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NTPC LIMITED
Training at BTPS
I was appointed to do 6 week training at this esteemed organization from 11th June to 21st July, 2012. I was assigned to visit various division of the plant, which were:
Electrical Maintenance Department I (EMD-I) Electrical Maintenance Department II (EMD-II) Control and Instrumentation Department (C&I)
These 6 weeks training was a very educational adventure for me. It was really amazing to see the plant by yourself and learn how electricity, which is one of our daily requirements of life, is produced. This report has been made by my experience at BTPS. The material in this report has been gathered from my textbook, senior student reports and trainers manuals and power journals provided by training department. The specification and principles are as learned by me from the employees of each division of BTPS.
Anubhav Ghosh
INDEX
1) 2) 3) 4) 5)
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7) 8) 9) 10)
ABOUT NTPC STRATEGIES JOURNEY OF NTPC ABOUT BTPS OPERATION OF POWER PLANT PARTS OF A POWER PLANT VARIOUS CYCLES AT POWER STATION ELECTRICAL MAINTENANCE DEPARTMENTELECTRICAL MAINETNANCE DEPARTMENT-II CONTROL AND INSTRUMENTATION
ABOUT NTPC
Indias largest power company, NTPC was set up in 1975 to accelerate power development in India. NTPC became a Maharatna company in May, 2010, one of the only four companies to be awarded this status. The total installed capacity of the company is 39,174 MW (including JVs) with 16 coal based and 7 gas based stations, located across the country. In addition under JVs, 7 stations are coal based & another station uses naptha/LNG as fuel. The company has set a target to have an installed power generating capacity of 1,28,000 MW by the year 2032.
Strategies of NTPC
JOURNEY OF NTPC
About BTPS
BADARPUR THERMAL POWER STATION was established on 1973 and it was the part of Central Government. On 01/04/1978 is was given to NTPC. Since then operating performance of NTPC has been considerably above the national average. Badarpur thermal power station started with a single 95 mw unit. There were 2 more units (95 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 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 theyre installed
basic steps in the generation of electricity from coal involves following steps:
Coal to steam Steam to mechanical power Mechanical power to electrical power
AIR CYCLE SECONDARY AIR CYCLE COAL CYLCE ELECTRICITY CYCLE FLUE GAS CYCLE CONDENSATE CYCLE FEED WATER CYCLE STEAM CYCLE
It includes:
MOTORS
AC MOTORS
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: DISTRIBUTED WINDING : This type of winding is distributed over a number of slots. DOUBLE LAYER WINDING : Each stator slot contains sides of two different coils.
Squirrel cage 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
INSULATION Winding is an essential part so it should be insulated. Following types of insulation are widely used INSTRUMENTS SEEN MICROMETER This instrument is used for measuring inside as well as outside diameter of bearing. MEGGAR This instrument is used for measuring insulation resistance. VIBRATION TESTER It measures the vibration of the motor. It is measured in three dimensions-axial, vertical and horizontal.
SWITCH GEAR
Switchgear is one that makes or breaks the electrical circuit. It is a switching device that opens & closes a circuit that defined as apparatus used for switching, Lon rolling & protecting the electrical circuit & equipments. The switchgear equipment is essentially concerned with switching & interrupting currents either under normal or abnormal operating conditions. The tubular switch with ordinary fuse is simplest form of switchgear & is used 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.
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. In low tension switch gear thermal over load relays are used whereas in high tension 5 different types of relays are used.
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.
Isolator cannot operate unless breaker is open Bus 1 and bus 2 isolators cannot be closed simultaneously The interlock can be bypass in the event of closing of bus coupler breaker. No isolator can operate when the corresponding earth switch is on
SWITCHING ISOLATOR
Interrupting charging current Interrupting transformer magnetizing current 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.
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.
These are those interrupting devices which can make or break circuits. These are normally on same circuit, which are backed by circuit breakers 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.
EARTH SWITCHES
HT SWITCHGEAR
MINIMUM OIL CIRCUIT BREAKER These use oil as quenching medium.
AIR CIRCUIT BREAKER In this the compressed air pressure around 15 kg per cm^2 is used for extinction of arc caused by flow of air around the moving circuit . The breaker is closed by applying pressure at lower opening and opened by applying pressure at upper opening. When contacts operate, the cold air rushes around the movable contacts and blown the arc SF6 CIRCUIT BREAKER 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.
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.
Old Coal Handling Plant (OCHP) New Coal Handling Plant (NCHP)
The
OCHP supplies coal to Unit- I, II, III & NCHP supplies coal to Unit- IV and V. COAL SUPPLIED AT BTPS Coal is supplied to BTPS by Jharia coal mines.
COAL CYCLE
Wagon from coal yard come to the tippler and emptied here. There are 2 wagon tipplers in the OCHP. Conveyer belts are used in the OCHP to transfer coal from one place to other as required in a convenient & safe way. 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. 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. Both the plants i.e. OCHP & NCHP use TATA crusher powered by BHEL motor. Crusher is designed to crush the pieces to 20 mm size i.e. practically considered as the optimum size for transfer via conveyer. 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.
METAL DETECTOR
CRUSHER HOUSE
ROTARY BREAKER
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, then the switch can be used.
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. 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. The coal through conveyor belts 1A & 1B goes to the crusher house. Also the extra coal is sent to stockyard through these belts. In the crusher house the small size coal pieces goes directly to the belt 2A & 2B whereas the big size coal pieces are crushed in the crusher & then given to the belts 2A & 2B. The crushed coal is taken to the bunker house via the conveyor belts 3A & 3B where it can be used for further operations.
OCHP
Coal arrives in wagons and tipples into hoppers. if the coal is oversized (400mm sq), then it is broken manually so that it passes through the hopper mesh. From hopper it is taken to TP-6 12A & 12B. Conveyors 12A & 12B take the coal to the breaker house which renders the coal size to be 100 mm sq. Metal separator & metal detector are installed in conveyor belts 14A/B & 15A/B respectively to remove the metal impurities Stones which are not able to pass through the 100mm sq mesh of hammer are rejected via 18A & 18B to the rejection house. Extra coal is sent to the reclaim hopper via conveyor 16A & 16B. 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.
NCHP
GENERATORS
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.
MAKE CAPACITY POWER STATOR VOLTAGE STATOR CURRENT SPEED POWER FACTOR FREQUENCY EXCITATION
BHEL, Haridwar 117,500 KVA 100,000 KW 10,500 V 6475 A 5000rpm 0.85 50 HZ 280 V
TRANSFORMERS
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 FARADAYS LAW OF ELECTROMAGNETIC INDUCTION (self or mutual induction depending on the type of transformer).
2.
3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Secondary Winding Primary Winding. Oil Level Conservator Breather Drain Cock Cooling Tubes. Transformer Oil. Earth Point Explosion Vent Temperature Gauge. Buchholz Relay Secondary Terminal Primary Terminal
RATING TYPE OF COOLING TEMP OF OIL TEMP WINDING KV (no load) LINE AMPERES
125MVA OFB 45^C 60^C HV-233 KVA LV-10.5 KVA HV-310 A LV-6880 THREE 50 HZ 15% Y DELTA HV-900 KV LV-Neutral-38 110500 Kg 37200 Kg 188500 Kg 43900 lit
RATING TYPE OF COOLING TEMP OF OIL TEMP WINDING VOLTS AT NO LOAD LINE AMPERES PHASE FREQUENCY IMPEDANCE VOLTAGE VECTOR GROUP CORE AND WINDING WEIGHT WEIGHT OF OIL TOTAL WEIGHT OIL QUANTITY GUARANTEED MAX TEMP DIVISION YEAR
240MVA ON/OB/OFB 45 C 60 C HV-236000 LV-A5750 HV-587 A LV-8798 THREE 50 HZ 15.55% Y DELTA 138800 Kg 37850 Kg 234000 Kg 42500 lit 45 C KERELA 1977
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.
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 cant be stored like cells, so what we generate should be consumed instantaneously. But as the load is not constants therefore we generate electricity according to need i.e. the generation depends upon load. The yard is the places from where the electricity is send outside. It has both outdoor and indoor equipments. OUTDOOR EQUIPMENTS BUS BAR. LIGHTENING ARRESTER WAVE TRAP BREAKER CAPACITATIVE VOLTAGE TRANSFORMER EARTHING ROD CURRENT TRANSFORMER. POTENTIAL TRANSFORMER LIGHTENING MASK INDOOR EQUIPMENTS RELAYS. CONTROL PANELS CIRCUIT BREAKERS
BUS BAR Bus bars generally are of high conductive aluminum conforming to IS-5082 or copper 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.
WAVE TRAP 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 passthrough.
BREAKER Circuit breaker is an arrangement by which we can break the circuit or flow of current. A circuit breaker in station serves the same purpose as switch but it has many added and complex features. The basic construction of any circuit breaker requires the separation of contact in an insulating fluid that servers two functions:
extinguishes the arc drawn between the contacts when circuit breaker opens. It provides adequate insulation between the contacts and from each contact to earth.
EARTHING ROD Normally un-galvanized mild steel flats are used for earthling. Separate earthing electrodes are provided to earth the lightening arrestor whereas 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: Current relay Potential relay Electromagnetic relay Numerical relay etc. AIR BREAK EARTHING SWITCH The work of this equipment comes into picture when we want to shut down the supply for maintenance purpose. This help to neutralize the system from induced voltage from extra high voltage. This induced power is up to 2KV in case of 400 KV lines.
C&I
LABS CONTROL & MONITORING MECHENISM PRESSURE MONITORING TEMPERATURE MONITORING FLOW MEASUREMENT CONTROL VALVES
INTRODUCTION This division basically calibrates various instruments and takes care of any faults occur in any of the auxiliaries in the plant. Instrumentation can be well defined as a technology of using instruments to measure and control the physical and chemical properties of a material. C&I LABS Control and Instrumentation Department has following labs:
Manometry Lab. Protection and Interlocks Lab. Automation Lab. Electronics Lab. Water Treatment Plant. Furnaces Safety Supervisory System Lab
THANKU