CONTROL AND INSTRUMENTATION

This division is basically to calibrate various instruments and take care of

any faults that occur in any of the auxiliaries in the plant. It has the
following labs :

1. MANOMETRY LAB
2. PROTECTION AND INTERLOCKING LAB
3. AUTOMATION LAB
4. PYROMETRY LAB
5. TURBO SUPERVISORY INSTRUMENT LAB
6. WATER TREATMENT PLANT
7. FURNACE SAFETY SUPERVISORY SYSTEM
8. ELECTRONICS TEST LAB

This department is the brain of the plant, as from relays to transmitters

followed by the electronic computation chipsets and recorders and lastly
the controlling circuitry. The calibration and testing of new and repaired
instruments is also carried out by C & I labs.
 MANOMETRY LAB
The instruments are :

1. TRANSMITTERS

It is used for pressure measurement 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
below main process piping and for gas measurements transmitter is
placed above pipe.

2. MANOMETER

It has a liquid contained in a tube bent in the form of a ‘U’ and this
device corresponds to a difference in pressure across two limbs.

3. BOURDON PRESSURE GAUGE

The oval section tube, which has one fixed and other attached to the
rack and pinion arrangement, which has a pointer to indicate the
pressure on a calibrated scale. There are two types :
 Spiral type for low pressure
 Helical type for high pressure measurement
 PROTECTION AND INTERLOCKING LAB

INTERLOCKING

It is basically interconnecting two or more equipments so that if one

equipment fails the other can perform its task. This kind of
interdependence is also created so that the equipments connected together
are started and shut down in a specific sequence to avoid damage.

For protection of equipments tripping are provided for all equipments.

Tripping can be considered as a series of instructions connected through
OR gate. When a fault occurs and any one of the tripping is satisfied a
signal is sent to the relay which trips the circuit.

The main equipments of this lab are relays and miniature circuit breakers.

RELAY

Protective relays are devices that detect abnormal conditions in electrical

circuits by constantly measuring the electrical quantities that are different
under normal and faulty conditions. The basic electrical quantities which
may change during fault conditions are voltage, current, phase angle and
frequency.

Having detected the fault the relay the operates to complete the trip circuit
which results in the opening of the circuit breaker and disconnects the
faulty circuit.
The various types of relays are :

1. CURRENT RELAY
It gets energized when the rated value of current flows through it. It is
always connected in series and its resistance is less than the resistance of
DC relay for accurate measurement.
 AC relays are used as potential relay may get falsely energized but
for a current relay the requisite amount of current has to flow.

Fuses are the cheapest forms of protection and it can afford current
limiting effect under short circuit conditions due to cut off. It
requires maintenance.

MINIATURE CIRCUIT BREAKERS

They are used in combination with control circuit:

1. To enable the starting of the plant and distributors.
2. To protect the circuit in case of a fault.

It consists of current carrying contacts, one movable and other fixed.

When a fault occurs the contact separate and arc is struck between them.
The ‘Arc Chute’ extinguishes this arc.

The miniature circuit breakers that are used to employ three tripping
mechanisms:

1. MANUAL TRIP

Manual trip implies that the MCB can be operated as an

electrical switch. The operator can easily turn on and off the
MCB as and when required. The modern MCBs come with an
additional feature of ‘Mid-Trip’, which means that in case of
a fault the MCB knob will stop in between the two extremes
of on and off. Also, those pointing upwards(opposite to the
normal switches) can also turn off the MCB by adjusting the
knob to the intermediate position in case of any emergency.

2. THERMAL TRIP

Thermal or over current trip is a bimetallic tripper. Depending on the class

of the MCB. When an excess current is drawn by the circuit the contact
between the two metal breaks due to temperature rise and the circuit
breaks.

3. SHORT CIRCUIT TRIP

The short circuit or electromagnetic trip works in the case of short

circuits. As the short circuit is many times the rated current, IT is allowed
to flow through a coil with a movable aluminum core attached to the
tripping spring which on being energized with sufficiently large pulls the
core releasing the spring.

PROTECTION AND INTERLOCK SYSTEMS

For H.T. systems, the control systems are excited from separate DC
supply. For starting the circuit conditions should be in series for
energizing the starting coil of the equipment, because if even a single
condition is not true, the system should not start. The example takes a
minimum of three conditions, viz. Luboil pressure, winding temperature
and the bearing temperature.

The tripper is a coil that de-energizes the close \ start coil so that the
equipment stops. The tripper derives signal from the tripping coil of the
H.T. tripping system. It should be noted that for tripping all the conditions
should be in parallel, because if even a single condition goes true the
circuit should be tripped.
The condition for NC contacts for starting the NO contacts for tripping is
achieved by relays which have one NC and one NO terminal for each of
the inputs. All the different types of relays have this system because of its
universality.
 AUTOMATION LAB

is This lab deals in automating the existing equipment and feeding routes.
Earlier, the old technology deals with only DAS (Data Acquisition System)
in the systems and came to be known as primary systems. The modern
technology, secondary systems are control systems coupled with the MIS
(Management Information Systems). This lab universally applies the
pressure measuring instruments as the controlling force. If it is a motor,
the fall in pressure of luboil directly implies heating of the machine. Like
wise, fall in water pressure in the water pipes implies over load or short
circuit of the feed or circulating pump motors. However, the relays are
also provided but that are used only for protection and interlocks.

Once the measurand is common i.e. Pressure, the control circuits can
easily be designed with the single chips having multiple applications. Next
comes universality of supply, the laws of electronics state that it can be
anywhere between 12 and 35V, at the plant all control instruments are
excited by 24V DC supply (4-20 mA). Because the voltage can be
mathematically handled with ease, therefore all the control systems use
voltage signals for computation. This involve the use of a resistance chip
for conversion of current to voltage, in case the output of pressure
detecting instruments is a current signal.

The pressure having been detected the level can easily be determined and
flow can also be found out easily. This signal might need further
conditioning, for this purpose a mathematical control circuitry id designed
in which potentiometer adjustments adjust the three constants of a
universal mathematical equation :

m(t) = kp e(t) + 1/ki t=0∫t=t e(t) dt + kd d/dt [e(t)]

Depending on the response curves the three constants are adjusted.

The latest technology is the use of ‘Ethernet’ for control signals, but at
B.T.P.S Ethernet is used only for recorders. For future proofing the plant,
it planned to first of all incorporate only computer controlled recorders
and then club them to automate the plant.

This figure shows automated system for pressure controlling valve.

 PYROMETRY LAB

It has various temperature measuring devices :

GLASS THERMOMETER

Mercury in a glass thermometer boils at approximately 340°C which limits

the range of temperature that can be measured. There is an L-shaped
thermometer that is designed to reach various inaccessible places.

UVS (ULTRA-VIOLET SENSOR)

This device is used in the furnace and it measures the intensity of the ultra
violet rays generated there and according to that a signal of the order of
mV is generated which directly indicated the temperature in the furnace.

This lab also has the responsibility of calibrating the various instruments.
Depending on the range of the device the method to calibrate the device is
adopted. The low range measuring devices are calibrated in the oil bath or
just by using boiling water. The high temperature measuring devices are
calibrated in small furnace.
 TURBO SUPERVISORY LAB
This lab takes care of all the instruments, which are part of the turbo
supervisory system to allow safe and proper operation of the turbine.
There are some important parameters of the turbine that have to be
monitored and they are as follows:

TURBINE SPEED

The speed of the turbine has to be kept constant so that the frequency of
the generated electricity is close to 50 Hz. The indicators of the speed
provide us with a remote indication, when the barring gear, which is used
to keep the turbine rotating so that the turbine does not get damaged,
rotates the rotor. It gives a remote and a logical digital indication of the
turbine speed, which is given by a photoelectric pick-up system.

The photoelectric has a white dot on the turbine, which reflects the light
given off by the pick-up device. The rate at which the light is sensed is
used to calculate the speed of the turbine. The measuring unit consists of a
zero crossing detector, electronic counter with a latch, recorder and
display. There are indicators, which also set off alarm signals at 10% and
16% over speed.

AXIAL SHIFT OF ROTOR

During the rotation of the turbine at high speeds where there is a wearing
down of the bearings, there is an axial shift. Depending on which bearing
has worn out the thrust collar is either on the working pads or the surge
pads. The position of the thrust collar is given with respect to the working
pads. If this parameter is not monitored properly, then severe rubbing and
mechanical interference can take place.

The position of the thrust collars is taken by a detector, which has two
elements. There is a variable type transducer and a bridge configuration.
The system consists of amplifiers to amplify the signal and comparators to
compare and detect the non-linearity in the position of rotor. The limit of
the axial shift is –2 mm to –1.5 mm.
SHAFT ECCENTRICITY

Eccentricity is the deviation of the mass center from the geometrical center
of the bearing journal. The eccentricity in the rotor usually occurs when
there is a shut down. If the eccentricity becomes large, then there will be a
lot of vibration, which could be dangerous. To measure the eccentricity
they use one passive and one active magnetic reluctance type transducer in
combination with the bridge circuit in unbalanced conditions. In this case
the tolerance is of the order of 0 to 500 microns.

BEARING VIBRATION

This is one of the most vital parameters of turbine, which has to be

monitored. Vibration is the to and fro motion of the machine under the
influences of oscillatory forces by unbalanced masses in the rotating
system.
 WATER TREATMENT PLANT
This plant has responsibility of purifying and de-mineralizing the water
used for producing steam. Water has the following impurities:

 Suspended Solids
 Dissolved Gases
 Dissolved Solids
 Organic Impurities (Algae, Fungi)

In the WTP water passes through two sections:

 Pre-treatment plant
 De-mineralizing section

In the pre-treatment section we have the following sections:

 Clarifier
 Auxiliary Clarifier
 Flash Mixer
 Flocculation Zone
 Sedimentation Zone
 Clarified tank that is connected to slurry tank
 Pump House

In the de-mineralize section, we have:

 Clarified Water Section

 Anthracite Coal Pressure Filter
 Cations Bed
 D/G
 Anions Bed

To remove the residual chlorine ACF (Actuated Carbon Filter) is used.

 FURNACE SAFETY SUPERVISORY SYSTEMS
LAB

This lab has the responsibility of starting the fire in the furnace to enable
the burning of coal. For stage one, coal burners are in the front and rear
of the furnace and for second and third stage corner firing is employed.
Unburned coal is removed using forced draft or induced draft fan. The
temperature inside the boiler as 1100°C and its height is 18 to 40 m. It is
made of mild steel. A UVS (Ultra Violet Sensor) is employed in the
furnace to measure the intensity of ultra violet rays inside the furnace and
according to that a signal in the order of mv is generated which directly
indicated the temperature of the furnace.

For firing, a 10 KV spark plug is operated for 10 seconds over a spray of

diesel oil and pre-heated air along each of the working feeder-mills. The
furnace has 6 feeder-mills each separated by warm air pipes fed from the
F.D. fan. In case of stage I, indirect firing is employed i.e. the feeder-mills
are not fed directly from the coal mills instead are fed from the Pulverized
Coal Bunkers. The furnace can operate on a minimum feed from three
feeder but under no circumstances should any of the intermediate mills be
left out under operation, to prevent creation of pressure difference within
the furnace which threatens to blast it.
 ELECTRONICS LAB

This lab undertakes the calibration and testing of various cards. It houses
various types of analytical instruments like oscilloscope, cards,
auotanalyzer etc.

 Transmitter converts mV to mA.

 Autoanalyzer purifies the sample before it is sent to electrodes for
testing. It extracts the magnetic portion.
 Annunciation Cards : They are used to keep any parameter like
temperature etc. within limits. It gets a signal when the parameter
goes beyond limits. It has a switching transistor connected to relay
that helps in alerting the UCB.
 The different reading, instead being fed to the hard-wired circuitry,
it is fed to the microprocessor-controlled recorders. BTPS employs
upto 30 channel recorders, all of which are used by the UCB as the
microprocessor at the plant seldom goes below that. The
temperature at many places near the furnace-boiler unit goes to
even 60°C in summer.
 National Thermal Power Corporation

National thermal power corporation (NTPC) is the largest thermal power

generating company of India. A public sector company is wholly owned by
the government of India, it was incorporated in the year 1975 to accelerate
the development in the country. Within a span of 29 years, NTPC has truly
emerged as a national power company, with power generating facilities in
all the major regions in the country. Based on 1998 data, carried out by
Data monitor UK, NTPC is the 6th largest in terms of thermal power
generation and second most in terms of capacity utilization amongst the
thermal utilities in the world.

NTPC’s core business is engineering, construction and

operation of power generating plants and also provides consultancy to
power utilities in India and abroad. As on date, installed capacity of NTPC
is 21,249 MW through its 13 coal based (16,980 MW), 7 gas based (3,955
MW) and 3 joint venture projects (314 MW). NTPC acquired 50% equity
of the SAIL power supply corporation Ltd. (SPSCL). This JV company
operates the captive power plants of Durganagar (120 MW), Rourkela
(120 MW) and Bhilai (74 MW). NTPC is also managing BTPS (Badarpur
thermal power station), (705 MW) of government of India. NTPC’s share
on 31st march’2003 in the total installed capacity of the country was
19.5% and this contributes to 20.05% of the total power generation of the
country.

NTPC has set new benchmarks for the power industry both in
the area of power plant construction and operations. It is providing power
at the cheapest average tariff in the country. With its experience and
expertise in the power sector, NTPC is extending consultancy services to
various organizations in the power business. NTPC has emerged into a
joint venture with Alston, Germany for renovation and modernization of
power plants in India.
 NTPC is committed to the environment, generating power at
minimal environmental cost and preserving the ecology in the vicinity of
the plants. NTPC has undertaken massive afforestation in the vicinity of
the plants. Plantations have increased forest area and reduced barren
land. The massive afforestation by NTPC in and around at Ramagundam
power station (2100 MW) have contributed to reducing temperature in the
areas by 3 degrees Celsius .NTPC has also taken proactive steps to ash
utilization. In 1991, it set up Ash Utilization Division to manage efficient
use of the ash produced at its coal stations. This quality of ash produced is
ideal for use in cement, concrete, cellular concrete, building material etc.

A “Centre for Power Efficiency and Environment Protection

(CENPEEP)” has been established in NTPC with the assistance of United
States Agency for International Development (USAID). CENPEEP is an
efficiency oriented, eco-friendly and eco-nurturing initiative—a symbol of
NTPC’s concern towards environmental protection and continued
commitment to sustainable power development in India.

As a responsible corporate citizen, NTPC is making constant

efforts to improve the socio-economic status of the people affected by its
projects. Through its Rehabilitation and Resettlement programmer, the
company endeavors to improve the overall socio-economic status of project
affected persons.

NTPC was among the first public sector enterprises to enter into a
memorandum of understanding (MOU) with the government in 1987-88.
NTPC has been placed under the “Excellent Category” every year since
the MOU system became operative.

Recognizing its excellent performance and vast potential,

government of India has identified NTPC as one of the jewels of public
sector “NAVRATNAS”- a potential global giant Inspired by its glorious
past and vibrant present. NTPC is well on its way to realize its vision of
being” one of the world’s largest and best power utilities, powering India’s
growth”
 HUMAN RESOURCES

Powering India’s growth:

Through people, NTPC believes in achieving
organizational excellence through continuous development of its human
resources. Therefore, a comprehensive human resource strategy spanning
activities preceding the pre-employment of the personnel to the activities
following their separation is in place.

The Executive Trainee Scheme was introduced in 1977 for

inducting talented fresh graduates and grooming them into a dedicated
cadre of power professionals. The scheme comprises recruitment in the
disciplines of Mechanical, Electrical, Civil, Control & Instrumentation,
Computer science Chemistry, HR and Finance.

NTPC Has created 18 projects training centers, 2 simulator training

centers and an apex institute called “Power Management Institute (PMI)”.
While the project training centers have specialized in imparting technical
skills and knowledge, PMI places emphasis on management development.
A systematic training plan is in the place, comprising level-wise planned
interventions designed to groom people for assuming positions of higher
responsibility, and specified need-based interventions designed after
scientific Trainee Needs Analysis.

NTPC has been making concerned efforts to build structures and

processes that enable dissemination of knowledge and putting that
knowledge to practical use. One such initiative is NTPC Open Competition
for Executive talent (NOCET), in which teams of executives compete
annually through oral and written presentations on a theme chosen by the
CMD.
 Another developmental initiative is the Mentoring system which
NTPC has introduced for the new recruits. Under this system, every
executive trainee is associated with a senior employee of the company to
enable him to built their knowledge base and integrate them into NTPC’s
culture. A management journal called “Horizon” is published to enable
the employees, to share their ideas and experiences across the
organization.

As part of enhancing knowledge at senior levels, senior executives

of the company are put through management development programs in
reputed institutions.

In order to systematically diagnose the current and potential

knowledge requirements of the employees with the objective of aiding their
development in a planned and scientific manner, NTPC is
institutionalizing development centers in the company. Through these
centers, employees can learn their strengths and weaknesses and gain and
understanding of gaps in their competencies.

Organizational learning needs to be on a continuous basis. NTPC,

therefore, has foray like professional circles and quality circles which
provide employees learning opportunities on a continuous basis.
Professional circles have been formed department –wise where employees
of the department meet every fortnight to share their knowledge and
discuss topical issues.

In order to trap the latent talent among workmen and make use of
their potential for creativity and innovation, Quality Circles were set up in
all the departments of the power plants. As of now, over 250 Quality
Circles are in operation in various units/ offices of NTPC.

NTPC has been laying emphasis on culture-enabling processes. For

instance, with the objective of leveraging the emotional intelligence of the
employees and for creating a positive and progressive organizational
culture, attitudinal training was initiated. About 2000 executives have
been put through attitudinal training programs.
 GLOBAL STATURE

As per DATA MONITOR UK, during the year 1998- NTPC was the SIXTH
largest thermal power utility in terms of generation of electricity and the
SECOND most efficient in capacity utilization among the thermal utilities of
the world.
As per Asia Week’s survey of top 1000 companies of Asia Pacific
region including Japan NTPC improved its ranking to 295 in the year
2000 on sales (up from 299 in 1999). In India, NTPC ranks 7th in terms of
sales and 2nd in terms of profit.

CORPORATE OBJECTIVES

GROWTH
 to add generating capacity within prescribed time and cost
 to expand consultancy operations and to participate in venture
abroad
 to diversify into hydro and non-conventional energy sources for
power generation
 to diversify into power related business to ensure integrated
development of energy sector in India

PERFORMANCE LEADERSHIP
 To achieve continuous performance improvement in the areas
of project implementations, plant operation and maintenance,
generation efficiency etc. and to acquire and sustain
internationally comparable standards in these areas with good
business ethics and values.

HUMAN RESOURCE DEVELOPMENT

 to develop a learning organization having knowledge-based
competitive edge
 To create a culture of team building, empowerment and
accountability to convert knowledge into productive action with
speed, creativity and flexibility.
 NTPC MISSION
 make available reliable and quality power in increasingly large
quantities at appropriate tariffs, and ensure timely realization of
revenues
 speedily plan and implement power projects, with contemporary
technologies
 implement strategic diversifications in the area of R&M, hydro,
LNG and non-conventional and eco-friendly fuels and explore new
areas like transmissions, IT etc
 promote consultancy
 make prudent acquisitions
 continuously develop competent human resources to match world
standards
 be a responsible and corporate citizen with thrust on environmental
protection, rehabilitation and ash utilization

NTPC POWER STATIONS: AN OVERVIEW

Nos capacity
(MW)
NTPC OWNED
COAL 13 16,890
GAS/LIQUID FUEL 7 3,955
TOTAL 20 20,955
OWNED BY JVC’S
COAL 3 314
BTPS
COAL 1 705
GRAND TOTAL 24 21,954
 BADARPUR THERMAL POWER
STATION
B.T.P.S. is owned by govt. of India, ministry of energy and is managed by
N.T.P.C. since April 1,1978.At the time of change over of management the
installed capacity was 300 MW and under N.T.P.C. two more units of 210
MW each were erected and commissioned. N.T.P.C is the frontrunner in the
power sector presently having total installed capacity of 21,249 MW. Power
is supplied to a 220 kV network which is part of the northern grid. There are
10 circuits through which the power is evacuated from the plant namely
being: Mehrauli 1 and 2, Okhla 1 and 2C, Ballabhgarh 1 and 2, U.P. and
Jaipur.
There are in total five units in the power station. Details of the units are as
follows:
 1973 : 95 mw
 1974 : 95 mw
 1975 : 95 mw
 1978 : 210 mw
 1981 : 210 mw

The installed capacity of BTPS is 705 mw.

The coal sources include:
 CCL (Central Coal Fields Ltd.)
 BCCL (Bharat Coking Coals Ltd.)
 ECL (Eastern Coal Fields Ltd.)

The water supply is taken from Agra Irrigation Canal and is used for
cooling. There are cooling towers provided so that the plant can operate in
a closed cycle. BTPS is designed and engineered by central water and
power.
 ELECTRICITY FROM COAL

Coal from the coal wagons is unloaded with the help of wagon tipplers in
the coal handling plant. This coal is taken to raw coal bunkers with the help
of conveyor belts. Coal is then transported to bowl mills by coal feeders
where it is pulverized and ground in the powdered form. This crushed coal is
taken away to the furnace through coal pipes with the help of hot and cold
mixture from P.A. fan. This fan takes atmospheric air, apart of which is sent
to preheaters for heating while a part goes to the mill for temperature
control. Atmospheric air from F.D. fan is heated in the air heater and sent to
the furnace as Combustion air. Water from boiler feed pump passes through
economizer and reaches the boiler drum. Water from the drum passes
through down comers and goes to bottom ring header.
Water from the bottom ring header is divided to all the four sides of the
furnace. Due to heat and density difference the water rises up in the water
wall tubes. Water is partly converted to steam as it rises up in the furnace.
This steam and Water mixture is again taken to the boiler drum where the
steam is sent to super heaters for Superheating. The super heaters are
located inside the furnace and the superheated (540C) and finally it goes to
the turbine. Flue gases from the furnace are extracted from the induced
draft fan, which maintains Balance draft in the furnace with forced draft
fans. These flue gases emit their heat energy to the various super heaters
and finally pass through air preheaters and goes to electrostatic
Precipitator where the ash particles are extracted. This ash is mixed with
water to form slurry and is pumped to ash pond. The steam from the boiler is
conveyed to the turbine through the steam pipes and through the stop valve
and control valve that automatically regulate the supply of steam to the
turbine. Stop valves and control valves are located in a steam chest and
governor driven from the main turbine shaft operates the control valves to
regulate the amount used. Steam from the control valves enters the high-
pressure cylinder of the turbine, where it passes through the ring of blades
fixed to the cylinder wall. These act as nozzles and direct the steam into a
second ring of moving blades mounted on the disc secured to the turbine
shaft. The second ring turns the shaft as a result of the force of steam. The
stationary and moving blades together constitute a ‘stage’ of a turbine and
in practice many stages are necessary, so that the cylinder contains a
number of rings of stationary blades arranged between them. The steam
passes through each stage in turn until it reaches the end of the high –
pressure cylinder and in its passage some of its heat energy is changed into
mechanical energy Then by a further pipe to the intermediate pressure
cylinder Here it passes through another series of stationary and moving
blades. Finally the steam is taken to the low pressure cylinders, each of
which it enters at the center flowing outwards in the opposite directions
through the rows of turbine blades an arrangement known as a double flow
– to extremities of the cylinder.
As the steam gives up is heat energy to drive the turbine its temperature,
Pressure falls and it expands. Because of this expansion the blades are
much larger and longer towards the low – pressure ends of the turbine. The
turbine shaft usually rotates at 3000rpm. This speed is determined by the
frequency of the electrical system used in this country and is the speed at
which a 2- pole generator must be driven to generate alternating current at
a frequency of 50Hz.When as much energy as possible has been extracted
from the steam it is exhausted directly to the condenser. This runs the length
of the low – pressure part of the turbine and may be beneath on either of it.
The condenser consists of a large vessel containing some 20000 tubes each
about 25mm in diameter. Cold water from the river, estuary, sea or cooling
tower is circulated through these tubes and as the steam from the turbine
passes round them it is rapidly condensed into water condensate. Because
water has a much smaller volume than steam, a vacuum is created in the
condenser. This allows the steam to reduce down to pressure below its
normal atmosphere and more energy can be utilized. From the condenser,
its pressure is raised to boiler pressure by the boiler feed pump. It is passed
through further feed heaters to the economizer and the boiler for the
conversion into steam.
 MAIN GENERATOR
Main data of generator:

Maximum continuous KVA 247000 KVA

rating
Maximum continuous KW 210000 KW
Rated terminal voltage 15750 V
Rated stator current 9050 A
Rated power factor 0.75 lag
Excitation current at MCR 2600 A
condition
Slip ring voltage at MCR 310 V
condition
Rated speed 3000 RPM
Rated frequency 50 Hz
Short circuit ratio 0.49
Efficiency at MCR condition 98.4%
Direction of rotation viewed Anticlockwise
Phase connection Double star
Number of terminals brought 9 (6 neutral and 3 phase)
out
 MAIN TURBINE DATA

Rated output of turbine 210 MW

Rated speed 3000 RPM
Rated pressure of steam before 130 Kg/cm2
emergency
Stop valve rated live steam 535C
temperature
Rated steam temperature after 535C
reheat at inlet to receptor valve
Steam flow at valve wide open 670 tons/hr
condition
Rated quantity of circulating 27000 cum/hr
water through condenser
For cooling water temperature 24,27,30,33
(C)

1. Reheated steam pressure 23.99,24.21,24.49,

at inlet of interceptor valve 24.84
(Kg/cm) ABS

2. Steam flow required for 68,645,652,662

210 MW (ton/hr)

3. Rated pressure at exhaust 19.9,55.5,65.4,67.

of LP 7
turbine ( mm of hg)
 PRIMARY CONSTITUTES OF BTPS
BOILER AUXILIARIES:
PULVERIZER
In the pulverizer the coal is powdered so that almost 70 – 80% of the
coal can pass through a 200 – mesh sieve. There are many types of
pulverizer and ball mills which run at a speed of 17 – 20 rpm. The
crushing is done by centrifugal force in the container with metal
balls, which can easily be replaced. However, the disadvantage is
that this mill requires a lot of power to pulverize the coal. Then there
is the bowl mill, which rotates at the speed of 32 – 100 rpm. The coal
is crushed by the action of rollers in a bowl like structure, which
crushes the coal. The advantages of this mill are that they require
minimal maintenance and power. The major disadvantage is that
they require air sealing so that mill is leak proof.
BOILER ACCESSORIES:
 Boiler drum
 Burner
 Super heater
 Reheater
 Economizer

BOILER DRUM:
The boiler drum is made of carbon steel metal, its primary
Functions being to separate the water from steam in the furnace walls by
employing a spinning action and to reduce the dissolved solid particles to a
minimum of 1 ppm by using scriber and dryers. Steam in the drums comes
out at a pressure of 150.7kg/cm2, while the temperature of the drum is
342C.

BURNER:
There are a total of 24 burners for the corner type fired boilers with 12 oil
burners provided each in between two pulverized fuel burners. The coal
burners are arranged so that 6 mills at the four corners of the furnace can
supply them.

SUPERHEATERS:

There are basically 3 types of super heaters in the boilers. They use
the heat of the flue gases to increase the temperature of the steam to
about 540C, which makes the steam super saturated in nature.

RE-HEATER:

The function of the re-heater is to increase the temperature of the

steam to 540C, thereby increasing the heat content of the steam.
This is only employed in the 210 MW units because of the greater
demand for heat energy. The inlet temperature and pressure to the
re-heater is 332C and 26.4 kg/cm^2 while the outlet temperature
and pressure of the re- heater is 540C and 24.5 kg/cm^2.

ECONOMIZER:
The economizer re-heats the boiler feed water before it is introduced into
the steam drum by reusing the heat from the flue gases. This particular
accessory increases the efficiency of the boiler. The steam enters at 247 C
and leaves at 278C. The water in the economizer flows in the upward
direction thereby giving heat to the boiler feed water.

TURBINE AUXILIARIES:
GLAND STEAM AND GLAND STEAM COOLERS:
Steam from the de-aerators or from the auxiliary steam header is
supplied to the end seal of high – pressure rotor generally at a
pressure of 1.01 and 1.03 atm. Thus, to prevent entrance of
atmospheric air into the turbine through the end clearance, stem is
supplied to the end seal and is extracted by the gland steam cooler
by action of Single steam ejector.
DE – AERATOR:
This component removes oxygen, carbon dioxide, ammonia and
other
Corrosive gases that are dissolved in the water to be sent to the
boiler.
The main Function of the de-aerator is to minimize the amount of
oxygen
In the water so that there may be minimal corrosion in the boiler
internals where the water has to flow through.

EJECTORS:
Two 100% capacity ejectors whose purpose is to evacuate air and
other
Non-Condensing gases from condenser and thus maintains the
vacuum
In the condenser steam from the de-aerator with 11 atm header as
Working medium for ejectors.
 THERMAL POWER PLANT

Thermal power plant converts the heat energy of coal to electrical

energy. Coal is burned in the boiler that converts water to steam.
The expansion of steam in turbine produces mechanical power that
drives the alternator. Thus the main equipment in the thermal power
plant consists of boiler steam turbine and alternator. To achieve
efficient conversion of heat energy to electrical energy a variety of
auxiliary equipments are needed.

BASIC PRINCIPLE:
The coal handling plant supplies coal to the burner. The ash
handling plant disposes off the ash formed. Air taken from
atmosphere by the action of forced or induced draft fan is heated in
the pre-heater before being fed to the boiler. The flue gases pass
through the dust collector, air pre-heater and economizer before
being discharged to the atmosphere through chimney. The boiler
vaporizes water. Steam is further heated in the superheated and fed
to the high pressure After expanding in high pressure turbine steam
is again heated in the boiler and fed to low-pressure turbine. The
exhaust steam from the low-pressure turbine is condensed and the
condensate, along with makeup water, is passed through economizer
before being fed to the boiler.

The basic components of a thermal power plant are:

 COAL HANDLING PLANT

 PULVERIZING PLANT
 DRAFT FANS
 BOILER
 ASH HANDLING
 TURBINE
 CONDENSER
 COOLING TOWERS AND PONDS
 FEED WATER TREATMENT
 ECONOMISER
 SUPERHEATER AND RE-HEATER
 AIR PREHEATER
COAL HANDLING PLANT:

The function of the coal handling plant is automatic supply of coal

To the boiler furnace. A grate at the bottom of the furnace holds the
Fuel bed. Coal is weighted and led to a hopper through a conveyor
Mechanism. From the hopper it is fed to the grate through some form of
stroke mechanism. A thermal plant burns enormous amount of coal.

PULVERISING PLANT:

In power plants coal is pulverized and carried to the furnace

In a steam of hot air. Pulverization is a means of exposing a large
Area to the oxygen and thus facilitates combustion. Pulverization
Have various advantages:

 Rate of combustion can be controlled

 Banking losses are reduced
 The percentage of excess air required is low
 A wide variety of low – grade coals can be used
 The boiler can be started from the cold conditions very rapidly
 The pulverizing mill, being outside the mill can be repaired without
cooling down the unit

PULVERIZING MILL:
They are classified as:
Contact mill: It has stationary and power driven rotating elements having
a rolling action with respect to each other. Coal is made to pass through
these elements again and again till it is pulverized. Hot air is Circulated
which takes away the fine particles to the burner.

Boiler mill: a large cylinder or drum partly filled wit various sized Steel
balls is used in this mill. The cylinder is rotated at approximately 17 to 20
rpm. While coal is continuously fed into it, hot air enters the cylinder,
dries the coal during pulverization and carries the pulverized coal to the
burner. The coal remains in the mill for several minutes; this feature
prevents the fire from going out in case of slight interruption of coal
supply. This mill can successfully pulverize anthracite and bituminous
coal.
Impact mill: coal remains in suspension and the grinding elements
including the primary air fan are mounted on a single shaft. The flowing
Air carries the coal to the primary stage where it is pulverized by the
impact with the series of hammers. The coal is then carried to the final
stage by the air. In this stage the pulverized coal is carried to the center of
the pulverizing mill where large sized particles are thrown back into the
grinding section.
Bowl mill:
In the bowl mill crushed coal is pulverized and further dried by hot primary
air. A portion of the primary air from P.A. fan discharge is heated in the
Lzengstrom type sector air preheater and mixed proportionally with the cold
tempering air prior to admission to the mill to provide the required drying,
as indicated by coal air temperature at the pulverized outlet. A constant
total airflow is maintained through each pulverizer irrespective of coal
feeding rate to transport the coal from the pulverizer through classifier and
coal piping to the entire four burners on an elevation. The pulverized coal
and air discharge from the coal nozzle is directed towards the center of the
furnace to form a fixing cycle. Fully preheated secondary air enters the
furnace around the pulverized coal nozzle and through auxiliary air
compartments directly adjacent to the coal nozzle compartment. The
pulverized coal entering with the air stream is initially ignited by a surface
ignition source at nozzle exit. Above a predicted minimum loading condition
the ignition becomes self – sustaining. Combustion is completed on the gas
spiral tip in furnace.

Mill Specifications:

1. Total no. per boiler 6

2. Type Pressurized
3. Capacity 39.100 T/hr
4. Size 803
5. Design coal grind ability55
HGI scale
6. Maximum moisture 12%
content
7. Fineness through 200 75%
mesh

Motor:
1. Power rating 340 KW
2. Voltage 6.6 KV (3-)
3. Frequency 50 cps
4. Revolutions per minute 980
5. Rated current 41.1 AMP
6. No load current 15-16 AMP

DRAFT:
It is differential air pressure between the atmosphere and the boiler and this
causes circulation of air. This required difference is proportional to the
square of the rate of flow. It is of two types:
1. Natural draft: it is provided by the chimney. Chimney has two
purposes:

(a) To produce a draft so that air can flow into the boiler and
Products of combustion are discharged into the atmosphere.
(b) To deliver the products of combustion and fly ash to a
higher altitude so that pollution is reduced. The intensity of the natural
draft depends upon the height of the chimney and difference between
outside gas temperature and inside gas temperature. It is used only for
small boilers.

2. Mechanical draft: a mechanical draft consists of forced draft,

induced draft or both. The fans in these cases have high efficiency
and aerofoil blades are inclined backwards to the direction of
rotation.

FORCED DRAFT FAN:

The fan consists of the following components:
 Silencer
 Inlet bends
  Fan housing
 Impeller with blades and sitting mechanism
 Guide wheel casing with guide vanes and diffuser.

The centrifugal and setting force of the blades are taken up by the blade
bearings. The blade shafts are placed in combined radial and axial
antifriction bearings which are sealed from outside.
The characteristic pressure volume curves of the fan may be changed in
the large range without essentially modifying the efficiency. The fan can
be easily adapted to changing operating conditions. Lubrication and
cooling of these bearings is assured by a combined oil level and circulating
lubricating system.
 Specification of F.D. fan:

Fan type Axial reaction type ( API-10111 )

Fan orientation Horizontal
Location Ground level
Medium handled Air ( 1.135 kg/m )
Number of fans per boiler 2
Fan design rating

1. I capacity m/sec 103.8 m/sec

2. Total head developed 520.5 mm of WC

3. Temperature 50C
Fan speed 1480 rpm
Power absorption at fan shaft 632 KW
Control oil pressure 8 to 12 atm ( g )

Fan reserves

1. Flow 25%

2. Pressure 50%
Lubricating 0.8 – 3 atm ( g )
Lubricating temperature at oil
cobbler outlet

1. Normal 40 - 45 C

2. Maximum 60 C
Oil charge ( approx ) 250 liter
Direction of rotation Counter – clockwise
Fan drive coupling Intermediate shaft with
regiflex shaft coupling
1. Coupling size 1001

2. Tutride dia 370 mm

 3. Gap 23.5 mm

4. Type 12 V M 20
Fan weight 12000kg
Bearings:

1. Impeller side bearing Cylindrical roller

no:230C3
Cylindrical roller
2. Coupling side bearing
no:230C3
Number of fan blades 23
Type of regulation Variable pitch blades

PRIMARY AIR FAN:

P.A. fan is flange – mounted design, single stage suction, NDFV type, and
backward curved radial fan operating on the principle of energy
transformation due to centrifugal forces. Some amount of the velocity energy
is converted to pressure energy in the spiral casing. The fan is driven at a
constant speed.

DRAFT SYSTEM:
The draft system provides air required for combustion of fuel and push out
the flue gases through stages maintaining a balance draft. F.D. fans are
provided to supply the necessary secondary air for combustion. Two axial
flow impulse type Induced Draft fans are provided to evacuate the flue gases
from boiler and push tem into stack at a pressure sufficient to discharge the
stack emission at 150 m height.
As we know the major byproduct of the thermal power plant is ash, which
acts as a pollutant in the environment and can bring about changes in
atmospheric properties from the obvious observation of heavy smoke to
subtle effects on urban temperature and regional precipitation. These active
pollutants can be either gases or particles. It is only with the understanding
of some of the basic physics of pollutants in the environment that adequate
program of monitoring and impact assessment can be made.
In a F.D. system the fan is installed near the base of boiler. This fan forces
air through the furnace, economizer, air preheater and chimney. The
pressure of air throughout the system is above atmosphere and is forced to
flow through the system. In induced draft the fan is installed near the base of
the chimney. The burnt gases are sucked out of the boiler thus reducing the
pressure too less than atmospheric. This induces fresh air to enter the
furnace.
Usually a balanced draft is used which consists of a forced fan near the base
of the chimney. The forced draft helps in overcoming the resistance inside
the boiler and the induced fan helps sucking the products of combustion out
of the system.

BOILER:
A boiler is a closed vessel where water is converted into steam. It is one of
the major components of the power plant. It is always designed to absorb the
maximum amount of heat released in the process of combustion. This heat is
transferred to the boiler by all the three modes of transfer: conduction,
convection and radiation.
Boilers can be classified as water tube and fire tube boilers.
FIRE TUBE BOILER: in this boiler products of combustion pass through
tubes, which are surrounded by water. Depending upon whether the tubes
are horizontal or vertical the boilers are classified as vertical or horizontal.
They may be internally or externally fed. An internally fed boiler has a
grate and combustion chamber enclosed within the boiler shelf. In the
externally fed boiler the setting, including furnace and grates is separate
and distinct from the boiler shelf. A fire tube boiler is simple, compact, and
rugged in construction. Its initial cost is low. A vertical fire tube boiler
occupies less floor space. However, they are economical only for low
pressure and are therefore available in small sizes having capacity of
about 15000kg/hr.
(a) WATER TUBE BOILER: in this boiler the water is inside and hot
gases are flowing outside. The tubes are interconnected to a common
water channel and to steam outlet. Water tube boiler is classified as
vertical, horizontal or inclined depending upon whether the tubes are
vertical or horizontal or inclined. The number of drums may be more than
one. The circulation of water in the boiler may be natural (due to
difference in density between hot and cold water) or forced through the
action pump. Forced circulation has the advantages of:

 lesser weight of boiler and cheaper foundations

 lighter tubes
 freedom from scaling problem
 Greater freedom in configuration of furnace, tubes etc.
 uniform heating of all parts
 increased efficiency of the boiler
 better control of temperature
 Quicker response to load changes.

All these modern boilers use forced circulation. However forced circulation
means higher investments, costlier maintenance and increase in auxiliary
power consumption.
Nowadays, supercritical boilers with pressure as 5000 psi/g, temperature
1155F and capacity above 10, 00,000kg/hr are available. They have an
efficiency of 0.9 %. The factors that influence the choice of a boiler are:
initial cost, availability, maintenance cost, and labor cost space and fuel
cost. The total cost of fuel used by the boiler in its lifetime may be three to
four times the initial investment.

SUPERHEATER AND PREHEATER:

Superheated steam is that steam, which contains more heat than the
saturated steam at the same pressure i.e. it, has been above temperature
corresponding to is pressure. This additional heat provides more energy to
the turbine and thus the electrical output power is more. Superheated steam
causes lesser erosion of turbine blades and can be transmitted for longer
distances with little heat lost. The function of the superheated is to remove
the traces of moisture from the saturated steam leaving the boiler tube and
also to raise the temperature of this steam.
Super heaters are classified as convection, radiation or combination of both.
A convection superheated is placed somewhere in the gas steam and
receives most of the heat by convection. A radiant superheated is placed
near the furnace where it receives most of the heat by radiation. In the
combination of superheated the steam leaving the boiler drum first passes
through the convection section and then through the radiation section and
then to the steam header. In addition to the superheated there is a re –
heater. It is to reheat the partially expanded steam from the turbine. This
ensures that the steam remains dry throughout the last stage of the turbine.

STEAM TURBINE:
A steam turbine converts heat energy to mechanical energy and drives the
generator. It uses the principle that steam issuing from a small opening
attains a high velocity. This velocity attained during expansion depends
upon the heat content and represents the heat energy converted into kinetic
energy.
Steam turbines are manufactured in a variety of sizes up to 1,000,00 HP or
even more and have horizontal configuration. The standard speeds are 3000
rpm and 5000 rpm for coupling to 50 Hz generators.
They are of two types:
(a) Impulse turbine: in impulse turbine steam is expanded in turbine
nozzle and attains a high velocity. The rotor may be built-up rotor
or integral rotor. A built – up rotor consists of a forced steel shaft
on which separate forged steel discs are shrunken and keyed. In
an integral rotor one solid forging forms the wheel and the shaft.
The built – up rotor is cheap and easy to manufacture.
(b) Reaction turbine: the reaction turbine only partial expansion takes
place in the nozzle and further expansion takes place as the
Steam flows over the rotor blades. The relative velocity of the steam
increases as it expands. While passing over the rotor blades, there is a
difference in pressure on the two sides on the moving blades. Blades have
an aerofoil section. It is seen from above that in reaction turbine also
partial expansion takes place. In the nozzle that is an impulse section. The
modern reaction turbine has both stationary and moving blades. The
blades are similar; each so arranged that the area through which it enters,
pressure drops take place in both the stationary and moving blades. The
restricted area at the outlet of the blades causes the steam velocity to
increase as steam leaves the blades.

ASH HANDLING PLANT:

The percentage of ash in coal varies from about 5 % to 40 %.
Power plants generally use poor quality coal. As a result of this amount of
ash produced by a plant is quite large. A modern 210 MW plant produces
5000 tones of ash daily. Of this about 25 % is furnace bottom ash and
remaining 75 % is pulverized fuel ash or fly ash. In small stations there is a
conveyor arrangement to carry ash to dump sites directly or for carrying
and loading it to trucks and wagon which transports it to the site of disposal.
Large systems use more elaborate arrangements for separate system of
furnace bottom and fly ash is quite acidic due to sulphur dioxide in the flue
gases.
A sliding system is generally used for removal of furnace bottom ash. The
ash falls into a dry hopper that is fitted with excess doors and high- pressure
water jets. The collected ash is jet sluiced from the hopper into a sluiced
way and is carried by water into a settling tank, outside the power station
building, where it can be drained, dried and disposed of. This ash can be
used as landfill.
A pneumatic system is usually employed for disposal of fly ash. In this
system a high velocity of air causes the ash to flow into the separator where
the ash is collected in hoppers. The dusty air is filtered and exhausted to the
atmosphere through the fan. Fly ash is generally stored in reinforced
concrete bunkers of about 100 tones capacity each. In recent years the
possibility of using fly ash has been investigated and its commercial use has
increased. Some of these uses are: mixing with clay to produce bricks, use
as a constituent of concrete, making of light weight aggregate by sintering.

CONDENSER:
It condenses the steam exhausted from the turbine. Thus it helps in
maintaining low pressure at the exhaust, thereby permitting expansion of
steam in the turbine to a very low pressure. This improves the plant
efficiency. The exhaust steam is condensed and acts as feed water for the
boiler. Maintenance of high vacuum in the condenser destroys the vacuum.
For this purpose vacuum pump is needed to remove the air leaking into the
condenser.
Modern power plants mostly use surface condenser consisting of an airtight
cylindrical shell having a chamber at each end. Water tubes extend between
the chambers. These shells are made of welded steel plate construction and
tubes are made of copper zinc alloy. Cooling water flows through the tubes.
The steam is admitted from the top and gets condensed due to contact with
the tube surfaces. The condensate leaves from the bottom. For efficient
operation the temperature rise in cooling water passing through the
condenser should be around 10 C.

COOLING TOWERS AND PONDS:

A condenser needs huge quantity of water to condense the steam.
Approximately 1 kg of steam needs 100 kg of cooling water for the
condenser. Typically a 2000 MW plant needs about 150010^6 gallons per
day of cooling water. Large source of water supply is usually not available
near a thermal plant, therefore most plants use a closed cooling water
system where the warm water coming out of the condenser is cooled and
reused. Small plants use spray ponds and medium and large plants use
cooling towers. In these ponds and towers warm water loses its heat to the
atmosphere and is reused again. Modern steam stations invariably use large
sizes cooling towers that from the most prominent structures in the plant.
A cooling tower is a steel or concrete hyperbolic structure having a
reservoir at the bottom for the storage of cool water. Warm water is led to
the top. Air flows from the bottom to the top. The water drops falling from
the top come in contact with air, lose heat to the air and get cooled.
Eliminators are provided at the top to prevent the escape of water particles
with air. Such a tower is known as wet cooling tower. In such systems the
loss of water due to evaporation is about 1 %. Another 2 % of water
circulated is used in purging the system of dissolved salts. Hence the total
quantity of makeup water is about 3 % of the quantity circulated in the
system. The height of the cooling tower may be about 150 m and the
diameter at the base is about 150 m.

FEED WATER HEATERS:

The steam coming out of the turbine is condensed and the condensate is fed
back to the boiler as feed water. It is necessary to heat water before feeding
it back to the boiler for the following reasons:
1. Feed water heating improves overall plant efficiency

2. The dissolved oxygen and carbon dioxide that would otherwise cause
boiler corrosion are removed in the feed water heater.
3. Thermal stresses due to cold water entering the boiler drum are
Avoided

4. Quantity of steam produced by the boiler is increased.

ECONOMISER:
Flue gases coming out of the boiler carry lot of heat. An economizer extracts
a part of this heat from the flue gases and uses it for heating feed water. Use
of an economizer results in saving in coal consumption and higher boiler
efficiency that needs extra investments and increase in extra maintenance of
cost of floor area placed between two headers.
AIR PREHEATERS:
After the flue gases leave the economizer some further heat can be extracted
from them and used to heat the incoming air of combustion. Cooling of flue
gases by 200 C increases plant efficiency by 1 %. Air preheater can be
plate type, tabular type or regenerative type. Plate type air preheater has
alternate narrow lane for gas and air passage. The two fluids flow in
opposite directions in tabular air heaters. The gases flow inside the tubes
and the air of corrugated steel plate. The rotor is fixed onto a shaft that is
rotated at a low speed of 2 – 4 rpm. As the rotor rotates, it alternatively
passes through flue gases and air zone.

COAL HANDLING PLANT

The plant has two coal handling plants:
1. Coal Handling Plant (C.H.P.)
2. New Coal Handling Plant (N.C.H.P.)

The old coal handling plant caters to the needs of units II, III, IV, V and I
whereas the latter supplies coal to units IV and V. O.C.H.P. supplies coal
to second and third stages in the advent of failure of N.C.H.P. The
function of the coal handling plant is to convert the coal to usable form
(crushed) from its raw form and sends it to bunkers, from where it is sent
to the furnace.
The major components of the coal handling plant are:
1. WAGON TIPPLER : wagons from coal yard come to the
Tippler and are emptied here. The process is performed by a slip ring
motor of rating: 55kw, 415V, 102A, and 1480 rpm. This motor turns the
wagon by 135deg and coal falls directly on the conveyor through vibrators.
This tippler has raised lower systems, which enables it to switch off the
motor when required till it reached, this is called raised limit. Similarly
there is lower switch to put the wagon back to its original position. The
wagon is tilted by weight balancing principle. The motor in facts lowers
the hanging balancing weights, which in turn tilt the conveyor. Estimate
of the weight of the conveyor is made through a 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 move with the speed of 250-300m/min. The motor employed for
the conveyors has a capacity of 150HP. Conveyors has a capacity of
carrying coal at the rate of 400tons/hr. few conveyors in the plant are
double belt conveyors , this is done for the important conveyors so that if a
belt develops any problem the is not stalled. The conveyor belt has pull out
switch after every 25-
 ELECTRICAL MAINTAINANCE DEPARTMENT – I

This division is usually responsible for the maintenance of the following

portions of the plant:-

 Boiler side motor

 Turbine motor
 Outside motors
 Switch gear (HT & LT)

Hence the electrical maintenance division takes care of all the different
types of motors working inside the NTPC.

A description of different motors is given below:-

BOILER SIDE MOTORS

The following motors constitutes of the Boiler side motors…

FOR STAGE 1 UNIT 1, 2, 3 :-

ID FANS
FD FANS
PA FANS
MILL FANS
BALL MILL FANS
RC FEEDERS
SLAG CRUSHERS
DM MAKE UP PUMP
PC FEEDER

FOR STAGE 2 UNIT 4, 5 :-

ID FANS
FD FANS
PA FANS
BOWL MILLS
RC FEEDER
SCRAPPERS
SEAL AIR PUMP
HYDROGEN DRYING

HT MOTOR WINDINGS

3 Ø SQUIRREL CAGES INDUCTION MOTOR SPECIFICATIONS:-

AC MOTOR 50 Hz
STATOR VOLTAGE 6600 V
CURRENT 23.5 A
COS Ø .85
EFFICIENCY η 91.8%
R.P.M 1430
YEAR 1971
INSULATION CLASS F
WEIGHT 410 Kg

DESIGNING

Now if an induction motor has 60 slots, as the winding are double layered
each slot has 2 coils.
Slots can be varied from
48, 36, 60 and 90
Then
Speed = 1430
No of slots = 60
Pole =4
Speed = 120 x frequency /pole

Pole = (120 x 50/1500)

= 4 pole/phase

Slots per phase = 60/3 =20

Slots per pole = 20/4 =5

Coil pitch = 1 to 11

This means 1 phase makes 4 poles. Semi conducting paint is used to

protect it from the corona. Conductors are interconnected to each other.
The insulation is done with the help of different classes of insulation
materials. Generally F class insulation is used. The temperature level for
the F class insulation lies between 120 to 140 degrees. For the case of HT
windings, the windings are not hand made while in case of LT winding the
windings are hand made.

These windings can be tested using different tests which are mentioned in
the following article.

POLARISATION INDUCTION TEST

Megger is achieved by 220 volts single phase. This supply rotates the rotor
of a small generator. Due to this a voltage is produced and thus voltage is
used to calculate the resistance of the winding. In this type of Megger we
are using supply because with AC supply rotator of the rotor becomes
constant and the readings become more accurate. All the readings should
be taken for about 10 minutes for accurate readings.

1 READING 15 SEC
2 READING 60 SEC
3 READING 600 SEC

READING = 100,200,600

PA rotor = value of 10 min reading / value of 1 min reading

= 600/200
=3

If the value is greater than 2 then the value obtained is with in safe limits.
Readings should be taken for phase to earth. After this HV test is
performed.
HIGH VOLTAGE TEST

For performing the HIGH VOLTAGE TEST, a voltage equal to double the
rated voltage is applied. A DC supply is used for this purpose instead of
AC because AC will increase the effective cost as with the AC step up
transformer will be required.

METHODS –

1. Get the PA ratio greater than 2.

2. Then heat it to extract the moisture present in it.
3. Then varnish it so that there is minimum chance of corrosion.

Varnishing of the system is very important method and should be very

strictly done. Varnishing is done in a room totally vacuumed. This room
has an oven in it which increases the temperature of the room and hence
extracts the moisture from the winding. Vacuumed room is used so that
the varnish can go to every part of the winding. Varnish is done with the
help of becktol gel. This gel comes in two colors i.e. red and grey.
Sometimes thinners are also used. There are two types of thinners 234 and
205. It is spread by the combination of resin, epoxy gel, thinner 221 and
hardener 758. The important components are the following :
1. Bacting Rods
2. Ferrule
3. Nylon Cord
4. Polyester Tape
ELECTRICAL MAINTENANCE DIVISION 2

TRANSFORMER:

A transformer is a constant frequency static device comprising coils

coupled through a magnetic medium connecting two ports at different
voltage levels in an either electric system allowing the inter change of
electric energy between the two ports in either direction via magnetic field.
A transformer in its simplest form consists of two insulated windings
interlinked by a common magnetic field established in its core. When one
of the windings is termed as primary, it is connected to an alternating
voltage source; an alternating flux is produced depending upon the
primary voltage, no. of turns and frequency. This flux links the secondary
windings.
A voltage is induced in the secondary of the same frequency as primary
but its magnitude depends on the no. of turns of the secondary.

TYPES OF TRANSFORMERS:
 Step up
 Isolation
 Step down

MAJOR TRANSFORMERS IN THE POWER STATION:

1. GENERATOR TRANSFORMER: the generator is connected to

this transformer by means of isolated bus ducts. This transformer is used
to step up the generating voltage of 15.5 kV to the grid voltage. Generally
it is provided with OFB cooling and is oil immersed. Off circuits taps on
the high voltage side are also present. The transformer has elaborate
cooling system –of oil pumps and cooling fans.

2. UNIT AUXILLIARY TRANSFORMER:

 UAT draws its input from the main bus duct connecting the
generating transformer. Total KVA capacity UAT required can be
determined by using .85 p.f. and 0.9 efficiency for the total auxiliary motor
load.
 For large units, more than one transformer is used. Such
arrangement provides separate bus sections fed by separate aux.
Transformers with bus section breaker.

Following conditions should be satisfied:

# Max. Short circuit current on the aux. Bus should be limited within the
max. Switch gear rating available.
# Max. Permissible voltage dip while starting the largest single aux.
Motor, usually boiler feed pump should remain within acceptable limits.

3. STATION TRANSFORMER: it is needed to feed the auxiliaries

during the start ups. These are usually rated for the initial aux. Load
requirements of the unit. It is of the order of 60% of full load.

CONSTRUCTION:
 CORE AND WINDINGS
 CONSERVATOR
 BREATHER
 BUCHHOLZ BOX
 MARSHALLING BOX
 PRESSURE RELIEVE VALVE
 COOLING SYSTEM

CORE AND WINDING

Two arrangements are:
1. CORE TYPE
2. SHELL TYPE

In the core type, the winding is wound around the two legs of the
rectangular magnetic core, while in the shell type the windings are wound
on the central leg of a three legged core.

CONSERVATOR
It is the small tank placed on the top of the main tank. It maintains the
level of oil in the transformer. If the oil levels falls, more air comes in the
reservoir through the breather, which is nothing but silica gel. And if the
level of oil rises, the air is pumped out.

BREATHER
A breather is provided to prevent the contamination of the transformer oil
in the conservator by the moisture present in the air entering the
conservator. Outside air is drawn into the conservator through the
breather every time the transformer cools down. The breather is filled with
material of silica gel which has the property of absorbing. Dry silica is
blue in color; it is replaced after it turns red.

MARSHALLING BOX
It is a sort of control box which houses control for cooling fans and
pumps. There is an oil temperature indicator and winding temperature
indicator as well.

PRV/EXPLOSION VENT:

EXPLOSION VENT: in case of a severe fault in the transformer, the

internal pressure may build up to a very high level, which may result in
explosion of the tank. To avoid such contingency a relief vent is provided
which breaks and relieves the pressure.

PRV: this also releases pressure closes automatically.

COOLING SYSTEM:
It consists of
 Radiator
 fans
 Pump
The assembly circulates oil in the transformer, which provides insulation
as well as cooling along with air.
 HYDROGEN GAS PLANT

Hydrogen gas plant is also one of the main units associated with the plant.
With the help of this hydrogen gas plant, abundant quantity of hydrogen is
produced which is thus used for the cooling purpose.

The hydrogen gas produced at the hydrogen gas plant is used in the
main plant for the cooling purpose. This hydrogen obtained is filled into
hydrogen gas cylinders which are connected to the system in the main
plant. Thus with the help of this hydrogen gas cooling in the plant is
obtained.

In the hydrogen gas plant a large number of cells are used for the
production of the hydrogen gas. These cells are filled with caustic soda.
These cells contain two different types of plates called the MS and SS
plates. The MS plates are generally associated with the production of the
hydrogen gas while the SS plates produce the oxygen which is released in
the nature.

The plates of the cells which are being used for the production of
the hydrogen in the hydrogen gas plant are covered with Asbestos. The
power given to the cells for the production of the hydrogen is around 60-
75 watts.

The hydrogen gas thus obtained is filled into hydrogen gas

cylinders at a certain specified pressure. The most important part of the
HYDROGEN GAS PLANT is the percentage of purity of hydrogen. If the
percentage of purity of hydrogen is less than 98% the hydrogen is not used
in the cooling system.
 MAIN GENERATOR

Main data of generator:

Maximum continuous KVA 247000 KVA

rating
Maximum continuous KW 210000 KW
Rated terminal voltage 15750 V
Rated stator current 9050 A
Rated power factor 0.75 lag
Excitation current at MCR 2600 A
condition
Slip ring voltage at MCR 310 V
condition
Rated speed 3000 RPM
Rated frequency 50 Hz
Short circuit ratio 0.49
Efficiency at MCR condition 98.4%
Direction of rotation viewed Anticlockwise
Phase connection Double star
Number of terminals brought 9 (6 neutral and 3
out phase)
 MAIN TURBINE DATA

Rated output of turbine 210 MW

Rated speed 3000 RPM
Rated pressure of steam before 130 Kg/cm2
emergency
Stop valve rated live steam 535C
temperature
Rated steam temperature after 535C
reheat at inlet to receptor valve
Steam flow at valve wide open 670 tons/hr
condition
Rated quantity of circulating 27000 cum/hr
water through condenser
For cooling water temperature 24,27,30,33
(C)
23.99,24.21,24.49,
4. Reheated steam pressure 24.84
at inlet of
interceptor valve in Kg/cm
ABS 68,645,652,662

5. Steam flow required for

210 MW in 19.9,55.5,65.4,67.
ton/hr 7

6. Rated pressure at exhaust

of LP
turbine in mm of hg
 OPERATION
PRIMARY CONSTITUTES OF B.T.P.S

BOILER AUXILIARIES:

PULVERIZER

In the pulverizer the coal is powdered so that almost 70 –

80% of the coal can pass through a 200 – mesh sieve. There are many
types of pulverizer and ball mills which run at a speed of 17 – 20 rpm. The
crushing is done by centrifugal force in the container with metal balls,
which can easily be replaced. However, the disadvantage is that this mill
requires a lot of power to pulverize the coal. Then there is the bowl mill ,
which rotates at the speed of 32 – 100 rpm. The coal is crushed by the
action of rollers in a bowl like structure, which crushes the coal. The
advantages of this mill are that require minimal maintenance and power.
The major disadvantage is that they
Require air sealing so that mill is leak proof.

BOILER ACCESSORIES:

 Boiler drum
 Burner
 Superheated
 Reheater
 Economizer

BOILER DRUM:

The boiler drum is made of carbon steel metal, its primary

functions being to Separate the water from steam in the furnace walls by
employing a spinning action and to reduce the dissolved solid particles to a
minimum of 1 ppm by using scriber and dryers. Steam in the drums comes
out at a pressure of 150.7kg/cm2, while the temperature of the drum is
342C.
 BURNER:

There are a total of 24 burners for the corner type fired boilers
with 12 oil burners provided each in between two pulverized fuel
burners. The coal burners are arranged so that 6 mills at the four corners
of the furnace can supply them.

SUPERHEATERS

There are basically 3 types of super heaters in the boilers.

They use the heat of the flue gases to increase the temperature of the
steam to about 540C, which makes the steam super saturated in nature.

RE-HEATER:

The function of the re-heater is to increase the temperature

of the steam to 540C, thereby increasing the heat content of the steam.
This is only employed in the 210 MW units because of the greater demand
for heat energy. The temperature and pressure to the re-heater is 332 C
and 26.4 kg/cm^2 while outlet temperature and pressure of the re- heater
is 540C and 24.5 kg/cm^2.

ECONOMIZER:

The economizer re-heats the boiler feed water before it is

introduced into the steam drum by reusing the heat from the flue gases.
This particular accessory increases the efficiency of the boiler. The steam
enters at 247C and leaves at 278C. The water in the economizer flows in
the upward direction thereby giving heat to the boiler feed water.
 TURBINE AUXILIARIES:

GLAND STEAM AND GLAND STEAM COOLERS:

Steam from the de-aerators or from the auxiliary steam header is

supplied to the end seal of high pressure rotor generally at a pressure of
1.01 and 1.03 atm. Thus, to prevent entrance of atmospheric air into the
turbine through the end clearance, stem is supplied to the end seal and is
extracted by the gland stem cooler by action of Single steam ejector.

DE – AERATOR:

This component removes oxygen, carbon dioxide, ammonia and other

Corrosive gases that are dissolved in the water to be sent to the boiler. The
main Function of the de-aerator is to minimize the amount of oxygen in
the water so that there may be minimal corrosion in the boiler internals
where the water has to flow through.

EJECTORS:

Two 100% capacity ejectors whose purpose is to evacuate air and other
non-Condensing gases from condenser and thus maintain the vacuum in
the condenser steam from the de-aerator with 11 atm header as working
medium for ejectors.

SUPERHEATER AND PREHEATER:

Superheated steam is that steam, which contains more heat than the
saturated steam at the same pressure i.e. it, has been above temperature
corresponding to is pressure. This additional heat provides more energy to
the turbine and thus the electrical output power is more. Superheated
steam causes lesser erosion of turbine blades and can be transmitted for
longer distances with little heat lost. The function of the superheated is to
remove the traces of moisture from the saturated steam leaving the boiler
tube and also to raise the temperature of this steam.

Super heaters are classified as convection, radiation or combination of

both. A convection superheated is placed somewhere in the gas steam and
receives most of the heat by convection. A radiant superheated is placed
near the furnace where it receives most of the heat by radiation. In the
combination of superheated the steam leaving the boiler drum first passes
through the convection section and then through the radiation section and
then to the steam header. In addition to the superheated there is a re –
heater. It is to reheat the partially expanded steam from the turbine. This
ensures that the steam remains dry throughout the last stage of the
turbine.

STEAM TURBINE:

A steam turbine converts heat energy to mechanical energy and drives the
generator. It uses the principle that steam issuing from a small opening
attains a high velocity. This velocity attained during expansion depends
upon the heat content and represents the heat energy converted into
kinetic energy.

Steam turbines are manufactured in a variety of sizes up to 1,000,00 HP or

even more and have horizontal configuration. The standard speeds are
3000 rpm and 5000 rpm for coupling to 50 Hz generators.

They are of two types:

(a) Impulse turbine: in impulse turbine steam is expanded in turbine

nozzle and attains a high velocity. The rotor may be built-up rotor or
integral rotor. A built – up rotor consists of a forced steel shaft on which
separate forged steel discs are shrunken and keyed. In an integral rotor
one solid forging forms the wheel and the shaft. The built – up rotor is
cheap and easy to manufacture.

(c) Reaction turbine: the reaction turbine only partial expansion takes
place in the nozzle and further expansion takes place as the steam flows
over the rotor blades. The relative velocity of the steam increases as it
expands. While passing over the rotor blades, there is a difference in
pressure on the two sides on the moving blades. Blades have an aerofoil
section. It is seen from above that in reaction turbine also partial
expansion takes place. In the nozzle that is an impulse section. The
modern reaction turbine has both stationary and moving blades. The
blades are similar; each so arranged that the area through which it enters,
pressure drops take place in both the stationary and moving blades. The
restricted area at the outlet of the blades causes the steam velocity to
increase as steam leaves the blades.

ASH HANDLING PLANT:

The percentage of ash in coal varies from about 5 % to 40 %.
Power plants generally use poor quality coal. As a result of this amount of
ash produced by a plant is quite large. A modern 210 MW plant produces
5000 tones of ash daily. Of this about 25 % is furnace bottom ash and
remaining 75 % is pulverized fuel ash or fly ash. In small stations there is
a conveyor arrangement to carry ash to dump sites directly or for carrying
and loading it to trucks and wagon which transports it to the site of
disposal. Large systems use more elaborate arrangements for separate
system of furnace bottom and fly ash is quite acidic due to sulphur dioxide
in the flue gases.

A sliding system is generally used for removal of furnace bottom

ash. The ash falls into a dry hopper that is fitted with excess doors and
high- pressure water jets. The collected ash is jet sluiced from the hopper
into a sluiced way and is carried by water into a settling tank, outside the
power station building, where it can be drained, dried and disposed of.
This ash can be used as landfill.

A pneumatic system is usually employed for disposal of fly ash. In this

system a high velocity of air causes the ash to flow into the separator
where the ash is collected in hoppers. The dusty air is filtered and
exhausted to the atmosphere through the fan. Fly ash is generally stored
in reinforced concrete bunkers of about 100 tones capacity each. In recent
years the possibility of using fly ash has been investigated and its
commercial use has increased. Some of these uses are: mixing with clay to
produce bricks, use as a constituent of concrete, making of light weight
aggregate by sintering.
 CONDENSER:

It condenses the steam exhausted from the turbine. Thus it helps in

maintaining low pressure at the exhaust, thereby permitting expansion of
steam in the turbine to a very low pressure. This improves the plant
efficiency. The exhaust steam is condensed and acts as feed water for the
boiler. Maintenance of high vacuum in the condenser destroys the
vacuum. For this purpose vacuum pump is needed to remove the air
leaking into the condenser.

Modern power plants mostly use surface condenser consisting of an

airtight cylindrical shell having a chamber at each end. Water tubes
extend between the chambers. These shells are made of welded steel plate
construction and tubes are made of copper zinc alloy. Cooling water flows
through the tubes. The steam is admitted from the top and gets condensed
due to contact with the tube surfaces. The condensate leaves from the
bottom. For efficient operation the temperature rise in cooling water
passing through the condenser should be around 10 C.
 COOLING TOWERS AND PONDS:
A condenser needs huge quantity of water to condense the steam.
Approximately 1 kg of steam needs 100 kg of cooling water for the
condenser. Typically a 2000 MW plant needs about 1500 10^6 gallons per
day of cooling water. Large source of water supply is usually not available
near a thermal plant, therefore most plants use a closed cooling water
system where the warm water coming out of the condenser is cooled and
reused. Small plants use spray ponds and medium and large plants use
cooling towers. In these ponds and towers warm water loses its heat to the
atmosphere and is reused again. Modern steam stations invariably use
large sizes cooling towers that from the most prominent structures in the
plant.

A cooling tower is a steel or concrete hyperbolic structure having a

reservoir at the bottom for the storage of cool water. Warm water is led to
the top. Air flows from the bottom to the top. The water drops falling from
the top come in contact with air, lose heat to the air and get cooled.
Eliminators are provided at the top to prevent the escape of water particles
with air. Such a tower is known as wet cooling tower. In such systems the
loss of water due to evaporation is about 1 %. Another 2 % of water
circulated is used in purging the system of dissolved salts. Hence the total
quantity of makeup water is about 3 % of the quantity circulated in the
system. The height of the cooling tower may be about 150 m and the
diameter at the base is about 150 m.

FEED WATER HEATERS:

The steam coming out of the turbine is condensed and the condensate
is fed back to the boiler as feed water. It is necessary to heat water
before feeding it back to the boiler for the following reasons:
 Feed water heating improves overall plant efficiency

 The dissolved oxygen and carbon dioxide that would otherwise

cause boiler corrosion are removed in the feed water heater.

 Thermal stresses due to cold water entering the boiler drum are
avoided
  Quantity of steam produced by the boiler is increased.

ECONOMISER:
Flue gases coming out of the boiler carry lot of heat. An economizer
extracts a part of this heat from the flue gases and uses it for heating feed
water. Use of an economizer results in saving in coal consumption and
higher boiler efficiency that needs extra investments and increase in extra
maintenance of cost of floor area placed between two headers.

AIR PREHEATERS:
After the flue gases leave the economizer some further heat can be
extracted from them and used to heat the incoming air of combustion.
Cooling of flue gases by 200 C increases plant efficiency by 1 %. Air
preheater can be plate type, tabular type or regenerative type. Plate type air
preheater has alternate narrow lane for gas and air passage. The two
fluids flow in opposite directions in tabular air heaters. The gases flow
inside the tubes and the air of corrugated steel plate. The rotor is fixed
onto a shaft that is rotated at a low speed of 2 – 4 rpm. As the rotor rotates,
it alternatively passes through flue gases and air zone.