Beruflich Dokumente
Kultur Dokumente
SUBMITTED BY:KANIKA AGARWAL B.TECH 2nd Year ELECTRICAL & ELECTRONICS ENGINEERING Enrollment No: 0591484908 Maharaja Agrasen Institue of Technology, Rohini Sec-22, Delhi-110086.
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TABLE OF CONTENTS
Certificate
Acknowledgement
Training at BTPS
1. Introduction NTPC Badarpur Thermal Power Station 2. Operation . 3. Electrical Maintenance Division-I HT/LT Switch Gear HT/LT Motors, Turbine & Boilers Side CHP/NCHP 4. Electrical Maintenance Division-II Generator Transformer & Switchyard Protection Lighting EP 5. Control & Instrumentation Manometry Lab Protection and interlock Lab Automation Lab Water Treatment Plant Furnace Safeguard Supervisory System Electronic Test Lab
CERTIFICATE
This is to certify that KANIKA AGARWAL student of Electrical & Electronics Engineering (2nd Year); Maharaja Agrasen Institute of Technology has successfully completed her industrial training at Badarpur Thermal power station New Delhi lasting for a period of (01st June to 10th July). She has completed the whole training as per the training report submitted by her.
Acknowledgement
With profound respect and gratitude, I take this opportunity to convey my heartfelt gratitude to various individuals involved in making this training a truly learning and enriching experience. 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 incharge of NIT Trichy and all the faculty member of Electrical & Electronics department for their effort and constant cooperation which have been a significant factor in the accomplishment of my industrial training.
Training at BTPS
I was appointed to do six-week training at this esteemed organization from 01st June to 10th July 2010. In these six 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 six-week training was like an 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 from self-experience at BTPS. The material in this report has been gathered from my textbooks, senior student reports, and trainer manual provided by training department. The specification & principles have been learnt by me from the employees 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.
Electrostatic Precipitators:
The ash left behind after combustion of coal is arrested in high efficiency Electrostatic Precipitators (ESPs) and particulate emission is controlled well within the stipulated norms. The ash collected in the ESPs is disposed to Ash Ponds in slurry form.
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.
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).
far less requirement of land and less water requirement as compared to the wet ash disposal system.
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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.
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.
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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 Indias 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.
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NTPC GROUP
NTPC Limited
Subsidiaries
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Joint Ventures
NTPC-SAIL Power Company Pvt. Limited 50% NTPC-SAIL Power Company Pvt. Limited 50 Bhilai Electric Supply Co. Pvt. Limited 50% NTPC Alstom Power Services Pvt. Limited 50% Utility Powertech Limited 50%
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INSTALLED CAPACITY
AN OVERVIEW
Projects NTPC OWNED COAL GAS/LIQ. FUEL TOTAL OWNED BY JVCs Coal Gas/LIQ. FUEL GRAND TOTAL 3 1 26 314* 740** 27,904 15 07 22 22,895 3,955 26,850 No. of Projects Commissioned Capacity (MW)
* Captive Power Plant under JVs with SAIL ** Power Plant under JV with GAIL, FIs & MSEB
PROJECT PROFILE
Coal Based Power Stations Commissioned Capacity (MW) 2,000 2,100 2,600 1,600 3,260 2,000 1,340 15
State Uttar Pradesh Chattisgarh Andhra Pradesh West Bengal Madhya Pradesh Uttar Pradesh Bihar
MAIN GENERATOR
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Maximum continuous KVA rating Maximum continuous KW Rated terminal voltage Rated Stator current Rated Power Factor Excitation current at MCR Condition Slip-ring Voltage at MCR Condition Rated Speed Rated Frequency Short circuit ratio Efficiency at MCR Condition Direction of rotation viewed Phase Connection Number of terminals brought out
24700KVA 210000KW 15750V 9050 A 0.85 lag 2600 A 310 V 3000 rpm 50 Hz 0.49 98.4% Anti Clockwise Double Star 9( 6 neutral and 3 phase)
Rated output of Turbine Rated speed of turbine Rated pressure of steam before emergency Stop valve rated live steam temperature Rated steam temperature after reheat at inlet to receptor valve Steam flow at valve wide open condition Sustainable Rated quantity of circulating water through condenser Development 1. For cooling water temperature (degree Celsius)
210 MW 3000 rpm 130 kg/cm^2 535 degree Celsius 535 degree Celsius 670 tons/hour 27000 cm/hour
24,27,30,33 Maintain 1.Reheated steam pressure at inlet of interceptor valve in sector 23,99,24,21,24,49,24.82 kg/cm^2 ABS Nurturing Leadership position 2.Steam flowHuman for 210 MW in ton/hour required 68,645,652,662 Resource through 3.Rated pressure at exhaust of LP turbine in mm of Hg 19.9,55.5,65.4,67.7 expansion
STRATEGI ES - NTPC
17 Technology Further
fuel security
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.
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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.
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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 worlds 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.
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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.
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.
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
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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)
9. Pulverizer
A pulverizer is a device for grinding coal for combustion in a furnace in a fossil fuel power plant.
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been superheated is logically known as superheated steam; nonsuperheated 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 boilers 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 Greens 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.
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. ESPs continue to be excellent devices for control of many industrial particulate emissions, including smoke from electricity-generating utilities (coal and oil fired), salt cake collection from black liquor boilers in pump mills, and catalyst collection from fluidized bed catalytic crackers from several hundred thousand ACFM in the largest coalfired boiler application. The original parallel plate-Weighted wire design
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(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 ESPs to stay in operation for years at a time.
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Electrical Maintenance division I I was assigned to do training in Electrical maintenance division I from 01st June 2010 to 14th June 2010. These weeks of training in this division were divided as follows.
Electrical maintenance division 1 It is responsible for maintenance of: 1. Boiler side motors 2. Turbine side motors 3. Outside motors 4. Switchgear
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Boiler side motors: For 1, units 1, 2, 3 1.1D Fans 2.F.D Fans 3.P.A.Fans 4.Mill Fans 5.Ball mill fans 6.RC feeders 7.Slag Crushers 8.DM Make up Pump 9.PC Feeders 10.Worm Conveyor 11.Furnikets
2 in no. 2 in no. 2 in no. 3 in no. 3 in no. 3 in no. 5 in no. 2 in no. 4 in no. 1 in no. 4 in no.
1.I.D Fans 2.F.D Fans 3.P.A Fans 4.Bowl Mills 5.R.C Feeders 6.Clinker Grinder 7.Scrapper 8.Seal Air Fans 9.Hydrazine and Phosphorous Dozing
2 in no. 2 in no. 2 in no. 6 in no. 6 in no. 2 in no. 2 in no. 2 in no. 2 in no. 2/3 in no.
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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
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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 & 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 Voltage6.6 KV Lubrication-by oil Type of operation-continuous
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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-1516 A
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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
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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. 6.
7.
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
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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 Celsius0.25 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 Voltage12 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
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EMD II
Electrical Maintenance division II- I was assigned to do training in Electrical maintenance division II from 14th June 2010 to 28th June 2010. This week of training in this division was divided as follows.
- Generator ,ESP,lighting.
-Excitation,Protection.
-Testing,Transformer.
-Switchyard.
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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 Webers. 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. 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.
Generator components
This Chapter deals with the two main components of the Generator viz. Rotor, its winding & balancing and stator, its frame, core & windings.
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
Rotor
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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.
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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.
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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.
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.
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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
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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 worlds 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 faradays 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
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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.
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
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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 42
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.
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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 Its 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 Its 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.
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sent to the relay, which trips the circuit. The main equipments of this lab are relay and circuit breakers. Some of the instrument used 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. 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.
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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.
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.
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 .
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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 (347C). 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.
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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.
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