UNIVERSITY OF PETROLEUM & ENERGY STUDIES

SUMMER INDUSTRIAL PROGRAMME

NATIONAL THERMAL POWER CORPORATION,

BADARPUR PLANT

Ishan Tiwari

500023684
R840212012

B.Tech Energy Technology + LL.B [I.P.R]

2012-2018

UNDER THE GUIDANCE OF

Dr. MADHU SHARMA Mr. MANMOHAN SINGH

FACULTY COORDINATOR INDUSTRY COORDINATOR

ELECTRICAL, POWER & ENERGY DEPARTMENT BTPS, NTPC BADARPUR

UPES, DEHRADUN

NEW DELHI 110044 CERTIFICATE

This is to certify that the Internship Report is submitted by ISHAN TIWARI, in partial fulfillment of
the requirements of INTERNSHIP at NTPC Limited, BADARPUR as part of degree of BACHELOR
OF TECHNOLOGY in ENERGY TECHNOLOGY of UNIVERSITY OF PETROLEUM AND ENERGY
STUDIES, session 2015-2016 is a record of bonafide work carried out under our supervision.

(Signature of student)

11 JULY 2015 ISHAN TIWARI

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

It has been a great honor and privilege to undergo training at NTPC Limited, Badarpur, New
Delhi, India. I am very grateful to Mr. MANMOHAN SINGH (DGM HR BADARPUR) & Mr.
ASHUTOSH PANDE (DEPUTY MANAGER PMI NOIDA) 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 i short period of time without their kind
encouragement and valuable guidance.
 ABOUT NTPC
India‟s largest power company, NTPC was set up in 1975 to accelerate power
development in India. NTPC is emerging as a diversified power major with presence
in the entire value chain of the power generation business. Apart from power
generation, which is the mainstay of the company, NTPC has already ventured into
consultancy,
st
power trading, ash utilization and coal mining. NTPC ranked 341 in the 2010 Forbes
Global 2000 ranking of the World’s biggest companies. NTPC became a Maharatna
company in May, 2010, one of the only four companies to be awarded this status.

The total installed capacity of the company is 39,174 MW (including JVs) with 16 coal
based and 7 gas based stations, located across the country. In addition under JVs, 7
stations are coal based & another station uses naphtha/LNG as fuel. The company has

set a target to have an installed power generating capacity of 1,28,000 MW by the year
2032. The capacity will have a diversified fuel mix comprising 56% coal, 16% Gas,
11% Nuclear and 17% Renewable Energy Sources(RES) including hydro. By 2032,
non-fossil fuel based generation capacity shall make up nearly 28% of NTPC‟s
portfolio.

NTPC has been operating its plants at high efficiency levels. Although the company has
17.75% of the total national capacity, it contributes 27.40% of total power generation due
to its focus on high efficiency.
In October 2004, NTPC launched its Initial Public Offering (IPO) consisting of 5.25% as
fresh issue and 5.25% as offer for sale by Government of India. NTPC thus became a
listed company in November 2004 with the Government holding 89.5% of the equity
share capital. In February 2010, the Shareholding of Government of India was reduced
from 89.5% to 84.5% through Further Public Offer. The rest is held by Institutional
Investors and the Public.
 Strategies of NTPC

Technological Initiatives

· Introduction of steam generators (boilers) of the size of 800 MW.

· Integrated Gasification Combined Cycle (IGCC) Technology.

· Launch of Energy Technology Centre -A new initiative for development

of technologies with focus on fundamental R&D.
· The company sets aside up to 0.5% of the profits for R&D.

· Roadmap developed for adopting µClean Development.

· Mechanism to help get / earn µCertified Emission Reduction.

Corporate Social Responsibility

· As a responsible corporate citizen NTPC has taken up number of CSR initiatives.

· NTPC Foundation formed to address Social issues at national level

· NTPC has framed Corporate Social Responsibility Guidelines committing up

to0.5% of net profit annually for Community Welfare.
· The welfare of project affected persons and the local population around
NTPC projects are taken care of through well drawn Rehabilitation and
Resettlement policies.
· The company has also taken up distributed generation for remote rural areas

Partnering government in various initiatives

· Consultant role to modernize and improvise several plants across the country.

· Disseminate technologies to other players in the sector.

· Consultant role ³Partnership in Excellence´ Programme for improvement of

PLF of 15 Power Stations of SEBs.

· Rural Electrification work under Rajiv Gandhi Garmin Vidyutikaran.

Environment management
· All stations of NTPC are ISO 14001 certified.

· Various groups to care of environmental issues.

· The Environment Management Group.

· Ash utilization Division.

· Afforestation Group.

· Centre for Power Efficiency & Environment Protection.

· Group on Clean Development Mechanism.

· NTPC is the second largest owner of trees in the country after the
Forest department
 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
 NTPC Environment Policy

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- CENPEE" 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
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.

NTPC is the second largest owner of trees in the country after the Forest department.

8
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 is 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.

Environment 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 E nvironmental
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.

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
complies 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 left behind after combustion of coa l is arrested in high efficiency
Electrostatic Precipitators (ESPs) and particulate emission is controlled well within
the stipulated norms. The ash collected in the ESPs 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 stati ons, 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:

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 arrangement for changeover of the ash slurry feed points for
even filling of the pond and for effective settlement of the ash parti cles.
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 mon itored.
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:

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. After
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, Jhan or
Gandhar, Faridabad, Farakka, Kahalgaon and Talcher Kaniha. These plants have helped
to control quality and quantity of the effluents discharged from the stations.

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.
 ABOUT BTPS

BADARPUR THERMAL POWER STATION was established on 1973 and it was the
part of Central Government. On 01/04/1978 is was given as No Loss No Profit Plant of
NTPC. Since then operating performance of NTPC has been considerably above the
national average. The availability factor for coal stations has increased from 85.03 %
in
1997-98 to 90.09 % in 2006-07, which compares favorably with international standards.
The PLF has increased from 75.2% in1997-98 to 89.4% during the year 2006-07 which is
the highest since the inception of NTPC.

Badarpur thermal power station started with a single 95 mw unit. There were 2 more units
(95 MW each) installed in next 2 consecutive years. Now it has total five units with total
capacity of
720 MW. Ownership of BTPS was transferred to NTPC with effect from 01.06.2006 through
GOIs Gazette Notification .

The power is supplied to a 220 KV network that is a part of the northern grid. The ten
circuits through which the power is evacuated from the plant are:

1. Mehrauli

2. Okhla

3. Ballabgarh

4. Indraprastha

5. UP (Noida)

6. Jaipur
Given below are the details of unit with the year they’re installed.
Station Location

Badarpur is situated only 20 km away from Delhi. The plant is located on the left side of
the National Highway (Delhi-Mathura Road) and it comprises of 430 hectares (678 acres)
bordered by the Agra Canal from East and by Mathura-Delhi Road from West.
However, the area for ash disposal is done in the Delhi Municipal limit and is maintained
with the help of Delhi Development Authority. The plant is also close to the project of 220
kv Double Circuit Transmission line between the I.P. station and Ballabgarh Cooling Water
is obtained from Agra Canal for the cooling
system. Additional 60 cusecs channel has also been constructed parallel to the Agra
Canal so as to obtain uninterrupted water supply during the slit removing operation in
Agra Canal.
 OPERATION OF A POWER PLANT

Basic Principle

As per FARADAY‟s Law-“Whenever the amount of magnetic flux linked with a

circuit changes, an EMF is produced in the circuit. Generator works on the principle of
producing electricity. To change the flux in the generator turbine is moved in a great
speed with steam.” To produce steam, water is heated in the boilers by burning the
coal.

In a Badarpur Thermal PowerStation, steam is produced and used to spin a turbine that
operates a generator. Water is heated, turns into steam and spins a steam turbine which
drives an electrical generator. After it passes through the turbine, the steam is condensed
in a condenser; this is known as a Rankine cycle.

The electricity generated at the plant is sent to consumers through high-voltage power
lines The Badarpur Thermal Power Plant has Steam Turbine-Driven Generators which
has a collective capacity of 705MW. The fuel being used is Coal which is supplied
from the Jharia Coal Field in Jharkhand. Water supply is given from the Agra Canal.
 Basic Steps of Electricity Generation

The basic steps inthe generation of electricity from coal involves following steps:

• Coal to steam

• Steam to mechanical power

• Mechanical power to electrical power

Thermal
Gas
power plant
tt) 1 Coal conveyer
2 Stoker
3 Pulverizer
4 Boiler
5 Coal Ash
6 Air preheater
7 Electrostatic
precipitator
8 Smokestack
9 Turbine
10 Condenser
11 Transformers
12 Cooling towers
13 Genera tor
14 High-voltage
power lines

•••
16
 Coal to Electricity : Basics

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Coa lto Stea m

Coal from the coal wagons is unloaded in t he 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 coa l 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 fa ll. This table is r
otated with the help of a motor. There are three large steel rollers, which are spaced 120
apart. When there is no coa l, these rollers do not rotate but when the coal is fed to the table it
packs up between roller and t he table and ths forces the rollers to rotate. Coal is crushed
by the crushing action between t he rollers and the rotat ing ta be. This crushed coa l 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. At mospheric air from FD. 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 t hrough down comersand 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
densi ty 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 mi>.."ture is again taken to thee boiler
drum where the steam is separated from water.
18
1
 PARTS OF A POWER PLANT

The various parts are listed below:-

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

1. Cooling Tower
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove process
heat and cool the working fluid to near the wet-bulb air temperature or in the case of
closed circuit dry cooling towers rely solely on air to cool the working fluid to near the
dry-bulb air temperature. Common applications include cooling the circulating water
used in oil refineries, chemical plants, power stations and building cooling.
The towers 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 structures 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 absorbed heat is rejected to the atmosphere
by the evaporation of some of the cooling water in mechanical forced-draft or induced
1
Draft towers or in natural draft hyperbolic shaped cooling towers as seen at most
nuclear power plants.

2. Cooling Water Pump

it pumps the water from the cooling tower which goes to the condenser.

3. 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 conductive 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 current in one conductor as the reference, the currents in the other two are delayed
in time by one-third and two-third of one cycle .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 of one cycle. Generators output at a voltage that
ranges from hundreds of volts to 30,000 volts.

4. Unit transformer (3-phase)

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 ( or wild leg) and
neutral and 240 V between any two phase) to be available from the same supply.

5. 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 maybe water falling through the turbine or steam turning a turbine (as is the case
with thermal power plants). There are several classifications for modern steam
turbines. Steam turbines are used in our entire 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 stati ons 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.

6. Low Pressure Turbine

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 stages 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 and direct the flow
onto the
rotating blades. The rotating blades convert the kinetic energy into impulse and
reaction 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.
Low Pressure Turbine (LPT) consists of 4x2 stages. After passing through Intermediate
Pressure Turbine steam is passed through LPT which is made up of two parts- LPC
REAR & LPC FRONT. As water gets cooler here it gathers into a HOTWELL placed in
lower parts of turbine.

7. Condensation Extraction 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 returning 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. Some pumps contain a two-stage switch. As liquid
lowers to the trigger point of the first stage, the pump is activated. If 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.
8. Condenser
The steam coming out from the Low Pressure Turbine (a little above its boiling pump) is
brought into thermal contact with cold water (pumped in from the cooling tower) in the
condenser, where it condenses rapidly back into water, creating near Vacuum-like
conditions inside the condenser chest.

9. Intermediate Pressure Turbine

Intermediate Pressure Turbine (IPT) consists of 11 stages. When the steam has been
passed through HPT it enters into IPT. IPT has two ends named as FRONT & REAR.
Steam enters through front end and leaves from Rear end.

10. Steam Governor Valve

Steam locomotives and the steam engines used on ships and stationary applications such
as power plants also required feed water pumps. In this situation, though, the pump was
often powered using a small steam engine that ran using the steam produced by the
boiler a means had to be provided, of course, to put the initial charge of water into the
boiler (before steam power was available to operate the steam-powered feed water
pump).The pump was often a positive displacement pump that had steam valves and
cylinders at one end and feed water cylinders at the other end; no crankshaft was
required. In thermal plants, the primary purpose of surface condenser is to condense the
exhaust steam from a steam turbine to obtain maximum efficiency and also to convert
the turbine exhaust
steam into pure water so that it may be reused in the steam generator or boiler as boiler
feed water. By condensing the exhaust steam of a turbine at a pressure below atmospheric
pressure, the steam pressure drop between the inlet and exhaust of the turbine is
increased, which increases the amount heat available for conversion to mechanical
power. Most of the heat liberated due to condensation of the exhaust steam is carried
away by the cooling medium (water or air) used by the surface condenser. Control valves
are valves used within industrial plants and elsewhere to control operating conditions
such as temperature, pressure, flow and liquid level by fully or 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.

11.High Pressure Turbine

Steam coming from Boiler directly feeds into HPT at a temperature of 540°C and at a
pressure of 136 kg/cm2. Here it passes through 12 different stages due to which its
temperature goes down to 329°C and pressure as 27 kg/cm2. This line is also called as
CRH – COLD REHEAT LINE. It is now passed to a REHEATER where its temperature
rises to 540°C and called as HRH-HOT REHEATED LINE.

12. Deaerator
A Deaerator 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 rise 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)

13. 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 irreversibility 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 introduced back into the steam cycle. In a steam power
(usually modelled as a modified Rankine cycle), feed water heaters allow the feed water
to be brought up to the saturation temperature very gradually. This minimizes the
inevitable irreversibility associated with heat transfer to the working fluid (water).

14. Coal conveyor

Coal conveyors are belts which are used to transfer coal from its storage place to Coal
Hopper. 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.

15. Coal Hopper

Coal Hoppers are the places which are used to feed coal to Fuel Mill. It also has the
arrangement of entering Hot Air at 200°C inside it which solves our two purposes: -
1. If our Coal has moisture content then it dries it so that a proper combustion takes place.
2. It raises the temperature of coal so that its temperature is more near to its Ignite
Temperature so that combustion is easy.

16. Pulverized Fuel Mill

A pulveriser is a device for grinding coal for combustion in a furnace in a fossil fuel
power plant.

17. Boiler 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 involve temperature of 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.

18. Ash Hopper

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
accumulate at the bottom.

19. 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. 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 also stationary steam engines including power stations.

20. Force Draught Fan

External fans are provided to give sufficient air for combustion. The forced draught
fan takes air from the atmosphere and, warms it in the air preheater for better
combustion, injects it via the air nozzles on the furnace wall.

21. Reheater
Reheater is a heater which is used to raise the temperature of steam which has fallen from
the intermediate pressure turbine.
22. Air Intake
Air is taken from the environment by an air intake tower which is fed to the fuel.

23. 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, 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 devices fitted to a boiler which save energy by using the exhaust
gases from the boiler to preheat the cold water used to 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 there are turbines before it is
pumped to the boilers. A common application of economizer in steam power plants is to
capture the waste heat 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.

24. Air Preheater

Air preheater is a general term to describe any device design ed 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 flue 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.
25. Precipitator
An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that
removes particles from a flowing gas (such as air) using the force of an induced
electrostatic charge. Electrostatic precipitators are highly efficient filtration devices,
and can easily remove fine particulate matter such as dust and smoke from the air
steam. ESPs continue to be excellent devices for control of many industrial particulate
emissions, including smoke from electricity-generating utilities (coal and oil fired), salt
cake collection from black liquor boilers in pump mills, and catalyst collection from
fluidized bed catalytic crackers from several hundred thousand ACFM in the largest coal
- fired boiler applications. The original parallel plate-Weighted wire design (described
above) has evolved as more efficient (and robust) discharge electrode designs, today
focus is on rigid discharge electrodes to which many sharpened spikes are attached ,
maximizing corona production. Transformer –rectifier systems apply voltages of
50-100 Kilovolts at relatively high current densities. Modern controls minimize sparking
and prevent arcing, avoiding damage to the components. Automatic rapping systems and
hopper evacuation systems remove the collected particulate matter while on line
allowing ESPs to stay in operation for years at a time.

26. Induced Draught Fan

The induced draft fan assists the FD fan by drawing out combustible gases from the
furnace, maintaining a slightly negative pressure in the furnace to avoid backfiring
through any opening. At the furnace outlet and before the furnace gases are handled by
the ID fan, fine dust carried by the outlet gases is removed to avoid atmospheric
pollution. This is an environmental limitation prescribed by law, which additionally
minimizes erosion of the ID fan.

27. Flue gas stack

A Flue gas stack is a type of chimney, a vertical pipe, channel or similar structure
through which combustion product gases called flue gases are exhausted to the outside
air. Flue gases are produced when coal, oil, natural gas, wood or any other large
combustion
device. Flue gas is usually composed of carbon dioxide (CO2) and water vapour 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 sulphur 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 area and thereby
reduce the concentration of the pollutants to the levels required by government's
environmental policies and regulations. The flue gases are exhausted from stoves, ovens,
fireplaces or other small sources within residential abodes, restaurants, hotels through
other stacks which are referred to as chimneys.
 VARIOUS CYCLES AT POWER STATION

· PRIMARY AIR CYCLE

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

P A FAN

COLD AIR DUCT APH

SEAL AIR FAN

HOT AIR DUCT

PULVERISER
 SECONDARY AIR CYCLE

W
I
FD FAN IGNITER FAN N
D

B
SCANNER AIR FAN O
SCAPH
X

SCANNER COOLING
APH

WIND BOX

BOILER
 ELECTRICITY CYCLE

GENERATOR

UAT UAT
To Auxiliaries
To Auxiliaries

MAIN TRANSFORMER

SWITCH YARD

OUTGOING FEEDER
 CONDENSATE CYCLE

HOT WELL

CONDENSATE PUMPS

MAIN EJECTOR

GLAND STEAM COOLER WITH EJECTOR

LP HEATER 2

LP HEATER 3

LP HEATER 4

DEAERATOR

BOILER
36 FEED PUMP
FEED WATER CYCLE

BOILER FEED PUMP

HP HEATOR 5

HP HEATOR 6

HP HEATOR 7

FEED REGULATING STN

ECONOMISER

BOILER DRUM

DOWN COMERS

UPRISERS

BOILER DRUM
37
STEAM CYCLE

BOILER DRUM

L.T.S.H.

FLATEN S.H.

FINAL S.H.

H P TURBINE

C.R.H.

H.R.H

I P TURBINE

L P TURBINE

CONDENSER

•••
1
 Coal Cycle

--

\VAGON TIPPLER

CAU H£R

--

MAGNEnc
FILTER

TRIPPER

RC BUNKER

RCfE£DER

Mill

FURNACE

•••
1
 Flue Gas Cycle

1150'C

362"C
 ELECTRICAL MAINTENANCE DEPARTMENT – I (EMD-I)

Electrical maintenance division 1

Ø It includes:

· Motors

· High Tension/Low Tension Switchgear

· Coal handling plant

rd th
I was assigned to do training in this division from 3 June to 28 June.

1
 MOTORS

Motors can be classified as AC and

DC
.
AC MOTORS

1. Squirrel cage motor

2. Wound motor
3. Slip ring induction motor

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

THREE PHASE INDUCTION MOTOR

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

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

2. DOUBLELAYERWINDING:
Each stator slot contains sides of two different coils.

SQUIRREL CAGE INDUCTION MOTOR

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

BEARINGS AND LUBRICATIONS

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

1. Oil lubrication
2. Grease lubrication
3. Insulation

INSULATIO
N
Winding is an essential part so it should be insulated. Following types of insulation are
widely used

TYPES OF INSULATION

CLASS TEMP UPTO WH I C H THEY ARE

EFFECTIVE (DEGREE CENTIGRADE)

Y 90
A 105
E 120
B 130
F 155
H 180
 C more than 180

Ø F class insulation is generally preferred.

MAIN MOTOR USED IN BOILER AND OFF SIDE AREA

1. ID FAN( 2 PER UNIT)

It is located between EP and chimney used for creating induced draft in the furnace.

2. PA FAN(2 PER UNIT)

It is used for handling atmospheric air up to temperature 50 degree centigrade

3. FD FAN(2 PER UNIT)

It is used for handling secondary air for the boiler.

4. SCANNER FAN( 2 PER UNIT )

It is required for requisite air for scanner cooling.

5. IGNITOR FAN
It supplies air for cooling of igniters.

INSTRUMENTS SEEN

1. MICROMETER
This instrument is used for measuring inside as well as outside diameter of bearing.
2. MEGGAR
This instrument is used for measuring insulation resistance.
3. VIBRATION TESTER
It measures the vibration of the motor. It is measured in three dimensions-axial,
vertical and horizontal.
 SWITCH
GEAR

INTRODUCTION
Switchgear is one that makes or breaks the electrical circuit. It is a switching device that
opens& closes a circuit that defined as apparatus used for switching, Lon rolling &
protecting the electrical circuit & equipments. The switchgear equipment is essentially
concerned with switching & interrupting currents either under normal or abnormal operating
conditions. The tubular switch with ordinary fuse is simplest form of switchgear & is used
to control & protect& other equipments in homes, offices etc. For circuits of higher ratings, a
High Rupturing Capacity (H.R.C) fuse in
condition with a switch may serve the purpose of controlling &protecting the circuit.
However such switchgear cannot be used profitably on high voltage system (3.3 KV) for 2
reasons. Firstly, when a fuse blows, it takes some time to replace it &consequently there is
interruption of service to customer. Secondly, the fuse cannot successfully interrupt large
currents that result from the High Voltage System. In order to interrupt heavy fault
currents, automatic circuit breakers are used. There are very few types of circuit breakers
in B.P.T.S they are VCB, OCB, and SF6 gas circuit breaker. The most expensive circuit
breaker is the SF6 type due to gas. There are various companies which manufacture these
circuit breakers: VOLTAS, JYOTI, and KIRLOSKAR. Switchgear includes switches, fuses,
circuit breakers, relays & other equipments
THE EQUIPMENTS THAT NORMALLY FALL IN THIS CATEGORY ARE:-

1. ISOLATOR
An isolator is one that can break the electrical circuit when the circuit is to be switched on
no load. These are used in various circuits for isolating the certain portion when
required for maintenance etc. An operating mechanism box normally installed at ground
level drives the isolator. The box has an operating mechanism in addition to its contactor
circuit and auxiliary contacts may be solenoid operated pneumatic three phase motor or
DC motor transmitting through a spur gear to the torsion shaft of the isolator. Certain
interlocks are also provided with the isolator

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

2. SWITCHING ISOLATOR
Switching isolator is capable of:
1. Interrupting charging current
2. Interrupting transformer magnetizing current
3. Load transformer switching. Its main application is in connection with the
transformer feeder as the unit makes it possible to switch gear one
transformer while the other is still on load.

3. CIRCUIT BREAKER
One which can make or break the circuit on load and even on faults is referred to as
circuit breakers. This equipment is the most important and is heavy duty equipment
mainly utilized for protection 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.

Ø LT SWITCHGEAR
In LT switchgear there is no interlocking. 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 the 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. 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. CONTACTORS
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 overload relay are best suited for this purpose. They
operate due to the action of heat generated by passage of current through relay
element.

5. AIR CIRCUIT BREAKERS

It is seen that use of oil in circuit breaker may cause a fire. So in all circuits breakers at
large capacity air at high pressure is used which is maximum at the time of quick tripping
of contacts. This reduces the possibility of sparking. The pressure may vary from
50-60kg/cm^2 for high and medium capacity circuit breakers.
 Ø HT SWITCHGEAR

1. MINIMUM OIL CIRCUIT BREAKER

These use oil as quenching medium. It comprises of simple dead tank row pursuing
projection from it. The moving contracts are carried on an iron arm lifted by a long
insulating tension rod and are closed simultaneously pneumatic operating mechanism
by means of tensions but throw off spring to be provided at mouth of the control the
main current within the controlled device.

§ Type-HKH 12/1000c·
§ Rated Voltage-66 KV
§ Normal Current-1250A·
§ Frequency-5Hz·
§ Breaking Capacity-3.4+KA Symmetrical
§ 3.4+KA Asymmetrical
§ 360 MVA Symmetrical
§ Motor Voltage-220 V/DC
 2. AIR CIRCUIT BREAKER

In this the compressed air pressure around 15 kg per cm^2 is used for extinction of arc
caused by flow of air around the moving circuit . The breaker is closed by applying
pressure at lower opening and opened by applying pressure at upper opening. When
contacts operate, the cold air rushes around the movable contacts and blown the arc:
It has the following advantages over OCB:-
i. Fire hazard due to oil are eliminated.
ii. Operation takes place quickly.
iii. There is less burning of contacts since the duration is short and consistent.
iv. Facility for frequent operation since the cooling medium is replaced
constantly.
Rated Voltage-6.6 KV
Current-630 A
Auxiliary current-220 V/DC
 3. SF6 CIRCUIT BREAKER

This type of circuit breaker is of construction to dead tank bulk oil to circuit breaker but
the principle of current interruption is similar to that of air blast circuit breaker. It
simply employs the arc extinguishing medium namely SF6. 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
 4. VACUUM CIRCUIT BREAKER
It works on the principle that vacuum is used to save the purpose of insulation and. In
regards of insulation and strength, vacuum is 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
 COALHANDLINGPLANT(C
HP)

The coal handling plant consists of two plants:

§ Old Coal Handling Plant (OCHP)
§ New Coal Handling Plant (NCHP)

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

NCHP supplies coal to Unit- IV and V.

COALSUPPLIEDATBTPS
Coal is supplied to BTPS by Jharia coal mines. It is non-cooking coal and has following
specifications:-
§ Moisture- less than 8%
§ Volatile matter-17% to 19%
§ Ash- 35% - 40%
§ Calorific Value- 4500 to 5300 Kcal/kg
§ Coal is received in railway box racks containing 20 - 42 wagons in each rack.
§ Capacity of each box wagon is about 55 ton.
§ These wagons are placed on 2 wagon tippler in OCHP & one wagon tippler in
NCHP, in total 3, capacity 80 ton each.
COAL CYCLE

•5•4
•
OLD COAL HANDLING PLANT (OCHP)

KEY DIAGRAM

1
The main constituents of OCHP plant are:-

WAGON TIPPLER
Wagon from coal yard come to the tippler and emptied here. There are 2 wagon tipplers
in the OCHP. The tippler is tilted to about 137°- 141° so that coal from the wagon is
emptied into the hopper. Elliptics feeder is used in OCHP. Total 8 feeders are used, 4 in
each hopper.

Slip Ring Induction Motor is used to operate a wagon tippler. This type of IM is used in
the tippler because of its high resistance, low speed & high torque characteristics. The
rating of the motor used is:

o Power 55 Kw
o Voltage 415V
o Current 102A
o Speed 1480rpm
o Phase 3
o Frequency 50Hz

Three types of wagon tipplers are used:-

a) ROTASIDE: - It is used for open type wagons in which each wagon carries around 50-
56 tons of coal. The wagon is tilted by 150° to put the coal in the unloading hopper.

b) ROTARY: - In this case the unloading hopper is placed directly under the tippler table.
This is also used to tilt the wagon tippler to 180°.

c) ROCKING TYPE: - It is used for close type wagons. In this hoppers is placed by the
side of end rocking is provided to facilitate unloading of coal at corners of the wagon.
CONVEYER
Conveyer belts are used in the OCHP to transfer coal from one place to other as required
in a convenient & safe way. All the belts are numbered accordingly so that their function can
be easily demarcated. These belts are made of rubber & move with a speed of 250-300
m/min. Motor employed for the conveyer has a capacity of 150 HP. These conveyers have a
capacity of carrying the coal at the rate of 400 ton/hr.

ZERO SPEED SWITCH

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

METAL DETECTOR
As the conveyer belt take coal from wagon to crusher house, no metal piece should go
along with coal. To achieve this objective, metal detectors & separators are used. In the
OCHP, these MD‟s are installed in the conveyer belts 2A & 2B.

CRUSHER HOUSE
Both the plants i.e. OCHP & NCHP use TATA crusher powered by BHEL motor.
Crusher is of ring type and the motor is a HT motor of rating 400HP & 6.6 KV. Crusher is
designed to crush the pieces to 20 mm size i.e. practically considered as the optimum size
for transfer via conveyer.

ROTARY BREAKER
If any large piece of metal of any hard substances like metal impurities comes in the
conveyer belt which cause load on the metal separator, then the rotary breaker rejects them
reducing the load on the metal detector.
STACKER-CUM-
RECLAIMER
It is used for stacking & reclaiming the coal from the stockyard in case of unavailability
of wagons from coal mines.

PLOUGH
FEEDER
These plough feeders are generally installed under slot bunkers or hoppers. These are used top
lough the coal to the belt from the coal fed from stockyard. These feeders used in this
power station are generally of rotary type.

TRIPPER
S
Trippers are provided in the conveyer to collect the material at desired location on either side
or along the conveyer with the help of chute/ducts fitted with tripper itself. The motor in the
tripper can make it move both in forward and reverse direction.

PULL GUARD
SWITCH
These are the switches which are installed at every 10m gap in a conveyer belt to ensure the
safety of motors running the conveyer belts. If at any time some accident happens or coal
jumps from belt and starts collecting at a place, this switch can be moved to NO(normally
open) position from NC (normally closed) position to stop conveyor belt from moving.
At this time the problem can be corrected & then again the switch can be moved to NC
(normally closed) position for normal working again.

INTERLOCKS:
-
The CHP is normally spread over a wide area with centralized control room. Elaborate
scheme is therefore provided. If due to any emergency either the conveyor belt or the
motor has to be stopped, due to this interlocking all the other motors connected to it
will automatically stop &will not work till signal is given from the control room.
The control & protection scheme normally includes: -

§ A hooter system to warn that the plant is going to be started. The plant can be
started only after a definite time after the hooter is energized.
§ Sequential starting of conveyor system and tripping of all proceeding system if
any equipment in the chain is tripped.
§ Tripping of conveyor from speed switch for protection against belt slippage.

SEQUENTIALOPERATIONOFOCHP:-

I. Unloading the coal

II. Crushing & storage.
III. Conveying to boiler bunkers.
a) Coal arrives to plant via road, rail, sea, and river or canal route from collieries.
Most of it arrives by rail route only in railway wagons. Coal requirement by this
plant is approximately 10,500 metric ton/day.

b) This coal is tippled into hoppers. If the coal is oversized (400 mm sq), then it is
broken manually so that it passes the hopper mesh where through elliptic feeder it is
put into vibrators & then to conveyor belt 1A & 1B.

c) The coal through conveyor belts 1A & 1B goes to the crusher house. Also the
extra coal is sent to stockyard through these belts.

d) In the crusher house the small size coal pieces goes directly to the belt 2A & 2B
whereas the big size coal pieces are crushed in the crusher & then given to the belts
2A & 2B.

e) The crushed coal is taken to the bunker house via the conveyor belts 3A & 3B
where it can be used for further operations.
NEW COAL HNDLING PLANT
(NCHP)

KEY
DIAGRAM
The main constituents of NCHP plant are:-

Most of the constituents of the NCHP are the same as that of OCHP.

WAGON TIPPLER

In NCHP there is only one wagon tippler. In this it takes 52 sec to raise a wagon, 10 sec to
empty the wagon completely & then again 52 sec to bring the tippler down. A semicircular
huge WT gear is used to run the tippler. Protocol cameras have been installed for safety to
ensure that no moving creature or object is near the wagon which is on the tippler.
COAL FEEDER TO THE PLANT
Vibro feeders are installed below the hopper which helps in putting the coal to the conveyor
belts. There are 2 conveyor belts & 3 vibro feeder per plant, so in total there are 6
vibrofeeders.

Given below are the feeder motor specifications:

§ Power 15HP
§ Voltage 415V
§ Speed 1450rpm

CONVEYOR TURNING POINT-6BREAKER HOUSE

This house is required to render the coal size to 100mm sq. A 415W LT motor is used
in the breaker house.

REJECTION HOUSE
The coal comes to breaker house via conveyor belts 12A & 12B. Now in the breaker
house the huge stones & metal impurities are separated & sent to reject bin house
through belts 18A
&18B.

RECLAIM HOPPER
It is the stockyard in which coal is stored for emergency purposes. Around 3 lakh ton of
coal can be stored in it

TURNING POINT 7

CRUSHER HOUSE

To ensure that the coal is of uniform size it is passed through crusher. The crusher is of
ring type. Has a motor rating of 400HP,606KV.It is designed to crush the pieces to 20mm
size
EXIT
SEQUENTIAL OPERATION OF NCHP:-

a) Coal arrives in wagons and tipples into hoppers.

b) if the coal is oversized (400mm sq), then it is broken manually so that it passes through
the hopper mesh.

c) From hopper it is taken to TP-6 12A & 12B.

d) Conveyors 12A & 12B take the coal to the breaker house which renders the coal size to be
100 mm sq.

e) Metal separator & metal detector are installed in conveyor belts 14A/B & 15A/B
respectively to remove the metal impurities

.f) Stones which are not able to pass through the 100mm sq mesh of hammer are
rejected via 18A & 18B to the rejection house.

g) Extra coal is sent to the reclaim hopper via conveyor 16A & 16B.

h)From TP-7, coal is taken by conveyor 14A & 14B to the crusher house whose function
is to render size of the coal to 20mm sq.

SPECIFICATIONS OF MOTORS USED IN NCHP:-

I. Crusher: - BHEL ILAT/12B HD/02, 736rpm, 550Kw, 6600V.

II. Wagon Tippler: - 5D315l, 98Kw slip ring motor.
III. Conveyors: -
1)11A/B, 12A/B: - 125Kw, 315m, 1485rpm.
2)13A/B: - 55Kw, 250m, 1480rpm.
3)14A/B, 15A/B: - 150Kw, 355m, 1485rpm.
4)16A/B, 17A/B: - 110Kw, 315m, 1485rpm.
5)18A/B: - 37Kw, 225m, 1470rpm.
IV. Rotary Breaker: - 110Kw, 315m, 1485rpm
 V. Belt Feeder: - 15Kw, 180L, 1445rpm
VI. Reversible Belt Feeder: - 18.7Kw, 200L, 1485rp
VII. VF 1-6: - 7.5Kw, 160m, 1485rpm
VIII. VF 7-8: - 15Kw, 180L, 1485rpm
IX. VF 9-12: - 11Kw,160L, 1485rpm
X. WSP Crusher House: - 15Kw, 160m, 4000rpm
XI. WSP Breaker House: - 7.5Kw, 132m, 1865rpm
XII. Metal Separator: - 5KV, 132m, 1410rpm
XIII. Spray Precipitator: - 18.5Kw, 200L, 3000rpm

SAFETY DEVICES FOR BELT CONVEYORS

Sometimes the belt is wet due to any reason, so it may not run due to reduced friction. A
switch senses this and prevents the belt from choking.
Sometime any accident may occur which requires the belt to stop, the pull cords are
pulled to stop the conveyor. This system starts again only when the pull cords are rest.
There is a push button in the control room from where the belt can be stopped in case
of emergency stoppage. Other equipments are pulley. Pulleys are made of mild steel,
rubber logging is provided to increase the friction factor between the pulley and belt.

MILLING
SYSTEM

1. RCBUNKER
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. BALLMILL:
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. In ball mill coal is
converted to powdered form and due to pneumatic action the powdered form of
coal is transferred upwards.

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. MILL FAN
From ball mill the powdered coal is sucked through mill fan.

6. CYCLONE SEPARATORS
It separates the pulverized coal from carrying medium. The mixture of pulverized coal
vapour caters the cyclone separators tangentially in the upper part of the separator. Due
to decrease in the velocity the centrifugal action, the pulverized coal separated from the
vapour &falls down to the lower epical part.
 7. THE TURNIGATE
It serves to transport pulverized coal from cyclone separators to pulverized coal bunker or
to worm conveyors. There are 4 turnigates per boiler.

8. WORMCONVEYOR
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
 ELECTRICAL MAINTENANCE DEPARTMENT –II (EMD-II)

Electrical maintenance division 2

Ø It includes:

· Generators

· Transformers

· Switch yard

th th
I was assigned to do training in this division from 29 June to 11 July.
 GENERATOR
S

The generator works on the principle of electromagnetic induction. There are two
components stator and rotor. The rotor is the moving part and the stator is the stationary
part. The rotor, which has a field winding, is given a excitation through a set of 3000rpm
to give the required frequency of HZ. The rotor is cooled by Hydrogen gas, which is locally
manufactured by the plant and has high heat carrying capacity of low density. If oxygen
and hydrogen get mixed then they will form very high explosive and to prevent their
combining in any way there is seal oil system. The stator cooling is done by de-mineralized
(DM) water through hollow conductors. Water is fed by one end by Teflon tube. A boiler and
a turbine are coupled to electric generators. Steam from the boiler is fed to the turbine
through the connecting pipe. Steam drives the turbine rotor. The turbine rotor drives the
generator rotor which turns the electromagnet within the coil of wire conductors.

Carbon dioxide is provided from the top and oil is provided from bottom to the generator.
With the help of carbon dioxide the oil is drained out to the oil tank.

§ Hydrogen gas is used to cool down the rotor.

1
§ Lube oil is used to cool the bearings.

2
§ DM water is used to cool the stator.
§ Seal oil is used to prevent hydrogen leakage
§ Seal oil coolers are present to cool the seal oil
§ Hydrogen dryer are used which removes the moisture from hydrogen gas and then
is supplied to the generator.
§ Clarified water in cooling tower is used to cool down the hydrogen gas.

RATINGSOFTHEGENERATORSUSED

§ Turbo generator 100MW

§ TURBO GENERATOR 210 MW

The 100 MW generator generates 10.75 KV and 210 MW generates 15.75 KV. The
voltage is stepped up to 220 KV with the help of generator transformer and is connected
to the grid.

The voltage is stepped down to 6.6 KV with the help of UNIT AUXILLARY
TRANSFORMER (UAT) and this voltage is used to drive the HT motors. The
voltage is further stepped down to 415 V and then to 220 V and this voltage is used
to drive Lt Motors.
 TURBOGENERATOR100
MW

MAKE BHEL, Haridwar

CAPACITY 117,500 KVA
POWER 100,000 KW
STATOR VOLTAGE 10,500 V
STATOR CURRENT 6475 A
SP EED 5 0 0 0 rpm
POWER FACTOR 0.85
FRE Q UEN CY 50 HZ
EXCITATION 280 V

TURBO GENERATOR
210MW

MAKE BHEL, Haridwar

CAPACITY 247,000 KVA

POWER 210,000 KW

STATOR VOLTAGE 15,750 V

STATOR CURRENT 9050 A

SPEED 5000 rpm

POWER FACTOR 0.85

FREQUENCY 50 HZ

EXCITATION 310 V

1
GAS PRESSURE 3.5 kg/cm

2
 TRANSFORMER
S

INTRODUCTION

It is a static machine which increases or decreases the AC voltage without changing

the frequency of the supply.
It is a device that:
§ Transfer electric power from one circuit to another.
§ It accomplishes this by electromagnetic induction.
§ In this the two electric circuits are in mutual inductive influence of each other.

WORKING
PRINCIPLE:

It works on FARADAY‟S LAW OF ELECTROMAGNETIC INDUCTION (self

or mutual induction depending on the type of transformer).
 MAIN
PARTS

§ CONSERVATOR
It is used generally to conserve the insulating property of the oil from deterioration&
protect the transformer against failure on account of bad quality of oil.

§ SILICAGEL DEHYDRATING BREATHER

It is used to prevent entry of moisture inside the transformer tank. The breather
consists of silica gel.

§ GAS OPERATED RELAY (BUCHHOLZ RELAY)

It is a gas actuated relay used for protecting oil immersed transformer against all
types of faults. It indicates presence of gases in case of some minor fault & take
out the transformer out of circuit in case of serious fault.

§ BUSHINGS
It is made from highly insulating material to insulate & to bring out the terminals
of the transformer from the container. The bushings are of 3 types:

a. Porcelain bushings used for low voltage transformer

b. Oil filled bushings used for voltage up to 33KV.
c. Condensed type bushings used for voltage above 33KV.

§ OIL GUAGE
Every transformer with an oil guage to indicate the oil level. The oil guage may be
provided with the alarm contacts which gave an alarm the oil level has dropped
beyond permissible height due to oil leak etc.

§ TAPPINGS
The transformer are usually provided with few tappings on secondary side so
that output voltage can be varied for constant input voltage.

§ RADIATORS
It increases the surface area of the tank & more heat is thus radiated in less time.

§ WINDINGS TEMPERATURE INDICATOR (OIL GUAGE)

Device which indicates the temperature of winding of transformer & possible damage
to the transformer due too overload can be prevented.
CONSTRUCTIONAL FEATURES:

§ 3 phase transformer is constructed in the core type construction

§ For reducing losses a smaller thickness of lamination is used.
§ For the above reason it is also called cold-rolled steel instead hot-rolled steel
is used.
§ High flux densities (1.4 to 1.7 Wb/sq m) are used in the core of power transformer
which carry load throughout.
§ For high voltage winding, disc type coils are used.

CLASSIFICATION:

(I) ACCORDINGTO
THECORE:

a) Core type transformer

b) shell type transformer
c) Berry type transformer

(II) ACCORDINGTO
PHASES:

a) 1phase transformer
b) 3phase transformer

(III) ACCORDINGTOTHE PURPOSEFORWHICHUSED

:
a) Distribution transformer
b) Transmission transformer
c) Generator transformer
d) Station transformer
e) Unit Auxiliary transformer (UAT)
 COOLING OF TRANSFORMERS OF LARGE MVA:

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

TYPES OF

COOLING: Air

cooling
1. Air Natural (AN)

2. Air Forced (AF)

Oil immersed cooling

1. Oil Natural Air Natural (ONAN)

2. Oil Natural Air Forced (ONAF)
3. Oil Forced Air Natural (OFAN)
4. Oil Forced Air Forced (OFAF)

Oil immersed Water cooling

1. Oil Natural Water Forced (ONWF)

2. Oil Forced Water Forced (OFWF)

MAIN PARTS OF TRANSFORMER

i. Secondary Winding
ii. Primary Winding.
iii. Oil Level
iv. Conservator
v. Breather
vi. Drain Cock
vii. Cooling Tubes.
viii. Transformer Oil.
ix. Earth Point
x. Explosion Vent
xi. Temperature Gauge.
xii. Buchholz Relay
xiii. Secondary Terminal
xiv. Primary Terminal

GENERATORTRANSFORMER(125MVA UNIT-I & UNIT-

III)

RATING 125MVA
TYPE OF COOLING OFB
TEMP OF OIL 45^C
TEMP WINDING 60^C
KV (no load) HV-233 KVA
LV-10.5 KVA
LINE AMPERES HV-310 A
LV-6880
PHASE THREE
FREQUENCY 50 HZ
IMPEDANCE VOLTAGE 15%
VECTOR GROUP Y DELTA
INSULATION LEVEL HV-900 KV
LV-Neutral-38
CORE AND WINDING WEIGHT 110500 Kg
WEIGHT OF OIL 37200 Kg
TOTAL WEIGHT 188500 Kg
OIL QUANTITY 43900 lit
GENERATOR TRANSFORMER (166 MVA UNIT-IV)

RATING 240MVA
TYPE OF COOLING ON/OB/OFB

TEMP OF OIL

TEMP WINDING

VOLTS AT NO LOAD HV-236000

LV-A5750
LINE AMPERES HV-587 A
LV-8798
PHASE THREE
FREQUENCY 50 HZ
IMPEDANCE VOLTAGE 15.55%
VECTOR GROUP Y DELTA
CORE AND WINDING WEIGHT 138800 Kg
WEIGHT OF OIL 37850 Kg
TOTAL WEIGHT 234000 Kg
OIL QUANTITY 42500 lit

GUARANTEED MAX TEMP

DIVISION KERELA
YEAR 1977
 UNIT AUXILIARY TRANSFORMER
(UAT)

Unit I & V- 12.5 MVA

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

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

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

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

OUTDOOR EQUIPMENTS
i. BUS BAR.
ii. LIGHTENING ARRESTER
iii. WAVE TRAP
iv. BREAKER
v. CAPACITATIVE VOLTAGE TRANSFORMER
vi. EARTHING ROD
vii. CURRENT
TRANSFORMER. viii.
POTENTIAL
TRANSFORMER ix.
LIGHTENING MASK

INDOOR EQUIPMENTS
i. RELAYS.
ii. CONTROL PANELS
iii. CIRCUIT BREAKERS
§ BUS BAR
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.

§ BY PASS BUS
This bus is a backup bus which comes handy when any of the buses become faulty.
When any operation bus has fault, this bus is brought into circuit and then faulty line
is removed there by restoring healthy power line.

§ LIGHTENING ARRESTOR
It saves the transformer and reactor from over voltage and over currents. It
grounds the overload if there is fault on the line and it prevents the generator
transformer. The practice is to install lightening arrestor at the incoming terminal of
the line. We have to use the lightning arrester both in primary and secondary of
transformer and in reactors. A meter is provided which indicates the surface leakage
and internal grading current of arrester.

§ WAVE TRAP
Power line carrier communication (PLCC) is mainly used for telecommunication,
tele-protection and tele-monitoring between electrical substations through power
lines at high voltages, such as 110 kV, 220 kV, and 400 kV. PLCC integrates the
transmission of communication signal and 50/60 Hz power signal through the
same electric power cable. The major benefit is the union of two important
applications in a single system. WAVETRAP is connected in series with
the power (transmission) line. It blocks the high frequency carrier waves (24
KHz to 500 KHz) and let power waves (50 Hz - 60 Hz) to pass-through.
§ BREAKER
Circuit breaker is an arrangement by which we can break the circuit or flow of
current. A circuit breaker in station serves the same purpose as switch but it has
many added and complex features. The basic construction of any circuit breaker
requires the separation of contact in an insulating fluid that servers two
functions:

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

§ CAPACITATIVE VOLTAGE TRANSFORMER

A capacitor voltage transformer (CVT) is a transformer used in power systems to
step-down extra high voltage signals and provide low voltage signals either for
measurement or to operate a protective relay. It is located in the last in the
switchyard as it increases the ground resistance. Finally the voltage from CVT in
the switchyard is sent out from the station through transmission lines.

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

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

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

§ AIR BREAK EARTHING SWITCH

The work of this equipment comes into picture when we want to shut down the
supply for maintenance purpose. This help to neutralize the system from
induced voltage from extra high voltage. This induced power is up to 2KV in
case of 400 KV lines.

§ ELECTROSTATIC PRECIPITATOR
An electrostatic precipitator ( ESP) or electrostatic air cleaner
is a particulate collection 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 that minimally impede the flow
of gases through the device, and can easily remove fine particulate matter such
as dust and smoke from the air stream.
In contrast to wet scrubbers which apply energy directly to the flowing fluid
medium, an ESP applies energy only to the particulate matter being collected and
therefore is very efficient in its consumption of energy (in the form of
electricity).The most basic precipitator contains a row of thin vertical wires, and
followed by a stack of large flat metal plates oriented vertically, with the plates
typically spaced about 1 cm to18 cm apart, depending on the application. The air
or gas stream flows horizontally through the spaces between the wires, and then
passes through the stack of plates. A negative voltage of several thousand volts is
applied between wire and plate. If the applied voltage is high enough an electric
(corona) discharge ionizes the gas around the electrodes. Negative ions flow to
the plates and charge the gas-flow particles.
The ionized particles, following the negative electric field created by the
power supply, move to the grounded plates. Particles build up on the collection
plates and form a layer. The layer does not collapse, thanks to electrostatic
pressure (given from layer resistivity, electric field, and current flowing in the
collected layer).
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