1.

Projected view of Kalisindh Thermal Power Plant,

Jhalawar

PROJECT BRIEF DESCRIPTION

The site of Kalisindh Thermal Power Project is located in Nimoda, Undal, Motipura, Singharia and Devri villages of Tehsil Jhalarapatan, Distt. Jhalawar. The proposed capacity of coal based Thermal Power Project is 1200 MW(600*2). The project site is about 12 km from Jhalawar (Distt. Head quarter) met from Kalisindh River. The total water allocated for Plant is 1200 MCFT per year and will be

SAILENT FEATURES
Projectv Current Capacity Project Site Kalisindh Super Thermal Power Project Jhalawar 1200 MW(2x600 MW) Village-Undel, Motipura, Nimoda, Singhania & Deveri of Tehsil Jhalarapatan, Distt. Jhalawar Project Location Land Area Water source The project site is about 12 km from NH-12. 2230 Bigha/564 Hq. and Dam on Kalisindh river. 3400 CuM/ Hrs. Coal-560 Lacs TPA 275 Mtr. Rs.5416 Crores

quantity Quantity of Fuel Stack Height Estimated Cost

Sl. No. 01 02 03
5

Start of

Start of

Boiler D

Introductory overview Almost all coal, nuclear, geothermal, solar thermal electric, and waste incineration plants, as well as many natural gas power plants are thermal. Natural gas is frequently combusted in gas turbines as well as boilers. The waste heat from a gas turbine can be used to raise steam, in a combined cycle plant that improves overall efficiency. Power plants burning coal, fuel oil, or natural gas are often called fossil-fuel power plants. Some biomass-fueled thermal power plants have appeared also. Non-nuclear thermal power plants, particularly fossil-fueled plants, which do not use co-generation are sometimes referred to as conventional power plants. Commercial electric utility power stations are usually constructed on a large scale and designed for continuous operation. Electric power plants typically use three-phase electrical generators to produce alternating current (AC) electric power at a frequency of 50 Hz or 60 Hz. Large companies or institutions may have their own power plants to supply heating or electricity to their facilities, especially if steam is created anyway for other purposes. Steam-driven power plants have been used in various large ships, but are now usually used in large naval ships. Shipboard power plants usually directly couple the turbine to the ship's propellers through gearboxes. Power plants in such ships also provide steam to smaller turbines driving electric generators to supply electricity. Shipboard steam power plants can be either fossil fuel or nuclear. Nuclear marine propulsion is, with few exceptions, used only in naval vessels. There have been perhaps about a dozen turbo-electric ships in which a steam-driven turbine drives an electric generator which powers an electric motor for propulsion. combined heat and power (CH&P) plants, often called co-generation plants, produce both electric power and heat for process heat, space heating, or process heat. Steam and hot water lose energy when piped over substantial distance, so carrying heat energy by steam or hot water is often only worthwhile within a local area, such as a ship, industrial plant, or district heating of nearby buildings.

History
Reciprocating steam engines have been used for mechanical power sources since the 18th Century, with notable improvements being made by James Watt. The very first commercial central electrical generating stations in the Pearl Street Station, New York and the Holborn Viaduct power station, London, in 1882, also used reciprocating steam engines. The development of the steam turbine allowed larger and more efficient central generating stations to be built. By 1892 it was considered as an alternative to reciprocating engines [2] Turbines offered higher speeds, more compact machinery, and stable speed regulation allowing for parallel synchronous operation of generators on a common bus. Turbines entirely replaced reciprocating engines in large central stations after about 1905. The largest reciprocating engine-generator sets ever built were completed in 1901 for the Manhattan Elevated Railway. Each of seventeen units weighed about 500 tons and was rated 6000 kilowatts; a contemporary turbine-set of similar rating would have weighed about 20% as much. [3]

Efficiency
The energy efficiency of a conventional thermal power station, considered as salable energy as a percent of the heating value of the fuel consumed, is typically 33% to 48%. This efficiency is limited as all heat engines are governed by the laws of thermodynamics. The rest of the energy must leave the plant in the form of heat. This waste heat can go through a condenser and be disposed of with cooling water or in cooling towers. If the waste heat is instead utilized for district heating, it is called co-generation. An important class of thermal power station are associated with desalination facilities; these are typically found in desert countries with large supplies of natural gas and in these plants, freshwater production and electricity are equally important co-products.

A Rankine cycle with a two-stage steam turbine and a single feed water heater. Since the efficiency of the plant is fundamentally limited by the ratio of the absolute temperatures of the steam at turbine input and output, efficiency improvements require use of higher temperature, and therefore higher pressure, steam. Historically, other working fluids such as mercury have been used in a mercury vapor turbine power plant, since these can attain higher temperatures than water at lower working pressures. However, the obvious hazards of toxicity, high cost, and poor heat transfer properties, have ruled out mercury as a working fluid. Above the critical point for water of 705 F (374 C) and 3212 psi (22.06 MPa), there is no phase transition from water to steam, but only a gradual decrease in density. Boiling does not occur and it is not possible to remove impurities via steam separation. In this case a super critical steam plant is required to utilize the increased thermodynamic efficiency by operating at higher temperatures. These plants, also called once-through plants because boiler water does not circulate multiple times, require additional water purification steps to ensure that any impurities 8

picked up during the cycle will be removed. This purification takes the form of high pressure ion exchange units called condensate polishers between the steam condenser and the feed water heaters. Sub-critical fossil fuel power plants can achieve 3640% efficiency. Super critical designs have efficiencies in the low to mid 40% range, with new "ultra critical" designs using pressures of 4400 psi (30.3 MPa) and dual stage reheat reaching about 48% efficiency. Current nuclear power plants operate below the temperatures and pressures that coal-fired plants do. This limits their thermodynamic efficiency to 3032%. Some advanced reactor designs being studied, such as the Very high temperature reactor, Advanced gas-cooled reactor and Super critical water reactor, would operate at temperatures and pressures similar to current coal plants, producing comparable thermodynamic efficiency.

Cost of electricity
See also: Relative cost of electricity generated by different sources. The direct cost of electric energy produced by a thermal power station is the result of cost of fuel, capital cost for the plant, operator labour, maintenance, and such factors as ash handling and disposal. Indirect, social or environmental costs such as the economic value of environmental impacts, or environmental and health effects of the complete fuel cycle and plant decommissioning, are not usually assigned to generation costs for thermal stations in utility practice, but may form part of an environmental impact assessment.

Diagram of a typical coal-fired thermal power station

Typical diagram of a coal-fired thermal power station 1. Cooling tower 10. Steam Control valve 19. Superheater 11. High pressure steam 2. Cooling water pump 20. Forced draught (draft) fan turbine 3. transmission line (3-phase) 12. Deaerator 21. Reheater 4. Step-up transformer (3-phase) 13. Feedwater heater 22. Combustion air intake 5. Electrical generator (3-phase) 14. Coal conveyor 23. Economiser 6. Low pressure steam turbine 15. Coal hopper 24. Air preheater 7. Condensate pump 16. Coal pulverizer 25. Precipitator 8. Surface condenser 17. Boiler steam drum 26. Induced draught (draft) fan 9. Intermediate pressure steam 18. Bottom ash hopper 27. Flue gas stack turbine For units over about 200 MW capacity, redundancy of key components is provided by installing duplicates of the forced and induced draft fans, air preheaters, and fly ash collectors. On some units of about 60 MW, two boilers per unit may instead be provided. 10

 ADVANTAGES & DISADVANTAGES OF A THERMAL POWER PLANT Some of the advantages and disadvantages of the Thermal Power Plant are given below. Advantages 1. The fuel used is quite cheap. 2. Less initial cost as compared to other generating plants. 3. It can beinstalled at any place iirespective of the existence of coal. The coal can be transported to the site of the plant by rail or road. 4. It require less space as compared to Hydro power plants. 5. Cost of generation is less than that of diesel power plants. Disadvantages 1. It pollutes the atmosphere due to production of large amount of smoke and fumes. 2. It is costlier in running cost as compared to Hydro electric plants.

LAYOUT OF THERMAL POWER PLANT

ADMN. BLOCK
COOLING TOWER 3 COOLING 11 TOWER 4

COOLING TOWER 2

COOLING TOWER 1

C.I.S.F. OFFIC E

FIRE BRIGE DE

CANTE EN

WOR K SHO P WATER TREATM ENT PLANT

SWITCH SWITCH
YARD BOILER AREA T/F ARE A

YARD

CHIMNE YES

POWER HOUSE

CIVIL OFFIC E

COAL YARD

COOLIN G TOWER

3 .COAL HANDLING PLANT

12

Coal delivery equipment is one of the major components of plant cost. Coal handling consists of the following steps:1. Coal delivery 2. Unloading 3. Preparation 4. Transfer (Conveyor) 5. Storage (Yard) 6. Implant handling 7. Crushing and pulverizing 8. Weighing and measuring 9. Feeding the coal into furnace NOTE: - The coal storage capacity of the plant is 3, 00,000 tones and the feeding capacity is 500 tones/hr. 13

The source of coal is Khalari and Barkakana .QUALITY OF COAL 1. Grade of Coal: E.F. 2. Calorific value of coal: 4000 K cal/kg. 3. Ash content of the coal: 41% EQUIPMEMTS USED:1. Wagon Tripler: - Unloading capacity is 500 tones/hr.

2. Swing feeder 3. Traveling Tripler 4. Reclaim hopper 5. Vibrator feeder 6. Magnetic drum 7. Belt scales 8. Belt feeders 9. Crushers 10. Bunker hopper 11. R C Bunker Material Used Width Top cover Bottom cover Grade : : : : : Nylon (6 ply) 1200mm 3.15mm 1.50mm 24m

For the generation of steam, we used coal in large amount. It is fossil fuels. Coal is classified as:14

*Peat

*Lignite

*Bituminous

and

*Anthracite

The manpower of coal handling is: 1. Russian 400MW, Indian 440MW 2. To know the calorific value (required fire as steam used) 3. To Crush large size raw coal into small size (40mm) 4. To remove impurities & provide good flame to boiler. Main Parts:1. Wagon Tripler: - It is a set of motor, gearbox, railway bogey. It helps in loading. 2. Bunker Hopper: - Bunker Hopper, in which square holes so that large size coal dont pass to conveyor. 3. B.F. (Belt Feeder):- Help to carry this coal. 4. Conveyor: - Set of belt of different sizes it is used to Carry coal from one place to another. 5. Crusher: - To crush or break the coal into 40mm size. 6. RCH (Reclaim hopper) + swing feeder (SF):- To send coal to yard to swing feeder with the help of Bull Dozer. Fixed Tripler A&B Plough Feeder Blade Feeder (BF) Traveling Tripler: - For every conveyor two tripler give to bunker coal on both sides as requirement.

4. WATER TREATMENT PLANT

15

Water is an essential part of any power house for electricity generation. In the Thermal Plant, steam is produced by heating of water and steam passed through turbine to move the generator for the production of electricity. To produce steam, pure water is required. But the water available contains many impurities, which are:1. Un-dissolved and suspended materials mud, solid like

sediment,

sand, sodium and potassium etc. iron, salts,

Sometimes manganese

or silica are also present. 2. Dissolved and which carbonates, bicarbonates, sulphates chlorides calcium magnesium. 16 and of and salts

impurities include

3. Dissolved such as

gases carbon and

dioxide bicarbonates. 4. Other

materials

such as oil, acid, etc. Therefore the above impurities damage the boiler and turbine to a great extent. Thus it is required to check the water and make special treatment before using it in the power plant. In Patratu Thermal Power Station, water is treated in two stages:ii.) iii.) At the source (Filtration Plant) At the plant.

AT THE SOURCE: - In the filtration plant water is treated in three stages to remove solid particles by mixing alum, chloride and bleaching powder. In the filtration plant water is treated in three stages to remove slid particles. Here removes the impurities by mixing alum, chlorides & bleaching powder. 1. USE OF ALUM:-Firstly water is stored in the water tank. Water contains muddy particles. When the alum is dissolved the muddy particles being heavy settle at the bottom and the fresh water is collected. 2. BY USE OF BLEACHING POWDER:-After collection of the fresh water, bleaching powder is used for the extraction of bacteria. 3. BY USE OF CHLORINE:-Water is passed through the chlorine layer which results in removal of oil or acidic particles.

17

After this the collected water reaches the Chemical Water Treatment Plant (C.W.T.P). Here it goes through various processes discussed below:1. Stored in the raw water tank. The starting of CWTP. 2. Passed through M.G.T (Multi Grade Filter), by the help of feed pumps. There are 2 feed pumps present at P.T.P.S. One feed pump is working and the other is kept reserve for emergency. In this process sand particles are extracted and the sand free water is collected. 3. Filtration through A.C.F (Activated Carbon Filter):- In this process organic carbon is removed. 4. Filtration by C.E (Cation Exchanger):-After passing through A.C.F, water is passed through C.E. This process removes all the acidic particles in water. 5. Use of Degasser:-Here the reaction gases produced after passing through the cation exchanger are released into the atmosphere. 6. Filtration by A.E (Anion Exchanger):-By passing through the anion exchanger, mixed salts which are present in the water are removed. The anion resin used in P.T.P.S.C.W.T.P is FFI. This is a complex polymer compound which contains free ions. 7. M.B (Mixed Bed):-It is also called ion separator. In this two layers are formed, one of cation and the other of anion. Due to light weight anion is collected at the upper part and the heavy cation ions are collected at the bottom part. After all these processes, water is collected in the D.M.W.T (De-Mineralized Water Tank). TEST OF WATER:Before feeding the water to boiler, the de-mineralized water is tested for satisfaction. De-mineralized water should have the following specifications:Hardness Nil Silica Less than 0.02 ppm 18

Conductivity Less than 1 /cm.

5. STEAM BOILER
In the Thermal Power Plant Steam is the first necessary source to generate the Electricity. Equipment is used for the production of named boiler. There is a phenomenon occurs that water 19

is heated up to certain temperature and got steam. Steam is generated by boiler and after passing through super heaters, turbine, L.P. Heaters, H.P. Heaters. It again sent into the boiler.

Fig No. 5.1

MAIN PARTS OF BOILER:1. BOILER DRUM: - It is stock of water which is situated at the top of the furnace. The shape of the boiler is spherical and dimensions used in P.T.P.S is:Length Diameter : 15000 mm : 1800 mm

Capacity of drum : 70 tones/hr. Thickness : 97 mm

2. WATER WALLIS: - Inside the furnace there is a large number of vertical tubes for the production of steam. All the tubes are connected with bottom header by which water is filled

20

inside the tube and very nearer to each other when water is heated, steam is collected in the upper part of the tubes and through the upper header steam is ejected. 3. FURNACE CHAMBER:-Furnace chamber is a closed vessel inside the chamber fire bents. There is provision for entry of coal oil through the pipes inside the chamber for burning. 4. ECONOMISER: - Economizer is used to preheat the feed water. The furnace chamber economizer is situated in the way of exhaust flue gases. When flue gases pass through that area, the economizer is also heated which in turn heats the feed water flowing through it. 5. AIR PREHEATER:-Air pre-heater is a equipment used for heating the passing air before reaching the boiler furnace. 6. SUPER HEATER:-By the super heaters, we get superheated steam with very high temperatures. Super heaters are placed in the boiler before the steam inlet into the turbine. 7. BURNERS:-Burners are used for firing into the furnace chamber. 8. REHEATERS:-Reheaters are used to raise the temperature of steam. Reheaters are connected into the furnace chamber. Through reheater, the steam pipe is injected and after passing steam, temperature of steam is raised.

AUXILARIES:1. P.A FAN (Primary Air Fan):-It is used for carrying pulverized coal dust from p.c.feeder. Two primary fans are used for each unit at P.T.P.S. 2. CYCLONE SEPARATOR:-It is connected with the ceiling inside the furnace. Inside the cyclone separator, the moisture of steam and water be massed and through separator steam be taken with steam raise. 3. INDUCED DRAUGHT FAN: - Induced draught fan is used for evacuating flue gases through the chimney. 21

4. FORCED DRAUGHT FAN:-Forced draught fan is used for the supply of air inside the furnace for burning. 5. CONDENSATE PUMP: - It is used for pumping the hot condensate back to the boiler. 6. BOILER FEED PUMP: - The cooling the hot water is ejected from hot well. 7. BOILER FEED PUMP: - Bolder feed pump is used for water supply into the boiler drum. In the PTPS 2. No. of boiler feed pump is used (one is reserved and one is working with one boiler.) 8. CIRCULATING WATER PUMP:-By the use of circulating water pump, we pass the cold water which is used to cool the hydrogen gas present in the turbine. COAL FEEDERS: - for feeding the pulverized coal inside the furnace. In P.T.P.S, 6nos. is share 1+4 each boiler, 16nos is shore III and inbuilt phase tout reach boiler.

22

6. STEAM TURBINE

Fig No. 6.1 The 110 MW condensing steam turbine is designed directly coupling with Hydrogen cooled generator. The steam turbine is designated for operation with live steam at 36 kg. pressure and 535-540C temperature as measured before the entry into the turbine emergency stop valve. The steam turbine has three cylinder mixed blades with a wheel as the governing stage and so pressure stage. The turbine is divided into three parts:1. H.P High pressure 2. M.P Medium pressure 23

3. L.P Low pressure After each pressure section in the steam turbine, bearings are connected. Due to this movement of the rotor, the turbine is easy to operate. PRINCIPLE:-There are two parts of a turbine:1. Stator part 2. Rotor part The blades of the turbine make some angle with the shaft. Due to injection of steam, rotor is rotating and a generator is directly coupled with the steam turbine shaft. Rotational energy of the turbine shaft is directly transferred to the rotor of generator and after rotation, electricity is produced WORKING:At the starting position, steam is firstly injected in the medium pressure cylinder of the turbine. Before this operation, by the bearing gear, we give some rotation (approx. 63 rpm), which is operated electrically. Due to injection we raise the speed of turbine rotor blades up to 500 rpm. After this operation, main steam line stop valve is opened which is operated at the H.P Cylinder side. After rotation the steam pressure is constant but temperature decreases. So again the steam is extracted and is injected in the M.P Cylinder section for reheating. After this operation, steam is injected to the L.P Cylinder section. Turbine rotor is a flexible one with a critical speed of 1755 rpm.

24

STEAM EXTRACTION:The steam turbine has five outlet steam extraction pipe for the extraction of steam after operation. Pipes are insulated with thermosetting materials. The rest steam again goes to the boiler. Extraction steam turbine is designated for feed water heating up to 218C in L.P. heater; steam up to 25 t/hr. is extracted from 1st, 2nd and 3rd extraction line. Besides steam up to 7 t/hr. is used for heating up deareator from 2nd or 3rd extraction line steam pipes. Precaution- to be taking at start of rotating of turbines. DIFFERENTIAL EXPANSION:H.P. - 1.5mm to 3.5mm M.P. - 1.5mm to 3.5mm L.P. - 2.0mm to 4.0mmM AXIAL SHIFT DISPLACEMENT: +/- 0.65mm H.P. Total Expansion- 25m SYSTEM OF THE TURBINE (110 MW) 1. 4 control valve + 2 interceptor valves

H.P. cylinder:-2 rows of Curtis wheel + 8 action wheel 2. Medium pressure cylinder:-2 action wheels. Weight of M.P. cylinder:-11000 kg. (approx.) 3. Low pressure cylinder:

4. Action wheel of double flow direction Weight of low pressure rotor (approx):-4000 kgs. Direction of the turbine rotation to the right wheel Rotors rotate at 62 rpm on bearing gears. Number of non-regulated extractions = 8 25

7.GENERATOR
INTRODUCTION:Alternators (A.C generator) are also known as synchronous generator. Its main function is to convert mechanical power from a prime mover to electric power at a specific voltage and frequency. Large generators are used to generate bulk power at thermal, hydroelectric and nuclear power stations. 3-phase synchronize generators are used in 3-phase generation, transmission & distribution. A) STATOR:Stationary part, comes the armature winding in which voltage is generated i.e. output is taken from stator. YOKE (frame): Cast iron for small machine and welded steel for large machine. CORE: Assembled with high grade silicon content steel lamination to reduce iron losses. STATOR WINDING: A 3-phase winding puts in the slot in star connection. B) ROTOR:*salient pole rotor *cylindrical rotor

Rotor is a rotating part, which produces the main field flux in which supply is given through D.C. Generator is excited. In PTPS cylindrical rotor is used. 1. Slots are at regular intervals & parallel to the shaft on which D.C. field winding occurs. 2. Rotor is smoother machine, makes less winding losses & the operation is less noisy (due to uniform air gap). 3. Cylindrical rotor is two or four pole type alternator, which provides greater mechanical strength & permits more accurate balancing. 4. It is driven by steam or gas turbine i.e. turbo generator or turbo. 26

D.C.EXCITER:Excitation means production of flux by passing current in the field winding (rotor) from D.C. generator. As a rotor has no more residual magnetism, so first of all to make it electromagnetic i.e. dc is supplied to the rotor through brushes and slip ring. Brushes excite in which to eliminate the use of brushes & slip ring. PRINCIPLE-VOLTAGE GENERATION:A prime mover (machine) supplies the mechanical energy input to the alternator i.e. steam gas turbine-turbine. Actually, armature conductor on the stator, the field flux the armature conductors, voltage is generated. AVR (Automatic Voltage Regulated): It controls the system voltage with alternators. If any fault in the system-to increase the excitation for maximum synchronizing. F) SYNCHRONISM CASE:1. Frequency- supply frequency & grid frequency should be matched 2. Voltage- generated voltage & that voltage should be matched 3. Phase sequence- matching phase sequence (i.e. positive phase sequence) it should be at 60deg. either lagging or leading. G) PROTECTION:I. Negative phase sequence relay

II. Phase to phase fault. III. Phase to earth. IV. A) Over fluxing (B) over current and (C) over load over balanced load. V. Loss of excitation under power. 27

VI. Anti-motoring (Failure of Prime Mover). FAILURE:1. Prime Mover 2. AVR 3. Generator Breaker. INUCTION MOTOR:-If Prime Mover & remaining three will function. INDUCTION GENERATOR:-Only generator beaker fails & remaining three is function.

28

8. MOTOR

A.C. Motor

D.C. Motor

Universal Motor

Single Phase

Three Phase

Series

Compound

Shunt

Squirrel Cage Motor

Slip Ring Motor

There are mainly two parts of motor:a) Stator a) I. b) Rotor

Stator: - it consists following parts: Core: - Ferromagnetic material.

II. Coil :- (Double layer winding) Insulating material bakelite or fiber Each winding are stamped. It s main function to minimize the iron loss (eddy current loss and Hysteresis loss ) . III. Yoke (Frame) Winding are as flatted copper wire with insulator (F.Class insulator) i.e. glass tape, polyester etc. IV. Vent its main purpose is to pass air for cooling between stamping. V. Terminal box From Where terminal is pick cooling between Stamping. VI. Air circulating Fan: - Air is given from outside to keep the cool of winding.

29

b) Rotor:I. Slots Copper road or aluminum rod (Flatted) placed in the slot to minimize the iron loss. Both ends is shorted (cage). Vent for Cooling.

II Shaft: - it is a solid material of mild steel on which rotor mounted. III Bearing section. IV F.D. fan: - Outside from Both sides. V Coupling: - Connect to other Shaft 1. Faults :a) Fault in stator Breakdown of Shaft: - Friction will take place and damage it. Overload:- If within the time of tripping not care be taken, gets

Heating and damage due to overloading If any one phase found to be fault that means high voltage from Phase due to which it gets heating and damage. 2. Fault in rotor:Material failure- chance of braking Overload i.e. high mechanical load. To shear the shaft and the chance of breaking If any type of joint takes place in shaft, temp. Variation changes and the chance of damage.

Protection:30

i)

Joint should be welded or silver blazed

9. TRANSFORMERS

FIG.NO-9.1 A transformer is a device that transfers electrical energy from one circuit to another through inductively coupled conductors the transformer's coils. Except for air-core transformers, the conductors are commonly wound around a single iron-rich core, or around separate but 31

magnetically-coupled cores. A varying current in the first or "primary" winding creates a varying magnetic field in the core (or cores) of the transformer. This varying magnetic field induces a varying electromotive force (EMF) or "voltage" in the "secondary" winding. This effect is called mutual induction. If a load is connected to the secondary, an electric current will flow in the secondary winding and electrical energy will flow from the primary circuit through the transformer to the load. In an ideal transformer, the induced voltage in the secondary winding (VS) is in proportion to the primary voltage (VP), and is given by the ratio of the number of turns in the secondary to the number of turns in the primary as follows: Vs/Vp = Ns/Np By appropriate selection of the ratio of turns, a transformer thus allows an alternating current (AC) voltage to be "stepped up" by making Ns greater than Np, or "stepped down" by making Ns less than Np. Transformers come in a range of sizes from a thumbnail-sized coupling transformer hidden inside a stage microphone to huge units weighing hundreds of tons used to interconnect portions of national power grids. All operate with the same basic principles, although the range of designs is wide. While new technologies have eliminated the need for transformers in some electronic circuits, transformers are still found in nearly all electronic devices designed for household ("mains") voltage. Transformers are essential for high voltage power transmission, which makes long distance transmission economically practical. Transformers are an integral part of the power production and distribution system. There are different varities of transformers, at power plants, at switchyards, at substation and at localities. They differ in terms of their size, functions, properties etc. 32

_ COMPONENTS OF A TRANSFORMER :(1) Main Tank The main tank contains the primary and secondary coils and the oil which is utilized for cooling as well as insulation. The cooling oil is termed as Power oil or Mineral oil.

(2) Conservator Tank Due to the fluctuations in the connected load, the temperature inside the main tank may go up or down. Correspondingly the oil also may expand or contract. Thu to provide a free space to the expanded oil, we have the Conservator. (3) Buchholz Relay It is situated between the main tank and the conservator tank. It has the following two functions :(A) To evolve away the unwanted gases formed due to the heat generation through the valves. (B) To sense the rate of flow of the oil from the main tank to the conservator tank or vice-versa. A high rate of flow indicates sudden rise or drop in temperature which indicates fault occurrences. It raises an alarm when such a condition arises. (4) Breather The breather is connected to the conservator tank through a pipe and allows the entry of air through it. The air entering the pipe must be free from moisture and dust. Hence the following arrangments are made :(A) Silica-Gel It traps the moisture in the air, else the moisture would cause corrosion inside the system. 33

(B) Oil -- Its function is to absorb the dust particles, they would reduce the insulation of the system inside. The Silica-Gel and the Oil are kept in a container called Keep. (5) Valves It is placed on the upper part of the main tank. It is used for taking out sample oil for testing and reconditioning. (6) Tap Changer It is used to adjust the incoming voltage and outgoing voltage by adjusting the number of turns of the coil. (7) Drain Valve It is placed at the bottom of the main tank to drain away the oil completely for reconditioning. Name Plate Readings :(33/11 kV & 4 MVA) Transformer at Construction Power Switchyard Rated kVA 4000 kVA Rated kV 33,000 kV (HV) 11,500 kV (LV) Rated Line Current 70.0 A (HV) 200.8 A (LV) Phase & Connection 3 _ , Dyn ( Primary Delta ) (Secondary Star ),(Neutral - Grnd) Frequency 50 Hz. Tye of cooling ONAN Ambient Temperature Top Oil = 50 degrees Centigrate Avg. Winding Temperature = 55 degrees Centigrate % Impedence (HV-LV) 7.25 Volume of Oil 2220 litres WEIGHT:Mass of Oil 5020 kg 34

Core & Oil 1950 kg Tank & Fittings 2950 kg Total Mass 9900 kg Transportable Mass 8250 kg

10. SWITCHYARD

Since Barh Super Thermal Power Project is under construction phase, there is no erection at Barh during this period. Thus NTPC Barh has taken two 33kV feeder lines from Bihar State Electricity Board (BSEB). This power is called CONSTRUCTION POWER , and is used by NTPC at Barh campus for construction work, residential areas and offices.There are two feeder lines of 33kV each and it is being converted to 11kV at construction power switchyard. The feeder lines are connected to Isolators-1 and then the two feeders are coupled through a BusCoupler Isolator and then passed through Isolators-2, then they are feeded into the Power Transformer (P.T), which steps down the voltage to feed to the VCB (Vaccum Circuit Breakers). Thereafter, it is sent to the Current Transformer (C.T) which steps up the voltage and sends to the Incomer Panel. There are two Incomer Panels and four Outgoing panels, out of which one is spare. The 11kV outgoing line is sent through the Outgoing panels 2, 3 and 4 via cables, to the feeders of 11kV line each. Out of the 3 feeder lines, the first one is used for constructional areas, second one serves the residential areas and third one is used by the offices. From the 3 feeders of 11kV line, there are 17 different substations, converting 11kV to 440 volts and serving to the agencies through MCCB panels. 35

The MCCB panels have one incomer panel of 600 A and 6 outgoing panels which are as follows :(1) 2 panels of 100 A. (2) 2 panels of 200 A. (3) 2 panels of 400 A. The agencies take up power as per requirement. The structure of construction power generally as follows:Two numbers of 33KV overhead lines from State Electricity board Construction of (1W+1SB)X 4MVA 33/11.5 KV substation in main plant area Construction of 11KV overhear radial system Construction of 500KVA 36

distribution substations 26 A VIEW OF A SWITCHYARD IS GIVEN BELOW.

_ BRIEF DESCRIPTION OF SWITCHYARD EQUIPMENTS (1) Circuit breakers :A Circuit Breaker is one which can break or make the circuit on load and even on faults. The equipment is most important and is heavy duty equipment mainly utilized for the protection of the various circuits and operation at load.Circuit breaker consists of a fixed contact and a moving contact. These contacts are enclosed in an interrupting chamber. The interrupting chamber contains any arc quenching medium such as oil, air or SF6 gas. The arc is initiated due to separation of contacts which carry high current.Interlocks for Circuit Breaker: 1) Breaker should not close until permission from the check synchronizing relay is available to ensure that the generator is connected to the end only after proper synchronization. 2) Breaker should not close unless field breaker is closed to avoid motoring of the generator. 3) Breaker should not close unless contacts of Master Trip Relay are reset, to avoid spurious tripping. 400KV SF6 CIRCUIT BREAKER Name Plate Details : Type Outdoor SF6 , Single pressure, live tank type 37

 Rated Frequency 50 Hz Number of poles 3 Rated operating duty cycle 0- 0.3Second -CO -3 min - CO Rated Short Circuit breaking current at rated voltage 40 kArms Symmetrical Interrupting Capability 40 kA Short Time current carrying capability 40 kA rms for 1 second Short Circuit making current capability 100 kApeak Reclosing 1 and 3- high speed Total closing time Not more than 150 ms Trip and Closing coil voltage 220 V DC Noise Level maximum 140 dB at 50 m (2) Isolators :An isolator is one which can break electric circuit when the circuit is to be switched on no load. These are normally used in electric circuits for the purposes of isolating a certain portion when required for maintenance etc. The isolators are driven by operating mechanism box normally installed near the ground level. The box has the operating mechanism in addition to its control circuit. The operating mechanism may be solenoid operated, pneumatic or simple motorized system. The following interlocks are provided with isolator 1). Isolator cannot operate unless the breaker is open. 2). Bus I and II isolators can not be closed simultaneously. 3). No isolator can operate when corresponding earth switch is ON. Name Plate Details : Type of Isolator outdoor type 38

 Rated frequency 50 Hz Number of poles 3 Operating time not more than 12 second Rated short time withstand current of isolator and earth switch 400 kArms for 1 second Control voltage 220 V DC Minimum creepage distance 10500mm System neutral earthing effectively earthed. Operating mechanism of isolator& motor operated earth switch 400KV HORIZONTAL CENTRAL BREAK TYPE ISOLATOR (3) Surge arrestor :Surge arrestors are provided at the terminals of the transformer and at the incoming terminals of line for protection against lightning or any surge developing in the system. The surge arrestor is made up of a non-linear resistance material usually of silicon carbide which has low resistance to high current and high resistance to low current. When a surge voltage of high magnitude having very high current is incident at the terminal of arrestor, a low resistance path is provided to the surge to the ground through non-linear resistor element. The surge arrestors shall be capable of discharging over voltages occurring due to switching of unloaded transformers, reactors and long lines. It shall be suitable for circuit breaker duty cycle in the system. The surge arrestors shall protect power transformers, Circuit Breakers, disconnecting switches, instrument transformers, shunt reactors with rated insulation levels.The non-linear blocks shall be sintered metal oxide material. 400KV CLASS SURGE ARRESTOR Name Plate Details :39

 System Neutral earthing effectively earthed Installation outdoor Rated frequency 50 Hz Prospective symmetrical fault current 40kA(rms)for 1 second

Particular 400 kV 132 kV Rated system voltage 420 kV 145 kV Rated arrestor voltage 390 kV 120 kV Minimum discharge capability 8 kJ/kV corresponding to minimum discharge characteristic 5kJ/kV corresponding to minimum discharge characteristic Switching surge residual voltage (1kA) 730 kVP minimum 780 kVP maximum 280 kVP maximum One minute dry/wet power 40

frequency withstand voltage of arrestor housing 630 kV(rms) 275 kV(rms) Impulse withstand voltage of arrestor housing with 1.2/50 microsecond wave 1425 kVP 650 kVP Maximum residual voltage at 1) 10 kA nominal discharge current 2) 20 kA " " 3) 5 kA " " 4) 10 kA" " 900 kVP 975 kVP --------310 kVP 330 kVP (4) Shunt Reactor :41

Services to be performed by the Shunt Reactor are as follows :(1) SR will be connected to the 400 kV bus for reactive load compensation and will be capable of controlling the dynamic over voltage occurring in the system. (2) SR should operate continuously at a voltage of 5% higher than their rated voltage without exceeding hot spot temperature of 140C at any part of the reactor. (3) Temperature rise shall be guaranteed when reactor is operating at rated voltage. (4) The reactor shall be subjected to switching surge over voltage up to 2.5 PU and temporary over voltage of the order of 2.3 PU for few cycles followed by power frequency over voltage up to 1.5 PU. The reactor must withstand the stresses due to above transient dynamic conditions which may cause additional current flow as a result of changed saturation characteristic/slope beyond 1.5 PU voltage. 400KV CLASS SHUNT REACTOR Name Plate Details : Rated voltage 420 kV(L.P.U.) Rated MVAR 80 at rated voltage Number of phases 3 System fault level 40 kA Connection _ with neutral through load Insulation level 33 1) Lightning impulse 1.2/50 1300 kV(peak) microsecond withstand voltage 2) Switching surge withstand voltage 1050 kV(peak) 3) One minute power frequency 630 kV(rms) 42

withstand voltage Cooling system ONAN Ratio of zero sequence reactance to positive reactance(X0/X1) Between 0.9 to 1 Clearance Phase to Phase 4000 mm Phase to Ground 3500 mm (5) Post Insulators :It is used for supporting bus bars, CTs, PTs, CBs etc. in the switchyard. Post type insulator consists of a particular part permanently secured in a metal base to be mounted on the supporting structure. It must be able to withstand any shocks to which they may be subjected to by the operation of the associated equipment. Parameters 400 kV 132 kV Type Solid core type -doVoltage class(kV) 400 145 Dry and wet 1minute power frequency withstand voltage(kV) 680 275 Dry impulse withstand voltage positive & negative (kVP) 1550 650 Total height of 43

Insulator(mm) 3650 1500 34 POST INSULATOR

(6) Wave Trap :Wave trap is inserted into high voltage transmission line to prevent undue loss of carrier signal for all power system conditions. Its impedance is negligible at power frequency so as not to disturb power transmission but is relatively high over the frequency band of carrier. It consists of a main coil designed to carry rated current continuously. For protection purpose, it also contains a lightning arrestor which is shunt connected to the main coil and tuning device. Name Plate Details : Rated power frequency 50 Hz 35 Rated system voltage 400 kV Rated continuous current 2000 A/3150 A Type of tuning Broad band Inductance 1.0 mH to 0.5 Mh 400KV CLASS WAVE TRAP

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11. CONCLUSION
The training at NTPC Barh successfully accomplished through the full co-operation and support of the engineers and officials of NTPC Barh. The training has been extremely beneficial and it also gave an exposure to the Industrial functioning and management of the entire corporation. From the point of concern of an Electrical Engineer, it gave a great experience to get on face to face with all the components and heavy engineering equipments in the Thermal Power Plant. How the generation is being done and what are the steps taken to transmit it over to larger distances was explained. Moreover, the functioning and equipment details of the Construction Power (33/11 kV) switchyard gave a chance to understand properly the working, precautions and the steps taken at times of faults. A detailed study and exposure to transformers gave a great insight to what had been taught to us in our course and has enhanced our knowledge towards the practical aspect of the entire system.

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1. B.R.GUP

P122, P12
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