SUMMER TRAINING REPORT

12th July to 21st August

Submitted By:-

Chetan Anand
B.Tech 3rdyear
G.N.I.T College
 Certificate
This is to certify that CHETAN ANAND, student of 2007-2011,Batch of \
Electronics & Instrumentation branch in 3rd year of Greater Noida
Institute of Technology, Greater Noida has successfully completed his
industrial training at Badarpur Thermal Power Station- NTPC, New Delhi
for six weeks from 12th july to 21st august 2010. He has completed the
whole training as per the training report submitted by him.

Training In-charge
Badarpur Thermal Power Station
NTPC, Badarpur New Delhi.
Contents

1. Acknowledgement
2. About the Company
3. NTPC Overview
4. Thermal Power Plant
 Introduction
 Operation
 Functioning

5. Electricity Generation Process

6. Control & Instrumentation
7. Switch Gear
8. Switch Yard
 Acknowledgement
With profound respect and gratitude, I take the opportunity to convey my thanks to
complete the training here. I express gratitude to the Program Manager and other
faculty members of Control & Instrumentation Department of SELECT of Greater
Noida Institute of Technology for providing this opportunity to undergo industrial
training at National Thermal Power Corporation, Badarpur, New Delhi.

I do extend my heartfelt thanks to Ms. Rachna Singh Bhal for providing me this
opportunity to be a part of this esteemed organization.

I am extremely grateful to Mr. G.D.Sharma, Superintendent of Im-Plant Training

at BTPS-NTPC, Badarpur for his guidance during whole training.

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

Finally, I am indebted to all whosoever have contributed in this report work and
friendly stay at Badarpur Thermal Power Station, Badarpur, New Delhi.
 ABOUT THE COMPANY
CORPORATE VISION

“A world class integrated power major, powering India's growth with increasing
global presence.”

CORE VALUES:

BCOMIT

B- Business ethics

C- Customer focus

O- Organizational & professional pride

M- Mutual respect & trust

I- Innovation & speed

T- Total quality for excellence

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

NTPC's core business is engineering, construction and operation of power

generating plants and providing consultancy to power utilities in India and abroad.
The total installed capacity of the company is 31134 MW (including JVs) with 15
coal based and 7 gas based stations, located across the country. In addition under
JVs, 3 stations are coal based & another station uses naphtha/LNG as fuel. By
2017, the power generation portfolio is expected to have a diversified fuel mix
with coal based capacity of around 53000 MW, 10000 MW through gas, 9000 MW
through Hydro generation, about 2000 MW from nuclear sources and around 1000
MW from Renewable Energy Sources (RES). NTPC has adopted a multi-pronged
growth strategy which includes capacity addition through green field projects,
expansion of existing stations, joint ventures, subsidiaries and takeover of stations.
NTPC has been operating its plants at high efficiency levels. Although the
company has 18.79% of the total national capacity it contributes 28.60% of total
power generation due to its focus on high efficiency. NTPC’s share at 31 Mar 2001
of the total installed capacity of the country was 24.51% and it generated 29.68%
of the power of the country in 2008-09. Every fourth home in India is lit by NTPC.
170.88BU of electricity was produced by its stations in the financial year 2005-
2006. The Net Profit after Tax on March 31, 2006 was INR 58,202 million. Net
Profit after Tax for the quarter ended June 30, 2006 was INR 15528 million, which
is 18.65% more than for the same quarter in the previous financial year. 2005).
Pursuant to a special resolution passed by the Shareholders at the Company’s
Annual General Meeting on September 23, 2005 and the approval of the Central
Government under section 21 of the Companies Act, 1956, the name of the
Company "National Thermal Power Corporation Limited" has been changed to
"NTPC Limited" with effect from October 28, 2005. The primary reason for this is
the company's foray into hydro and nuclear based power generation along with
backward integration by coal mining.
A graphical overview
 NTPC Limited

Type Public

Founded 1975

Delhi, India
Headquarters
R S Sharma, Chairman & Managing Director
Key people
Electricity generation
Industry

Products Electricity

▲INR 416.37 billion (2008)

Revenue
▲INR 70.47 billion (2008)
Net income
23867 (2006)
Employees
Website http://www.ntpc.co.in

STRATEGIES
JOURNEY OF NTPC
 NTPC was set up in 1975 with 100% ownership by the
1975 Government of India. In the last 30 years, NTPC has grown
into the largest power utility in India.

In 1997, Government of India granted NTPC status of

1997 “Navratna’ being one of the nine jewels of India, enhancing
the powers to the Board of Directors.

NTPC became a listed company with majority Government

ownership of 89.5%.
2004 NTPC becomes third largest by Market Capitalization of
listed companies.

The company rechristened as NTPC Limited in line with its

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

National Thermal Power Corporation is the largest power

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

National Thermal Power Corporation is the largest power

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

2012 NTPC has also set up a plan to achieve a target of 50,000

MW generation capacity.

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

2017 company by 2017.

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

BADARPUR THEMAL POWER PLANT

• Introduction

• Classification

• Functioning

INTRODUCTION
Power Station (also referred to as generating station or power plant) is an industrial
facility for the generation of electric power. Power plant is also used to refer to the
engine in ships, aircraft and other large vehicles. Some prefer to use the term
energy center because it more accurately describes what the plants do, which is the
conversion of other forms of energy, like chemical energy, gravitational potential
energy or heat energy into electrical energy. However, power plant is the most
common term in the U.S., while elsewhere power station and power plant are both
widely used, power station prevailing in many Commonwealth countries and
especially in the United Kingdom.

At the center of nearly all power stations is a generator, a rotating machine that
converts Mechanical energy into Electrical energy by creating relative motion
between a magnetic field and a conductor. The energy source harnessed to turn the
generator varies widely. It depends chiefly on what fuels are easily available and
the types of technology that the power company has access to.

In thermal power stations, mechanical power is produced by a heat engine, which

transforms Thermal energy (often from combustion of a fuel) into rotational
energy. Most thermal power stations produce steam, and these are sometimes
called steam power stations. About 80% of all electric power is generated by use of
steam turbines. Not all thermal energy can be transformed to mechanical power,
according to the second law of thermodynamics. Therefore, there is always heat
lost to the environment. If this loss is employed as useful heat, for industrial
processes or district heating, the power plant is referred to as a cogeneration power
plant or CHP (combined heat-and-power) plant. In countries where district heating
is common, there are dedicated heat plants called heat-only boiler stations. An
important class of power stations in the Middle East uses by-product heat for
desalination of water.

CLASSIFICATION
By fuel
• Nuclear power plants use a nuclear reactor's heat to operate a steam turbine
generator.

• Fossil fuelled power plants may also use a steam turbine generator or in the case
of natural gas fired plants may use a combustion turbine.

• Geothermal power plants use steam extracted from hot underground rocks.

• Renewable energy plants may be fuelled by waste from sugar cane, municipal
solid waste, landfill methane, or other forms of biomass.

• In integrated steel mills, blast furnace exhaust gas is a low-cost, although low-
energy density, fuel.
• Waste heat from industrial processes is occasionally concentrated enough to use
for power generation, usually in a steam boiler and turbine.

By prime mover

• Steam turbine plants use the dynamic pressure generated by expanding steam to
turn the blades of a turbine. Almost all large non-hydro plants use this system.

• Gas turbine plants use the dynamic pressure from flowing gases to directly
operate the turbine. Natural-gas fuelled turbine plants can start rapidly and so are
used to supply "peak" energy during periods of high demand, though at higher cost
than base-loaded plants. These may be comparatively small units, and sometimes
completely unmanned, being remotely operated. This type was pioneered by the
UK, Prince town being the world's first, commissioned in 1959.

• Combined cycle plants have both a gas turbine fired by natural gas, and a steam
boiler and steam turbine which use the exhaust gas from the gas turbine to produce
electricity. This greatly increases the overall efficiency of the plant, and many new
base load power plants are combined cycle plants fired by natural gas.

• Internal combustion Reciprocating engines are used to provide power for isolated
communities and are frequently used for small cogeneration plants. Hospitals,
office buildings, industrial plants, and other critical facilities also use them to
provide backup power in case of a power outage. These are usually fuelled by
diesel oil, heavy oil, natural gas and landfill gas.

• Micro turbines, Sterling engine and internal combustion reciprocating engines are
low cost solutions for using opportunity fuels, such as landfill gas, digester gas
from water treatment plants and waste gas from oil production.

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

Process of a Thermal Power Plant

Detailed process of power generation in a thermal power plant:

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

2) Boiler heating: The boiler is heated with the help of oil, coal or natural gas. A
furnace is used to heat the fuel and supply the heat produced to the boiler. The
increase in temperature helps in the transformation of water into steam.

3) Steam Turbine: The steam generated in the boiler is sent through a steam
turbine. The turbine has blades that rotate when high velocity steam flows across
them. This rotation of turbine blades is used to generate electricity.

4) Generator: A generator is connected to the steam turbine. When the turbine

rotates, the generator produces electricity which is then passed on to the power
distribution systems.

5) Special mountings: There is some other equipment like the economizer and air
pre-heater.
An economizer uses the heat from the exhaust gases to heat the feed water. An air
pre-heater heats the air sent into the combustion chamber to improve the efficiency
of the combustion process.

6) Ash collection system: There is a separate residue and ash collection system in
place to collect all the waste materials from the combustion process and to prevent
them from escaping into the atmosphere.
Apart from this, there are various other monitoring systems and instruments in
place to keep track of the functioning of all the devices. This prevents any hazards
from taking place in the plant.
 OPERATION

• Introduction
• Steam Generator or Boiler
• Steam Turbine
• Electric Generator
• Condenser

Introduction
The 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 favourably with international
standards. The PLF has increased from 75.2% in 1997-98 to 89.4% during the year
2006-07 which is the highest since the inception of NTPC.

In Badarpur Thermal Power Station, 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. Shown here
is a diagram of a conventional thermal power plant, which uses coal, oil, or natural
gas as fuel to boil water to produce the steam. 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.

Table: Capacity of Badarpur Thermal Power Station, (BTPS) New Delhi

There are basically three main units of a thermal power plant:

1. Steam Generator or Boiler

2. Steam Turbine

3. Electric Generator
We have discussed about the processes of electrical generation further. A complete
detailed description of two (except 2) units is given further.

Coal is conveyed (14) from an external stack and ground to a very fine powder by
large metal spheres in the pulverised fuel mill (16). There it is mixed with
preheated air (24) driven by the forced draught fan (20). The hot air-fuel mixture is
forced at high pressure into the boiler where it rapidly ignites. Water of a high
purity flows vertically up the tube-lined walls of the boiler, where it turns into
steam, and is passed to the boiler drum, where steam is separated from any
remaining water. The steam passes through a manifold in the roof of the drum into
the pendant super heater (19) where its temperature and pressure increase rapidly
to around 200 bar and 540°C,
sufficient to make the tube walls glow a dull red. The steam is piped to the high
pressure turbine (11), the first of a three-stage turbine process. A steam governor
valve (10) allows for both manual control of the turbine and automatic set-point
following. The steam is exhausted from the high pressure turbine, and reduced in
both pressure and temperature, is returned to the boiler reheater (21). The reheated
steam is then passed to the intermediate pressure turbine (9), and from there passed
directly to the low pressure turbine set (6). The exiting steam, now a little above its
boiling point, is brought into thermal contact with cold water (pumped in from the
Cooling tower) in the condenser (8), where it condenses rapidly back into water,
creating near vacuum-like conditions inside the condensor chest. The condensed
water is then passed by a feed pump (7) through a deaerator (12), and pre-warmed,
first in a feed heater (13) powered by steam drawn from the high pressure set, and
then in the economiser (23), before being returned
to the boiler drum. The cooling water from the condensor is sprayed inside a
cooling tower (1), creating a highly visible plume of water vapour, before being
pumped back to the condensor (8) in cooling water cycle. The three turbine sets are
sometimes coupled on the same shaft as the three-phase electrical generator (5)
which generates an intermediate level voltage (typically 20-25 kV). This is stepped
up by the unit transformer (4) to a voltage more suitable for transmission (typically
250-500 kV) and is sent out onto the three-phase transmission system (3). Exhaust
gas from the boiler is drawn by the induced draft fan (26) through an electrostatic
precipitator (25) and is then vented through the chimney stack (27).
 Steam Generator/Boiler
The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m)
tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60
mm) in diameter. Pulverized coal is air-blown into the furnace from fuel nozzles at
the four corners and it rapidly burns, forming a large fireball at the center. The
thermal radiation of the fireball heats the water
that circulates through the boiler tubes near the boiler perimeter. The water
circulation rate in the boiler is three to four times the throughput and is typically
driven by pumps. As the water in the boiler circulates it absorbs heat and changes
into steam at 700 °F (370 °C) and 3,200 psi (22.1MPa). It is separated from the
water inside a drum at the top of the furnace. The saturated steam is introduced
into superheat pendant tubes that hang in the hottest part of the combustion gases
as they exit the furnace. Here the steam is superheated to 1,000 °F (540 °C) to
prepare it for the turbine. The steam generating boiler has to produce steam at the
high purity, pressure and temperature required for the steam turbine that drives the
electrical generator. The generator includes the economizer, the steam drum, the
chemical dosing equipment, and the furnace with its steam generating tubes and
the superheater coils. Necessary safety valves are located at suitable points to avoid
excessive boiler pressure. The air and flue gas path equipment include: forced draft
(FD) fan, air preheater (APH), boiler furnace, induced draft (ID) fan, fly ash
collectors (electrostatic precipitator or baghouse) and the flue gas stack.

For units over about 210 MW capacity, redundancy of key components is provided
by installing duplicates of the FD fan, APH, fly ash collectors and ID fan with
isolating dampers. On some units of about 60 MW, two boilers per unit may
instead be provided.
 Schematic diagram of a coal-fired power plant steam generator

Boiler Furnace and Steam Drum:

Once water inside the boiler or steam generator, the process of adding the latent
heat of vaporization or enthalpy is underway. The boiler transfers energy to the
water by the chemical reaction of burning some type of fuel.
The water enters the boiler through a section in the convection pass called the
economizer. From the economizer it passes to the steam drum. Once the water
enters the steam drum it goes down the down comers to the lower inlet water wall
headers. From the inlet headers the water rises through the water walls and is
eventually turned into steam due to the heat being generated by
the burners located on the front and rear water walls (typically). As the water is
turned into steam/vapour in the water walls, the steam/vapour once again enters the
steam drum.

The steam/vapour is passed through a series of steam and water separators and then
dryers inside the steam drum. The steam separators and dryers remove the water
droplets from the steam and the cycle through the water walls is repeated. This
process is known as natural circulation. The boiler furnace auxiliary equipment
includes coal feed nozzles and igniter guns, soot blowers, water lancing and
observation ports (in the furnace walls) for observation of the furnace interior.
Furnace explosions due to any accumulation of combustible gases after a tripout
are avoided by flushing out such gases from the combustion zone before igniting
the coal. The steam drum (as well as the superheater coils and headers) have air
vents and drains needed for initial start-up. The steam drum has an internal device
that removes moisture from the wet steam entering the drum from the steam
generating tubes. The dry steam then flows into the superheater coils. Geothermal
plants need no boiler since they use naturally occurring steam sources. Heat
exchangers may be used where the geothermal steam is very corrosive or contains
excessive suspended solids. Nuclear plants also boil water to raise steam, either
directly passing the working steam through the reactor or else using an
intermediate heat exchanger.
As the steam is conditioned by the drying equipment inside the drum, it is piped
from the upper drum area into an elaborate set up of tubing in different areas of the
boiler. The areas known as superheater and reheater. The steam vapour picks up
energy and its temperature is now superheated above the saturation temperature.
The superheated steam is then piped through the main steam lines to the valves of
the high pressure turbine.
Re-heaters:
The function of the re-heater is to increase the temperature of the steamto 5400C
thereby increasing the heat content of the stem. This is only employed in the
210MW units because of the greater demand for heat energy.
Economizer:
Economizer reheats the boiler feed water before it is introduced into the drum by
reusing the heat from the flue gases. This particular accessory increases the
efficiency of the boiler. Steam enters at 247OC and leaves at 278OC. The water in
the economizer flows in the upward direction thereby giving heat to the boiler feed
water.
Electrostatic Precipitator:
These are generally two plate type located between the boiler and the chimney.
The precipitator is arranged for horizontal gas flow and is constructed with welded
steel casing.
Boiler Parameters
Stem Temperature (in degree Celsius)
1. Stem entering horizontal SH 340
2. Stem leaving horizontal SH 434
3. Stem entering final SH 515
4. Stem leaving final SH 540
Design Parameters
1. Capacity of boiler 700T/hrs
2. Stem temperature leaving 540oC
3. Pressure at SH outlet 137 kg/cm2

STEAM TURBINE
A steam turbine converts the heat energy of steam into mechanical energy and
drives the generator. It uses the principle that the steam from a small opening
attains high velocity. The velocity attained during expansion depends on the
initial and final heat content of the steam. This difference between initial and final
heat content represents the heat energy converted into kinetic energy.
In the 210MW units there are three types of turbine. High Pressure
Turbine(HPT) which works from super heated stem at 540oC, the stem after
losing its energy is the again re-heated and is feed to Intermediate Pressure
Turbine(IPT), the steam coming out of the IPT is then feed to Low Pressure
Turbine(LPT). These turbine rotated around 3000 rpm(usually 2930-2970).

TURBINE AUXILLARIES
De-aerator:
This component removes oxygen, carbon dioxide(CO2), ammonia(NH3) and other
corrosive gases that are dissolved in the water to be sent to the boiler. The main
function of the de-aerator is to minimize the amount of oxygen in the water so that
there may be minimal corrosion in the boiler internals where the water has to flow
through .
A steam generating boiler requires that the boiler feed water should be devoid of
air and other dissolved gases, particularly corrosive ones, in order to avoid
corrosion of the metal. Generally, power stations use a de-aerator to provide for the
removal of air and other dissolved gases from the boiler feed water. A de-aerator
typically includes a vertical, domed deaeration section mounted on top of a
horizontal cylindrical vessel which serves as the de-aerated boiler feed water
storage tank.

Boiler Feed Water De-aerator

There are many different designs for a de-aerator and the designs will vary from
one manufacturer to another. The adjacent diagram depicts a typical conventional
trayed de-aerator. If operated properly, most de-aerator manufacturers will
guarantee that oxygen in the deaerated water will not exceed 7 ppb by weight
(0.005 cm3/L).
Ejector:
There are two 100% capacity ejectors whose purpose is to evacuate air and others
non-condensing gases from condenser and maintain vacuum in the condenser, stem
from de-aerator with 11 atm. headers as working medium for ejectors.
 Electric Generator
The three turbine and the generator is connected with a single common shaft. So
when the shaft is rotated magnetic flux changes thus producing electricity.
The steam turbine-driven generators have auxiliary systems enabling them to work
satisfactorily and safely. The steam turbine generator being rotating equipment
generally has a heavy, large diameter shaft. The shaft therefore requires not only
supports but also has to be kept in position while running. To minimize the
frictional resistance to the rotation, the shaft has a number of bearings. The bearing
shells, in which the shaft rotates, are lined with a low friction material like Babbitt
metal. Oil lubrication is provided to further reduce the friction between shaft and
bearing surface and to limit the heat generated.

Generator Reading (UCB-5)

1. Station battery volt 240V

2. Turbine speed 2937 rpm
3. Hydrogen purity 97.87
4. Generator 210MW
5. Generator current 7900A
6. Generator frequency 49Hz
7. Field current 204x10A
8. Field voltage 220V
9. Stator water conductivity 280k-ohm-cm

Generator (210MW)
1. Maximum constant KVA rating 247000
2. Maximum constant KW rating 210000
3. Rated power factor 15.75 kv
4. Rated terminal voltage 0.85pf in lag
5. Rated speed 3000 rpm
6. Stator current 9050A
7. Stator volt 15750 v
8. Direction of rotation anticlockwise
 Rotor Cooling

1. Hydrogen Pressure 4.5 kg/cm2

2. Purity 97%
3. Gas Volume 66m3

Stator Cooling

1. Water Pressure 3.5 kg/cm2

2. Quantity of water 130 m3/hr
Condenser
The surface condenser is a shell and tube heat exchanger in which cooling water is
circulated through the tubes. The exhaust steam from the low pressure turbine
enters the shell where it is cooled and converted to condensate (water) by flowing
over the tubes as shown in the adjacent diagram. Such condensers use steam
ejectors or rotary motor-driven exhausters for continuous removal of air and gases
from the steam side to maintain vacuum. A Typical Water Cooled Condenser
For best efficiency, the temperature in the condenser must be kept as low as
practical in order to achieve the lowest possible pressure in the condensing steam.
Since the condenser temperature can almost always be kept significantly below
ο
100 C where the vapour pressure of water is much less than atmospheric pressure,
the condenser generally works under vacuum. Thus leaks of noncondensible air
into the closed loop must be prevented. Plants operating in hot climates may have
to reduce output if their source of condenser cooling water becomes warmer;
unfortunately this usually coincides with periods of high electrical demand for air
conditioning. The condenser generally uses either circulating cooling water from a
cooling tower to reject waste heat to the atmosphere, or once-through water from a
river, lake or ocean.

A typical water cooled condensor

 Auxiliary Systems

Oil System:
An auxiliary oil system pump is used to supply oil at the start-up of the steam
turbine generator. It supplies the hydraulic oil system required for steam turbine's
main inlet steam stop valve, the governing control valves, the bearing and seal oil
systems, the relevant hydraulic relays and other mechanisms. At a preset speed of
the turbine during start-ups, a pump driven by the turbine main shaft takes over the
functions of the auxiliary system.

Generator Heat Dissipation:

The electricity generator requires cooling to dissipate the heat that it generates.
While small units may be cooled by air drawn through filters at the inlet, larger
units generally require special cooling arrangements. Hydrogen gas cooling, in an
oil-sealed casing, is used because it has the highest known heat transfer coefficient
of any gas and for its low viscosity which reduces windage losses. This system
requires special handling during start-up, with air in the chamber first displaced by
carbon dioxide before filling with hydrogen. This ensures that the highly
flammable hydrogen does not mix with oxygen in the air. The hydrogen pressure
inside the casing is maintained slightly higher than atmospheric pressure to avoid
outside air ingress. The hydrogen must be sealed against outward leakage where
the shaft emerges from the casing. Mechanical seals around the shaft are installed
with a very small annular gap to avoid rubbing between the shaft and the seals.
Seal oil is used to prevent the hydrogen gas leakage to atmosphere. The generator
also uses water cooling. Since the generator coils are at a potential of about
15.75kV and water is conductive, an insulating barrier such as Teflon is used to
interconnect the water line and the generator high voltage windings. Demineralised
water of low conductivity is used.

Generator High Voltage System:

The generator voltage ranges from 10.5 kV in smaller units to 15.75 kV in larger
units. The generator high voltage leads are normally large aluminum channels
because of their high current as compared to the cables used in smaller machines.
They are enclosed in well-grounded aluminum bus ducts and are supported on
suitable insulators. The generator high voltage channels are connected to step-up
transformers for connecting to a high voltage electrical substation (of the order of
220 kV) for further transmission by the local power grid. The necessary protection
and metering devices are included for the high voltage leads. Thus, the steam
turbine generator and the transformer form one unit. In smaller units, generating at
10.5kV, a breaker is provided to connect it to a common 10.5 kV bus system.
Other Systems
Monitoring and Alarm system
Most of the power plant’s operational controls are automatic. However, at times,
manual intervention may be required. Thus, the plant is provided with monitors
and alarm systems that alert the plant operators when certain operating parameters
are seriously deviating from their normal range.

Battery Supplied Emergency Lighting & Communication:

A central battery system consisting of lead acid cell units is provided to supply
emergency electric power, when needed, to essential items such as the power
plant's control systems, communication systems, turbine lube oil pumps, and
emergency lighting. This is essential for safe, damage-free shutdown of the units in
an emergency situation.
 CONTROL AND INSTRUMENTATION

This division basically calibrates various instruments and takes care of any faults
occur in any of the auxiliaries in the plant.

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

Instrumentation can be well defined as a technology of using instruments to

measure and control the physical and chhemical properties of a material.
Control and instrumentation has following labs:
1. Manometry lab
2. Protection and interlocks lab
3. Automation lab
4. Pyrometry Lab
• Pressure measurement
• Temperature measurement
• Flow measurement
• Control valves
5. Water treatment plant
6. Furnaces Safety Supervisory System Lab
 Manometry lab
• Transmitters- Transmitter is used for pressure measurements of gases and
liquids, its working principle is that the input pressure is converted into
electrostatic capacitance and from there it is conditioned and amplified. It
gives an output of 4-20 ma DC. It can be mounted on a pipe or a wall. For
liquid or steam measurement transmitters is mounted below main process
piping and for gas measurement transmitter is placed above pipe.

• Manometer- It’s a tube which is bent, in U shape. It is filled with a liquid.

This device corresponds to a difference in pressure across the two limbs.

• Bourden Pressure Gauge- It’s an oval section tube. Its one end is fixed. It
is provided with a pointer to indicate the pressure on a calibrated scale. It is
of two types : (a) Spiral type : for low pressure measurement and (b) Helical
type : for high pressure measurement
 Protection and Interlock Lab
• Interlocking: It is basically interconnecting two or more equipments so that
if one equipments fails other one can perform the tasks. This type of
interdependence is also created so that equipments connected together are
started and shut down in the specific sequence to avoid damage. For
protection of equipments tripping are provided for all the equipments.
Tripping can be considered as the series of instructions connected through
OR GATE. When The main equipments of this lab are relay and circuit
breakers. Some of the instrument uses for protection are:
• RELAY: It is a protective device. It can detect wrong condition in electrical
circuits by constantly measuring the electrical quantities flowing under
normal and faulty conditions. Some of the electrical quantities are voltage,
current, phase angle and velocity.
• FUSES: It is a short piece of metal inserted in the circuit, which melts when
heavy current flows through it and thus breaks the circuit. Usually silver is
used as a fuse material because: a) The coefficient of expansion of silver is
very small. As a result no critical fatigue occurs and thus the continuous full
capacity normal current ratings are assured for the long time. b) The
conductivity of the silver is unimpaired by the surges of the current that
produces temperatures just near the melting point. c) Silver fusible elements
can be raised from normal operating temperature to vaporization quicker
than any other material because of its comparatively low specific heat.
• Miniature Circuit Breaker: They are used with combination of the control
circuits to. a) Enable the staring of plant and distributors. b) Protect the
circuit in case of a fault. In consists of current carrying contacts, one
movable and other fixed. When a fault occurs the contacts separate and are
is stuck between them. There are three types of –
 MANUAL TRIP
 THERMAL TRIP
 SHORT CIRCUIT TRIP.
• Protection and Interlock System:
1. HIGH TENSION CONTROL CIRCUIT: For high tension system the
control system are excited by separate D.C supply. For starting the circuit
conditions should be in series with the starting coil of the equipment to
energize it. Because if even a single condition is not true then system will
not start.
2. LOW TENSION CONTROL CIRCUIT: For low tension system the
control circuits are directly excited from the 0.415 KV A.C supply. The
same circuit achieves both excitation and tripping. Hence the tripping coil is
provided for emergency tripping if the interconnection fails.
 Automation Lab
This lab deals in automating the existing equipment and feeding routes. Earlier,
the old technology dealt with only (DAS) Data Acquisition System and came to be
known as primary systems. The modern technology or the secondary systems are
coupled with (MIS) Management Information System. But this lab universally
applies the pressure measuring instruments as the controlling force. However, the
relays are also provided but they are used only for protection and interlocks.
This lab deals in automating the equipment and feeding routes. The automatic
control system provide safe peration under all plant disturbances and component
faliures.
This lab universally applies the pressure measuring instruments as the controlling
force. Once the control circuit can easily be designed with single chip having
multiple. In the plant all control instruments are excited by 24V DC supply(4-
20mA).
The systems installed here in BTPS are old Russion systems these are
ACS(Automatic Controll System) which are slowly being replaced by DCS(Digital
Controll System ). In the present ACS system mosy of the decision making has to
be done manually like opening or closing of any pressure valve.

Pyrometry Lab
• Liquid in glass thermometer - Mercury in the glass thermometer boils at
340 degree Celsius which limits the range of temperature that can be
measured. It is L shaped thermometer which is designed to reach all
inaccessible places.
• Ultra violet censor- This device is used in furnace and it measures the
intensity of ultra violet rays there and according to the wave generated
which directly indicates the temperature in the furnace.
• Thermocouples - This device is based on SEEBACK and PELTIER effect.
It comprises of two junctions at different temperature. Then the emf is
induced in the circuit due to the flow of electrons. This is an important part
in the plant.
• RTD(Resistance temperature detector) - It performs the function of
thermocouple basically but the difference is of a resistance. In this due to the
change in the resistance the temperature difference is measured. In this lab,
also the measuring devices can be calibrated in the oil bath or just boiling
water (for low range devices) and in small furnace (for high range devices).
PRESSURE MEASUREMENT:
Pressure can be monitored by three types of basic mechanisms

 Switches
 Gauges
 Transmitter type

For gauges we use Bourden tubes : The Bourdon Tube is a non liquid pressure
measurement device. It is widely used in applications where inexpensive static
pressure measurements are needed.

A typical Bourdon tube contains a curved tube that is open to external pressure
input on one end and is coupled mechanically to an indicating needle on the other
end, as shown schematically below.

Typical Bourdon Tube Pressure Gages

For Switches pressure swithes are used and they can be used for digital means of
monitoring as swith being ON is referred as high and being OFF is as low.
All the monitored data is converted to either Current or Voltage parameter.
The Plant standard for current and voltage are as under

• Voltage : 0 – 10 Volts range

• Current : 4 – 20 milliAmperes
We use 4mA as the lower value so as to check for disturbances and wire breaks.
Accuracy of such systems is very high .
ACCURACY : + - 0.1 %
The whole system used is SCADA based.
Programmable Logic Circuits ( PLCs) are used in the process as they are the heardt
of Instrumentation .

Pressure
HL switch Electricity
Start ANLevel
low Pressure in line D High
Level
LL switch

High level
pump Electricity
OR
Stop
Pressure

Electricity

BASIC PRESSURE CONTROL MECHANISM

TEMPERATURE MESUREMENT:

We can use Thernocouples or RTDs for temperature monitoring

Normally RTDs are used for low temperatures.

Thermocoupkle selection depends upon two factors:

 Temperature Range
 Accuracy Required

Normally used Thermocouple is K Type Thermocouple:

Chromel (Nickel-Chromium Alloy) / Alumel (Nickel-Aluminium Alloy)
This is the most commonly used general purpose thermocouple. It is inexpensive
and, owing to its popularity, available in a wide variety of probes. They are
available in the −200 °C to +1200 °C range. Sensitivity is approximately 41
µV/°C.

RTDs are also used but not in protection systems due to vibrational errors.

We pass a constant curre t through the RTD. So that if R changes then the Voltage
also changes RTDs used in Industries are Pt100 and Pt1000

Pt100 : 0 0C – 100 Ω ( 1 Ω = 2.5 0C )

Pt1000 : 0 0C - 1000Ω
Pt1000 is used for higher accuracy
The gauges used for Temperature measurements are mercury filled Temperature
gauges. For Analog medium thermocouples are used And for Digital medium
Switches are used which are basically mercury switches.
FLOW MEASUREMENT:
Flow measurement does not signify much and is measured just for metering
purposes and for monitoring the processes

ROTAMETERS:
A Rotameter is a device that measures the flow rate of liquid or gas in a closed
tube. It is occasionally misspelled as 'rotometer'.

It belongs to a class of meters called variable area meters, which measure flow rate
by allowing the cross sectional area the fluid travels through to vary, causing some
measurable effect.
A rotameter consists of a tapered tube, typically made of glass, with a float inside
that is pushed up by flow and pulled down by gravity. At a higher flow rate more
area (between the float and the tube) is needed to accommodate the flow, so the
float rises. Floats are made in many different shapes, with spheres and spherical
ellipses being the most common. The float is shaped so that it rotates axially as the
fluid passes. This allows you to tell if the float is stuck since it will only rotate if it
is not.
For Digital measurements Flap system is used.
For Analog measurements we can use the following methods :

 Flowmeters
 Venurimeters / Orifice meters
 Turbines
 Massflow meters ( oil level )
 Ultrasonic Flow meters
 Magnetic Flowmeter ( water level )

Selection of flow meter depends upon the purpose , accuracy and liquid to be
measured so different types of meters used.
Turbine type are the simplest of all.
They work on the principle that on each rotation of the turbine a pulse is generated
and that pulse is counted to get the flow rate.
VENTURIMETERS :

Referring to the diagram, using Bernoulli's equation in the special case of

incompressible fluids (such as the approximation of a water jet), the theoretical
pressure drop at the constriction would be given by (ρ/2)(v22 - v12).

And we know that rate of flow is given by:

Flow = k √ (D.P)
Where DP is Differential Presure or the Pressure Drop.
CONTROL VALVES:

A valve is a device that regulates the flow of substances (either gases, fluidized
solids, slurries, or liquids) by opening, closing, or partially obstructing various
passageways. Valves are technically pipe fittings, but usually are discussed
separately.

Valves are used in a variety of applications including industrial, military,

commercial, residential, transportation. Plumbing valves are the most obvious in
everyday life, but many more are used.

Some valves are driven by pressure only, they are mainly used for safety purposes
in steam engines and domestic heating or cooking appliances. Others are used in a
controlled way, like in Otto cycle engines driven by a camshaft, where they play a
major role in engine cycle control.

Many valves are controlled manually with a handle attached to the valve stem. If
the handle is turned a quarter of a full turn (90°) between operating positions, the
valve is called a quarter-turn valve. Butterfly valves, ball valves, and plug valves
are often quarter-turn valves. Valves can also be controlled by devices called
actuators attached to the stem. They can be electromechanical actuators such as an
electric motor or solenoid, pneumatic actuators which are controlled by air
pressure, or hydraulic actuators which are controlled by the pressure of a liquid
such as oil or water.

So there are basically three types of valves that are used in power industries
besides the handle valves. They are :
• Pneumatic Valves – they are air or gas controlled which is compressed
to turn or move them
• Hydraulic valves – they utilize oil in place of Air as oil has better
compression
• Motorised valves – these valves are controlled by electric motors
 Water Treatment Plant
Since there is continuous withdrawal of steam and continuous return of condensate
to the boiler, losses due to blow-down and leakages have to be made up for so as to
maintain the desired water level in the boiler steam drum. For this, continuous
make-up water is added to the boiler water system. The impurities in the raw water
input to the plant generally consist of calcium and magnesium salts which impart
hardness to the water. Hardness in the make-up water to the boiler will form
deposits on the tube water surfaces which will lead to overheating and failure of
the tubes. Thus, the salts have to be removed from the water and that is done by a
Water Treatment Plant or Demineralised Water (DM).

A DM plant generally consists of cation, anion and mixed bed exchangers. The
final water from this process consists essentially of hydrogen ions and hydroxide
ions which is the chemical composition of pure water. The DM water, being very
pure, becomes highly corrosive once it absorbs oxygen from the atmosphere
because of its very high affinity for oxygen absorption. The capacity of the DM
plant is dictated by the type and quantity of salts in the raw water input. However,
some storage is essential as the DM plant may be down for maintenance. For this
purpose, a storage tank is installed from which DM water is continuously
withdrawn for boiler make-up. The storage tank for DM water is made from
materials not affected by corrosive water, such as PVC. The piping and valves are
generally of stainless steel. Sometimes, a steam blanketing arrangement or
stainless steel doughnut float is provided on top of the water in the tank to avoid
contact with atmospheric air. DM water make-up is generally added at the steam
space of the surface condenser (i.e., the vacuum side). This arrangement not only
sprays the water but also DM water gets deaerated, with the dissolved gases being
removed by the ejector of the condenser itself.
 FURNACE SAFEGUARD SUPERVISORY
SYSTEM

FSSS is also called as Burner Management System (BMS). It is a microprocessor

based programmable logic controller of proven design incorporating all protection
facilities required for such system. Main objective of FSSS is to ensure safety of
the boiler.

The 95 MW boilers are indirect type boilers. Fire takes place in front and in rear
side. That’s why it’s called front and rear type boiler. The 210 MW boilers are
direct type boilers (which mean that HSD is in direct contact with coal) firing takes
place from the corner. Thus it is also known as corner type boiler.

IGNITER SYSTEM

Igniter system is an automatic system, it takes the charge from 110kv and this
spark is brought in front of the oil guns, which spray aerated HSD on the coal for
coal combustion. There is a 5 minute delay cycle before igniting, this is to evacuate
or burn the HSD. This method is known as PURGING.

PRESSURE SWITCH

Pressure switches are the devices that make or break a circuit. When pressure is
applied, the switch under the switch gets pressed which is attached to a relay that
makes or break the circuit. Time delay can also be included in sensing the pressure
with the help of pressure valves.
1. Manual valves (tap)
2. Motorized valves (actuator) – works on motor action
3. Pneumatic valve (actuator) _ works due to pressure of compressed air
4. Hydraulic valve
 SWITCHGEAR
The term switchgear, used in association with the electric power system, or grid,
refers to the combination of electrical disconnects, fuses and/or circuit breakers
used to isolate electrical equipment. Switchgear is used both to de-energize
equipment to allow work to be done and to clear faults downstream. Switchgear is
already a plural, much like the software term code/codes, and is never used as
switchgears.
The very earliest central power stations used simple open knife switches, mounted
on insulating panels of marble or asbestos. Power levels and voltages rapidly
escalated, making open manually-operated switches too dangerous to use for
anything other than isolation of a de-energized circuit. Oil-filled equipment
allowed arc energy to be contained and safely controlled. By the early 20th
century, a switchgear line-up would be a metal-enclosed structure with electrically-
operated switching elements, using oil circuit breakers. Today, oil-filled equipment
has largely been replaced by air-blast, vacuum, or SF6 equipment, allowing large
currents and power levels to be safely controlled by automatic equipment
incorporating digital controls, protection, metering and communications.
Typically switchgear in substations is located on both the high voltage and the low
voltage side of large power transformers. The switchgear located on the low
voltage side of the transformers in distribution type substations, now are typically
located in what is called a Power Distribution Center (PDC). Inside this building
are typically smaller, medium-voltage (~15kV) circuit breakers feeding the
distribution system. Also contained inside these Power Control Centers are various
relays, meters, and other communication equipment allowing for intelligent control
of the substation.
For industrial applications, a transformer and switchgear line-up may be combined
in one housing, called a unit substation.
Housing
Switchgear for low voltages may be entirely enclosed within a building. For
transmission levels of voltage (high voltages over 66 kV), often switchgear will be
mounted outdoors and insulated by air, though this requires a large amount of
space. Gas- [or oil- or vacuum-] insulated switchgear used for transmission-level
voltages saves space, although it has a higher equipment cost.
At small substations, switches may be manually operated, but at important
switching stations on the transmission network all devices have motor operators to
allow for remote control.
A piece of switchgear may be a simple open air isolator switch or it may be
insulated by some other substance. An effective although more costly form of
switchgear is "gas insulated switchgear" (GIS), where the conductors and contacts
are insulated by pressurized (SF6) sulfur hexafluoride gas. Other common types
are oil [or vacuum] insulated switchgear.
Circuit breakers are a special type of switchgear that are able to interrupt fault
currents. Their construction allows them to interrupt fault currents of many
hundreds or thousands of amps. The quenching of the arc when the contacts open
requires careful design, and falls into four types:
Oil circuit breakers rely upon vaporisation of some of the oil to blast a jet of oil
through the arc.
Gas (SF6) circuit breakers sometimes stretch the arc using a magnetic field, and
then rely upon the dielectric strength of the SF6 to quench the stretched arc.
Vacuum circuit breakers have minimal arcing (as there is nothing to ionise other
than the contact material), so the arc quenches when it is stretched a very small
amount (<2-3 mm). Vacuum circuit breakers are frequently used in modern
medium-voltage switchgear to 35,000 volts.
Air circuit breakers may use compressed air to blow out the arc, or alternatively,
the contacts are rapidly swung into a small sealed chamber, the escaping of the
displaced air thus blowing out the arc.
Circuit breakers are usually able to terminate all current flow very quickly:
typically between 30 ms and 150 ms depending upon the age and construction of
the device.
A single line-up may incorporate several different types of devices, for example,
air-insulated bus, vacuum circuit breakers, and manually-operated switches may all
exist in the same row of cubicles.
Ratings, design, specifications and details of switchgear are set by a multitude of
standards. In North America mostly IEEE and ANSI standards are used, much of
the rest of the world uses IEC standards, sometimes with local national derivatives
or variations.
Functions One of the basic functions of switchgear is protection, which is
interruption of short-circuit and overload fault currents while maintaining service
to unaffected circuits. Switchgear also provides isolation of circuits from power
supplies. Switchgear also is used to enhance system availability by allowing more
than one source to feed a load.
To help ensure safe operation sequences of switchgear, trapped key interlocking
provides predefined scenarios of operation. James Harry Castell invented this
technique in 1922. For example, if only one of two sources of supply is permitted
to be connected at a given time, the interlock scheme may require that the first
switch must be opened to release a key that will allow closing the second switch.
Complex schemes are possible.
 SWITCHYARD
Switchyard forms an integral part of any power plant i.e. Industrial CPP, Thermal
Power Utilities, Gas Turbines based power plants or Hydel power plants. These
power plants have their main plant equipment integral controls (Boiler / Turbine /
Gas Turbine / Hydro Turbine) as well as plant DCS System (BoP / Station C & I).
While the entire power plant is integrated at the DCS level, true unification is
achieved by incorporating / integrating switchyard controls (SCADA) also in the
plant DCS.
NTPC has incorporated switchyard SCADA on IBS hardware (Multibus
compatible) and integrated with main plant DCS in a few projects. With the
Technical Collaboration Agreement for the state-of-the art max DNA system,
NTPC is now well position to provide this unification on the same platform as the
plant level DCS system.
The Supervisory control and data acquisition system (SCADA) of switchyard
consists of Operator Stations, Engineer's Stations, Historical Storage, Computers
and associated peripherals and the switchyard bay control systems interconnected
through a high speed network . The system constitutes several operator work
stations and engineer's work station with high resolution Color display monitors,
touch screen, function key board, mouse, track ball and printers.
The system collects digital and analog information available throughout the plant
and presents information in various graphic displays, alarms, logs, reports.
The operator can perform control via CRT.