SINGRAULI

SUMMER TRAINING REPORT

SUBMITTED BY: SUBMITTED TO:

Amit kumar singh Mr. Mona Subrahmanyam

B.Tech :EEE(G)
Galgotias college of
engg. and tech. Gr. noida
CONTENT:
• Introduction
• Operation
• Stage 1 & 2
• Coal handling plant
• Switchyard
• Reference
ACKNOWLEDGEMENT:
With profound respect and gratitude, I take the opportunity to convey my thanks to complete
training department of NTPC singrauli . I express gratitude to the Program Manager and
other faculty members of Electrical & Electronics Engineering Department of Galgotias
college of engineering and technology for providing this opportunity to undergo industrial
training at National Thermal Power Corporation singrauli sonebhadra.

I am extremely grateful to all the technical staff of NTPC singrauli for their co-operation and
guidance that helped me a lot during the course of training. I have learnt a lot working under
them and I will always be indebted of them for this value addition in me
INTRODUCTION:

ABOUT NTPC

NTPC Limited, the largest thermal power generating company in India, was incepted in
year 1975. It is a public sector company wholly owned by Government of India (GOI). In
a span of 30 years, NTPC has emerged as a major power company of international
repute and standard. NTPC’s core business includes engineering, construction and
operation of power generating stations and providing consultancy to power utilities as
well. Presently, the total installed capacity of NTPC stands at more than 27904
MW, which includes 18 coal and 8 gas/naphtha based power stations.
.

DETAILS OF POWER GENERATION:NTPC (COAL BASED)

• Singrauli Uttar Pradesh - 2000
• Korba Chhattisgarh -2100
• Ramagundam Andhra Pradesh- 2600
• Farakka West Bengal -1600
• Vindhyachal Madhya Pradesh- 3260
• Rihand Uttar Pradesh -2000
• Kahalgaon Bihar -2340
• Dadri Uttar Pradesh -1330
• Talchar Kaniha Orissa- 3000
• Unchahar Uttar Pradesh -1050
• Thermal Orissa -460
• Tanda Uttar Pradesh -440
• Simhadri Andhra Pradesh -1000
• Badarpur Delhi -705
• Sipat-II Chhattisgarh -1000
Total: 24885 MW
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. NTPC has set new benchmarks for the
power industry both in the area of power plant construction and operation .Its providing power
at the cheapest average tariff in the country..

NTPC has been operating its plants at high efficiency levels. Although the company has 19% of
the total national capacity it contributes 29% of total power generation due to its focus on high
efficiency. NTPC’s share at 31 Mar 2001 of the total installed capacity of the country was
24.51% and it generated 29.68% of the power of the country in 2008–09. Every fourth home in
India is lit by NTPC. As at 31 Mar 2011 NTPC's share of the country's total installed capacity is
17.75% and it generated 27.4% of the power generation of the country in 2010–11. NTPC is
lighting every third bulb in India. 170.88BU of electricity was produced by its stations in the
financial year 2005–2006. The Net Profit after Tax on 31 March 2006 was 58.202 billion. Net
profit after tax for the quarter ended 30 June 2006 was 15.528 billion, which is 18.65% more
than that for the same quarter in the previous financial year. It is listed in Forbes Global 2000 for
2011 ranked it 348th I n the world.

About NTPC Singrauli:

Singrauli Super Thermal Power

Station
Singrauli Super Thermal Power Plant is located at Singrauli in Singrauli
district in Indian state of Uttar Pradesh. The power plant is one of the
coal based power plants of NTPC.The unit wise capacity and other details are
as follows.

3. Installed 4. Date of
2. Unit Commissio
1. Stage Capacity
Number ning
(MW)

1st 1 200 1982 February

1st 2 200 1982 November

1st 3 200 1983 March

1st 4 200 1983 November

1st 5 200 1984 February

2nd 6 500 1986 December

2nd 7 500 1987 November

Total Seven 2000

In stage 1 there are five units of 200 Mw
200*5=1000 Mw
In stage 2 there are two units of 500 Mw
500*2=1000 Mw
Total installed capacity =1000+1000= 2000 Mw

OPERATION OF THERMAL POWER

PLANT:
In a thermal power plant, one of coal, oil or natural gas is used to heat the boiler to convert the
water into steam. The steam is used to turn a turbine, which is connected to a generator. When
the turbine turns, electricity is generated and given as output by the generator, which is then
supplied to the consumers through high-voltage power lines.
Detailed process of power generation in a thermal power plant:

1) Water intake:Firstly, water is taken into the boiler through a water source. If water is available
in a plenty in the region, then the source is an open pond or river .If water is scarce, then it is
recycled and the same water is used over and over again.

2) Boiler heating: The boiler is heated with the help of oil, coal or natural gas. A furnace is used
to heat the fuel and supply the heat produced to the boiler. The increase in temperature helps in
the transformation of water into steam.
3) Steam Turbine: The steam generated in the boiler is sent through a steam turbine. The
turbine has blades that rotate when high velocity steam flows across them. This rotation of
turbine blades is used to generate electricity
4) Generator: A generator is connected to the steam turbine. When the turbine rotates, the
generator produces electricity which is then passed on to the power distribution systems.
6) Ash collection system: There is a separate residue and ash collection system in place to
collect all the waste materials from the combustion process and to prevent them from escaping
into the atmosphere.
STAGE 1 & STAGE 2:
Stage 1 consist of five units of 200 Mw generators
i.e. 200*5=1000 Mw
stage 2 consist of two units of 500 Mw generators
i.e. 500*2=1000 Mw
stage 1 and stage 2 consist following sub sections

- Cooling water pump

-Three-phase transmission line
-Step up transformer
- Electrical Generator
-Low pressure steam
-Boiler feed water pump
-Surface condenser
-Intermediate pressure steam turbine
-Steam control valve
-High pressure steam turbine
-Deaerator Feed water heater
-Coal conveyor
-Coal hopper
-Coal pulverizer
-boiler steam drum
-Bottom ash hoper
-Super heater
-Forced draught(draft) fan
-Reheater
- Combustion air intake
-Economizer
-Air preheater
-Precipitator
-Induced draught(draft) fan
-Fuel gas stack

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

1. Cooling towers

Cooling Towers are evaporative coolers used for cooling water or other working medium to
near the ambivalent web-bulb air temperature. Cooling tower use evaporation of water to reject
heat from processes such as cooling the circulating water used in oil refineries, Chemical plants,
power plants and building cooling, for example. The tower vary in size from small roof-top
units to very large hyperboloid structures that can be up to 200 meters tall and 100 meters in
diameter, or rectangular structure that can be over 40 meters tall and 80 meters long. Smaller
towers are normally factory built, while larger ones are constructed on site.
The primary use of large , industrial cooling tower system is to remove the heat absorbed in the
circulating cooling water systems used in power plants , petroleum refineries, petrochemical
and chemical plants, natural gas processing plants and other industrial facilities . The absorbed
heat is rejected to the atmosphere by the evaporation of some of the cooling water in
mechanical forced-draft or induced draft towers or in natural draft hyperbolic shaped cooling
towers as seen at most nuclear power plants.

2.Three phase transmission line

Three phase electric power is a common method of electric power transmission. It is a type of
polyphase system mainly used to power motors and many other devices. A Three phase system
uses less conductor material to transmit electric power than equivalent single phase, two phase,
or direct current system at the same voltage. In a three phase system, three circuits reach their
instantaneous peak values at different times. Taking one conductor as the reference, the other
two current are delayed in time by one-third and two-third of one cycle of the electrical current.
This delay between “phases” has the effect of giving constant power transfer over each cycle of
the current and also makes it possible to produce a rotating magnetic field in an electric motor.
At the power station, an electric generator converts mechanical power into a set of electric
currents, one from each electromagnetic coil or winding of the generator. The current are
sinusoidal functions of time, all at the same frequency but offset in time to give different phases.
In a three phase system the phases are spaced equally, giving a phase separation of one-third
one cycle. Generators output at a voltage that ranges from hundreds of volts to 30,000 volts. At
the power station, transformers: step-up” this voltage to one more suitable for transmission.
After numerous further conversions in the transmission and distribution network the power is
finally transformed to the standard mains voltage (i.e. the “household” voltage).
The power may already have been split into single phase at this point or it may still be three
phase. Where the step-down is 3 phase, the output of this transformer is usually star connected
with the standard mains voltage being the phase-neutral voltage. Another system commonly
seen in North America is to have a delta connected secondary with a center tap on one of the
windings supplying the ground and neutral. This allows for 240 V three phase as well as three
different single phase voltages( 120 V between two of the phases and neutral , 208 V between
the third phase ( known as a wild leg) and neutral and 240 V between any two phase) to be
available from the same supply.
3.Electrical generator
An Electrical generator is a device that converts kinetic energy to electrical energy, generally
using electromagnetic induction. The task of converting the electrical energy into mechanical
energy is accomplished by using a motor. The source of mechanical energy may be a
reciprocating or turbine steam engine, , water falling through the turbine are made in a variety of
sizes ranging from small 1 hp (0.75 kW) units (rare) used as mechanical drives for pumps,
compressors and other shaft driven equipment , to 2,000,000 hp(1,500,000 kW) turbines used
to generate electricity. There are several classifications for modern steam turbines.
Steam turbines are used in all of our major coal fired power stations to drive the generators or
alternators, which produce electricity. The turbines themselves are driven by steam generated in
‘Boilers’ or ‘steam generators’ as they are sometimes called.
Electrical power station use large stem turbines driving electric generators to produce most
(about 86%) of the 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
often 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 after it leaves the boiler is converted into rotational energy as it passes
through the turbine. The turbine normally consists of several stage with each stages consisting
of a stationary blade (or nozzle) and a rotating blade. Stationary blades convert the potential
energy of the steam into kinetic energy into forces, caused by pressure drop, which results in the
rotation of the turbine shaft. The turbine shaft is connected to a generator, which produces the
electrical energy.
STATOR:

The stator winding is made up of insulated copper conductor bars that are distributed around the
inside diameter of the stator core, commonly called the stator bore, in equally spaced slots in the
core to ensure symmetrical flux linkage with the field produced by the rotor. Each slot contains
two conductor bars, one on top of the other. These are generally referred to as top and bottom
bars. Top bars are the ones nearest the slot opening (just under the wedge) and the bottom bars
are the ones at the slot bottom. The core area between slots is generally called a core tooth
ROTOR:

The rotor winding is installed in the slots machined in the forging main body and is distributed
symmetrically around the rotor between the poles. The winding itself is made up of
many turns of copper to form the entire series connected winding.

All of the turns associated with a single slot are generally called a coil. The coils
are wound into the winding slots in the forging, concentrically in
corresponding positions on opposite sides of a pole. The series connection
essentially creates a single multi-turn coil overall, that develops the total ampere-
turns of the rotor (which is the total current flowing in the rotor winding times the
total number of turns)

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
shaft 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 its forming an explosive mixture with
oxygen, proper arrangement for filling, purging and maintaining its purity inside the generator
have to be made. Also, in order to prevent escape of hydrogen from the generator casing, shaft
sealing system is used to provide oil sealing.
The hydrogen cooling system mainly comprises of a gas control stand, a drier, an liquid level
indicator, hydrogen control panel, gas purity measuring and indicating instruments,

4.Boiler feed water pump:

A Boiler feed water pump is a specific type of pump used to pump water into a steam boiler.
The water may be freshly supplied or retuning condensation of the steam produced by the
boiler. These pumps are normally high pressure units that use suction from a condensate return
system and can be of the centrifugal pump type or positive displacement type.

Construction and operation

Feed water pumps range in size up to many horsepower and the electric motor is usually
separated from the pump body by some form of mechanical coupling. Large industrial
condensate pumps may also serve as the feed water pump. In either case, to force the water
into the boiler; the pump must generate sufficient pressure to overcome the steam pressure
developed by the boiler. This is usually accomplished through the use of a centrifugal pump.
Feed water pumps usually run intermittently and are controlled by a float switch or other
similar level-sensing device energizing the pump when it detects a lowered liquid level in the
boiler is substantially increased. Some pumps contain a two-stage switch. As liquid lowers to
the trigger point of the first stage, the pump is activated. I f the liquid continues to drop (perhaps
because the pump has failed, its supply has been cut off or exhausted, or its discharge is
blocked); the second stage will be triggered. This stage may switch off the boiler equipment
(preventing the boiler from running dry and overheating), trigger an alarm, or both.

5 . 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

6. Deaerator
A Dearator is a device for air removal and used to remove dissolved gases (an alternate would
be the use of water treatment chemicals) from boiler feed water to make it non-corrosive. A
dearator typically includes a vertical domed deaeration section as the deaeration boiler feed
water tank. A Steam generating boiler requires that the circulating steam, condensate, and feed
water should be devoid of dissolved gases, particularly corrosive ones and dissolved or
suspended solids. The gases will give rise to corrosion of the metal. The solids will deposit on
the heating surfaces giving rise to localized heating and tube ruptures due to overheating.
Under some conditions it may give to stress corrosion cracking.
Deaerator level and pressure must be controlled by adjusting control valves- the level by
regulating condensate flow and the pressure by regulating steam flow. If operated properly,
most deaerator vendors will guarantee that oxygen in the deaerated water will not exceed 7 ppb
by weight (0.005 cm3/L)

7. Feed water heater

A Feed water heater is a power plant component used to pre-heat water delivered to a steam
generating boiler. Preheating the feed water reduces the irreversible involved in steam
generation and therefore improves the thermodynamic efficiency of the system.[4] This
reduces plant operating costs and also helps to avoid thermal shock to the boiler metal when
the feed water is introduces back into the steam cycle.
In a steam power (usually modeled as a modified Ranking cycle), feed water heaters allow the
feed water to be brought up to the saturation temperature very gradually. This minimizes the
inevitable 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.

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

9. Boiler Steam Drum

Steam Drums are a regular feature of water tube boilers. It is reservoir of water/steam at the top
end of the water tubes in the water-tube boiler. They store the steam generated in the water
tubes and act as a phase separator for the steam/water mixture. The difference in densities
between hot and cold water helps in the accumulation of the “hotter”-water/and saturated –
steam into steam drum. Made from high-grade steel (probably stainless) and its working
involves temperatures 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.

10. 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.

11. 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 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.

12 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.

13. 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.

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.

14. Fuel gas stack

A Fuel gas stack is a type of chimney, a vertical pipe, channel or similar structure through
which combustion product gases called fuel gases are exhausted to the outside air. Fuel gases
are produced when coal, oil, natural gas, wood or any other large combustion device. Fuel gas
is usually composed of carbon dioxide (CO2) and water vapor as well as nitrogen and excess
oxygen remaining from the intake combustion air. It also contains a small percentage of
pollutants such as particulates matter, carbon mono oxide, nitrogen oxides and sulfur oxides.
The flue gas stacks are often quite tall, up to 400 meters (1300 feet) or more, so as to disperse
the exhaust pollutants over a greater aria and thereby reduce the concentration of the pollutants
to the levels required by governmental environmental policies and regulations.
When the fuel gases exhausted from stoves, ovens, fireplaces or other small sources within
residential abodes, restaurants , hotels or other stacks are referred to as chimneys.
15 Transformer:

A transformer is a device that transfers electrical energy from one circuit to another by magnetic
coupling with out requiring relative motion between its parts. It usually comprises two or more
coupled windings, and in most cases, a core to concentrate magnetic flux. An alternating
voltage applied to one winding creates a time-varying magnetic flux in the core, which includes
a voltage in the other windings. Varying the relative number of turns between primary and
secondary windings determines the ratio of the input and output voltages, thus transforming the
voltage by stepping it up or down between circuits. By transforming electrical power to a 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 trough a series of transformer by the time it
reaches the consumer.

Basic principles

The principles of the transformer are illustrated by consideration of a hypothetical ideal

transformer consisting of two windings of zero resistance around a core of negligible reluctance.
A voltage applied to the primary winding causes a current, which develops a magneto motive
force (MMF) in the core. The current required to create the MMF is termed the magnetizing
current; in the ideal transformer it is considered to be negligible, although its presence is still
required to drive flux around the magnetic circuit of the core. An electromotive force (MMF) is
induced across each winding, an effect known as mutual inductance. In accordance with
faraday’s law of induction, the EMFs are proportional to the rate of change of flux. The primary
EMF, acting as it does in opposition to the primary voltage, is sometimes termed the back
EMF”. Energy losses An ideal transformer would have no energy losses and would have no
energy losses, and would therefore be 100% efficient. Despite the transformer being amongst
the most efficient of electrical machines with ex the most efficient of electrical machines with
experimental models using superconducting windings achieving efficiency of 99.85%, energy
is dissipated in the windings, core, and surrounding structures. Larger transformers are generally
more efficient, and those rated for electricity distribution usually perform better than 95%. A
small transformer such as plug-in “power brick” used for low-power consumer electronics may
be less than 85% efficient. Transformer losses are attributable to several causes and may be
differentiated between those originated in the windings, some times termed copper loss, and
those arising from the magnetic circuit, sometimes termed iron loss. The losses vary with load
current, and may furthermore be expressed as “no load” or “full load” loss, or at an intermediate
loading. Winding resistance dominates load losses contribute to over 99% of the no-load loss
can be significant, meaning that even an idle transformer constitutes a drain on an electrical
supply, and lending impetus to development of low-loss transformers. Losses in the transformer
arise from: Winding resistance Current flowing trough the windings causes resistive heating of
the conductors. At higher frequencies, skin effect and proximity effect create additional winding
resistance and losses. Hysteresis losses Each time the magnetic field is reversed, a small amount
of energy is lost due to hysteresis within the core. For a given core material, the loss is
proportional to the frequency, and is a function of the peak flux density to which it is subjected.
Eddy current Ferromagnetic materials are also good conductors, and a solid core made from
such a material also constitutes a single short-circuited turn trough out its entire length. Eddy
currents therefore circulate with in a core in a plane normal to the flux, and are responsible for
resistive heating of the core material. The eddy current loss is a complex function of the square
of supply frequency and inverse square of the material thickness. Magnetostriction Magnetic
flux in a ferromagnetic material, such as the core, causes it to physically expand and contract
slightly with each cycle of the magnetic field, an effect known as magnetostriction. This
produces the buzzing sound commonly associated with transformers, and in turn causes losses
due to frictional heating in susceptible cores. Mechanical losses In addition to magnetostriction,
the alternating magnetic field causes fluctuating electromagnetic field between primary and
secondary windings. These incite vibration with in near by metal work, adding to the buzzing
noise, and consuming a small amount of power. Stray losses Leakage inductance is by itself
loss less, since energy supplied to its magnetic fields is returned to the supply with the next half-
cycle. However, any leakage flux that intercepts nearby conductive material such as the
transformers support structure will give rise to eddy currents and be converted to heat. Cooling
system Large power transformers may be equipped with cooling fans, oil pumps or water-
cooler heat exchangers design to remove heat. Power used to operate the

Types of transformer
Power transformers : Used in transmission network of higher voltages, deployed for step-up
and step down transformer application (400 kV, 200 kV, 110 kV, 66 kV, 33kV,22kV)
Distribution transformers: Used for lower voltage distribution networks as a means to end
user connectivity. (11kV, 6.6 kV, 3.3 kV, 440V, 230V)

Classification
Transformers are adapted to numerous engineering applications and may be classified in many
ways:
• By power level:
(from fraction of a volt-ampere(VA) to over a thousand MVA),
 • By application:
(power supply, impedance matching, circuit isolation),
• By frequency range:
(power, audio, radio frequency(RF))
• By voltage class:
(a few volts to about 765 kilovolts

• By cooling type:
(air cooled, oil filled, fan cooled, water cooled (Natural/ Forced) etc.)
• By purpose:
(distribution, rectifier, arc furnace, amplifier output, etc.).
• By ratio of the number of turns in the coils
(Step-up The secondary has more turns than the primary.
Step-down The secondary has fewer turns than the
• By Connection :
Single phase, Star / star, Star delta etc
• By Construction :
(Core Type Shell Type )

Transformer Insulation

Minor insulation Like inter turn insulation, is achieved using cellulogic paper.
Major insulation Between primary and secondary, phase to phase and inner coil to core. This
is achieved by Bakelite, wooden blocks, cellulogic paper cylinders.
Transformer Oil: derivative or petroleum crude. This has good dielectric strength.
also a good cooling medium and absorbs heat from the windings in transformer
Thus mineral oil has a flash point of 140°C and 160°C fire point. This also 'can Sustain the
combustion with its own energy, once it catches fire. Thus this is unsuitable for the transformer
located indoors. The indoor transformers are filled with a synthetic liquid known as silicate
liquid. This is fire assistant and has flash point well above 300°C
Transformer Oil

NAPTHANIC BASE OILS GENERALLY HAVE HIGHER RESISTIVITY VALUES

WHEN COMPARED TO PARAFFINIC BASE OILS AND HAVE BETTER
OXIDATION STABILITY.
• EQUALLY GOOD PARAMETERS CAN BE ACHIEVED WITH PARAFFINIC
BASE OILS ALSO, WHEN PROPERLY REFINED.
• OIL PARAMETERS ARE IMPORTANT. BASE OF OIL IS NOT
IMPORTANT(NONE OF THE STANDARDS SPECIFY THE BASE OF OIL)
• SUGGESTED IS TO HAVE OIL WITH LOW VISCOSITY AS COMPARED TO
PRESENTLY BEING USED FOR BETTER COOLING AND FOR BETTER OIL
FLOW.
BHEL IS IN THE PROCESS OF FURTHER UPGRADING THE TRANSFORMER OIL
PARAMETERS FOR HIGHER VOLTAGE CLASS TRANSFORMERS TO HAVE
BETTER STABILITY OF OIL CHARACTERISTICS
Accessories & Auxiliaries
Tap Changer(s)-(On load/Off load)
• Tank
• Radiators
• cooling fans, oil pumps, oil to water heat exchangers (Cooling ONAN / ONAF/ OFAF/
OFWF external coolers)
• Bushings
• Buchholz Relay/Oil Surge Relay
• Temperature Indicators- WTI , OTI
• Oil Level Indicators
• Pressure Relief Device
• Marshalling Box/Control cubicle
• Oil Preservation Systems: Conservators (gas sealed, Bellows/membrane sealed)
Breathers
Thermo siphon Filters

Conservator:

Conservator With the variation of temperature there is corresponding variation in the

oil volume. To account for this, an expansion vessel called conservator is added to the
transformer with a connecting pipe to the main tank. In smaller transformers this vessel
is open to atmosphere through dehydrating breathers (to keep the air dry). In larger
transformers, an air bag is mounted inside the conservator with the inside of bag open to
atmosphere through the breathers and the outside surface of the bag in contact with the oil
surface.
SILICA GEL BREATHER
COAL HANDLING PLANT (C.H.P.)
Coal is delivered by highway truck, rail, barge or collier ship. Some plants are
even built near coal mines and coal is delivered by conveyors.

A large coal train called a" unit train" may be a kilo metres (over a mile) long,
containing 60 cars with 100tons of coal in each one, for a total load of 6,000 tons.

A large plant under full load requires at least one coal delivery this size every day.
Plants may get as many as three to five trains a day, especially in "peak season", during the
summer months when power consumption is high.

A large thermal power plant such as the Badarpur Thermal Power Station, New
Delhi stores several million tons of coal for use when there is no wagon supply.
Coal is prepared for use by crushing the rough coal to pieces less than 2 inches (50mm) in
size. The coal is then transported from the storage yard to in-plant storage silos by rubberized
conveyor belts at rates up to 4,000 tons/hour. In plants that burn pulverized coal, silos feed coal
pulverisers (coal mill) that take the larger 2inch pieces grind them into the consistency of face
powder, classify them, and mixes them with primary combustion air which transports the coal
to the furnace and preheats the coal to drive off excess moisture content. In plants that do not
burn pulverized coal, the larger 2 inch pieces may be directly fed into the silos which then feed
the cyclone burners, a specific kind of combust or that can efficiently burn larger pieces of fuel
Run-of-Mine (ROM) Coal

The coal delivered from the mine that reports to the Coal Handling Plant is called
Run-of-mine, or ROM, coal. This is the raw material for the CHP, and consists
of coal, rocks, middlings, minerals and contamination. Contamination is usually
Introduced by the mining process and may include machine parts, used consumables and
parts of ground engaging tools. ROM coal can have a large variability of moisture and
maximum particle size.

Coal Handling

Coal needs to be stored at various stages of the preparation process, and conveyed
around the CHP facilities. Coal handling is part of the larger field of bulk material
handling, and is a complex and vital part of the CHP.

Stockpiles

Stockpiles provide surge capacity to various parts of the CHP. ROM coal is
delivered with large variations in production rate of tonnes per hour (tph).
A ROM stockpile is used to allow the wash plant to be fed coal at lower, constant rate.

Stacking

Travelling, lugging boom stackers that straddle a feed conveyor are commonly
used to create coal stockpiles. Stackers are nominally rated in tph (tonnes per hour)
for capacity and normally travel on a rail between stockpiles in the stockyard.
A stacker can usually move in at least two directions typically: horizontally along the rail and
vertically by luffing its boom. Luffing of the boom minimises dust by reducing the
height that the coal needs to fall to the top of the stockpile. The boomis luffed upwards as the
stockpile height grows.

Coal Sampling

Sampling of coal is an important part of the process control in the CHP.

A grab sample is a one off sample of the coal at a point in the process stream, and
tends not to be very representative. A routine sample is taken at a set frequency,
either over a period of time or per shipment.

Screening

Screens are used to group process particles into ranges by size. These size ranges
are also called grades. Dewatering screens are used to remove water from
the product. Screens can be static, or mechanically vibrated. Screen decks can
be made from different materials such as high tensile steel, stainless steel, or
polyethylene

Magnetic Separation

Magnetic separators shall be used in coal conveying systems to separate tramp

iron(including steel) from the coal. Basically, two types are available.

One type incorporates permanent or electromagnets into the head pulley of a belt
conveyor. The tramp iron clings to the belt as it goes around the pulley drum and falls off into
a collection hopper or trough after the point at which coal is charged from the belt
.The other type consists of permanent or electromagnets incorporated into a belt
conveyor that is suspended above a belt conveyor carrying coal. The tramp iron
is pulled from the moving coal to the face of the separating conveyor, which in turn holds and
carries the tramp iron to a collection hopper or trough. Magnetic separators shall be
used just ahead of the coal crusher, if any, and/or just prior to coal discharge to the
in-plant bunker or silo fill system.

Coal Crusher

Before the coal is sent to the plant it has to be ensured that the coal is of uniform
size, and so it is passed through coal crushers.

Also power plants using pulverized coal specify a maximum coal size that can be fed into
the pulverizer and so thecoal has to be crushed to the specified size using the coal
crusher. Rotary crushers are very commonly used for this purpose as they can
provide a continuous flow of coal to the pulverizer.
Pulverizer

Most commonly used pulverizer is the Boul Mill. The arrangement consists of
2stationary rollers and a power driven boul in which pulverization takes place
as the coal passes through the sides of the rollers and the boul

A primary air induced draught fan draws a stream of heated air through the mill
carrying the pulverizedcoal into a stationary classifier at the top of the pulverizer.
The classifier separates the pulverized coal from the un pulverised coal
 SWITCHYARD:
The current transformer:

These transformers are used with low range ammeters to measure currents in high voltage
alternating current circuits. In addition to insulating the instrument from the high voltage line,
they step-down the current in a known ratio. The current or series transformer has a primary coil
of one or more turns of thick wire connected in series with the line whose current is to be
measured. The secondary consists of large number of turns of line wire and connected across
the ammeter terminals. It should be noted that, since the ammeter resistance is very low, the
current transformer normally works short-circuited. If for any reason the ammeter is taken out
of the secondary winding, then this winding must be short-circuited. If this is not done, then due
to the absence of counter amp-turns of the secondary, the unopposed primary m.m.f. will set up
an abnormally high flux in the core, which will produce excessive core loss with subsequent
heating and a high voltage across the secondary terminals. Hence the secondary of a current
transformer should never be left open under any circumstances.

The voltage transformer:

The voltage transformer performs its task, similar to a current transformer. But
unlike the former, it is used to step down the voltage. The voltage transformer is
also used for the calibration purpose, and the same is also employed for the
protection of various devices.
These transformers are extremely accurate-ratio step-down transformers and are
used in conjunction with standard low-range voltmeters whose deflection when
divided by transformation ratio, gives the true voltage on the high-voltage side. In
general, they are of the shell-type and do not differ much from the ordinary two-
winding transformers. For safety, the secondary should be completely insulated
from the high-voltage primary and should be, in addition, grounded for affording
protection to the operator.

Capacitor voltage transformers:

Voltage transformers can work effectively and properly up to a voltage of 33 kV.
But above that voltage, insulation protection becomes a major factor of
consideration, and therefore we apply a capacitor, as shown below. The
arrangement thus illustrated is referred to as a capacitor voltage transformer
(CVT). The same circuitry basically helps to step down the secondary voltage to a
great extent, hence keeping the insulation level to a considerable safe level.
Lightning arresters:
Electrical equipments, which are situated in the switchyard, are open to the
atmosphere, and hence may face situations of high voltages (also referred to as
surge voltages), or lightning. This leads to a major problem, because the
magnitude and intensity of the same is about 4-5 times the normal voltage, and
hence is detrimental for the electrical circuitry situated there. Therefore, in order to
prevent that, we have electrical equipments, referred to as lightning arresters,
which are situated in the switchyard. Whenever such a dangerous situation arises,
the same current is forced to flow through the lightning arresters and hence it goes
to the ground. Hence, the lightning arresters play an important role in the
protection of the electrical equipments, actually situated in the switchyard. They
actually provide the least resistance path during a situation of enormous voltage
flow.
Isolators:
The isolators serve a similar function as the circuit breaker. The only difference is
that a circuit breaker is used to interrupt the fault current when the circuit is on
load, or line-line. But the isolator is used to isolate the circuit, when the circuit is
off load, or dead-line. The isolators are classified as:

1) Bus isolator(or pantograph isolator)

2) Sequential isolator

Refrence
www.wikipedia.com
www.ntpc.co.in
www.google.com
Electrical machines by P.S. Bimbhra