Training Report
Training Report
I would firstly wish to thank Mr. M.K. SHARMA for allowing me to undergo summer training at NTPC AURAIYA, SPECIALLY TO MR. R.K. KANOJIA THE DEPUTY GENERAL MANAGER (O&M-EM), MR. ROCHAK SAXENA SENIOR MANAGER(O&M-EM).I would also wish to convey my warm regards to Mr. ASHUTOSH Singh Bhadoria, Mr. RAJAT Rastogi ENGINEER (O&M-EM)for providing me with all the knowledge & GUIDANCE database that I needed for this report.
I would also like to thank Mr. B.C. SAHANA, TPO for providing me this wonderful opportunity to work with the NTPC family.
Ashutosh engg.(o&m-em)
CONTENTS
S.NO.
(1) (2) (3) (4) (5) (6) (7) (8)
DESCRIPTION
ABOUT THE COMPANY NTPC SUBSIDARIES NTPC HUMAN RESOURCES AWARDS INSTALLED POWER PLANTS NTPC STRATEGIES BRIEF DESCRIPTION OF THE PLANT ELECTRICAL MAINTENANCE
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EVOLUTION OF NTPC
1975 NTPC was set up in 1975 with 100% ownership by the Government of India. In the last 30 years, NTPC has into the largest power utility in India. 1997 In 1997, Government of India granted NTPC status of Navratna being one of the nine jewels of India, the powers to the Board of Directors. 2004 NTPC became a listed company with majority Government ownership of 89.5%. NTPC becomes third largest by Capitalisation of listed companies 2005 The company rechristened as NTPC Limited in line with changing business portfolio and transform itself from a thermal power utility to an integrated power utility. 2010 Government of india granted NTPC the status maharatna company.
5 NTPC
is the largest power utility in India, accounting for about 20% of Indias installed capacity.
Human Resources
People before PLF (Plant Load Factor) is the guiding philosophy behind the entire gamut of HR policies at NTPC. We are strongly committed to the development and growth of all our employees as individuals and not just as employees. We currently employ approximately 24500 people at NTPC. Competence building, Commitment building, Culture building and Systems building are the four building blocks on which our HR systems are based.
Awards
NTPC has a glorious record of excellence in every field of its activities ever since its inception in 1975. Leading the countrys power sector with a vision to become a 75,000 MW company by 2017, we take pride in our people and their performance which has been acknowledged time and again at various national and international fora.
NTPC named in Platts Top 250 Global Energy Company Rankings 2009 Business Standard Award - Star Company (Public Sector Undertaking) of the year, Business Standard Water Digest Water Awards 2008-09, Water Digest 'Golden Peacock Environment Management Award - 2008 Institute of Directors NTPC Baged 4 awards at the Great Places to Work Awards-2009 NTPC bags Gold Trophy at India Pride Awards International Gold Star Award for Quality 2009 for NTPCCenPEEP Conferred at International Star Quality Convention Geneva 2009 ICAI Award for Excellence in Financial Reporting, The Institute of Chartered Accountants of India International Project Management Award 2008, International Project Management Association (IPMA) CII-Exim Excellence Award 2008, Confederation of Indian Industry India Power Awards 2008, Council of Power Utilities Enterprise Excellence Award 2007, Indian Institution of Industrial Engineering Golden Peacock Award for Occupational Health & Safety -2008 Institute of Directors
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662 MW
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Natural gas is ideal fuel because it provides high thermal efficiency and reliability with two operation and maintenance cost. Liquid fuels, particularly heavy oils, usually contain contaminants, which cause corrosion and fueling in the gas turbine. Contaminants, which cannot be removed from the fuel, may leave deposit in the gas turbine, which reduces performance and adds to maintenance costs. Dual fuel systems are commonly used enabling the gas turbine to burn back up fuels. When the primary fuel source is not available, dual fuel systems can be used fire both fuels simultaneously.
LIQUID FUEL SYSTEM: it consists of the liquid fuels storage and handling system. The liquid fuel storage and handling system provides means for unloading storage and distribution of the fuel oil within the plant and typically composed the following major components. a) Fuel oil unloading pumps b) Fuel oil transfer pumps c) Fuel oil storage tanks d) Flow motor e) Strainers f) Pressure and level control
NAPHTHA PRESSURING SYSTEM: By the forwarding pumps Naphtha is pumped up to the GTs and kept under recirculation for firing, separated pressure pump sallied filters and measurements and recirculation system is used. This pressurizing is required because in the naphtha burner this fuel is mechanically atomized.
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11. Valves: In gas power plant, valves are used to control the flow.
On the basis of activating, control valves are classified as follows: a) Pneumatic valves- These type of valves are operated by air. These are fast controlling valves. These are as follows: (i) Diaphragm actuated: --- Position control type (can be adjusted to various levels) --- On soft type b) Position type: Air to case- fails safe open Air to open- fails safe close Air to close means gas pipe is connected to the upper surface of the diaphragm. (ii) Piston (cylindrical) actuated: --- Electric valve: these are operated by electricity and are slow --- Manual valve: these are operated by humans --- Hydraulic valve: these are operated by liquids. On the basis of mechanical construction: a) Globe valve: these are also called control valves. b) Gate valve: these are called on/off valve. c) Needle valve: these are used for small flow. d) Non-return valve: these are used for unidirectional flow. e) Butterfly valve: these are used for large flow. 12. Pump: After heat rejection, in the condenser the water is sent to the pump. For the pump, the ideal process would be reversible adiabatic compression of this liquid ending at the initial pressure (increase its pressure). In the gas power plant, there is centrifugal type pump. In this type of 18 pump, inlet and outlet are connected to the peripheral of the pump. After pumping, outlet water is sent to the boiler.
ELECTRICAL MAINTENANCE
SWITCH GEAR A Switch gear is one which makes or breaks an electrical circuit. The devices which comes under this category are: 1.Isolator 2.Circuit Breaker 3.Earth switch 4.Load Break Switch 5.Switching Isolater An Isolator is one which can break an electric circuit when the circuit is to be switched on no load.These are normally used in various circuits for the purposes of isolating a certain portion when required for maintenance. A Circuit Breaker is one which can break or make the circuit on load and even on faults. Normally Circuit Breakers are installed accompanied by isolators. Earth switches are devices which are normally used to earth a particular system to avoid accident , which may happen due to induction on account of live adjoining circuit . These do not handle any appreciable current at all. Load break switches are those interrupting devices which can make or break circuits at 8 times the rated current . These are normally installed on the same circuit or on the circuits which are backed up by circuit breakers.
Switching isolators are capable of 1. 19 Interrupting transformer magnetize current and line charging
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CIRCUIT BREAKER
Classification based on medium used for arc quenching 1. Minimum oil circuit breaker 2. Bulk oil circuit breaker
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Lightening arrester:They are provided at the terminals of the transformers for protection against lightening or any surges developing in the system. Current transformer:They are single phase oil immersed type.The secondary current is generally 1 amp but also 5 amp in certain cases. Capacitor voltage transformer: They are used at 220kv and above.For the lower voltages electromagnetic type of voltage transformers are mostly used. Bus bar arrangement:They are single bus single main and transfer bus,main I and main II with transfer bus.The type of arrangement depends uponthe reliability of supply from the substation. Bus bar supporting structures:They are generally of steel latticed type.Recent trend is to adopt RCC structures for supporting the buses. Earthing resistance of the substation:For substaion it is of the order of .5 ohms and for transmission lines it varies from 10 to 20 ohms.Earthing of the substation is done by laying mat in and around the switch yard area.Normally ungalvanised mild steel flats are used for earthing and risers. Soak pits: They are provided in respect of all the transformers where the quantity of oil exceeds 2000 litres.
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66 KV PT BHEL make, current ratio 1000/1 Amp 6 Nos. 5 core 66 KV PT BHEL make, 66 KV/110 V, 3 core 6 Nos. 66 KV Isolator S&S make RC 300, I = 1250 A 8 Nos. Voltage 245 KV
66 KV Earth switch S&S make for Isolators RC 300, 12 Nos. I = 1250 A, V = 245 KV 93 Surge Capacitor BHEL make 40 KV, 0.125 6 Nos. 40 KV Rated V = 40 KV, I = 1.57 A
Lightening Arrester Elpro international make Type 9L 9 Nos. 111 AH/A / 18.5 KV each stack.
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6.6 KV Switchgear
(1) Incomer/Bus Tie /Bus Tie Isolator Breaker
Make MELCO Type 6-SFG-40K Rated Voltage 7.2 KV Rated Breaking Current 40 KA Rated Making Current 100 KA Rated Normal Current 2850 Amps Rated control Voltage DC 220 Volts
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GENERATOR SYSTEM
Generator The generator is of hydrogen cooled (rated hydrogen pressure=2 Kg/cm2) 3000 rpm, 50 Hz with static excitation system. The rated output of gas turbine generator is 141.08 MVA (at cooling water temperature 32 0 C) at power factor 0.8 with rated terminal voltage 11.5kV. The rated output of steam turbine generator is 144.19 MVA (at cooling water temperature 37 0C) at power factor 0.8 with rated terminal voltage 11.5kV. The insulation of stator winding is of Class F (type of insulation: impregnated epoxy resin mica). The impulse voltage strength is 115 LVP. The insulation of rotor winding is of class F (type of insulation: impregnated epoxy resin mica).
Excitation System Static excitation system (MEC-3400) is adopted for both gas turbine generator and steam turbine generator. Basically, the excitation system consists of the following cubicles: a) AVR cubicle (with Power System Stabilizer PSS) 34 b) Thyristor cubicle. c) Surge absorber cubicle.
The power for initial excitation of the generator is obtained from the station 220 V DC system. Under normal operation, the power source of the excitation system is from the associated excitation transformer, which is of dry type (natural aircooling) 11.5 kV/360 V star/delta connected and nominal output capacity 1200 kVA. The excitation transformer is protected by duplicated instantaneous and inverse time over current relays. Each relay leads to the operation of its associated lockout relay (relay 186 or 286). The excitation system and PSS can be controlled and monitored from the electrical control board (ECB) in the central control room. NGR Cubicle The neutral point of the generator is earthed through grounding transformer. Grounding resistor is connected at the secondary side of the grounding transformer. The grounding transformer is of single phase, encapsulated winding dry type, indoor type, with class F insulation, rated capacity 40 kVA (10-minute rating), rated voltage 11.5 kV/ 190 V. The grounding resistor is of 110 V rated voltage. 195 A (10 35 min.) and 0.563
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Generator Transformer
The gas turbine generator transformers are supplied by MELCO, which are rated at 148 MVA (at 270 C), 235/11.5 kV (Yd11) and with OFAF. The transformer is of shell type. The short time rating of the transformer is 31.5 kA 3 second. Each transformer has an automatic TCG (Total Combustible Gas) analyzer, which takes oil sample automatically from the transformer tank at pre-set time interval. The combustible gas content of the oil sample is analyzed. If the gas content or the trend of gas content exceeds certain level, an alarm would be given to the control center. After the analysis, the oil sample would be returned to the transformer tank automatically and the TCG analyzer is ready for the next sample check. The transformer is equipped with wheels with rail gauge 1676 mm. The transformer has two radiator banks (each bank has 50% cooling capacity). Each bank has: - 6x10% fans (1x10% as spare ) - 3x25% oil pump (1x25% as spare) Impact recorder was mounted on the tank during 37 transportation. The steam turbine generator transformers are supplied by
Potential Transformer and surge Absorber Cubicle Surge absorbers are provided to protect the generator from lightening. The lightening surges flow through the transmission lines to the generator transformer. A surge absorber consists of a surge capacitor and lightening arrester. a) Surge Capacitor - Type : Synthetic liquid filled - Rated : 11.5/3 kV - Rated capacity : 0.13 mF b) Lightening Arrester - Type : Metal oxide type - Rated Voltage : 12 kV - Power frequency-starting voltage: 15 kV (crest) - Max. discharge Voltage for : 25.2 kV (crest) 1500A discharge current There are 3 potential transformers for generator protection and metering purpose.
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a) Potential transformer for voltage balance relay and reverse power relay (or low forward relay for steam turbine generator and performance test at ECB). Connection : Star/star Voltage : (11500/3) 110/3 V Capacity : 100 VA Accuracy class : 0.2 b) Potential transformer for various protection and metering purposes Connection : Star/star/Open Delta Voltage : (11500/3)/3/)(190/3) V Capacity : 100 VA/ 200 VA Accuracy : 0.5/ 3P class c) Potential transformer for AVR : Connection : Star/Star Voltage : 11500/3)/110/3V Capacity : 200 VA Accuracy : 1.0 Class The surge absorber and potential transformers are housed inside PT & SA cubicle, which is to IP52. The cubicle is of isolated phase type, which is suitable for connection on to the IPB. The impulse withstand voltage of PT & SA cubicle is 95 kV.
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STATION TRANSFORMER
The auxiliary power of the power station is supplied by two 220/6.9 kV (star-star connection) 27 MVA ONAF station transformers. The capacity of each station transformer is sufficient for all auxiliaries of the power station operating at the same time. So switching out of one station transformer will not affect the normal operation of power station. The station transformer is equipped with on load tap changer at HV side with range 10% in 1% step. Each station transformer is also with an automatic TCG analyser for monitoring the transformer oil at pre-set interval. Full wave lightening impulse withstand levels for HV and LV winding are 950 kV and 60 kV respectively. Station transformer is of core type. HV side of the transformer is connected to 220 kV switchyard by overhead line. LV side is connected to 6.6 kV switchgear through nonsegregated bus duct. Nominal voltage rating of LV winding is 6.9 kV to take into consideration the voltage variation (+10%) at 220 kV system and voltage 40 drop at 6.6 kV and 415 V side.
The capacity of 6.6 kV neutral grounding resistor is 400 A 10 seconds. In the design of the resistance grounding system, the following is considered: a) Co-ordination of protection relays. b) Overvoltage during single line to earth fault condition. c) Fault current
. For motors with rating larger than 100 kW, the starting current is 720% of full load current. For motors with rating less 100 kW, the starting current is 800% of full load current. All motors rated above 30 kW are provided with spare heaters.
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