownership of 89.5%. NTPC becomes third largest by market
capitalisation of listed companies.

The company rechristened as NTPC Limited in line with its

2005
changing business portfolio and transforms itself from a thermal
power utility to an integrated power utility.

National Thermal Power Corporation is the largest power

2008 generation company in India. Forbes Global 2000 for 2008 ranked
it 411th the world.

National Thermal Power Corporation is the largest power

2009
generation company in India. Forbes Global 2000 for 2008 ranked
it 317th in the world.

NTPC has also set up a plan to achieve a target of 50,000 MW

2012
generation capacities.

NTPC has embarked on plans to become a 75,000 MW company by

2017
2017.

10
NTPC is the largest power utility in India, accounting for about 20% of India’s installed
capacity.

STRATEGIES

Figure 3: NTPC STRATEGIES

NTPC HEADQUARTERS

NTPC Limited is divided in 8 Headquarters

S. NO. HEADQUARTERS CITY
1. NCRHQ DELHI
2. ER HEADQUARTER-1 BHUBANESHWAR
3. ER HEADQUARTER-2 PATNA
4. NRHQ LUCKNOW
5. SR HEADQUARTER HYDERABAD
6. WR-1 HEADQUARTER MUMBAI
7. HYDRO HEADQUARTER DELHI
8. WR-2 HEADQUARTER RAIPUR

NTPC PLANTS
1. Thermal-Coal based

S. NO. CITY STATE INSTALLED

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 CAPACITY(MW)
1. SINGRAULI UTTAR PRADESH 2000
2. KORBA CHATTISGHAR 2600
3. RAMAGUNDAM ANDHRA PRADESH 2600
4. FARAKKA WEST BENGAL 2100
5. VINDHYACHAL MADHYA PRADESH 3260
6. RIHAND UTTAR PRADESH 2500
7. KAHALGAON BIHAR 2300
8. DADRI UTTAR PRADESH 1820
9. TALCHER ORISSA 3000
10. UNCHAHAR UTTAR PRADESH 1050
11. TALCHER ORISSA 460
12. SIMHADRI ANDHRA PRADESH 1500
13. TANDA UTTAR PRADESH 440
14. BADARPUR DELHI 705
15. SIPAT CHHATTISGHAR 2320
16. SIPAT CHHATTISGHAR 1980
17. BONGAIGAON ASSAM 750
18. MOUDA MAHARASHTRA 1000(2*500MW)
19. RIHAND UTTAR PRADESH 2*500MW
20. BARH BIHAR 3300(5*660)
TOTAL 31495MW

2. COAL BASED (Owned by JVs)

S.NO. NAME OF THE CITY STATE INSTALLED

JV CAPACITY(MW)
1. NSPCL DURGAPUR WEST BENGAL 120
2. NSPCL ROURKELA ORISSA 120
3. NSPCL BHILAI CHHATTISGHAR 574
4. NPGC AURANGABAD BIHAR 1980
5. M.T.P.S. KANTI BIHAR 110
6. BRBCL NABINAGAR BIHAR 1000
TOTAL 3904MW

3. GAS Based

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 S.NO. CITY STATE INSTALLED
CAPACITY(MW)
1. ANTA RAJSTHAN 419
2. AURAIYA UTTAR PRADESH 652
3. KAWAS GUJARAT 645
4. DADRI UTTAR PRADESH 817
5. JHANOR GUJARAT 648
6. KAYAMKULAM KERALA 350
7. FARIDABAD HARYANA 430
TOTAL 3995MW

NTPC HYDEL

The company has also stepped up its hydroelectric power (hydel) projects
implementation. Currently the company is mainly interested in the North-east India
wherein the Ministry of Power in India has projected a hydel power feasibility of 3000
MW.

There are few run of the river hydro projects are under construction on tributory of the
Ganges. In which three are being made by NTPC Limited. These are:

Loharinag Pala Hydro Power Project by NTPC Ltd: In Loharinag Pala Hydro Power Project
with a capacity of 600 MW (150 MW x 4 Units). The main package has been awarded.
The present executives' strength is 100+. The project is located on river Bhagirathi (a
tributory of the Ganges) in Uttarkashi district of Uttarakhand state. This is the first
project downstream from the origin of the Ganges at Gangotri(Project has been
discontinued by GoI).

Tapovan Vishnugad 520MW Hydro Power Project by NTPC Ltd: In Joshimath town.#Lata
Tapovan 130MW Hydro Power Project by NTPC Ltd: is further upstream to Joshimath

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(under environmental revision) Koldam Hydro Power Project 800 MW in Himachal
Pradesh (130 km from Chandigarh)Amochu in Bhutan Rupasiyabagar Khasiabara HPP,
261 MW in Pithoragarh,uttarakhand State, near China Border.

FUTURE GOALS
The company has also set a serious goal of having 50000 MW of installed capacity by
2012 and 75000 MW by 2017. The company has taken many steps like step-up its
recruitment, reviewing feasibilities of various sites for project implementations etc. and
has been quite successful till date. NTPC will invest about Rs 20,000 crore to set up a
3,900-megawatt (MW) coal-based power project in Madhya Pradesh. Company will also
start coal production from its captive mine in Jharkhand in 2011–12, for which the
company will be investing about 18 billion. ALSTOM would be a part of its 660-MW
supercritical projects for Solapur II and Mouda II in Maharashtra.ALSTOM would execute
turnkey station control and instrumentation (C&I) for this project.

POWER BURDEN
India, as a developing country is characterized by increase in demand for electricity and
as of moment the power plants are able to meet only about 60–75% of this demand on
an yearly average. The only way to meet the requirement completely is to achieve a rate
of power capacity addition (implementing power projects) higher than the rate of
demand addition. NTPC strives to achieve this and undoubtedly leads in sharing this
burden on the country.

ENVIRONMENT POLICY & ENVIRONMENT MANAGEMENT SYSTEM

Driven by its commitment for sustainable growth of power, NTPC has evolved a well
defined environment management policy and sound environment practices for
minimizing environmental impact arising out of setting up of power plants and
preserving the natural ecology.

14
NATIONAL ENVIRONMENT POLICY
At the national level, the Ministry of Environment and Forests had prepared a draf
Environment Policy (NEP) and the Ministry of Power along with NTPC actively
participated in the deliberations of the draf NEP. The NEP 2006 has since been approved
by the Union Cabinet in May 2006.

NTPC ENVIRONMENT POLICY

As early as in November 1995, NTPC brought out a comprehensive document entitled
"NTPC Environment Policy and Environment Management System". Amongst the guiding
principles adopted in the document are company's proactive approach to environment,
optimum utilization of equipment, adoption of latest technologies and continual
environment improvement. The policy also envisages efficient utilization of resources,
thereby minimizing waste, maximizing ash utilization and providing green belt all around
the plant for maintaining ecological balance.

ENVIRONMET MANAGEMENT, OCCUPATIONAL HEALTH and SAFETY

SYSTEMS
NTPC has actively gone for adoption of best international practices on environment,
occupational health and safety areas. The organization has pursued the Environmental
Management System (EMS) ISO 14001 and the Occupational Health and Safety
Assessment System OHSAS 18001 at its different establishments. As a result of pursuing
these practices, all NTPC power stations have been certified for ISO 14001 & OHSAS
18001 by reputed national and international Certifying Agencies .

15
POLLUTION CONTROL SYSTEMS
While deciding the appropriate technology for its projects, NTPC integrates many
environmental provisions into the plant design. In order to ensure that NTPC comply
with all the stipulated environment norms, various state-of-the-art pollution control
systems / devices as discussed below have been installed to control air and water
pollution.

Electrostatic Precipitators

The ash lef behind afer combustion of coal is arrested in high efficiency Electrostatic
Precipitators (ESP’s) and particulate emission is controlled well within the stipulated
norms. The ash collected in the ESP’s is disposed to Ash Ponds in slurry form.

Flue Gas Stacks

Tall Flue Gas Stacks have been provided for wide dispersion of the gaseous emissions
(SOX, NOX etc) into the atmosphere.

Low-NOX Burners

In gas based NTPC power stations, NOx emissions are controlled by provision of Low-NOx
Burners (dry or wet type) and in coal fired stations, by adopting best combustion
practices.

Neutralization Pits

Neutralization pits have been provided in the Water Treatment Plant (WTP) for pH
correction of the effluents before discharge into Effluent Treatment Plant (ETP) for
further treatment and use.

Coal Settling Pits / Oil Settling Pits

16
In these Pits, coal dust and oil are removed from the effluents emanating from the Coal
Handling Plant (CHP), coal yard and Fuel Oil Handling areas before discharge into ETP.

DE & DS Systems

Dust Extraction (DE) and Dust Suppression (DS) systems have been installed in all coal
fired power stations in NTPC to contain and extract the fugitive dust released in the Coal
Handling Plant (CHP).

Cooling Towers

Cooling Towers have been provided for cooling the hot Condenser cooling water in
closed cycle Condenser Cooling Water (CCW) Systems. This helps in reduction in thermal
pollution and conservation of fresh water.

Ash Dykes & Ash Disposal systems

Ash ponds have been provided at all coal based stations except Dadri where Dry Ash
Disposal System has been provided. Ash Ponds have been divided into lagoons and
provided with garlanding arrangements for change over of the ash slurry feed points for
even filling of the pond and for effective settlement of the ash particles.

Ash in slurry form is discharged into the lagoons where ash particles get settled from the
slurry and clear effluent water is discharged from the ash pond. The discharged effluents
conform to standards specified by CPCB and the same is regularly monitored.

At its Dadri Power Station, NTPC has set up a unique system for dry ash collection and
disposal facility with Ash Mound formation. This has been envisaged for the first time in
Asia which has resulted in progressive development of green belt besides far less
requirement of land and less water requirement as compared to the wet ash disposal
system.

Ash Water Recycling System

17
Further, in a number of NTPC stations, as a proactive measure, Ash Water Recycling
System (AWRS) has been provided. In the AWRS, the effluent from ash pond is circulated
back to the station for further ash sluicing to the ash pond. This helps in savings of fresh
water requirements for transportation of ash from the plant.

The ash water recycling system has already been installed and is in operation at
Ramagundam, Simhadri, Rihand, Talcher Kaniha, Talcher Thermal, Kahalgaon, Korba and
Vindhyachal. The scheme has helped stations to save huge quantity of fresh water
required as make-up water for disposal of ash.

Dry Ash Extraction System (DAES)

Dry ash has much higher utilization potential in ash-based products (such as bricks,
aerated autoclaved concrete blocks, concrete, Portland pozzolana cement, etc.). DAES
has been installed at Unchahar, Dadri, Simhadri, Ramagundam, Singrauli, Kahalgaon,
Farakka, Talcher Thermal, Korba, Vindhyachal, Talcher Kaniha and BTPS.

Liquid Waste Treatment Plants & Management System

The objective of industrial liquid effluent treatment plant (ETP) is to discharge lesser and
cleaner effluent from the power plants to meet environmental regulations. Afer primary
treatment at the source of their generation, the effluents are sent to the ETP for further
treatment. The composite liquid effluent treatment plant has been designed to treat all
liquid effluents which originate within the power station e.g. Water Treatment Plant
(WTP), Condensate Polishing Unit (CPU) effluent, Coal Handling Plant (CHP) effluent,
floor washings, service water drains etc. The scheme involves collection of various
effluents and their appropriate treatment centrally and re-circulation of the treated
effluent for various plant uses.

NTPC has implemented such systems in a number of its power stations such as
Ramagundam, Simhadri, Kayamkulam, Singrauli, Rihand, Vindhyachal, Korba, Jhanor
Gandhar, Faridabad, Farakka, Kahalgaon and Talcher Kaniha. These plants have helped to
control quality and quantity of the effluents discharged from the stations.

18
Sewage Treatment Plants & Facilities

Sewage Treatment Plants (STPs) sewage treatment facilities have been provided at all
NTPC stations to take care of Sewage Effluent from Plant and township areas. In a
number of NTPC projects modern type STPs with Clarifloculators, Mechanical Agitators,
sludge drying beds, Gas Collection Chambers etc have been provided to improve the
effluent quality. The effluent quality is monitored regularly and treated effluent
conforming to the prescribed limit is discharged from the station. At several stations,
treated effluents of STPs are being used for horticulture purpose.

Environmental Institutional Set-up

Realizing the importance of protection of the environment with speedy development of

the power sector, the company has constituted different groups at project, regional and
Corporate Centre level to carry out specific environment related functions. The
Environment Management Group, Ash Utilisation Group and Centre for Power Efficiency
& Environment Protection (CENPEEP) function from the Corporate Centre and initiate
measures to mitigate the impact of power project implementation on the environment
and preserve ecology in the vicinity of the projects. Environment Management and Ash
Utilisation Groups established at each station, look afer various environmental issues of
the individual station.

Environment Reviews

To maintain constant vigil on environmental compliance, Environmental Reviews are

carried out at all operating stations and remedial measures have been taken wherever
necessary. As a feedback and follow-up of these Environmental Reviews, a number of
retrofit and up-gradation measures have been undertaken at different stations.

19
Such periodic Environmental Reviews and extensive monitoring of the facilities carried
out at all stations have helped in compliance with the environmental norms and timely
renewal of the Air and Water Consents.

UP GRADATION & RETROFITTING of POLLUTION CONTROL SYSTEMS

Waste Management

Various types of wastes such as Municipal or domestic wastes, hazardous wastes, Bio-
Medical wastes get generated in power plant areas, plant hospital and the townships of
projects. The wastes generated are a number of solid and hazardous wastes like used oils
& waste oils, grease, lead acid batteries, other lead bearing wastes (such as garkets etc.),
oil & clarifier sludge, used resin, used photo-chemicals, asbestos packing, e-waste, metal
scrap, C&I wastes, electricial scrap, empty cylinders (refillable), paper, rubber products,
canteen (bio-degradable) wastes, buidling material wastes, silica gel, glass wool, fused
lamps & tubes, fire resistant fluids etc. These wastes fall either under hazardous wastes
category or non-hazardous wastes category as per classification given in Government of
India’s notification on Hazardous Wastes (Management and Handling) Rules 1989 (as
amended on 06.01.2000 & 20.05.2003). Handling and management of these wastes in
NTPC stations have been discussed below.

Advanced / Eco-friendly Technologies

NTPC has gained expertise in operation and management of 200 MW and 500 MW Units
installed at different Stations all over the country and is looking ahead for higher capacity
Unit sizes with super critical steam parameters for higher efficiencies and for associated
environmental gains. At Sipat, higher capacity Units of size of 660 MW and advanced
Steam Generators employing super critical steam parameters have already been
implemented as a green field project.

Higher efficiency Combined Cycle Gas Power Plants are already under operation at all
gas-based power projects in NTPC. Advanced clean coal technologies such as Integrated
Gasification Combined Cycle (IGCC) have higher efficiencies of the order of 45% as

20
compared to about 38% for conventional plants. NTPC has initiated a techno-economic
study under USDOE / USAID for setting up a commercial scale demonstration power
plant by using IGCC technology. These plants can use low-grade coals and have higher
efficiency as compared to conventional plants.

With the massive expansion of power generation, there is also growing awareness
among all concerned to keep the pollution under control and preserve the health and
quality of the natural environment in the vicinity of the power stations. NTPC is
committed to provide affordable and sustainable power in increasingly larger quantity.
NTPC is conscious of its role in the national endeavour of mitigating energy poverty,
heralding economic prosperity and thereby contributing towards India’s emergence as a
major global economy.

OVERALL POWER GENERATION

UNIT 1997-98 2006-07 % OF
INCREASE
INSTALLED CAPACITY MW 16,847 26,350 56.40
GENERATION MUs 97,609 1,88,674 93.29
NO. OF EMPLOYEES NO. 23,585 24,375 3.34
GENERATION/EMPLOYEE MUs 4.14 7.74 86.95

The table below shows the detailed operational performance of coal based stations over
the years.

Operational Performance of Coal Based NTPC Stations

UNIT 97- 98- 99- 00- 01- 02-03 03-04 04-05 05-06 06-07
98 99 00 01 02
GENERATIO 106. 109. 118. 130. 133. 140.8 149.1 159.1 170.8 188.6
N BU 2 5 7 1 2 6 6 1 8 7
PL % 75.2 76.6 80.3 81.8 81.1 83.60 84.40 87.51 87.54 89.43
0 0 9 0 0
AVAILABILIT 85.0 89.3 90.0 88.5 81.8 88.70 88.80 91.20 89.91 90.09
Y FACTOR 3 6 6 4 0

21
 CHAPTER-2

ABOUT BADARPUR THERMAL POWER STATION

Badarpur Thermal Power Station is located at Badarpur area in NCT Delhi. The power
plant is one of the coal based power plants of NTPC. The National Power Training
Institute (NPTI) for North India Region under Ministry of Power, Government of India was
established at Badarpur in 1974, within the Badarpur Thermal power plant (BTPS)
complex.

It is situated in south east corner of Delhi on Mathura Road near Faridabad. It was the
first central sector power plant conceived in India, in 1965. It was originally conceived to
provide power to neighbouring states of Haryana, Punjab, Jammu and Kashmir,U.P.,
Rajasthan, and Delhi.But since year 1987 Delhi has become its sole beneficiary.

BADARPUR THERMAL POWER STATION

COUNTRY INDIA
LOCATION MATHURA ROAD, BADARPUR, NEW DELHI
STATUS ACTIVE
COMISSION DATE 1973
OPERATOR(S) NTPC
POWER STATION INFORMATION

PRIMARY FUEL COAL-FIRED

22
 GENERATION UNITS 5

POWER GENERATION INFORMATION

INSTALLED CAPACITY 705.00 MW

FROM COAL TO ELECTRICITY PROCESS

Figure 4: FLOW CHART of COAL TO ELECTRICITY

Coal to Steam

Coal from the coal wagons is unloaded in the coal handling plant. This Coal is
transported up to the raw coal bunkers with the help of belt conveyors. Coal is
transported to Bowl mills by Coal Feeders. The coal is pulverized in the Bowl Mill,
where it is ground to powder form. The mill consists of a round metallic table on
which coal particles fall. This table is rotated with the help of a motor. There are
three large steel rollers, which are spaced 120 apart. When there is no coal, these

23
rollers do not rotate but when the coal is fed to the table it pack up between roller
and the table and ths forces the rollers to rotate. Coal is crushed by the crushing
action between the rollers and the rotating table. This crushed coal is taken away to
the furnace through coal pipes with the help of hot and cold air mixture from P.A. Fan.
P.A. Fan takes atmospheric air, a part of which is sent to Air-Preheaters for heating
while a part goes directly to the mill for temperature control. Atmospheric air from
F.D. Fan is heated in the air heaters and sent to the furnace as combustion air.
Water from the boiler feed pump passes through economizer and reaches the
boiler drum. Water from the drum passes through 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 and density difference, the water rises up in the
water wall tubes. Water is partly converted to steam as it rises up in the furnace.
This steam and water mixture is again taken to thee boiler drum where the steam is
separated from water.

Figure 5: TYPICAL DIAGRAM OF COAL BASED THERMAL POWER PLANT

Water follows the same path while the steam is sent to superheaters for
superheating. The superheaters are located inside the furnace and the steam is
superheated (540 oC) and finally it goes to the turbine.

24
Flue gases from the furnace are extracted by induced draft fan, which maintains
balance draft in the furnace (-5 to –10 mm of wcl) with forced draft fan. These flue
gases emit their heat energy to various super heaters in the pent house and finally
pass through air-preheaters and goes to electrostatic precipitators where the ash
particles are extracted. Electrostatic Precipitator consists of metal plates, which
are electrically charged. Ash particles are attracted on to these plates, so that
they do not pass through the chimney to pollute t he atmosphere. Regular
mechanical hammer blows cause the accumulation of ash to fall to the bottom of the
precipitator where they are collected in a hopper for disposal.

25
Steam to Mechanical Power
From the boiler, a steam pipe conveys steam to the turbine through a stop valve
(which can be used to shut-off the steam in case of emergency) and through control
valves that automatically regulate the supply of steam to the turbine. Stop valve and
control valves are located in a steam chest and a governor, driven from the main
turbine shaft, operates the control valves to regulate the amount of steam used.
(This depends upon the speed of the turbine and the amount of electricity required
from the generator).
Steam from the control valves enters the high pressure cylinder of the turbine, where
it passes through a ring of stationary blades fixed to the cylinder wall. These act as
nozzles and direct the steam into a second ring of moving blades mounted on a disc
secured to the turbine shaft. The second ring turns the shafts as a result of the force
of steam. The stationary and moving blades together constitute a „stage‟ of turbine
and in practice many stages are necessary, so that the cylinder contains a number of
rings of stationary blades with rings of moving blades arranged between them. The
steam passes through each stage in turn until it reaches the end of the high-pressure
cylinder and in its passage some of its heat energy is changed into mechanical energy.

The steam leaving the high pressure cylinder goes back to the boiler for reheating and
returns by a further pipe to the intermediate pressure cylinder. Here it passes
through another series of stationary and moving blades.

Finally, the steam is taken to the low-pressure cylinders, each of which enters at the
centre flowing outwards in opposite directions through the rows of turbine blades
through an arrangement called the „double flow‟- to the extremities of the cylinder.
As the steam gives up its heat energy to drive the turbine, its temperature and
pressure fall and it expands. Because of this expansion the blades are much larger
and longer towards the low pressure ends of the turbine.
Mechanical Power to Electrical Power
As the blades of turbine rotate, the shaft of the generator, which is coupled to
tha of t he turbine, also rotates. It results in rotation of the coil of the generator,
which causes induced electricity to be produced.

26
Basic Power Plant Cycle

Figure 6: COMPONENTS OF A COAL FIRED THERMAL PLANT

The thermal (steam) power plant uses a dual (vapour+ liquid) phase cycle. It is a close
cycle to enable the working fluid (water) to be used again and again. The cycle used
is Rankine Cycle modified to include superheating of steam, regenerative feed water
heating and reheating of steam. On large turbines, it becomes economical to
increase the cycle efficiency by using reheat, which is a way of partially overcoming
temperature limitations. By returning partially expanded steam, to a reheat, the
average temperature at which the heat is added, is increased and, by expanding this
reheated steam to the remaining stages of the turbine, the exhaust wetness is
considerably less than it would otherwise be conversely, if the maximum tolerable
wetness is allowed, the initial pressure of the steam can be appreciably increased.
Bleed Steam Extraction: For regenerative system, nos. of non-regulated extractions is
taken from HP, IP turbine. Regenerative heating of the boiler feed water is widely
used in modern power plants; the effect being to increase the average temperature
at which heat is added to the cycle, thus improving the cycle efficiency.

27
On large turbines, it becomes economical to increase the cycle efficiency by using
reheat, which is a way of partially overcoming temperature limitations. By returning
partially expanded steam, to a reheat, the average temperature at which the heat is
added, is increased and, by expanding this reheated steam to the remaining stages
of the turbine, the exhaust wetness is considerably less than it would otherwise be
conversely, if the maximum tolerable wetness is allowed, the initial pressure of the
steam can be appreciably increased.
Bleed Steam Extraction: For regenerative system, nos. of non-regulated extractions is
taken from HP, IP turbine. Regenerative heating of the boiler feed water is widely
used in modern power plants; the effect being to increase the average temperature
at which heat is added to the cycle, thus improving the cycle efficiency.

Figure 7: INTSALLED CAPACITY OF NTPC, BADARPUR

MAIN GENERATOR
Maximum continuous KVA rating 24700KVA

Maximum continuous KW 210000KW

Rated terminal voltage 15750V

Rated Stator current 9050 A

Rated Power Factor 0.85 lag

Excitation current at MCR Condition 2600 A

Slip-ring Voltage at MCR Condition 310 V

28
Rated Speed 3000 rpm

Rated Frequency 50 Hz

Short circuit ratio 0.49

Efficiency at MCR Condition 98.4%

Direction of rotation viewed Anti Clockwise

Phase Connection Double Star

Number of terminals brought out 9(6 neutral and 3 phases)

MAIN TURBINE DATA

Rated output of Turbine 210 MW

Rated speed of turbine 3000 rpm

Rated pressure of steam before emergency 130 kg/cm^2

Stop valve rated live steam temperature 535 o Celsius

Rated steam temperature afer reheat at inlet to receptor valve 535 o Celsius

Steam flow at valve wide open condition 670 tons/hour

Rated quantity of circulating water through condenser 27000

cm/hour

1. For cooling water temperature (o Celsius) 24,27,30,33

2. Steam flow required for 210 MW in ton/hour 68,645,652,662

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

OPERATION
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,

29
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.

Typical elements of a coal fired thermal power station

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

30
18. Forced draught (draf) fan

19. Reheater

20. Combustion air intake

21. Economizer

22. Air preheater

23. Precipitator

24. Induced draught (draf) 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 towers 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-draf or induced draf towers or in natural draf
hyperbolic shaped cooling towers as seen at most nuclear power plants.

31
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.

Afer 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

32
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 shaf 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 stations use large steam turbines driving electric generators to produce
most (about 86%) of the world’s 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 ofen directly coupled to their-generators .As the generators must
rotate at constant synchronous speeds according to the frequency of the electric power
system, the most common speeds are 3000 r/min for 50 Hz systems, and 3600 r/min for
60 Hz systems. Most large nuclear sets rotate at half those speeds, and have a 4-pole
generator rather than the more common 2-pole one.

Energy in the steam afer 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 shaf. The turbine shaf is
connected to a generator, which produces the electrical energy.

4. Boiler feed water pump

33
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.

Figure 8: EXTERNAL VIEW OF BOILER

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.

5. Steam-powered pumps

34
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
ofen 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 ofen a positive displacement pump that had steam valves and
cylinders at one end and feed water cylinders at the other end; no crankshaf 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

35
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.
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 irreversibility’s 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

36
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 390’C 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 boiler’s efficiency. They are a device fitted to a boiler which saves energy by using the

37
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 Green’s 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.

ESP’s 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.

38
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 ESP’s 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 ofen 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 other small sources
within residential abodes, restaurants , hotels or other stacks are referred to as
chimneys.

39
 CHAPTER-3

EMD- I

Electrical Maintenance Division I

It is responsible for the maintenance of:

HT/LT MOTORS TURBINE & BOILER SIDE

Boiler Side Motors:

For 1, units 1, 2, 3

1. ID Fans 2 in no.

2. FD Fans 2 in no.

3. PA Fans 2 in no.

4. Mill Fans 3 in no.

5. Ball mill fans 3 in no.

6. RC feeders 3 in no.

7. Slag Crushers 5 in no.

8. DM Make up Pump 2 in no.

9. PC Feeders 4 in no.

10. Worm Conveyor 1 in no.

11. Furnikets 4 in no.

For stage units 1, 2, 3

1. I.D Fans 2 in no.

2. F.D Fans 2 in no.

3. P.A Fans 2 in no.

4. Bowl Mills 6 in no.

5. R.C Feeders 6 in no.

40
6. Clinker Grinder 2 in no.

7. Scrapper 2 in no.

8. Seal Air Fans 2 in no.

9. Hydrazine & Phosphorous Dozing 2 in no.

Figure 9: EXTERNAL VIEW OF ID, PA & FD FANS

COAL HANDLING PLANT (C.H.P) & NEW COAL HANDLING PLANT (N.C.H.P)
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.

Figure 10: FLOW CHART OF COAL HANDLING PLANT

41
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 afer 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

42
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.

3. MILLING SYSTEM

1. RC Bunker: - Raw coal is fed directly to these bunkers. These are 3 in no. per boiler. 4 &
½ 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 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.

43
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 chimney.

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.

Type-Double suction radial

Rating-300 KW

Voltage-6.6 KV

44
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

4. NEW COAL HANDLING PLANT

1. Wagon Tippler:

Motor Specification

(i) H.P 75 HP

(ii) Voltage 415, 3 phase

(iii) Speed 1480 rpm

(iv) Frequency 50 Hz

(v) Current rating 102 A

45
2. Coal feed to plant:

Feeder motor specification

(i) Horse power 15 HP

(ii) Voltage 415V, 3 phase

(iii) Speed 1480 rpm

(iv) Frequency 50 Hz

3. Conveyors:-

10A, 10B

11A, 11B

12A, 12B

13A, 13B

14A, 14B

15A, 15B

16A, 16B

17A, 17B

18A, 18B

4. Transfer Point 6

5. Breaker House

6. Rejection House

7. Reclaim House

46
8. Transfer Point 7

9. Crusher House

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.
Afer being crushed, if any metal is still present it is taken care of by metal detectors
employed in conveyor 10.

5. 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

47
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

48
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 lifed 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.

49
It has the following advantages over OCB:-

i. Fire hazard due to oil are eliminated.

ii. Operation takes place quickly.

iii. There are less burning 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

50
· 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 is
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

51
 CHAPTER-3

EMD II

Electrical Maintenance division II

This division is divided as follows

Generator and Auxiliaries

Generator Fundamentals

The transformation of mechanical energy into electrical energy is carried out by the
Generator. This Chapter seeks to provide basic understanding about the working
principles and development of Generator.

Figure 11: CROSS-SECTIONAL VIEW OF A 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 (i.e. magnetic field) cut through the stator windings.

52
This induces an electromagnetic force (EMF) in the stator windings. The magnitude of
this EMF is given by the following expression.

E = 4.44 /O FN volts

0 = Strength of magnetic field in Weber’s.

F = Frequency in cycles per second or Hertz.

N = Number of turns in a coil of stator winding

F = Frequency = P*n/120

Where P = Number of poles

n = revolutions per second of rotor.

From the expression it is clear that for the same frequency, number of poles increases
with decrease in speed and vice versa. Therefore, low speed hydro turbine drives
generators have 14 to 20 poles were as high speed steam turbine driven generators have
generally 2 poles.

Generator component

This deals with the two main components of the Generator viz. Rotor, its winding &
balancing and stator, its frame, core & windings.

Rotor

The electrical rotor is the most difficult part of the generator to design. It revolves in
most modern generators at a speed of 3,000 revolutions per minute. The problem of
guaranteeing the dynamic strength and operating stability of such a rotor is complicated
by the fact that a massive non-uniform shaf subjected to a multiplicity of differential
stresses must operate in oil lubricated sleeve bearings supported by a structure mounted
on foundations all of which possess complex dynamic be behavior peculiar to them. It is
also an electromagnet and to give it the necessary magnetic strength

53
The windings must carry a fairly high current. The passage of the current through the
windings generates heat but the temperature must not be allowed to become so high,
otherwise difficulties will be experienced with insulation. To keep the temperature down,
the cross section of the conductor could not be increased but this would introduce
another problems. In order to make room for the large conductors, body and this would
cause mechanical weakness. The problem is really to get the maximum amount of
copper into the windings without reducing the mechanical strength. With good design
and great care in construction this can be achieved. The rotor is a cast steel ingot, and it
is further forged and machined. Very ofen 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 lif 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 means that a
check is made to see if it will run up to normal speed without vibration. To do this it
would have to be uniform about its central axis and it is most unlikely that this will be so
to the degree necessary for perfect balance. Arrangements are therefore made in all
designs to fix adjustable balance weights around the circumference at each end.

54
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 shaf seals. In large generators the frame is constructed as two separate parts. The
fabricated inner cage is inserted in the outer frame afer 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

55
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. This Chapter deals with the rotor-hydrogen cooling system and stator water
cooling system along with the shaf sealing and bearing cooling systems.

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 it’s 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, shaf 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,

56
The system is capable of performing the following functions:

I. Filling in and purging of hydrogen safely without bringing in contact with air.
II. Maintaining the gas pressure inside the machine at the desired value at all the
times.
III. Provide indication to the operator about the condition of the gas inside the
machine i.e. its pressure, temperature and purity.
IV. Continuous circulation of gas inside the machine through a drier in order to
remove any water vapor that may be present in it.
V. Indication of liquid level in the generator and alarm in case of high level.

Stator Cooling System

The stator winding is cooled by distillate.

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 400C.

Rating of 95 MW Generator-

Manufacture by Bharat heavy electrical Limited (BHEL)

Capacity - 117500 KVA

Voltage - 10500V

Speed - 3000 rpm

Hydrogen - 2.5 Kg/cm2

Power factor - 0.85 (lagging)

Stator current - 6475 A

Frequency - 50 Hz

57
Stator winding connection - 3 phase

Rating of 210 MW Generator-

Manufacture by Bharat heavy electrical Limited (BHEL)

Capacity - 247000 KVA

Voltage (stator) - 15750 V

Current (stator) - 9050 A

Voltage (rotor) - 310 V

Current (rotor) - 2600 V

Speed - 3000 rpm

Power factor - 0.85

Frequency - 50 Hz

Hydrogen - 3.5 Kg/cm2

Stator winding connection - 3 phase star connection

Insulation class -B

Transformer
A transformer is a device that transfers electrical energy from one circuit to another by
magnetic coupling without 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 high-voltage, _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 world’s electrical power has passed through a series of transformer
by the time it reaches the consumer.

58
Rating of transformer

Manufactured by Bharat Heavy Electrical Limited

No load voltage (HV) - 229 KV

No load Voltage (LV) -10.5 KV

Line current (HV) -315.2 A

Line current (LV) - 873.2 A

Temp rise - 45 Celsius

Oil quantity - 40180 lit

Weight of oil - 34985 Kg

Total weight - 147725 Kg

Core & winding - 84325 Kg

Phase -3

Frequency - 50 Hz

CHAPTER-4

CONTROL AND INSTRUMENTATION

59
This division is basically brain of the power plant and this division is responsible for:

1. Fr controlling the entire process of boiler, turbine n generator.

2. Is responsible for protection of boiler turbine & generator & associated

auxiliaries.

3. It is responsible for display of all the parameters to the operator for taking the
manual action in case of emergency.

4. Responsible for logging of sequence of events taking place in the control room

Figure 12: CONTROL UNIT

This department is the brain of the plant because from the relays to transmitters
followed by the electronic computation chipsets and recorders and lastly the controlling
circuitry, all fall under this.

This division also calibrates various instruments and takes care of any faults occurring in
any of the auxiliaries in the plant provided for all the equipments. Tripping can be

60
considered as the series of instructions connected through OR GATE. When the main
equipments of this laboratories are relay and circuit breakers.

GENESIS OF THE PROJECT:

There are very transient conditions during the light up of the boiler. At this point, the
level in the drum fluctuates heavily & frequently. So, if the drum level works on properly
on auto loop, then it will be huge relief to operator and it may even save the unit from
tripping on drum level protection. That is why this project is chosen.

OBJECTIVE:

The objective of the boiler drum level control strategy is to maintain the water/steam
interface at its optimum level to provide a continuous mass/heat balance by replacing
every pound of steam leaving the boiler with a pound of feed water to replace it. As
mentioned above if the level is above +175mm then the turbine may get damaged or if
the level is below -175mm then the boiler happens to starvation. The objective of the
entire project is to design the controlling element for the control of valve of drum which
can be designed manually and automatically both. The controlling element will control
the opening and closing of valve of drum according to error signal generated by I-06R
mini card. To serve this purpose the following steps are to be taken

The following are the main objectives of the project:

1) Understanding the input measurement techniques.

2) Understanding the control logic and hence designing it.

3) Understanding and simulating the controlling element i.e. valve actuator.

MAIN OUTLINE:

The level in the drum has to be controlled effectively.

61
If level in the drum is very low say below -175 mmwcl, then the starvation of the water
tubes will take place & hence huge financial loss to the plant will take place.

If the level in the drum is very high say +175 mmwcl then, water particle may enter in the
turbine & turbine blades may get damaged. So, again a huge financial loss to the plant
may take place that is why the drum level is of very high importance.

The entire functioning of any auto loop may be primarily being divided in to four parts.

1) Measurement of Input: This is the first step towards designing the auto controller. In
this project, we will study the various measurement techniques of the drum level.
Primarily we will focus on the two techniques as-

62
 i) Drum level measurement technique by differential pressure
measurement: In this variable head is compared with constant head and
thus giving the variable electrical signal in terms of the 4 to 20 ma. This
DP signal is corrected for the density by measuring the drum pressure
and temperature of the saturated steam.

ii) Hydra step measurement: This method is based on the principle of the
resistivity difference of the steam & water. This method gives the
discrete signal hence cannot be used for the auto controlling of the
drum level

2) Designing the control logic: The Corrected drum level signal is compared with the
desired set point & hence error signal is generated. Based on the error signal, the
raise or lower command goes to the controlling element. Here in the auto controlling
of the drum level, we may go for two types of logic-

i) Single element control logic: In this only drum level signal is compared
with the desired set point & thus on the basis of the error signal, raise &
lower command is sent to the controlling element. Here in this project
we are focusing on the single element controller.

ii) Three element control logic: In this, instead of considering only the
drum level we will focus on the two other parameters which are Total
Feed water flow and total steam flow. Designing the three element
controller may be the extension of this project.

3) Designing the controlling element: There are three control elements as follows:
a) Electrical/Linear Actuator: A linear actuator is an actuator that creates motion in
a straight line, as contrasted with circular motion of a conventional electric motor.
Linear actuators are used in machine tools and industrial machinery, in computer
peripherals such as disk drives and printers, in valves and dampers, and in many
other places where linear motion is required. Hydraulic or pneumatic cylinders
inherently produce linear motion; many other mechanisms are used to provide a
linear motion from a rotating motor.

63
 b) Pneumatic Actuator: A pneumatic actuator converts energy (typically in the form
of compressed air) into mechanical motion. The motion can be rotary or linear,
depending on the type of actuator. Some types of pneumatic actuators include:
 Tie rod cylinders
 Rotary actuators
 Grippers
 Rod Less actuators with magnetic linkage or rotary cylinder
 Rod Less actuators with mechanical linkage
 Pneumatic artificial muscles
 Vacuum generators

c) Hydraulic Actuator: A Hydraulic cylinder is a mechanical actuator that is used to

give a unidirectional force through a unidirectional stroke. It has many
applications, notably in engineering vehicles. Hydraulic cylinders get their power
from pressurized hydraulic fluid, which is typically oil. The hydraulic cylinder
consists of a cylinder barrel, in which a piston connected to a piston rod moves
back and forth. The barrel is closed on each end by the cylinder bottom (also
called the cap end) and by the cylinder head where the piston rod comes out of
the cylinder. The piston has sliding rings and seals. The piston divides the inside
of the cylinder in two chambers, the bottom chamber (cap end) and the piston
rod side chamber (rod end). The hydraulic pressure acts on the piston to do
linear work and motion.

BLOCK DIAGRAM

64
DESCRIPTION OF BLOCK DIAGRAM

There are two main circuits used in this project. The command for valve actuator can be
given in manual and auto mode both. The circuits for manual & auto command are
different. The circuit for auto command is in parallel with the circuit for manual
command. The block diagram for the circuit for is shown below.

In the circuit of manual mode, the main supply is of 230V AC. The supply is given to the
AC to DC converter. The converter converts 230V AC to 24V DC. This DC supply is given to
the dextile, the dextile and limit switches are connected in parallel. The output of dextile
is given to the DC relays. The DC relays provide 24V as input and 230V as output. The
output of DC relay is given to the contactor which accepts 230V as input and output both
& the output of the contactor is fed to the single phase AC motor.

If boundary limits are reached as full open or full close then on giving any further
command will not be executed by the motor.

The energized relay will rotate the motor either in clockwise or in anticlockwise direction
depending upon the energisation. The opening and closing of the valve will depend on
the direction of motor. The motor will control the opening and closing of valve which will
control the level of water in drum. It is necessary to keep track of one thing that at one
time only one relay should get energized either forward relay or backward relay, hence

65
 forward or reverse connectors are used to avoid the simultaneous energization of both
forward and backward relays. The forward relay helps the motor to rotate in clockwise
direction and the backward relay makes the motor to rotate in anticlockwise direction.

In the circuit of auto mode the I 06 R mini card is used. The I-06 R card is used to make
the

summator subtractor circuit. The card is uses a low current offset differential amplifier,
with feedback arranged to produce the required computing function. The amplifier
which is used to make this 06 r card is used in non-inverting mode. For current input
signals, conditioning resistors are fitted across the input terminals. These resistors are
placed in specific order. There are two inputs of the I-06 R card as one is reference level
and other is variable supply. The 06 R mini card gives error signal as its output. According
to this error signal the trigger circuit will energize the corresponding relay.

The output of I-06 computing Mini Card which is an error signal will be send to the
trigger circuit. The trigger circuit will generate the pulses of +20 V and -20 V which is
send to the forward or backward relays.

The output of the trigger circuit will energize one of the relay either forward or reverse
relay. The 555 timer IC is used in the trigger circuit. The output of the trigger circuit is fed
to the 12V dc relays. Then these 12V relays will energize the 24 V DC relays.

CIRCUIT DIAGRAM

66
There are two main circuits used in this project. The command for valve actuator can be
given in manual and auto mode both. The circuits for manual & auto command are
different. The circuit for auto command is in parallel with the circuit for manual
command.

CIRCUIT DESCRIPTION OF AUTO MODE

CIRCUIT DIAGRAM FOR SET POINT:

The 7805 IC is used for the set input which is given to the I-06R mini card. 20V is given as
input to the 7805 voltage regulator IC. The output of the 7805 is 5V which is constant
and we are using 5V as set point of the I 06 R mini card. The 20v is fed to the pin 1 of IC
and output is being taken from pin 3 of IC

CIRCUIT DAIGRAM FOR VARIABLE INPUT

67
The output voltage is stabilized and is regulated in the region from 0V until + 15V dc,
with biggest provided current 1 A. The regulation becomes with the R2. The Q1 of is
classic power transistor and it needs it is placed in heat sink, one and heating when it
works continuously in the region of biggest current. The type of transformer is standard
in the market. The variable resistor or potentiometer gives as variable output from 0 to
+15V which are given as one of the input of I-06 R mini card.

I-06R MINI CARD CIRCUIT DIAGRAM

68
The I-06 R card is used to make the summator subtractor circuit. The card is uses a low
current offset differential amplifier, with feedback arranged to produce the required
computing function. The amplifier which is used to make this 06 r card is used in non-
inverting mode. For current input signals, conditioning resistors are fitted across the
input terminals. These resistors are placed in specific order. There are two inputs of the I-
06 R card as one is reference level and other is the output of potentiometer which is
variable in nature.

There are three input pins of this card as 1, 2. And 3 of the I 06 R mini card .There are two
inputs applied to the 06 R mini card to generate the error signal. One is reference or set
point which is applied to the pin 1 of this card and second is variable input which is
applied to the pin 2 of the card+20V is applied to the pin 8 of card and -20V is applied to
the pin 10 of the card. The +20V and -20V are applied to the card to drive the card. The
output is being taken from the pin 4 of the card with reference to the ground which is at
pin 09 of card. When less than the total available inputs are in use, the unused inputs
should be connected to the common line hence pin 3 is connected to the common line
or 0V.

TRIGGER CIRCUIT

The output of I-06 computing Mini Card which is an error signal will be send to the
trigger circuit. The trigger circuit will generate the pulses of +20 V and -20 V which is
send to the forward or backward relays.

69
The two comparator inputs (pin 2 & 6) are tied together and biased at 1/2 Vcc through a
voltage divider R1 and R2.Since the threshold comparator wil trip at 2/3 Vcc and the
trigger comparator will trip at 1/3Vcc,the bias provided by the resistors R1 & R2 are
centered within the comparators trip limits.

By modifying the input time constant on the circuit,reducing the value of input capacitor
(C1) to 0.001 uF so that the input pulse get differentiated,the arrangement can also be
used either as a bistable device or to invert pulse wave forms.In the later case ,the fast
time combination of C1 with R1 & R2 causes only the edges of the input pulse or
rectangular waveform to be passed. These pulses set and reset the flip-flop and a high
level inverted output is the result.

ELECTRICAL ACTUATOR CIRCUIT

The output of the trigger circuit will energize one of the relay either forward or reverse
relay. The energized relay will rotate the motor either in clockwise or anticlockwise
direction depends on the type of energized relay. The opening and closing of valve will
depend on the direction of motor. The motor will control the opening and closing of
valve which will control the level of water in drum. It is necessary to keep track of one
thing that at one time only one relay should get energized either forward relay or
backward relay, hence forward or reverse connectors are used to avoid the simultaneous
energization of both forward and backward relays.

DEXTILE, LIMIT SWITCH and RELAY PIN DESCRIPTION

The port P12 and P11 gets supply of negative and positive 24 volts respectively. The
positive terminal of limit switch is connected to P4 and P6 terminal of the dextile,
negative terminal of limit switch is connected to fourth port of relay. The port 12 of the
dextile is connected to the eight port of the relay. P1 and P3 of dextile is connected to
the fourth port of forward and backward relay respectively. The connection on port P1
helps to glows yellow colour LED and green colour LED on P3. The port 3 of the relays
gets a supply of 230 volts. NC of contactor is connected to the second port of relays. The

70
A1 port of both parts of the contactor is on neutral. A1 port of the first part of contactor
is connected to NC of second part of contactor and vice versa. L1 port of both parts of
contactor gets a supply of 230 volts. The first part of the contactor is directly connected
to the motor and the second part of the contactor is connected to the motor in series
with a capacitor to provide an anticlockwise movement.

CONCLUSION:

. Practically there are many parameters to be controlled to maintain the level of water in

drum according to the requirement but we have considered only one parameter of flow
of water in our project. The content of steam which is going in turbine depends on the
level of water in drum hence water level should be in control. To fulfill this purpose we
had designed a controlling element which is receiving command by the trigger circuit.
The trigger circuit is correcting the error signal generated by I-06R mini card and
providing appropriate command to the motor.

EXTENSIONS

1) Triggering circuit may be the economical replace of the 74 R card.

2) If drum level is put on auto loop during the lighted up condition of the
boiler, there will be huge saving of monetary losses.

3) Timely synchronisation of the unit is possible and hence can better serve
the society.

COMPONENTS DESCRIPTION

LIMIT SWITCH
In electrical engineering a limit switch is a switch operated by the motion of a machine
part or presence of an object. They are used for control of a machine, as
safety interlocks, or to count objects passing a point.

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Limit switch is one type Of " Contact Sensor”, In that there is Normally Open Contact &
Normally Close Contact, In limit switch there is Plunger it is Directly Connected to NO &
NC Contact if we press the plunger NO contact become NC & NC contact become NO,
Working Principle same as Contactor (DOL starter) main difference is in contactor There
is Coil to attract the Plunger But In Limit Switch Plunger is Operated Mechanically. Limit
Switches is used mainly for Safety Purpose & to take Feed back for PLC in Automation
industries.

Many limit switches have three terminals. One is the normally closed contact, another
the normally open contact and the third is the common that switches between these two
as the mechanism is moved.

The limit switch is mounted in such a way when the mechanism driven by motor reaches
one of the limit positions, it will engage the limit switch at that position. This will cause
NC contacts of that switch to open and its NO to close.

RELAY

A relay is an electrically operated switch. Many relays use an electromagnet to operate a

switching mechanism mechanically, but other operating principles are also used. Relays
are used where it is necessary to control a circuit by a low-power signal (with complete
electrical isolation between control and controlled circuits), or where several circuits
must be controlled by one signal. The first relays were used in long distance telegraph
circuits, repeating the signal coming in from one circuit and re-transmitting it to another.
Relays were used extensively in telephone exchanges and early computers to perform
logical operations.

A type of relay that can handle the high power required to directly control an electric
motor or other loads is called a contactor. Solid-state relays control power circuits with
no moving parts, instead using a semiconductor device to perform switching. Relays with
calibrated operating characteristics and sometimes multiple operating coils are used to
protect electrical circuits from overload or faults; in modern electric power systems
these functions are performed by digital instruments still called "protective relays".

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It is a protective device. It can detect wrong condition in electrical circuits by constantly
measuring the electrical quantities flowing under normal and faulty conditions. Some of
the electrical quantities are voltage, current, phase angle and velocity.

CONTACTOR RELAY
A contactor is a very heavy-duty relay used for switching electric motors and lighting loads,
although contactors are not generally called relays. Continuous current ratings for common
contactors range from 10 amps to several hundred amps. High-current contacts are made with
alloys containing silver. The unavoidable arcing causes the contacts to oxidize; however, silver
oxide is still a good conductor. Such devices are ofen used for motor starters. A motor starter is a
contactor with overload protection devices attached. The overload sensing devices are a form of
heat operated relay where a coil heats a bi-metal strip, or where a solder pot melts, releasing a
spring to operate auxiliary contacts. These auxiliary contacts are in series with the coil. If the
overload senses excess current in the load, the coil is de-energized. Contactor relays can be
extremely loud to operate, making them unfit for use where noise is a chief concern.

A simple electromagnetic relay consists of a coil of wire wrapped around a sof iron core,
an iron yoke which provides a low reluctance path for magnetic flux, a movable
iron armature, and one or more sets of contacts (there are two in the relay pictured). The
armature is hinged to the yoke and mechanically linked to one or more sets of moving
contacts. It is held in place by a spring so that when the relay is de-energized there is an
air gap in the magnetic circuit. In this condition, one of the two sets of contacts in the
relay pictured is closed, and the other set is open. Other relays may have more or fewer
sets of contacts depending on their function. The relay in the picture also has a wire
connecting the armature to the yoke. This ensures continuity of the circuit between the

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moving contacts on the armature, and the circuit track on the printed circuit board (PCB)
via the yoke, which is soldered to the PCB

When an electric current is passed through the coil it generates a magnetic field that
activates the armature and the consequent movement of the movable contact either
makes or breaks (depending upon construction) a connection with a fixed contact. If the
set of contacts was closed when the relay was de-energized, then the movement opens
the contacts and breaks the connection, and vice versa if the contacts were open. When
the current to the coil is switched off, the armature is returned by a force, approximately
half as strong as the magnetic force, to its relaxed position. Usually this force is provided
by a spring, but gravity is also used commonly in industrial motor starters.

When the coil is energized with direct current, a diode is ofen placed across the coil to
dissipate the energy from the collapsing magnetic field at deactivation, which would
otherwise generate a voltage spike dangerous to semiconductor circuit components.
Some automotive relays include a diode inside the relay case. Alternatively, a contact
protection network consisting of a capacitor and resistor in series (snubber circuit) may
absorb the surge. If the coil is designed to be energized with alternating current (AC), a
small copper "shading ring" can be crimped to the end of the solenoid, creating a small
out-of-phase current which increases the minimum pull on the armature during the AC
cycle.

A solid-state relay uses a thyristor or other solid-state switching device, activated by the
control signal, to switch the controlled load, instead of a solenoid.
An optocoupler (a light-emitting diode (LED) coupled with a photo transistor) can be
used to isolate control and controlled circuits.

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 OPERATING PRINCIPLE

Unlike general-purpose relays, contactors are designed to be directly connected to high-

current load devices. Relays tend to be of lower capacity and are usually designed for
both normally closed and normally open applications. Devices switching more than 15
amperes or in circuits rated more than a few kilowatts are usually called contactors.
Apart from optional auxiliary low current contacts, contactors are almost exclusively
fitted with normally open contacts. Unlike relays, contactors are designed with features
to control and suppress the arc produced when interrupting heavy motor currents.

When current passes through the electromagnet, a magnetic field is produced, which
attracts the moving core of the contactor? The electromagnet coil draws more current
initially, until its inductance increases when the metal core enters the coil. The moving
contact is propelled by the moving core; the force developed by the electromagnet holds
the moving and fixed contacts together. When the contactor coil is de-energized, gravity
or a spring returns the electromagnet core to its initial position and opens the contacts.

For contactors energized with alternating current, a small part of the core is surrounded
with a shading coil, which slightly delays the magnetic flux in the core. The effect is to
average out the alternating pull of the magnetic field and so prevent the core from
buzzing at twice line frequency.

7805 VOLTAGE REGULATOR IC

The 7805 is a self-contained fixed linear voltage regulator integrated circuit.. The voltage
regulator ic family is commonly used in electronic circuits requiring a regulated power supply due
to their ease-of-use and low cost. The 7805 line is positive voltage regulators: they produce a
voltage that is positive relative to a common ground.

7805 ICs have three terminals and are commonly found in the TO220 form factor,
although smaller surface-mount and larger TO3 packages are available. These devices
support an input voltage anywhere from a couple of volts over the intended output
voltage, up to a maximum of 35 to 40 volts depending on the make, and typically provide
1 or 1.5 amperes of current (though smaller or larger packages may have a lower or
higher current rating).

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7805 series ICs do not require additional components to provide a constant, regulated
source of power, making them easy to use, as well as economical and efficient uses of
space. Other voltage regulators may require additional components to set the output
voltage level, or to assist in the regulation process. Some other designs (such as
a switched-mode power supply) may need substantial engineering expertise to
implement.

7805 series ICs have built-in protection against a circuit drawing too much power. They have
protection against overheating and short-circuits, making them quite robust in most applications.
In some cases, the current-limiting features of the 7805 devices can provide protection not only
for the 7805 itself, but also for other parts of the circuit.

7805 ICs are easy to use and handle but these cannot give an altering voltage required so
LM317 series of ICs are available to obtain a voltage output from 1.25 volts to 37 volts.

2N3055 TRANSISTOR
The 2N3055 is a silicon NPN power transistor intended for general purpose applications.
The horizontal output transformer from a CRT type TV can be driven using just two resistors and
a 2N3055 in fly back mode, transforming a low voltage, such as 12 volts, into several kilovolts.
The output is very low current, so there is a minimal chance of dangerous electric shock.
However, the design is limited by the 2N3055's ability to handle this sort of circuit, and will
overheat and quickly fail from the inductive voltage feedback spikes from the transformer.
Hobbyists would, afer gaining an understanding of high voltage, then move on to higher power
circuits and transformers. This transistor must be counted among the hobbyists as the most used
power transistor, afer being used in audio power amplifier with powers ranging from 10W to
400W.

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555 TIMER IC
The 555 timer IC is an integrated circuit (chip) used in a variety of timer, pulse generation, and
oscillator applications. The 555 can be used to provide time delays, as an oscillator, and as a flip-
flop element. Derivatives provide up to four timing circuits in one package.

The IC was designed in 1971 by Hans R. Camenzind under contract to Signetics, which
was later acquired by Philips.Depending on the manufacturer, the standard 555 package
includes 25 transistors, 2 diodes and 15 resistors on a silicon chip installed in an 8-pin
mini dual-in-line package (DIP-8).[2] Variants available include the 556 (a 14-pin DIP
combining two 555s on one chip), and the two 558 & 559s (both a 16-pin DIP combining
four slightly modified 555s with DIS & THR connected internally, and TR is falling edge
sensitive instead of level sensitive). There is no 557.

The NE555 parts were commercial temperature range, 0 °C to +70 °C, and the SE555 part
number designated the military temperature range, −55 °C to +125 °C. These were
available in both high-reliability metal can (T package) and inexpensive epoxy plastic (V
package) packages. Thus the full part numbers were NE555V, NE555T, SE555V, and
SE555T. It has been hypothesized that the 555 got its name from the three 5 kΩ resistors
used within, but Hans Camenzind has stated that the number was arbitrary.

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Pin Diagram

The connection of the pins for a DIP package is as follows:

Pin Name Purpose

1 GND Ground, low level (0 V)

2 TRIG OUT rises, and interval starts, when this input falls below 1/2 of CTRL voltage.

3 OUT This output is driven to approximately 1.7V below +VCC or GND.

4 RESET
A timing interval may be reset by driving this input to GND, but the timing
does not begin again until RESET rises above approximately 0.7 volts. Overrides TRIG
which overrides THR.

5 CTRL "Control" access to the internal voltage divider (by default, 2/3 VCC).

6 THR The interval ends when the voltage at THR is greater than at CTRL.

Open collector output; may discharge a capacitor between intervals. In phase

7 DIS
with output.

8 VCC Positive supply voltage is usually between 3 and 15 V.

Note-PIN 5 is also called the CONTROL VOLTAGE pin by applying a voltage to the
CONTROL VOLTAGE input you can alter the timing characteristics of the device. In most
applications, the CONTROL VOLTAGE input is not used. It is usual to connect a 10 nF

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capacitor between pin 5 and 0 V to prevent interference. The CONTROL VOLTAGE input
can be used to build an astable with a frequency modulated output.

SPECIFICATION

These specifications apply to the NE555. Other 555 timers can have
different specifications depending on the grade (military, medical, etc.).

Supply voltage (VCC) 4.5 to 15 V

Supply current (VCC = +5 V) 3 to 6 mA

Supply current (VCC = +15 V) 10 to 15 mA

Output current (maximum) 200 mA

Maximum Power dissipation 600 mW

Power consumption (minimum operating) 30 mW@5V, 225 mW@15V

Operating temperature 0 to 70 °C

SINGLE PHASE AC MOTOR

An AC motor is an electric motor driven by an alternating current.

It commonly consists of two basic parts, an outside stationary stator having coils supplied
with alternating current to produce a rotating magnetic field, and an inside rotor
attached to the output shaf that is given a torque by the rotating field.

There are two main types of AC motors, depending on the type of rotor used. The first
type is the induction motor, which runs slightly slower than the supply frequency. The
magnetic field on the rotor of this motor is created by an induced current. The second
type is the synchronous motor, which does not rely on induction and as a result, can
rotate exactly at the supply frequency or a sub-multiple of the supply frequency. The
magnetic field on the rotor is either generated by current delivered through slip rings or
by a permanent magnet. Other types of motors include eddy current motors, and also

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AC/DC mechanically commutated machines in which speed is dependent on voltage and
winding connection

Induction motor has a rotating (relative to the rotor) magnetic field on the rotor. In a
squirrel cage motor, this field is created because the motion of the stator field relative to
the shorted rotor cage induces currents in the rotor. These currents generate the rotor
field, which interacts with the stator field to create torque. A wound-rotor induction
machine has rotor windings similar to a synchronous machine, in which currents are
induced by the rotating stator field. Induction motors always rotate in some narrow
speed range that is less than synchronous speed. This speed difference, which is
necessary to generate the rotor field, is called the "slip." Low slip machines, which turn
at very near synchronous speed, are more efficient than high slip machines, but have
lower starting torque. Induction machines can produce some torque at zero speed, so
they are capable of starting themselves if the load torque is low enough at zero speed.
The torque-speed characteristic of induction machines at rated speed has a negative
slope (as speed decreases, torque increases). As a result, induction machines do not
require controls to operate - the feedback mechanism is built into the machine.
The winding resistance a wound-rotor induction machine can be varied by connecting
resistors to the rotor windings via the slip rings. This allows the torque-speed
characteristics of the wound-rotor machine to be varied as needed (e.g., high resistance
and high slip for high starting torque and then low resistance and low slip for high
efficiency at rated speed).
The absence of a rotor winding makes squirrel cage induction machines significantly
cheaper to manufacture than synchronous machines (or wound-rotor induction
machines). Squirrel cage machines are extremely rugged because of the lack of a wound
rotor (the cage is usually cast right into the rotor laminations), and the lack of slip rings
makes them more suitable for explosive environments because there is no arcing
mechanism. The circulating currents in an induction machine rotor lead to resistive
losses that make induction machines less efficient that synchronous motor.

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MAIN CHARACTERSTICS OF INDUCTION MOTOR:

 Wound-rotor or squirrel cage to generate the rotor magnetic field.

 Rotor magnetic field rotates with respect to the rotor.

 Always turn at less than synchronous speed.

 Do not require control.

 Much cheaper to produce (true for squirrel cage machines).

 Self-starting.

 Less efficient than synchronous machines.

 More suitable for explosive environments.

 No maintenance (for squirrel cage machines).

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