INDUSTRIAL TRAINING REPORT

BADARPUR THERMAL POWER STATION NTPC Ltd.

Submitted By:By:MD. KHALID AKHTAR 06-EES-23, 7th SEMESTER B.TECH. (ELECTRICAL ENGG.) F/O ENGINEERING & TECHNOLOGY JAMIA MILLIA ISLAMIA, NEW DELHI

Acknowledgement
An engineer with theoretical knowledge is not a complete engineer. Practical knowledge is very important for an engineer to develop and apply engineering skills.

Knowledge in itself is a continuous process. At this moment of my substantial enhancement, I really find enough words to express gratitude towards those who were constantly involved with me.

First of all I am thankful to training coordinator Mr. Manmohan Singh (sr. engineer) & Mrs. Rachna Singh (HR-EDC) for providing me with an opportunity to undergo my training at NTPC (Badarpur).

I wish to thank the NTPC authorities, managers, engineers, foremen, technicians & workers under whose initiations I had the opportunities to gain immense knowledge in the summer training held in the months of May & June, 2009.

Md. Khalid Akhtar

THANKFUL NOTE
I want to express my heartiest gratitude and token of thanks to all the employees cum teachers who had been associated with my training during this short span of weeks.
ELECTRICAL MAINTAINANCE DIVISIONDIVISION-1 (EMD(EMD-1)

Mr. ANIL KUMAR SHARMA SS (EMDEMD-1) Department

1) CHP/NCHP 2) LT/HT sw/gr

Reporting off(sr. engg)

Sh. M K Chopra Sh. K P Singh

Helping off(emp)
Sh. A K Dabas 1) Sh. Roshan lal 2) Sh. Lukman Ahmad 3) Sh. Laxhmi Chand

3) LT/HT Motors

Sh. Ramesh chand

1) Sh. R P Dube 2) Sh. Sharma

ELECTRICAL MAINTAINANCE DIVISIONDIVISION-2 (EMDEMD-2)

Mr. M S CHHABRA SS (EMDEMD-2) Area 1) Generator 2) Exct. System & elect. Lab 3) Switchyard & Transformer Reporting off(sr. engg) Sh. Yogesh Kumar Sh. M M Arora Sh. S K Marwah Sh. Sunil Kumar 4) Lighting Sh. B P Sinha

SPECIALS THANKS
I want to convey my special thanks to my faculty teacher as well. They have been very helpful imparting quality education and served as proper guidance.

I found the knowledge given by them extremely helpful and found it easy to apply it in practical situation while doing industrial training. Had not been their proper guidance, i would not have completed our project effectively.

ABOUT NTPC
National Thermal Power Corporation Limited (NTPC) is the largest thermal power generating company of India. A public sector company wholly owned by Government of India, it was incorporated in the year 1975 to accelerate power development in the country. Within a span of 33 years, NTPC has emerged as a truly national power company, with power generating facilities in all the major regions of the country. Based on 1998 data, carried out by Data-monitor UK, NTPC is the 6th largest in terms of thermal power generation and the second most efficient in terms of capacity utilization amongst the thermal utilities in the world. NTPC's core business is engineering, construction and operation of power generating plants and also provides consultancy to power utilities in India and abroad. NTPC acquired 50% equity of the SAIL Power Supply Corporation Ltd. (SPSCL). This company operates the captive power plants of Durgapur (120 MW), Rourkela (120 MW) and Bhilai (74 MW). NTPC is also managing Badarpur thermal power station (705 MW). NTPC is providing power at the cheapest average tariff in the country. With its experience and expertise in the power sector, NTPC is extending consultancy services to various organizations in the power business. It has entered into a joint venture with Alstom , Germany for renovation and modernization of power plants in India. NTPC is committed to the environment, generating power at minimal environmental cost and preserving the ecology in the vicinity of the plants. It has undertaken massive afforestation in the vicinity of its plants. Plantations have increased forest area and reduced barren land. The massive afforestation by NTPC in and around its Ramagundam Power station (2100 MW) have contributed reducing the temperature in the areas by about 3c. NTPC has also taken proactive steps for ash utilization. In 1991, it set up Ash Utilization Division to manage efficient use of the ash produced at its coal stations. This quality of ash produced is ideal for use in cement, concrete, cellular concrete, building material. A "Centre for Power Efficiency and Environment Protection (CENPEEP)" has been established in NTPC with the assistance of United States Agency for International Development. (USAID). Cenpeep is an efficiency oriented, Eco-friendly and Eco-nurturing initiative - a symbol of NTPC's

concern towards environmental protection and continued commitment to sustainable power development in India. As a responsible corporate citizen, NTPC is making constant efforts to improve the socio-economic status of the people affected by the its projects. Through it's Rehabilitation and Resettlement programmes, the company endeavors to improve the overall socio-economic status of Project Affected Persons. It was among the first Public Sector Enterprises to enter into a Memorandum of Understanding (MOU) with the Government in 1987-88. The emerging competition from Independent Power Producers (IPPs), stringent environmental regulations, uncertainties in fuel linkages, funds constraints, restraints, restructuring of reforms in the power sector are all crucial and interrelated factors having major impact on business decisions. These fundamental changes have necessitated a fresh look at how we do our business and what it is that we must do to achieve our vision: "To be one of the world's largest and best power utilities, powering India's growth". Considering multidimensional opportunities in the energy sector, NTPC will adopt a multi-pronged growth strategy for capacity addition through greenfield sites, expansion of existing stations, takeovers and joint ventures. NTPC also have plans to venture into the following areas: Investment in LNG terminal Investment in coal mining and washeries Renovation and modernization of old power stations Setting up of power plants abroad Joint ventures for ash-based industries Setting up of small pilot plants using renewable energy sources; Setting up of hydel power plants to facilitate techno-economic operation of thermal-hydro mix of NTPC stations; Setting up of associated extra high voltage transmission lines / inter-regional EHV transmission lines so as to ensure evacuation of power from NTPC station.

About BTPS
Badarpur Thermal Power Station (BTPS) is owned by Govt. of INDIA, Ministry of energy and is managed by NTPC since April 1, 1978. At the time of changeover of management the installed capacity was 300MW and under NTPC two more units of 210MW is were erected and commissioned. NTPC is the frontrunner in the power sector presently having total installed capacity of 21,904MW. Power is supplied to 220kv network, which is part of the northern grid. There ten circuits through which power is evacuated from the plant namely being: Mehrauli 1 & 2, Okhla 1 & 2, Ballabhgarh 1 & 2, U.P. and Jaipur.

There are total five units in the power station. Details of units are as follows: 1973 : 1974 : 1975 : 1978 : 1981 : 95 MW 95 MW 95 MW 210 MW 210 MW

The installed capacity of BTPS is 720 MW and De-rated capacity is 705 MW out of which 70 MW is used for in-house purpose. Today plant is sharing the total PLANT LOAD FACTOR OF 80% and cycle efficiency of each 95 MW unit as 40-42% and cycle efficiency of each 210 MW unit as 42-44%.

Coal are taken from Jharia coal fields, BIHAR, M.P. ,A.P. and Orissa.The coal sources include:

1. CCL (Central Coal Fields Ltd.) 2. BCCL (Bharat Coking Coals Ltd.) 3. ECL (Eastern Coal Ltd.) The water is taken from Agra Irrigation Canal and is used for cooling. There are cooling towers provided so that the plant can operate in closed cycle. BTPS is designed and engineered by CENTRAL ELECTRICITY AUTHORITY (C.E.A) formally known as CENTRAL WATER AND POWER COMMISSION.

PROJECT ANALYSIS

AIM: To study the Electrical Maintenance Division of Badarpur Thermal Power Plant.

PROJECT ANALYSIS

EMD I

EMD II

COAL HANDLING PLANT

LT MOTORS AND SWITCHGEAR

HT EP MOTORS AND SWITCHGEAR

SWITCH YARD

XMERS GENERATOR

Coal Based Power Stations

With 15 coal based power stations, NTPC is the largest thermal power generating company in the country. The company has a coal based installed capacity of 24,395 MW.

COAL BASED(Owned by NTPC)

STATE

COMMISSIONED CAPACITY(MW)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Singrauli Korba Ramagundam Farakka Vindhyachal Rihand Kahalgaon NCTPP, Dadri Talcher Kaniha Feroze Gandhi, Unchahar Talcher Thermal Simhadri Tanda Badarpur Sipat-II

Uttar Pradesh Chhattisgarh Andhra Pradesh West Bengal Madhya Pradesh Uttar Pradesh Bihar Uttar Pradesh Orissa Uttar Pradesh Orissa Andhra Pradesh Uttar Pradesh Delhi Chhattisgarh

2,000 2,100 2,600 1,600 3,260 2,000 2,340 840 3,000 1,050 460 1,000 440 705 1,000

Total

24,395

Electrical Maintenance Department

Emd-1

COAL HANDLING PLANT

The fuel used in the Badarpur thermal power station is coal. Therefore it is necessary to handle this fuel carefully and deliver it to the site of power plant. Following diagram shows various stages in coal handling plant.

TRANSFER POINT 6

REJECT BIN HOUSE

TRANSFER POINT 7

CRUSHER HOUSE

BREAKER HOUSE

WAGON TRIPPLER

TRANSFER POINT 8

A railway siding line is taken into the power station and the coal is delivered in the storage yard. The coal is unloaded from the point of delivery by means of wagon tippler. It is rack and pinion type. The coal is taken from the unloading site to dead storage by belt conveyors. The

11A-belt deliver the coal to 0m level to the pent house and further moves to transfer point 8. The transfer points are used to transfer coal to the next belt. The belt 12A elevates the coal to breaker house. It consists of a rotary machine, which rotates the coal and separates the light dust from it through the action of gravity and transfer this dust to reject bin house through belt 18A. The belt-13A further elevates the coal to the transfer point 7 and it reaches the crusher through belt-14A. In the crusher a high-speed 3-induction motor is used to crush the coal to a size of 50mm so as to be suitable for milling system. Coal rises from crusher house and reaches the dead storage by passing through transfer point 8 and belts 15A and 10A respectively.
EQUIPMENTS USED IN A COAL HANDLING PLANT: PLANT:

1. Pull chord switch: a series of such switches are arranged in series at a 1m distance on the side of conveyor belt. The power supply to rotor of the conveyor belt is established only if all switches in series are connected. 2. Vibrating feeder: The coal stored in a huge hub is collected on the belt through vibrations created by the vibrating feeder. 3. Flap gates: These are used to channelize the route of coal through another belt in case the former is broken or unhealthy. The flap gates open let the coal pass and if closed stop its movement. 4. Magnetic separator: these are used to separate the ferrous impurities from the coal. 5. Metal detector: These are detect the presence of any ferrous and nonferrous metal in the coal and sends a signal to a relay which closes to seize the movement of belt until the metal is removed. It basically consists of a transmitter and a receiver. The transmitter consists of a high frequency oscillator, which produces a oscillations of 1500 Hz at 15V. The receiver receives this frequency signal. If there is any presence of metal in the coal. Then this frequency is disturbed and a tripping signal is send to relay to stop the conveyor belt. 6. Belt weightier: It is used to keep an account of the tension on the belt carrying coal and is moves accordingly to release tension on the belt.

7. Reclaim hopper: Reclaimation is a process of taking coal from the dead storage for preparation or further feeding to reclaim hoppers. This is accomplished by belt conveyors. BASIC POWER PLANT CYCLE The thermal (steam) power plant uses a dual (vapour+liquid) phase cycle. It is a closed cycle to enable the working fluid (water) to be used again and again. The cycle used is Rankine cycle modified to include super heating of steam, regenerative feed water heating and reheating of steam.
COAL TO STEAM 1. Tipplers

Coal from the coal wagons is unloaded in the coal handling plant. This unloading is done by the Tipplers. This coal is transported up to the raw coal bunkers with the help of conveyor belts. Coal Requirement: 210 MW : 120T/hr 95 MW : 65T/hr
2. Crush House

After hand picking foreign material, coal is transported to the Crush house by conveyor belts where it is crushed to small pieces of about 20 mm diameter. The crushed coal is then transported to the store yard. Coal is transported to bowl mills by coal feeders.
3. Bowl Mill

The coal is pulverized in the bowl mill, where it is grounded to a powder form. The mill consists of a round metallic table on which coal particles fall. This table is rotated with the help of a motor. There are three large steel rollers, which are spaced 120 apart. When there is no coa, these rollers do not rotate but when the coal is fed to the table it packs up between rollers and the table and this forces the rollers to rotate. Coal is crushed by the crushing actions between the rollers and rotating tables.

SPECIFICATIONS

Total no. per boiler Type Capacity Max. moisture content Fitness through 200 mesh Bowl Mill Motor Ratings Rated power Rated voltage Frequency Speed Rated current No load current 4. Furnaces : : : : : :

6 : Pressurized : 39.1T/hr : 12% : 75%

340 KW 6.6 KV (3-phase) 50 Hz 980 rpm 41.1 amp 15-16 amp

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

Boiler used in the power plant is suspended type. This prevents it from getting deformed, when a subjected to very high temperatures. The boiler is divided into two cylindrical parts namely the Primary and the Secondary boiler. Water from the boiler feed pump passes through economizer and reaches the boiler drum. Water from the drum passes through down comers and goes to bottom ring header. Water from the ring header is divided to all the four side of furnace. Due to heat and density difference the water rises up in the water wall tubes. Water is partly converted to steam as it rises up in the furnace. This steam and water mixture is again taken to the boiler drum where the steam is sent to super heaters for superheating. The super heaters are located inside the furnace and the steam is superheated (540C) and finally it goes to turbine. Flue gasses from the furnace are extracted by induced draft fan, which maintains balance draft in the furnaces with forced draft fan. These flue

gasses emit their heat energy to various super heaters in the pant house and finally pass through air pre-heaters and goes to electrostatic precipitator where the ash particles are extracted. Electrostatic precipitator consists of metal plates, which are electrically charged. Ash particles are attracted on to these plates, so that they do not pass through the chimney to pollute the atmosphere. Regular mechanical hammers blows cause the accumulation of ash to fall to the bottom of the precipitator where the bottom of the precipitator where they are collected in a hopper for disposal. This ash is mixed with water to form slurry and is pumped to ash pond.

Electrostatic Precipitator The ash content in the Indian coal is of the order of 30-40%.When coal is fired in the boiler, ashes are liberated and about 80% of ash is carried along with the flue gas. If these ashes are allowed to atmosphere, it will create an air pollution thereby resulting in health hazards. Hence it is necessary to precipitate the dust from the flue gas and in this process electrostatic precipitator finds a place in the boiler (in a 200MW boile, we will be burning about 110 tons of coal per hour roughly and if the coal maintains 30% ash, the ashes carried along with the flue gas will be of the order of 27 T/hr). The additional advantage obtained because of the installation of precipitator is that the wear of the ID fan blades are reduced due to precipitation of dust, resulting in reduced maintenance work in ID fan. The electrostatic precipitator is efficient in precipitation of particles from submicron to large sizes of particles and hence they are preferred to mechanical precipitators. The efficiency of modern ESPs is of the order of 99.9%. Constructional Details of E.P. The electrostatic precipitator consist of a large chamber in which collecting and discharge electrodes are suspended. The collecting electrodes are made out of steel plates with a special profile and discharge electrodes are made of thin wire (2.5mm dia) wound to a helical form. The discharge electrodes are kept in between collecting electrodes are arranged alternatively. At the inlet of the chambers, gas distributor screens are provided which are nothing but perforated steel plate. These are for uniform gas distribution across the section of the chamber.

The collecting plates at its power portion contain shock bars over which rapping is provided for discharge or emitting electrodes to dislodge ash from wire.

RATINGS OF THE MOTORS MOTORS USED IN COAL HANDLING HANDLING PLANT:

1. FOR CONVEYOR BELT 3- squirrel cage induction motor 55kw Horse power: 75 Volts: 415 AC Amps: 98.5A Class of the motor: B Frame size: 250m Speed: 1480 rpm Synchronous speed: 1500 rpm 2. FOR WAGON TIPPLER 3- slip ring induction motor Horse power: 90 Volts: 415 AC LT motor

HT SWITCHGEAR SWITCHGEAR
The 6.6KV switchgear manufactured and supplied mainly by M/s. Jyoti Calor-Enag. Ltd. consists of unit auxiliary bus in two sections for each unit (1A and 1B for unit 1, 2A and 2B for unit 2, 3A and 3B for unit 3, 4A and 4B for unit 4, 5A and 5B for unit 5) respectively, four general

auxiliary of station buses SA, SB, 3SA, 3SB and four cooling tower buses TA, TB, 3TA, 3TB respectively. The unit and station buses are linked by bus tie breakers which permit the unit auxiliaries to be supplied from the station buses for start up and in the event of a unit transformer or the main incoming breaker for any section of the unit bus is out of service. The arrangement is such that section 1 bus SA can be connected to unit section buses 1A, 2A, 3A section 2 bus SB can be connected to unit section buses 1B, 2B, 3B.The unit section buses 4A, 5A and 4B, 5B are connected to buses 3SA and 3SB respectively. The 6.6KV system operates with isolated neutral. The 6.6KV station switchgear is located at 0m level. The 6.6KV, SA, SB, 3SA and 3SB buses are energized by their respective transformers and bus tiebreakers. Buses SA and SB can be connected through bus couplers. Similarly buses 3SA and 3SB can be connected through bus couplers. Bus SA is also connected to bus 3SA through a bus coupler and similarly for SB and 3SB. The unit auxiliarys arrangement is for reserve supply to the unit sections. The unit section breakers and reserve breakers are interlocked in such a way that if the main breaker opens the reserve breaker will close. When the main supply to unit section, being supplied by reserve supply from the station section is to be restored, the main breaker on the breaker unit section will be closed first and reserve breaker on the unit section will be opened later. The 6.6KV switchgear for cooling towers in two sections TA, TB and 3TA, 3TB is housed in cooling tower building, are connected to cables through breakers to buses SA, SB and 3SA, 3SB respectively. Each of the 6.6KV switchgear circuit breaker is electrically operated. A local control device with red and green indicating lights is provided on each switchgear cubicle. This device is of self-reset type and permits closing and tripping of the breaker in the racked-in and test positions. Remote closing and tripping of the circuit breaker is inoperative in the test and draw-out position of the breaker.

The diagram below shows the feeders of buses 3SA, 3SB and 5A, 5B for UNIT 5 BTPS

RATINGS OF BREAKERS USED IN THE HT SWITCHGEAR SWITCHGEAR 1. VACUUM CIRCUIT BREAKER-VCB (JYOTI) When two current carrying contacts are separated in a vacuum module, an arc is drawn between them. An intensely hot spot or sparks are created at the instant of contact separation from which metal vapour shoot off, constituting plasma. The amount of vapour in the plasma is proportional to the rate of vapour emission from the electrodes, hence to the arc current. With alternating current arc, the current decreases during a portion of wave and tends to zero. Thereby the rate of vapour emission tends to zero and the amount of plasma tends to zero. Soon after natural current zero, the remaining metal vapour condenses and the dielectric strength builds up rapidly, and restriking of arc is prevented.
This principle is used in vacuum circuit breakers

Rated frequency: 50Hz Rated voltage: 7.2 kV Rated current: 1250A Ins. Level: Imp. 75 kVp PF 28kV Rated breaking current: 44KA Rated making current: 110-peak kA Supply voltage closing: 220DC Rated short time current: 44KA 3s Wt. Of breaker: 100Kg

2. MINIMUM OIL CIRCUIT BREAKER-MOCB (KILOSKAR)

Bulk oil circuit breakers are suitable for voltage up to 336 kV as it is simple sturdy. For higher voltages the size becomes large. This type of breaker is rapidly being replaced by other types of breakers Oil circuit breakers use Dielectric oil (Transformer oil) for the purpose of arc extinction. In bulk oil circuit breakers the arc extinction takes place in a tank; whereas in minimum oil circuit breakers the arc extinction takes place in insulating housing enclosed in ceramic enclosures.

The ratings for the minimum oil circuit breaker is given below: Rated frequency: 50Hz Rated voltage: 6.6 kV Rated current: 1250A Breaking capacity: 34.7 kA symmetrical 34.7 kA Asymmetrical 360 MVA symmetrical Supply voltage closing: 220DC

Diagram of Minimum oil circuit breaker(MOCB)

3. SF6 CIRCUIT BREAKER (JYOTI) Sulphur hexafluoride (SF6) is an inert, heavy gas having good dielectric and arc extinguishing properties. The dielectric strength of the gas increases with pressure and is more than of dielectric strength of oil at 3 kg/cm2. SF6 is now being widely used in electrical equipment like high voltage metal enclosed cables; high voltage metal clad switchgear, capacitors, circuit breakers, current transformers, bushings, etc. The gas is liquefied at certain low temperature, liquefaction temperature increases with pressure. Sulphur hexafluoride gas is prepared by burning coarsely crushed roll sulphur in the fluorine gas, in a steel box, provided with staggered horizontal shelves, each bearing about 4 kg of sulphur. The steel box is made gas tight. The gas thus obtained contains other fluorides such as S2F10, SF4 and must be purified further SF6 gas generally supplier by chemical firms. The cost of gas is low if manufactured in large scale.

During the arcing period SF6 gas is blown axially along the arc. The gas removes the heat from the arc by axial convection and radial dissipation. As a result, the arc diameter reduces during the decreasing mode of the current wave. The diameter becomes small during the current zero and the arc is extinguished. Due to its electronegativity and low arc time constant, the SF6 gas regains its dielectric strength rapidly after the current zero, the rate of rise of dielectric strength is very high and the time constant is very small.

The ratings are:

Rated frequency: 50Hz Rated voltage: 12 kV Rated current: 1600A Ins. Level: Imp. 75 kVp PF 28kV Rated breaking current: 40KA Rated making current: 110 peak kA Supply voltage closing: 220DC Rated short time current: 1/3s Wt. Of breaker: 150Kg SF6 pressure at 20C: 2-2.5 bar (0.2 to .25 Mpa) SF6 gas per pole: .25 Kg

4. MINIMUM OIL CIRCUIT BREAKER (JYOTI) The working for this type of circuit breaker is already explained above and the diagram is also shown above. The ratings are given below for the minimum oil circuit breaker made by JYOTI PRIVATE LTD.
Rated frequency: 50Hz Rated voltage: 11/6.6 kV Rated current: 630A Impulse sec: 65 kA peak STC (1sec): 40 kA Breaking capacity: 350/280 kA symmetrical 55 kA Asymmetrical 360 MVA symmetrical Supply voltage closing: 220DC

5. SF6 CIRCUIT BREAKER (KILOSKAR) The working and the explanation is already given in the above sub heading of SF6 circuit breaker. The ratings for this circuit breaker made by KILOSKAR is given below:
Rated frequency: 50Hz Rated voltage: 6.6 kV Rated current: 1600A Tripping coil: 220V DC Spring charge motor: 220V DC

6. SF6 CIRCUIT BREAKER (VOLTAS) The working and the explanation is already given in the above sub heading of SF6 circuit breaker. The ratings for this circuit breaker made by VOLTAS is given below:
Rated frequency: 50Hz Rated voltage: 6.6 kV Rated current: 1600A Tripping coil: 220V DC Spring charge motor: 220V DC

7. AIR BLAST CIRCUIT BREAKER (VOLTAS) Fast operations, suitability for repeated operation, auto reclosure, unit type multi break constructions, simple assembly, modest maintenance are some of the main features of air blast circuit breakers. A compressors plant necessary to maintain high air pressure in the air receiver. The air blast circuit breakers are especially suitable for railways and arc furnaces, where the breaker operates repeatedly. Air blast circuit breakers is used for interconnected lines and important lines where rapid operation is desired. High pressure air at a pressure between 20 to 30 kg/ cm2 stored in the air reservoir. Air is taken from the compressed air system. Three hollow insulator columns are mounted on the reservoir with valves at their basis. The double arc extinguished chambers are mounted on the top of the hollow insulator chambers. The current carrying parts connect the three arc extinction chambers to each other in series and the pole to the neighbouring equipment. Since there exists a very high voltage between the conductor and the air reservoir, the entire arc extinction chambers assembly is mounted on insulators.

PRINCIPLE OF AIR QUENCHING IN AIR CIRCUIT BREAKER: It needs an auxiliary compressed air system which supplies air to the air receiver of the breaker. For opening operation, the air is admitted in the arc extinction chamber. It pushes away the moving contacts. In doing so, the contacts are separated and the air blast takes away the ionized gases along with it and assists in extinction. After a few cycles the arc is extinguished by the air blast and the arc extinction chamber is filled with high pressure air (30 kg/cm2). The high pressure air has higher dielectric strength than that of atmospheric pressure. Hence a small contact gap of few centimeters is enough.

In axial blast type air flow, the air flows from high pressure reservoir to the atmospheric through a convergent divergent nozzle. The difference is pressure and the design of the nozzle is such that the air expands into the low pressure zone, it attains almost supersonic velocity. The mass flow of air through the nozzle is governed by the parameters like pressure ratio, area of throat, nozzle throat diameter and is influenced by the diameter of the arc itself. The air flowing at a high speed axially along the arc causes the removal of heat from the periphery of the arc and the diameter of the arc reduces to a low value at current zero. At this instant the arc is interrupted and the contact space is flushed with fresh air flowing through the nozzle. The flow of fresh air through the contact space ensures removal of hot gases and rapid building up of dielectric strength.

The ratings are:

Rated frequency: 50Hz Rated voltage: 6.6 kV Rated current: 680A Tripping coil: 220V DC Spring charge motor: 220V DC

8. AIR BLAST CIRCUIT BREAKER (USA COMP.) The working and the explanation is already given in the above sub heading of air blast circuit breaker. The ratings for this circuit breaker made by USA COMP is given below:

Rated frequency: 50Hz Rated voltage: 25 kV Rated current: 2500A Symmetrical MVA 6.9-8.25: 600 KV Rated symmetrical SC current: 42000 A Asymmetrical rated factor: 1.2 Tripping coil: 220V DC Spring charge motor: 220V DC

PROTECTION AND RELAYS RELAYS USED IN IN 6.6 KV SWITCHGEAR 1. Instantaneous overcurrent relays for short circuit protection 2. Inverse time ground detection relay for zero sequence voltage protection. 3. Under voltage protection. The relays are Jyoti type RMA and timer Jyoti type RT RATINGS OF OVER CURRENT RELAYS 1. FOR FEEDER AND UNIT BUSES
CT ratio: 600/5A RMA: 18A RT: 0.5 sec

2. FOR STATION BUSES

CT ratio: 2000/5/1A RMA: 15A RT: 1.5 sec

3. FOR RESERVE SUPPLY

CT ratio: 1000/5/1A RMA: 14A RT: 1.0 sec

4. FOR COOLING TOWERS

CT ratio: 400/5/1A RMA: 16A RT: 1.0 sec

5. FOR XMERS (SAY TRANSFORMER NO. 1(630 KVA))

CT ratio: 100/5/1A RMA: 14A RT: 0.5 sec Rest Xmers have almost similar relay ratings

RATINGS FOR INVERSE TIME OVER CURRENT RELAYS RELAYS

FOR FEEDERS (SAY ID FAN) CT ratio: 100/5/1A ICT tap: 6/1A Overload: plug setting: 15% TMS: 0.4 SC RMA: 32 A Rest feeders have almost similar relay ratings

RATINGS FOR UNDER VOLTAGE RELAYS 3 VAGM-22 relays with RT of 0.5 sec., 9sec. and 1.5 sec Stage 1: 70%, -, Stage 2: -, 50%, Res. Closure: -, -, 20%

HT MOTORS
HT AC motors are normally designed for operation on 3 phase, AC supply with normal frequency of 50c/s Standard nominal voltages for which motors are designed are:

Voltages 3.3 kV 6.6kV 11kV

Capacity 160-200 kW 160-800Kw 1000 kW and above

INSULATING MATERIALS 1. Sunmica 2. Effoflux: It is an oil and waterproof material. 3. Nylon chord: It is used to cover the stator coil to provide necessary insulation. 4. Silver bridging: It employs the soldering of joint of the series coil. Silver is used instead of solder material due to its high melting point. 5. Piping ship: It is made up of fiberglass. It is used to fill gap between the stator coils to prevent vibrations and prevents the cutting of slot base. It also helps in even cooling of the stator. 6. Epoxy red gel coat: It is an insulation varnish used with thinner of no. 221 for dilution and hardener of no. 758. 7. Bectal Grey/red: It is a general type insulation varnish of B class used with thinner no. 205. HT AC MOTORS FOR THERMAL POWER APPLICATIONS BOILER AUXILIARY:
ID (induced draught) fan FD (forced draught) fan GR fan PA(primary air) fan Mills

COOLING WATER SYSTEM

CW pumps (circulating water)

TURBINE AUXILIARIES
Boiler feed pump Condensate extraction pump Starting oil pump

ASH HANDLING SYSTEM

Pumps

COAL HANDLING PLANT

Crushers Conveyors

SPECIFICATIONS of HT MOTOR
Frequency Voltage Current Speed Power Factor Weight : : : : : : 50 Hz 6.6KV 23.5 Amp. 1430 rpm 0.85 lag 410 kg

BOILER FEED PUMP MOTOR(210 mw UNIT)

Power Speed Frequency Voltage Current Peak load Type of braking Recommended Lubricant : : : : : : : : 4000KW 1483 rpm 50 Hz 6.6KV 421 A 200% Sleeve DTE medium of equity

SPECIFIC PERFORMANCE REQUIREMENTS OF MOTORS ARE:

High ambient temperature 50C Voltage and frequency variations : Voltage: 10% Frequency: 5% Combined: 10% (ABSOLUTE SUM) High starting torque ( ST) / pull out torque (MAX.) low starting current (IST) Voltage dip conditions / minimum permissible voltage at start Bus transfer conditions

Suitability to stand transients Long bearing life Low noise level Low vibration level

Insulation: class F, but temp. rise limited to class B Enclosure: Totally enclosed TEFC/ CACA/ CACW Degree of protection: IP44 / IP54 / IP55

LT SWITCHEGEAR

Power for 415/240V auxiliaries of unit and station is distributed from indoor type metal enclosed switchboards and motor control centers (MCC) having 415/240V, 3phase, 4wire, 50 Hz earthed system. The following switchboards and MCCs have been supplied by M/s Larsen and Toubro. Switchboards:
1. 2. 3. 4. 5. 6. 7. Unit auxiliary switchboards Station auxiliary switch boards Coal handling switchboards Standby switch boards Combined auxiliary house switchboard Lighting switchboard Makeup water pump house switchboard

Motor control centers:

1. Turbo generator MCC 2. Boiler unit MCC 3. Pulverized coal feeder 4. Turbine MCC 5. Boiler house MCC 6. Ash handling MCC 7. Switchyard compressor room MCC 8. Intake structure pump house MCC 9. Electrical repair, tool room, carpentry and electrical fitting shop MCC 10. Fitting, smithing, welding, testing job MCC 11. Machine shop MCC 12. Service room MCC 13. Turbo generator gate valve MCC 14. Boiler gate valve MCC 15. Electrostatic precipitator MCC 16. MCCs for rapping motors 17. Water treatment plant MCC 18. Fuel oil facilities MCC 19. Coal handling MCC 20. Hydrogen generating plant MCC

The 6.6kV supply is step down to .415 kV using a step down transformer. The .415KV supply system consists of unit auxiliary bus in two sections

for each unit (1C and 1D for unit 1, 2C and 2D for unit 2, 3C and 3D for unit 3, 4C and 4D for unit 4, 5C and 5C for unit 5), four general auxiliary of station buses SC, SD, 3SC, 3SD respectively. The 415/240V switchgear is located at 0m level. The 415/240V, SC, SD, 3SC and 3SD buses are energized by their respective transformers and bus tiebreakers. Buses SC and SD can be connected through bus couplers. Similarly buses 3SC and 3SD can be connected through bus couplers. Bus SC is also connected to bus 3SD through a bus coupler and similarly for SD and 3SD. The unit auxiliarys arrangement is for reserve supply to the unit sections. The unit section breakers and reserve breakers are interlocked in such a way that if the main breaker opens the reserve breaker will close. When the main supply to unit section, being supplied by reserve supply from the station section is to be restored, the main breaker on the breaker unit section will be closed first and reserve breaker on the unit section will be opened later. Each of the 415/240V-switchgear circuit breaker is electrically operated. A local control device with red and green indicating lights is provided on each switchgear cubicle. This device is of self-reset type and permits closing and tripping of the breaker in the racked-in and test positions. Remote closing and tripping of the circuit breaker is inoperative in the test and draw-out position of the breaker. PROTECTION AND RELAYS USED IN 415/240V SWITCHGEAR
1. Earth fault relay for earth protection. 2. Under voltage and no voltage relays for under voltage protection 1. UNDER VOLTAGE RELAY English Electric type VAGM22 connected through potential transformer pick up when bus voltage goes down by 50% 2. NO VOLTAGE RELAY English Electric type VAG11 picks up and trips incoming main supply breaker when bus voltage goes down by 25% 3. EARTH FAULT RELAY CDG 14 has been connected through CT in the secondary neutral of all auxiliary transformers and trips 6.6 kV breaker in case earth fault in 415V switchgear bus

LT MOTORS

The low-tension motors are different from the HT motors in terms of operating voltage. They generally operate at 415V. The most popular type of motor used for above applications is the DOL started squirrel cage induction motor.
Insulation: Since the operating voltage for LT motors is less than that of

HT motors hence insulation of class B is used in case of LT motors. Normally paper insulation and insulation tape is employed for insulation purposes.
Heat treatment:The stator after being wounded is given heat treatment.

It kept in an electrical furnace for about hours. The metal stator expands and heating effect absorbs all the moisture content in the stator. The stator is then immersed in a varnish solution so as to fill all the gaps with this insulating material. The varnish used is Elfmothran 1450.
Ac contactors: AC contactors are 3 pole suitable for DOL starting of

motors and protecting the connected motors. The contactors of the following motors are equipped with special arrangement to provide immediate reclosing of the contactor when voltage fails and reappears with 1.5-3 sec.
Fuse switches:Upto 25 A are rotary switches with fuses; for 63A and

100A are quick make, quick break, double break switch fuses and for 250A, 400A and 630A are fuse switches.

Specifications of LT Motors Power Speed Frequency Stator Voltage Current Power factor : : : : : : : 1600KW 2980 rpm 50 Hz star connection 415 V 163 A 0.9 lag

Electrical Maintenance Department

Emd-2

TRANSFORMERS

INTRODUCTION: A transformer is a device that transfers electrical energy from one circuit to another through inductively coupled conductors the transformer's coils or "windings". Except for air core transformers, the conductors are commonly wound around a single iron-rich core, or around separate but magnetically-coupled cores. A varying current in the first or "primary" winding creates a varying magnetic field in the core (or cores) of the transformer. This varying magnetic field induces a varying electromotive force (EMF) or "voltage" in the "secondary" winding. This effect is called mutual induction The primary winding is connected to a 50 hertz ac voltage source. The magnetic field (flux) builds up (expands) and collapses (contracts) about the primary winding. The expanding and contracting magnetic field around the primary winding cuts the secondary winding and induces an alternating voltage into the winding. This voltage causes alternating current to flow through the load. The voltage may be stepped up or down depending on the design of the primary and secondary windings. Basic transformer action:

If a load is connected to the secondary, an electric current will flow in the secondary winding and electrical energy will flow from the primary circuit through the transformer to the load. In an ideal transformer, the induced voltage in the secondary winding (VS) is in proportion to the primary voltage (VP), and is given by the ratio of the number of turns in the secondary to the number of turns in the primary as follows:

By appropriate selection of the ratio of turns, a transformer thus allows an alternating voltage to be "stepped up" by making NS greater than NP, or "stepped down" by making NS less than NP.

THE COMPONENTS OF A TRANSFORMER : Two coils of wire (called windings) are wound on some type of core material. In some cases the coils of wire are wound on a cylindrical or rectangular cardboard form. In effect, the core material is air and the transformer is called an AIR-CORE TRANSFORMER. Transformers used at low frequencies, such as 60 hertz and 400 hertz, require a core of low-reluctance magnetic material, usually iron. This type of transformer is called an IRON-CORE TRANSFORMER. Most power transformers are of the iron-core type. The principle parts of a transformer and their functions are:

The CORE, which provides a path for the magnetic lines of The PRIMARY WINDING, which receives energy from the ac source. The SECONDARY WINDING, which receives energy from the primary winding and delivers it to the load. The ENCLOSURE, which protects the above components from dirt, moisture, and mechanical damage.

CORE CHARACTERISTICS The composition of a transformer core depends on such factors as voltage, current, and frequency. Size limitations and construction costs are also factors to be considered. Commonly used core materials are air,

soft iron, and steel. Each of these materials is suitable for particular applications and unsuitable for others. Generally, air-core transformers are used when the voltage source has a high frequency (above 20 kHz). Iron-core transformers are usually used when the source frequency is low (below 20 kHz). A soft-iron-core transformer is very useful where the transformer must be physically small, yet efficient. The iron-core transformer provides better power transfer than does the air-core transformer. A transformer whose core is constructed of laminated sheets of steel dissipates heat readily thus it provides for the efficient transfer of power. The majority of transformers you will encounter in Navy equipment contain laminated-steel cores. These steel laminations (see figure ) are insulated with a non conducting material, such as varnish, and then formed into a core. It takes about 50 such laminations to make a core an inch thick. The purpose of the laminations is to reduce copper and eddy current losses. An important point to remember is that the most efficient transformer core is one that offers the best path for the most lines of flux with the least loss in magnetic and electrical energy.

Figure: Hollow core construction

Hollow-Core Transformers There are two main shapes of cores used in laminated-steel-core transformers. One is the HOLLOW-CORE, so named because the core is shaped with a hollow square through the centre. Figure below illustrates this shape of core. Notice that the core is made up of many laminations of steel. Figure illustrates how the transformer windings are wrapped around both sides of the core. Figure. - Windings wrapped around laminations.

Shell-Core Transformers The most popular and efficient transformer core is the SHELL CORE, as illustrated in figure below. As shown, each layer of the core consists of Eand I-shaped sections of metal. These sections are butted together to form the laminations. The laminations are insulated from each other and then pressed together to form the core.

Figure - Shell-type core construction

TRANSFORMER WINDINGS As stated above, the transformer consists of two coils called WINDINGS which are wrapped around a core. The transformer operates when a source of ac voltage is connected to one of the windings and a load device is connected to the other. The winding that is connected to the source is called the PRIMARY WINDING. The winding that is connected to the load is called the SECONDARY WINDING. (Note: In this chapter the terms "primary winding" and "primary" are used interchangeably; the term: "secondary winding" and "secondary" are also used interchangeably.) Figure below shows an exploded view of a shell-type transformer. The primary is wound in layers directly on a rectangular cardboard form.

Figure - Exploded view of shell-type transformer construction.

In the transformer shown in the cutaway view in figure below, the primary consists of many turns of relatively small wire. The wire is coated with varnish so that each turn of the winding is insulated from every other turn. In a transformer designed for high-voltage applications, sheets of insulating material, such as paper, are placed between the layers of windings to provide additional insulation.

Figure: cutaway view of shell type core windings

When the primary winding is completely wound, it is wrapped in insulating paper or cloth. The secondary winding is then wound on top of the primary winding. After the secondary winding is complete, it too is covered with insulating paper. Next, the E and I sections of the iron core are inserted into and around the windings as shown. The leads from the windings are normally brought out through a hole in the enclosure of the transformer. Sometimes, terminals may be provided on the enclosure for connections to the windings. The figure shows four leads, two from the primary and two from the secondary. These leads are to be connected to the source and load, respectively. HOW A TRANSFORMER WORKS Let us understand the working of transformer under no load condition and loaded condition. NO-LOAD CONDITION You have learned that a transformer is capable of supplying voltages which are usually higher or lower than the source voltage. This is accomplished through mutual induction, which takes place when the changing magnetic field produced by the primary voltage cuts the secondary winding. A no-load condition is said to exist when a voltage is applied to the primary, but no load is connected to the secondary, as illustrated by figure

below. Because of the open switch, there is no current flowing in the secondary winding. With the switch open and an ac voltage applied to the primary, there is, however, a very small amount of current called EXCITING CURRENT flowing in the primary. Essentially, what the exciting current does is "excite" the coil of the primary to create a magnetic field. The amount of exciting current is determined by three factors: (1) the amount of voltage applied (Ea) (2) the resistance (R) of the primary coil's wire and core losses (3) the XL which is dependent on the frequency of the exciting current. These last two factors are controlled by transformer design. Figure - Transformer under no-load conditions.

This very small amount of exciting current serves two functions:

Most of the exciting energy is used to maintain the magnetic field of the primary. A small amount of energy is used to overcome the resistance of the wire and core losses which are dissipated in the form of heat (power loss).

Exciting current will flow in the primary winding at all times to maintain this magnetic field, but no transfer of energy will take place as long as the secondary circuit is open.

COEFFICIENT OF COUPLING The COEFFICIENT OF COUPLING of a transformer is dependent on the portion of the total flux lines that cuts both primary and secondary windings. Ideally, all the flux lines generated by the primary should cut the secondary, and all the lines of the flux generated by the secondary should cut the primary. The coefficient of coupling would then be one (unity), and maximum energy would be transferred from the primary to the secondary. Practical power transformers use high-permeability silicon steel cores and close spacing between the windings to provide a high coefficient of coupling. Lines of flux generated by one winding which do not link with the other winding are called LEAKAGE FLUX. Since leakage flux generated by the primary does not cut the secondary, it cannot induce a voltage into the secondary. The voltage induced into the secondary is therefore less than it would be if the leakage flux did not exist. Since the effect of leakage flux is to lower the voltage induced into the secondary, the effect can be duplicated by assuming an inductor to be connected in series with the primary. This series LEAKAGE INDUCTANCE is assumed to drop part of the applied voltage, leaving less voltage across the primary. Energy losses An ideal transformer would have no energy losses, and would be 100% efficient. In practical transformers 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 98%. Though individual power loss is small, the aggregate losses from the very large number of such devices is coming under increased scrutiny. The losses vary with load current, and may be expressed as "no-load" or "full-load" loss. Winding resistance dominates load losses, whereas hysteresis and eddy currents losses contribute to over 99% of the no-load loss. The no-load loss can be significant, meaning that even an idle transformer constitutes a drain on an electrical supply, which encourages development of low-loss transformers

Transformer losses are divided into two: 1.losses in the windings, termed copper loss 2.losses in the magnetic circuit, termed iron loss. Losses in the transformer arise from: Winding resistance Current flowing through 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 currents Ferromagnetic materials are also good conductors, and a solid core made from such a material also constitutes a single short-circuited turn throughout its entire length. Eddy currents therefore circulate within the 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 forces between the primary and secondary windings. These incite vibrations within nearby metalwork, adding to the buzzing noise, and consuming a small amount of power. Stray losses Leakage inductance is by itself lossless, 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 materials such as the transformer's support structure will give rise to eddy currents and be converted to heat.

Equivalent circuit The physical limitations of the practical transformer may be brought together as an equivalent circuit model (shown below) built around an ideal lossless transformer. Power loss in the windings is currentdependent and is represented as in-series resistances RP and RS. Flux leakage results in a fraction of the applied voltage dropped without contributing to the mutual coupling, and thus can be modeled as reactances of each leakage inductance XP and XS in series with the perfectly-coupled region. Iron losses are caused mostly by hysteresis and eddy current effects in the core, and are proportional to the square of the core flux for operation at a given frequency.Since the core flux is proportional to the applied voltage, the iron loss can be represented by a resistance RC in parallel with the ideal transformer. A core with finite permeability requires a magnetizing current IM to maintain the mutual flux in the core. The magnetizing current is in phase with the flux; saturation effects cause the relationship between the two to be non-linear, but for simplicity this effect tends to be ignored in most circuit equivalents. With a sinusoidal supply, the core flux lags the induced EMF by 90 and this effect can be modeled as a magnetizing reactance (reactance of an effective inductance) XM in parallel with the core loss component. RC and XM are sometimes together termed the magnetizing branch of the model. If the secondary winding is made opencircuit, the current I0 taken by the magnetizing branch represents the transformer's no-load current. The secondary impedance RS and XS is frequently moved (or "referred") to the primary side after multiplying the components by the impedance scaling factor . The equivalent circuit is shown below:

Coolant: Coolant:-

Cut away view of three-phase oil-cooled transformer. The oil reservoir is visible at the top. Radiative fins aid the dissipation of heat. High temperatures damage the winding insulation. Small transformers which do not generate significant heat are cooled by air circulation and radiation of heat.

Power transformers rated up to several hundred kVA can be adequately cooled by natural convective air-cooling, sometimes assisted by fans. In larger transformers, part of the design problem is removal of heat. Some power transformers are immersed in transformer oil that both cools and insulates the windings.The oil is a highly refined mineral oil that remains stable at transformer operating temperature. Indoor liquid-filled transformers must use a non-flammable liquid, or must be located in fire resistant rooms. Air-cooled dry transformers are preferred for indoor applications even at capacity ratings where oil-cooled construction would be more economical, because their cost is offset by the reduced building construction cost. The oil-filled tank often has radiators through which the oil circulates by natural convection; some large transformers employ forced circulation of the oil by electric pumps, aided by external fans or water-cooled heat exchangers. Oil-filled transformers undergo prolonged drying processes to ensure that the transformer is completely free of water vapour before the cooling oil is introduced. This helps prevent electrical breakdown under load. Oil-filled transformers may be equipped with Buchholz relays which is explained below, which detect gas evolved during internal arcing and rapidly de-energize the transformer to avert catastrophic failure. Today, non-toxic, stable silicone-based oils, or fluorinated hydrocarbons may be used where the expense of a fire-resistant liquid offsets additional building cost for a transformer vault. Some "dry" transformers (containing no liquid) are enclosed in sealed, pressurized tanks and cooled by nitrogen or sulfur hexafluoride gas. Experimental power transformers in the 2 MVA range have been built with superconducting windings which eliminates the copper losses, but not the core steel loss. These are cooled by liquid nitrogen or helium.

Buchholz relay:-

In the field of electric power distribution and transmission, a Buchholz relay, also called a gas relay or a sudden pressure relay, is a safety device mounted on some oil-filled power transformers and reactors, equipped with an external overhead oil reservoir called a conservator. The Buchholz Relay is used as a protective device sensitive to the effects of dielectric failure inside the equipment. The relay has two different detection modes. On a slow accumulation of gas, due perhaps to slight overload, gas produced by decomposition of insulating oil accumulates in the top of the relay and forces the oil level down. A float operated switch in the relay is used to initiate an alarm signal. This same switch will also operate on low oil level, such as a slow oil leak. If an arc forms, gas accumulation is rapid, and oil flows rapidly into the conservator. This flow of oil operates a switch attached to a vane located in the path of the moving oil. This switch normally will operate a circuit breaker to isolate the apparatus before the fault causes additional damage. Buchholz relays have a test port to allow the accumulated gas to be withdrawn for testing. Flammable gas found in the relay indicates some internal fault such as overheating or arcing, whereas air found in the relay may only indicate low oil level or a leak. Buchholz relays have been applied to large power transformers at least since the 1940's. The relay was first developed by Max Buchholz

MAIN POWER TRANSFORMERS BTPS has 5 generator transformer units. These transformers are referred as main power transformers. The HV line terminals are connected to the 220KV switchyard via a short overhead transmission line, a 220KV-air circuit breaker and 3 pneumatic operated isolators. Th neutral point of HV windings is brought out and solidly grounded. Two current transformers(CTs) are provided on the neutral connection for ground fault protection. The transformers have two force oil / forced air coolers which are free standing. Each cooler is equipped with a motor driven oil pump and two fans. The load carrying capacity of the transformer is very limited without forced cooling, therefore one selected cooler is started automatically when the transformer is excited. With the switch set for the automatic, one cooler is started when the generator field circuit breaker closes. The second cooler is controlled automatically by means of a contact on the transformer-winding temp. indicator which closes when the temperature rises to a set value. When the field breaker is tripped the coolers shut down automatically. A selector switch permits selection of the cooler group operation to equalize wear. Power is supplied for operation of the cooling fans and the pumps at 415V, 3 phase, 50 cycles from a unit motor control center as an alternate. RATINGS OF MAIN POWER TRANSFORMERS The transformer manufactured by Heavy Electricals (India) is rated as follows: 1. STAGE I TRANSFORMERS
Voltage: 10.5/233KV at no load with 2.5% full capacity no load taps, above rated voltage and two below. Vector symbol: YD-I, %Z: 15 ohms, LINE Amps: HV 310 Amps. LV- 6880 Amps Cooling: OFB with 2x1364-litres/min.-oil circulation and 4x424.8m3/min. air circulatn with two nos. of coolers containing 2 pp. and 4 fans. Oil temperature: 450C Winding temperature: 600C Type of tap changer: off load

2. STAGE II TRANSFORMERS
Voltage: 15.75/233KV at no load with 2.5% full capacity no load taps, above rated voltage and two below. Vector symbol: YD-I, %Z: 15 ohms, LINE Amps: HV 310 Amps. LV- 6880 Amps Cooling: OFB with 2x1364-litres/min.-oil circulation and 4x424.8m3/min. air circulation with two nos. of coolers containing two pp. and 4 fans. Oil temperature: 450C Winding temperature: 600C Type of tap changer: off load

UNIT AUXILIARY TRANSFORMER: The transformer tank is of sealed type construction wherein the gas space above the insulating liquid is sealed to prevent breathing under normal operation. The primary of the unit aux. Xmer is connected to a tee tap on the generator main leads by isolated phase bus duct. Ratings of the unit auxiliary transformers The Unit Auxiliary Power transformer manufactured by Heavy Electricals (India) is 3 phase self cooled delta/delta Xmer of 12500KVA capacity and is rated as follows: 1. STAGE I UAT
Voltage: 10.5/6.9KV at no load with 2.5% full capacity no load taps, above rated voltage and two below. Vector symbol: YD-I, %Z: 7.5 ohms, LINE Amps: HV 687 Amps. LV- 1047 Amps Wt. Of core and winding: 18640 Kg Wt. Of oil: 6900 Kg Total wt.: 35480 Kg Oil quantity: 8130 litres Oil temperature: 450C Winding temperature: 550C Type of tap changer: off load

2. STAGE II UAT
Voltage: 10.5/6.9KV at no load with 2.5% full capacity no load taps, above rated voltage and two below. Vector symbol: YD-I, %Z: 7.5 ohms, LINE Amps: HV 687 Amps. LV- 1047 Amps Wt. Of core and winding: 18640 Kg Wt. Of oil: 6900 Kg Total wt.: 35480 Kg Oil quantity: 8130 litres Oil temperature: 450C Winding temperature: 550C Type of tap changer: on load

3 WINDING TIE IN TRANSFORMER: These transformers are rated as follows: 1. Stationary transformer I: 63/43/20 MVA, 220/34.5/6.9kV 2. Stationary transformer II: 31.5 MVA, 220/34.5/6.9kV. 3. Stationary transformer II: 25 MVA, 220/34.5/6.9kV The windings are connected Y/Y/d1. The coolers are provided with each Xmer. On load tap changers are provided on the HV winding has 16 full capacity 1.25% taps, eight above and eight below rated voltage. The HV line terminals are connected to the 220KV switchyard via a short overhead transmission line, a 220KV-air circuit breaker and 3 pneumatic operated isolators. The LV sides are connected to the 6.6KV station bus through a series reactor. The tertiary winding of the 3 winding Xmer is used to supply station auxiliary requirements and standby power. The medium voltage terminal 34.5KV is not in use nowadays.
Types of transformer cooling

1. ONAN cooling: oil natural air natural cooling. 2. ONAF cooling: oil natural air forced cooling. 3. OFAB cooling: oil forced air blast cooling.

Types of tap changing 1. OFB: off load tap changing. The generator transformer units in BTPS have off load tap changing facility. 2. OLT: on load tap changing. The three stationary transformers and four unit auxiliary transformers have on load tap changing facility. Accessories of transformer Oil temperature indicator: If the temp. of transformer oil crosses 85C an alarm is annunciated and on reaching the 95C mark the Xmer is tripped. Winding temperature indicator: If the winding temp. crosses 95C an alarm is annunciated and on reaching the 105C mark the unit is tripped. Breather: when transformer becomes warm, the oil and gas expand. The gas at the top of the oil is expelled out. When the transformer cools, air is drawn into the transformer and moisture is drawn during this process called breathing due to which dielectric properties of oil is reduced. The air can be made moisture free by letting it pass through an apparatus called breather which consists of a vent pipe and dehydrating material called silica gel which is blue when dry and pink when damp. Conservator: when transformer suffers short circuit and temp. rise becomes excessively high. This causes vaporization of large part of oil. The oil vapours form explosive mixture with air that ignites and may cause a considerable damage. For this reasons a conservator is provided so that the oil level has to be kept some distance below the top cover to provide space for oil expansion under temperature rise. In this context diaphragm and air cell are also used along with the conservator. Surge relay: this type of relay is provided in case of on load tap changing transformers. When the taps are changed on load a surge voltage appears which when crosses a predefined level trips the relay and in turn the transformer. Buchholz relay: it is gas and oil actuated protective device and it is used on all oil-immersed transformers having rating more than 750kVA. It is installed in the pipe joining the main tank of the transformer to the conservator and is used to give alarm in case of minor faults and to disconnect transformer from supply mains in case of severe internal fault.

GENERATOR
The BHEL LTD., Hardwar, has supplied five number turbo-generator sets, three of 100MW and two of 210MW capacity together with the excitation system. INTRODUCTION In electricity generation, an electrical generator is a device that converts mechanical energy to electrical energy generally using electromagnetic induction. The reverse conversion of electrical energy into mechanical energy is done by a motor motors and generators have many similarities. A generator forces electric charges to move through an external electrical circuit, but it does not create electricity or charge, which is already present in the wire of its windings. It is somewhat analogous to a water pump, which creates a flow of water but does not create the water inside. The source of mechanical energy may be a reciprocating or turbine steam engine, water falling through a turbine or waterwheel, an internal combustion engine, a wind turbine, a hand crank, compressed air or any other source of mechanical energy.In our case mechanical energy is given by turbine generator which is run by the steam produced by the boiler.
The figure shown below is of the NRC modern steam turbine generator

SALIENT FEATURES OF GENERATOR Stator: It is the stationary part of the generator. It has totally enclosed casing. The casing is welded steel type and cylindrical in shape. The stator has a gas type structure so that 86 kg of gas causes no deformation. It has end sled fabricated in two halves for convenience in maintenance. The core is made up of cold grain oriented (CGRO) silicon steel laminations. The stator has slots where the windings are placed. There are wedges on the winding to prevent vibrations. The windings have glass fiber, mica insulation. Rotor: The rotor of an AC generator is the rotating component of the generator. The cylindrical type rotor is being used. The shaft and rotor body is made up of forged steel. The field winding is made up of cold rolled electrical copper with small quantities of copper for increasing annealing temperature and creep resistance of metal. The windings are in shape of bars and retaining rings are placed at end of the windings for dynamic stability. Open ducts are being employed. The type of carbon brushes used is LFC554. The slip rings are made up of cast steel forging and fitted on steel hub covered with mica. As shown in Figure the rotor is driven by the generators prime mover, which may be a steam turbine, gas turbine, or diesel engine. Depending on the type of generator, this component may be the armature or the field. The rotor will be the armature if the voltage output is generated there; the rotor will be the field if the field excitation is applied there.

RATINGS: 1. STAGE I GENERATORS (100MW)

Pf: 0.85 lag Capacity: 117.5 MVA Voltage: 10.5 kV Speed: 3000 rpm Hydrogen pressure: 2.5 kg/cm2/gauge Stator winding connection: 3- double star Stator current: 6475 A Frequency: 50 Hz

2. STAGE II GENERATORS (210MW)

Pf: 0.85 lag Capacity: 247 MVA Voltage: 15.75 kV Speed: 3000 rpm Hydrogen pressure: 3.5 kg/cm2/gauge Stator winding connection: 3- double star Stator current: 8050 A Rotor voltage: 310 V

Rotor current: 2600 A Frequency: 50 Hz Cooling: water, H2

EXCITER: Six pole DC generator with compensating winding is used as the exciter for 100MW-turbo generator. The machine is having continuos rating of 470 kW at 280 V and operates at a speed of 3000 rpm. The exciter is driven from the generator shaft by means of coupling. The exciter is air cooled with the filtered air intake and discharge below the operating floor. Mercury thermometers are provided in the foundation plate of the exciter to indicate the temperature of the hot cold air to the exciter. RESERVE EXCITER: The reserve exciter set is intended for excitation of turbo generator in case of a failure of main exciter and can be connected for any one of the any one of the generators at a time. The set consists of a Ac driven motor and a DC generator coupled and assembled on a common foundation plate. EXCITATION SYSTEM OF GENERATOR: It regulates the voltage (flow of reactive power during parallel operation) from synchronous machine (generator) by direct control of the rotor current (field current) using static thyristor converters. It basically consists of four units 1. Excitation Xmer (T1) 2. Control unit (REG) 3. Thyristor converter (TY) 4. Field flashing and De excitation equipment

Shunt excitation: The power is drawn from the generator stator. The rotor current (field current) flows into T1, TY, FCB A, FCB B (Field current breaker). The T1 reduces the generator voltage to input voltage and provides galvanic separation between the generator terminals and field winding and act as commutating reactance for thyristor.

REG

TY

FF

To accomplish this, special field flashing equipment is being supplied with power from a DC power source; a resistor is used to limit the field Flashing current. When it is being supplied from an AC power grid, a Xmer serves, as adapter needed. Power supply system: in the shunt excitation system the excitation Xmer also provides the power supply for the electronic equipments and converter fans. The fans receive their supply when the field breaker is closed. A station battery is necessary for the control of the field circuit breaker. It is the power source for the electronic devices till the generator is able to supply voltage. Auxiliary power to the field flashing equipment must be present in order to build up the generator excitation. The power supply for standstill heating and cubicle lighting is also from station auxiliary supply. Power supply to rotor temperature recording circuit and rotor earth fault detection circuit too is from station auxiliary supply. Power supply distribution system: electronic equipment is supplied redundantly from 3 phase shunt supply station battery Xmer supplies power supply unit with AC voltage matched to battery voltage. This module rectifies AC voltage and connects it to diode DC coupled battery voltage.

The voltages brought together in this way supply a common DC bus across an interference suppression filter. The power supplied is then distributed across protective circuit breaker.

Digital voltage regulator: to regulate the voltage and the reactive power of a synchronous machine, the field voltage must be adjusted quickly to the changes in operating conditions. To accomplish this, analog control system including amplifiers which make continuous comparison of actual values against the reference values and vary control variable to converter with almost no delay. Most of the delay that occurs originates in converter. Since firing pulses for changing rectifier phase angle are only issued periodically. Basic structure: Digital voltage regulator is broken into several autonomous p system, automatic channels, programmable controls and excitation monitoring each consisting of UN 0660 p modules. Each of these process systems has a common bus circuit board including the power supply bus, address lines, 2 data lines to input and output and control lines. Operation: 1. To regulate generator voltage. 2. To regulate effect of reactive /active current. 3. To limit volt/Hz 4. To limit max. field current 5. To limit inductive stator current 6. To limit capacitive stator current 7. To limit load angle 8. To stabilize the power system 9. To regulate cos Power system stabilizer: it generates excitation to damp electromechanical oscillations between the network and generator. In order to produce the torque magnetic field of rotor and stator must form a given angle. The ME increases as the increases, just as with a torsion spring. Because the ME of generator and mechanical driving torque MA from turbine are in equilibrium during steady state operation, angle remains in a given position. Whenever this steady state of equilibrium between MA and ME is disturbed, the load angle moves to a stationary position.

Due to mass inertia of rotor, this can only take place periodically. In order to damp oscillations, there must be a damping torque produced depending not on ME associated with angle, but on the difference in frequency between rotor and stator field. ie. Slippage.

Mainly the damper winding in rotor produces this torque but dimensions of this are subject to limits imposed by considerations of design and economy. Some further action is therefore needed to increase the damping effect. PE = If.Vg Xd It can be seen from the above relationship that the active power that the generator transfers depends not only on the load angle, but also on the field current. That means that a transient change can be made in active power PE and with that in the effect electrical torque ME by varying field current. It is assumed that oscillations in the network frequency generates load oscillations with mass inertia of rotor, then the active load of the generator (MW measured) is influenced by a sinusoidal value -PE (MEMA). By inversion of -PE, one obtains the fluctuations in power provided by rotor +PE, as it is known that the slip signal f follows +PE with a phase delayed by 900. The +ME produced by periodic changes in load angle is in phase with +PE. A good damping is attained if ME is varied in phase with slip f. TEMPERATURE CONTROL SYSTEM: Temperature of winding and stator core is measured by means of resistance thermometers inserted at the hot spots. These are inserted between the bars of the winding and for measuring the temperature of the core, at the bottom of the slots. Temperature of cold and hot gas of the generator is measured by resistance and mercury thermometers located in the stator body and end shields and in the middle of stator body respectively. Temperatures of cold and hot air in the exciter are measured by resistance and mercury thermometers located at the outlet of cold air and in the foundation frame respectively. Oil temperature is checked by means of mercury thermometer installed on the drainpipes of the generator bearing, exciter bearings and shaft seals.

Water temperature is checked by means of mercury thermometer installed on generator water feeder, drainpipes of gas coolers of the generator and air coolers of exciter.

Temperature recorder is also provided in the unit control room and suitable alarms have been provided to annunciate any abnormality. ISOLATED AND SEGREGATED BUS DUCT: The isolated bus duct connects the line terminals of the generator through the turbine building wall to the generator step up transformer with a tap off through disconnecting links outside the building for a unit auxiliary transformer. Segregated bus duct connects the LV terminals of the unit terminals of the unit auxiliary transformer, following the same route as that of the isolated bus duct to the 6.6 kV auxiliary switchgear. COOLING SYSTEM: Hydrogen cooling system: The stator core is cooled by hydrogen passing through the radial ventilating ducts, while the rotor carrier circumferencial slots through which the hydrogen comes in direct contact with the current carrying conductors and exchange the heat. Two propeller type fans are provided fitted on the rotor shaft circulate the hydrogen and transmit it gas coolers also. The gas coolers are water cooled through water coolers. The hydrogen cooling system ensures proper operation for hydrogen pressure 3.4 atg. and hydrogen purity from 97% to 98%. Prior to filling generator with hydrogen, air is purged from it by CO2 Hydrogen is checked for its purity by gas analyzer and pressure by pressure gauge. For drying out hydrogen, a hydrogen drier (silica gel) is used. Seal oil system: Shaft seals are at turbine and exciter are provided to prevent escape of hydrogen. In this a sealing bush, faced with bobbit surrounds the shaft and is held in contact with a collar machined on the rotor shaft by the gauge pressure of the gas inside the casing of the generator and by helical spring. The sealing bush is free to slide axially within the seal body. Sealing oil under pressure, higher than that of gas in the generator, flow into delivery chamber, which is annular space between the bush and the body of the seal. From here through the radical holes in the bush, the sealing oil passes into the circular canal machined in the bobbit riving of the bush. Oil from this circular canal spreads to both sides and fills the radical grooves and wedge shaped tapering on the bobbit surface to form a continuous oil

film, which seals the passage of hydrogen. Body of the shaft seal is connected on one side rigidly and on the other side to the pedestal of the bearing by means of flexible plastic gasket. Hydraulic float seal: The oil flowing from this hydrogen side of seals is delivered through the pipelines into hydraulic float seal, which is a tank with float level regulator. Oil injector: Oil is continuously supplied to the shaft seals by means of oil injector, which injects oil delivered from turbine governor system as well as oil sucked from the turbine lubricating system. Oil pumps: The standby oil pumps are automatically started under the low-pressure conditions. The AC motor driven standby oil pump is started up at oil pressure drop by 1.5 kg/sq.cm. The DC motor driven emergency oil pump is started up at oil pressure drop by 2.5 kg/sq.cm. Damper tank: A damper tank is provided in the oil supply system to feed the seals with oil in case of failure of oil supply system. Differential pressure regulator (DPR): It is used to maintain oil pressure in shaft seals automatically. DM water-cooling: The De-Mineralised water is used for cooling of stator. The DM water is least conductive hence can be used for cooling for current carrying conductors in the stator slots. This facility is available only in stage II generators.

PROTECTION OF GENERATORS AND TRANSFORMERS 1. Generator differential protection(87/G1): the protection is provided with high speed, high stability circulating current relays. The relays has a pick up range of 10 to 40% of 5A and shall have suitable stabilizing for ensuring stability against external faults. The relays shall be tuned to fundamental frequency to reject harmonics produced by CT saturation. 2. Generator-transformer differential protection(87/GT1): the diff. relays for the generator-transformer has to be of sensitive high speed percentage bias type with harmonic restraint and has CT ratio matching devices. The relay should have all required restraints to make it inoperative for fault current, magnetizing inrush current and abnormal magnetizing inrush current during short time over voltage conditions.

3. Unit auxiliary transformer differential protection (87T1A): percentage biased differential relays are used along with ratio matching device. The relay shall not operate for magnetizing inrush current. High set instantaneous over current relays shall be provided in series with the previous relay, set for magnetizing inrush current, for fast protection from internal faults. 4. Generator stator earth fault protection (64GI): the stator earth fault protection shall consist of a zero sequence voltage relay connected to the broken delta winding of generator voltage transformer. The protection shall act to initiate a time-delayed signal only and hence the relay shall be continuously rated for 110V. the relay shall incorporate arrangements to make it insensitive to third harmonic voltages.

5. Generator inter-turn protection(87TG): the protection shall be by means of an instantaneous over current relay. The relay shall incorporate filtering arrangements to make it inoperative for third harmonics. The relay shall have suitable range to cover 20-50% of generator current. 6. Generator rotor earth fault protection(64-1,64-2): the first rotor earth fault of generator shall be detected by means of super imposing of separate Dc bias on the field winding. The DC bias shall be such that the faults at any point in the winding is covered by the protection. Also the relay shall withstand the voltage encountered. Second rotor earth fault protection for generators shall also be provided, with suitable relays common for two units. The protection shall incorporate feature for compensating the effects of induced alternating currents in rotor circuit and shall have minimum dead zone. 7. Generator loss of field protection(40G): this protection shall be single phase off set impedance type. The relays shall have impedance settings to cover the usual range of impedance of large turbo generators. 8. Generator backup protection(21G): the generator backup relay shall be of three phase impedance type for one zone protection together

with required auxiliary relays and two stage timer to give backup protection for faults in the generator, main transformer and transmission system. 9. Generator negative sequence current protection(46G): the negative sequence current relays shall protect the generator from damage by overheating due to sustained flow of unbalanced phase currents, and the operating characteristics of the relay shall be adjustable to match I2Rt thermal characteristics 10.Generator under power and anti motoring protection (67-1G, 672G): the step up transformer back up earth fault protection current relays shall be of IDMT characteristics. One of the two relays shall be set with higher time dial setting to provide second stage of protection.

11.Generator overload protection(51G): one over current relay shall be provided to initiate an overload alarm. The relay shall have high reset ratio and adequate continuos thermal rating. 12.Generator over voltage protection(59G): suitable over-voltage relays preferably with volt/cycle characteristics shall be provided. 13.Back-up protection for unit auxiliary transformer(50T1A): two instantaneous over current relays with an external DC timer shall be provided for back-up protection for unit 6.6 kV bus bar. 14.Fuse failure protection(95G): this protection shall block the operation of all protections associated with voltage circuits in the event of failure of a fuse of generator. 15.Lockout relays(86G and 86GT): lockout relays shall be provided for each generator unit which will be multi contact , hand reset type. The latching mechanism shall be positive and insensitive to vibration and shock
Diagram on the next shows the flow diagram of protection schemes

Following are the denotations used in the diagram MS: main steam

ES: extraction steam AS: auxiliary steam BF: boiler feed water OA: atmospheric air MC: main condensate FO: fuel oil PA: primary air PC: pulverized coal

220V DC SYSTEM
The 220 V DC system supplies direct current as source of operating power for control, signaling, relays, tripping and closing of switchgears, emergency motors of most important auxiliary systems. Under normal conditions of station generation, the storage battery units are kept floating in DC bus bars by means of the trickle chargers (also known as float chargers). The trickle chargers of each battery unit, which is a rectifier with AC input, is normally made to take all DC requirements of the power station without allowing the battery to discharge. This is achieved by maintaining the DC output voltage of trickle charger a few volts higher than the voltage of the battery. With this, the trickle charger besides meeting all the DC requirements of the power station, supplies a few hundred milliamps of direct current to the battery to compensate the loss in the capacity of the battery due to action between the plates of the cell. With this arrangement, the battery remains connected to the DC bus bars as a standby supply source and immediately supplies the DC load in the vent of temporary failure of complete AC system. The complete AC power system failure in a power station is known as emergency situation. DC battery units are designed to supply station DC loads for an emergency period of one hour. The tickle charger normally supplies the station DC load and the momentary loads will also be catered for by the trickle charger and if such a load is more than its capacity, the battery being in parallel with the trickle charger will supply the excessive load. The trickle charger will normally be kept operating at around 115x2.15 V ie 247 volts. In case of AC mains failure the full battery of

115 cells will supply the load ie 230 volts. If the emergency lasts for one hour with an appropriate load of 450 Amps, then battery will supply the load for one hour when its end voltage will drop down to 1.75 volts per cell ie 201 volts. After the emergency when the quick charger is closed the full battery will receive a boost charge and at the same time only the voltage of 98 cells will appear across the load. If a second emergency occurs during quick charging, then immediately all the 115 cells are connected to the bus by closing the switch meant for the purpose. During routine daily testing of emergency DC motors connected to main distribution board middle section, supply has to be taken from the quick charger and the middle section has to be kept isolated from the left and right sections of main distribution board. This is to test the quick charger.

TYPES OF BATTERY BEING USED

1. Lead-acid battery tubular 2. Lead-acid battery plaint 3. Ni-Cd battery

PROCEDURE FOLLOWED IN COMMISSIONING A BATTERY

1. The battery is charged initially to its capacity. The lead acid Battery has a capacity of 1000AH ie it may be charged for 10 hrs with charging current of 100 A or 5 hrs with charging current of 200 A. in case of Ni-Cd battery with a capacity of 2500 AH is charged for 12.5 hrs. with a charging current of 200A. 2. Now the battery is discharged at the rate of 10% of its capacity in case of lead-acid battery and 20% or 40% of its capacity in case of Ni-Cd battery. 3. Now the battery is recharged to its capacity. 4. Constant voltage charging of battery is called float charging. A lead acid battery of cell voltage 2.2V is float charged upto 2.42 V. A Ni-Cd battery of cell voltage 1.2V is float charged upto 1.41 V. 5. Constant current charging of a battery is called boost charging. A lead acid battery with bank voltage 237 may be boost charged to 279V. A Ni-Cd battery with bank voltage 242 may be boost charged to 283V.

EQUIPMENTS USED IN 220V DC SUPPLY SYSTEM

Sources of AC power: Two sources of AC power have been provided for both quick charger and trickle charger, one is the normal source and other is standby. AC power supply to the chargers is through transformers having off-load tap changing arrangement. An AC voltage-signaling relay communicates; AC voltage low when the supply voltage becomes low. Voltage level indicating device: A voltage level indicating device in MDB gives audio and visual annunciation when the DC bus voltage changes beyond set low (180-210) and high limits (240-270).

AVR: The DC voltage is maintained at desired value automatically by means of AVR unit provided at panel board. Insulation monitoring device: This device annunciates when the insulation resistance of either positive bus to earth or negative bus to earth falls below 20 kilo ohms and also when the ratio of insulation resistance of positive bus to earth to negative bus to earth is 1.5 or above. Measurement of insulation resistance of positive and negative buses: Select either left or right section bus bars of main distribution system board by means of control switch-c. Put the control switch-e in position-I. Adjust the potentiometer switch-g till voltmeter-b reads zero If R1- insulation resistance between positive bus and earth. R2- insulation resistance between negative bus and earth. R- potentiometer resistance. XR- fraction of the resistance adjusted. V- voltage between positive and negative bus Rv- voltmeter resistance. Vv-Voltmeter reading. Then And R1/R2= R+XR/R-XR R1R2/R1+R2 = Rv( 0.5V/Vv -1)

Flickering light device: This has been installed in the MDB, for flicker supply to control and check whether device is in order or not.

Control and signaling panels have two sets of bus bars, one fed by main distribution board left section and the other by MDB right section. The loads of the first panel should be kept switched to the set of bus bars fed by MDB. Left section and the loads of the second panel should be kept connected to the set of bus bars fed by MDB right section.

ELECTROSTATIC PRECIPITATOR Dust extraction from industrial gases has become necessity for environmental reasons or for improving production. Most of the plants in India use coal as fuel for generating steam. The exhaust gases contain large amount of smoke and dust, which are being emitted into the atmosphere. This has posed a real threat to the mankind as a devastating health hazard. Hence it becomes necessary to free the exhaust from smoke and dust. There are various ways of extracting dust. Electrostatic dust precipitation method is most widely used as its efficiency is excellent and it is easier to maintain. Its other advantages are: Ability to treat large volumes of gases at high temperature Ability to cope up corrosive atmosphere Offer low resistance path for gas flow. An electrostatic precipitator is equipment, which utilizes an intense electric force to separate suspended particles from the flue gases. The process involves: Electrical charging of suspended particles Collection of charged particles from collecting electrode. Removal of particles from collecting electrode. The flue gases pass between electrodes and are subjected to an intense electric field. The emissive electrodes are connected to the negative polarity of HV power supply while collecting electrodes are connected to positive polarity and grounded. The HV power supply equipment is supplied in two parts: The high voltage transformer rectifier (HVR) The electronic controller (EC)

The EC-HVR equipment provides high voltage DC across the precipitator electrodes. The EC provides controlled AC voltage through thyristors (SCR) and associated controls to the primary of step up transformer. The EC has been designed to supply 0 to 415V to the primary of step up transformer through AC reactor. The equipment operates as constant current controller.

Three electrostatic precipitators are provided for UNITS 1,2,3(Stage1) and two of them for UNITS 4 and 5(stages II). Heaters: Heaters are provided to raise the temperature of flue gases, as they become conductive when heated. 24 heaters are provided for stage I electrostatic precipitators. Rating: 550W heaters Zones: The flue gases from the boiler section reaches electrostatic precipitator section through ducts. The flue gases are allowed to pass through various zones each having its own heaters, collecting and emissive electrodes and DC supply. These zones are provided to lessen the burden on a single zone and to take the load of other zone in case of maintenance or damage of a particular zone. Stage I have 16 zones eight belonging to PASS A and rest to PASS B. Stage II has 20 Zones five belonging to each PASS A, PASS B, PASS C and PASS D. Diodes: These are provided to rectify the AC voltage to the required DC voltage for electrostatic precipitators to work. The required DC voltage is 70 kV, 1000 mA. Type: BY 127 Motors: Rapping motors are provided along with each zone. A hammer is coupled to each of the motors shaft. Due to rotary motion of motor these hammers hit the collecting electrodes after a certain time delay and the ash is allowed to flow down through outlet in form of slurry. There are 26 motors for each of electrostatic precipitator of UNITS 1, 2, 3 and 40 motors for UNITS 4, 5. Rating: .5A motors A GD screen (gas diverting) motor is also provided in UNIT 1 electrostatic precipitator to provide a zigzag motion of flue gas so as to allow the heavy dust particles to settle down and removed.

FEATURES:

Spark regulation: Flashovers of extremely low intensity are difficult to detect using the comparator technique. Non detection results in sustained arcing which may damage the collecting electrode. For such digital detection system is adopted. Fast ramp control: in case of fast changes in operating conditions of precipitator many sparks may occur within a short time reducing current to a low value, when the disturbance disappears, it may take a relatively long time before the current can assume its normal value. This is the case particularly if selected rate of rise is low.
MODES OF OPERATION

Back corona mode: In this mode the precipitator voltage decreases with increase in precipitator current. This reduces the efficiency of precipitator and consumes unnecessary power. Charge ratio mode: In a high resistive dust a potential gradient is created within the dust layers which causes occurrence of local sparks in dust layer. This spurious discharges or BACK CORONA occurs as soon as potential gradient is high. This has negative impact on efficiency. Charge ratio: This mode supplies current in pulses and provides a dense corona for a short circuit time and at same time give a low current to avoid back corona.

220 KV SWITCHYARD
BUS BARS: The arrangement in the 220kV switchyard comprises of a 220kV double bus bar system, with a bus coupler and a by pass bus. With this arrangement it is possible to take out any one breaker for maintenance without interruption of supply. In the eventuality of a bus bar or a circuit breaker fault the period for which supply is interrupted is the time taken to transfer the feeders from the faulty bus to the healthy one or replacing the faulty circuit breaker by the by-pass breaker. It is only in the case of a line fault that supply cannot be restored to the feeder until the fault is rectified. For maintenance of a particular bus all feeders connected to the bus requiring the maintenance shall be transferred to the other bus by closing one bus isolator and opening the other. The bus coupler shall be tripped and the earthing switch closed. After the maintenance work is over, the earthing switch must be opened before the respective bus bar is energized. For maintenance of the by-pass bus, it should be ensured that by-pass breaker is open and all the by pass isolators of various bays are open. 220KV CIRCUIT BREAKERS: There are two types of 220kV breakers being used in BTPS switchyard: Air blast ciruit breaker SF6 circuit breaker These breakers operate with sequential isolators and suitable for threephase auto-reclosing facility. These breakers can be operated from the switch yard control board. In case of failure, emergency manual handles are provided in the control kiosk. Feeder breaker: When it is required to maintain either a line or a generator or a transformer breaker, the feeder is transferred to the by-pass breaker. The earthing switches on isolators must be earthed before maintaining the breaker. By-pass breaker: the main purpose of the by pass breaker is to facilitate maintenance/repair of other 220 kV breakers without the necessity of tripping out the associated circuit.

Bus coupler breaker: The two bus bars can be kept coupled through bus couplers. The by pass breaker cannot act as a substitute for bus coupler breaker when the bus coupler breaker is being maintained. If buses I and II are paralleled by means of bus coupler and by pass breaker then in order to maintain the bus coupler breaker all feeders must be transferred to one bus depending upon the prevalent load. RATINGS OF CIRCUIT BREAKERS: 1. AIR BLAST CIRCUIT BREAKER (BHEL)
Volts: 220 kV Amperes: 1200A Breaking capacity: symmetrical 26.31 kA Equivalent 10000 MVA Asymmetrical 32.1 kA Making capacity: peak 67.1 kA Short circuit time: 3 sec. 26.3 kA Closing coil voltage: 220V DC Tripping coil voltage: 220V DC Working pressure: max. 28.1 kg/cm2-g Min. 26.0 kg/cm2-g Lockout pressure: 21.1 kg/cm2-g

2. AIR BLAST CIRCUIT BREAKER (ABB)

Volts: 245 kV Amperes: 1200A Breaking capacity: symmetrical 31.5 kA Asymmetrical 38.4 kA Short circuit time: 3 sec. 31.5 kA Closing coil voltage: 220V DC Tripping coil voltage: 220V DC RIL at 50 Hz: 480 kV VI impulse: 1.2/50s 1050 kV per sec. U switching impulse: first pole to clear 1.3 Mass: 1830 Kg Working pressure: max. 27.31 kg/cm2-g

3. AIR BLAST CIRCUIT BREAKER (BHEL)

Volts: 245 kV Amperes: 2000A Short circuit time: 3 sec. 26.3 kA Closing coil voltage: 220V DC Tripping coil voltage: 220V DC Working gas pressure: 6.1 kg/cm2-g at 200c Rated frequency and voltage for auxiliary: 415AC 50Hz Total weight of gas: 3900 Kg Rated operating scheme: O-0.3sec-CO-3 min.-CO Rated lightening impulse withstands voltage: 1050 kVp Rated short circuit breaking current: 40 kA Rated operating pressure: 15 kg/cm2-g First pole to clear factor: 1.3 Rated duration of short circuit current: 40 kA for 3 sec Rated line charging breaking current: 125 A Gas weight: 21 kg

ISOLATORS: These are single break, single pole isolators supplied by M/s. Hvelm limited, Madras. These are pneumatically operated at a pressure of 15 kg/cm2. These isolators and earthing switches are interlocked with each other and with the circuit breakers to prevent mal-operation. No interlocking arrangements are provided for the bus earthing switches. Main bus isolators: to maintain the main bus isolators the corresponding bus has to be shut down by transferring loads to other bus, bus earthed and circuit breaker and isolator opened, after transferring the requisite feeder on to the by pass breaker and the earthing switches are closed. By pass isolator: to maintain the by-pass isolators the by-pass bus has to be shut down, isolators opened and the earthing switches are closed. Feeder isolators: when the feeder is working on bus I or bus II, the earthing switches on both sides of the isolator are closed after opening the breaker and isolators and shutting down the feeder. PT isolators: The corresponding bus must be shut down and earthing switches on the isolator closed for maintenance.

PNEUMATIC SYSTEM: This system consists of seven compressors with one spare air compressor. All the seven compressors are connected to two wet air cylinders, which are coupled to each other. This wet air is dried through an air drier and fed into six dry cylinders divided into a two groups each having three dry cylinders. The dry air through these two groups is passed through two separate air drier for further dryness of air up to a dew point of -70C. The dried air from these two dryers is fed into two separate dry cylinders which feed dry air into pressure reducers. From these pressure reducers the pressurized dry air is supplied to air blast circuit breakers. High pressure and low-pressure alarms are arranged on the pressure gauges and any mal-operation noticed must be rectified immediately. POWER LINE COMMUNICATION EQUIPMENT: To maintain the power line carrier communication equipment like wave trap or coupling capacitor the conditions would be same as those of maintaining the concerned feeder isolator. Depending upon whether inter-circuit coupling or phase to ground coupling is used either both the circuits or the single circuit must be shut down along with the feeder isolator. 220KV CURRENT TRANSFORMERS: The 220kV single phase 4 core current transformers supplied by Hindustan Brown Broveri Ltd. (Baroda). The transformation ratio 1200-600/1/1/1/1 amps are used in Tie in transformer, generator and transmission line bays and bus coupler bay. The secondary windings of these CTs are connected to protection and measurement circuits. 220KV POTENTIAL TRANSFORMERS: These single phase potential transformers supplied by HE(I) Ltd., Bhopal are connected to 220kV buses. These are required for measurement and protection purposes. The main PTs are of ratio 22000/53/110/53 volts and the auxiliary PTs are of ratio 62.5/63.5 volts. The auxiliary PTs will operate in conjunction with the main PT to provide one more secondary winding. Consequent by the combined set of main and auxiliary PTs will provide to secondary winding each of 110/53 voltage ratings. LIGHTING ARRESTORS: These have been supplied by M/s. W.S. insulators of India Ltd. (Madras). These are installed for protection of transformers and other electrical equipments against voltage surges.

One set of lighting arrestors have been provided on each power transformers, tie in transformers and to the bus PTs. The 195kV, 10000 amps single pole heavy duty station class SVS type self supporting L.A. comprises of one metal top and metal base, having mobile arc, pressure relief and a transfer device. The mobile arc gap assembly consists of a permanent ceramic ring magnet, radially magnetized, m series with air gap. Thus it provides a constant magnetic field in the air gap which is always preset at full strength regardless of the current of the discharge, when lighting wave discharges through it, the spark discharge takes place in the annular space, causing an arc at right angles to the magnetic field. This field forces the arc to spin around the gap electrode surfaces. Pressure relief device is provided to take care of the gas formed at the time of short circuit when the arrestor is damaged. When the diaphragm bursts due to a gas pressure, the ionized gases come out and are vented through the exhaust ports. The gas from the top of the unit is deflected downward and that from the bottom is deflected upward. The gas steams meet and transfer the fault current is from inside the arrestor to the outside in less than half cycle of fault current. 220KV LINES: all the feeders from the 220 kV bus bars are shown in the diagram on the previous page. All the metering and protection should normally be connected only to the bus VT supplies. However when necessary CVTs can be used for metering and protection. Bus-1 1. Gen-Tr-1 2. Gen-Tr-3 3. Gen-Tr-5 4. IP line I 5. Mehrauli line I 6. Ballabgarh line I 7. Alwar line 8. Okhla line-1 9. Stn Tr-1 10.Stn Tr-3 Bus-2 1. Gen-Tr-2 2. Gen-Tr-4 3. IP line I 4. Mehrauli line II 5. Ballabgarh line II 6. Noida line 7. Okhla line-1I 8. Stn Tr-2 9. Bus coupler 10. By pass bay

SYNCHRONISING: synchronizing facility with check feature has been provided for all 220KV breakers. Whenever a breaker is proposed to be closed, its synchronizing switch should be unlocked and synchronizing check relay by pass switch is in circuit position. It is ensured that voltage and frequency of the incoming and running supplies are nearly same, and the red out of synchronism lamp is not continuously on. After the breaker has been closed, its synchronizing switch should be returned to off position and locked. Synchronizing check relay SKE prevents closing of a breaker when incoming and running supplies are out of synchronism. This relay has to be bypassed when closing a breaker one side of, which is dead. ANNUNCIATION SYSTEM: All breaker tripped alarms have been classed as emergency alarms. Whenever a breaker trips, the breaker tripped facia/flashes and a separate buzzer sounds to draw immediate attention of operator to tripping of a breaker. Whenever an alarm initiating contact closes, the corresponding facia of that alarm starts flashing. Simultaneously, the bell /buzzer starts ringing. Ringing of buzzer stops automatically after a preset time. Flashing continues unit accepts push button pressed, whereupon facia becomes steadily lighted if the initiating contact is still closed. Facial lamps should be tested for operation regularly by pressing lamp test button, provided separately for each control panel
PROTECTION AND RELAYS USED IN MAIN CIRCUIT BOARD

1. High speed biased differential relay: the DMH type relay provides high speed biased differential protection for two or three winding transformers. The relay is immune to high inrush current and has a high degree of stability against through faults. It requires a max of two cycles operating time for current above twice relay rated current. Instantaneous over current protection clears heavy internal faults immediately. This relay is available in two forms. Firstly for use with time Cts, the ratios of line which are matched to the load current to give zero differential current under normal working conditions. Secondly with tapped interposing transformers for use with standard line current transformers of any ratio.

2. Directional inverse time overcurrent and earth fault relays: the CDD type relays are applied for directional or earth fault protection of ring mains, parallel transformers or parallel feeders with the time graded principle. It is induction disc type relay with induction cup used to add directional feature. 3. Instantaneous voltage relay: the type VAG relay is an instantaneous protection against abnormal voltage conditions such as over voltage, under voltage or no voltage in AC and DC circuits and for definite time operation when used with a timer. It is an attracted armature type relay. 4. Auxiliary relays: the VAA/CAA type auxiliary relays are applied for control alarm, indication and other auxiliary duties in AC or DC systems. CAA is a current operated and VAA is a voltage operated relay.. it is attracted armature type. 5. High speed tripping relays: this VAJH type relay is employed with a high speed tripping duties where a number of simultaneous switching operations are required. This is a fast operating multi contact attracted armature relay. 6. Definite time delay relay: this VAT type relay is used in auto reclosing and control schemes and to provide a definite time feature for instantaneous protective relay. It is an Electro mechanical definite time relay. It has two pair of contacts. The shorter time setting is provided by a passing contact and longer time setting by the final contact. 7. Trip circuit supervision relay: this VAX relay is applied for after closing or continuous supervision of the trip circuit of circuit breakers. They detect the following conditions: a) Failure of trip relay b) Open circuit of trip coil c) Failure of mechanism to complete the tripping operation 8. Instantaneous over current and earth fault relay: an instantaneous phase or earth fault protection and for definite time operation when used with a timer. It is a CAG 12/12G standard attracted armature relay with adjustable settings. It may be a single pole or triple pole relay.

9. Inverse time over current and earth fault relay: this CDG 11-type relay is applied for selective phase and earth fault protection in time graded systems for AC machines. Transformers, feeders etc. this is a non-directional relay with a definite minimum time which has an adjustable inverse time/current characteristics. It may be a single pole or triple pole relay. 10. Fuse failure relay: this VAP type relay is used to detect the failure or inadvertent removal of voltage transformer sec. fuses and to prevent incorrect tripping of circuit breaker. It is three units, instantaneous attracted armature type relay the coil of each unit connected across one of the VTs. The secondary fuses under healthy conditions, the coil is SC by fuses and cant be energized. But one or more fuses blow the coil is energized and relay operates. 11.Instantaneous high stability circulating current relay: it is used to serve the following three purposes a) Differential protection of Ac machines , reactors auto transformers and bus bars b) Balanced and restricted earth fault protection of generator of generator and transformer windings c) Transverse differential protection of generators and parallel feeders. This CAG type relay is a standard attracted armature relay. In circulating current protection schemes, the sudden and often asymmetrical growth of the system current during external fault conditions can cause the protection current transformers to go into saturation, resulting in high unbalance current to insure stability under these conditions. The modern practice is to use a voltage operated high impedance relay, set to operate at a voltage slightly higher than that developed by CT under max fault conditions. Hence this type of relay is used with a stabilizing resistor. 12.Local breaker back up relay: this is a CTIG type three phase or two phase earth fault instantaneous over current unit intended for use with a time delay unit to give back up protection in the event of a circuit breaker failure. 13.Poly-phase directional relay: the PGD relay is a high speed induction cup unit used to give directional properties to three phase IDMT over-current relays, for the protection of parallel feeders, inter

connected networks and parallel transformers against phase to phase and three phase faults. Owing to low sensitivity on phase to earth faults the relay is used with discretion on solidly earthed systems.

14.Auto reclose relay: Five types of auto reclose relays are available VAR21 giving one reclosure. The dead time and reclaim time are adjustable form 5 to 25 secs. If the circuit breaker reopens during reclaim time, it remains open and locked out. VAR41B is a single shot scheme for air blast circuit breakers. Reclaim time is fixed at between 15 to 20 secs. Dead time adjustment is from 0.1 to 1.0 sec of which first 300 millisec will be circuit breaker opening time. VAR 42 giving four reclosure. It is precision timed from 0 to 60 sec. it can be set for max four enclosures at min intervals of 10 sec and instantaneous protection can be suppressed after the first reclosure so that persistent faults are referred to time graded protection. VAR 71 giving single shot medium speed reclosure with alarm and lockout for circuit breaker. This allows up to 10 faults clearance before initiating an alarm. The alarm is followed by lockout if selected no. of faults clearances exceed. If the circuit breaker reopens during reclaim time, it remains open and locked out. It offers delay in reclosing sequence. Instantaneous lockout on low current earth fault and suppressing instantaneous protection during reclamation time. Var81 is a single shot high-speed reclosure with alarm and lockout for circuit breaker This allows up to 10 faults clearance before initiating an alarm.

a)

b)

c)

d)

e)

REACTANCE DISTANCE SCHEME: this scheme consists of the following relays, XCG22-3 for phase to phase and 3 for phase to ground, YCG17, mho starting unit one in each place, VAT51 along with timing unit for zone 2 and 3, 86-X aux. tripping relay and 30G, H, and J for 1st, 2nd and 3rd. Zone indication VAA51, CAG12 and VAA31. Theses schemes provide three zone phase and earth fault protection using reactance relays type XCG22 and also starting relays YCG17. They are applicable to important line sections where high values of arc resistance would otherwise effect the accuracy of measurement and where high speed tripping is essential. High-speed protection is provided for phase and earth faults on 80-90% of the line section and faults on the remaining

section are cleared in second zone, time. The third zone provides backup protection after further time interval. Each mho starting unit Y3 and its auxiliary Y3 X is associated with one phase and operates for all faults involving this phase. Each reactance unit X is connected to measure phase or earth fault distance, but is prevented from operating by short circuit across the polarizing coils

LINE FAULT DETECTORS Y3

EARTH FAULT DETECTORS 64

ZONE TIMING 2

DETECTOR AUXILIARIES Y3X

RANGE EXTEN SION 2X2X PHASE FAULT REACTANCE UNIT X1

EARTH FAULT REACTANCE UNITS X2

TRIPPING AND INDICATION 30

TRIP REINFORCING 86X

The principle of distance scheme is shown in the above block diagram

Under the phase fault conditions, the Y3 X units unblock the appropriate X1 reactance units, which initiate tripping immediately for faults within their setting. Operation of the earth auxiliary relay 64 in conjunction with the Y3 X units selects the appropriate reactance units for measurement of earth faults. The reach of reactance units is extended by the timer, 2 after

successive intervals to cover faults in zone 2 and 3. Discrimination is not affected by changing faults, for example a zone 2 earth fault which develops into a double phase to earth fault will be cleared correctly by the X1 (phase fault) units in zone 2 time. In the rare event of two faults occurring simultaneously at different points on the line; the scheme will measure to a distance approx. half way