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PRESENTATION ON INDUSTRIAL TRAINING AT NTPC BADARPUR

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PRESENTATION ON INDUSTRIAL TRAINING Click to edit Master subtitle style AT

NTPC BADARPUR4/11/12

Table of Contents1) Brief Introduction of NTPC Badarpur 2) Operation Coal to Electricity 3) EMD I a) Offsite b) HT/LT Switchgear c) HT/LT Motors d) Coal Handling Plant (CHP/NCHP) 4) EMD II4/11/12

a) Lighting and DC Supply

NTPC Badarpur NTPC Ltd is largest power generating public sector

company in India with total installed capacity of 34,854 MW. in 1973 with 100 MW generation.

The first unit at NTPC, Badarpur came into existence Total Generating Capacity of the plant: 705 MW It consists of three units of 95 MW capacity and two

units of 210 MW capacity.

Coal comes from Jharia coal mines and Agra canal

acts as the source of water4/11/12

Units Configuration at NTPC BadarpurGT1 GT2 GT3 GT4 GT4 95 MW197374 197475 197475 197879 1981824/11/12

10.5 KV 10.5K V 10.5 KV 15.75 KV

TRANSFORME R TRANSFORME R TRANSFORME RB U S B A R 2 2 0 K V

95 MW 95 MW 210 MW 210 MW

TRANSFORME R

15.75 TRANSFORME R KV Total Capacity 705 MW

Coal to Electricity

4/11/12

1. Supply of coal 2. Pulverization 3. Steam generation in Boiler 4. Removal of fly ash in Precipitator 5. Steam rotates Turbine, Generator produces

Electricity6. Condensation and the Cooling Water System 7. Water Treatment Plant: Water Purification 8. Ash Systems 9. Substation, Transformer, Transmission Lines 4/11/12

Idealized cycle for Steam Turbines. Rankine cycle consists of 1-2 Reversible Adiabatic. Water from

Rankine Cycle

the condenser at low pressure is pumped into the boiler at high pressure. 2-5 Water is converted into steam at

constant pressure by the addition of heat in the boiler. 5-6 Reversible Adiabatic expansion of

steam in the steam turbine.

6-1 Constant pressure heat rejection in

the condenser to convert condensate into water. Thermal efficiency of Rankine cycle4/11/12

R = net work/heat supplied =

EMD I

4/11/12

OFFSITE Cooling Tower and Water Treatment PlantA Cooling Tower is a steel or concrete hyperbolic structure having a reservoir at the bottom for the storage of cool water. Warm water is lead to the top. Air flows from bottom to the top. The water drops falling from the top come in contact with air, loose their heat and get cooled. Cooling Tower Pump House (Stage I 95MW): Control panel of 12 CT fans Each fan has 90 hp motor4/11/12 3 Transformers with 1 as spare

Protection includes Relays of the following type (along with fuses of rating 250 A) : Digital Earth Fault Relay Instantaneous Under Voltage Relay Neutral Displacement Relay Overload Relay

Earthing protects the system at the start of the motor when fuse fails to operate4/11/12

Water Treatment Plant

4/11/12 A Schematic

Diagram of Water Treatment Process to

Objectives No scale formation causing resistance to passage of

heat and burning of tube

No corrosion No foaming problem

Types of Water Used in the Plant :1) Raw Water for Condenser cooling. 2) Clarified Water for cooling of the equipments. 3) Demineralized Water (DM Water) as main

medium 4/11/12

of Rankine cycle, Generator Stator

HT/LT Switchgear

4/11/12

The term Switchgear, used in association with the electric power system, or grid, refers to the combination of electrical disconnects, fuses or circuit breakers used to isolate electrical equipment. Switchgear is used both to de-energize equipment and to clear faults. Functional Classification1) Isolators (Disconnectors) and Earthing Switches 2) Fuses4/11/12

3) Circuit Breakers(CB) Oil Circuit Breakers Gas (SF6) Circuit Breakers Vacuum Circuit Breakers Air blast Circuit Breakers High voltage switchgear is any switchgear and switchgear assembly of rated voltage higher than 1000 volts for alternating current and 1500 volts for direct current.4/11/12

Control of the Circuit Breaker and Relay trip coil is

DOL StartersMCC group of starters A motor starter is an electrical/electronic circuit composed of electro-mechanical and electronic devices which are employed to start an electric motor. A DOL starter connects the motor terminals directly to the power supply. Hence, the motor is subjected to the full voltage of the power supply. Consequently, high starting current flows through the motor.4/11/12

Major Components 1. Switch 2. Fuse 3. Contactor (Electromagnetic) 4. Thermal Overload Relay (Heat & Temperature) The Direct on Line (DOL) Starter is used because for star-delta starter more number of relays, contactors etc are required for each phase.4/11/12

4/11/12

Circuit Diagram of DOL Starter

HT/LT MotorsAn electric motor uses electrical energy to produce mechanical energy. The reverse process of using mechanical energy to produce electrical energy is accomplished by a generator or dynamo. There are varieties of Motors and according to their application they are classified as High Tension and Low Tension. Most of the motors at BTPS are Induction Motor (double squirrel cage).

4/11/12

Benefits : At Starting, Rotor resistance is high but while

running it is low.

Rugged construction. Lack of brushes.

Minor damages, matching of bearing, rewinding of motors and testing is done in the workshop at the plant itself to save time as well as money in special workshops meant for this purpose.4/11/12

HT Motors at Boiler side, of Motors Rating BTPS Number MOTOR 2 2 FD Fans Motors 2 PA Fans Motors 2 Mill Fans Motors 2 Ball Mill Motors LT Motors at Boiler side, BTPSID Fans Motors Place of Use of Motors Raw Coal Feeder Pulverization Tunicate Warm Conveyer 4/11/12 Number of Motors 3 14 4 1 7.5KW/410V 3KW 2.2KW 11KW 630KW/6.6KV 440KW/6.6KV 300KW 300KW 630KW Rating

CHP/NCHPCoal is supplied to BTPS by Jharia coal fields. It is non-cooking coal and has following specifications: Moisture less than 8% Ash 25 - 35% Volatile matter 17 19% Calorific value 4500 5300 Kcal/kg The function of the CHP/NCHP is to convert the coal to usable (crushed) form from its raw form and send it to bunkers for further sending it to furnace after the impurities are removed.4/11/12

Major components of CHP/NCHPWAGON TIPPLERWagons

from coal yard come to the tipplers and are emptied here process is performed by slip-ring motor of rating

The4/11/12

Conveyer

There are 14 conveyers in the plant. They are 1m wide,3cm thick and made

of chemically treated vulcanized rubber and move with speed of 250-300m/min. capacity of 150 hp.

Motors employed for conveyers have a Have a capacity of carrying a coal at

the rate of 400 tons per hour.

Few are double belt so that if a belt

develops any problem then the process is not stalled. to stop belt in case of emergency. device for motors i.e. moving and motor is on checks the speed of switches off the motor zero.

It also has a switch after every 25-30 m ZERO SPEED SWITCH- It is a safety

4/11/12

if belt is not then the switch the belt and when speed is

Magnetic Separator It is used to separateThis process takes

Coal CrusherTo ensure that the coal

any metal pieces from the coal. place before the coal is being sent through the conveyer belt for crushing. device is around 50kg.4/11/12

is of uniform size it is passed through crusher. type.

The crusher is of ring Has a motor rating of

The capacity of this

400HP, 606KV.

It is designed to crush

the pieces to 20mm

Pulverizati on

Pulverization takes

place in two stationary rollers and a power driven boul.

Its main functions are Drying of coal Grinding Separation of particles

4/11/12

of the desired size Coal is thus pulverized to increase its surface

It becomes easy to burn wide variety of coal. Powdered coal has more heating surface area. High rates of combustion. Rate of combustion can be adjusted to meet

Advantages of Pulverization

varying loads.High temperature can be produced in the furnace.

4/11/12

Ash handling plant Coal

contains large amount of ash varying from 5% to 40% . BTPS about 5000 tons of ash is produced daily. Of this 25% is furnace bottom ash and rest is fly ash. but fly ash is acidic due to SO2 in the flue gas.

At

The bottom ash is inert4/11/12

EMD II

4/11/12

Lighting SystemFunction - to make light available in the plant every time, everywhere to enhance the visibility and thus assure for security of the employees. The Lighting System is divided into three types:1. General Lighting System (GLS) 2. Middle Boom (7m above the ground) 3. High Volt (36m above the ground)

4/11/12

Wiring of the plant can be divided into three parts:

1. Conceal Wiring found beneath the wall and

thus is not visible. of the wall.

2. Surface Wiring wiring done on the surface 3. Temporary Wiring wiring done on temporary

basis without permanent connections. Supply mainly through 24V transformer at places like inside the Boilers.

In all types of wiring Earthing plays a very 4/11/12

A metal piece, generally copper, is buried inside the Earth about 3m below for normal Earthing. A whole is dig and is then filled by mixture of charcoal and salt, water is put regularly in it to maintain the conductivity of the soil. Earthing can be done in four ways:Plate Earthing: half inch thick plate is used. Pipe Earthing: 3 inch pipe bored to 4 inch pit. Chemical Earthing Mesh Earthing: mainly used in Switchyards.4/11/12

DC Supply SystemBattery backed DC power supply is required in power plants for those critical applications which include high level of security. For Power plant application, there are two main types of Station batteries namely Lead acid and Nickel-Cadmium. The latter type has a longer life, are more robust, have higher Energy/Weight ratio. However, these are much costlier. Thus Lead acid batteries are mostly

4/11/12

The DC Supply requirement can be classified in two categories depending upon the type of load:For

emergency auxiliaries, which are not in operation while the unit is running but have to be switch on in case of AC supply failure. The requirement of DC lubricating oil, seal oil pump along with DC emergency lighting can be classified in this category.

Load in which continuous supply is required,

control and protection supply for switchgear, indication, communication system are under this category. The common used voltage levels are 4/11/12 220V for motors, control and protection schemes

Generators

4/11/12

The Generator works on the principle of electro-

magnetic induction. It has two main components, the rotor and the stator. high heat carrying capacity at low density. There is an oil sealed system to prevent mixing of Hydrogen and Oxygen. through hollow conductors.

The rotor is cooled by Hydrogen gas, which has

The Stator cooling is done by Demineralized water A Boiler and a Turbine is coupled to the Generator.4/11/12

Steam from the boiler is fed to the turbine which drives its rotor.

The class of generator under consideration is

commonly called Turbo generators. The generators particular to this category are of the two- and four-pole design employing round-rotors. Hz generators are used of capacities 210 MW and 95 MW.

At Badarpur Thermal Power Station 3000 rpm, 50

The major auxiliary systems that may be used in a

generator. 1. Lubricating Oil System 2. Hydrogen Cooling System 3. 4/11/12 Seal Oil System

The lube-oil system provides oil for all of the turbine and generator bearings as well as being the source of seal oil for the seal-oil system.Lubricating Oil System Layout

The seal prevents hydrogen in the and react

oil system the gas to leak atmosphere with water .

4/11/12

Seal oil package

Hydrogen Cooling System Hydrogen cooling gas picks up heat from the

various generator components. surface area for cooling.

Cooling tubes with fins are used to enlarge the Clarified Water is pumped through the tubes to

take the heat away from the hydrogen gas and outside the generator.4/11/12

TransformersA transformer is a static electrical device, involving no continuously moving parts, used in electric power systems to transfer power between circuits through the use of electromagnetic induction. In Badarpur Thermal Power Station, we deal with power transformer applications. The term power transformer is used to refer to those transformers used between the generators and the distribution circuits, and these are usually rated at 220 kVA and above. Power transformers are available for step-up operation, primarily used at the generator and referred to as generator step-up (GSU)transformers4/11/12

Basic parts in a transformer: Primary winding Secondary winding Core Insulation system

Heat and contamination are the two greatest enemies to the transformers operation.

4/11/12

Name plate data Serial Number : It was 6002657 for Stage III Generator

Transformer.

Class : The class will indicate the transformers cooling

requirements. KVA Rating : At Badarpur, it is 125MVA for Stage III. Voltage Rating : It is 229KV on HV side and 10.5KV on

LV side for Stage III. Temperature

Rise : The temperature rise is the allowable temperature change from ambient that the transformer can undergo without incurring damage. Temperature Rise for oil = 45 degree C and for Winding 4/11/12 = 60 degree C.

Polarity (single phase) : The polarity is important

when the transformer is to be paralleled or used in conjunction with other transformers.

Phasor Diagrams : Phasor diagrams indicate the

order in which the three phases will reach their peak voltages, and also the angular displacement (rotation) between the primary and secondary. when moving or untanking the transformer. Weight of oil = 43065 kg and of Core & winding = 101000 kg.

Weight : Knowledge of the weight is important

Insulating Fluid : The type of insulating fluid is

important 4/11/12

when additional fluid must be added or

220KV SwitchyardA Switchyard can said to be a combination of switches which are controlled from the Main Control Board. At Badarpur there is 3 Bus system out of which only two work at a time. Main components of Switchyard are : Isolators Circuit-breakers Earth switches Wave-trap Lightening Arrestor4/11/12

Isolator (current carrying capacity 1200A)q Operates under no load condition. q While opening a circuit, the circuit breaker is opened first,

then isolator, while closing a circuit isolator is closed first, then circuit breaker. order to ensure isolation of the circuit breaker from live parts for the maintenance purpose.

q Isolator are necessary on supply side of circuit breakers in

Circuit Breakerq

It is one which can break or make the circuit on load and even on faults.

q 4/11/12circuit breakers are classified according to the medium The

Wave-trapq Used to exclude unwanted frequency components,

such as noise or other interferenceq Its shape is like a drum. q It is connected to the main outgoing feeder.

Current Transformerq Step-down heavy currents (primary) to 1 or 5 A

(secondary) .

4/11/12 Potential

transformer/Capacitive

Voltage

Lightening Arresterq Simple conductive terminals

always earthed and never energized.q Used to protect power system from

lightening and switching surges. ground.

q It diverts the lightening surges to q Connected in parallel with the

equipment to be protected. oxide varistor)

q Main component is MOV (metal4/11/12

q At normal voltage MOV is a perfect

Breaking Capacity

SF6 Circuit Breaker

2000A

Merits q Super arc quenching

propertyq Short arching time q High dielectric

strength of SF6q Noiseless operation q Non-inflammable SF6 q Low maintenance cost4/11/12

Gain Enhancement in technical knowledge, Best part

was to know that even Lighting Unit is a separate important part of a Power Plant . controlled in a systematic way.

Understanding how things are managed and Improvement in personality.

4/11/12

THANK YOU

4/11/12