TRAINING REPORT

ON
DADRI GAS POWER STATION

OF

NATIONAL THERMAL POWER

STATION, DADRI
National Thermal Power Corporation Limited
National Capital Power Station - Dadri
P.O. Vidyut Nagar, District Gautam Budh Nagar - 201
008 (UP)

MADE BY:-
About NTPC, Dadri
NTPC Dadri has a total installed capacity of 1669.78 Mega Watts.
The coal plant has 4 units which were commissioned one by one
from 1991 to 1994 .Each unit has a generation capacity of 210 MW.
The coal for the plant is sourced from the Piparwar mines of
Jharkhand while the Upper Ganga canal acts as the water source.
The Gas plant has 6 units which have a combined capacity of
829.78 MW. It has 4 gas turbine units which were commissioned in
1992 while the 2 steam turbine units were commissioned in 1994.
The gas turbine units have a capacity of 130.19 MW each while the
steam turbines have a capacity of 154.51 MW each

About the Gas plant

The plant receives gas through the HBJ pipeline , with the gas
originating at Hazira. The plant works on the combined cycle which
has a very high efficiency of 48.33 percent as opposed to the 32
percent offered by the open cycle.
The main fuel is natural gas and the alternate being HSD. The
Upper Ganga canal headwork provides a source of cooling water,
during the closure of the canal a network of tube wells serves this
purpose. The consumption of gas amounts to 4, 0 MCMD.

Other features:-
• Startup power: Black Start DG set 2.6 MVA capacity
• Heart rate-open cycle: 2692 Kw / Kwh
combined cycle: 1748 kw / Kwh
• Consumption-open cycle: 0.3167 m3/Kwh
-combined cycle: 0.205 m3/Kwh
• HP/LP bypass capacity (for steam turbine): 1000% MCR
 • Time required from barring speed to synchronization: 4
minutes
• Time required from Synchronization to base load
At normal gradient : 16 minutes
At Fast gradient : 9 minutes

OPEN CYCLE AND COMBINED CYCLE

In the open cycle the natural gas is compressed ignited and used to
drive Gas Turbines which in turn run a generator and produce
electricity. The left over gas which is at very high temperatures is
exhausted. This cycle has a meager efficiency of 32%.
In the combined cycle the gas left after ignition is further is driven
into a boiler and used to heat water to steam .This steam is in turn
used to run steam turbines. Such system is used in the Dadri power
station. The efficiency of the combined cycle comes out to be a very
much improved 48%.

TRANSFORMER
From the stage of generation to the stage of transmission (400kv
lines) a series of transformers
are involved.

INTER CONNECTING TRANFORMERS (ICT)

These are for uplifting the voltage from 220KV to the 400KV for
transmission purposes. There are 2 ICTs in the GP switchyard. (s.no
3 & 4). They differ from other transformers in a way as they have a
different unit for each phase. Manufactured at BHEL, Bhopal they
are rated 167MVA (each phase) and fitted with an on load tap
changer having 17 steps. The connection is Star/Auto/Delta. The
type of cooling system is OFAF. There are a total of 7 transformers
(3 for each bay and 1 extra). There are 5 ICTs in all (including for
thermal plant).ICT#5 acts as a common for both the plants and can
be used by any of the plants.

UNIT TRANSFORMERS (GT #1, 2, 3 & 4)

The unit transformers for the gas turbines are in 4 in number(one
for each generator).They are responsible for uplift from 10.5KV that
is produced by the generator to 220KV that enters the switchyard.
These are 166MVA transformers manufactured by BHEL, Bhopal.
The type of tap changer it acquired is offload owing to the large
amount of current that flows in the LV side. The windings are 3
phase Star/Delta connected. Type of cooling is OFAF.

UNIT TRANSFORMERS (ST #1&2)

Connected to the steam turbines they are 2 in number and similar
to their counterpart in many aspects lest the fact that they are not
preceded by a Unit Auxiliary Transformer. They are 193MVA rated.
The auxiliary power for the STs is provided by the GT UATs.

UNIT AUXILLARY TRANSFORMERS

They precede the GT s and used for 10.5KV/6.6KV step down of
voltage. They are relatively small transformers rated only 16MVA.
The use of this transformer is to supply the necessary power to the
plant so no external power is needed to run the plant. Only present
in the GTs .They have an on load tap changer and are Delta/Star
connected. The type of cooling is ONAN. The 2 UATs of the
respective GTs provide power for the auxiliary equipment of both
the GTs as well as the corresponding ST. In case of failure/trip of
one of the GT, the other UAT of GT provides the necessary power to
run all the auxiliary equipment of the ST. Same is the case for the
tripping of the other pair of GTs.

COOLING SYSTEM IN TRANSFORMERS

The windings and core are immersed in oil which acts as a coolant
and also an insulator. The main oil storage is done in the
conservator. The oil circulates within the transformer and goes
through thin flat tubes having large surface area exposed to air.

OIL TEMPERATURE INDICATOR (OTI)

Fitted inside the main tank they depict the temperature of the oil. If
the temperature of the oil rises to 85 degrees the fan banks operate
to enhance further cooling. Further on if the temperature reaches
95 degrees pump is operated to enhance the circulation of oil, also
an alarm is sounded. Finally if there is further rise in the
temperature the OTI tips at 100 degrees Celsius operating the fire
fighting system.

WINDING TEMPERATURE INDICATOR (WTI)

Since Transformer winding temperature measurement cannot be
made direct methods due to insulation problems. The setup consists
of (a) current transformer (b) Winding temperature indicator or a
RTD sensor (c) shunt resistance box (d) remote winding
temperature indicator and (e) a power supply unit.
The RTD sensor is placed in the an oil filled packet on the
transformer on the tank cover. Inside is placed a heating resistance
which is fed current proportional to that of the loaded winding of the
transformer through a current transformer. Thus the temperature
increase of the heating resistance is proportional to that of the
winding. The winding temperature indicator is located in the zone of
the hottest oil in this way the transmitter measures the hot spot
temperature
OTHER TRANSFORMER COMPONENTS

1. CONSERVATOR AND AIR CELL

The main storage of tank in an transformer is called the
conservator. It is fitted with a magnetic oil gauge to depict the level
of oil. Also fitted are 3 air release plugs, a pressure gauge, breather,
Buchholz relay, shut off valve and an air cell. In conventional
transformers, whenever the oil level went down the air sucked
through the breather came in direct contact with the oil in the
conservator. This led to degradation of the oil as it came in contact
with air. To avoid this conservators are now fitted with an air cell.
Air cell is a flexible oil resistance nitrile rubber that floats on the oil.
The air sucked through the breather comes into the air cell thus
avoiding any air contact with the oil. Thus the dielectric and the
insulation properties of the oil are retained.

2. AIR BREATHER
A dehydrating breather is used to dry the air that enters a
transformer as the volume if oil decreases because of the fall in
temperature. Air entering the breather is first drawn through an oil
seal and passes upwards through the silica gel crystals to the
connecting pipes at the top. During this upward passing of air any
moisture present is absorbed by the silica gel. The oil seal ensures
that the gel absorbs moisture only when the transformer is
breathing.

3. BUCHHOLZ RELAY AND GAS COLLECTING DEVICE

The operation of the Buchholz relay is based upon the fact that
every kind of fault in an oil filled transformer causes decomposition
of the insulating material either liquid or solid, due to over heating
in the fault zone or due to the action of an intense electric field
which in turn result in a more or less violent generation of gases.
These reach the relay through the pipe connecting the transformer
to the conservator. When a slight fault occurs in the transformer,
the small bubble of gas. The circuit is designed as such that it
results in the going of an alarm and the gas is collected. When a
serious fault occurs the gas generation is violent. This oil surge will
result in the trip connection of the circuit breaker and the
transformer is disconnected. Also if there is a loss of oil same effect
takes place and the CB trips.
SIGNIFICANCE OF THE GASES COLLECTED

1. Rate of collection of gas: helps in judging the severity of the

fault. Greater the rate the more severe the fault.
2. Colour of the gas: This helps in finding out the affected
material.
3. Combustibility of the gas: This helps in distinguishing the
gases generated by the disintegration of insulation from air.

4. PRESSURE RELIEF VALVE

The PRV has got a port sealed by a stainless steel diaphragm.
Whenever the pressure in the tank rises due to any reason, the
same pressure acts on the diaphragm from inside. When pressure
rises above the predetermined safe limit, the diaphragm gets lifted
from the seat. This lifting is instantaneous and allows vapours,
gases or liquids to come out of tank depending upon the position of
valve on the tank. The diaphragm restores its position as soon as
the pressure in the tank drops below set limit.

5. BUSHINGS
The types of bushings in the transformer are HV, LV, IV and neutral
type. The general construction consists of an Oil Impregnated Paper
(O.I.P) condenser core manufactured from Kraft paper wound in a
brass tube. Thus the electrical stresses are controlled throughout
the thickness and along the surface. The insulation is measured by
the tan delta test.

TRANSFORMER ELECTRICAL TESTS

The following transformer tests are undertaken in a transformer

before implementing it.
1. WINDING RESISTANSE (BOTH HV AND LV): This test is
carried out to measure the phase to phase winding resistance
(when the transformer is delta connected), and phase to neutral
when the transformer is star connected.
2. INSULATION RESISTANCE TEST: This measures the insulation
between two windings or between winding and the earth. The
device used to perform this test is called a MEGGER. It can be
either hand driven or motorized or electronic Megger. A Megger
is connected between the two ends of the device or between the
 one end and the ground which gives the insulation of the device
with respect to the ground. The working principle is simple. The
device generates voltage and measures the current thus giving
us the resistance or the insulation level of the test points. It gives
the result in Mega ohms.
3. TAN DELTA BUSHING TEST: Tan Delta test is used to measure
the insulation of the bushing of the transformer. It gives the
insulation level between the test point and the HV terminal. The
result is represented in percent. The max limit of the tan delta of
the bushing is about 7%.
4. MAGNETIZING CURRENT TEST: This measures the amount of
magnetizing or the no load current flowing in the transformer.
5. WINDING RATIO TEST : This involves the determination of the
winding ratio of the primary and the secondary windings of the
transformer.
6. OTI AND WTI CALIBRATION: This involves the calibrating of the
oil and the winding temperature indicators.
7. DISSOLVED GAS ANALYSIS: This test gives the info about the
fault occurring in the transformer and the severity of the fault.

TESTS CARRIED OUT ON GENERATOR:

STATOR TESTS:
1) Polarization Index Test 2) Winding Resistance 3) Tan delta 4)
ELCID 5) Wedge tightness

ROTOR TESTS:
1) Insulation Resistance 2) Winding Resistance 3) Winding
impedance
3) Pole balance test

ON A 220KV CIRCUIT BREAKER:

1) Closing and tripping timings 2) Contact resistance 3)
Insulation resistance
4) Pole discrepancy time

ON A 220KV CT
1) Insulation resistance 2) Tan Delta 3) Ratio
test
4) Polarity test 5) Magnetization characteristics

ON A 220KV CVT
1) Insulation resistance 2) Tan Delta 3) Polarity
test 4)Ratio test

GENERATOR TRANSFORMER PROTECTION RELAYS

Here is a brief summary of the protective relays that are
implemented in the protection of the generator transformer. These
relays are controlled from their respective turbine control rooms.
1. PHASE INVERSE OVERCURRENT PROTECTION: The single
phase over current time protection relay is used as a short circuit
protection for the detection earth faults in solidly and low
ohmically earthed networks.
2. SOLID STATE DIFFERENTIAL PROTECTION: The generator
differential protection relay is a sensitive comparison protection
providing selective clearance of short circuit within the protected
zone which is defined by 2 current transformer sets. It detects all
1, 2 and 3 phase s.c. faults and double earth faults.
3. SOLID STATE EARTH FAULT PROTECTION: The stator earth
fault protection is used to detect earth faults in the stator winding
of the 3 phase machines which are all connected via a block
transformer to the system.
4. ROTOR EARTH FAULT PROTECTION: The rotor earth fault
protection relay is used to detect high and low ohmic earth faults
in the excitation circuits of synchronous machines.
5. NEGATIVE PHASE SEQUENCE PROTECTION: The negative
phase sequence protection is used to detect asymmetrical
loading in the 3 phase machines. This type of disturbance occurs
during 2 phase faults and in solidly or low ohmic earth systems,
during single phase earth faults.
6. SOLID STATE TRANSFORMER DIFFFERENTIAL PROTECTION:
Same as the case for the generator transformer this provides
protection for the 3 phase transformer
7. STATIC PROTECTION FOR MACHINES / RESTRICTED EARTH
FAULT PROTECTION: The restricted earth fault protection is a
 selective for transformers having directly earthed neutrals or with
earthing having artificial star points.
8. UNDER EXCITATION PROTECTION : The under excitation
protection protects the synchronous machines in the event of
faulty excitation from asynchronous operation and from localized
overheating in the rotor . Further more it prevents under
excitation of large machines from endangering the stability of the
system.
9. SOLID STATE OVERVOLTAGE PROTECTION: Over voltage
protection has the task of initiating a trip signal if the machine
voltage exceeds the set value. This protects the machine and the
galvanically connected electrical plant from the effects of
impermissible voltage increase.
10. SOLID STATE 80% STATOR EARTH PROTECTION: The stator
earth fault protection is designed to detect earth faults in the
stator winding or 3 phase machines which are directly connected
to the unit transformer.
11. SOLID STATE DC VOLTAGE TIME PROTECTION: This DC
voltage monitoring relay is designed for the detection of, for
example earth faults in the DC circuit of the static converter sets,
especially those used for starting turbo alternator units.
12. SOLID STATE OVEREXCITATION PROTECTION: The over
excitation protection is used to measure the quotient voltage/
frequency which is proportional to the induction B ~ U/f .This
permits the detection of impermissible over excitation conditions
which can partially endanger transformers.
13. REVERSE POWER PROTECTION: This is used to protect the
turbine generator units on failure if energy to the prime mover
which causes the synchronous generator to run as a motor and
drive the turbine whereby the driving power is drawn
From the power system. The single phase reverse protection
senses the reverse power and outputs a tripping signal with a
long time delay.
14. SOLID STATE FREQUENCY PROTECTION: Frequency relays
are used for decoupling networks or for load shedding if there is a
threat that the network might collapse due to an impermissible
drop in frequency.
15. SOLID STATE DEFINITE TIME OVERCURRENT PROT: Definite
time over current protection is applied as a short circuit
protection in high voltage systems with in feed at a single point.
It is also used as a back up for comparison protection such as
line, transformer, generator and bus bar differential protection.
16. IMPEDENCE PROTECTION FOR THE MACHINES: Used as a
selective time graded protection to provide shortest possible
tripping rimes for short circuit in the asynchronous machines on
the terminal leads as well as in the lower voltage winding of the
machine transformer

DG SET
The use of a DG set is to providing startup power during a power
black out resulting in the shutdown of the whole plant.
Black start Diesel Generator is capable of supplying startup power
for one Gas Turbine. DG Set is always kept in pre-lubricated
condition. At any time through pre Lubricated Pump on failure of
supply this Pump stops. DG start with air motor. Prior to start of air
motor air operated Lubricating Oil Pump starts & ensure proper
lubrication to all bearings. DG Set takes 15 seconds from initiations
of start signal. Gas Turbine takes 6 minutes for synchronization
from start command of Gas Turbine.

ABOUT STATION TRANSFORMERS, UAT AND GERNERATOR

CB
The electrical system at the Dadri Gas Power station has no
provision for a station transformer (to convert 220KV/6.6KV).
Instead the generator circuit breakers and the unit auxiliary
transformers take its job. The UAT is with every GT and generator
circuit breaker for each of the STs.

UNIT AUXILLARY TRANSFORMER

Placed in parallel to each of the GTs, this transformer does the
lowering of the voltage from the generated 10.5KV to 6.6KV that
can be used for the operation of the plant. This provision of a more
bulky and expensive station transformer with the small sized 16
MVA auxiliary transformers.

GENERATOR CIRCUIT BREAKER

SF6 circuit breaker having rated capacity of 10,000 A has been
installed between bus duct and generator transformer. During start
up the generator circuit breaker remains open and aux. power is
supplied by back feeding from the generator transformer. When
generator is synchronized and loaded part of its power supplied to
UAT and rest goes to grid. This breaker has eliminated need of a
separate station transformer and additional benefit achieved from
increased flexibility and the reduction of voltage and surge problem
on auxiliary drives of the gas turbine which would have been
subjected to frequent change over of supply from station to unit and
unit to station supply for each start and trips.

STATIC FREQUENCY CONVERTER (SFC)

A gas turbine generator is not self starting machine i.e. It can not
accelerate to rated speed from standstill/from turning gear speed;
by its own energy (combustion and force of hot gases). Separate
power is required for startup. For this a static frequency converter is
installed. Generator is run as motor which accelerate. Coupled gas
turbine from turning speed. At 480 RPM ignition takes place and at
600 RPM combustion in combustion chamber starts. The whole
mass accelerated upto 2100 RPM with SFC and turbine power. At
this speed SFC switched off. At this speed turbine accelerate with its
own power achieved through flew gases and reaches to rated speed
of 3000 RPM. At 2900 RPM excitation breaker switched on and
generation of power takes place after getting synchronized to grid.

SFC MAIN COMPONENTS

1. Mains Converter.
2. Inductive coil for DC smoothening.
3. Motor Converter (Inverter)
4. Isolators
5. Control circuit and protection as (LOGISTAT) is the control system
in “PC” (Programmable Control Techniques) used for SFC &
excitation system.

ADVANTAGES OF SFC GENERATORS

Gas turbines are designed for Black start hence starting GT via SFC
has a high degree of availability. As in starting for SFC power is
increased from zero to required value of 2840 KVA with practically
small rate of rise where as if it is started from external electric
motor it needs to have starting power six times the rated value
which means we have to install DG set of higher capacity. Where as
starting with SFC we need DG set of 2600 KVA with overload
capacity of 2840 KVA for few minutes

THE SWITCHYARD
The switchyard consists of an arrangement of circuit breakers,
isolators, current transformers, capacitive voltage transformers,
lightning arrestors, bus bar arrangement and bay arrangements.
The 220KV gas switchyard has the following equipment:

1. Circuit breaker type SF6 10 nos

2. Isolator without earth switch staggered type 1600A 5
nos
3. Isolator with two earth switch 1250 A 6 nos
4. Isolator with two earth switch 2500A 2 nos
5. Isolator without earth switch staggered type 1250A 12 nos
6. Isolator with one earth switch 1600A 3 nos
7. Isolator with two earth switch 1600A 3 nos
8. Isolator with one earth switch 1250A 6 nos
9. Current transformer 27 nos
10. Capacitor voltage transformer 6 nos
11. Post insulators 74 nos
12. Current transformer with extended current 150% 3 nos
13. Lighting Arrestors 18 nos

MINIMUM CLEARANCE FOR 245 KV

1. Phase to Phase 2700
2. Phase to Earth 2300
3. Ground clearance 5500
4. Section clearance 5000
5. To the nearest part not on earth 2500

245KV SF6 CIRCUIT BREAKER

The breakers in the 220KV switch yard are 245KV rated BHEL made
breakers. The rated short circuit current is 40KA for duration of 3
seconds. The normal current being 2000A. SF6 gas is very effective
in arc extinguishing as it is 5 times heavier than air and has
approximately twice the dielectric strength. The circuit breaker is
completely sealed and operates as a closed system thereby no
flame is released during operation and the noise level is
considerably reduced.

ISOLATORS
The isolators are used to remove the excess voltage remaining on
the bus and bays after the operating of a circuit breaker. The type is
rotating centre post type. The following interlocks are provided with
the isolator:
1. Isolator cannot operate unless the breaker is open
2. Bus 1 and 2 cannot operate simultaneously
3. This interlock can be bypassed in the event of closing of bus
coupler breaker.
4. No isolator can operate when the corresponding earth switch is
open.
5. Only one bay can be taken on the bypass bus.
The isolators are 245KV rated with control unit of 220V DC, The
rated current is 1250A.

CURRENT TRANSFORMER
The current transformer is placed for measuring current and for
differential protection of the transformers. They have highest
system temperature of 945 with rated primary current of 1600A.
The extended thermal current ratings of the CTs are 2400A, and
insulation level of 460/1050.

CAPACITIVE VOLATAGE TRANSFORMER

These are used for the voltage and capacitance measurement. They
have highest system voltage of245KV, and rated insulation level of
245/460/1050 KV. The HV capacitance (C1) is 4840 pf and sec cap
of 48400 pf. The rated voltage is 220/53KV and total thermal
burden of 1000VA.

LIGHTENING ARRESTORS
Lightening Arrestors are a protection against surge and in case of
lightening strikes. They provide much needed protection against
surges to transformers and other equipment. The type of LA is ZnO
type. It consists of 3 enclosures of ZnO each capable of bearing a
voltage of 73KV. In case of higher voltages in the line, are allowed
to pass through the LA into the ground. LA consists of a strike
counter and an ammeter to measure normal conditions.
INFRARED THERMOGRAPHY
It is a technique for producing an image of invisible (to our eyes)
infrared light emitted by objects due to their thermal condition.
Thermography cameras can actually measure the temperatures of
an object and produce images that make interpretation of thermal
patterns easier.

ELECTRONICS INVOLVED IN THE CAMERA

The electronics contains circuit to process, digitize and reformat the
IR signal to color or black and white images in the view finder. A
microprocessor performs internal calibration as camera
temperature changes, as lenses are installed or control settings are
altered. The microprocessor also accesses each picture element
and then calculates temperature, using tables corresponding to the
combination of optical filters and lens in use.

METHOD OF MAINTENANCE
All the points which are generating hot spots (ie high temperature)
or dangerous temperature zones are taken for maintenance
depending upon availability of permit to work. If the point is in
danger zone immediately shutdown is taken for repair. If the
temperature of the equipment are not too much then periodically
check the temperature of that particular point and if it remains in
safe region then this point is attended in the next coming shutdown,
mean while the required materials are arranged.

COOLING PROCESS (STIRLING CYCLE)

High performance detector systems such as one here require
cooling to cryogenic temperatures for peak performance. Typically
these detectors are cooled to liquid nitrogen temperatures (77K,
-196 C). The sterling cycle cooling engine is fundamentally a
compression- expansion refrigerator with no valves, instead , it
incorporates a regenerator is a tube of porous material that has low
thermal conductivity to maintain a temperature gradient and high
heat capacity to act as an efficient heat exchanger. The process
involves:
STEP 1: ISOTHERMAL EXPANSION
STEP 2: CONSTANT VOLUME GAS TRANSFER
STEP 3: ISOTHERMAL EXPANSION
STEP 4: CONSTANT VOLUME GAS TRANSFER
HVDC TRANSMISSION
HVDC Transmission is a low loss mode of transmission used to
transmit power at very high voltages of +/-500KV.A HVDC line runs
from Rihand to Dadri with capacity of 1500MW. The transmission
loss is about 3% as compared to 8% in AC transmission. Another
advantage of HVDC is that it can be used to transmit power both
ways. The conversion from DC/AC is done by using 12 step
Thyristors. The power transfer can be changed by changing the
firing angle which is another advantage of HVDC. An inverter is
stationed at Dadri which can be used as a converter as well. The
power after conversion to AC is transmitted from the combined
switchyard which is the largest in Asia having a capacity of
4500MW. There are 4 HVDC lines in India; all are maintained by the
Power Grid Corporation of India.

HVDC LINE DATA

1. Line length 815 kms
2. No. of towers 2142
3. Conductor per pole 4
4. Area 725mm2
5. Line to line clearance 12.75 m
6. Line to ground clearance 12.50 m TERMINAL DATA
1. Rating 2*750MW, +/- 500KV
2. Overload rating 1650MW (low ambient or 2 hour
o/l)
3. Short time overload 1000MW per pole (5 sec)
4. Thyristor values 6.5KV, 1568A, Water cooled
5. Converter transformer 1phase, 3 wdg, 305 MVA
6. AC filters 3*230MVAR
7. DC filters 2*(12th, HP24)