Acknowledgement 

With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training here.

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

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.

I would also like to thank the training in charge of Skyline Institute of Engineering & Technology Gr. Noida and all
the faculty member of Electrical & Electronics department for their effort of constant co-operation. Which have been
significant factor in the accomplishment of my industrial training. 

Training at BTPS 

I was appointed to do eight-week training at this esteemed organization from 18th June to 11th august 2007. In these
eight weeks I was assigned to visit various division of the plant which were

1. Operation
2. Control and instrumentation (C&I)
3. Electrical maintenance division I (EMD-I)
4. Electrical maintenance division II (EMD-II)

This eight-week training was a very educational adventure for me. It was really amazing to see the plant by your self
and learn how electricity, which is one of our daily requirements of life, is produced.

This report has been made by self-experience at BTPS. The material in this report has been gathered from my
textbooks, senior student report, and trainer manual provided by training department. The specification & principles
are at learned by me from the employee of each division of BTPS.
ABOUT NTPC

NTPC Limited is the largest thermal power generating company of India. A public sector company, it was
incorporated in the year 1975 to accelerate power development in the country as a wholly owned company of the
Government of India. At present, Government of India holds 89.5% of the total equity shares of the company and
FIIs, Domestic Banks, Public and others hold the balance 10.5%. With in 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. 

POWER GENERATION IN INDIA

NTPC’s core business is engineering, construction and operation of power generating plants. It also provides
consultancy in the area of power plant constructions and power generation to companies in India and abroad. As on
date the installed capacity of NTPC is 27,904 MW through its 15 coal based (22,895 MW), 7 gas based (3,955 MW)
and 4 Joint Venture Projects (1,054 MW). NTPC acquired 50% equity of the SAIL Power Supply Corporation Ltd.
(SPSCL). This JV Company operates the captive power plants of Durgapur (120 MW), Rourkela (120 MW) and
Bhilai (74 MW). NTPC also has 28.33% stake in Ratnagiri Gas & Power Private Limited (RGPPL) a joint venture
company between NTPC, GAIL, Indian Financial Institutions and Maharashtra SEB Co Ltd. 
NTPC has set new benchmarks for the power industry both in the area of power plant construction and operations.
Its providing power at the cheapest average tariff in the country..
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 (CENPEEP)" 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. 

Environment Policy & Environment Management System

Driven by its commitment for sustainable growth of power, NTPC has evolved a well defined environment
management policy and sound environment practices for minimizing environmental impact arising out of setting up
of power plants and preserving the natural ecology.

National Environment Policy: 

At the national level, the Ministry of Environment and Forests had prepared a draft Environment Policy (NEP) and
the Ministry of Power along with NTPC actively participated in the deliberations of the draft NEP. The NEP 2006
has since been approved by the Union Cabinet in May 2006. 
NTPC Environment Policy: 
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 are 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 Environmental 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 comply 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 coal is arrested in high efficiency Electrostatic Precipitators (ESP’s) and
particulate emission is controlled well within the stipulated norms. The ash collected in the ESP’s 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-NOXBurners:
In gas based NTPC power stations, NOx emissions are controlled by provision of Low-NOx Burners (dry or wet type)
and in coal fired stations, by adopting best combustion practices. 
Neutralisation Pits: 
Neutralisation 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 arrangements for change over of
the ash slurry feed points for even filling of the pond and for effective settlement of the ash particles.
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 monitored. 
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, Jhanor 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.

Environmental Institutional Set-up: 

Realizing the importance of protection of the environment with speedy development of the power sector, the company
has constituted different groups at project, regional and Corporate Centre level to carry out specific environment
related functions. The Environment Management Group, Ash Utilisation Group and Centre for Power Efficiency &
Environment Protection (CENPEEP) function from the Corporate Centre and initiate measures to mitigate the
impact of power project implementation on the environment and preserve ecology in the vicinity of the projects.
Environment Management and Ash Utilisation Groups established at each station, look after various environmental
issues of the individual station.
Environment Reviews: 
To maintain constant vigil on environmental compliance, Environmental Reviews are carried out at all operating
stations and remedial measures have been taken wherever necessary. As a feedback and follow-up of these
Environmental Reviews, a number of retrofit and up-gradation measures have been undertaken at different stations.
Such periodic Environmental Reviews and extensive monitoring of the facilities carried out at all stations have helped
in compliance with the environmental norms and timely renewal of the Air and Water Consents.

Up gradation & retrofitting of Pollution Control Systems: 

Waste Management
Various types of wastes such as Municipal or domestic wastes, hazardous wastes, Bio-Medical wastes get generated in
power plant areas, plant hospital and the townships of projects. The wastes generated are a number of solid and
hazardous wastes like used oils & waste oils, grease, lead acid batteries, other lead bearing wastes (such as garkets
etc.), oil & clarifier sludge, used resin, used photo-chemicals, asbestos packing, e-waste, metal scrap, C&I wastes,
electricial scrap, empty cylinders (refillable), paper, rubber products, canteen (bio-degradable) wastes, buidling
material wastes, silica gel, glass wool, fused lamps & tubes, fire resistant fluids etc. These wastes fall either under
hazardous wastes category or non-hazardous wastes category as per classification given in Government of India’s
notification on Hazardous Wastes (Management and Handling) Rules 1989 (as amended on 06.01.2000 & 20.05.2003).
Handling and management of these wastes in NTPC stations have been discussed below.

Advanced / Eco-friendly Technologies

NTPC has gained expertise in operation and management of 200 MW and 500 MW Units installed at different
Stations all over the country and is looking ahead for higher capacity Unit sizes with super critical steam parameters
for higher efficiencies and for associated environmental gains. At Sipat, higher capacity Units of size of 660 MW and
advanced Steam Generators employing super critical steam parameters have already been implemented as a green
field project. 
Higher efficiency Combined Cycle Gas Power Plants are already under operation at all gas-based power projects in
NTPC. Advanced clean coal technologies such as Integrated Gasification Combined Cycle (IGCC) have higher
efficiencies of the order of 45% as compared to about 38% for conventional plants. NTPC has initiated a techno-
economic study under USDOE / USAID for setting up a commercial scale demonstration power plant by using IGCC
technology. These plants can use low-grade coals and have higher efficiency as compared to conventional plants.
With the massive expansion of power generation, there is also growing awareness among all concerned to keep the
pollution under control and preserve the health and quality of the natural environment in the vicinity of the power
stations. NTPC is committed to provide affordable and sustainable power in increasingly larger quantity. NTPC is
conscious of its role in the national endeavour of mitigating energy poverty, heralding economic prosperity and
thereby contributing towards India’s emergence as a major global economy.
Lay out of Employee’s

Overall Power Generation

Unit 1997-98 2006-07 % of increase

Installed Capacity MW 16,847 26,350 56.40
Generation MUs 97,609 1,88,674 93.29
No. of employees No. 23,585 24,375 3.34
Generation/employee MUs 4.14 7.74 86.95

The table below shows the detailed operational performance of coal based stations over the years. 
OPERATIONAL PERFORMANCE OF COAL BASED NTPC STATIONS
Unit 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06 06-07
Generation BU 106.2 109.5 118.7 130.1 133.2 140.86 149.16 159.11 170.88 188.67
PLF % 75.20 76.60 80.39 81.8 81.1 83.6 84.4 87.51 87.54 89.43
Availability % 85.03 89.36 90.06 88.54 81.8 88.7 88.8 91.20 89.91 90.09
Factor

The energy conservation parameters like specific oil consumption and auxiliary power consumption have also shown
considerable improvement over the years.

ABOUT BADARPUR THERMAL POWER STATION 

I was assigned to do training in operation division from 18th June 2007 to 23rd June 2007 

ELECTRICITY FROM COAL

Coal from the coal wagons is unloaded with the help of wagon tipplers in the C.H.P. this coal is taken to the raw coal
bunkers with the help of conveyor belts. Coal is then transported to bowl mills by coal feeders where it is pulverized
and ground in the powered form.

This crushed coal is taken away to the furnace through coal pipes with the help of hot and cold mixture P.A fan. This
fan takes atmospheric air, a part of which is sent to pre heaters while a part goes to the mill for temperature control.
Atmospheric air from F.D fan in the air heaters and sent to the furnace as combustion air.

Water from boiler feed pump passes through economizer and reaches the boiler drum . Water from the drum passes
through the down comers and 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 density difference the water rises up in the water wall tubes. This steam and
water mixture is again taken to the boiler drum where the steam is sent to super heaters for super heating. The super
heaters are located inside the furnace and the steam is super heated (540 degree Celsius) and finally it goes to the
turbine.

Fuel gases from the furnace are extracted from the induced draft fan, which maintains balance draft in the furnace
with F.D fan. These fuel gases heat energy to the various super heaters and finally through air pre heaters and goes to
electrostatic precipitators where the ash particles are extracted. This ash is mixed with the water to from slurry is
pumped to ash period.

The steam from boiler is conveyed to turbine through the steam pipes and through stop valve and control valve that
automatically regulate the supply of steam to the turbine. Stop valves and controls valves are located in steam chest
and governor driven from main turbine shaft operates the control valves the amount used.

Steam from controlled valves enter high pressure cylinder of turbines, where it passes through the ring of blades
fixed to the cylinder wall. These act as nozzles and direct the steam into a second ring of moving blades mounted on
the disc secured in the turbine shaft. The second ring turns the shaft as a result of force of steam. The stationary and
moving blades together.

MAIN GENERATOR 
Maximum continuous KVA rating 24700KVA
Maximum continuous KW 210000KW
Rated terminal voltage 15750V
Rated Stator current 9050 A
Rated Power Factor 0.85 lag
Excitation current at MCR Condition 2600 A
Slip-ring Voltage at MCR Condition 310 V
Rated Speed 3000 rpm
Rated Frequency 50 Hz
Short circuit ratio 0.49
Efficiency at MCR Condition 98.4%
Direction of rotation viewed Anti Clockwise
Phase Connection Double Star
Number of terminals brought out 9( 6 neutral and 3 phase)

MAIN TURBINE DATA

Rated output of Turbine 210 MW

Rated speed of turbine 3000 rpm
Rated pressure of steam before emergency 130 kg/cm^2
Stop valve rated live steam temperature 535 degree Celsius
Rated steam temperature after reheat at inlet to receptor valve 535 degree Celsius
Steam flow at valve wide open condition 670 tons/hour
Rated quantity of circulating water through condenser 27000 cm/hour
1. For cooling water temperature (degree Celsius) 24,27,30,33
1.Reheated steam pressure at inlet of interceptor valve in kg/cm^2 23,99,24,21,24,49,24.82
ABS
2.Steam flow required for 210 MW in ton/hour 68,645,652,662
3.Rated pressure at exhaust of LP turbine in mm of Hg 19.9,55.5,65.4,67.7
THERMAL POWER PLANT

A Thermal Power Station comprises all of the equipment and a subsystem required to produce electricity by using a
steam generating boiler fired with fossil fuels or befouls to drive an electrical generator. Some prefer to use the term
ENERGY CENTER because such facilities convert forms of energy, like nuclear energy, gravitational potential
energy or heat energy (derived from the combustion of fuel) into electrical energy. However, POWER PLANT is the
most common term in the united state; While POWER STATION prevails in many Commonwealth countries and
especially in the United Kingdom.
Such power stations are most usually constructed on a very large scale and designed for continuous operation.
Typical diagram of a coal fired thermal power station
1. Cooling water pump
2. Three-phase transmission line 
3. Step up transformer
4. Electrical Generator
5. Low pressure steam
6. Boiler feed water pump
7. Surface condenser
8. Intermediate pressure steam turbine
9. Steam control valve
10. High pressure steam turbine
11. Deaerator Feed water heater
12. Coal conveyor
13. Coal hopper
14. Coal pulverizer
15. boiler steam drum 
16. Bottom ash hoper 
17. Super heater
18. Forced draught(draft) fan
19. Reheater
20. Combustion air intake
21. Economizer
22. Air preheater
23. Precipitator
24. Induced draught(draft) fan
25. Fuel gas stack

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

1. Cooling towers 

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

2.Three phase transmission line

Three phase electric power is a common method of electric power transmission. It is a type of polyphase system
mainly used to power motors and many other devices. A Three phase system uses less conductor material to transmit
electric power than equivalent single phase, two phase, or direct current system at the same voltage. In a three phase
system, three circuits reach their instantaneous peak values at different times. Taking one conductor as the reference,
the other two current are delayed in time by one-third and two-third of one cycle of the electrical current. This delay
between “phases” has the effect of giving constant power transfer over each cycle of the current and also makes it
possible to produce a rotating magnetic field in an electric motor.
At the power station, an electric generator converts mechanical power into a set of electric currents, one from each
electromagnetic coil or winding of the generator. The current are sinusoidal functions of time, all at the same
frequency but offset in time to give different phases. In a three phase system the phases are spaced equally, giving a
phase separation of one-third one cycle. Generators output at a voltage that ranges from hundreds of volts to 30,000
volts. At the power station, transformers: step-up” this voltage to one more suitable for transmission.
After numerous further conversions in the transmission and distribution network the power is finally transformed to
the standard mains voltage (i.e. the “household” voltage).
The power may already have been split into single phase at this point or it may still be three phase. Where the step-
down is 3 phase, the output of this transformer is usually star connected with the standard mains voltage being the
phase-neutral voltage. Another system commonly seen in North America is to have a delta connected secondary with
a center tap on one of the windings supplying the ground and neutral. This allows for 240 V three phase as well as
three different single phase voltages( 120 V between two of the phases and neutral , 208 V between the third phase
( known as a wild leg) and neutral and 240 V between any two phase) to be available from the same supply.
3.Electrical generator 

An Electrical generator is a device that converts kinetic energy to electrical energy, generally using electromagnetic
induction. The task of converting the electrical energy into mechanical energy is accomplished by using a motor. The
source of mechanical energy may be a reciprocating or turbine steam engine, , water falling through the turbine are
made in a variety of sizes ranging from small 1 hp (0.75 kW) units (rare) used as mechanical drives for pumps,
compressors and other shaft driven equipment , to 2,000,000 hp(1,500,000 kW) turbines used to generate electricity.
There are several classifications for modern steam turbines.
Steam turbines are used in all of our major coal fired power stations to drive the generators or alternators, which
produce electricity. The turbines themselves are driven by steam generated in ‘Boilers’ or ‘steam generators’ as they
are sometimes called.
Electrical power station use large stem turbines driving electric generators to produce most (about 86%) of the
world’s electricity. These centralized stations are of two types: fossil fuel power plants and nuclear power plants. The
turbines used for electric power generation are most often directly coupled to their-generators .As the generators
must rotate at constant synchronous speeds according to the frequency of the electric power system, the most
common speeds are 3000 r/min for 50 Hz systems, and 3600 r/min for 60 Hz systems. Most large nuclear sets rotate at
half those speeds, and have a 4-pole generator rather than the more common 2-pole one.

Energy in the steam after it leaves the boiler is converted into rotational energy as it passes through the turbine. The
turbine normally consists of several stage with each stages consisting of a stationary blade (or nozzle) and a rotating
blade. Stationary blades convert the potential energy of the steam into kinetic energy into forces, caused by pressure
drop, which results in the rotation of the turbine shaft. The turbine shaft is connected to a generator, which produces
the electrical energy.

4.Boiler feed water pump

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

Construction and operation

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

6. Control valves
Control valves are valves used within industrial plants and elsewhere to control operating conditions such as
temperature,pressure,flow,and liquid Level by fully partially opening or closing in response to signals received from
controllers that compares a “set point” to a “process variable” whose value is provided by sensors that monitor
changes in such conditions. The opening or closing of control valves is done by means of electrical, hydraulic or
pneumatic systems

7. Deaerator

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

8. Feed water heater

A Feed water heater is a power plant component used to pre-heat water delivered to a steam generating boiler.
Preheating the feed water reduces the irreversible involved in steam generation and therefore improves the
thermodynamic efficiency of the system.[4] This reduces plant operating costs and also helps to avoid thermal shock
to the boiler metal when the feed water is introduces back into the steam cycle.
In a steam power (usually modeled as a modified Ranking cycle), feed water heaters allow the feed water to be
brought up to the saturation temperature very gradually. This minimizes the inevitable irreversibility’s associated
with heat transfer to the working fluid (water). A belt conveyor consists of two pulleys, with a continuous loop of
material- the conveyor Belt – that rotates about them. The pulleys are powered, moving the belt and the material on
the belt forward. Conveyor belts are extensively used to transport industrial and agricultural material, such as grain,
coal, ores etc.

9. Pulverizer

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

10. Boiler Steam Drum

Steam Drums are a regular feature of water tube boilers. It is reservoir of water/steam at the top end of the water
tubes in the water-tube boiler. They store the steam generated in the water tubes and act as a phase separator for the
steam/water mixture. The difference in densities between hot and cold water helps in the accumulation of the
“hotter”-water/and saturated –steam into steam drum. Made from high-grade steel (probably stainless) and its
working involves temperatures 390’C and pressure well above 350psi (2.4MPa). The separated steam is drawn out
from the top section of the drum. Saturated steam is drawn off the top of the drum. The steam will re-enter the
furnace in through a super heater, while the saturated water at the bottom of steam drum flows down to the mud-
drum /feed water drum by down comer tubes accessories include a safety valve, water level indicator and fuse plug. A
steam drum is used in the company of a mud-drum/feed water drum which is located at a lower level. So that it acts
as a sump for the sludge or sediments which have a tendency to the bottom.

11. Super Heater

A Super heater is a device in a steam engine that heats the steam generated by the boiler again increasing its thermal
energy and decreasing the likelihood that it will condense inside the engine. Super heaters increase the efficiency of
the steam engine, and were widely adopted. Steam which has been superheated is logically known as superheated
steam; non-superheated steam is called saturated steam or wet steam; Super heaters were applied to steam
locomotives in quantity from the early 20th century, to most steam vehicles, and so stationary steam engines
including power stations.

12. Economizers
Economizer, or in the UK economizer, are mechanical devices intended to reduce energy consumption, or to perform
another useful function like preheating a fluid. The term economizer is used for other purposes as well. Boiler, power
plant, and heating, ventilating and air conditioning. In boilers, economizer are heat exchange devices that heat fluids ,
usually water, up to but not normally beyond the boiling point of the fluid. Economizers are so named because they
can make use of the enthalpy and improving the boiler’s efficiency. They are a device fitted to a boiler which saves
energy by using the exhaust gases from the boiler to preheat the cold water used the fill it (the feed water). Modern
day boilers, such as those in cold fired power stations, are still fitted with economizer which is decedents of Green’s
original design. In this context they are turbines before it is pumped to the boilers. A common application of
economizer is steam power plants is to capture the waste hit from boiler stack gases (flue gas) and transfer thus it to
the boiler feed water thus lowering the needed energy input , in turn reducing the firing rates to accomplish the rated
boiler output . Economizer lower stack temperatures which may cause condensation of acidic combustion gases and
serious equipment corrosion damage if care is not taken in their design and material selection.

13. Air Preheater

Air preheater is a general term to describe any device designed to heat air before another process (for example,
combustion in a boiler). The purpose of the air preheater is to recover the heat from the boiler flue gas which
increases the thermal efficiency of the boiler by reducing the useful heat lost in the fuel gas. As a consequence, the
flue gases are also sent to the flue gas stack (or chimney) at a lower temperature allowing simplified design of the
ducting and the flue gas stack. It also allows control over the temperature of gases leaving the stack.

14. Precipitator

An Electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate device that removes particles from a
flowing gas (such As air) using the force of an induced electrostatic charge. Electrostatic precipitators are highly
efficient filtration devices, and can easily remove fine particulate matter such as dust and smoke from the air steam.
ESP’s continue to be excellent devices for control of many industrial particulate emissions, including smoke from
electricity-generating utilities (coal and oil fired), salt cake collection from black liquor boilers in pump mills, and
catalyst collection from fluidized bed catalytic crackers from several hundred thousand ACFM in the largest coal-
fired boiler application.

The original parallel plate-Weighted wire design (described above) has evolved as more efficient ( and robust)
discharge electrode designs were developed, today focusing on rigid discharge electrodes to which many sharpened
spikes are attached , maximizing corona production. Transformer –rectifier systems apply voltages of 50-100
Kilovolts at relatively high current densities. Modern controls minimize sparking and prevent arcing, avoiding
damage to the components. Automatic rapping systems and hopper evacuation systems remove the collected
particulate matter while on line allowing ESP’s to stay in operation for years at a time.

15. Fuel gas stack

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

(CONTROL AND INSTRUMENTATION)

I was assigned to do training in control and instrumentation from 25th June 2007 to 14th July 2007 

CONTROL AND INSTRUMENTATION

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

It has following labs:

1. MANOMETRY LAB
2. PROTECTION AND INTERLOCK LAB
3. AUTOMATION LAB
4. WATER TREATEMENT LAB
5. FURNACE SAFETY SUPERVISORY SYSTEM(FSSS)
6. ELECTRONICS TEST LAB

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.

5.0 MANOMETRY LAB

5.0.1 TRANSMITTERS
It 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.

5.0.2 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.

5.0.3 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 2 types:

(a) Spiral type: for Low pressure measurement.

(b) Helical Type: for High pressure measurement.

5.1 PROTECTION AND INTERLOCK LAB

5.1.1 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 a fault occurs and any one of the tripping is satisfied a signal is
sent to the relay, which trips the circuit. The main equipments of this lab are relay and circuit breakers. Some of the
instrument uses for protection are:
1. 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.
2. 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. 

5.1.2 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

5.1.3 ROTECTION 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.
5.2 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.
Once the measured is common i.e. pressure the control circuits can easily be designed with single chips having
multiple applications. Another point is the universality of the supply, the laws of electronic state that it can be any
where between 12V and 35V in the plant. All the control instruments are excited by 24V supply (4-20mA) because
voltage can be mathematically handled with ease therefore all control systems use voltage system for computation.
The latest technology is the use of ‘ETHERNET’ for control signals. 5.3 PYROMETER LAB 
(1) 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.

(2) 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.

(3) 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.

(4) 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). 5.4 FURNACE SAFETY AND SUPERVISORY SYSTEM LAB 
This lab has the responsibility of starting fire in the furnace to enable the burning of coal. For first stage coal burners
are in the front and rear of the furnace and for the second and third stage corner firing is employed. Unburnt coal is
removed using forced draft or induced draft fan. The temperature inside the boiler is 1100 degree Celsius and its
height is 18 to 40 m. It is made up of mild steel. An ultra violet sensor is employed in furnace to measure the intensity
of ultra violet rays inside the furnace and according to it a signal in the same order of same mV is generated which
directly indicates the temperature of the furnace.
For firing the furnace a 10 KV spark plug is operated for ten seconds over a spray of diesel fuel and pre-heater air
along each of the feeder-mills. The furnace has six feeder mills each separated by warm air pipes fed from forced
draft fans. In first stage indirect firing is employed that is feeder mills are not fed directly from coal but are fed from
three feeders but are fed from pulverized coalbunkers. The furnace can operate on the minimum feed from three
feeders but under not circumstances should any one be left out under operation, to prevent creation of pressure
different with in the furnace, which threatens to blast it.

5.5 ELECTRONICS LAB

This lab undertakes the calibration and testing of various cards. It houses various types of analytical instruments like
oscilloscopes, integrated circuits, cards auto analyzers etc.
Various processes undertaken in this lab are:
1. Transmitter converts mV to mA.
2. Auto analyzer purifies the sample before it is sent to electrodes. It extracts the magnetic portion.

5.6 ANNUNCIATIN CARDS 

They are used to keep any parameter like temperature etc. within limits. It gets a signal if parameter goes beyond
limit. It has a switching transistor connected to relay that helps in alerting the UCB.

39. Control and Instrumentation Control and Instrumentation 

Measuring Instrumentsments 

In any process the philosophy of instrumentation should provide a comprehensive intelligence feed back on the
important parameters viz. Temperature, Pressure, Level and Flow. This Chapter Seeks to provide a basic
understanding of the prevalent instruments used for measuring the above parameters. 
Temperature Measurement 

The most important parameter in thermal power plant is temperature and its measurement plays a vital role in safe
operation of the plant. Rise of temperature in a substance is due to the resultant increase in molecular activity of the
substance on application of heat; which increases the internal energy of the material. Therefore there exists some
property of the substance, which changes with its energy content. The change may be observed with substance itself
or in a subsidiary system in thermodynamic equilibrium, which is called testing body and the system itself is called
the hot body. 

Expansion Thermometer 

Solid Rod Thermometers a temperature sensing - Controlling device may be designed incorporating in its
construction the principle that some metals expand more than others for the same temperature range. Such a device
is the thermostat used with water heaters (Refer Fig. 69). 

Fig No.-69 Rod Type Thermostat 

The mercury will occupy a greater fraction of the volume of the container than it will at a low temperature.
Under normal atmospheric conditions mercury normally boils at a temperature of (347°C). To extend the range of
mercury in glass thermometer beyond this point the top end of a thermometer bore opens into a bulb which is many
times larger in capacity than the bore. This bulb plus the bore above the mercury, is then filled with nitrogen or
carbon dioxide gas at a sufficiently high pressure to prevent boiling at the highest temperature to which the
thermometer may be used.
Mercury in Steel the range of liquid in glass thermometers although quite large, does not lend itself to all industrial
practices. This fact is obvious by the delicate nature of glass also the position of the measuring element is not always
the best position to read the result. Types of Hg in Steel Thermometers are: 

Bourdon Tube
Most common and simplest type (Refer Fig. 71) 

Spiral type
More sensitive and used where compactness is necessary

Helical Type
Most sensitive and compact. Pointer may be mounted direct on end of helix
Which rotates, thus eliminating backlash and lost motion?
Linkages, which only allow the pointer to operate over a selected range of pressure to either side of the normal steam
pressure. (Refer Fig No.77) 

Dewrance Critical Pressure Gauge Measurement of Level 

Direct Methods 

'Sight Glass' is used for local indication on closed or open vessels. A sight glass is a tube of toughened glass connected
at both ends through packed unions and vessel. The liquid level will be the same as that in the vessel. Valves are
provided for isolation and blow down. 
"Float with Gauge Post" is normally used to local indication on closed or open vessels. 
"Float Operated Dial" is used for small tanks and congested areas. The float arm is connected to a quadrant and
pinion which rotates the pointer over a scale. 
Bourden Pressure Gauge a Bourdon pressure gauge calibrated in any fact head is often connected to a tank at or
near the datum level. 
"Mercury Manometer" is used for remote indication of liquid level. The working principle is the same as that of a
manometer one limp of a U-tube is connected to the tank, the other being open to atmosphere. The manometer liquid
must not mix with the liquid in the vessel, and where the manometer is at a different level to the vessel, the static head
must be allowed in the design of the manometer. 
'Diaphragm Type' is used for remote level indication in open tanks or docks etc. A pressure change created by the
movement of a diaphragm is proportional to a change in liquid level above the diaphragm. This consists of a
cylindrical box with a rubber or plastic diaphragm across its open end as the level increases .the liquid pressure on
the diaphragm increases and the air inside is compressed. This pressure is transmitted via a capillary tube to an
indicator or recorder incorporating a pressure 
Measuring element. 

Sealed Capsule Type The application and principle is the same as for the diaphragm box. In this type, a capsule filled
with an inert gas under a slight pressure is exposed to the pressure due to the head of liquid and is connected by a
capillary to an indicator. In some cases the capsule is fitted external to the tank and is so arranged that it can be
removed whilst the tank is still full, a spring loaded valve automatically shutting off the tapping point. 
Air Purge System This system provides the simplest means of obtaining an indication of level, or volume, at a
reasonable distance and above or below, the liquid being measured. The pressure exerted inside an open ended tube
below the surface of a liquid is proportional to the depth of the liquid 

The Measurement of Flow 

Two principle measurements are made by flow meters viz. quantity of flow and rate of flow. 'Quantity of flow' is the
quantity of fluid passing a given point in a given time, i.e. gallons or pounds. ‘Rate of flow' is the speed of. a fluid
passing a given point at a given instant and is proportional to quantity passing at a given instant, i.e. gallons per
minute or pounds per hour. There are two groups of measuring devices: -

Positive, or volumetric, which measure flow by transferring a measured quantity of fluid from the inlet to the outlet. 

Inferential, which measures the velocity of the flow and the volume passed is inferred, it being equal to the velocity
times the cross sectional area of the flow. The inferential type is the most widely used. 

Measurement of Fluid Flow through Pipes: 

"The Rotating Impeller Type" is a positive type device which is used for medium quantity flow measurement i.e.,
petroleum and other commercial liquids. It consists of 
Two fluted rotors mounted in a liquid tight case fluid flow and transmitted to a counter. 
Rotating Oscillating Piston Type This is also a positive type device and is used for measuring low and medium
quantity flows, e.g. domestic water supplies. This consists of a brass meter body into which is fitted a machined brass
working chamber and cover, containing a piston made of ebonite. This piston acts as a moving chamber and transfers
a definite volume of fluid from the inlet to the outlet for each cycle. 
Helical Vane Type For larger rates of flow, a helical vane is mounted centrally in the body of the meter. The helix
chamber may be vertical or horizontal and is geared to a counter. Usually of pipe sizes 3" to 10" Typical example is
the Kent Torrent Meter. 
Turbine Type this like the helical Vane type is a inference type of device used for 
large flows with the minimum of pressure drop. This consists of a turbine or drum 
revolving in upright bearings, retaining at the top by a collar. Water enters the drum 
from the top and leaves tangentially casings to rotate at a speed dependent upon the 
quantity of water passed. The cross sectional area of the meter throughout is equal to 
the area of the inlet and outlet pipes and is commonly used on direct supply water 
mains, 
Combination Meters this is used for widely fluctuating flows. It consists of a larger 
meter (helical, turbine or fan) in the main with a small rotary meter or suitable type in a 
bypass. Flow is directed into either the main or bypass according to the quantity of flow 
by an automatic valve. By this means flows of 45 to 40,000 gallons per hour can be 
measured. 

Measurement of Fluid Flow through Open Channels: 

The Weir If a fluid is allowed to flow over a square weir of notch, The height of the liquid above the still of the weir,
or the bottom of the notch will be a measure of the rate of flow.

A formula relates the rate of flow to the height and is dependent upon the design of the 
Venturi Flumes The head loss caused by the weir flow meter is considerable and its 
construction is sometimes complicated, therefore the flume is sometimes used. The 
principle is same as that of venture except that the rate of flow is proportional to the 
depth of the liquid in the upstream section. It consists of a local contraction in the cross 
section of flow through a channel in the shape of a venturi. It is only necessary to 
measure the depth of the upstream section which is a measure of the rate of flow. This 
may be done by pressure tapping at the datum point or by a float in an adjacent level 
chamber. 
Pressure Difference Flow meters These are the most widely used type of flow meter since they are capable of
measuring the flow of all industrial fluids passing through pipes. They consists of a primary element inserted in the
pipeline which generates a differential pressure, ^he magnitude of which is proportional to the square of the rate of
flow and a secondary element which measures this differential pressure and translates it into terms of flow. (Refer
fig. 79). 
Fig. No-79 Pressure Differential Flow meters

Primary elements Bernoulli's theorem states that the quantity of fluid or gas flowing is proportional to the square
root of the differential pressure. There are four principal types of primary elements (or restrictions) as enumerate
below: 
Venturi; This is generally used for medium and high quantity fluid flow and it consists of two hollow truncated cones,
the smaller diameters of which are connected together by a short length of parallel pipe, the smallest diameter of the
tube formed by this length of parallel pipe is known as the throat section and the lower of the two pressures, (the
throat, or downstream pressure) is measured here. 
Orifice Plate This is the oldest and most common form of pressure differential device. In its simplest form it consists
of a thin metal plate with a central hold clamped between two pipe flanges. In the metering of dirty fluids or fluids
containing solids the hole is placed so that its lower edge coincides with the inside bottom of the pipe. (Refer Fig.80) It
is essential that the leading edge of the hole is absolutely sharp rounding or burring would have a very marked effect
on the flow. 

Fig No.-80 Typical Orifice Plate Pressure Tapping 

EMD I

Electrical Maintenance division I

I was assigned to do training in Electrical maintenance division I from 17th July 2007 to 28th July 2007. 

This two week of training in this division were divided as follows.

· 17th to 19th July 2007- HT/LT switchgear
· 21st to 24th July 2007 - HT/LT Motors, Turbine &Boiler side
· 26th to 28th July 2007- CHP/NCHP Electrical

Electrical maintenance division 1

It is responsible for maintenance of:

1. Boiler side motors

2. Turbine side motors
3. Outside motors
4. Switchgear

1. Boiler side motors:

For 1, units 1, 2, 3

1.1D Fans 2 in no.

2.F.D Fans 2 in no.
3.P.A.Fans 2 in no.
4.Mill Fans 3 in no.
5.Ball mill fans 3 in no.
6.RC feeders 3 in no.
7.Slag Crushers 5 in no.
8.DM Make up Pump 2 in no.
9.PC Feeders 4 in no.
10.Worm Conveyor 1 in no.
11.Furnikets 4 in no.

For stage units 1, 2, 3

1.I.D Fans 2 in no.

2.F.D Fans 2 in no.
3.P.A Fans 2 in no.
4.Bowl Mills 6 in no.
5.R.C Feeders 6 in no.
6.Clinker Grinder 2 in no.
7.Scrapper 2 in no.
8.Seal Air Fans 2 in no.
9.Hydrazine and Phosphorous Dozing 2 in no.
2/3 in no.

1. COAL HANDLING PLANT (C.H.P)

2. NEW COAL HANDLING PLANT (N.C.H.P)
The old coal handling plant caters to the need of units 2,3,4,5 and 1 whereas the latter supplies coal to units 4 and
V.O.C.H.P. supplies coal to second and third stages in the advent coal to usable form to (crushed) form its raw form
and send it to bunkers, from where it is send to furnace.
Major Components

1. Wagon Tippler: - Wagons from the coal yard come to the tippler and are emptied here. The process is performed
by a slip –ring motor of rating: 55 KW, 415V, 1480 RPM. This motor turns the wagon by 135 degrees and coal falls
directly on the conveyor through vibrators. Tippler has raised lower system which enables is to switch off motor
when required till is wagon back to its original position. It is titled by weight balancing principle. The motor lowers
the hanging balancing weights, which in turn tilts the conveyor. Estimate of the weight of the conveyor is made
through hydraulic weighing machine.
2. Conveyor: - There are 14 conveyors in the plant. They are numbered so that their function can be easily
demarcated. Conveyors are made of rubber and more with a speed of 250-300m/min. Motors employed for conveyors
has a capacity of 150 HP. Conveyors have a capacity of carrying coal at the rate of 400 tons per hour. Few conveyors
are double belt, this is done for imp. Conveyors so that if a belt develops any problem the process is not stalled. The
conveyor belt has a switch after every 25-30 m on both sides so stop the belt in case of emergency. The conveyors are
1m wide, 3 cm thick and made of chemically treated vulcanized rubber. The max angular elevation of conveyor is
designed such as never to exceed half of the angle of response and comes out to be around 20 degrees.

3. Zero Speed Switch:-It is safety device for motors, i.e., if belt is not moving and the motor is on the motor may burn.
So to protect this switch checks the speed of the belt and switches off the motor when speed is zero.

4. Metal Separators: - As the belt takes coal to the crusher, No metal pieces should go along with coal. To achieve this
objective, we use metal separators. When coal is dropped to the crusher hoots, the separator drops metal pieces
ahead of coal. It has a magnet and a belt and the belt is moving, the pieces are thrown away. The capacity of this
device is around 50 kg. .The CHP is supposed to transfer 600 tons of coal/hr, but practically only 300-400 tons coal is
transfer
5. Crusher: - Both the plants use TATA crushers powered by BHEL. Motors. The crusher is of ring type and motor
ratings are 400 HP, 606 KV. Crusher is designed to crush the pieces to 20 mm size i.e. practically considered as the
optimum size of transfer via conveyor.

6. Rotatory Breaker: - OCHP employs mesh type of filters and allows particles of 20mm size to go directly to RC
bunker, larger particles are sent to crushes. This leads to frequent clogging. NCHP uses a technique that crushes the
larger of harder substance like metal impurities easing the load on the magnetic separators.
MILLING SYSTEM

1. RC Bunker: - 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. Ball Mill: - 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.

4. Classifier:- It is an 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. Cyclone Separators: - It separates the pulverized coal from carrying medium. The mixture of pulverized coal
vapour caters the cyclone separators.

6. The Tturniket: - It serves to transport pulverized coal from cyclone separators to pulverized coal bunker or to
worm conveyors. There are 4 turnikets per boiler. 

7. Worm Conveyor: - 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.

8. Mills Fans: - It is of 3 types:

Six in all and are running condition all the time.
(a) ID Fans: - Located between electrostatic precipitator and chimney.
Type-radical
Speed-1490 rpm
Rating-300 KW
Voltage-6.6 KV
Lubrication-by oil
(b) FD Fans: - Designed to handle secondary air for boiler. 2 in number and provide ignition of coal.

Type-axial
Speed-990 rpm
Rating-440 KW
Voltage-6.6 KV

(c)Primary Air Fans: - Designed for handling the atmospheric air up to 50 degrees Celsius, 2 in number

And they transfer the powered coal to burners to firing.

Type-Double suction radial

Rating-300 KW
Voltage-6.6 KV
Lubrication-by oil
Type of operation-continuous

9. Bowl Mill: - One of the most advanced designs of coal pulverizes presently manufactured.

Motor specification –squirrel cage induction motor

Rating-340 KW
Voltage-6600KV
Curreen-41.7A
Speed-980 rpm
Frequency-50 Hz
No-load current-15-16 A

NCHP 

1. Wagon Tippler:- 

Motor Specification
(i) H.P 75 HP
(ii) Voltage 415, 3 phase
(iii) Speed 1480 rpm
(iv) Frequency 50 Hz
(v) Current rating 102 A 

2. Coal feed to plant:- 

Feeder motor specification 

(i) Horse power 15 HP

(ii) Voltage 415V,3 phase
(iii) Speed 1480 rpm
(iv) Frequency 50 Hz

3. Conveyors:-
10A, 10B
11A, 11B
12A, 12B
13A, 13B
14A, 14B
15A, 15B
16A, 16B
17A, 17B
18A, 18B

4. Transfer Point 6

5. Breaker House

6. Rejection House
7. Reclaim House

8. Transfer Point 7

9. Crusher House

10. Exit

The coal arrives in wagons via railways and is tippled by the wagon tipplers into the hoppers. If coal is oversized
(>400 mm sq) then it is broken manually so that it passes the hopper mesh. From the hopper mesh it is taken to the
transfer point TP6 by conveyor 12A ,12B which takes the coal to the breaker house , which renders the coal size to be
100mm sq. the stones which are not able to pass through the 100mm sq of hammer are rejected via conveyors
18A,18B to the rejection house . Extra coal is to sent to the reclaim hopper via conveyor 16. From breaker house coal
is taken to the TP7 via Conveyor 13A, 13B. Conveyor 17A, 17B also supplies coal from reclaim hopper, From TP7
coal is taken by conveyors 14A, 14B to crusher house whose function is to render the size of coal to 20mm sq. now the
conveyor labors are present whose function is to recognize and remove any stones moving in the conveyors . In
crusher before it enters the crusher. After being crushed, if any metal is still present it is taken care of by metal
detectors employed in conveyor 10.

SWITCH GEAR-

It makes or breaks an electrical circuit.

1. Isolation: - A device which breaks an electrical circuit when circuit is switched on to no load. Isolation is normally
used in various ways for purpose of isolating a certain portion when required for maintenance.

2. Switching Isolation: - It is capable of doing things like interrupting transformer magnetized current, interrupting
line charging current and even perform load transfer switching. The main application of switching isolation is in
connection with transformer feeders as unit makes it possible to switch out one transformer while other is still on
load.

3. Circuit Breakers: - 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.

LT Switchgear 

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 tha 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. Rotary switch up to 25A. 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. Contractors: - 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 over 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 50-60 kg/cm^2 for high and medium capacity circuit
breakers.
HT SWITCH GEAR:- 

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
· Operating Coils-CC 220 V/DC
§ FC 220V/DC
· 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 o that of air blast circuit breaker. It simply employs the arc
extinguishing medium namely SF6. the performance of gas . 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
· Rated Short Time Current 1/3s -40 A
· Mass Approximation-185 KG
· Auxiliary Voltage
§ Closing Coil-220 V/DC
§ Opening Coil-220 V/DC
· Motor-220 V/DC
· SF6 Pressure at 20 Degree Celsius-0.25 KG
· SF6 Gas Per pole-0.25 KG

4. Vacuum Circuit Breaker: - It works on the principle that vacuum is used to save the purpose of insulation and it
implies that pr. Of gas at which breakdown voltage independent of pressure. It 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
· Rated Current-1250 A
· Supply Voltage Tripping-220 V/DC
· Insulation Level-IMP 75 KVP
· Rated Short Time Current-40 KA (3 SEC)
· Weight of Breaker-8 KG

EMD II

Electrical Maintenance division II

I was assigned to do training in Electrical maintenance division II from 31st July 2007 to 11th August 2007. 
This two week of training in this division were divided as follows.

· 31st to 2nd August 2007- Generator

· 4th August 2007 - Transformer &switchyard
· 7th August 2007 - protection
· 9th August2007 - Lightning
· 11th August 2007 - EP

Generator and Auxiliaries Generator and Auxiliaries 

Generator Fundamentals Fundamentals 
The transformation of mechanical energy into electrical energy is carried out by the Generator. This Chapter seeks
to provide basic understanding about the working principles and development of Generator. 

Working Principle 

The A.C. Generator or alternator is based upon the principle of electromagnetic induction and consists generally of a
stationary part called stator and a rotating part called rotor. The stator housed the armature windings. The rotor
houses the field windings. D.C. voltage is applied to the field windings through slip rings. When the rotor is rotated,
the lines of magnetic flux (viz magnetic field) cut through the stator windings. This induces an electromagnetic force
(e.m.f.) in the stator windings. The magnitude of this e.m.f. is given by the following expression. 

E = 4.44 /O FN volts
0 = Strength of magnetic field in Weber’s.
F = Frequency in cycles per second or Hertz.
N = Number of turns in a coil of stator winding
F = Frequency = Pn/120
Where P = Number of poles
n = revolutions per second of rotor.

From the expression it is clear that for the same frequency, number of poles increases with decrease in speed and vice
versa. Therefore, low speed hydro turbine drives generators have 14 to 20 poles where as high speed steam turbine
driven generators have generally 2 poles. Pole rotors are used in low speed generators, because the cost advantage as
well as easier construction. 

Development 

The first A.C. Generator concept was enunciated by Michael Faraday in 1831. In 1889 Sir Charles A. Parsons
developed the first AC turbo-generator. Although slow speed AC generators have been built for some time, it was not
long before that the high-speed generators made its impact. 
Development contained until, in 1922, the increased use of solid forgings and improved techniques permitted an
increase in generator rating to 20MW at 300rpm. Up to the out break of second world war, in 1939, most large
generator;- were of the order of 30 to 50 MW at 3000 rpm. 
During the war, the development and installation of power plants was delayed and in order to catch up with the delay
in plant installation, a large number of 30 MW and 60 MW at 3000 rpm units were constructed during the years
immediately following the war. The changes in design in this period were relatively small. 
In any development programme the. Costs of material and labour involved in manufacturing and erection must be a
basic consideration. Coupled very closely with 
these considerations is the restriction is size and weight imposed by transport limitations. 

Development of suitable insulating materials for large turbo-generators is one of the 

most important tasks and need continues watch as size and ratings of machines 
increase. The present trend is the use only class "B" and higher grade materials and 
extensive work has gone into compositions of mica; glass and asbestos with 
appropriate bonding material. An insulation to meet the stresses in generator slots must 
follow very closely the thermal expansion of the insulated conductor without cracking or 
any plastic deformation. Insulation for rotor is subjected to lower dielectric stress but 
must withstand high dynamic stresses and the newly developed epoxy resins, glass 
and/or asbestos molded in resin and other synthetic resins are finding wide 
applications. 

Generator component
This Chapter deals with the two main components of the Generator viz. Rotor, its winding & balancing and stator, its
frame, core & windings. 

Rotor 

The electrical rotor is the most difficult part of the generator to design. It revolves in 
most modern generators at a speed of 3,000 revolutions per minute. The problem of 
guaranteeing the dynamic strength and operating stability of such a rotor is complicated 
by the fact that a massive non-uniform shaft subjected to a multiplicity of differential 
stresses must operate in oil lubricated sleeve bearings supported by a structure 
mounted on foundations all of which possess complex dynamic be behavior peculiar to 
themselves. It is also an electromagnet and to give it the necessary magnetic strength 
the windings must carry a fairly high current. The passage of the current through the 
windings generates heat but the temperature must not be allowed to become so high, 
otherwise difficulties will be experienced with insulation. To keep the temperature down, 
the cross section of the conductor could not be increased but this would introduce 
another problems. In order to make room for the large conductors, body and this would 
cause mechanical weakness. The problem is really to get the maximum amount of 
copper into the windings without reducing the mechanical strength. With good design 
and great care in construction this can be achieved. The rotor is a cast steel ingot, and 
it is further forged and machined. Very often a hole is bored through the centre of the 
rotor axially from one end of the other for inspection. Slots are then machined for 
windings and ventilation. 

Rotor winding 

Silver bearing copper is used for the winding with mica as the insulation between conductors. A mechanically strong
insulator such as micanite is used for lining the slots. Later designs of windings for large rotor incorporate
combination of hollow conductors with slots or holes arranged to provide for circulation of the cooling gas 
through the actual conductors. When rotating at high speed. Centrifugal force tries to lift 
the windings out of the slots and they are contained by wedges. The end rings are 
secured to a turned recess in the rotor body, by shrinking or screwing and supported at 
the other end by fittings carried by the rotor body. The two ends of windings are 

connected to slip rings, usually made of forged steel, and mounted on insulated 
sleeves. 

Rotor balancing 

When completed the rotor must be tested for mechanical balance, which means that a 
check is made to see if it will run up to normal speed without vibration. To do this it 
would have to be uniform about its central axis and it is most unlikely that this 
will be so to the degree necessary for perfect balance. Arrangements are therefore 
made in all designs to fix adjustable balance weights around the circumference at each 
end. 

Stator 

Stator frame: The stator is the heaviest load to be transported. The major part of this load is the stator core. This
comprises an inner frame and outer frame. The outer frame is a rigid fabricated structure of welded steel plates,
within this shell is a fixed cage of girder built circular and axial ribs. The ribs divide the yoke in the compartments
through which hydrogen flows into radial ducts in the stator core and circulate through the gas coolers housed in the
frame. The inner cage is usually fixed in to the yoke by an arrangement of springs to dampen the double frequency
vibrations inherent in 2 pole generators. The end shields of hydrogen cooled generators must be strong enough to
carry shaft seals. In large generators the frame is constructed as two separate parts. The fabricated inner cage is
inserted in the outer frame after the stator core has been constructed and the winding completed. Stator core: The
stator core is built up from a large number of 'punching" or sections of thin steel plates. The use of cold rolled grain-
oriented steel can contribute to reduction in the weight of stator core for two main reasons: 

a) There is an increase in core stacking factor with improvement in lamination cold

Rolling and in cold buildings techniques.

b) The advantage can be taken of the high magnetic permeance of grain-oriented 

steels of work the stator core at comparatively high magnetic saturation without 
fear or excessive iron loss of two heavy a demand for excitation ampere turns 
from the generator rotor. 

Stator Windings 

Each stator conductor must be capable of carrying the rated current without overheating. The insulation must be
sufficient to prevent leakage currents flowing between the phases to earth. Windings for the stator are made up from
copper strips wound with insulated tape which is impregnated with varnish, dried under vacuum and hot pressed to
form a solid insulation bar. These bars are then place in the stator slots and held in with wedges to form the complete
winding which is connected together at each end of the core forming the end turns. These end turns are rigidly
braced and packed with blocks of insulation material to withstand the heavy forces which might result from a short
circuit or other fault conditions. The generator terminals are usually arranged below the stator. On recent generators
(210 MW) the windings are made up from copper tubes instead of strips through which water is circulated for
cooling purposes. The water is fed to the windings through plastic tubes. 

Generator Cooling System 

The 200/210 MW Generator is provided with an efficient cooling system to avoid excessive heating and consequent
wear and tear of its main components during operation. This Chapter deals with the rotor-hydrogen cooling system
and stator water cooling system along with the shaft sealing and bearing cooling systems. 

Rotor Cooling System 

The rotor is cooled by means of gap pick-up cooling, wherein the hydrogen gas in the 
air gap is sucked through the scoops on the rotor wedges and is directed to flow along 
the ventilating canals milled on the sides of the rotor coil, to the bottom of the slot where 
it takes a turn and comes out on the similar canal milled on the other side of the rotor 
coil to the hot zone of the rotor. Due to the rotation of the rotor, a positive suction as 
well as discharge is created due to which a certain quantity of gas flows and cools the 
rotor. This method of cooling gives uniform distribution of temperature. Also, this 
method has an inherent advantage of eliminating the deformation of copper due to 
varying temperatures. 

Hydrogen Cooling System 

Hydrogen is used as a cooling medium in large capacity generator in view of its high heat carrying capacity and low
density. But in view of its forming an explosive mixture with oxygen, proper arrangement for filling, purging and
maintaining its purity inside the generator have to be made. Also, in order to prevent escape of hydrogen from the
generator casing, shaft sealing system is used to provide oil sealing. 

The hydrogen cooling system mainly comprises of a gas control stand, a drier, an liquid level indicator, hydrogen
control panel, gas purity measuring and indicating instruments, 
The system is capable of performing the following functions : 

Filling in and purging of hydrogen safely without bringing in contact with air.
Maintaining the gas pressure inside the machine at the desired value at all the
times.
Provide indication to the operator about the condition of the gas inside the
machine i.e. its pressure, temperature and purity.
Continuous circulation of gas inside the machine through a drier in order to 
remove any water vapour that may be present in it. 
Indication of liquid level in the generator and alarm in case of high level. 

Stator Cooling System 

The stator winding is cooled by distillate. Which is fed from one end of the machine by Teflon tube and flows through
the upper bar and returns back through the lower bar of another slot? 
Turbo generators require water cooling arrangement over and above the usual hydrogen cooling arrangement. The
stator winding is cooled in this system by circulating demineralised water (DM water) through hollow conductors.
The cooling water used for cooling stator winding calls for the use of very high quality of cooling water. For this
purpose DM water of proper specific resistance is selected. Generator is to be loaded within a very short period if the
specific resistance of the cooling DM water goes beyond certain preset values. The system is designed to maintain a
constant rate of cooling water flow to the stator winding at a nominal inlet water temperature of 40 deg.C. 

Rating of 95 MW Generator
Manufacture by Bharat heavy electrical Limited (BHEL)

Capacity - 117500 KVA

Voltage - 10500V
Speed - 3000 rpm
Hydrogen - 2.5 Kg/cm2 
Power factor - 0.85 (lagging)
Stator current - 6475 A
Frequency - 50 Hz 
Stator wdg connection - 3 phase 

Rating of 210 MW Generator

Capacity - 247000 KVA

Voltage (stator) - 15750 V
Current (stator) - 9050 A
Voltage (rotor) - 310 V
Current (rotor) - 2600 V
Speed - 3000 rpm
Power factor - 0.85
Frequency - 50 Hz
Hydrogen - 3.5 Kg/cm2
Stator wdg connection - 3 phase star connection
Insulation class - B

TRANFORMER

A transformer is a device that transfers electrical energy from one circuit to another by magnetic
coupling with out requiring relative motion between its parts. It usually comprises two or more coupled
windings, and in most cases, a core to concentrate magnetic flux. An alternating voltage applied to one
winding creates a time-varying magnetic flux in the core, which includes a voltage in the other windings.
Varying the relative number of turns between primary and secondary windings determines the ratio of
the input and output voltages, thus transforming the voltage by stepping it up or down between circuits.
By transforming electrical power to a high-voltage,_low-current form and back again, the transformer
greatly reduces energy losses and so enables the economic transmission of power over long distances.
It has thus shape the electricity supply industry, permitting generation to be located remotely from point
of demand. All but a fraction of the world’s electrical power has passed trough a series of transformer by
the time it reaches the consumer.

Basic principles 

The principles of the transformer are illustrated by consideration of a

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

Rating of transformer
Manufactured by Bharat heavy electrical limited
No load voltage (hv) - 229 KV
No load Voltage (lv) -10.5 KV
Line current (hv) - 315.2 A
Line current (lv) - 873.2 A
Temp rise - 45 Celsius
Oil quantity -40180 lit
Weight of oil -34985 Kg
Total weight - 147725 Kg
Core & winding - 84325 Kg
Phase - 3
Frequency - 50 Hz