NATIONAL THERMAL POWER CORPORATION LIMITED

PROJECT REPORT ON

ELECTRICAL POWER GENERATION, TRANSMISSION & PROTECTION

SU BMITTED BY:

AMIT TRIPATHI MNNIT,A LLAHABAD

ACKNOWLEDGEMENT
I express my sincere gratitude to NTPC for giving me the opportunity of undertaking summer training of 42 days at BTPS. I thank all technicians, foreman and executives for explaining the practical aspects of theoretical knowledge that I have acquired from my college. I take the opportunity to thanks the various labs in charges for taking pain in demonstrating the internal circuitry of various instruments. I specially thank Mr. M.S. Chabbra, Mr. Anil Sharma, Mr. Yogeshwarchand for their kind support and encouragement at every point of training without which this training would not have been successful.

AUTHOR

CERITIFICATE
This is to certify that Mr. Amit Tripathi, student of Electrical Engineering, Motilal Nehru National Institude Of Technology, Allahabad has successfully completed vocational training at National Thermal Power Corporation (NTPC), Badarpur, New Delhi for a period of six weeks from 23-05-2011 to 02-07-2011. He has completed whole training as per project report submitted by him.

Training Incharge
(BTPS New Delhi)

INTRODUCTION
National Thermal Power Corporation L.T.D.(N.T.P.C.) is the company, which is working at Badarpur Thermal Power Station, which is situated in New Delhi in India. N.T.P.C. is the largest thermal power generation company of India. It was incorporated in the year 1975 with the objective of planning, promoting and organising an integrated development of thermal power in the country. N.T.P.C. is the public limited company wholly owned by the government of India. It has power generating capacity in all the four major regions of the country.

Badarpur Thermal Power Station

Approved capacity MW installed Location New Delhi Coal source Jharia coal field

705

Water Agra canal Beneficiary state Delhi Unit size X 95 MW X 210 MW 3 2

ELECTRICAL MAINTAINANCE DIVISION I

The EMD I at BTPS is in charge of the switchgears, LT motors, HT motors etc. The training however was restricted to the above three areas only.

COAL HANDLING PLANT -

Coal being carried by conveyors

Layout of new coal handling plant at NTPC, Badarpur

ElectroStatic Precipitator-

ESP is meant for air pollution control. The working of ESP is based on CORONA DISCHARGE. An electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate collection 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 that minimally impede the flow of gases through the device, and can easily remove fine particulate matter such as dust and smoke from the air stream. In contrast to wet scrubbers which apply energy directly to the flowing fluid medium, an ESP applies energy only to the particulate matter being collected and therefore is very efficient in its consumption of energy (in the form of electricity).

SWITCHGEARS -

Switchgear is a switching/ interrupting device used in connection with generation, transmission, distribution and conversion of electric power for controlling, metering protecting and regulating devices. It is a combination of electrical disconnects fuses and/or circuit breakers used to isolate electrical equipment. Switchgear is used both to de-energize equipment to allow work to be done and to clear faults downstream. These are located in substations on both the high and low voltage sides of the large power transformers. One of the basic functions of switchgear is protection, which is interruption of short-circuit and overload fault currents while maintaining service to unaffected circuits. Switchgear also provides isolation of circuits from power supplies. Switchgear also is used to enhance system availability by allowing more than one source to feed a load. The various types of switchgears are -

1.Isolator Switch - It is a part of an electrical circuit which

electrically isolates the circuit that is continually powered. It breaks the electrical circuit when the circuit is to be switched in no load. These are normally used in various circuits for the purpose of isolating a certain portion when required for maintenance etc.. The most common isolator is the rotating centre post type in which each phase has three insulator posts, with the outer post carrying fixed contacts and connections while the centre post having the contact arm which is arranged to move through 90 degrees on its axis. However in some cases two post design is used wherein earth fault carries a half length contact arm linked together with the ability to rotate through 90 degrees in opposite directions. The design was introduced so as to economise on insulation but has been found to occupy a greater area than the three post type and necessitates making the break structure extremely rigid to avoid deflection of insulation under load. The modern trend is again to return back to the three post type. It has been possible to reduce the isolator size by limiting the moving contact blade to move a fully open position of 70 degrees to the axis of 3 phases of isolator instead of 90 degrees but last 20 degrees of movement is used to rotate the moving contact in its own axis, while the full diameter of the contact is presented to the fixed contact fingers so that necessary contact pressure is achieved. The concept of using that last 20 degrees of movement of the rotating centre post to turn the moving contacts through this angle about their own axis enables very high contact pressure to be achieved without the need for a very powerful operating mechanism.

2. Load Break Switch - An electric switch in a circuit with several

hundred thousand volts, designed to carry a large amount of current without overheating the open position, having enough insulation to isolate the circuit in closed position, and equipped with arc interrupters to interrupt the load current.

3. Earth Switches Devices which are used normally to earth a

particular system, to avoid any accidents which may happen due to induction on account of live adjoining circuit. These equipments do not handle any appreciable current at all. Apart from this equipment, there are a no. of relays etc. which are used in the switchgear.

Circuit Breakers - A circuit breaker is an automatically-operated

electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Unlike a fuse, which operates once and then has to be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation. Circuit breakers are made in varying sizes, from small devices that protect an individual household appliance up to large switchgear designed to protect high voltage circuits feeding an entire city. The circuit breaker must detect a fault condition like overload current etc. Once a fault is detected, contacts within the circuit breaker must open to interrupt the circuit; some mechanically stored energy within the breaker is used to separate the contacts, although some of the energy required may be obtained from the fault current itself. The stored energy may be in the form of springs or compressed air. The circuit breaker contacts must carry the load current without excessive heating, and must also withstand the heat of the arc produced when interrupting the circuit. Contacts are made of copper or copper alloys, silver alloys, and other materials. Service life of the contacts is limited by the erosion due to interrupting the arc. When a current is interrupted, an arc is generated - this arc must be contained, cooled, and extinguished in a controlled way, so that the gap between the contacts can again withstand the voltage in the circuit. Different circuit breakers use vacuum, air, insulating gas, or oil as the medium in which the arc forms. Different techniques are used to extinguish the arc including: Lengthening of the arc Intensive cooling (in jet chambers) Division into partial arcs Zero point quenching Connecting capacitors in parallel with contacts in DC circuits Finally, once the fault condition has been cleared, the contacts must again be closed to restore power to the interrupted circuit. Depending on the method of extinguishing the arc, the high voltage circuit breakers can be classified as:

1. SF6 Circuit Breaker - The SF6 circuit breaker installed at BTPS is

HPA by ABB as per standard IEC56. HPA is a medium-voltage circuit breaker using SF6 gas as the insulation and breaking medium. Its design is compact and space-saving. The breaker is also available in a version with synchronised making for maximum damping of transients for different applications. The HPA breaker works according to the puffer principle, implying that when breaking, the gas is compressed between a fixed plunger and a moving cylinder and then blown on to the arc between the fixed and moving arc contacts. When the breaker is closed, the current flows via the main contacts and the cylinder. When a tripping impulse is given, the cylinder moves downwards, whereupon the upper main contact opens and the current commutes over to the arc contact. At the same time, the gas in the cylinder is compressed. When the nozzle has left the arc contact, the compressed gas is blown along the arc and cools it. The breaking process is completed as the current passes through zero. SF6 (sulphur hexafluoride) gas possesses a unique combination of properties that makes it extremely suitable for use in circuit breakers. SF6 gas has insulation strength some three times higher than that of air at an overpressure of 2 bar, which is even higher than that of transformer oil.

SF6 gas properties High insulation strength Excellent ability to quench arcs

 Chemically stable Non-toxic Non-flammable Another SF6 breaker used at BTPS is Voltas SF6 circuit breaker.

ABB SF6 Circuit Breaker

Circuit breaker Standard Rated voltage Insulation level Rated frequency Breaking current Rated current Making capacity Rated short time current Weight Auxiliary voltage Closing coil Opening coil Motor SF6 pressure at 20C SF6 gas per pole

HPA IEC 56 12 kV 28/75 kV 50 Hz 40 kA 1600 A 110 kA 40 kA/3s 185 kg 220 V DC 220 V DC 220 V DC 2-2.5 Bar (.2-.25 MPa) 0.25 kg

Voltas SF6 circuit breaker

Rated Current Rated Voltage Frequency Breaking Capacity Short time current SF6 gas pressure

1250 A 9.2 KV 50 Hz 40 KA symmetrical 43.45 KA asymmetrical 40 KA 3s 2.5 bar

2. Minimum Oil Circuit Breaker (MOCB) - The MOCB at BTPS is

Kirloskar HKH 1/1000C.

In minimum oil circuit breakers the arc extinction takes place in insulating housing enclosed in ceramic enclosures. The medium used is dielectric oil and the breaking capacity is 3.6 - 145 KV. In the bulk oil breakers, the oil serves as both arcs extinguishing medium and main insulation. The minimum oil breakers were developed to reduce the oil volume only to amount needed for extinguishing of the arc about 10% of the bulk- oil amount. The interrupter containers of the minimum oil breakers are made of insulating material and are insulated from the ground. This is usually referred to as live tank construction. For high voltages (above 132 kV), the interrupters are arranged in series.

MOCB Kirloskar

Type Rated Voltage Normal Current Frequency Breaking Capacity Operating Coils

HKH 12/1000C 6.6 KV 1250 A 50 Hz 34.7 KA symmetrical 34.7 KA asymmetrical 360 MVA symmetrical CC 220 V/DC FC 220 V/DC

3. Air Circuit Breaker - The air type circuit breaker at BTPS is Tata
Merlin & Gerin Ltd.

Air Circuit Breaker (Tata Merlin & Gerin Ltd.)

Rated Voltage Rated Current Auxiliary Circuit

6.6 KV 630 A 220 V/DC

4. Vacuum Circuit Breaker - By Jyoti Ltd., Vacuum circuit breakers

have minimal arcing (as there is nothing to ionize other than the contact material), so the arc quenches when it is stretched a very small amount (<2-3 mm). Vacuum circuit breakers are frequently used in modern medium-voltage switchgear to 35,000 volts.

Jyoti Ltd. Vacuum circuit breaker

Rated frequency Rated Voltage Supply Voltage closing Rated Current Rated short time Current Rated Breaking Current Weight 50 Hz 12 KV 220 V/DC 1250 A 40 KA 3s 40 KA 85 Kg

Vacuum circuit breaker

Relays A relay is an electrical switch that opens and closes under the control of another electrical circuit. In the original form, the switch is operated by an electromagnet to open or close one or many sets of contacts. When a current flows through the coil, the resulting magnetic field attracts an armature that is mechanically linked to a moving contact. The movement either makes or breaks a connection with a fixed contact. When the current to the coil is switched off, the armature is returned by a force approximately half as strong as the magnetic force to its relaxed position. Usually this is a spring, but gravity is also used commonly in industrial motor starters. Most relays are manufactured to operate quickly. In a low voltage application, this is to reduce noise. In a high voltage or high current application, this is to reduce arcing.

Since relays are switches, the terminology applied to switches is also applied to relays. A relay will switch one or more poles, each of whose contacts can be thrown by energizing the coil in one of three ways:

Normally-open (NO) contacts connect the circuit when the

relay is activated; the circuit is disconnected when the relay is inactive. It is also called a Form A contact or "make" contact.

Normally-closed (NC) contacts disconnect the circuit when the

relay is activated; the circuit is connected when the relay is inactive. It is also called a Form B contact or "break" contact.

Change-over, or double-throw, contacts control two circuits:

one normally-open contact and one normally-closed contact with a common terminal. It is also called a Form C contact or "transfer" contact. If this type of contact utilizesmake before break" functionality, then it is called a Form D contact. The relay was used as:

Master Trip Relay (MTR) Flag Relay Closed Position Relay (CPR) Trip Position Relay (TPR) Unit Trip Relay (UTR) Unit Signal Relay (USR)

MOTORS

 The AC induction motor is a rotating electric machine designed to operate from a three-phase source of alternating voltage. The stator is a classic three phase stator with the winding displaced by 120. The most common type of induction motor has a squirrel cage rotor.

3 Phase Squirrel Cage Induction Motor - A squirrel cage rotor

is the rotating part often used in an AC induction motor. An electric motor with a squirrel cage rotor is sometimes called a squirrel cage motor. In overall shape it is a cylinder mounted on a shaft. Internally it contains longitudinal conductive bars of aluminium or copper set into grooves and connected together at both ends by shorting rings forming a cage-like shape.

Specifications: Frequency Voltage Current Efficiency Rpm Power factor Weight 50 Hz 6600 V 23.5 A 91.8% 1430 0.85 410 kg

Design60 slots Double Layered Each slot has 2 coils, no. Of slots vary as 36, 48, 60, and 90 Speed = 1430 rpm Poles = 4 Speed = 120*f/poles Poles = 4 poles/phase Slots per phase = 60/3 = 20 Slots/pole = 20/4 = 5 Coil pitch = 1 to 11 1 phase has 4 poles.

Motor Starting
The methods employed in starting a motor are extremely varied, being dependent on the system, type, starting repetition and environment etc. Probably the simplest and the most common method is to connect the supply directly to the motor allow it to accelerate normally to its running speed. This method is referred to as Direct On Line (DOL) starting.

DOL Starting
The choice of this method depends on number of conditions. If for example, the load has high inertia, then DOL will not be ideal because the prolonged starting current could be six times the normal running current. This in turn (assuming the switch used can carry this large current) would put an excessive drain on the supply system. In fact, for large horse power motors the supply authorities do not allow DOL starting. DOL starting is however used extensively in modern power stations one reason being that it is less expensive than others. Excessive current surge is more tolerable in power stations than on consumer premises.

DOL Starters

The simplest electric motor drive consists of a squirrel cage motor switched direct on line and an associated automatic motor starter consists of basically a contactor to connect the motor to supply and an overload relay to prevent over heating of the motor.

Star Delta Starter

This method involves starting motor from rest, with the stator windings connected in star configuration. In this condition, the effective voltage across each winding is 1/3 of the line voltage or 59%. The current and torque are reduced to 33% of the values obtained if the motor was started as DOL. After a period of acceleration, the supply is removed from the motor and by suitable switching process the windings are connected in the delta configuration. Before the motor has chance to decelerate, the supply is re-established with full voltage across each winding. Some deceleration does takes place in practice and mechanical shock is introduced to the drive on reconnection at full voltage. This would not be practical on large units but can be accepted on many small and medium drives.

ELECTRICAL MAINTAINANCE DEPARTMENT II

TRANSFORMER

A transformer is a constant frequency static device comprising coils coupled through a magnetic medium connecting two ports at different voltage levels (in general) in an electrical system allowing the interchange 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 or mutual magnetic field established in a core. When one of the windings is termed as primary, it is connected to a alternating voltage source, an alternating flux is produced in the core depending upon the primary voltage, number of turns and frequency. The mutual flux links the other winding called the secondary. A voltage is induced in the secondary of the same frequency as primary but its magnitude depends on the number of turns of secondary.

Types of Transformers Step up Isolation Step down

Major transformers in the power station

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 about 15 KV to the grid voltage .It is

generally provided with OFB cooling and is oil immersed .Off circuit taps on the high voltage side are also present. The transformer has elaborate cooling system consisting of a number of oil pumps and cooling fans apart from various accessories discussed later.

Unit Auxiliary transformer

UAT draws its input from the Main bus duct connecting the generating transformer. Total KVA capacity UAT required can be determined by using 0.85 p.f. and 0.9 efficiency for the total auxiliary motor load. It is usually safe and desired to provide 20% excess capacity then calculated to provide for miscellaneous auxiliaries and possible increase in the auxiliary load. For large units it has become necessary to use more than one UAT. Such arrangement normally provide separate bus section fed by separate auxiliary transformer, with bus section breaker while selecting one thing is to be taken care of is that the percent impedence of the transformer for the proposed unit should satisfy the following conditions. Maximum short circuit current on the auxiliary bus should be limited within the maximum switchgear rating available. Maximum permissible voltage dip while starting the largest single auxiliary motor usually boiler feed pump should remain within acceptable limit. Maximum voltage drop permitted on starting largest motor is about 15-20% . if the voltage drop is higher than the permissible limits, then transformer impedence has to be reduced ,the consequent increase in the short circuit current duty may require the use of higher rated switchgear. Thus to create balance for larger units, it becomes imperative to use more than one UAT.

Station Transformer

It is needed to feed the auxiliaries during the start-ups. These are usually rated for the initial auxiliary load requirements of the unit. Typically this load is of the order of 60% of the load of the full generating capacity. But in the large stations where more than one units are operating, the station transformer should have sufficient capacity to start two units at the same time. It is also provided with on load tap changer to cater to fluctuating voltage of the grid.

Construction
Transformer consists of the following partsCore and winding Conservator Breather Buchholzbox Marshalling box Cooling system

Core and winding

Two types of arrangements are provided Core type 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 winding 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 level falls more air comes in conservator through the breather which is nothing but

silica gel. And if the level of the oil rises the air pumped out to maintain the pressure. The level of the oil can be monitored by an indicator on the surface of the conservator. This arrangement also ensures that surface area of the transformer oil exposed to the atmosphere is limited so as to prevent fast oxidation and consequent deterioration of insulating properties of the oil.

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 like anhydrous calcium chloride or silica gel, which has the property of absorbing all water vapour contained in the air passing through it there by making the air quite dry. After sometime the calcium chloride or the silica gel gets saturated with moisture completely and can no longer absorb moisture. It is thereby very important to replace when it turns pink in colour. The old silica gel can be reconditioned and used again by heating up to 150-200 C.

Marshalling box
It is a sort of local control box which houses control for cooling fans and pumps. There is an oil temperature indicator and winding temperature 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. This may result in an explosion of the tank. To avoid such contingency a relief vent is provided with a Bakelite diaphragm at the top, which breaks and relieves the pressure in case of excessive pressure building up.

Pressure relief valve: It also releases excess pressure by opening a

pressure valve and then closes automatically.

Cooling Systems:
It consists of the following: Radiator Fans Pumps The assembly circulates oil in the transformer, which provides insulation as well as cooling along with the air. Application Important tasks performed by the transformer are:1. Changing current and voltage levels in electrical power systems. 2. Matching source load impedance for maximum transfer in control and electronic circuitry. 3. Electrical isolation Transformers are used extensively on ac power systems. They make possible power generation at most desirable and economical transmission level (10-20 KV). Power transmission voltage (220-1000 KV) and power utilization at most convenient distribution voltage (230-415 V). The input to main transformer is through ducts at generated level of voltage. Output is at 220 KV and connected to infinite Bus Bar through brushes (insulators).

SWITCHYARD

It consists of: Two buses (operation) at 220 kV level and one by-pass back up also at 220 kV. Air blast circuit breakers Isolators Current transformers Potential transformers Feeders Bus coupler

Bus Odd numbered bus is connected to generating unit by convention. This is also considered keeping in mind the fact that every bus has a separate set of protection unit for reliability. Thus, bus no. 1 is connected to unit no. 1 and bus no. 2 is connected to unit no. 2. Distribution is done through the feeders. The buses operate at 220 kV voltage levels. The output of the main transformer is coupled and joined to the bus 1 and 2.

By pass bus This bus is a back up bus which comes handy when any of the buses become faulty, when any operating bus has a fault. The bypass bus is brought into the circuit and then the faulty line is removed, thereby, restoring the healthy power line.

Air blast circuit breaker

The ABCB has air at pressure of about 32kg/cm2. It isolates the circuit when the current in the circuit exceeds certain limit. It operates in milliseconds and works on no load

Isolator
It operates off load and is mechanical in nature. If any part of the circuit is to be isolated to work on it during the off load condition, only the circuit is isolated using isolator. The essential difference between a circuit breaker and isolator is the presence of quenching such as air or oil in the circuit breaker. An isolator cannot be used in on load condition because an arc is formed which may touch the earth thus converting it into a line fault.

Current and Potential Transformer

These are primarily used to measure high current and voltage (of order of KA and KV).

CVT-Capacitor Voltage Transformer

These are also used for measuring voltage but have higher accuracy than PTs. A capacitor voltage transformer (CVT) is a transformer used in power systems to step-down extra high voltage signals and provide low voltage signals either for measurement or to operate a protective relay. In its most basic form the device consists of three parts: two capacitors across which the voltage signal is split, an inductive element used to tune the device to the supply frequency and a transformer used to isolate and further step-down the voltage for the instrumentation or protective relay.

The device has at least four terminals, a high-voltage terminal for connection to the high voltage signal, a ground terminal and at least one set of secondary terminals for connection to the instrumentation or protective relay. CVTs are typically single-phase devices used for measuring voltages in excess of one hundred kilovolts where the use of voltage transformers would be uneconomical. In practice the first capacitor, C1, is often replaced by a stack of capacitors connected in series. This results in a large voltage drop across the stack of capacitors that replaced the first capacitor and a comparatively small voltage drop across the second capacitor C2, and hence the secondary terminals.

Rating-220KV/110V

Feeders The following are feeders: IP Extension 1&2 Okhla 1&2 Mehrauli 1&2 Badarpur 1&2 Noida Alwar By Pass Feeder

Bus Coupler Buses are coupled using the bus coupler. The main function of the bus coupler is separate the supply from two sources. It helps to shut fault supply.

GENERATOR
The two main parts of a generator or motor can be described in either mechanical or electrical terms

Mechanical:
Rotor: The rotating part of an alternator, generator, dynamo or motor. Stator: The stationary part of an alternator, generator, dynamo or motor.

Electrical:
Armature: The power-producing component of an alternator, generator, dynamo or motor. In a generator, alternator, or dynamo the armature windings generate the electrical current. The armature can be on either the rotor or the stator. Field: The magnetic field component of an alternator, generator, dynamo or motor. The magnetic field of the dynamo or alternator can be provided by either electromagnets or permanent magnets mounted on either the rotor or the stator.

Because power transferred into the field circuit is much less than in the armature circuit, AC generators nearly always have the field winding on the rotor and the stator as the armature winding. Only a small amount of field current must be transferred to the moving rotor, using slip rings. Direct current machines necessarily have the commutator on the rotating shaft, so the armature winding is on the rotor of the machine.

ExcitationAn electric generator or electric motor that uses field coils rather than permanent magnets will require a current flow to be present in the field coils for the device to be able to work. If the field coils are not powered, the rotor in a generator can spin without producing any usable electrical energy, while the rotor of a motor may not spin at all. Very large power station generators often utilize a separate smaller generator to excite the field coils of the larger. In the event of a severe widespread power outage where islanding of power stations has occurred, the stations may need to perform a black start to excite the fields of their largest generators, in order to restore customer power service. Given below are the specifications of the 210 MW unit turbo generator:

GENERATOR 210 MW
Max. Constant kVA rating Max constant kW rating Rated terminal voltage Rated power factor Rated speed Phase connection Stator volts Stator amps Rotor volts Rotor amps 247000 210000 15.75 kv 0.85 pf 3000 rpm Double star 15750 9050 310 2600

TURBO GENERATOR 100 MW

Make Speed Capacity(kva) Power factor Power Frequency Stator current Excitation Gas pressure BHEL 3000 rpm 117500 0.85 lagging 100 MW 50 Hz 6475 amp 280 v 2.5 kg/cm2

ROTOR COOLING
Hydrogen pressure Purity Gas volume 4.5 kg/cm2 97% 66 cubic meter

STATOR COOLING
Water pressure Quantity of water 3.5 kg/cm2 130 m3/hr