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: 06th JUNE to 14th August, 2010

SUBMITTED TO: SUBMITTED BY:

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TABLE OF CONTENT

Certificate

Acknowledgement
Training at BTPS

1. Introduction

¨ NTPC
¨ Badarpur Thermal Power Station
2. Operation
3. Control & Instrumentation
¨ Manometry Lab
¨ Protection and interlock Lab
¨ Automation Lab
¨ Water Treatment Plant
¨ Furnace Safeguard Supervisory System
¨ Electronic Test Lab

4. Electrical Maintenance Division-I

¨ HT/LT Switch Gear
¨ HT/LT Motors, Turbine & Boilers Side
¨ CHP/NCHP

5. Electrical Maintenance Division-II

¨ Generator
¨ Transformer & Switchyard
¨ Protection
¨ Light

¨ EP
 CERTIFICATE

This is to certify that------------------------- student of Batch Electronics & Instrumentation Branch IIIrd
Year; Hindustan Institute of Technology Greater Noida has successfully completed her industrial
training at Badarpur Thermal power station New Delhi for eight week from 6th June to 14th august
2010
She has completed the whole training as per the training report submitted by her.

Training Incharge
BTPS/NTPC
NEW DELHI
 Acknowledgement

With profound respect and gratitude, I take the opportunity to convey my thanks to complete the
training here.
I do extend my heartfelt thanks to Mrs. Rachna Singh for providing me this opportunity to be a part
of this esteemed organization.
I am extremely grateful to all the technical staff of BTPS/NTPC for their co-operation and guidance
that helped me a lot during the course of training. I have learnt a lot working under them and I will
always be indebted of them for this value addition in me.
I would also like to thank the training in charge of Hindustan Institute of Technology Gr. Noida and
all the faculty member of Electronics department for their effort of constant co-operation. Which
has been significant factor in the accomplishment of my industrial training.
 Training at BTPS

I was appointed to do eight-week training at this esteemed organization from 06th June to 14th
august 2010. In these eight weeks I was assigned to visit various division of the plant which were

Operation

Control and instrumentation (C&I)

Electrical maintenance division I (EMD-I)

Electrical maintenance division II (EMD-II)

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

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

NTPC Limited is the largest thermal power generating company of India. A public sector company, it
was incorporated in the year 1975 to accelerate power development in the country as a wholly
owned company of the Government of India. At present, Government of India holds 89.5% of the
total equity shares of the company and FIIs, Domestic Banks, Public and others hold the balance
10.5%. With in a span of 31 years, NTPC has emerged as a truly national power company, with power
generating facilities in all the major regions of the country.
 ABOUT BADARPUR THERMAL POWER STATION

ELECTRICITY FROM COAL

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

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

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

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

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

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

Maximum continuous KVA rating 24700KVA

Maximum continuous KW 210000KW

Rated terminal voltage 15750V

Rated Stator current 9050 A

Rated Power Factor 0.85 lag

Excitation current at MCR Condition 2600 A

Slip-ring Voltage at MCR Condition 310 V

Rated Speed 3000 rpm

Rated Frequency 50 Hz

Short circuit ratio 0.49

Efficiency at MCR Condition 98.4%

Direction of rotation viewed Anti Clockwise

Phase Connection Double Star

Number of terminals brought out 9( 6 neutral and 3 phase)

MAIN TURBINE DATA

Rated output of Turbine 210 MW

Rated speed of turbine 3000 rpm

Rated pressure of steam before emergency 130 kg/cm^2

Stop valve rated live steam temperature 535 degree Celsius

Rated steam temperature after reheat at inlet to receptor valve 535 degree Celsius

Steam flow at valve wide open condition 670 tons/hour

Rated quantity of circulating water through condenser 27000 cm/hour

1. For cooling water temperature (degree Celsius) 24,27,30,33

2.Steam flow required for 210 MW in ton/hr 68,645,652,662

 THERMAL POWER PLANT

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

23. Precipitator
24. Induced draught(draft) fan
25. Fuel gas stack
The description of some of the components written above is described as follows:
1. Cooling towers

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

2.Three phase transmission line

Three phase electric power is a common method of electric power transmission. It is a type of
polyphase system mainly used to power motors and many other devices. A Three phase system uses
less conductor material to transmit electric power than equivalent single phase, two phase, or direct
current system at the same voltage. In a three phase system, three circuits reach their instantaneous
peak values at different times. Taking one conductor as the reference, the other two current are
delayed in time by one-third and two-third of one cycle of the electrical current. This delay between
͞phases͟ 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-up͟ 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 ͞household͟ voltage).
The power may already have been split into single phase at this point or it may still be three phase.
Where the step-down is 3 phase, the output of this transformer is usually star connected with the
standard mains voltage being the phase-neutral voltage. Another system commonly seen in North
America is to have a delta connected secondary with a center tap on one of the windings supplying
the ground and neutral. This allows for 240 V three phase as well as three different single phase
voltages( 120 V between two of the phases and neutral , 208 V between the third phase ( known as a
wild leg) and neutral and 240 V between any two phase) to be available from the same supply.
3.Electrical generator

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

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

4.Boiler feed water pump

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

Construction and operation

Feed water pumps range in size up to many horsepower and the electric motor is usually separated
from the pump body by some form of mechanical coupling. Large industrial condensate pumps may
also serve as the feed water pump. In either case, to force the water into the boiler; the pump must
generate sufficient pressure to overcome the steam pressure developed by the boiler. This is usually
accomplished through the use of a centrifugal pump.
Feed water pumps usually run intermittently and are controlled by a float switch or other similar
level-sensing device energizing the pump when it detects a lowered liquid level in the boiler is
substantially increased. Some pumps contain a two-stage switch. As liquid lowers to the trigger point
of the first stage, the pump is activated. I f the liquid continues to drop (perhaps because the pump
has failed, its supply has been cut off or exhausted, or its discharge is blocked); the second stage will
be triggered. This stage may switch off the boiler equipment (preventing the boiler from running dry
and overheating), trigger an alarm, or both.
5. Steam-powered pumps
Steam locomotives and the steam engines used on ships and stationary applications such as power
plants also required feed water pumps. In this situation, though, the pump was often powered using
a small steam engine that ran using the steam produced by the boiler. A means had to be provided,
of course, to put the initial charge of water into the boiler(before steam power was available to
operate the steam-powered feed water pump).the pump was often a positive displacement pump
that had steam valves and cylinders at one end and feed water cylinders at the other end; no
crankshaft was required.

In thermal plants, the primary purpose of surface condenser is to condense the exhaust steam from
a steam turbine to obtain maximum efficiency and also to convert the turbine exhaust steam into
pure water so that it may be reused in the steam generator or boiler as boiler feed water. By
condensing the exhaust steam of a turbine at a pressure below atmospheric pressure, the steam
pressure drop between the inlet and exhaust of the turbine is increased, which increases the
amount heat available for conversion to mechanical power. Most of the heat liberated due to
condensation of the exhaust steam is carried away by the cooling medium (water or air) used by the
surface condenser.

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

7. Deaerator

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

8. Feed water heater

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

9. Pulverizer

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

10. Boiler Steam Drum

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

11. Super Heater

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

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

13. Air Preheater

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

14. Precipitator

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

The original parallel plate-Weighted wire design (described above) has evolved as more efficient (
and robust) discharge electrode designs were developed, today focusing on rigid discharge
electrodes to which many sharpened spikes are attached , maximizing corona production.
Transformer ʹrectifier 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 ESP͛s to stay in operation for years at a time.

oxides and sulfur oxides. The flue gas stacks are often quite tall, up to 400 meters (1300 feet) or
more, so as to disperse the exhaust pollutants over a greater aria and thereby reduce the
concentration of the
 C&I(CONTROL AND INSTRUMENTATION)

I was assigned to do training in control and instrumentation from 2nd july to 14th aug 2010

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:

MANOMETRY LAB

PROTECTION AND INTERLOCK LAB

AUTOMATION LAB

WATER TREATEMENT LAB

FURNACE SAFETY SUPERVISORY SYSTEM(FSSS)

ELECTRONICS TEST LAB

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

5.0 MANOMETRY LAB

5.0.1 TRANSMITTERS
It is used for pressure measurements of gases and liquids, its working principle is that the input
pressure is converted into electrostatic capacitance and from there it is conditioned and amplified. It
gives an output of 4-20 ma DC. It can be mounted on a pipe or a wall. For liquid or steam
measurement transmitters is mounted below main process piping and for gas measurement
transmitter is placed above pipe.

5.0.2 MANOMETER
It͛s 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
It͛s an oval section tube. Its one end is fixed. It is provided with a pointer to indicate the pressure on
a calibrated scale. It is of 2 types:

(a) Spiral type: for Low pressure measurement.

(b) Helical Type: for High pressure measurement.

5.1 PROTECTION AND INTERLOCK LAB

5.1.1 INTERLOCKING
It is basically interconnecting two or more equipments so that if one equipments fails other one can
perform the tasks. This type of interdependence is also created so that equipments connected
together are started and shut down in the specific sequence to avoid damage.
For protection of equipments tripping are provided for all the equipments. Tripping can be
considered as the series of instructions connected through OR GATE. When a fault occurs and any
one of the tripping is satisfied a signal is sent to the relay, which trips the circuit. The main
equipments of this lab are relay and circuit breakers. Some of the instrument uses for protection are:
1. RELAY

It is a protective device. It can detect wrong condition in electrical circuits by constantly measuring
the electrical quantities flowing under normal and faulty conditions. Some of the electrical quantities
are voltage, current, phase angle and velocity.
2. FUSES

It is a short piece of metal inserted in the circuit, which melts when heavy current flows through it
and thus breaks the circuit. Usually silver is used as a fuse material because:
a) The coefficient of expansion of silver is very small. As a result no critical fatigue occurs and thus
the continuous full capacity normal current ratings are assured for the long time.
b) The conductivity of the silver is unimpaired by the surges of the current that produces
temperatures just near the melting point.
c) Silver fusible elements can be raised from normal operating temperature to vaporization quicker
than any other material because of its comparatively low specific heat.

5.1.2 MINIATURE CIRCUIT BREAKER

They are used with combination of the control circuits to.

a) Enable the staring of plant and distributors.
b) Protect the circuit in case of a fault.
In consists of current carrying contacts, one movable and other fixed. When a fault occurs the
contacts separate and are is stuck between them. There are three types of

5.1.3 ROTECTION AND INTERLOCK SYSTEM

1. HIGH TENSION CONTROL CIRCUIT

For high tension system the control system are excited by separate D.C supply. For starting the
circuit conditions should be in series with the starting coil of the equipment to energize it. Because if
even a single condition is not true then system will not start.

2. LOW TENSION CONTROL CIRCUIT

For low tension system the control circuits are directly excited from the 0.415 KV A.C supply. The
same circuit achieves both excitation and tripping. Hence the tripping coil is provided for emergency
tripping if the interconnection fails.

5.2 AUTOMATION LAB

This lab deals in automating the existing equipment and feeding routes.
Earlier, the old technology dealt with only (DAS) Data Acquisition System and came to be known as
primary systems. The modern technology or the secondary systems are coupled with (MIS)
Management Information System. But this lab universally applies the pressure measuring
instruments as the controlling force. However, the relays are also provided but they are used only
for protection and interlocks.
Once the measured is common i.e. pressure the control circuits can easily be designed with single
chips having multiple applications. Another point is the universality of the supply, the laws of
electronic state that it can be any where between 12V and 35V in the plant. All the control
instruments are excited by 24V supply (4-20mA) because voltage can be mathematically handled
with ease therefore all control systems use voltage system for computation. The latest technology is
the use of ͚ETHERNET͛ for control signals. 5.3 PYROMETER LAB
(1) LIQUID IN GLASS THERMOMETER
Mercury in the glass thermometer boils at 340 degree Celsius which limits the range of temperature
that can be measured. It is L shaped thermometer which is designed to reach all inaccessible places.
(2) ULTRA VIOLET CENSOR
This device is used in furnace and it measures the intensity of ultra violet rays there and according to
the wave generated which directly indicates the temperature in the furnace.

(3) THERMOCOUPLES
This device is based on SEEBACK and PELTIER effect. It comprises of two junctions at different
temperature. Then the emf is induced in the circuit due to the flow of electrons. This is an important
part in the plant.

(4) RTD (RESISTANCE TEMPERATURE DETECTOR)

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

5.5 ELECTRONICS LAB

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

5.6 ANNUNCIATIN CARDS

They are used to keep any parameter like temperature etc. within limits. It gets a signal if parameter
goes beyond limit. It has a switching transistor connected to relay that helps in alerting the UCB.
39. Control and Instrumentation 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
The mercury will occupy a greater fraction of the volume of the container than it will at a low
temperature.
Under normal atmospheric conditions mercury normally boils at a temperature of (347°C). To extend
the range of mercury in glass thermometer beyond this point the top end of a thermometer bore
opens into a bulb which is many times larger in capacity than the bore. This bulb plus the bore above
the mercury, is then filled with nitrogen or carbon dioxide gas at a sufficiently high pressure to
prevent boiling at the highest temperature to which the thermometer may be used.
Mercury in Steel the range of liquid in glass thermometers although quite large, does not lend itself
to all industrial practices. This fact is obvious by the delicate nature of glass also the position of the
measuring element is not always the best position to read the result. Types of Hg in Steel
Thermometers are:

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

Spiral type(
More sensitive and used where compactness is necessary

Helical Type(
Most sensitive and compact. Pointer may be mounted direct on end of helix
Which rotates, thus eliminating backlash and lost motion?
Linkages, which only allow the pointer to operate over a selected range of pressure to either side of
the normal steam pressure.

Dewrance Critical Pressure Gauge Measurement of Level

Direct Methods

'Sight Glass' is used for local indication on closed or open vessels. A sight glass is a tube of toughened
glass connected at both ends through packed unions and vessel. The liquid level will be the same as
that in the vessel. Valves are provided for isolation and blow down.
"Float with Gauge Post" is normally used to local indication on closed or open vessels.
"Float Operated Dial" is used for small tanks and congested areas. The float arm is connected to a
quadrant and pinion which rotates the pointer over a scale.

Bourden Pressure Gauge a Bourdon pressure gauge calibrated in any fact head is often connected to
a tank at or near the datum level.
"Mercury Manometer" is used for remote indication of liquid level. The working principle is the same
as that of a manometer one limp of a U-tube is connected to the tank, the other being open to
atmosphere. The manometer liquid must not mix with the liquid in the vessel, and where the
manometer is at a different level to the vessel, the static head must be allowed in the design of the
manometer.
'Diaphragm Type' is used for remote level indication in open tanks or docks etc. A pressure change
created by the movement of a diaphragm is proportional to a change in liquid level above the
diaphragm. This consists of a cylindrical box with a rubber or plastic diaphragm across its open end
as the level increases .the liquid pressure on the diaphragm increases and the air inside is
compressed. This pressure is transmitted via a capillary tube to an indicator or recorder
incorporating a pressure
Measuring element.

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

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

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

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

Measurement of Fluid Flow through Pipes:

"The Rotating Impeller Type" is a positive type device which is used for medium quantity flow
measurement i.e., petroleum and other commercial liquids. It consists of
Two fluted rotors mounted in a liquid tight case fluid flow and transmitted to a counter.
Rotating Oscillating Piston Type This is also a positive type device and is used for measuring low and
medium quantity flows, e.g. domestic water supplies. This consists of a brass meter body into which
is fitted a machined brass working chamber and cover, containing a piston made of ebonite. This
piston acts as a moving chamber and transfers a definite volume of fluid from the inlet to the outlet
for each cycle.
Helical Vane Type For larger rates of flow, a helical vane is mounted centrally in the body of the
meter. The helix chamber may be vertical or horizontal and is geared to a counter. Usually of pipe
sizes 3" to 10" Typical example is the Kent Torrent Meter.
Turbine Type this like the helical Vane type is a inference type of device used for
large flows with the minimum of pressure drop. This consists of a turbine or drum
revolving in upright bearings, retaining at the top by a collar. Water enters the drum
from the top and leaves tangentially casings to rotate at a speed dependent upon the
quantity of water passed. The cross sectional area of the meter throughout is equal to
the area of the inlet and outlet pipes and is commonly used on direct supply water
mains,
Combination Meters this is used for widely fluctuating flows. It consists of a larger
meter (helical, turbine or fan) in the main with a small rotary meter or suitable type in a
bypass. Flow is directed into either the main or bypass according to the quantity of flow
by an automatic valve. By this means flows of 45 to 40,000 gallons per hour can be measured.
Measurement of Fluid Flow through Open Channels:
The Weir If a fluid is allowed to flow over a square weir of notch, The height of the liquid above the
still of the weir, or the bottom of the notch will be a measure of the rate of flow.
A formula relates the rate of flow to the height and is dependent upon the design of the
Venturi Flumes The head loss caused by the weir flow meter is considerable and its
construction is sometimes complicated, therefore the flume is sometimes used. The
principle is same as that of venture except that the rate of flow is proportional to the
depth of the liquid in the upstream section. It consists of a local contraction in the cross
section of flow through a channel in the shape of a venturi. It is only necessary to
measure the depth of the upstream section which is a measure of the rate of flow. This
may be done by pressure tapping at the datum point or by a float in an adjacent level
chamber.
Pressure Difference Flow meters These are the most widely used type of flow meter since they are
capable of measuring the flow of all industrial fluids passing through pipes. They consists of a
primary element inserted in the pipeline which generates a differential pressure, ^he magnitude of
which is proportional to the square of the rate of flow and a secondary element which measures this
differential pressure and translates it into terms of flow.

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

I was assigned to do training in Electrical maintenance division I from 26th june to 31st june 2010

Electrical maintenance division 1

It is responsible for maintenance of:

1. Boiler side motors

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

1. Boiler side motors:

For 1, units 1, 2, 3

1.1D Fans 2 in no.

2.F.D Fans 2 in no.

3.P.A.Fans 2 in no.

4.Mill Fans 3 in no.

5.Ball mill fans 3 in no.

6.RC feeders 3 in no.

7.Slag Crushers 5 in no.

8.DM Make up Pump 2 in no.

9.PC Feeders 4 in no.

10.Worm Conveyor 1 in no.

11.Furnikets 4 in no.
For stage units 1, 2, 3

1.I.D Fans 2 in no.

2.F.D Fans 2 in no.

3.P.A Fans 2 in no.

4.Bowl Mills 6 in no.

5.R.C Feeders 6 in no.

6.Clinker Grinder 2 in no.

7.Scrapper 2 in no.

8.Seal Air Fans 2 in no.

9.Hydrazine and Phosphorous Dozing 2 in no.

2/3 in no.

1. COAL HANDLING PLANT (C.H.P)(6th to 10th june)

2. NEW COAL HANDLING PLANT (N.C.H.P)

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

Major Components

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

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

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

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

1. RC Bunker: - Raw coal is fed directly to these bunkers. These are 3 in no. per boiler. 4 & ½ tons of
coal are fed in 1 hr. the depth of bunkers is 10m.

2. RC Feeder: - It transports pre crust coal from raw coal bunker to mill. The quantity of raw coal fed
in mill can be controlled by speed control of aviator drive controlling damper and aviator change.

3. Ball Mill: - The ball mill crushes the raw coal to a certain height and then allows it to fall down.
Due to impact of ball on coal and attraction as per the particles move over each other as well as over
the Armor lines, the coal gets crushed. Large particles are broken by impact and full grinding is done
by attraction. The Drying and grinding option takes place simultaneously inside the mill.

4. Classifier:- It is an equipment which serves separation of fine pulverized coal particles medium
from coarse medium. The pulverized coal along with the carrying medium strikes the impact plate
through the lower part. Large particles are then transferred to the ball mill.

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

6. The Tturniket: - It serves to transport pulverized coal from cyclone separators to pulverized coal
bunker or to worm conveyors. There are 4 turnikets per boiler.
7. Worm Conveyor: - It is equipment used to distribute the pulverized coal from bunker of one
system to bunker of other system. It can be operated in both directions.

8. Mills Fans: - It is of 3 types:

Six in all and are running condition all the time.
(a) ID Fans: - Located between electrostatic precipitator and chimney.
Type-radical
Speed-1490 rpm
Rating-300 KW
Voltage-6.6 KV
Lubrication-by oil

(b) FD Fans: - Designed to handle secondary air for boiler. 2 in number and provide ignition of coal.

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

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

And they transfer the powered coal to burners to firing.

Type-Double suction radial

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

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

Motor specification ʹsquirrel cage induction motor

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

NCHP

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

2. Coal feed to plant:-

Feeder motor specification

(i) Horse power 15 HP

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

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

4. Transfer Point 6

5. Breaker House

6. Rejection House

7. Reclaim House

8. Transfer Point 7

9. Crusher House

10. Exit

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

SWITCH GEAR-

It makes or breaks an electrical circuit.

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

2. Switching Isolation: - It is capable of doing things like interrupting transformer magnetized

current, interrupting line charging current and even perform load transfer switching. The main
application of switching isolation is in connection with transformer feeders as unit makes it possible
to switch out one transformer while other is still on load.

3. Circuit Breakers: - One which can make or break the circuit on load and even on faults is referred
to as circuit breakers. This equipment is the most important and is heavy duty equipment mainly
utilized for protection of various circuits and operations on load. Normally circuit breakers installed
are accompanied by isolators

4. Load Break Switches: - These are those interrupting devices which can make or break circuits.
These are normally on same circuit, which are backed by circuit breakers.

5. Earth Switches: - Devices which are used normally to earth a particular system, to avoid any
accident happening due to induction on account of live adjoining circuits. These equipments do not
handle any appreciable current at all. Apart from this equipment there are a number of relays etc.
which are used in switchgear.

LT Switchgear

It is classified in following ways:-

1. Main Switch:- Main switch is control equipment which controls or disconnects the main supply.
The main switch for 3 phase supply is available for tha range 32A, 63A, 100A, 200Q, 300A at 500V
grade.
2. Fuses: - With Avery high generating capacity of the modern power stations extremely heavy
carnets would flow in the fault and the fuse clearing the fault would be required to withstand
extremely heavy stress in process.
It is used for supplying power to auxiliaries with backup fuse protection. Rotary switch up to 25A.
With fuses, quick break, quick make and double break switch fuses for 63A and 100A, switch fuses
for 200A, 400A, 600A, 800A and 1000A are used.

3. Contractors: - AC Contractors are 3 poles suitable for D.O.L Starting of motors and protecting the
connected motors.

4. Overload Relay: - For overload protection, thermal over relay are best suited for this purpose.
They operate due to the action of heat generated by passage of current through relay element.

5. Air Circuit Breakers: - It is seen that use of oil in circuit breaker may cause a fire. So in all circuits
breakers at large capacity air at high pressure is used which is maximum at the time of quick tripping
of contacts. This reduces the possibility of sparking. The pressure may vary from 50-60 kg/cm^2 for
high and medium capacity circuit breakers.

HT SWITCH GEAR:-

1. Minimum oil Circuit Breaker: - These use oil as quenching medium. It comprises of simple dead
tank row pursuing projection from it. The moving contracts are carried on an iron arm lifted by a
long insulating tension rod and are closed simultaneously pneumatic operating mechanism by
means of tensions but throw off spring to be provided at mouth of the control the main current
within the controlled device.

Type-HKH 12/1000c
· Rated Voltage-66 KV
· Normal Current-1250A
· Frequency-5Hz
· Breaking Capacity-3.4+KA Symmetrical
· 3.4+KA Asymmetrical
· 360 MVA Symmetrical
· Operating Coils-CC 220 V/DC
§ FC 220V/DC
· Motor Voltage-220 V/DC

2. Air Circuit Breaker: - In this the compressed air pressure around 15 kg per cm^2 is used for
extinction of arc caused by flow of air around the moving circuit . The breaker is closed by applying
pressure at lower opening and opened by applying pressure at upper opening. When contacts
operate, the cold air rushes around the movable contacts and blown the arc.

It has the following advantages over OCB:-

i. Fire hazard due to oil are eliminated.
ii. Operation takes place quickly.
iii. There is less burning of contacts since the duration is short and consistent.
iv. Facility for frequent operation since the cooling medium is replaced constantly.
Rated Voltage-6.6 KV
Current-630 A
Auxiliary current-220 V/DC

3. SF6 Circuit Breaker: - This type of circuit breaker is of construction to dead tank bulk oil to circuit
breaker but the principle of current interruption is similar o that of air blast circuit breaker. It simply
employs the arc extinguishing medium namely SF6. the performance of gas . When it is broken down
under an electrical stress. It will quickly reconstitute itself

· Circuit Breakers-HPA
· Standard-1 EC 56
· Rated Voltage-12 KV
· Insulation Level-28/75 KV
· Rated Frequency-50 Hz
· Breaking Current-40 KA
· Rated Current-1600 A
· Making Capacity-110 KA
· Rated Short Time Current 1/3s -40 A
· Mass Approximation-185 KG
· Auxiliary Voltage

4. Vacuum Circuit Breaker: - It works on the principle that vacuum is used to save the purpose of
insulation and it implies that pr. Of gas at which breakdown voltage independent of pressure. It
regards of insulation and strength, vacuum is superior dielectric medium and is better that all other
medium except air and sulphur which are generally used at high pressure.
· Rated frequency-50 Hz
· Rated making Current-10 Peak KA
· Rated Voltage-12 KV
· Supply Voltage Closing-220 V/DC
· Rated Current-1250 A

· Supply Voltage Tripping-220 V/DC

· Insulation Level-IMP 75 KVP
· Rated Short Time Current-40 KA (3 SEC)
· Weight of Breaker-8 KG
 EMD II (Electrical Maintenance division II)

I was assigned to do training in Electrical maintenance division II from 19th to 24th june 2010

Generator and Auxiliaries Generator Fundamentals

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

Working Principle

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

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

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

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

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

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

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

Rotor

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

Rotor winding

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

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

Rotor balancing

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

Stator

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

Stator core: The stator core is built up from a large number of 'punching" or sections of thin steel
plates. The use of cold rolled grain-oriented steel can contribute to reduction in the weight of stator
core for two main reasons:

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

Rolling and in cold buildings techniques.

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

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

Stator Windings

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

Generator Cooling System

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

Rotor Cooling System

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

Hydrogen Cooling System

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

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

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

Stator Cooling System

The stator winding is cooled by distillate. Which is fed from one end of the machine by Teflon tube
and flows through the upper bar and returns back through the lower bar of another slot?
Turbo generators require water cooling arrangement over and above the usual hydrogen cooling
arrangement. The stator winding is cooled in this system by circulating demineralised water (DM
water) through hollow conductors. The cooling water used for cooling stator winding calls for the
use of very high quality of cooling water. For this purpose DM water of proper specific resistance is
selected. Generator is to be loaded within a very short period if the specific resistance of the cooling
DM water goes beyond certain preset values. The system is designed to maintain a constant rate of
cooling water flow to the stator winding at a nominal inlet water temperature of 40 deg.C.
Rating of 95 MW Generator

Manufacture by Bharat heavy electrical Limited (BHEL)

Capacity - 117500 KVA

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

Rating of 210 MW Generator

Capacity - 247000 KVA

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

TRANFORMER

A transformer is a device that transfers electrical energy from one circuit to another by magnetic
coupling with out requiring relative motion between its parts. It usually comprises two or more
coupled windings, and in most cases, a core to concentrate magnetic flux. An alternating voltage
applied to one winding creates a time-varying magnetic flux in the core, which includes a voltage in
the other windings. Varying the relative number of turns between primary and secondary windings
determines the ratio of the input and output voltages, thus transforming the voltage by stepping it
up or down between circuits. By transforming electrical power to a high-voltage,_low-current form
and back again, the transformer greatly reduces energy losses and so enables the economic
transmission of power over long distances. It has thus shape the electricity supply industry,
permitting generation to be located remotely from point of demand. All but a fraction of the world͛s
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 faraday͛s 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 EMF͟. Energy losses An ideal transformer
would have no energy losses and would have no energy losses, and would therefore be 100%
efficient. Despite the transformer being amongst the most efficient of electrical machines with ex
the most efficient of electrical machines with experimental models using superconducting windings
achieving efficiency of 99.85%, energy is dissipated in the windings, core, and surrounding
structures. Larger transformers are generally more efficient, and those rated for electricity
distribution usually perform better than 95%. A small transformer such as plug-in ͞power brick͟ 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 load͟ or ͞full load͟
loss, or at an intermediate loading. Winding resistance dominates load losses contribute to over 99%
of the no-load loss can be significant, meaning that even an idle transformer constitutes a drain on
an electrical supply, and lending impetus to development of low-loss transformers. Losses in the
transformer arise from: Winding resistance Current flowing trough the windings causes resistive
heating of the conductors. At higher frequencies, skin effect and proximity effect create additional
winding resistance and losses. Hysteresis losses Each time the magnetic field is reversed, a small
amount of energy is lost due to hysteresis within the core. For a given core material, the loss is
proportional to the frequency, and is a function of the peak flux density to which it is subjected.
Eddy current Ferromagnetic materials are also good conductors, and a solid core made from such a
material also constitutes a single short-circuited turn trough out its entire length. Eddy currents
therefore circulate with in a core in a plane normal to the flux, and are responsible for resistive
heating of the core material. The eddy current loss is a complex function of the square of supply
frequency and inverse square of the material thickness. Magnetostriction Magnetic flux in a
ferromagnetic material, such as the core, causes it to physically expand and contract slightly with
each cycle of the magnetic field, an effect known as magnetostriction. This produces the buzzing
sound commonly associated with transformers, and in turn causes losses due to frictional heating in
susceptible cores. Mechanical losses In addition to magnetostriction, the alternating magnetic field
causes fluctuating electromagnetic field between primary and secondary windings. These incite
vibration with in near by metal work, adding to the buzzing noise, and consuming a small amount of
power. Stray losses Leakage inductance is by itself loss less, since energy supplied to its magnetic
fields is returned to the supply with the next half-cycle. However, any leakage flux that intercepts
nearby conductive material such as the transformers support structure will give rise to eddy currents
and be converted to heat. Cooling system Large power transformers may be equipped with cooling
fans, oil pumps or water-cooler heat exchangers design to remove heat. Power used to operate the
cooling system is typically considered part of the losses of the transformer

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