A Practical Training Report on

AN OVERVIEW OF THE GAS POWER PLANT

NTPC FARIDABAD
Submitted By
ANIL JADON
Roll No. 1204320011
EE VII Semester

To

Mr. V K Bhatia
Head, Training Department
NTPC , FARIDABAD

BUNDELKHAND INSTITUTE OF ENGINEERING AND TECHNOLOGY

EE , DEPARTMENT
June –July 2015
 1. ABOUT THE COMPANY

Figure 1.1: NTPC logo

Corporate Vision
A world class integrated power major, powering India’s growth,with increasing global
presence.
Core Values: (BE COMMITTED)
B-Business Ethics
E-Environmentally and Econamically Sustainable
C-Customer Focus
O-Organizational Pride
M-Mutual Respect and Trust
I-Innovation and Speed
T-Total Quality For Excellence
T-Transparent and Respected Organization
E-Enterprising
D-Devoted
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 the balance 10.5% is held by
FIIs, Domestic Banks, Public and others.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. 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 43,582 MW through its 17 coal based (31,445
MW), gas based (3,955 MW), 3 Hydro based (1,328 MW) and 7 Joint Venture Projects
(5,754 MW). NTPC’s share on 31 Mar 2007 in the total installed capacity of the country was
20.18% and it contributed 28.50% of the total power generation of the country during 2006-
07

Figure 1.2: NTPC generation growth

 2. INTRODUCTION OF NTPC FARIDABAD

2.1 Location
Located near village Mujedi & Neemka in Faridabad district of Haryana State.

2.2 Major Milestones

 Ever since then honorable Prime Minister Sh. I.K. Gujral laid down the foundation
stone on 03rd august 1997.
 First two units of 138MW were commissioned on 21st Jan 2000 and 22nd March,
2000 and one unit of 156MW was commissioned on 16th July 2001 by Haryana
Vidyut Prasaran Nigam.
 Faridabad project was taken over by NTPC from HVPN on 13th Feb, 2002.
 It is the only power plant in this country to supply its entire power to a state i.e.
Haryana rather than to the national grid.

Figure 2.1: Plant overview

2.3 Installed Capacity

 Stage I (GT) = 2 X 138 MW
 Stage II (ST) = 1 X 156 MW
2.4 Production source
2.4.1 Inputs Water Source :
Rampur Distributaries of Gurgaon Canal

2.4.2 Fuel:
 Natural Gas (Main Fuel) (To be piped from HVJ pipeline by GAIL)
 Naphtha (Alternate Fuel)
 High Speed Diesel

2.5 Requirements
 Gas – average 1.58 at 68.5% PLF & 2.30 at 100% PLF
 Natural Gas 6.79 KG/Sec., Naphtha 6.58 KG/Sec
 Water – 700 tones/ hr / unit

2.6 Anti-Salient Features

 Cost of Generation: Rs. 2.05 / Kwh
 Mode of Operation: Base Load
 Rated Output: 135 MVA for GTG & 191.6 MVA for STG
 Rated Terminal Vol.: 10.5 KV for GTG & 15.75 KV FOR STG
 Rated Speed: 3000 rpm
 Type of Cooling: Air Cooled
 Black start facility:3.5 MW Diesel Generator Set: 2000 rpm
 1kw power = 1975kcal of fuel
 3.PARTS OF THE POWER PLANT

3.1 Combined Cycle Power Generation

A gas power station turns the chemical energy in natural gas into electrical energy that can be
used in homes and business .Natural gas is pumped into the gas turbine, where it is mixed
with air and burned, converting its chemical energy into heat energy. As well as heat, burning
natural gas produces a mixture of gases called the combustion gas. The heat makes the
combustion gas expand.

In the enclosed gas turbine, this causes a build-up of pressure .The pressure drives the
combustion gas over the blades of the gas turbine, causing it to spin, converting some of the
heat energy into mechanical energy .A shaft connects the gas turbine to the gas turbine
generator , so when the turbine spins, the generator does too. The generator uses an
electromagnetic field to convert this mechanical energy into electrical energy .After passing
through the gas turbine, the still-hot combustion gas is piped to the heat recovery steam
generator. Here it is used to heat pipes full of water, turning the water to steam, before
escaping through the exhaust stack.

Natural gas burns very cleanly, but the stack is still built tall so that the exhaust gas plume
can disperse before it touches the ground .This ensures that it does not affect the quality of
the air around the station. The hot steam expands in the pipes, so when it emerges it is under
high pressure.
These high-pressure steam jets spin the steam turbine , just like the combustion gas spins the
gas turbine. The steam turbine is connected by a shaft to the steam turbine generator , which
converts the turbine’s mechanical energy into electrical energy .After passing through the
turbine, the steam comes into contact with pipes full of cold water .Here water is pumped
from Rampur distributaries of gurgaon canal. The cold pipes cool the steam so that it
condenses back into water. It is then piped back to the heat recovery steam generator to be
reused.

Finally, a transformer converts the electrical energy from the generator to a high voltage.
The national grid uses high voltages to transmit electricity efficiently through the power lines
to the homes and businesses that need it. Here, other transformers reduce the voltage back
down to a usable level.

Figure 3.1: Combined Cycle Power Generation

Figure 3.2: Flow diagram depicting process of conversion of Natural Gas to Electricity
The above diagram depicts the process of conversion of natural gas to electricity. It is a
combined cycle which utilizes the heat of the fuel gas to heat the water and operate the steam
turbine.
The step by step description of the process and the machinery is as follows:
3.1.1. Air Intake System:
The air intake system consists of huge suction pumps in order to meet the air requirements.
The air to fuel ratio is 11:1. Thus the amount of air being taken in is controlled so as to keep
this ratio constant.

Figure 3.3: The view of air intake system at NTPC Faridabad

3.1.2. Air filters:

The air obtained from the environment contains numerous pollutants and unwanted
compounds which may harm the machinery and reduce the efficiency of the system. These
unwanted compounds may also react with the surface of the machinery and cause scaling
which would subsequently reduce the lifetime of the machinery. To overcome this problem,
the air is passed through the filter section. This section consists of an array of 576 filters to
eliminate all the unwanted particles and compounds present in the air.

3.1.3. Air compressor

The filtered air is then passed through the compressor section. The compression of air takes
place in 16 stages. The compression reduces the temperature of air. To compensate the heat
loss and prevent the temperature shock in the next stage, heat addition is done in the next
stage of combustion.

Figure 3.4: A sectional view of an air compressor

3.1.4. Combustion chamber

After compression, the air is sent to the combustion chamber where 11 parts of air is burnt
with one part of natural gas. This leads to the expansion of air which is used to rotate the
turbine.
Each turbine section is preceded by two combustors. Each combustor consists of eight
burners.

Figure3.5: cross- sectional view of a combustor used in the combustion chamber.

Fuel enters the front of the burner as an atomized spray or in a pre-vaporized form. Air flows
in around the fuel nozzle and through the first row of combustion air holes in the liner. Air
near the burner nozzle stays close to the front liner wall for cooling and cleaning purposes.
Air entering the opposing liner holes mixes rapidly with the fuel to form a combustible
mixture. Air entering the forward section of the liner re-circulates and moves upstream
against the fuel spray. During combustion, this action permits rapid mixing and prevents
flame blowout by forming a low-velocity stabilization zone. This zone acts as a continuous
pilot for the rest of the burner. Air entering the downstream part of the liner provides the
correct mixture for combustion. This air also creates the intense turbulence necessary for
mixing the fuel and air and for transferring energy from the burned to the un-burnt gases.
Since an engine usually has two ignition plugs, cross ignition tubes are necessary in the can
and can-annular types of burners. These tubes allow burning to start in the other cans or inner
liners.
3.1.5. Gas turbine

It is a single shaft (with line compressive unit). It is a 50 Hz; 135MW machine which runs on
natural gas could also be operated on the liquid Naphtha. The gas turbine is very heavy,
industrial type, within line compressor multistage flow type. The combustion chamber is of
annular type.

Figure 3.6: Gas Turbine

According to the flow of the air; compressor is placed first, combustion chamber is next to it
and turbine at the end of gas turbine. Two bearings are placed to support the shaft of the
machine, these turbines are provided at the compressor starting end, and other are placed at
the turbine end. The shaft of the unit is provided with the blades in the turbine region.
3.1.6. Generator
The rotation of gas turbine leads to the rotation of the rotor part of the generator which is
connected to the same shaft as that of the turbine.
 Figure 3.7: Turbine and the generator mounted on a single shaft

3.1.7. Step up transformer

The electricity is generated at 10.5KV. But this voltage is very less for the purpose of
transmission over a long distance and hence the step-up transformer is used to step up the
voltage from 10.5KV to 220KV.

Figure 3.8: Step Up Transformer

3.1.8. Unit auxiliary transformer

For the purpose of running the machinery of the plant and exciting the generator, the power
obtained from the gas turbine is utilized. Since the machinery is operated at 6.6KV, the
voltage is first stepped down from 10.5KV to 6.6KV using the unit auxiliary transformer and
then supplied within the plant.
 Figure 3.9: An auxiliary transformer

3.1.9. High pressure boiler drum

The flue gas from the turbine has a very high temperature of 5400 o C. This is utilized to heat
the water in the boiler drums. High power boiler drum absorbs most of the heat from the flue
gas and thus generates high power steam.

3.1.10. Low pressure boiler drum

The remaining heat is absorbed by the low power boiler drum. Thus low power steam is
generated.
Both the low power and high power steams are sent to the steam turbine.

3.1.11. Steam turbine

The plant is provided with one steam turbine generating unit. The turbine is a 3000 rpm
condensing set without any extraction for feed heating. It is a 160 MW, 50 Hz two cylinder
condensing type turbines. The first cylinder (H.P) is a single flow type 25 reactions stages
and the second cylinder (L.P) is a double flow with 7 reaction stages. It is provided with two
main and two LP stop and control valves. The H.P and L.P sections have individual turbine
rotors, which are connected to each other, and the generator with rigid couplings.
 Figure 3.10: A steam turbine

3.1.12. Condenser
The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to
be pumped. If the condenser is made cooler, the pressure of the exhaust steam is reduced and
efficiency of the cycle increases.
The surface condenser is a shell and tube heat exchanger in which cooling water is circulated
through the tubes. The exhaust steam from the low pressure turbine enters the shell where it
is cooled and converted to condensate (water) by flowing over the tubes.

Figure 3.11: Condenser

For best efficiency, the temperature in the condenser must be kept low practically in order to
achieve the lowest possible pressure in the condensing steam. Since the condenser
temperature can be kept below 100°C, where the vapour pressure of water is much less than
atmospheric pressure, the condenser generally works under vacuum. Thus two vacuum
pumps are used to maintain the vacuum pressure of 0.9 Kg/cm2. A third vacuum pump is
kept on standby in case of emergency.
The water thus condensed is sent to the de-aerator for the removal of air. This is done by the
condensate extraction pumps.

3.1.13. Steam turbine generator

As the thrust is created on the steam turbine blades, the rotor section of the generator to
which the turbine is connected, is rotated due to the rotation of the turbine shaft. This
generates power of 156 MW and a voltage of 15.75 KV is generated which is then stepped up
at the next stage and sent for transmission.
Constructional view

Figure 3.12 : Constructional view of Heat Recovery Steam Generator

 Figure 3.13 :A view of the steam turbine generator

3.1.14. Waste Heat Recovery Steam Generator

The waste heat generator are unfired, heat recovery type design to accept the maximum
exhaust temperature along with flue gas flow from the turbine. It is a natural circulation dual
unit. All heat transfer surface are of fin type. The feed control system is located in between
the economizer and drain to eliminate the possibility of streaming in the economizer and to
enable operation with zero approach point thereby increasing in the efficiency of the combine
cycle plant. A condensate preheated is added to low temperature zone of WHRG. There are
two types of steam produced in this unit (H.P & L.P).
 Figure 3.14: WHRSG

3.1.14. Step up transformer

The voltage generated from the steam turbine is 15.75 KV which is very less for the purpose
of transmission over a long distance. The voltage is thus stepped up using a voltage step up
transformer.

Figure 3.15: A typical step up transformer

3.1.15. De-aerator
The water from the condenser is led here by the condensate extraction pumps. The de-
aerating boiler feed water system eliminates the need of expensive oxygen scavenger
chemicals and also offers the following advantages:
  Removes carbon dioxide as well as oxygen.
 Raises the boiler feed water temperature, eliminating thermal shock in boilers.
 Improves overall boiler room efficiency.
 Feed water pumps are sized for each individual application - assuring total
compatibility and optimum operation.

Figure 3.16: De-aerator

3.1.16. Feed storage

The de-aerated water is then stored into the feed storage tank and is pumped out when
required.
3.1.17. Boiler feed pumps
They are used to pump the water from the feed storage tank to the respective boiler drums.
They are classified as high and low pressure boiler feed pumps based on the boiler drum to
which they pump the water.
3.1.18. Cooling towers
A cooling tower is equipment used to reduce the temperature of a water stream by extracting
heat from water and emitting it to the atmosphere. Cooling towers make use of evaporation
whereby some of the water is evaporated into a moving air stream and subsequently
discharged into the atmosphere.
Figure 3.17: Cooling towers
 4. FUEL
Gas turbines are capable of burning a range of fuels including Naphtha, crude oil and natural
gas. Selection of fuel depend upon several factors including availability of fuel, fuel cost,
cleanliness of the fuel. Natural gas is an ideal fuel because it provides efficiency and
reliability with low operation and maintenance cost. Liquid fuels particularly heavy oils;
usually contain contaminants, which cause corrosion and fouling in gas turbine.
Contaminants which cannot be removed from fuel may leave deposits in gas turbine, which
reduces the performance and adds to the maintenance cost.
Duel fuel system is commonly used, enabling the gas turbine to burn up the fuels when
primary fuel sources are not available. Duel fuel system can be designed to fire both fuels
simultaneously.
4.1. Natural gas
Natural gas is an ideal fuel in gas turbine. It contains primarily Methane (CH 4 ) other gases
are ethane (C 2 H6 ), Nitrogen (N 2 ), Carbon dioxide (CO 2 ) and Sulphur(S). It has following
advantages:

For FGPP, This gas comes from Bombay High through medium of pipelines and one pipeline
from Village Chhainsa (Faridabad).
 Fig 4.1:Pipelines of gas source

4.2. Naphtha
FGPP works on natural gas but if there is shortage of natural gas then plant is run on
Naphtha. Naphtha as compared to natural gas has less calorific value but there is no alternate
fuel other than Naphtha. It is cheaper than any other fuel and the amount of flue gases that
comes out of the Naphtha can also be sent out to boiler to boil the water for manufacturing of
steam for running the steam turbine.
 5. ELECTRICAL SYSTEM

5.1 SWITCHYARD

Figure 5.1: Switchyard of NTPC

The switch yard is the place from where the electricity is send outside. We know that
electrical energy can’t be stored like cells, so what we generate should be consumed
instantaneously. But as the load is not constant, therefore we generate electricity according to
need i.e. the generation depends upon load. It has both outdoor and indoor equipments .

5.1.1. Outdoor Equipments

 Bus Bar
 Circuit Breaker
 Lightening Arrester
 Earth Switch
 Capacitor Voltage Transformer
 Wave Trap
 PLCC
  Current Transformer
 Isolators
 Potential Transformer

5.1.2. Indoor Equipments

 Relays
 Control Panels

5.1.1.1 Bus Bar

There are three buses viz. two main buses (bus 1 and bus 2) and one transfer bus. The two
main buses are further divided into two sections thus giving us a total of five buses. Bus bars
generally are of high conductive aluminum conforming to IS-5082 or copper of adequate
cross section .Bus bar located in air –insulated enclosures & segregated from all other
components .Bus bar is preferably cover with polyurethane.

Figure 5.2: Bus Bar

5.1.1.2 Circuit Breaker

The code for circuit breaker is 52. An electric power system needs some form of switchgear
in order to operate it safely & efficiently under both normal and abnormal conditions. Circuit
breaker is an arrangement by which we can break the circuit or flow of current. A circuit
breaker in station serves the same purpose as switch but it has many added and complex
features. The basic construction of any circuit breaker requires the separation of contact in an
insulating fluid that servers two functions:

 It extinguishes the arc drawn between the contacts when circuit breaker opens.
 It provides adequate insulation between the contacts and from each contact to earth.
The insulating fluids commonly used in circuit breakers are:
 Compressed air
 Oil which produces hydrogen for arc excitation.
 Vacuum
 Sulphur hexafluoride (SF6 ) There are two makes of Circuit Breakers used at NTPC
Faridabad switchyard:

i. SF6 Circuit Breaker – manufactured by ALSTOM

ii. Gas Circuit Breaker – manufactured by CGL

Figure 5.3:Circuit Breaker

5.1.1.3 Lightening Arrester

These are provided to combat the effect of over voltages and surges caused due to lighting
strokes on the transmission lines. These are generally provided at the end near the instrument
which we want to protect. The lightening arrestors provide an easy path to the surge current
to the ground thereby not 36 letting the Equipments to fail. It saves the transformer and
reactor from over voltage and over currents. It has a round metal cap type structure on the top
called CORONA RING, meant for providing corona losses. A meter is provided which
indicates the surface leakage and internal grading current of arrester.

 Green – arrester is healthy

 Red – arrester is defective

In case of red, we first de-energize the arrester and then do the operation.

Figure 5.4: Lightning Arresters

5.1.1.4 Air Break Earthling Switch

These are used to ground the circuit and to discharge the CB when CB is in off condition.
The code of earthling switch is 5, 6, 7.The work of this equipment comes into picture when
we want to shut down the supply for maintenance purpose. This help to neutralize the system
from induced voltage from extra high voltage. This induced power is up to 2KV in case of
400 KV lines.
 Figure 5.5:Air Break Earthling Switch

5.1.1.5 Capacitor Voltage Transformer (CVT)

The carrier current equipment can be connected via the capacitor of CVT. Thereby there is no
need of separate coupling capacitor. The reactor connected in series with the burden is
adjusted to such a value that at supply frequency it resonates with the sum of two capacitors.
This eliminates the error. CVT is attached at end of each transmission, line and buses. The
CVT is used for line voltage measurements on loaded conditions. The basic construction of a
cvt is as follows. Each CVT consists of a coupling capacitor (CC) which acts as a voltage
driver and an Electro Magnetic Unit (EMU) which transforms the high voltage to standard
low voltage. Depending on the system voltage the CC can be a single or a multi stack unit.
245 kV & 420kV CVTs no normally comprise of 2 units. Make Voltage Motor volt (ac)
Control volt (dc) S & S power 245 kV 415 volts 220 volts .The main points of difference
between a CVT and a potential transformer (PT) is that in a PT full line voltage is impressed
upon the transformer while in cvt line voltage after standard reduction is applied to the
transformer. It is used for three purposes:

 Metering
 Protection
 PLCC
 Figure 5.6: CVT

5.1.1.6 Wave Trap

It is used in PLCC system to trap frequency higher than 50 Hz. It is lightly inductive having
very less resistance. It is attached at each end of transmission line. It is of cylindrical shape
mounted on top of the transmission line.

Figure 5.7: Wave Trap

5.1.1.7. PLCC (Power Line Carrier Communication)

In addition to power supply transfer, transmission line is also used for communication
purpose. This is done by PLCC system. Here line conductors itself are used as channel for
carrying information between two end of line. The PLCC system is used to trap the frequency
higher than 50 Hz through high inductance and low resistance along with a coupling
capacitor. The main components of PLCC are:-
 Wave trap
 Co-axial cable
 CVT
  PLCC cabinet
 LMU ( Line matching Unit)

5.1.1.8. Current Transformer (CT)

These are used for stepping down AC current from higher value to lower value for
measurement, protection and control. Here N2 gas is used to prevent oil from moisture. Its
secondary winding has 5 cores. Terminal 1,2,4,5  protection 3 Metering Turns ratio – 800/1
5.1.1.9. Isolators
The isolators can be thought of switches that can either make or break the circuit at the
operator’s wish. Sequence of operation while opening / closing a circuit:
While opening:
 open circuit breaker
 open isolator
 close earthing switch (if any)

While closing:
 ensure circuit breaker is open
 close isolator
 open earthing switch
 Close circuit breaker.

It is used as off line circuit breaker. It is normally used for purpose of isolating a certain
portion when required for maintenance. It operates at 2000 A. In switchyard there are 3 types
of isolators:
 Line isolator
 Transfer bus isolator
 Bus isolator
 Figure 5.8:Isolator

5.2 TRANSFORMERS
The transformer is a device that transfers electrical energy from one electrical circuit to
another through the medium of magnetic field and without the change of frequency. It is an
electromagnetic energy conversion device, since the energy received by the primary is first
converted to magnetic and is then reconverted to electrical energy in the secondary. Thus
these windings are not connected electrically but coupled magnetically. Its efficiency is in the
range of 97 to 98 %.
5.2.1 Transformer accessories
(a) Conservator: with the variation of temperature there is a corresponding variation in the
volume of oil due to expansion and contraction of oil caused by the temperature change. To
account for this, an expansion vessel called the conservator is connected to the outside
atmosphere through a dehydrating breather to keep the air in the conservator dry. An oil
gauge shows the level of oil in the conservator.

(b) Breather: it is provided to prevent the contamination of oil in the conservator by the
moisture present in the outside air entering the conservator. The outside air is drawn into the
conservator every time the transformer cools down which results in the contraction of the
volume occupied by the oil in the conservator. The breather contains a desiccators usually
Silica gel which has the property of absorbing moisture from the air. After sometime silica
gel gets saturated and then it changes it colour from purple to pink indicating that it has
become saturated and hence needs to be replaced or regenerated.
(c) Relief vent:
In case of severe internal fault in the transformer, the pressure may be built to a very high
level which may result in the explosion in the tank. Hence to avoid such condition a relief
vent is provided with a bakelite diaphragm which breaks beyond certain pressure and releases
the pressure.
(d) Bushings:
They consist of concentric porcelain discs which are used for insulation and bringing out the
terminals of the windings from the tank.
(e) Buchcholz relay:
Buchholz relay in transformer is an oil container housed the connecting pipe from main
tank to conservator tank.

Figure 5.9:buchcholz relay

this is a protection scheme for the transformer to protect of against anticipated faults. It is
applicable to the oil immersed transformer and depends on the fact that transformer
breakdowns are always preceded by violent generation of gas which might occur due to
sparking or arcing.
(f) Temperature indicators:
Transformers are provided with two temperature indicators that indicate the temperature of
the winding and that of the oil in the transformer for an oil filled transformer.
The temperature indicators are also protective in nature whereby the first create an alarm and
then trip the respective transformer in case the temperature of the respective parts rises
beyond a certain value.
(g) Tap changers:
These are also provided and are mounted on the transformer. In case some kind of load
fluctuations the taps can be changed or adjusted as per the need. There are two types of tap
changers: On load tap hanger and off load tap changer.
5.2.1 Cooling Of Transformers
Heat is produced in the transformers due to the current flowing in the conductors of the
windings and on account of the eddy current in the core and also because of the hysteresis
loss. In small dry type transformers the heat is directly dissipated to the atmosphere. In oil
immersed systems oil serves as the medium for transferring the heat produced. Because of the
difference in the temperatures of the parts of the transformers circulating currents are set. On
account of these circulating currents hot oil is moved to the cooler region namely the heat
exchanger and the cooler oil is forced towards the hot region. The heat exchangers generally
consist of radiators with fins which might be provided with forced or natural type air
circulation for removal of heat. The oil in oil immersed transformers may also be of forced or
natural circulation type. The oil used for cooling is silicone oil or a mixture of naphthalene
and paraffin. When forced oil circulation is used then pumps are used for the circulation of
the oil. The oil forced air forced type cooling is used in large transformers of very high KVA
rating.

Simple Cooling
AN:
Natural cooling by atmospheric circulation, without any special devices. The transformer
core and coils are open all round to the air. This method is confined to very small units at a
few kV at low voltages.
AB:
In this case the cooling is improved by an air blast, directed by suitable trunking and
produced by a fan.
ON:
The great majority of transformers are oil-immersed with natural cooling, i.e. the heat
developed in the cores and coils is passed to the oil and thence to the tank walls, from which
it is dissipated.
OB:
In this method the cooling of an ON-type transformer is improved by air blast over the
outside of the tank.
OFN:
The oil is circulated by pump to natural air coolers.
OFB:
For large transformers artificial cooling may be used. The OFB method comprises a forced
circulation of the oil to a refrigerator, where it is cooled by air-blast.
OW:
An oil-immersed transformer of this type is cooled by the circulation of water in cooling
tubes situated at the top of the tank but below oil-level.
OFW:
Similar to OFB, except that the refrigerator employs water instead of air blast for cooling the
oil,
which is circulated by pump from the transformer to the cooler.
Mixed Cooling ON/OB:
As ON, but with alternative additional air-blast cooling. ON/OFN, ON/OFB, ON/OFW,
ON/OB/OFB, ON/OW/OFW. A transformer may have two or three ratings when more than
one method of cooling is provided. For an ON/OB arrangement these ratings are
approximately in the ratio 1/1.5; for ON/OB/OFB in the ratio 1/1.5/2.
5.2.2 Main Transformers
1) Generator Transformer:
This is a step up transformer. This supply gets its primary supply from generator and its
secondary supplies the switchyard from where it is transmitted to grid. This transformer is oil
cooled. The primary of this transformer is connected in star. The secondary is connected in
delta. These are two in number.
2) Station Transformer:
This transformer has almost the same rating as the generator transformer. Its primary is
connected in delta and secondary in star. It is a step down transformer. These are 4 in
number.
3) Unit Auxiliary Transformer:

This is a step down transformer. The primary receives from generator and secondary supplies
a 6.6 KV bus. This is oil cooled. These are 10 in number. iv. Neutral Grounded Transformer:
This is used to ground the excess voltage if occurs in the secondary of UAT in spite of rated
voltage.
5.3 D.C SYSTEM
5.3.1 Requirement of DC System
There are some auxiliaries which need to run even when the ac supply fails such as seal oil
pumps, the scanner system, valve control, lights, etc. So we require the DC system. All the
circuit breakers in the power plant operate on DC. The DC system comprises of batteries,
chargers & control circuit to maintain a continuous supply for the DC feeders. There are five
units in unchahar power plant and in each unit separate battery rooms are made from which
we have 220V as well as 24V DC supply.
5.3.2 Description of battery:
1. Capacity = 220 V (1400 AH) / 24 V (400 AH)
2. Per unit cell = 2.2 V
3. Battery plate:
 Positive terminal = PbO2
 Negative terminal = Pb
 Electrolyte = H2SO4
4. Reactions occurring in the battery:
i. At the time of charging:
 At positive plate – PbSO4 + SO4 + 2H2O = PbO2 + 2H2O
 At negative plate – PbSO4 + H2 = Pb + H2S
ii. At the time of Discharging:
 At positive plate – PbO2 + H2 + H2SO4= PbSO4 + 2 H2O
 At negative plate – Pb + SO4= PbSO4

Battery charger Battery charger normally operates in two modes.

 Float charging:

It is constant voltage mode and works as a trickle charger. Boost charging: It is constant
current mode and works as a quick charger.
 Trickle Charger

It operates at 220V. It is used for continuous charging of the battery. Full time battery is
charged by the trickle charger and remains in float condition. Quick charger – It is also
known as Boost Charger. This is used at the time of overhauling.
5.4 SWITCHGEAR
Switchgear is an electrical functional switch used for starting any drive and provide
protection to the drive during on load condition. It is of two types:-
 Low tension switchgear (below 1000 V)
 High tension switchgear (above 1000 V)

5.4.1 L.T Switchgear OPERATING VOLTAGE- 415VOLT

The main components are:
 Relays: the purpose of protective relaying systemas m is to operate the circuit breaker so as
to disconnect only the faulty equipment from the system as quickly as possible thus
minimizing trouble damage caused by faults when they do occur. The general relay used is
BMR (Bi-Metallic Relay). It trips due to thermal overloading when overcurrent passes
through the bimetallic strips causes different expansions in different parts as a result the BMR
strip is bent.
 Contactors: these are used on-load operations under normal conditions. Contactor is a
mechanical switching device capable of making carrying and breaking electric current under
normal circuit conditions including operating overload conditions
 Isolators: These are disconnecting switches used for off-load operations. These are operated
manually. Before operation power is switched off. Isolators are kept in closed position when
the system components are in operation. During any maintenance work isolators are kept
open.
 Fuses: It is a device used in circuit for protecting electrical equipments against overload or
short circuit. The fuse wire melts when an excessive current flows in the circuit and thus
isolates the faulty device from the supply circuit. 10.2
5.4.2 H.T. Switchgear OPERATING VOLTAGE - 6.6KV
5.4.2.1 Circuit breaker:
For low voltage circuits fuses may be used to isolate the faulty circuit. For voltage higher
than 3.3 kV isolation is achieved by circuit breaker. Requirement of circuit breaker:
 After occurrence of fault the switchgears must isolate the faulty circuit as quickly as
possible i.e. keeping the delay to minimum.
 It should not operate when an over current flows under healthy condition.
Basic principal of operation of circuit breaker:
Circuit breaker consists of a fix contact and sliding contact into which moves a moving
contact. The end of moving contact it attached to a handle that can be manually operated or
may operate automatically with the help of mechanism that has a trip coil energized by
secondary of CT. Under normal condition the secondary of CT is not energized sufficiently to
trip the coil but under false condition the coil is energized fully to operate the trip coil and the
circuit breaker is operated.
 MOCB (Minimum oil circuit breaker)
 SF6 (Sulphur hexafluoride circuit breaker) Here oil and SF6 are used to quench the arc. Bus
ducts: These serve as interconnection between transformer and switchgear and are non-
segregated phase type. These are natural air cooled.
5.4.2.2 Bus coupler:
It acts as interconnection between the two buses. If the supply of one bus fails then the bus
coupler connects the two buses and charges the bus from the other bus. Different relays used:
 Motor protection system
 Earth fault relay
 Over load relay
 Lock out relay
 Check synchronizing relay
 Differential protection relay
 Auxiliary relay

6. DISTRIBUTION OF ELECTRICITY
Table 6.1: Project scope of ntpc

Figure 6.2 line diagram of plant

 7. CONTROL AND INSTRUMENTATION DEPARTMENT
Control and instrumentation in any process industry, can be compared to the nerve system in
the human being .The way the nerve system controlling the operation of various limbs of
human being, C & I in the same way controlling and operating various motors, pumps,
dampers, valves etc. and helping us to achieve our targets. Control and instrumentation, as the
name indicates, is a branch in engineering which deals with various measurement, indication,
transmission and control in different technical fields. The Control & Instrumentation
Department(C&I) is responsible for the operation of all the electronic sensors, actuators and
controllers besides maintaining the pressures, temperatures, level and the flow in the various
tanks, pipes and also in the various heat exchangers present in the plant. It is thus the brain of
the plant.
The main functions of the C&I dept. at NTPC Faridabad are:
1. Measurement and display of various parameters.
2. To control the various parameters by Automatic feedback controlling which involves the
taking of decision based on inputs from measurements by the processor.
3. Protection of various equipments (pumps, generators etc.) and workers from hazards by
automatically tripping a cycle when hazardous conditions are reached.
4. Alarm generation in case of a mechanical or an electrical failure.
The Faridabad plant has outsourced its automaton to various companies on a Package Based
Deal.

Figure: 7.1 C&I department

 8. ADVANTAGE AND PRECAUTION
8.1 Advantage of using Natural Gas for Generating Electricity

1. Less Harmful than Coal or Oil: As compared to petroleum or coal, natural gas causes
less damage to the environment. It is made up of methane and results in less carbon
emissions. In fact emissions of carbon dioxide are 45% lesser than other conventional fuels
and 30% less than oil.

2. Easy Storage and Transport: Natural gas is easier to preserve than other fuels. It can be
stored and transported through pipelines, small storage units, cylinders or tankers on land and
sea.

3. Residential Use: Natural gas can be piped into houses for heating and cooking purposes
and running a variety of appliances. Where there are no pipes, it can be supplied in small
tanks.

4. Vehicle Fuel: Natural gas can be used as a fuel for vehicles (cars, trucks, jet engines). It is
a cleaner, cheaper fuel than diesel or gasoline.

5. Burns Cleaner: Natural gas burns cleaner without leaving any smell, ash or smoke.

6. Instant energy: Natural gas is an economic and instant fuel for heating water and large
areas as well as cooking. It is ideal because it provides precise control and quick results. It
helps in oven cooking as it does not require pre-heating.

7. Precision in Kitchen: Natural gas is the best fuel to power kitchens because of its control,
reliability and precision. A gas flame provides for precise temperature control and variety of
heat settings allowing shift from hot to cold or vice versa, with the turning of the knob.

8. Industrial use: Natural gas is used for producing hydrogen, ammonia for fertilizers and
some paints and plastics.

9. Abundant: It is relatively abundant compared to other fossil fuels, burns more cleanly and
is easy to distribute.
10. Safer: It is lighter than air and tends to dissipate when there is a leakage unlike Propane,
which being heavier than air, collects into explosive pockets.

11. Versatile: It can be used for heating, drying clothes, cooking, backing up generator
power, and many other uses.

12. Cheaper: Natural gas is cheaper than electricity. It is quicker when used for cooking and
heating water and majority of gas appliances are cheaper than electric appliances.

13. Neater: Gas appliances do not create electric fields which are unhealthy near your homes.

14. Used to Produce Electricity: In the U.S., itself, 30% of natural gas is used to produce
electricity.

8.2 Precaution
1. Normally, the natural gas is non toxic. However, if having high content of hydrogen
sulfide; the gas can harm people whom inhale the gas. It can irritate skin, eyes, the
respiratory tract and lung.
2. Fire and explosion. Natural gas can be flammable when it leaks and mixes with air,
cause fire at a right proportion of air and natural gas and there is a source of ignition
or a flame. It can cause explosion if it accumulates in a confined space such as in the
building where there is not enough ventilation.
 9. CONCLUSION
On completion of my vocational training at NTPC Faridabad, I have come to know about
how the very necessity of our lives now a days i.e. how electricity is generated & what all
processes are needed to generate and run the plant on a 24x7 basis. NTPC Faridabad is one
the plants in India to be under highest load factor for the maximum duration of time and that
to operating at highest plant efficiencies. This plant is an example in terms of working
efficiency and management of resources to all other thermal plants in our country. The
operating of the NTPC as compared to the rest of country is the highest with 95 % the highest
since its inception. The training gave me an opportunity to clear my concepts from practical
point of view with the availability of machinery of diverse ratings.
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