Ind. Training Report - NTPC DADRI

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JUNE - JULY
2010
Industrial Training Report
SUBMITTED BY:
ABHINAV SRIVASTAV
ELECTRICAL (FINAL YEAR)
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ACKOWLEDGEMET
INDUSTRIAL TRAINING
REPORT
ON
‘ NTPC DADRI’
THERMAL POWER PLANT
National Thermal Power Corporation

Limited
National Capital Power Station - Dadri
P.O. Vidyut Nagar, District Gautam Budh
Nagar
- 201 008 (UP)
“NTPC was set up in the central sector in

the 1975.Only PSU to achieve excellent
rating in respect of MOU targets signed
with Govt. of India each year. NTPC Dadri
station has also bagged ISO 14001
certification.
Today NTPC contributes more than 3 / 5th
INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV
of
Emailthe total power generation in India.”
Id- [email protected]
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I am highly grateful to the Mr. Sunil Kumar,

HOD EE, IEC College of Engineering &
Technology Gr. Noida, for providing this
opportunity to carry out the four weeks
industrial training at NATIONAL THERMAL
POWER CORPORATION, DADRI
I express my sincere gratitude towards
NATIONAL THERMAL POWER CORPORATION,
DADRI for giving me an opportunity to
undergo my summer training for 4 weeks. I
also thanks to all the technicians, staffs for
explaining all the practical aspects involved
during my training.
As I completed my training want to thanks my
faculties, Mr. Dinesh Dayal Sir, Mr. Mashood
Hasan Sir, who were directly and indirectly
involved in imparting me the various practical
knowledge of the instruments installed at
various locations in industries.
Abh
inav Srivastav

Email Id- [email protected]
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Overview of NTPC
NTPC was set up in the central sector in the 1975 in response to widening
demand & supply gap with the main objective of planning, promoting &
organizing an integrated development to thermal power in India. Ever since
its inception, NTPC has never looked back and the corporation is treading
steps of success one after the other. The only PSU to have achieved

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excellent rating in respect of MOU targets signed with Govt. of India each
year. NTPC is poised to become a 40,000 MW gint corporation by the end
of XI plan i.e. 2012 AD. Lighting up one fourth of the nation, NTPC has an
installed capacity of 19,291 MW from its commitment to provide quality
power; all the operating stations of NTPC located in the National Capital
Region & western have acquired ISO 9002 certification. The service groups
like Engineering, Contracts, materials and operation Services have also
bagged the ISO 9001 certification. NTPC Dadri, Ramagundam,
Vindhyachal and Korba station have also bagged ISO 14001
certification.Today NTPC contributes more than 3 / 5th of the total power
generation in India.
NTPC Limited is the largest thermal power generating company of

India. A public sector company, it was incorporated in the year 1975
to accelerate power development in the country as a wholly owned
company of the Government of India. NTPC ranked 317th in the ‘2009,
Forbes Global 2000’ ranking of the world’s biggest companies. Within
a span of 34 years , NTPC has emerged as a truly national power
company, with power generating facilities in all the major regions of
the country. With a current generating Capacity of 30,644 MW, NTPC
has embarked on plans to become a 75,000 MW company by 2017.
Apart from power generation from coal and gas, it has also diversified
into hydro power, coal mining, power equipment manufacturing, oil
and gas exploration, consultancy in the area of power plant
constructions and power generation, power trading and distribution
in the form of joint ventures with various other entities in India and
abroad.

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Fig.1 Major thermal power plants of India

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ROJECT PROFILE OF NTPC -

Coal based power stations
Coal based State Commissioned
Capacity (MW)
1 Singraulli Uttar pradesh 2,000

2 Korba chattisgarh 2,100
3 Ramagundam Andhra pradesh 2,600
4 Farakka West bengal 1,600
5 Vindhyachal Madhya pradesh 3,260
6 Rihand Uttar pradesh 2,000
7 Kahalgaon Bihar 1,840
8 Ntcpp Uttar pradesh 840
9 Talcher kaniha Orissa 3,000
10 Unchahar Uttar pradesh 1,050
11 Talcher thermal Orissa 460
12 Simhadri Andhra pradesh 1,000
13 Tanda Uttar pradesh 440
14 Badarpur Delhi 705
15 Sipat chattisgarh 500
Total(coal) 23,395

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Gas / liquid fuel based power station -

Gas based State Commissioned
Capacity(MW)
16 Anta rajasthan 413
17 Auraiya Uttar pradesh 652
18 Kawas Gujarat 645
19 Dadri Uttar pradesh 817
20 Jhanor-gandhar Gujarat 648
21 Rajiv Gandhi ccpp kayamkulam Kerala 350
22 Faridabad haryana 430

Total (gas) 3,955
Power plant with joint ventures-
Commissioned
Coal State Fuel Capacity(MW)
23 Durgapur West Bengal Coal 120

24 Rourkela Orissa Coal 120
25 Bhilia Chhittisgarh Coal 324
26 rgppl Maharasta Naptha /lng 1480
Total (jv) 2044
Grand total (Coal +gas +jv) 29,394
Project under implementation-

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Coal /hydro State fuel Additional cap.under

implementation(MW)
1 Kahalgaon Bihar Coal 500

2 Sipat Chattisgarh Coal 1,980
500
3 Barh Bihar Coal 1980

4 Bhilia Chattisgarh Coal 500
5 Korba Chattisgarh Coal 500
6 Farakka West Bengal Coal 500
7 Nctpp Uttar pradesh Coal 980
8 Simhadri Andra Pradesh Coal 1,000
9 i.g(tneb) Hrayana Coal 1,500
10 Vallur Tamilnadu Coal 1,000
11 Nabinagar Bihar Coal 1,000
12 Bongaigaon Assam Coal 750
13 Koldam Himachal hydro 800
Pradesh
14 Hepp uttarakhand hydro 600

15 Hepp uttarakhand hydro 520
Total (coal+hydro) 14,610
Station At Glance

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NTPC dadri is model project of NTPC . also it tit the best project of NTPC
also known as NCPS ( National capital power station ). Situated 60 kms
away from Delhi in the District of gautam budh Nagar, Uttar Pradesh. The
station has an installed capacity of 1669 MW of power – 840 MW from
Coal based units and 829 MW Gas Based Station . the station is excelling
in performance ever since it’s commercial operation . consistently in
receipts of meritorious projectivity awards, the coal based units of the
station stood first in the country in terms of PLF for the financial year
1999 – 2000 by generating an all time national high PLF of 96.12 % with
the most modern O & M Practices. NTPC – Dadri is committed to
generated clean and green Power. The Station also houses the first HVDC
station of the country (GEP project) in association with centre for power
efficiency and Environment protection (CENEEP) – NTPC & USAUID. The
station has bagged ISO 14001 & ISO 9002 certification during the financial
year 1999 – 2000, certified by Agency of International repute M/s DNV
Netherlands M/s DNV Germany respectively
DADRI THERMAL POWER STATION
The National Capital Power Station [NCPS] has the distinction of being the
country's only three in one project ; consisting of Stage-I 840 MW; Stage-II
490MW ( and 490 MW under construction) of coal based units , 829 MW
gas based modules , and a 1,500 MW H.V.D.C. converter station {under
the operational control of P.G.C.I.L. since October '93}. The stage-II
(490MW*2) coal based units are scheduled in 2010 to meet the common
wealth games power requirement. The commercial operation of Stage-II
Unit-V 490 MW has been declared w.e.f 31.01.2010. Also work for Stage-II
UNIT-VI 490MW is under full swings. Besides the station has the largest
switchyard in the country with a power handling capacity of 4,500 MW

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The station has the unique distinction of having Asia's first 100 percent dry
ash extraction with transit ash storage silos and final storage place
converted to an green ash mound . An Ash Technology park has also been
set up to demonstrate the uses of ash which has become the point of
attraction for the visitors.
Plant size-
Stage -1
Unit 1 210mw
Unit 2 210mw
Unit 3 210mw
Unit4 210mw
Stage-2
Unit 5 490mw
Unit 6 (under construction) 490mw
LOCATION-
The station's capacity allocation is mainly concentrated in northern region
of India . Spread over 2,465 acres , the station is situated on the Dadri
-Dhaulana road [10 kms. off Dadri G.T. road , and 12 kms. off the National
Highway # 24] . The route from New Delhi to NCPS is 60 kms. long and is
about 25 kms. from Ghaziabad
NTPC DADRI
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National Capital Power Station - Coal

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The coal-based station mainly meets power requirements of the National

Capital Region [NCR] , and the northern grid . With the World Bank funding
component , the capital cost of the units is Rs. 16.69 billion . There are four
210 MW coal based units. The units have a coal-fired boiler and a steam
turbine each . The boiler design is also suitable for 100% operations with
heavy furnace oil firing . For this , three storage tanks , each of capacity
15,000 kL , enough for 10 days continuous oil firing requirements have
been provided for the boilers .
Coal Source:
The coal is transported from the Piparwar block of mines of the North
Karanpura Coalfields of Bihar , over a distance of about 1,200 kms. , by the
Indian Railways bottom discharge , and Box 'N' type of wagons . The coal
requirements for the four units is 15,000 M.T. each day , 3.67 million
tonnes annually . The station has its' own 14 kms. Long rail track
from the Dadri Railway Station , to the site , and a 6 km in-plant
track , on electric traction.
National Capital Power Station - Gas

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The gas-based station at N.C.P.S. is the country's largest . It has two

modules; each module consists of two gas turbines of 130.19 MW each
with one waste heat recovery boiler and one steam turbine of 154.51 MW
capacity . The power from this plant is allocated to Uttar Pradesh , and also
to Delhi , Punjab , Jammu and Kashmir , Haryana , Himachal Pradesh and
Rajasthan . The cost of gas based modules is Rs. 9.75 billion , which
includes a German K.f. W. funding . The modules are fully commissioned .
Gas turbines generate power at an efficiency of about 32% only , and to
utilize the rest of this energy , a combined cycle system is adopted . The
waste heat from the gas turbine exhaust is routed through the waste heat
recovery boiler , and the steam thus generated is utilized in a conventional
steam turbine to generate additional power . By this , the overall efficiency
of fuel heat utilization reaches to about 48% .
Gas Source:
The source of fuel for this plant is the reserves of South Bassein fields in
South Tapi and mid Tapi delta in the Arabian Sea . The natural gas from
South Bassein off shore fields is transported through a submarine pipeline
to Hazira onshore terminal and then through the 1,700 kms. Long Hazira-
Bijapur pipeline via Shahjanpur and Babrala , to the project . For the 829
MW project , the requirement is 3.00 million cubic meters per day (yearly
average). It would be worthwhile to note that within a short span of less
than 7 years , both the coal and gas based power cycle units/modules have
been commissioned in a project . Both the projects have diverse modern
technologies , with the latest process controls .
HVDC

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This is a technological accomplishment in power by NTPC . Commissioned

in December '90 , the system is the first commercial long distance HVDC
link in India , and also the largest in Asia . The basic objective of the HVDC
link is to transmit the power generated at the RhSTPP efficiently to the
northern region , with significant reduction in transmission losses . It
consists of two converter stations - one located at Rihand (RhSTPP) acting
as a rectifier , and the other at Vidyutnagar (NCPP) as an inverter ,
involving a distance of about 900 kms. . These stations are connected by a
+/- 500 kV HVDC line for transmission of 1,500 MW power from Rihand to
Vidyutnagar .
DETAILS OF 220KV AND 400KV FEEDERS SOURCES

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Sl.No. Line Name Capacity Remarks
1. Generator - 1 210 MW
Thermal Plant
Gas Plant
9. Generator – 5 (Steam) 146.5 MW
10. Generator – 6 (Steam) 146.5 MW
11. HVDC Feeder 1500 MW HVDC

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TRANSMISSION LINES
Sl.No. Line Name Capacity States
1. Panipat - 1 500MW Haryana
2. Panipat - 2 600MW
3. Murad Nagar 500MW Utter Pradesh
4. Maler Kotla 500MW Puniab
5. Mandola - 1 750MW Delhi
6. Mandola - 2 750MW
7. Greator Noida 750MW Utter Pradesh

Delhi
8. Maharani Bagh 750MW

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THERMAL POWER PLANT

A thermal power station consists of all the equipments and a
subsystem required to produce electricity by using a steam
generating boiler fired with fossil fuels or befouls to drive an
electric generator. Some prefer to use the term ENERGY CENTER
because such facilities convert form of energy like nuclear
energy, gravitational potential energy or heat energy (derived
from the combustion of fuel) into electrical energy. Typical
diagram of a coal power thermal power station-
1. Cooling water pump

2. Three phase transmission line
3. Step up transformer
4. Electrical generator
5. Low pressure steam
6. Boiler feed water pump
7. Surface condenser
8. Intermediate pressure steam turbine
9. Steam control valve
10. High pressure steam turbine
11. Deaerator feed water heater
12. Coal conveyer
13. Coal hopper
14. Coal pulverizer
15. Boiler steam drum
16. Boiler ash hopper
17. Super heater
18. Force draught (draft) fan
19. Reheater
20. Combustion air intake
21. Economiser
22. Airpreheater
23. Precipitator
24. Induced draught(draft) fan
25. Fuel gas stack

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The description of some of the components above is as follows:
1.Cooling towers-
Cooling towers are eveporative coolers used for cooling water.
Cooling tower use evaporation of water to reject heat from
processes such as cooling the circulaing water used in oil
refineries, chemical plants, power plants, etc. The tower vary in
size from small roof – top units to very large hyperboloid
structures that can be upto 200 meters tall and 100 meters in
diameter, or rectangular structure that can be over 40 meters tall
and 80 meters long. Smaller towers are normally factory built
while larger ones are constructed on site. The primary use of
large, industrial cooling tower system is to remove the heat
absorbed in the circulating water system used in power plants,
petroleum refineries, petrochemical and chemical plants, natural
gas processing plants and other industrial facilities.
The absorbed heat is rejected to the atmosphere by the

evaporation of some of the cooling water in mechanical forced –
draft or induced draft towers or in natural draft hyperbolic shaped
cooling towers as seen at most nuclear power plants.
2.Three phase transmission line-

Three phase electric power is a common method of electric power
transmission. It is a type of polyphase system mainly used for
power motors and many other devices. In a three phase system,
three circuits reach their instantaneous peak values at different
times. Taking one conductor as reference, the other two
conductor are delayed in time by one-third and two-third of cycle
of the electrical current. This delay between phases has the effect
of giving constant power over each cycle of the current and also
makes it impossible to produce a rotating magnetic field in an
electric motor. At the power station, an electric generator

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converts mechanical power into a set of electric currents one

from each electromagnetic coil or winding of the generator. The
currents are sinusoidal functions of time, all at the same
frequency but offset in time to give different phases. In a three
phase system, the phases are spaced equally giving a phase
separation of one-third of one cycle. Generators output at a
voltage that ranges from hundreds of volts to 30,000 volts. At the
power station. Transformers step-up this voltage for suitable
transmission. After numerous further conversions in the
transmission and distribution network, the power is finally
transformed to standard mains voltage i.e. the household voltage.
The power may already have been split into single phase at this
point or it may be still three phase. Where the step-down is three
phase. The output of the transformer is usually star connected
with the standard mains voltage being the phase neutral voltage.
3.Electrical generator-
An electrical generator is a device that coverts mechanical energy
to electrical energy, using electromagnetic induction whereas
electrical energy is converted to mechanical energy with the help
of electric motor. The source of mechanical energy may be a
reciprocating turbine steam engine. Turbines are made in variety
of sizes ranging from small 1 hp(0.75 kW) used as mechanical
drives for pumps, compressors and other shaft driven equipment
to 2,000,000 hp(1,500,000 kW) turbines used to generate
electricity.
4.Boiler Feed Pump-

A Boiler Feed Pump is a specific type of pump used to pump water
into steam boiler. These pumps are normally high pressure units
that use suction from a condensate return system and can be of

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centrifugal pump type or positive displacement type. Construction

and Operation feed water pumps range in size upto many
horsepower and the electric motor is usually separated from the
pump body by some form of mechanical coupling. Large industrial
condensate pumps may also serve as the feed water pump. In
either case, to force water into the boiler, the pump must
generate sufficient pressure to overcome the steam pressure
developed by the boiler. This is usually accomplished through the
use of centrifugal pump.
5.Control valves-
Control Valves are the valves used within industrial plants and
elsewhere to control operating conditions such as temperature,
pressure, flow and liquid level by fully or partially opening or
closing in response to signals received from controllers that
compares a “set point” to a “process variable” whose value is
provided by sensors that monitor changes in such conditions. The
opening or closing of control valves is done by means of
electrical, hydraulic or pneumatic systems.
6.Deaerator-
A Deaerator is a device for air removal and used to remove
dissolved gases from boiler feed water to make it non-corrosive.
7.Feed Water Heater-

A feed water heater is a power plant component used to pre heat
water delivered to a steam generating boiler. Feed water heater
improves the efficiency of the system. This reduces plant
operating costs and also helps to avoid thermal shock to boiler
metal when the feed water is introduced back into the steam
cycle. Feed water heaters allow the feed water to be brought upto
the saturation temperature very gradually. This minimizes the
inevitable irreversibility associated with heat transfer to the

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working fluid(water). A belt conveyer consists of two pulleys, with

a continuous loop of material- the conveyer belt that rotates
around them. The pulleys are powered, moving the belt and the
material on the belt forward. Conveyer belts are extensively used
to transport industrial and agricultural material, such as grain,
coal, ores, etc.
8.Pulverizer-
A pulverizer is a device for grinding coal for combustion in a
furnace in a fossil fuel power plant.
9.Super Heater-
A Super heater is a device in a steam engine that heats the
steam generated by the boiler again increasing its thermal energy
and decreasing the likelihood that it will condense inside the
engine. Super heaters increase the efficiency of the steam
engine, and were widely adopted. Steam which has been
superheated is logically known as superheated steam; non-
superheated steam is called saturated steam or wet steam; Super
heaters were applied to steam locomotives in quantity from the
early 20th century, to most steam vehicles, and so stationary
steam engines including power stations.
10.Economizers-
Economizer, or in the UK economizer, are mechanical devices
intended to reduce energy consumption, or to perform another
useful function like preheating a fluid. The term economizer is
used for other purposes as well. Boiler, power plant, and heating,
ventilating and air conditioning. In boilers, economizer are heat
exchange devices that heat fluids , usually water, up to but not
normally beyond the boiling point of the fluid. Economizers are so
named because they can make use of the enthalpy and improving
the boiler’s efficiency. They are a device fitted to a boiler which

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saves energy by using the exhaust gases from the boiler to

preheat the cold water used the fill it (the feed water). Modern
day boilers, such as those in cold fired power stations, are still
fitted with economizer which is decedents of Green’s original
design. In this context they are turbines before it is pumped to
the boilers. A common application of economizer is steam power
plants is to capture the waste hit from boiler stack gases (flue
gas) and transfer thus it to the boiler feed water thus lowering the
needed energy input , in turn reducing the firing rates to
accomplish the rated boiler output . Economizer lower stack
temperatures which may cause condensation of acidic
combustion gases and serious equipment corrosion damage if
care is not taken in their design and material selection.
10.Air Preheater-
Air preheater is a general term to describe any device designed to
heat air before another process (for example, combustion in a
boiler). The purpose of the air preheater is to recover the heat
from the boiler flue gas which increases the thermal efficiency of
the boiler by reducing the useful heat lost in the fuel gas. As a
consequence, the flue gases are also sent to the flue gas stack (or
chimney) at a lower temperature allowing simplified design of the
ducting and the flue gas stack. It also allows control over the
temperature of gases leaving the stack.
11.Precipitator-
An Electrostatic precipitator (ESP) or electrostatic air cleaner is a
particulate device that removes particles from a flowing gas (such
As air) using the force of an induced electrostatic charge.
Electrostatic precipitators are highly efficient filtration devices,
and can easily remove fine particulate matter such as dust and

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smoke from the air steam. ESP’s continue to be excellent devices

for control of many industrial particulate emissions, including
smoke from electricity-generating utilities (coal and oil fired), salt
cake collection from black liquor boilers in pump mills, and
catalyst collection from fluidized bed catalytic crackers from
several hundred thousand ACFM in the largest coal-fired boiler
application. The original parallel plate-Weighted wire design
(described above) has evolved as more efficient ( and robust)
discharge electrode designs were developed, today focusing on
rigid discharge electrodes to which many sharpened spikes are
attached , maximizing corona production. Transformer –rectifier
systems apply voltages of 50-100 Kilovolts at relatively high
current densities. Modern controls minimize sparking and prevent
arcing, avoiding damage to the components. Automatic rapping
systems and hopper evacuation systems remove the collected
particulate matter while on line allowing ESP’s to stay in operation
for years at a time.
13.Fuel gas stack-

A Fuel gas stack is a type of chimney, a vertical pipe, channel or
similar structure through which combustion product gases called
fuel gases are exhausted to the outside air. Fuel gases are
produced when coal, oil, natural gas, wood or any other large
combustion device. Fuel gas is usually composed of carbon
dioxide (CO2) and water vapor as well as nitrogen and excess
oxygen remaining from the intake combustion air. It also contains
a small percentage of pollutants such as particulates matter,
carbon mono oxide, nitrogen oxides and sulfur oxides. The flue
gas stacks are often quite tall, up to 400 meters (1300 feet) or
more, so as to disperse the exhaust pollutants over a greater aria
and thereby reduce the concentration of the pollutants to the

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levels required by governmental environmental policies and

regulations.
COAL HANDLING PLANT(CHP)

This departments training starts on June 16,2010 under Sir A.
K.Chakrabrati(DGM- EM).
The fuel used in the Dadri thermal power station is coal. Therefore it is
necessary to handle this fuel carefully and deliver it safely to the site of power
plant. A railway siding line is taken into the power station and coal is
delivered in the storage yard.
Major Components:
1. Wagon Tippler
Wagons from the coal yard come to the tippler and are emptied here.
The process is performed by a slip –ring motor of rating: 55 KW, 415V,
1480 RPM. This motor turns the wagon by 135 degrees and coal falls
directly on the conveyor through vibrators. Tippler has raised lower
system which enables is to switch off motor when required till is wagon
back to its original position. It is titled by weight balancing principle.
The motor lowers the hanging balancing weights, which in turn tilts the
conveyor. Estimate of the weight of the conveyor is made through
hydraulic weighing machine
2. Conveyor
Conveyors are made of rubber and more with a speed of 250-300m/min.
Motors employed for conveyors has a capacity of 150 HP. Conveyors have a
capacity of carrying coal at the rate of 400 tons per hour. Few conveyors are
double belt, this is done for imp. Conveyors so that if a belt develops any
problem the process is not stalled. The conveyor belt has a switch after every
25-30 m on both sides so stop the belt in case of emergency. The conveyors are
1m wide, 3 cm thick and made of chemically treated vulcanized rubber. The

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max angular elevation of conveyor is designed such as never to exceed half of

the angle of response and comes out to be around 20 degrees. Crust coal from
raw coal bunker to mill. The quantity of raw coal fed in mill can be controlled
by speed control of aviator drive controlling damper and aviator change. 3.
Bowl Mill: - The ball mill crushes the raw coal to a certain height and then
allows Zero Speed Switch:-It is safety device for motors, i.e., if belt is not
moving and the motor is on the motor may burn. So to protect this switch
checks the speed of the belt and switches off the motor when speed is zero.
3. Metal Separators
As the belt takes coal to the crusher, No metal pieces should go along with
coal. To achieve this objective, we use metal separators. When coal is
dropped to the crusher hoots, the separator drops metal pieces ahead of
coal. It has a magnet and a belt and the belt is moving, the pieces are
thrown away. The capacity of this device is around 50 kg. The CHP is
supposed to transfer 600 tons of coal/hr, but practically only 300-400 tons
coal is transfer
4. Crusher
Both the plants use TATA crushers powered by BHEL. Motors. The
crusher is of ring type and motor ratings are 400 HP, 606 KV. Crusher is
designed to crush the pieces to 20 mm size i.e. practically considered as the
optimum size of transfer via conveyor
1.2 MILLING SYSTEM :
1.2.1 RC Bunker: -
Raw coal is fed directly to these bunkers. These are 3 in no. per boiler. 4 &
½ tons of coal are fed in 1 hr. the depth of bunkers is 10m.
1.2.2 RC Feeder: -
It transports pre it to fall down. Due to impact of ball on coal and
attraction as per the particles move over each other as well as over the
Armor lines, the coal gets crushed. Large particles are broken by impact
and full grinding is done by attraction. The Drying and grinding option
takes place simultaneously inside the mill.
1.2.3 Classifier:-

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It is an equipment which serves separation of fine pulverized coal particles

medium from coarse medium. The pulverized coal along with the carrying
medium strikes the impact plate through the lower part. Large particles
are then transferred to the ball mill.
1.2.4. Cyclone Separators: -

It separates the pulverized coal from carrying medium. The mixture of
pulverized coal vapour caters the cyclone separators.
1.2.5. Mills Fans: -

It is of 3 types: Six in all and are running condition all the time.
(a) ID Fans: - Located between electrostatic precipitator and chimney.

Type-radical Speed-1490 rpm Rating-300 KW Voltage-6.6 KV
Lubrication-by oil
(b) FD Fans: - Designed to handle secondary air for boiler. 2 in number

and provide ignition of coal. Type-axial Speed-990 rpm Rating-440 KW
Voltage-6.6 KV
(c)Primary Air Fans: - Designed for handling the atmospheric air up to 50

degrees Celsius, 2 in number And they transfer the powered coal to
burners to firing. Type-Double suction radial Rating-300 KW Voltage-6.6
KV Lubrication-by oil Type of operation-continuous
1.2.8 Bowl Mill: -

One of the most advanced designs of coal pulverizes presently
manufactured.
Motor specification –squirrel cage induction motor
Rating-340 KW
Voltage-6600KV
Current-41.7A
Speed-980 rpm
Frequency-50 Hz
No-load current-15-16 A
a) Wagon Tippler:-

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Motor Specification
(i) H.P 75 HP
(ii) Voltage 415, 3 phase
(iii) Speed 1480 rpm
(iv) Frequency 50 Hz
(v) Current rating 102 A
b) Coal feed to plant:-

Feeder motor specification
(i) Horse power 15 HP
(ii) Voltage 415V,3 phase
(iii) Speed 1480 rpm
(iv) Frequency 50 H
4. LT MOTORS :-
This departments training is dne under guidance of Sir K P Singh.
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.
4.1. 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.

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Fig 4.1 LT INDUCTION MOTOR
4.2 Heat treatment:
The stator after being wounded is given heat treatment. It kept in an electrical
furnance 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.
4.3 Ac contactor:
AC contactor are 3 pole suitable for DOL starting of motors and protecting the
connected motors. The contactor of the following motors are equipped with

P a g e | 30
special arrangements to provide immediate reclosing of the contactor when

voltage fails and reappears with 1.5 - 3 sec.
4.4 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
5. HT MOTORS
HT AC motors are normally designed for operation on 3 phase,AC supply with

normal frequency of 50Hz.
Standard nominal voltage for which motors are designed are:
VOLTAGE CAPACITY
3.3 kV 160-200 kW
6.6 kV 160-800 kW
11 kV 1000 kW and above
5.1 Insulating Materials :-
1. Sunmica
2. Effolux: it is an oil and waterproof materials.
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 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.

P a g e | 31
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 general type insulation varnish of B class used
with thinner no. 205.
5.2 HT AC MOTOR FOR THERMAL POWER APPLICATION:-
5.2.1 Boiler auxiliary :-
a) ID (induced draft) fan

b) FD (forced draft) fan
c) GR fan
d) PA (primary air)
e) Mills
5.2.2 Cooling water system :-
a) CW pumps (circulating water)
5.2.3 Turbine auxiliaries :-
b) Boiler feed pump

c) Condensate extraction pump
d) Starting oil pump
5.2.4 Ash handling system :-
a) Pumps
5.2.5 Coal handling plant :-
a) Crushers
b) Conveyors
5.3 SPECIFIC PERFORMANCE REQUIREMENTS OF MOTORS ARE :-

P a g e | 32
• High ambient temperature 50oC.

• Voltage and frequency variation should be ± 10%
• High starting/pull out torque
• Low starting current
• Voltage dip conditions/minimum permissible voltage at start
• Bus transfer condition
• Suitability to stand transients
• Long bearing life
• Low noise level
• Low vibration level
The most popular type of motor above applications is the DOL started
squirrel cage induction motors.
Fig.5.1 HT-MOTOR ROTOR Fig.5.2 HT-MOTOR STATOR

P a g e | 33
CIRCUIT BREAKER- Types of breakers operational at NTPC Dadri

Switchyard
(1) 400kV Air blast circuit breaker
(2) 220kV SF6 filled circuit breaker.
SPECIFICATION OF AIR BLAST CIRCUIT BREAKER
Type DLYF420 nc4
Normal Voltage 420KV
Normal Current 2000A
Trip coil voltage 220V dc
Close coil voltage 220V dc
Frequency 50HZ
Short time Current 40KA 3Sec.
Breaking Current Sym. 40KA
Asym. 48 KA
R I L at 50HZ 630KV
Voltage switching impulse 1050
Operating pressure 27-31 Kg
Mass 3850 Kg
Make Hindustan Brown Boveri
SPECIFICATION OF SF6 GAS CIRCUIT BREAKER

P a g e | 34
SR. NO CIRCUIT BREAKER
1. CIRCUIT BREAKER TYPE ELF SL 4-1
2. SR. NUMBER 20000070
3. Month and year of Mfg. JANUARY - 2001
4. Voltage 245 KV
5. Normal current 1600/2500 AMP.
6. Lightning impulse with stand voltage 1050 KV
7. Switching impulse with stand voltage - KV
8. Short circuit breaking current 40 KA
9. Short time with stand current & duration 40 LA 1 Sec.
10. Line charging breaking current 125 AMP.
11. Operating sequence 0-0 3S - CO – 3Min- CO
12. First - pole - to - clear factor 1.3
13. Gas pressure SF6 at 200C (abs) 7.0 bar
14. Closing & opening device supply voltage 220 V DC
15. Auxiliary circuit supply voltage 240 V AC
16. Air pressure 20.5 bar
17. Frequency 50 Hz
18. Mass (approx) for 3 poles 4000 kg
GENERATORS

P a g e | 35
Generator Fundamentals: The transformation of mechanical energy into

electrical energy is carried out by the Generator.
Working Principle:-
The A.C. Generator or alternator is based upon the principle of
electromagnetic induction and consists generally of a stationary part called
stator and a rotating part called rotor. The stator housed the armature
windings. The rotor houses the field windings. D.C. voltage is applied to the
field windings through slip rings. When the rotor is rotated, the lines of
magnetic flux (viz magnetic field) cut through the stator windings. This
induces an electromagnetic force (e.m.f.) in the stator windings. The
magnitude of this e.m.f. is given by the following expression.
E = 4.44ØFN volts
Ø = Strength of magnetic field in Weber’s.
F = Frequency in cycles per second or Hertz.
N = Number of turns in a coil of stator winding
F = Frequency = Pn/120
Where P = Number of poles,n = revolutions per second of rotor.
From the expression it is clear that for the same frequency, number of poles
increases with decrease in speed and vice versa. Therefore, low speed hydro
turbine drives generators have 14 to 20 poles where as high speed steam
turbine driven generators have generally 2 poles. Pole rotors are used in low
speed generators, because the cost advantage as well as easier construction.
Development The first A.C. Generator concept was enunciated by Michael

Faraday in 1831. In 1889 Sir Charles A. Parsons developed the first AC turbo-
generator. Although slow speed AC generators have been built for some time,

P a g e | 36
it was not long before that the high-speed generators made its impact.
Development contained until, in 1922, the increased use of solid forgings and
improved techniques permitted an increase in generator rating to 20MW at
300rpm. Up to the out break of second world war, in 1939, most large
generator;- were of the order of 30 to 50 MW at 3000 rpm. During the war,
the development and installation of power plants was delayed and in order to
catch up with the delay in plant installation, a large number of 30 MW and 60
MW at 3000 rpm units were constructed during the years immediately
following the war. The changes in design in this period were relatively small.
In any development programme the Costs of material and labour involved in
manufacturing and erection must be a basic consideration. Coupled very
closely with these considerations is the restriction is size and weight imposed
by transport limitations.
Generator component:-
This deals with the two main components of the Generator viz. Rotor
(winding & balancing) and Stator (its frame, core & windings).
Fig. GENERATOR’S ROTOR
Rotor :-

P a g e | 37
The electrical rotor is the most difficult part of the generator to design. It
revolves in most modern generators at a speed of 3,000 revolutions per
minute. The problem of guaranteeing the dynamic strength and operating
stability of such a rotor is complicated by the fact that a massive non-uniform
shaft subjected to a multiplicity of differential stresses must operate in oil
lubricated sleeve bearings supported by a structure mounted on foundations
all of which possess complex dynamic be behavior peculiar to themselves. It is
also an electromagnet and to give it the necessary magnetic strength the
windings must carry a fairly high current. The passage of the current through
the windings generates heat but the temperature must not be allowed to
become so high, otherwise difficulties will be experienced with insulation. To
keep the temperature down, the cross section of the conductor could not be
increased but this would introduce another problems. In order to make room
for the large conductors, body and this would cause mechanical weakness.
The problem is really to get the maximum amount of copper into the windings
without reducing the mechanical strength. With good design and great care in
construction this can be achieved. The rotor is a cast steel ingot, and it is
further forged and machined. Very often a hole is bored through the centre of
the rotor axially from one end of the other for inspection. Slots are then
machined for windings and ventilation.
Rotor winding:- Silver bearing copper is used for the winding with mica as
the insulation between conductors. A mechanically strong insulator such as
micanite is used for lining the slots. Later designs of windings for large rotor
incorporate combination of hollow conductors with slots or holes arranged to
provide for circulation of the cooling gas through the actual conductors.
When rotating at high speed. Centrifugal force tries to lift the windings out of
the slots and they are contained by wedges. The end rings are
secured to a turned recess in the rotor body, by shrinking or screwing and
supported at
the other end by fittings carried by the rotor body. The two ends of windings
are
connected to slip rings, usually made of forged steel, and mounted on
insulated sleeves. When completed the rotor must be tested for mechanical

P a g e | 38
balance, which means that a check is made to see if it will run up to normal
speed without vibration. To do this it would have to be uniform about its
central axis and it is most unlikely that this will be so to the degree necessary
for perfect balance. Arrangements are therefore made in aldesigns to fix
adjustable balance weights around the circumference at each end.
Stator :-
Stator frame:-
The stator is the heaviest load to be transported. The major part of this load is
the stator core. This comprises an inner frame and outer frame. The outer
frame is a rigid fabricated structure of welded steel plates, within this shell is
a fixed cage of girder built circular and axial ribs. The ribs divide the yoke in
the compartments through which hydrogen flows into radial ducts in the
stator core and circulate through the gas coolers housed in the frame. The
inner cage is usually fixed in to the yoke by an arrangement of springs to
dampen the double frequency vibrations inherent in 2 pole generators. The
end shields of hydrogen cooled generators must be strong enough to carry
shaft seals. In large generators the frame is constructed as two separate parts.
The fabricated inner cage is inserted in the outer frame after the stator core
has been constructed and the winding completed. Stator core: The stator core
is built up from a large number of 'punching" or sections of thin steel plates.
The use of cold rolled grain-oriented steel can contribute to reduction in the
weight of stator core for two main reasons:
a) There is an increase in core stacking factor with improvement in

lamination cold Rolling and in cold buildings techniques.
b) The advantage can be taken of the high magnetic permeance of grain-

oriented
steels of work the stator core at comparatively high magnetic saturation
without fear or excessive iron loss of two heavy a demand for excitation

P a g e | 39
ampere turns
from the generator rotor.
Stator Windings :-
Each stator conductor must be capable of carrying the rated current without
overheating. The insulation must be sufficient to prevent leakage currents
flowing between the phases to earth. Windings for the stator are made up
from copper strips wound with insulated tape which is impregnated with
varnish, dried under vacuum and hot pressed to form a solid insulation bar.
These bars are then place in the stator slots and held in with wedges to form
the complete winding which is connected together at each end of the core
forming the end turns. These end turns are rigidly braced and packed with
blocks of insulation material to withstand the heavy forces which might result
from a short circuit or other fault conditions. The generator terminals are
usually arranged below the stator. On recent generators (210 MW) the
windings are made up from copper tubes instead of strips through which
water is circulated for cooling purposes. The water is fed to the windings
through plastic tubes.
Generator Cooling System:-

The 200/210 MW Generator is provided with an efficient cooling system to
avoid excessive heating and consequent wear and tear of its main components
during operation. This Chapter deals with the rotor-hydrogen cooling system
and stator water cooling system along with the shaft sealing and bearing
cooling systems. Rotor Cooling System The rotor is cooled by means of gap
pick-up cooling, wherein the hydrogen gas in the air gap is sucked through the
scoops on the rotor wedges and is directed to flow along the ventilating canals
milled on the sides of the rotor coil, to the bottom of the slot where it takes a
turn and comes out on the similar canal milled on the other side of the rotor
coil to the hot zone of the rotor. Due to the rotation of the rotor, a positive

P a g e | 40
suction as well as discharge is created due to which a certain quantity of gas

flows and cools the rotor. This method of cooling gives uniform distribution of
temperature. Also, this method has an inherent advantage of eliminating the
deformation of copper due to varying temperatures.
Hydrogen Cooling System:-

Hydrogen is used as a cooling medium in large capacity generator in view of
its high heat carrying capacity and low density. But in view of its forming an
explosive mixture with oxygen, proper arrangement for filling, purging and
maintaining its purity inside the generator have to be made. Also, in order to
prevent escape of hydrogen from the generator casing, shaft sealing system is
used to provide oil sealing. The hydrogen cooling system mainly comprises of
a gas control stand, a drier, an liquid level indicator, hydrogen control panel,
gas purity measuring and indicating instruments.
The system is capable of performing the following functions :
1) Filling in and purying of hydrogen safely without bringing in contact

with air. Maintaining the gas pressure inside the machine at the desired
value at all the times.
2) Provide indication to the operator about the condition of the gas inside
the machine i.e. its pressure, temperature and purity.
3) Continuous circulation of gas inside the machine through a drier in

order to
remove any water vapour that may be present in it. Indication of liquid
level in the generator and alarm in case of high level.
Stator Cooling System :- The stator winding is cooled by distillate. Which

is fed from one end of the machine by Teflon tube and flows through the
upper bar and returns back through the lower bar of another slot? Turbo
generators require water cooling arrangement over and above the usual
hydrogen cooling arrangement. The stator winding is cooled in this system by

P a g e | 41
circulating demineralised water (DM water) through hollow conductors. The

cooling water used for cooling stator winding calls for the use of very high
quality of cooling water. For this purpose DM water of proper specific
resistance is selected. Generator is to be loaded within a very short period if
the specific resistance of the cooling DM water goes beyond certain preset
values. The system is designed to maintain a constant rate of cooling water
flow to the stator winding at a nominal inlet water temperature of 40 degC.
Rating of 210 MW Generator:-

Manufacture by Bharat heavy electrical Limited (BHEL)
Capacity - 247000 KVA
Voltage (stator) - 15750 V
Current (stator) - 9050 A
Voltage (rotor) - 310 V
Current (rotor) - 2600 V
Speed - 3000 rpm
Power factor - 0.85
Frequency - 50 Hz
Hydrogen - 3.5 Kg/cm2
Stator wdg connection - 3 phase star connection
Insulation class - B

P a g e | 42
TRANFORMERS
A transformer is a device that transfers electrical energy from one circuit
to another by magnetic coupling with out requiring relative motion
between its parts. It usually comprises two or more coupled windings, and
in most cases, a core to concentrate magnetic flux. An alternating voltage
applied to one winding creates a time-varying magnetic flux in the core,
which includes a voltage in the other windings. Varying the relative
number of turns between primary and secondary windings determines the
ratio of the input and output voltages, thus transforming the voltage by
stepping it up or down between circuits. By transforming electrical power
to a high-voltage,_low-current form and back again, the transformer
greatly reduces energy losses and so enables the economic transmission of
power over long distances. It has thus shape the electricity supply industry,
permitting generation to be located remotely from point of demand.
Fig. Power Transformer.

P a g e | 43
Basic principles:-
The principles of the transformer are illustrated by consideration of a
hypothetical ideal transformer consisting of two windings of zero resistance
around a core of negligible reluctance. A voltage applied to the primary
winding causes a current, which develops a magneto motive force (MMF) in
the core. The current required to create the MMF is termed the magnetizing
current; in the ideal transformer it is considered to be negligible, although its
presence is still required to drive flux around the magnetic circuit of the core.
An electromotive force (MMF) is induced across each winding, an effect
known as mutual inductance. In accordance with faraday’s law of induction,
the EMFs are proportional to the rate of change of flux. The primary EMF,
acting as it does in opposition to the primary voltage, is sometimes termed the
back EMF”. Energy losses An ideal transformer would have no energy losses
and would have no energy losses, and would therefore be 100% efficient.
Despite the transformer being amongst the most efficient of electrical
machines with ex the most efficient of electrical machines with experimental
models using superconducting windings achieving efficiency of 99.85%,
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 95%. A small transformer such as
plug-in “power brick” used for low-power consumer electronics may be less
than 85% efficient.
Losses:-
Transformer losses are attributable to several causes and may be
differentiated between those originated in the windings, some times termed
copper loss, and those arising from the magnetic circuit, sometimes termed
iron loss. The losses vary with load current, and may furthermore be
expressed as “no load” or “full load” loss, or at an intermediate loading.
Winding resistance dominates load losses contribute to over 99% of the no-
load loss can be significant, meaning that even an idle transformer constitutes
a drain on an electrical supply, and lending impetus to development of low-
loss transformers. Losses in the transformer arise from: Winding resistance

P a g e | 44
Current flowing trough 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 current Ferromagnetic materials are also good conductors, and a solid
core made from such a material also constitutes a single short-circuited turn
trough out its entire length. Eddy currents therefore circulate with in a 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 field between primary and
secondary windings. These incite vibration with in near by metal work,
adding to the buzzing noise, and consuming a small amount of power. Stray
losses Leakage inductance is by itself loss less, 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 material such as the
transformers support structure will give rise to eddy currents and be
converted to heat. Cooling system Large power transformers may be
equipped with cooling fans, oil pumps or water-cooler heat exchangers design
to remove heat. Power used to operate the cooling system is typically
considered part of the losses of the transformer

P a g e | 45
INTERCONNECTING TRANSFORMER (ICT)
Power transformers are the backbone of the large grid. The power is
generated at the low voltage level and has to be carried to far away load
centers. Typically the power is generated at the Pit heads i.e power source
like coal, water. It is uneconomical carry the bulk power at low voltage
levels. Depending upon the requirement the voltage level is stepped upto
the transmission level i.e 220 or 400kV. At higher voltages the transmission
losses are less. Similarly at the remote end the voltage is stepped down the
distribution level. To accomplish the task
Power transformers are installed and act as bi-directional element in the

system.
At NTPC Dadri this task is carried out by bank of Single Phase 400/220kV
Interconnecting transformers. Autotransformers are used when
transformation ratio is between 1 and 2 and above 315MVA, due to size
and weight constraints all the transformers are single phases. Three such
single phase transformers are installed three phases to make One bank of
transformer.
Three banks of transformers are installed to evacuate power from the

220kV switchyard generated by 4X 210MW thermal Units.
All these transformers are star- star connected transformers with neutral
solidly grounded. A third winding called tertiary winding at much lower
voltage i.e 33kV, is also provide and is connected in delta to facilitate the
flow of third harmonic current to reduce the distortion in the output voltage.

P a g e | 46
To reduce the overall size of the transformer, the transformer is provided

with Oil forced and Air forced type cooling at its 100% rating. However, to
save the energy, the cooling system is controlled by the temperature of the
winding. The transformers are also equipped with On Load Tap Changer to
meet the change in voltage variation. Typically the Tap changer provides
variation between ± 10% of the nominal voltage i.e. 400kV with a variation
of 0.5% at each tap.
SPECIFICATIONS
Make CROMPTON GREAVES Ltd.

No. 3
Rating 167*3 = 500 MVA
Tap 17
No load Voltage KV (HV 400/√3
side)
No load Voltage KV (IV side) 220/√3
No load Voltage KV (LV side) 33 KV
Line current Amp. (HV side) 289.25 , 433.88 , 723.13
Line current Amp. (IV side) 525.91, 788.87, 1314.78
Line current Amp. (LV side) 1688.48
Connection symbol YNaOd11 for 3 phase bank
Type of cooling ONAN / ONAF / OFAF
Frequency 50 Hz
Insulation level (HV) 1450kV
Insulation level (IV) 630kV
Insulation level (LV) 250kV
Temperature rise oil deg. c 350 above ambient
PROTECTION RELAYS

P a g e | 47
Relay is a device that detects the fault mostly in the high voltage circuits
and initiates the operation of the circuit breaker to isolate the defective
section from the rest of the circuit. Whenever fault occurs on the power
system, the relay detects that fault and closes the trip coil circuit. This
results in the opening of the circuit breaker, which disconnects the faulty
circuit. Thus the relay ensures the safety of the circuit equipment from
damage, which the fault may cause.
PURPOSE OF PROTECTIVE RELAYING
The capital investment involved in a power system for the generation,

transmission and distribution of electrical power is so great that the proper
precautions must be taken to ensure that the equipment not only operates
as nearly as possible to peak efficiency, but also that it is protected from
accidents. The normal path of the electric current is from the power source
through copper conductors in the generators, transformers and
transmission lines to the load and it is confined to this path by insulation.
The insulation however may be broken down, either by the effect of
temperature and age or by a physical accident, so that the current then
follows an abnormal path generally known as a short circuit or fault.
Whenever this occur the destructive capabilities of the enormous energy in
the power system may cause expensive damage to the equipment, severe
drop in the voltage and loss of revenue due to interruption of service. Such
faults may be made in frequent by good design of the power apparatus and
lines and the provision of protective devices, such as surge diverters and
ground fault neutralizers, but a certain number will occur inevitably due to
lightening and unforeseen accidental conditions.

P a g e | 48
The purpose of protective relays and relaying systems is to operate correct

circuit breaker so as to disconnect only the faulty equipment from the
system as quickly as possible, thus minimizing the trouble and damage
caused by faults when they do occurs. With all other equipment it is only
possible to mitigate the effects of
short circuit by disconnecting the equipment as quickly as

possible, so that the destructive effects of the energy into the
fault may be minimized.
UNDER VOLTAGE RELAY
Under voltage protection is provide for AC circuits, busbar, transformer,

motor, rectifier etc. Such protection is given by means of under voltage
relay. The relay coil is energized by voltage to be measured either directly
or via a voltage transformer.
OVER CURRENT RELAY
If a short circuit occurs the circuit impedance is reduced to a low value and
therefore a fault is accompanied by a large current, Over current protection
is that protection in which the relay pickup when the magnitude of current
exceeds the pickup level. The basic element in over current protection is an
over current relay. The over current relays are connected to the system
normally by means of CTs.
EARTH FAULT RELAY

P a g e | 49
Earth fault protection responds to single line to ground fault and double line
to ground faults. The current coil of the earth fault relay is connected either
in neutral to ground relay CT circuit. Core balance Cts are used for earth
fault protection.
DIFFERENTIAL RELAY
Differential protection responds to vector difference between two or more

similar quantities. In circulating current differential protections CTs are
connected on either side of the protected equipments. During the internal
faults the difference of secondary current flow through the relay coil.
Differential protection is used for protection of large transformer, generator,
motors feeders and busbars

P a g e | 50
DADRI SWITCHYARD:
Figure No. (5) Single line diagram for power

flow
Fig: single line diagram for power flow

P a g e | 51
BUS BAR SCHEME FOR 220KV SWITCHYARD
Transfer Bus
Main Bus#1
Main Bus#2
Bus Coupler Transfer Bus Coupler

Feeder
Figure: Double Main and transfer bus arrangement
BUS BAR SCHEME FOR 400KV SWITCHYARD

P a g e | 52
ICT Feeder
Bus#1
Bus#2
Feeder#1 Feeder#2
Figure : 400kV switchyard single line diagram

P a g e | 53
USES OF COAL ASH:

DADRI ash have been successfully used in the following
applications .
• LAND FILLS
• ROAD EMBANKMENTS
• ROAD CONSTRUCTION
• PORTLAND POZZOLONA CEMENT
• BUILDING PRODUCTS
• CONCRETE
Use of Dadri ash in above applications have resulted in saving in terms of

money , conservation of natural resources viz mother earth, lime stone,
coal, sand, energy, land and water apart from reduction in CO2 emission
and thus environment.
PRESENT SENARIO IN INDIA :

• 65% of the total installed power generation is coal
based.
• 230 - 250 million MT coal is being used every year.
• High ash contents vrying from 30 to 50%.
• 95 million MT ash generated every year.
• Ash generation likely to reach 170 million MT by 2010.
• Presently 65000 Acres of Land occupied by Ash
Ponds.
The NCPS Dadri project has the unique distinction of having Asia's
first 100 percent dry ash extraction with transit ash storage silos
and final storage place converted to an green ash mound.
Ash can be collected in following categories: -

P a g e | 54
• DRY FLY ASH:-

Dry ash is collected from different rows of electrostatic
precipitators. It is available in two different grades of
fineness in silos for use as resource material by different
users
• BOTTOM ASH:-
Bottom ash collected from bottom of boiler and transported
to hydro bins and then ash mound for use in Road
Embankment.
• CONDITIONED FLY ASH: -
Conditioned fly ash is also available in Ash mound for use in
Land fills and Ash Building prod
NTPC - A trend setter in the country has set up 100 % dry

ash extraction cum disposal in the form os Ash Mound at
NTPC Dadri .
Ash mound has come out as the most viable alternative
for ash disposal in an economic friendly way by minimum
use of land and water.

P a g e | 55

P a g e | 56
ADVANTAGES OF ASH MOUND :
• Less requirement of land only 1/3rd land requirement

as compared to wet disposal system.
• 375 acres of land is required as compared to 1000
acres for installed capacity of 840 MW at Dadri.
• Only 1/50th water required in comparison to wet
system
• Eliminates leaching effect.
• Separate storage of fly ash (PFA) and furnace bottom
ash(FBA).
• Facilitates large scale utilization at later stage.
• The green ash mound can be used as a useful piece of
land.

P a g e | 57
FEATURES OF ASH MOUND

• Ash mound covers area of 375 acres.
• Ultimate height 55 meters.
• Side slope 1:4 with haulage road at 15 m interval.
• Top most flat area 140 acres.
• Capacity of ash storage 53 million cum.
• Sufficient for running 840 MW for 40 years.
• Side slopes covered with green grass and plantations
of trees .
• Beautiful green spot in the vicinity of power house.
AUTOMATION
AUTOMATION: THE DEFINITION
The word automation is widely used today in relation to various types of

applications, such as office automation, plant or process automation.
This subsection presents the application of a control system for the automation of a
process / plant, such as a power station. In this last application, the automation
actively controls the plant during the three main phases of operation: plant start-up,
power generation in stable or put During plant start-up and shut-down, sequence
controllers as well as long range modulating controllers in or out of operation
every piece of the plant, at the correct time and in coordinated modes, taking into
account safety as well as overstressing limits.

P a g e | 58
During stable generation of power, the modulating portion of the automation

system keeps the actual generated power value within the limits of the desired load
demand.
During major load changes, the automation system automatically redefines new set
points and switches ON or OFF process pieces, to automatically bring the
individual processes in an optimally coordinated way to the new desired load
demand. This load transfer is executed according to pre- programmed adaptively
controlled load gradients and in a safe way.
AUTOMATION: THE BENEFITS
The main benefits of plant automation are to increase overall plant availability and
efficiency. The increase of these two factors is achieved through a series of
features summarized as follows:
 Optimisation of house load consumption during plant start- up, shut-down

and operation, via:
 Faster plant start-up through elimination of control errors creating delays.

 Faster sequence of control actions compared to manual ones. Figures 1
shows the sequence of a rapid restart using automation for a typical coal-
fired station. Even a well- trained operator crew would probably not be
able to bring the plant to full load in the same time without considerable
risks.
 Co-ordination of house load to the generated power output.

P a g e | 59
 Ensure and maintain plant operation, even in case of disturbances in the

control system, via:
 Coordinated ON / OFF and modulating control switchover capability

from a sub process to a redundant one.
 Prevent sub-process and process tripping chain reaction following a
process component trip.
 Reduce plant / process shutdown time for repair and maintenance as well
as repair costs, via:
 Protection of individual process components against overstress (in a

stable or unstable plant operation).
 Bringing processes in a safe stage of operation, where process
components are protected against overstress

P a g e | 60
CONCLUSION
As I have been undergoing training , I was able to
know the practical application of theory what I used
to study from books. With trainings help understood
that studies helps us to know things but practical
helps to apply theories for betterment of
Humankind . I would like to give special thanks to
the NTPC DADRI staff for their cordial support for
making the training a success.

P a g e | 61
ABHINAV SRIVASTAV
ELECTRICAL ENG. (4th YEAR)


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National Thermal Power Corporation

“NTPC was set up in the central sector in

I am highly grateful to the Mr. Sunil Kumar,

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

NTPC Limited is the largest thermal power generating company of

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

Fig.1 Major thermal power plants of India

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

ROJECT PROFILE OF NTPC -

1 Singraulli Uttar pradesh 2,000

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

Gas / liquid fuel based power station -

22 Faridabad haryana 430

Power plant with joint ventures-

23 Durgapur West Bengal Coal 120

Project under implementation-

Coal /hydro State fuel Additional cap.under

1 Kahalgaon Bihar Coal 500

3 Barh Bihar Coal 1980

14 Hepp uttarakhand hydro 600

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

DADRI THERMAL POWER STATION

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

Unit 6 (under construction) 490mw

National Capital Power Station - Coal

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

The coal-based station mainly meets power requirements of the National

National Capital Power Station - Gas

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

The gas-based station at N.C.P.S. is the country's largest . It has two

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

This is a technological accomplishment in power by NTPC . Commissioned

DETAILS OF 220KV AND 400KV FEEDERS SOURCES

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

Sl.No. Line Name Capacity Remarks

9. Generator – 5 (Steam) 146.5 MW

10. Generator – 6 (Steam) 146.5 MW

11. HVDC Feeder 1500 MW HVDC

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

Sl.No. Line Name Capacity States

1. Panipat - 1 500MW Haryana

3. Murad Nagar 500MW Utter Pradesh

4. Maler Kotla 500MW Puniab

5. Mandola - 1 750MW Delhi

7. Greator Noida 750MW Utter Pradesh

8. Maharani Bagh 750MW

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

THERMAL POWER PLANT

1. Cooling water pump

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

The description of some of the components above is as follows:

The absorbed heat is rejected to the atmosphere by the

2.Three phase transmission line-

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV

converts mechanical power into a set of electric currents one

4.Boiler Feed Pump-

INDUSTRIAL TRAINING REPORT BY ABHINAV SRIVASTAV