PROJECT / TRAINING REPORT

( PROJECT / TRAINING SEMESTER JANUARY JULY )

BTPS,NTPC BADARPUR ,NEW DELHI

A
DISSERTATION SUBMITTED TO
PANJAB UNIVERSITY, CHANDIGARH
SUBMITTED In Partial fulfillment of the
BACHELOR OF ENGINEERING (B.E)

SUBMITTED BY
ARVIND KUMAR NEGI
ROLL NO : SG 9414
UNDER THE GUIDANCE OF
Mr. JASPAL SINGH
FACULTY COORDINATOR

Mr. SONIA SINGH

INDUSTRY COORDINATOR

AP EEE DEPARTMENT

BTPS,NTPC BADARPUR

PUSSGRC HOSHIARPUR

NEW DELHI 110044

INSTITUTE: PANJAB UNIVERSITY SSG REGIONAL CENTER HOSHIARPUR

CERTIFICATE

This is to certify that the Internship Report is submitted by ARVIND

KUMAR NEGI, SG9414 in partial fulfillment of the requirements of
INTERNSHIP at NTPC Limited, BADARPUR as part of degree of
BACHELOR OF ENGINEERING in Electrical & Electronics Engineering
of PANJAB UNIVERSITY SSG REGIONAL CENTRE, HOSHIARPUR,
session 2012-2013 is a record of bonafide work carried out under our
supervision and has not be submitted anywhere else for any other
purpose.

(Signatu
re of student)
ARVIND KUMAR NEGI
3 JUNE 2013

SG-9414 , EEE 8TH SEM

Certified that the above statement made by the student is correct to

the best of our knowledge and belief.

Mr. JASPAL SINGH

FACULTY COORDINATOR

Ms. SONIA SINGH

INDUSTRY COORDINATOR

AP EEE DEPARTMENT

BTPS,NTPC BADARPUR ,

PUSSGRC HOSHIARPUR

NEW DELHI 110044

ACKNOWLEDGEMENT

It has been a great honor and privilege to undergo training at NTPC

Limited, Badarpur, Haryana, India. I

am

very

grateful

to Ms.

RACHNA SINGH BHAL (DGM HR) & Ms. SONIA SINGH (DEPUTY
MANAGER O&M) for giving their valuable time and constructive
guidance in preparing the internship report for Internship. It would
not have been possible to complete this report in short period of
time without their kind encouragement and valuable guidance.

3 JUNE, 2013

ARVIND KUMAR NEGI

B.E.-8TH Sem(EEE)
2009-13 Batch

TABLE OF CONTENT
Table of Contents
CHAPTER-1..........................................................................................................
COMPANY PROFILE..............................................................................................
VISION AND MISSION..........................................................................................
Core Values BE COMMITTED.............................................................................
POWER GENERATION IN INDIA............................................................................
EVOLUTION.........................................................................................................
STRATEGIES........................................................................................................
NTPC HEADQUARTERS........................................................................................
NTPC PLANTS......................................................................................................
FUTURE GOALS...................................................................................................
POWER BURDEN.................................................................................................
ENVIRONMENT POLICY & ENVIRONMENT MANAGEMENT SYSTEM.......................
NATIONAL ENVIRONMENT POLICY.......................................................................
NTPC ENVIRONMENT POLICY..............................................................................
ENVIRONMET MANAGEMENT, OCCUPATIONAL HEALTH and SAFETY SYSTEMS....
POLLUTION CONTROL SYSTEMS..........................................................................
UP GRADATION & RETROFITTING of POLLUTION CONTROL SYSTEMS.................
OVERALL POWER GENERATION...........................................................................
NTPC INTERNATIONAL CELL................................................................................
CHAPTER-2..........................................................................................................
ABOUT BADARPUR THERMAL POWER STATION...................................................
BADARPUR THERMAL POWER STATION...............................................................
FROM COAL TO ELECTRICITY PROCESS..............................................................
MAIN GENERATOR...............................................................................................
MAIN TURBINE DATA...........................................................................................
OPERATION.........................................................................................................
CHAPTER-3..........................................................................................................
EMD- I.................................................................................................................
4

HT/LT MOTORS TURBINE & BOILER SIDE.............................................................

COAL HANDLING PLANT (C.H.P) & NEW COAL HANDLING PLANT (N.C.H.P)........
CHAPTER-3..........................................................................................................
EMD II.................................................................................................................
Generator and Auxiliaries...................................................................................
Transformer........................................................................................................
CHAPTER-4..........................................................................................................
CONTROL AND INSTRUMENTATION.....................................................................
INTRODUCTION...................................................................................................
OBJECTIVE.........................................................................................................
MAIN OUTLINE....................................................................................................
BLOCK DIAGRAM.................................................................................................
DISCRIPTION OF BLOCK DIAGRAM......................................................................
CIRCUIT DISCRIPTION OF AUTO MODE................................................................
CIRCUIT DIAGRAM FOR SET POINT......................................................................
CIRCUIT DIAGRAM FOR VARIABLE INPUT.............................................................
I-06R MINI CARD CIRCUIT DIAGRAM....................................................................
TRIGGER CIRCUIT................................................................................................
ELECTRICAL ACTUATOR CIRCUIT.........................................................................
DEXTILE, LIMIT SWITCH AND RELAY PIN DIAGRAM.............................................
COMPONENT DISCRIPTION..................................................................................
LIMIT SWITCH......................................................................................................
RELAY.................................................................................................................
CONTACTOR RELAY.............................................................................................
7805 VOLTAGE REGULATOR IC............................................................................
2N3055 TRANSISTOR..........................................................................................
LIGHT EMITTING DIODE......................................................................................
ZENER DIODE.....................................................................................................
POTENTIOMETER................................................................................................
555 TIMER IC......................................................................................................
CAPACITOR ........................................................................................................
RESISTOR
.

SINGLE PHASE AC
MOTOR
..

CHAPTER-1
COMPANY PROFILE
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. At present, Government of India
holds 89.5% of the total equity shares of the company and FIIs,
Domestic Banks, Public and others hold the balance 10.5%. Within a
span of 31 years, NTPC has emerged as a truly national power
company, with power generating facilities in all the major regions of
the country.

VISION AND MISSION

Vision
To be the worlds largest and best power producer, powering Indias growth.
Mission
Develop and provide reliable power, related products and services at
competitive prices, integrating multiple energy sources with innovative and
eco-friendly technologies and contribute to society.

Core Values BE COMMITTED

B
E
C
O
M
M

Business Ethics
Environmentally & Economically Sustainable
Customer Focus
Organizational & Professional Pride
Mutual Respect & Trust
Motivating Self & others

I
T
T
E
D

Innovation & Speed

Total Quality for Excellence
Transparent & Respected Organization
Enterprising
Devoted

Figure 1: NTPC OPERATION GRAPH

POWER GENERATION IN INDIA

NTPCs core business is engineering, construction and operation of
power generating plants. It also provides consultancy in the area of
power plant constructions and power generation to companies in India
and abroad. As on date the installed capacity of NTPC is 27,904 MW
through its 15 coal based (22,895 MW), 7 gas based (3,955 MW) and 4
Joint Venture Projects (1,054 MW). NTPC acquired 50% equity of the
SAIL Power Supply Corporation Ltd. (SPSCL). This JV Company operates
the captive power plants of Durgapur (120 MW), Rourkela (120 MW)
and Bhilai (74 MW). NTPC also has 28.33% stake in Ratnagiri Gas &
Power Private Limited (RGPPL) a joint venture company between NTPC,
GAIL, Indian Financial Institutions and Maharashtra SEB Co Ltd.

Figure 2: TOTAL POWER GENERATION

NTPC has set new benchmarks for the power industry both in the area
of power plant construction and operations. Its providing power at the
cheapest average tariff in the country..
NTPC is committed to the environment, generating power at minimal
environmental cost and preserving the ecology in the vicinity of the
plants. NTPC has undertaken massive a forestation in the vicinity of its
plants. Plantations have increased forest area and reduced barren land.
The massive a forestation by NTPC in and around its Ramagundam
Power station (2600 MW) have contributed reducing the temperature in
the areas by about 3c. NTPC has also taken proactive steps for ash
utilization. In 1991, it set up Ash Utilization Division

A "Centre for Power Efficiency and Environment Protection (CENPEEP)"

has been established in NTPC with the assistance of United States
Agency for International Development (USAID). Cenpeep is efficiency
oriented, eco-friendly and eco-nurturing initiative - a symbol of NTPC's
concern towards environmental protection and continued commitment
to sustainable power development in India.
As a responsible corporate citizen, NTPC is making constant efforts to
improve the socio-economic status of the people affected by its
projects. Through its Rehabilitation and Resettlement programmes, the
company endeavors to improve the overall socio economic status
Project Affected Persons.
NTPC was among the first Public Sector Enterprises to enter into a
Memorandum of Understanding (MOU) with the Government in 198788. NTPC has been placed under the 'Excellent category' (the best
category) every year since the MOU system became operative.
Harmony between man and environment is the essence of healthy life
and growth. Therefore, maintenance of ecological balance and a
pristine environment has been of utmost importance to NTPC. It has
been taking various measures discussed below for mitigation of
environment pollution due to power generation.

EVOLUTION
1975

NTPC was set up in 1975 in 100% by the ownership of

Government of India. In the last 30 years NTPC has
grown into the largest power utility in India.

1997

In 1997, Government of India granted NTPC

status of Navratna being one of the nine jewels of
India, enhancing the powers to the Board of directors.

2004

NTPC

became

listed

company

with

majority

Government ownership of 89.5%. NTPC becomes

third

largest

by

market

capitalisation

of

listed

companies.

2005

The company rechristened as NTPC Limited in line

with its changing business portfolio and transforms
itself from a thermal power utility to an integrated
power utility.

National Thermal Power Corporation is the largest

2008

power generation company in India. Forbes Global

2000 for 2008 ranked it 411th the world.

2009

National Thermal Power Corporation is the largest

power generation company in India. Forbes Global
2000 for 2008 ranked it 317th in the world.

10

2012

2017

NTPC has also set up a plan to achieve a target of

50,000 MW generation capacities.

NTPC has embarked on plans to become a 75,000 MW

company by 2017.

NTPC is the largest power utility in India, accounting for about 20% of
Indias installed capacity.

STRATEGIES

Figure 3: NTPC STRATEGIES

NTPC HEADQUARTERS

NTPC Limited is divided in 8 Headquarters

S. NO.
HEADQUARTERS
1.
NCRHQ
2.
ER HEADQUARTER-1
3.
ER HEADQUARTER-2
4.
NRHQ
5.
SR HEADQUARTER
6.
WR-1 HEADQUARTER
7.
HYDRO HEADQUARTER
8.
WR-2 HEADQUARTER

CITY
DELHI
BHUBANESHWAR
PATNA
LUCKNOW
HYDERABAD
MUMBAI
DELHI
RAIPUR

11

NTPC PLANTS
1. Thermal-Coal based

S. NO.

CITY

STATE

INSTALLED

1.
2.
3.

SINGRAULI
KORBA
RAMAGUNDAM

UTTAR PRADESH
CHATTISGHAR
ANDHRA

CAPACITY(MW)
2000
2600
2600

4.
5.

FARAKKA
VINDHYACHAL

PRADESH
WEST BENGAL
MADHYA

2100
3260

6.
7.
8.
9.
10.
11.
12.

RIHAND
KAHALGAON
DADRI
TALCHER
UNCHAHAR
TALCHER
SIMHADRI

PRADESH
UTTAR PRADESH
BIHAR
UTTAR PRADESH
ORISSA
UTTAR PRADESH
ORISSA
ANDHRA

2500
2300
1820
3000
1050
460
1500

13.
14.
15.
16.
17.
18.
19.
20.
TOTAL

TANDA
BADARPUR
SIPAT
SIPAT
BONGAIGAON
MOUDA
RIHAND
BARH

PRADESH
UTTAR PRADESH
DELHI
CHHATTISGHAR
CHHATTISGHAR
ASSAM
MAHARASHTRA
UTTAR PRADESH
BIHAR

440
705
2320
1980
750
1000(2*500MW)
2*500MW
3300(5*660)
31495MW

2. COAL BASED (Owned by JVs)

S.NO.

NAME OF

CITY

STATE

THE JV
1.

NSPCL

INSTALLED
CAPACITY(M

DURGAPUR

WEST

W)
120
12

2.
3.

NSPCL
NSPCL

4.
5.
6.
TOTAL

NPGC
M.T.P.S.
BRBCL

ROURKELA
BHILAI

BENGAL
ORISSA
CHHATTISGH

AURANGABAD
KANTI
NABINAGAR

AR
BIHAR
BIHAR
BIHAR

120
574
1980
110
1000
3904MW

3. GAS Based
S.NO.

CITY

STATE

INSTALLED

1.
2.

ANTA
AURAIYA

RAJSTHAN
UTTAR

CAPACITY(MW)
419
652

3.
4.

KAWAS
DADRI

PRADESH
GUJARAT
UTTAR

645
817

JHANOR
KAYAMKULAM
FARIDABAD

PRADESH
GUJARAT
KERALA
HARYANA

5.
6.
7.
TOTAL

648
350
430
3995MW

NTPC HYDEL
The company has also stepped up its hydroelectric power (hydel)
projects implementation. Currently the company is mainly interested in
the North-east India wherein the Ministry of Power in India has
projected a hydel power feasibility of 3000 MW.

13

There are few run of the river hydro projects are under construction on
tributory of the Ganges. In which three are being made by NTPC
Limited. These are:
Loharinag Pala Hydro Power Project by NTPC Ltd: In Loharinag Pala
Hydro Power Project with a capacity of 600 MW (150 MW x 4 Units). The
main package has been awarded. The present executives' strength is
100+. The project is located on river Bhagirathi (a tributory of the
Ganges) in Uttarkashi district of Uttarakhand state. This is the first
project downstream from the origin of the Ganges at Gangotri(Project
has been discontinued by GoI).
Tapovan Vishnugad 520MW Hydro Power Project by NTPC Ltd: In
Joshimath town.#Lata Tapovan 130MW Hydro Power Project by NTPC
Ltd: is further upstream to Joshimath (under environmental revision)
Koldam Hydro Power Project 800 MW in Himachal Pradesh (130 km
from Chandigarh)Amochu in Bhutan Rupasiyabagar Khasiabara HPP,
261 MW in Pithoragarh,uttarakhand State, near China Border.

FUTURE GOALS
The company has also set a serious goal of having 50000 MW of
installed capacity by 2012 and 75000 MW by 2017. The company has
taken many steps like step-up its recruitment, reviewing feasibilities of
various sites for project implementations etc. and has been quite
successful till date. NTPC will invest about Rs 20,000 crore to set up a
3,900-megawatt (MW) coal-based power project in Madhya Pradesh.
Company will also start coal production from its captive mine in
Jharkhand in 201112, for which the company will be investing about
18 billion. ALSTOM would be a part of its 660-MW supercritical projects
for Solapur II and Mouda II in Maharashtra.ALSTOM would execute
turnkey station control and instrumentation (C&I) for this project.

14

POWER BURDEN
India, as a developing country is characterized by increase in demand
for electricity and as of moment the power plants are able to meet only
about 6075% of this demand on an yearly average. The only way to
meet the requirement completely is to achieve a rate of power capacity
addition (implementing power projects) higher than the rate of demand
addition. NTPC strives to achieve this and undoubtedly leads in sharing
this burden on the country.

ENVIRONMENT POLICY & ENVIRONMENT

MANAGEMENT SYSTEM
Driven by its commitment for sustainable growth of power, NTPC has
evolved a well defined environment management policy and sound
environment practices for minimizing environmental impact arising out
of setting up of power plants and preserving the natural ecology.

NATIONAL ENVIRONMENT POLICY

At the national level, the Ministry of Environment and Forests had
prepared a draft Environment Policy (NEP) and the Ministry of Power
along with NTPC actively participated in the deliberations of the draft
NEP. The NEP 2006 has since been approved by the Union Cabinet in
May 2006.

NTPC ENVIRONMENT POLICY

As early as in November 1995, NTPC brought out a comprehensive
document

entitled

"NTPC

Environment

Policy

and

Environment

Management System". Amongst the guiding principles adopted in the

document are company's proactive approach to environment, optimum

15

utilization of equipment, adoption of latest technologies and continual

environment

improvement.

The

policy

also

envisages

efficient

utilization of resources, thereby minimizing waste, maximizing ash

utilization and providing green belt all around the plant for maintaining
ecological balance.

ENVIRONMET MANAGEMENT, OCCUPATIONAL HEALTH

and SAFETY SYSTEMS
NTPC has actively gone for adoption of best international practices on
environment, occupational health and safety areas. The organization
has pursued the Environmental Management System (EMS) ISO 14001
and the Occupational Health and Safety Assessment System OHSAS
18001 at its different establishments. As a result of pursuing these
practices, all NTPC power stations have been certified for ISO 14001 &
OHSAS

18001

by

reputed

national

and

international

Certifying

Agencies.

POLLUTION CONTROL SYSTEMS

While deciding the appropriate technology for its projects, NTPC
integrates many environmental provisions into the plant design. In
order to ensure that NTPC comply with all the stipulated environment
norms, various state-of-the-art pollution control systems / devices as
discussed below have been installed to control air and water pollution.

Electrostatic Precipitators
The ash left behind after combustion of coal is arrested in high
efficiency Electrostatic Precipitators (ESPs) and particulate emission is

16

controlled well within the stipulated norms. The ash collected in the
ESPs is disposed to Ash Ponds in slurry form.
Flue Gas Stacks
Tall Flue Gas Stacks have been provided for wide dispersion of the
gaseous emissions (SOX, NOX etc) into the atmosphere.
Low-NOX Burners
In gas based NTPC power stations, NOx emissions are controlled by
provision of Low-NOx Burners (dry or wet type) and in coal fired
stations, by adopting best combustion practices.
Neutralization Pits
Neutralization pits have been provided in the Water Treatment Plant
(WTP) for pH correction of the effluents before discharge into Effluent
Treatment Plant (ETP) for further treatment and use.
Coal Settling Pits / Oil Settling Pits
In these Pits, coal dust and oil are removed from the effluents
emanating from the Coal Handling Plant (CHP), coal yard and Fuel Oil
Handling areas before discharge into ETP.

DE & DS Systems
Dust Extraction (DE) and Dust Suppression (DS) systems have been
installed in all coal fired power stations in NTPC to contain and extract
the fugitive dust released in the Coal Handling Plant (CHP).

Cooling Towers
Cooling Towers have been provided for cooling the hot Condenser
cooling water in closed cycle Condenser Cooling Water (CCW) Systems.
17

This helps in reduction in thermal pollution and conservation of fresh

water.
Ash Dykes & Ash Disposal systems
Ash ponds have been provided at all coal based stations except Dadri
where Dry Ash Disposal System has been provided. Ash Ponds have
been divided into lagoons and provided with garlanding arrangements
for change over of the ash slurry feed points for even filling of the pond
and for effective settlement of the ash particles.
Ash in slurry form is discharged into the lagoons where ash particles
get settled from the slurry and clear effluent water is discharged from
the ash pond. The discharged effluents conform to standards specified
by CPCB and the same is regularly monitored.
At its Dadri Power Station, NTPC has set up a unique system for dry ash
collection and disposal facility with Ash Mound formation. This has
been envisaged for the first time in Asia which has resulted in
progressive development of green belt besides far less requirement of
land and less water requirement as compared to the wet ash disposal
system.
Ash Water Recycling System
Further, in a number of NTPC stations, as a proactive measure, Ash
Water Recycling System (AWRS) has been provided. In the AWRS, the
effluent from ash pond is circulated back to the station for further ash
sluicing to the ash pond. This helps in savings of fresh water
requirements for transportation of ash from the plant.
The ash water recycling system has already been installed and is in
operation at Ramagundam, Simhadri, Rihand, Talcher Kaniha, Talcher
Thermal, Kahalgaon, Korba and Vindhyachal. The scheme has helped
stations to save huge quantity of fresh water required as make-up
water for disposal of ash.
18

Dry Ash Extraction System (DAES)

Dry ash has much higher utilization potential in ash-based products
(such as bricks, aerated autoclaved concrete blocks, concrete, Portland
pozzolana cement, etc.). DAES has been installed at Unchahar, Dadri,
Simhadri,

Ramagundam,

Singrauli,

Kahalgaon,

Farakka,

Talcher

Thermal, Korba, Vindhyachal, Talcher Kaniha and BTPS.

Liquid Waste Treatment Plants & Management System
The objective of industrial liquid effluent treatment plant (ETP) is to
discharge lesser and cleaner effluent from the power plants to meet
environmental regulations. After primary treatment at the source of
their generation, the effluents are sent to the ETP for further treatment.
The composite liquid effluent treatment plant has been designed to
treat all liquid effluents which originate within the power station e.g.
Water Treatment Plant (WTP), Condensate Polishing Unit (CPU) effluent,
Coal Handling Plant (CHP) effluent, floor washings, service water drains
etc. The scheme involves collection of various effluents and their
appropriate treatment centrally and re-circulation of the treated
effluent for various plant uses.
NTPC has implemented such systems in a number of its power stations
such as Ramagundam, Simhadri, Kayamkulam, Singrauli, Rihand,
Vindhyachal, Korba, Jhanor Gandhar, Faridabad, Farakka, Kahalgaon
and Talcher Kaniha. These plants have helped to control quality and
quantity of the effluents discharged from the stations.
Sewage Treatment Plants & Facilities
Sewage Treatment Plants (STPs) sewage treatment facilities have been
provided at all NTPC stations to take care of Sewage Effluent from Plant
and township areas. In a number of NTPC projects modern type STPs
with Clarifloculators, Mechanical Agitators, sludge drying beds, Gas
19

Collection Chambers etc have been provided to improve the effluent

quality. The effluent quality is monitored regularly and treated effluent
conforming to the prescribed limit is discharged from the station. At
several stations, treated effluents of STPs are being used for
horticulture purpose.

Environmental Institutional Set-up

Realizing the importance of protection of the environment with speedy
development of the power sector, the company has constituted
different groups at project, regional and Corporate Centre level to carry
out

specific

environment

related

functions.

The

Environment

Management Group, Ash Utilisation Group and Centre for Power

Efficiency & Environment Protection (CENPEEP) function from the
Corporate Centre and initiate measures to mitigate the impact of power
project implementation on the environment and preserve ecology in
the vicinity of the projects. Environment Management and Ash
Utilisation Groups established at each station, look after various
environmental issues of the individual station.
Environment Reviews
To maintain constant vigil on environmental compliance, Environmental
Reviews are carried out at all operating stations and remedial
measures have been taken wherever necessary. As a feedback and
follow-up of these Environmental Reviews, a number of retrofit and upgradation measures have been undertaken at different stations.
Such periodic Environmental Reviews and extensive monitoring of the
facilities carried out at all stations have helped in compliance with the

20

environmental norms and timely renewal of the Air and Water

Consents.

UP GRADATION & RETROFITTING of POLLUTION

CONTROL SYSTEMS
Waste Management
Various types of wastes such as Municipal or domestic wastes,
hazardous wastes, Bio-Medical wastes get generated in power plant
areas, plant hospital and the townships of projects. The wastes
generated are a number of solid and hazardous wastes like used oils &
waste oils, grease, lead acid batteries, other lead bearing wastes (such
as garkets etc.), oil & clarifier sludge, used resin, used photochemicals, asbestos packing, e-waste, metal scrap, C&I wastes,
electricial scrap, empty cylinders (refillable), paper, rubber products,
canteen (bio-degradable) wastes, buidling material wastes, silica gel,
glass wool, fused lamps & tubes, fire resistant fluids etc. These wastes
fall either under hazardous wastes category or non-hazardous wastes
category

as

per

classification

given

in

Government

of

Indias

notification on Hazardous Wastes (Management and Handling) Rules

1989 (as amended on 06.01.2000 & 20.05.2003). Handling and
management of these wastes in NTPC stations have been discussed
below.
Advanced / Eco-friendly Technologies
NTPC has gained expertise in operation and management of 200 MW
and 500 MW Units installed at different Stations all over the country
and is looking ahead for higher capacity Unit sizes with super critical
steam

parameters

for

higher

efficiencies

and

for

associated

environmental gains. At Sipat, higher capacity Units of size of 660 MW

and advanced Steam Generators employing super critical steam
parameters have already been implemented as a green field project.

21

Higher efficiency Combined Cycle Gas Power Plants are already under
operation at all gas-based power projects in NTPC. Advanced clean coal
technologies such as Integrated Gasification Combined Cycle (IGCC)
have higher efficiencies of the order of 45% as compared to about 38%
for conventional plants. NTPC has initiated a techno-economic study
under USDOE / USAID for setting up a commercial scale demonstration
power plant by using IGCC technology. These plants can use low-grade
coals and have higher efficiency as compared to conventional plants.
With the massive expansion of power generation, there is also growing
awareness among all concerned to keep the pollution under control and
preserve the health and quality of the natural environment in the
vicinity of the power stations. NTPC is committed to provide affordable
and sustainable power in increasingly larger quantity. NTPC is
conscious of its role in the national endeavour of mitigating energy
poverty, heralding economic prosperity and thereby contributing
towards Indias emergence as a major global economy.

OVERALL POWER GENERATION

UNIT

1997-98

2006-07

% OF

INSTALLED

MW

16,847

26,350

INCREASE
56.40

CAPACITY
GENERATION
NO. OF

MUs
NO.

97,609
23,585

1,88,674
24,375

93.29
3.34

EMPLOYEES
GENERATION/EMP

MUs

4.14

7.74

86.95

LOYEE

The table below shows the detailed operational performance of coal

based stations over the years.
Operational Performance of Coal Based NTPC Stations

22

UNIT

97-

98-

99-

00-

01-

02-

03-

04-

05-

06-

GENERAT

98
106

99
109

00
118

01
130

02
133

03
140.

04
149.

05
159.

06
170.

07
188.

ION BU
PL %

.2
75.

.5
76.

.7
80.

.1
81.

.2
81.

86
83.6

16
84.4

11
87.5

88
87.5

67
89.4

AVAILABI

20
85.

60
89.

39
90.

80
88.

10
81.

0
88.7

0
88.8

1
91.2

4
89.9

3
90.0

LITY

03

36

06

54

80

FACTOR

CHAPTER-2
ABOUT BADARPUR THERMAL POWER
STATION
Badarpur Thermal Power Station is located at Badarpur area in NCT
Delhi. The power plant is one of the coal based power plants of NTPC.
The National Power Training Institute (NPTI) for North India Region
under Ministry of Power, Government of India was established at
Badarpur in 1974, within the Badarpur Thermal power plant (BTPS)
complex.
It is situated in south east corner of Delhi on Mathura Road near
Faridabad. It was the first central sector power plant conceived in India,
in 1965. It was originally conceived to provide power to neighbouring

23

states of Haryana, Punjab, Jammu and Kashmir,U.P., Rajasthan, and

Delhi.But since year 1987 Delhi has become its sole beneficiary.

BADARPUR THERMAL POWER STATION

COUNTRY
LOCATION

INDIA
MATHURA ROAD, BADARPUR,

STATUS
COMISSION DATE
OPERATOR(S)

NEW DELHI
ACTIVE
1973
NTPC

POWER STATION INFORMATION

PRIMARY FUEL
GENERATION UNITS

COAL-FIRED
5

POWER GENERATION INFORMATION

INSTALLED CAPACITY

705.00 MW

FROM COAL TO ELECTRICITY PROCESS

Figure 4: FLOW CHART of COAL TO ELECTRICITY

24

Coal to Steam
Coal from the coal wagons is unloaded in the coal handling plant. This
Coal is transported up to the raw coal bunkers with the help of belt
conveyors. Coal is transported to Bowl mills by Coal Feeders. The
coal is pulverized in the Bowl Mill, where it is ground to powder
form. The mill consists of a round metallic table on which coal
particles fall. This table is rotated with the help of a motor. There
are three large steel rollers, which are spaced 120 apart. When
there is no coal, these rollers do not rotate but when the coal is fed
to the table it pack up between roller and the table and ths forces
the rollers to rotate. Coal is crushed by the crushing action between
the rollers and the rotating table. This crushed coal is taken away to
the furnace through coal pipes with the help of hot and cold air
mixture from P.A. Fan.
P.A. Fan takes atmospheric air, a part of which is sent to AirPreheaters for heating while a part goes directly to the mill for
temperature control. Atmospheric air from F.D. Fan is heated in the
air heaters and sent to the furnace as combustion air.
Water from the boiler feed pump passes through economizer and
reaches the boiler drum. Water from the drum passes through down
comers and goes to the bottom ring header. Water from the bottom
ring header is divided to all the four sides of the furnace. Due to heat
and density difference, the water rises up in the water wall tubes.
Water is partly converted to steam as it rises up in the furnace. This
steam and water mixture is again taken to thee boiler drum where
the steam is separated from water.

25

Figure 5: TYPICAL DIAGRAM OF COAL BASED THERMAL POWER PLANT

Water

follows

the

same

path

while

the

steam

is

sent

to

superheaters for superheating. The superheaters are located inside

the furnace and the steam is superheated (540 oC) and finally it goes
to the turbine.

Flue gases from the furnace are extracted by induced draft fan, which
maintains balance draft in the furnace (-5 to 10 mm of wcl) with
forced draft fan. These flue gases emit their heat energy to various
super heaters in the pent house and finally pass through airpreheaters and goes to electrostatic precipitators where the ash
particles are extracted. Electrostatic Precipitator consists of metal
plates, which are electrically charged. Ash particles are attracted
on to these plates, so that they do not pass through the chimney
to pollute t he atmosphere. Regular mechanical hammer blows cause
the accumulation of ash to fall to the bottom of the precipitator
where they are collected in a hopper for disposal.

26

Steam to Mechanical Power

From the boiler, a steam pipe conveys steam to the turbine through
a stop valve (which can be used to shut-off the steam in case of
emergency) and through control valves that automatically regulate
the supply of steam to the turbine. Stop valve and control valves are
located in a steam chest and a governor, driven from the main
turbine shaft, operates the control valves to regulate the amount of
steam used. (This depends upon the speed of the turbine and the
amount of electricity required from the generator).
Steam from the control valves enters the high pressure cylinder of the
turbine, where it passes through a ring of stationary blades fixed to
the cylinder wall. These act as nozzles and direct the steam into a
second ring of moving blades mounted on a disc secured to the
turbine shaft. The second ring turns the shafts as a result of the force
of steam. The stationary and moving blades together constitute a
stage of turbine and in practice many stages are necessary, so
that the cylinder contains a number of rings of stationary blades with
rings of moving blades arranged between them. The steam passes
through each stage in turn until it reaches the end of the highpressure cylinder and in its passage some of its heat energy is
changed into mechanical energy.
The steam leaving the high pressure cylinder goes back to the boiler
for reheating and returns by a further pipe to the intermediate
pressure cylinder. Here it passes through another series of stationary
and moving blades.
Finally, the steam is taken to the low-pressure cylinders, each of
which enters at the centre flowing outwards in opposite directions
through the rows of turbine blades through an arrangement called
the double flow- to the extremities of the cylinder. As the steam
gives up its heat energy to drive the turbine, its temperature and
pressure fall and it expands. Because of this expansion the blades

27

are much larger and longer towards the low pressure ends of the
turbine.
Mechanical Power to Electrical Power
As the blades of turbine rotate, the shaft of the generator, which is
coupled to tha of t he turbine, also rotates. It results in rotation of
the coil of the generator, which causes induced electricity to be
produced.

Basic Power Plant Cycle

Figure 6: COMPONENTS OF A COAL FIRED THERMAL PLANT

The thermal (steam) power plant uses a dual (vapour+ liquid) phase
cycle. It is a close cycle to enable the working fluid (water) to be
used again and again. The cycle used is Rankine Cycle modified to
include superheating of steam, regenerative feed water heating and
reheating of steam. On large turbines, it becomes economical to
increase the cycle efficiency by using reheat, which is a way of
partially overcoming temperature limitations. By returning partially
expanded steam, to a reheat, the average temperature at which the
heat is added, is increased and, by expanding this reheated steam
to the remaining stages of the turbine, the exhaust wetness is
considerably less than it would otherwise be conversely, if the

28

maximum tolerable wetness is allowed, the initial pressure of the

steam can be appreciably increased.
Bleed Steam Extraction: For regenerative system, nos. of nonregulated extractions is taken from HP, IP turbine. Regenerative
heating of the boiler feed water is widely used in modern power
plants; the effect being to increase the average temperature at which
heat is added to the cycle, thus improving the cycle efficiency.

29

On large turbines, it becomes economical to increase the cycle

efficiency by using reheat, which is a way of partially overcoming
temperature limitations. By returning partially expanded steam, to a
reheat, the average temperature at which the heat is added, is
increased and, by expanding this reheated steam to the remaining
stages of the turbine, the exhaust wetness is considerably less than
it would otherwise be conversely, if the maximum tolerable wetness is
allowed, the initial pressure of the steam can be appreciably
increased.
Bleed Steam Extraction: For regenerative system, nos. of nonregulated extractions is taken from HP, IP turbine. Regenerative
heating of the boiler feed water is widely used in modern power
plants; the effect being to increase the average temperature at which
heat is added to the cycle, thus improving the cycle efficiency.

Figure 7: INTSALLED CAPACITY OF NTPC, BADARPUR

MAIN GENERATOR
Maximum continuous

KVA rating

24700KVA

Maximum continuous

KW

210000KW

Rated terminal voltage

15750V

Rated Stator current

9050 A

Rated Power Factor

0.85 lag

Excitation current at MCR Condition

2600 A
30

Slip-ring Voltage at MCR Condition

310 V

Rated Speed

3000 rpm

Rated Frequency

50 Hz

Short circuit ratio

0.49

Efficiency at MCR Condition

98.4%

Direction of rotation viewed

Anti Clockwise

Phase Connection

Double Star

Number of terminals brought out

9(6 neutral and 3 phases)

MAIN TURBINE DATA

Rated output of Turbine
210 MW
Rated speed of turbine
3000 rpm
Rated pressure of steam before emergency
130 kg/cm^2
Stop valve rated live steam temperature
Celsius

535

Rated steam temperature after reheat at inlet to receptor valve

535 o Celsius
Steam flow at valve wide open condition
670 tons/hour
Rated quantity of circulating water through condenser
27000 cm/hour
1. For cooling water temperature (o Celsius)
24,27,30,33
2. Steam flow required for 210 MW in ton/hour
68,645,652,662
3. Rated pressure at exhaust of LP turbine in mm of Hg
19.9,55.5,65.4,67.7

31

OPERATION
THERMAL POWER PLANT
A Thermal Power Station comprises all of the equipment and a
subsystem required to produce electricity by using a steam generating
boiler fired with fossil fuels or befouls to drive an electrical generator.
Some prefer to use the term ENERGY CENTER because such facilities
convert forms of energy, like nuclear energy, gravitational potential
energy or heat energy (derived from the combustion of fuel) into
electrical energy. However, POWER PLANT is the most common term in
the

united

state;

While

POWER

STATION

prevails

in

many

Commonwealth countries and especially in the United Kingdom.

Such power stations are most usually constructed on a very large scale
and designed for continuous operation.
Typical elements of a coal fired 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

32

12. Coal conveyor

13. Coal hopper
14. Coal pulverizer
15. Boiler steam drum
16. Bottom ash hoper
17. Super heater
18. Forced draught (draft) fan
19. Reheater
20. Combustion air intake
21. Economizer
22. Air preheater
23. Precipitator
24. Induced draught (draft) fan
25. Fuel gas stack
The description of some of the components written above is described
as follows:
1. Cooling towers
Cooling Towers are evaporative coolers used for cooling water or other
working medium to near the ambivalent web-bulb air temperature.
Cooling towers use evaporation of water to reject heat from processes
such as cooling the circulating water used in oil refineries, Chemical
plants, power plants and building cooling, for example. The tower vary
in size from small roof-top units to very large hyperboloid structures
that can be up to 200 meters tall and 100 meters in diameter, or
rectangular structure that can be over 40 meters tall and 80 meters
33

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 cooling water systems 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 to power
motors and many other devices. A Three phase system uses less
conductor material to transmit electric power than equivalent single
phase, two phase, or direct current system at the same voltage. In a
three phase system, three circuits reach their instantaneous peak
values at different times. Taking one conductor as the reference, the
other two current are delayed in time by one-third and two-third of one
cycle of the electrical current. This delay between phases has the
effect of giving constant power transfer over each cycle of the current
and also makes it possible to produce a rotating magnetic field in an
electric motor.
At the power station, an electric generator converts mechanical power
into a set of electric currents, one from each electromagnetic coil or
winding of the generator. The current 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 one cycle. Generators output at a voltage that
34

ranges from hundreds of volts to 30,000 volts. At the power station,

transformers:

step-up

this

voltage

to

one

more

suitable

for

transmission.
After numerous further conversions in the transmission and distribution
network the power is finally transformed to the standard mains voltage
(i.e. the household voltage).
The power may already have been split into single phase at this point
or it may still be three phase. Where the step-down is 3 phase, the
output of this transformer is usually star connected with the standard
mains voltage being the phase-neutral voltage. Another system
commonly seen in North America is to have a delta connected
secondary with a center tap on one of the windings supplying the
ground and neutral. This allows for 240 V three phase as well as three
different single phase voltages( 120 V between two of the phases and
neutral , 208 V between the third phase ( known as a wild leg) and
neutral and 240 V between any two phase) to be available from the
same supply.
3. Electrical generator
An Electrical generator is a device that converts kinetic energy to
electrical energy, generally using electromagnetic induction. The task
of

converting

the

electrical

energy

into

mechanical

energy

is

accomplished by using a motor. The source of mechanical energy may

be a reciprocating or turbine steam engine, , water falling through the
turbine are made in a variety of sizes ranging from small 1 hp (0.75
kW) units (rare) 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. There are several classifications for
modern steam turbines.
Steam turbines are used in all of our major coal fired power stations to
drive the generators or alternators, which produce electricity. The
35

turbines themselves are driven by steam generated in Boilers or

steam generators as they are sometimes called.
Electrical power stations use large steam turbines driving electric
generators to produce most (about 86%) of the worlds electricity.
These centralized stations are of two types: fossil fuel power plants and
nuclear power plants. The turbines used for electric power generation
are most often directly coupled to their-generators .As the generators
must rotate at constant synchronous speeds according to the
frequency of the electric power system, the most common speeds are
3000 r/min for 50 Hz systems, and 3600 r/min for 60 Hz systems. Most
large nuclear sets rotate at half those speeds, and have a 4-pole
generator rather than the more common 2-pole one.
Energy in the steam after it leaves the boiler is converted into
rotational energy as it passes through the turbine. The turbine normally
consists of several stage with each stages consisting of a stationary
blade (or nozzle) and a rotating blade. Stationary blades convert the
potential energy of the steam into kinetic energy into forces, caused by
pressure drop, which results in the rotation of the turbine shaft. The
turbine shaft is connected to a generator, which produces the electrical
energy.

4. Boiler feed water pump

A Boiler feed water pump is a specific type of pump used to pump
water into a steam boiler. The water may be freshly supplied or
retuning condensation of the steam produced by the boiler. These
pumps are normally high pressure units that use suction from a
condensate return system and can be of the centrifugal pump type or
positive displacement type.

36

Figure 8: EXTERNAL VIEW OF BOILER

Construction and operation:

Feed water pumps range in size up to 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 the 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 a centrifugal pump.
Feed water pumps usually run intermittently and are controlled by a
float switch or other similar level-sensing device energizing the pump
when it detects a lowered liquid level in the boiler is substantially
increased. Some pumps contain a two-stage switch. As liquid lowers to
the trigger point of the first stage, the pump is activated. I f the liquid
continues to drop (perhaps because the pump has failed, its supply has
been cut off or exhausted, or its discharge is blocked); the second
stage will be triggered.

5. Steam-powered pumps
Steam locomotives and the steam engines used on ships and
stationary applications such as power plants also required feed water
pumps. In this situation, though, the pump was often powered using a
37

small steam engine that ran using the steam produced by the boiler. A
means had to be provided, of course, to put the initial charge of water
into the boiler(before steam power was available to operate the steampowered feed water pump).the pump was often a positive displacement
pump that had steam valves and cylinders at one end and feed water
cylinders at the other end; no crankshaft was required.In thermal
plants, the primary purpose of surface condenser is to condense the
exhaust steam from a steam turbine to obtain maximum efficiency and
also to convert the turbine exhaust steam into pure water so that it
may be reused in the steam generator or boiler as boiler feed water. By
condensing the exhaust steam of a turbine at a pressure below
atmospheric pressure, the steam pressure drop between the inlet and
exhaust of the turbine is increased, which increases the amount heat
available for conversion to mechanical power. Most of the heat
liberated due to condensation of the exhaust steam is carried away by
the cooling medium (water or air) used by the surface condenser.
6. Control valves
Control valves are valves used within industrial plants and elsewhere to
control operating conditions such as temperature, pressure, flow, and
liquid Level by fully 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
7. Deaerator
A Dearator is a device for air removal and used to remove dissolved
gases (an alternate would be the use of water treatment chemicals)
from boiler feed water to make it non-corrosive. A dearator typically
includes a vertical domed deaeration section as the deaeration boiler
feed water tank. A Steam generating boiler requires that the circulating

38

steam, condensate, and feed water should be devoid of dissolved

gases, particularly corrosive ones and dissolved or suspended solids.
The gases will give rise to corrosion of the metal. The solids will deposit
on the heating surfaces giving rise to localized heating and tube
ruptures due to overheating. Under some conditions it may give to
stress corrosion cracking.
Deaerator level and pressure must be controlled by adjusting control
valves- the level by regulating condensate flow and the pressure by
regulating steam flow. If operated properly, most deaerator vendors will
guarantee that oxygen in the deaerated water will not exceed 7 ppb by
weight (0.005 cm3/L)
8. Feed water heater
A Feed water heater is a power plant component used to pre-heat
water delivered to a steam generating boiler. Preheating the feed water
reduces the irreversible involved in steam generation and therefore
improves the thermodynamic efficiency of the system. This reduces
plant operating costs and also helps to avoid thermal shock to the
boiler metal when the feed water is introduces back into the steam
cycle.
In a steam power (usually modeled as a modified Ranking cycle), feed
water heaters allow the feed water to be brought up to the saturation
temperature

very

gradually.

This

minimizes

the

inevitable

irreversibilitys associated with heat transfer to the working fluid

(water). A belt conveyor consists of two pulleys, with a continuous loop
of material- the conveyor Belt that rotates about them. The pulleys
are powered, moving the belt and the material on the belt forward.
Conveyor belts are extensively used to transport industrial and
agricultural material, such as grain, coal, ores etc.
9. Pulverizer

39

A pulverizer is a device for grinding coal for combustion in a furnace in

a fossil fuel power plant.

10. Boiler Steam Drum

Steam Drums are a regular feature of water tube boilers. It is reservoir
of water/steam at the top end of the water tubes in the water-tube
boiler. They store the steam generated in the water tubes and act as a
phase separator for the steam/water mixture. The difference in
densities between hot and cold water helps in the accumulation of the
hotter-water/and saturated steam into steam drum. Made from highgrade steel (probably stainless) and its working involves temperatures
390C and pressure well above 350psi (2.4MPa). The separated steam
is drawn out from the top section of the drum. Saturated steam is
drawn off the top of the drum. The steam will re-enter the furnace in
through a super heater, while the saturated water at the bottom of
steam drum flows down to the mud-drum /feed water drum by down
comer tubes accessories include a safety valve, water level indicator
and fuse plug. A steam drum is used in the company of a muddrum/feed water drum which is located at a lower level. So that it acts
as a sump for the sludge or sediments which have a tendency to the
bottom.
11. 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

40

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.
12. 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 boilers efficiency. They are a
device fitted to a boiler which 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 Greens 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.
13. 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

41

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.
14. 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 smoke from the air
steam.
ESPs 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 ESPs to stay in operation for
years at a time.
15. 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

42

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 levels required by
governmental environmental policies and regulations.
When the fuel gases exhausted from stoves, ovens, fireplaces or other
small sources within residential abodes, restaurants , hotels or other
stacks are referred to as chimneys.

CHAPTER-3
EMD- I
Electrical Maintenance Division I
It is responsible for the maintenance of:

HT/LT MOTORS TURBINE & BOILER SIDE

Boiler Side Motors:
For 1, units 1, 2, 3

43

1. ID Fans

2 in no.

2. FD Fans

2 in no.

3. PA Fans

2 in no.

4. Mill Fans

3 in no.

5. Ball mill fans

3 in no.

6. RC feeders
7. Slag Crushers

3 in no.
5 in no.

8. DM Make up Pump

2 in no.

9. PC Feeders

4 in no.

10. Worm Conveyor

1 in no.

11. Furnikets

4 in no.

For stage units 1, 2, 3

1. I.D Fans

2 in no.

2. F.D Fans

2 in no.

3. P.A Fans

2 in no.

4. Bowl Mills

6 in no.

5. R.C Feeders

6 in no.

6. Clinker Grinder

2 in no.

7. Scrapper

2 in no.

8. Seal Air Fans

9. Hydrazine & Phosphorous Dozing

2 in no.
2 in no.

44

Figure 9: EXTERNAL VIEW OF ID, PA & FD FANS

COAL HANDLING PLANT (C.H.P) & NEW COAL

HANDLING PLANT (N.C.H.P)
The old coal handling plant caters to the need of units 2,3,4,5 and 1
whereas the latter supplies coal to units 4 and V.O.C.H.P. supplies coal
to second and third stages in the advent coal to usable form to
(crushed) form its raw form and send it to bunkers, from where it is
send to furnace.

Figure 10: FLOW CHART OF COAL HANDLING PLANT

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

45

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: - There are 14 conveyors in the plant. They are
numbered so that their function can be easily demarcated. 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 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.
3. 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.
4. 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

46

5. 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.
6. Rotatory Breaker: - OCHP employs mesh type of filters and allows
particles of 20mm size to go directly to RC bunker, larger particles are
sent to crushes. This leads to frequent clogging. NCHP uses a technique
that crushes the larger of harder substance like metal impurities easing
the load on the magnetic separators.

3.

MILLING SYSTEM

1. RC Bunker: - Raw coal is fed directly to these bunkers. These are 3

in no. per boiler. 4 & tons of coal are fed in 1 hr. the depth of bunkers
is 10m.
2. RC Feeder: - It transports pre 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. Ball Mill: - The ball mill crushes the raw coal to a certain height and
then allows 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.
4. Classifier: - It is 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.
5. Cyclone Separators: - It separates the pulverized coal from
carrying medium. The mixture of pulverized coal vapour caters the
cyclone separators.
47

6. The Tturniket: - It serves to transport pulverized coal from cyclone

separators to pulverized coal bunker or to worm conveyors. There are 4
turnikets per boiler.
7. Worm Conveyor: - It is equipment used to distribute the pulverized
coal from bunker of one system to bunker of other system. It can be
operated in both directions.
8. 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

48

Rating-300 KW
Voltage-6.6 KV
Lubrication-by oil
Type of operation-continuous
9. Bowl Mill: - One of the most advanced designs of coal pulverizes
presently manufactured.

Motor Specification
Squirrel cage induction motor
Rating-340 KW
Voltage-6600KV
Curreen-41.7A
Speed-980 rpm
Frequency-50 Hz
No-load current-15-16 A

4.

NEW COAL HANDLING PLANT

1. Wagon Tippler:
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

49

2. Coal feed to plant:

Feeder motor specification
(i) Horse power 15 HP
(ii) Voltage 415V, 3 phase
(iii) Speed 1480 rpm
(iv) Frequency 50 Hz

3. Conveyors:10A, 10B
11A, 11B
12A, 12B
13A, 13B
14A, 14B
15A, 15B
16A, 16B
17A, 17B
18A, 18B
4. Transfer Point 6
5. Breaker House
6. Rejection House
7. Reclaim House

50

8. Transfer Point 7
9. Crusher House
The coal arrives in wagons via railways and is tippled by the wagon
tipplers into the hoppers. If coal is oversized (>400 mm sq) then it is
broken manually so that it passes the hopper mesh. From the hopper
mesh it is taken to the transfer point TP6 by conveyor 12A ,12B which
takes the coal to the breaker house , which renders the coal size to be
100mm sq. the stones which are not able to pass through the 100mm
sq of hammer are rejected via conveyors 18A,18B to the rejection
house . Extra coal is to sent to the reclaim hopper via conveyor 16.
From breaker house coal is taken to the TP7 via Conveyor 13A, 13B.
Conveyor 17A, 17B also supplies coal from reclaim hopper, From TP7
coal is taken by conveyors 14A, 14B to crusher house whose function is
to render the size of coal to 20mm sq. now the conveyor labors are
present whose function is to recognize and remove any stones moving
in the conveyors . In crusher before it enters the crusher. After being
crushed, if any metal is still present it is taken care of by metal
detectors employed in conveyor 10.

5. SWITCH GEAR
It makes or breaks an electrical circuit.
1. Isolation: - A device which breaks an electrical circuit when circuit is
switched on to no load. Isolation is normally used in various ways for
purpose of isolating a certain portion when required for maintenance.
2. Switching Isolation: - It is capable of doing things like interrupting
transformer magnetized current, interrupting line charging current and
even perform load transfer switching. The main application of switching
isolation is in connection with transformer feeders as unit makes it
possible to switch out one transformer while other is still on load.

51

3. Circuit Breakers: - One which can make or break the circuit on load
and even on faults is referred to as circuit breakers. This equipment is
the most important and is heavy duty equipment mainly utilized for
protection of various circuits and operations on load. Normally circuit
breakers installed are accompanied by isolators
4. Load Break Switches: - These are those interrupting devices which
can make or break circuits. These are normally on same circuit, which
are backed by circuit breakers.
5. Earth Switches: - Devices which are used normally to earth a
particular system, to avoid any accident happening due to induction on
account of live adjoining circuits. These equipments do not handle any
appreciable current at all. Apart from this equipment there are a
number of relays etc. which are used in switchgear.
LT Switchgear
It is classified in following ways:1. Main Switch: - Main switch is control equipment which controls or
disconnects the main supply. The main switch for 3 phase supply is
available for tha range 32A, 63A, 100A, 200Q, 300A at 500V grade.
2. Fuses: - With Avery high generating capacity of the modern power
stations extremely heavy carnets would flow in the fault and the fuse
clearing the fault would be required to withstand extremely heavy
stress in process.
It is used for supplying power to auxiliaries with backup fuse protection,
rotary switch up to 25A. With fuses, quick break, quick make and
double break switch fuses for 63A and 100A, switch fuses for 200A,
400A, 600A, 800A and 1000A are used.
3. Contractors: - AC Contractors are 3 poles suitable for D.O.L Starting
of motors and protecting the connected motors.

52

4. Overload Relay: - For overload protection, thermal over relay are

best suited for this purpose. They operate due to the action of heat
generated by passage of current through relay element.
5. Air Circuit Breakers: - It is seen that use of oil in circuit breaker
may cause a fire. So in all circuits breakers at large capacity air at high
pressure is used which is maximum at the time of quick tripping of
contacts. This reduces the possibility of sparking. The pressure may
vary from 50-60 kg/cm^2 for high and medium capacity circuit
breakers.
HT Switch Gear
1. Minimum oil Circuit Breaker: - These use oil as quenching
medium. It comprises of simple dead tank row pursuing projection from
it. The moving contracts are carried on an iron arm lifted by a long
insulating tension rod and are closed simultaneously pneumatic
operating mechanism by means of tensions but throw off spring to be
provided at mouth of the control the main current within the controlled
device.
Type-HKH 12/1000c
Rated Voltage-66 KV
Normal Current-1250A
Frequency-5Hz
Breaking Capacity-3.4+KA Symmetrical
3.4+KA Asymmetrical
360 MVA Symmetrical
Operating Coils-CC 220 V/DC
FC 220V/DC

53

 Motor Voltage-220 V/DC

2. Air Circuit Breaker: - In this the compressed air pressure around 15
kg per cm^2 is used for extinction of arc caused by flow of air around
the moving circuit . The breaker is closed by applying pressure at lower
opening and opened by applying pressure at upper opening. When
contacts operate, the cold air rushes around the movable contacts and
blown the arc.

It has the following advantages over OCB:i. Fire hazard due to oil are eliminated.
ii. Operation takes place quickly.
iii. There are less burning contacts since the duration is short and
consistent.
iv. Facility for frequent operation since the cooling medium is replaced
constantly.
Rated Voltage-6.6 KV
Current-630 A
Auxiliary current-220 V/DC
3. SF6 Circuit Breaker: - This type of circuit breaker is of construction
to dead tank bulk oil to circuit breaker but the principle of current
interruption is similar o that of air blast circuit breaker. It simply
employs the arc extinguishing medium namely SF6 the performance of
gas. When it is broken down under an electrical stress, it will quickly
reconstitute itself
Circuit Breakers-HPA
Standard-1 EC 56

54

 Rated Voltage-12 KV
Insulation Level-28/75 KV
Rated Frequency-50 Hz
Breaking Current-40 KA
Rated Current-1600 A
Making Capacity-110 KA
Rated Short Time Current 1/3s -40 A
Mass Approximation-185 KG
Auxiliary Voltage
. Closing Coil-220 V/DC
. Opening Coil-220 V/DC
Motor-220 V/DC
SF6 Pressure at 20 Degree Celsius-0.25 KG
SF6 Gas Per pole-0.25 KG
4. Vacuum Circuit Breaker: - It works on the principle that vacuum is
used to save the purpose of insulation and it implies that pr of gas at
which breakdown voltage is independent of pressure. It regards of
insulation and strength, vacuum is superior dielectric medium and is
better that all other medium except air and sulphur which are generally
used at high pressure.
Rated frequency-50 Hz
Rated making Current-10 Peak KA
Rated Voltage-12 KV
Supply Voltage Closing-220 V/DC
55

 Rated Current-1250 A
Supply Voltage Tripping-220 V/DC
Insulation Level-IMP 75 KVP
Rated Short Time Current-40 KA (3 SEC), Weight of Breaker-8 KG

CHAPTER-3
EMD II
Electrical Maintenance division II
This division is divided as follows

Generator and Auxiliaries

Generator Fundamentals
The transformation of mechanical energy into electrical energy is
carried out by the Generator. This Chapter seeks to provide basic
understanding about the working principles and development of
Generator.

56

Figure 11: CROSS-SECTIONAL VIEW OF A 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 (i.e. magnetic field) cut through the
stator windings. This induces an electromagnetic force (EMF) in the
stator windings. The magnitude of this EMF is given by the following
expression.
E = 4.44 /O FN volts
0 = Strength of magnetic field in Webers.
F = Frequency in cycles per second or Hertz.
N = Number of turns in a coil of stator winding
F = Frequency = P*n/120
Where P = Number of poles

57

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 were as
high speed steam turbine driven generators have generally 2 poles.
Generator component
This deals with the two main components of the Generator viz. Rotor,
its winding & balancing and stator, its frame, core & windings.
Rotor
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 them. 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

58

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.
Rotor balancing
When completed the rotor must be tested for mechanical 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 all
designs 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

59

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 grainoriented 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 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

60

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 rotorhydrogen 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 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.

61

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:
I.

Filling in and purging of hydrogen safely without bringing in

II.

contact with air.

Maintaining the gas pressure inside the machine at the desired

III.

value at all the times.

Provide indication to the operator about the condition of the gas

IV.

inside the machine i.e. its pressure, temperature and purity.

Continuous circulation of gas inside the machine through a drier

V.

in order to remove any water vapor 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.
Turbo generators require water cooling arrangement over and above
the usual hydrogen cooling arrangement. The stator winding is cooled
in this system by 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 400C.
Rating of 95 MW GeneratorManufacture by Bharat heavy electrical Limited (BHEL)
Capacity
Voltage

- 117500 KVA
- 10500V

62

Speed

- 3000 rpm

Hydrogen

- 2.5 Kg/cm2

Power factor

- 0.85 (lagging)

Stator current

- 6475 A

Frequency

- 50 Hz

Stator winding connection

- 3 phase

Rating of 210 MW GeneratorManufacture by Bharat heavy electrical Limited (BHEL)

Capacity
Voltage (stator)

- 247000 KVA
- 15750 V

Current (stator)

- 9050 A

Voltage (rotor)

- 310 V

Current (rotor)

- 2600 V

Speed
Power factor

- 3000 rpm
- 0.85

Frequency

- 50 Hz

Hydrogen

- 3.5 Kg/cm2

Stator winding connection

- 3 phase star connection

Insulation class

-B

Transformer
A transformer is a device that transfers electrical energy from one
circuit to another by magnetic coupling without 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
63

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. All
but a fraction of the worlds electrical power has passed through a
series of transformer by the time it reaches the consumer.
Rating of transformer
Manufactured by Bharat Heavy Electrical Limited
No load voltage (HV)

- 229 KV

No load Voltage (LV)

-10.5 KV

Line current (HV)

-315.2 A

Line current (LV)

- 873.2 A

Temp rise

- 45 Celsius

Oil quantity

- 40180 lit

Weight of oil

- 34985 Kg

Total weight

- 147725 Kg

Core & winding

- 84325 Kg

Phase
Frequency

-3
- 50 Hz

64

CHAPTER-4
CONTROL AND INSTRUMENTATION
This division is basically brain of the power plant and this division is
responsible for:
1. Fr controlling the entire process of boiler, turbine n generator.
2. Is responsible for protection of boiler turbine & generator &
associated auxiliaries.
3. It is responsible for display of all the parameters to the operator
for taking the manual action in case of emergency.
4. Responsible for logging of sequence of events taking place in the
control room

65

Figure 12: CONTROL UNIT

This department is the brain of the plant because from the relays to
transmitters followed by the electronic computation chipsets and
recorders and lastly the controlling circuitry, all fall under this.
This division also calibrates various instruments and takes care of any
faults occurring in any of the auxiliaries in the plant provided for all the
equipments. Tripping can be considered as the series of instructions
connected through OR GATE. When the main equipments of this
laboratories are relay and circuit breakers.

GENESIS OF THE PROJECT:

There are very transient conditions during the light up of the boiler. At
this point, the level in the drum fluctuates heavily & frequently. So, if
the drum level works on properly on auto loop, then it will be huge
66

relief to operator and it may even save the unit from tripping on drum
level protection. That is why this project is chosen.

OBJECTIVE:
The objective of the boiler drum level control strategy is to maintain
the water/steam interface at its optimum level to provide a continuous
mass/heat balance by replacing every pound of steam leaving the
boiler with a pound of feed water to replace it. As mentioned above if
the level is above +175mm then the turbine may get damaged or if the
level is below -175mm then the boiler happens to starvation. The
objective of the entire project is to design the controlling element for
the control of valve of drum which can be designed manually and
automatically both. The controlling element will control the opening
and closing of valve of drum according to error signal generated by I06R mini card. To serve this purpose the following steps are to be taken
The following are the main objectives of the project:
1) Understanding the input measurement techniques.
2) Understanding the control logic and hence designing it.
3) Understanding and simulating the controlling element i.e. valve
actuator.

MAIN OUTLINE:
The level in the drum has to be controlled effectively.
If level in the drum is very low say below -175 mmwcl, then the
starvation of the water tubes will take place & hence huge financial loss
to the plant will take place.

67

If the level in the drum is very high say +175 mmwcl then, water
particle may enter in the turbine & turbine blades may get damaged.
So, again a huge financial loss to the plant may take place that is why
the drum level is of very high importance.

The entire functioning of any auto loop may be primarily being divided
in to four parts.

1) Measurement of Input: This is the first step towards designing the

auto

controller.

In

this

project,

we

will

study

the

various

measurement techniques of the drum level. Primarily we will focus

on the two techniques as-

68

i)

Drum level measurement technique by differential

pressure measurement: In this variable head is compared
with constant head and thus giving the variable electrical
signal in terms of the 4 to 20 ma. This DP signal is
corrected for the density by measuring the drum pressure
and temperature of the saturated steam.

ii)

Hydra step measurement: This method is based on the

principle of the resistivity difference of the steam & water.
This method gives the discrete signal hence cannot be
used for the auto controlling of the drum level

2) Designing the control logic: The Corrected drum level signal is

compared with

the desired set point & hence error signal is

generated. Based on the error signal, the raise or lower command

goes to the controlling element. Here in the auto controlling of the
drum level, we may go for two types of logici)

Single element control logic: In this only drum level

signal is compared with the desired set point & thus on
the basis of the error signal, raise & lower command is
sent to the controlling element. Here in this project we are
focusing on the single element controller.

ii)

Three

element

control

logic: In this, instead of

considering only the drum level we will focus on the two

other parameters which are Total Feed water flow and
total steam flow. Designing the three element controller
may be the extension of this project.

3) Designing the controlling element:

There are three

control elements as follows:

a) Electrical/Linear Actuator: A linear actuator is an actuator that

creates motion in a straight line, as contrasted with circular
motion of a conventional electric motor.

69

Linear actuators are used in machine tools and industrial

machinery, in computer peripherals such as disk drives and
printers, in valves and dampers, and in many other places where
linear motion is required. Hydraulic or pneumatic cylinders
inherently produce linear motion; many other mechanisms are
used to provide a linear motion from a rotating motor.
b) Pneumatic Actuator: A pneumatic actuator converts energy
(typically in the form of compressed air) into mechanical motion.
The motion can

be rotary or linear, depending on the type of

actuator. Some types of pneumatic actuators include:

Tie rod cylinders
Rotary actuators
Grippers
Rod Less actuators with magnetic linkage or rotary

cylinder
Rod Less actuators with mechanical linkage
Pneumatic artificial muscles
Vacuum generators

c) Hydraulic

Actuator:

mechanical actuator that

A Hydraulic
is

used

cylinder is
to

give

a
a

unidirectional force through a unidirectional stroke. It has many

applications, notably in engineering vehicles. Hydraulic cylinders
get their power from pressurized hydraulic fluid, which is
typically oil. The hydraulic cylinder consists of a cylinder barrel,
in which a piston connected to a piston rod moves back and
forth. The barrel is closed on each end by the cylinder bottom
(also called the cap end) and by the cylinder head where the
piston rod comes out of the cylinder. The piston has sliding rings
and seals. The piston divides the inside of the cylinder in two
chambers, the bottom chamber (cap end) and the piston rod side
chamber (rod end). The hydraulic pressure acts on the piston to
do linear work and motion.

70

BLOCK DIAGRAM

DESCRIPTION OF BLOCK DIAGRAM

There are two main circuits used in this project. The command for valve
actuator can be given in manual and auto mode both. The circuits for
manual & auto command are different. The circuit for auto command is
in parallel with the circuit for manual command. The block diagram for
the circuit for is shown below.
In the circuit of manual mode, the main supply is of 230V AC. The
supply is given to the AC to DC converter. The converter converts 230V
AC to 24V DC. This DC supply is given to the dextile, the dextile and
limit switches are connected in parallel. The output of dextile is given
to the DC relays. The DC relays provide 24V as input and 230V as
output. The output of DC relay is given to the contactor which accepts

71

230V as input and output both & the output of the contactor is fed to
the single phase AC motor.
If boundary limits are reached as full open or full close then on giving
any further command will not be executed by the motor.
The energized relay will rotate the motor either in clockwise or in
anticlockwise direction depending upon the energisation. The opening
and closing of the valve will depend on the direction of motor. The
motor will control the opening and closing of valve which will control
the level of water in drum. It is necessary to keep track of one thing
that at one time only one relay should get energized either forward
relay or backward relay, hence forward or reverse connectors are used
to avoid the simultaneous energization of both forward and backward
relays. The forward relay helps the motor to rotate in clockwise
direction and the backward relay makes the motor to rotate in
anticlockwise direction.
In the circuit of auto mode the I 06 R mini card is used. The I-06 R card
is used to make the
summator subtractor circuit. The card is uses a low current offset
differential amplifier, with feedback arranged to produce the required
computing function. The amplifier which is used to make this 06 r card
is used in non-inverting mode. For current input signals, conditioning
resistors are fitted across the input terminals. These resistors are
placed in specific order. There are two inputs of the I-06 R card as one
is reference level and other is variable supply. The 06 R mini card gives
error signal as its output. According to this error signal the trigger
circuit will energize the corresponding relay.
The output of I-06 computing Mini Card which is an error signal will be
send to the trigger circuit. The trigger circuit will generate the pulses of
+20 V and -20 V which is send to the forward or backward relays.

72

The output of the trigger circuit will energize one of the relay either
forward or reverse relay. The 555 timer IC is used in the trigger circuit.
The output of the trigger circuit is fed to the 12V dc relays. Then these
12V relays will energize the 24 V DC relays.

CIRCUIT DIAGRAM

There are two main circuits used in this project. The command for valve
actuator can be given in manual and auto mode both. The circuits for
manual & auto command are different. The circuit for auto command is
in parallel with the circuit for manual command.

CIRCUIT DESCRIPTION OF AUTO MODE

CIRCUIT DIAGRAM FOR SET POINT:

73

The 7805 IC is used for the set input which is given to the I-06R mini
card. 20V is given as input to the 7805 voltage regulator IC. The output
of the 7805 is 5V which is constant and we are using 5V as set point of
the I 06 R mini card. The 20v is fed to the pin 1 of IC and output is
being taken from pin 3 of IC

CIRCUIT DAIGRAM FOR VARIABLE INPUT

The output voltage is stabilized and is regulated in the region from 0V

until + 15V dc, with biggest provided current 1 A. The regulation
becomes with the R2. The Q1 of is classic power transistor and it needs
it is placed in heat sink, one and heating when it works continuously in
the region of biggest current. The type of transformer is standard in the

74

market. The variable resistor or potentiometer gives as variable output

from 0 to +15V which are given as one of the input of I-06 R mini card.

I-06R MINI CARD CIRCUIT DIAGRAM

The I-06 R card is used to make the summator subtractor circuit. The
card is uses a low current offset differential amplifier, with feedback
arranged to produce the required computing function. The amplifier
which is used to make this 06 r card is used in non-inverting mode. For
current input signals, conditioning resistors are fitted across the input
terminals. These resistors are placed in specific order. There are two
inputs of the I-06 R card as one is reference level and other is the
output of potentiometer which is variable in nature.
There are three input pins of this card as 1, 2. And 3 of the I 06 R mini
card .There are two inputs applied to the 06 R mini card to generate
the error signal. One is reference or set point which is applied to the pin
1 of this card and second is variable input which is applied to the pin 2
of the card+20V is applied to the pin 8 of card and -20V is applied to
the pin 10 of the card. The +20V and -20V are applied to the card to
drive the card. The output is being taken from the pin 4 of the card with
reference to the ground which is at pin 09 of card. When less than the
total available inputs are in use, the unused inputs should be
75

connected to the common line hence pin 3 is connected to the common

line or 0V.

TRIGGER CIRCUIT

The output of I-06 computing Mini Card which is an error signal will be
send to the trigger circuit. The trigger circuit will generate the pulses of
+20 V and -20 V which is send to the forward or backward relays.
The two comparator inputs (pin 2 & 6) are tied together and biased at
1/2 Vcc through a voltage divider R1 and R2.Since the threshold
comparator wil trip at 2/3 Vcc and the trigger comparator will trip at
1/3Vcc,the bias provided by the resistors R1 & R2 are centered within
the comparators trip limits.
By modifying the input time constant on the circuit,reducing the value
of input capacitor (C1) to 0.001 uF so that the input pulse get
differentiated,the arrangement can also be used either as a bistable
device or to invert pulse wave forms.In the later case ,the fast time
combination of C1 with R1 & R2 causes only the edges of the input
pulse or rectangular waveform to be passed. These pulses set and
reset the flip-flop and a high level inverted output is the result.

ELECTRICAL ACTUATOR CIRCUIT

76

The output of the trigger circuit will energize one of the relay either
forward or reverse relay. The energized relay will rotate the motor
either in clockwise or anticlockwise direction depends on the type of
energized relay. The opening and closing of valve will depend on the
direction of motor. The motor will control the opening and closing of
valve which will control the level of water in drum. It is necessary to
keep track of one thing that at one time only one relay should get
energized either forward relay or backward relay, hence forward or
reverse connectors are used to avoid the simultaneous energization of
both forward and backward relays.

DEXTILE, LIMIT SWITCH and RELAY PIN DESCRIPTION

The port P12 and P11 gets supply of negative and positive 24 volts
respectively. The positive terminal of limit switch is connected to P4
and P6 terminal of the dextile, negative terminal of limit switch is
connected to fourth port of relay. The port 12 of the dextile is
connected to the eight port of the relay. P1 and P3 of dextile is
connected

to

the

fourth

port

of

forward

and

backward

relay

respectively. The connection on port P1 helps to glows yellow colour

LED and green colour LED on P3. The port 3 of the relays gets a supply
of 230 volts. NC of contactor is connected to the second port of relays.
The A1 port of both parts of the contactor is on neutral. A1 port of the
first part of contactor is connected to NC of second part of contactor
and vice versa. L1 port of both parts of contactor gets a supply of 230
volts. The first part of the contactor is directly connected to the motor
and the second part of the contactor is connected to the motor in
series with a capacitor to provide an anticlockwise movement.

CONCLUSION:
. Practically there are many parameters to be controlled to maintain the

level of water in drum according to the requirement but we have

77

considered only one parameter of flow of water in our project. The

content of steam which is going in turbine depends on the level of
water in drum hence water level should be in control. To fulfill this
purpose we had designed a controlling element which is receiving
command by the trigger circuit. The trigger circuit is correcting the
error signal generated by I-06R mini card and providing appropriate
command to the motor.

EXTENSIONS
1) Triggering circuit may be the economical replace of the 74 R
card.
2) If drum level is put on auto loop during the lighted up
condition of the boiler, there will be huge saving of
monetary losses.
3) Timely synchronisation of the unit is possible and hence can
better serve the society.

COMPONENTS DESCRIPTION

LIMIT SWITCH
In electrical engineering a limit switch is a switch operated by the
motion of a machine part or presence of an object. They are used for
control of a machine, as safety interlocks, or to count objects passing a
point.
Limit switch is one type Of " Contact Sensor, In that there is Normally
Open Contact & Normally Close Contact, In limit switch there is Plunger
it is Directly Connected to NO & NC Contact if we press the plunger NO
contact become NC & NC contact become NO, Working Principle same
as Contactor (DOL starter) main difference is in contactor There is Coil
to attract the Plunger But In Limit Switch Plunger is Operated

78

Mechanically. Limit Switches is used mainly for Safety Purpose & to

take Feed back for PLC in Automation industries.
Many limit switches have three terminals. One is the normally closed
contact, another the normally open contact and the third is the
common that switches between these two as the mechanism is moved.
The limit switch is mounted in such a way when the mechanism driven
by motor reaches one of the limit positions, it will engage the limit
switch at that position. This will cause NC contacts of that switch to
open and its NO to close.

RELAY
A relay is

an electrically operated switch.

Many

relays

use

an electromagnet to operate a switching mechanism mechanically, but

other operating principles are also used. Relays are used where it is
necessary to control a circuit by a low-power signal (with complete
electrical isolation between control and controlled circuits), or where
several circuits must be controlled by one signal. The first relays were
used in long distance telegraph circuits, repeating the signal coming in
from one circuit and re-transmitting it to another. Relays were used
extensively in telephone exchanges and early computers to perform
logical operations.
A type of relay that can handle the high power required to directly
control an electric motor or other loads is called a contactor. Solid-state
relays control power circuits with no moving parts, instead using a
semiconductor device to perform switching. Relays with calibrated
operating characteristics and sometimes multiple operating coils are
used to protect electrical circuits from overload or faults; in modern
electric power systems these functions are performed by digital
instruments still called "protective relays".

79

It is a protective device. It can detect wrong condition in electrical

circuits by constantly

measuring the electrical quantities

flowing under normal and faulty conditions. Some of the

electrical

quantities are voltage, current, phase angle and velocity.

CONTACTOR RELAY
A contactor is a very heavy-duty relay used for switching electric motors and
lighting loads, although contactors are not generally called relays. Continuous
current ratings for common contactors range from 10 amps to several
hundred amps. High-current contacts are made with alloys containing silver.
The unavoidable arcing causes the contacts to oxidize; however, silver
oxide is still a good conductor. Such devices are often used for motor starters.
A motor starter is a contactor with overload protection devices attached. The
overload sensing devices are a form of heat operated relay where a coil heats
a bi-metal strip, or where a solder pot melts, releasing a spring to operate
auxiliary contacts. These auxiliary contacts are in series with the coil. If the
overload senses excess current in the load, the coil is de-energized. Contactor
relays can be extremely loud to operate, making them unfit for use where
noise is a chief concern.

A simple electromagnetic relay consists of a coil of wire wrapped

around a soft iron core, an iron yoke which provides a low reluctance
path for magnetic flux, a movable iron armature, and one or more sets
of contacts (there are two in the relay pictured). The armature is hinged
to the yoke and mechanically linked to one or more sets of moving
contacts. It is held in place by a spring so that when the relay is de-

80

energized there is an air gap in the magnetic circuit. In this condition,

one of the two sets of contacts in the relay pictured is closed, and the
other set is open. Other relays may have more or fewer sets of contacts
depending on their function. The relay in the picture also has a wire
connecting the armature to the yoke. This ensures continuity of the
circuit between the moving contacts on the armature, and the circuit
track on the printed circuit board (PCB) via the yoke, which is soldered
to the PCB
When an electric current is passed through the coil it generates
a magnetic field that activates the armature and the consequent
movement of the movable contact either makes or breaks (depending
upon construction) a connection with a fixed contact. If the set of
contacts was closed when the relay was de-energized, then the
movement opens the contacts and breaks the connection, and vice
versa if the contacts were open. When the current to the coil is
switched off, the armature is returned by a force, approximately half as
strong as the magnetic force, to its relaxed position. Usually this force
is provided by a spring, but gravity is also used commonly in industrial
motor starters.
When the coil is energized with direct current, a diode is often placed
across the coil to dissipate the energy from the collapsing magnetic
field at deactivation, which would otherwise generate a voltage
spike dangerous

to semiconductor circuit

components.

Some

automotive relays include a diode inside the relay case. Alternatively, a

contact protection network consisting of a capacitor and resistor in
series (snubber circuit) may absorb the surge. If the coil is designed to
be energized with alternating current (AC), a small copper "shading
ring" can be crimped to the end of the solenoid, creating a small out-ofphase current which increases the minimum pull on the armature
during the AC cycle.

81

A solid-state relay uses a thyristor or other solid-state switching device,

activated by the control signal, to switch the controlled load, instead of
a solenoid. An optocoupler (a light-emitting diode (LED) coupled with
a photo transistor) can be used to isolate control and controlled
circuits.

OPERATING PRINCIPLE
Unlike general-purpose relays, contactors are designed to be directly
connected to high-current load devices. Relays tend to be of lower
capacity

and

are

usually

designed

for

both normally

closed and normally open applications. Devices switching more than 15

amperes or in circuits rated more than a few kilowatts are usually
called contactors. Apart from optional auxiliary low current contacts,
contactors are almost exclusively fitted with normally open contacts.
Unlike relays, contactors are designed with features to control and
suppress the arc produced when interrupting heavy motor currents.
When current passes through the electromagnet, a magnetic field is
produced, which attracts the moving core of the contactor? The
electromagnet

coil

draws

more

current

initially,

until

its inductance increases when the metal core enters the coil. The
moving contact is propelled by the moving core; the force developed
by the electromagnet holds the moving and fixed contacts together.
When the contactor coil is de-energized, gravity or a spring returns the
electromagnet core to its initial position and opens the contacts.

82

For contactors energized with alternating current, a small part of the

core is surrounded with a shading coil, which slightly delays the
magnetic flux in the core. The effect is to average out the alternating
pull of the magnetic field and so prevent the core from buzzing at twice
line frequency.

7805 VOLTAGE REGULATOR IC

The 7805 is a self-contained fixed linear voltage regulator integrated circuit..
The voltage regulator ic family is commonly used in electronic circuits
requiring a regulated power supply due to their ease-of-use and low cost. The
7805 line is positive voltage regulators: they produce a voltage that is
positive relative to a common ground.

7805

ICs

have

the TO220 form

three
factor,

terminals
although

and

are

smaller

commonly

found

surface-mount

in
and

larger TO3 packages are available. These devices support an input

voltage anywhere from a couple of volts over the intended output
voltage, up to a maximum of 35 to 40 volts depending on the make,
and typically provide 1 or 1.5 amperes of current (though smaller or
larger packages may have a lower or higher current rating).

7805 series ICs do not require additional components to provide a

constant, regulated source of power, making them easy to use, as well
as economical and efficient uses of space. Other voltage regulators
may require additional components to set the output voltage level, or
to assist in the regulation process. Some other designs (such as
a switched-mode power supply) may need substantial engineering
expertise to implement.
7805 series ICs have built-in protection against a circuit drawing too much
power. They have protection against overheating and short-circuits, making
83

them quite robust in most applications. In some cases, the current-limiting

features of the 7805 devices can provide protection not only for the 7805
itself, but also for other parts of the circuit.

7805 ICs are easy to use and handle but these cannot give an altering
voltage required so LM317 series of ICs are available to obtain a
voltage output from 1.25 volts to 37 volts.

2N3055 TRANSISTOR
The 2N3055 is a silicon NPN power transistor intended for general purpose
applications. The horizontal output transformer from a CRT type TV can be
driven using just two resistors and a 2N3055 in fly back mode, transforming a
low voltage, such as 12 volts, into several kilovolts. The output is very low
current, so there is a minimal chance of dangerous electric shock. However,
the design is limited by the 2N3055's ability to handle this sort of circuit, and
will overheat and quickly fail from the inductive voltage feedback spikes from
the transformer. Hobbyists would, after gaining an understanding of high
voltage, then move on to higher power circuits and transformers. This
transistor must be counted among the hobbyists as the most used power
transistor, after being used in audio power amplifier with powers ranging from
10W to 400W.

555 TIMER IC
The 555 timer IC is an integrated circuit (chip) used in a variety of timer,
pulse generation, and oscillator applications. The 555 can be used to provide
84

time delays, as an oscillator, and as a flip-flop element. Derivatives provide up

to four timing circuits in one package.

The IC was designed in 1971 by Hans R. Camenzind under contract to

Signetics, which was later acquired by Philips.Depending on the
manufacturer, the standard 555 package includes 25 transistors, 2
diodes and 15 resistors on a silicon chip installed in an 8-pin mini dualin-line package (DIP-8).[2] Variants available include the 556 (a 14-pin
DIP combining two 555s on one chip), and the two 558 & 559s (both a
16-pin DIP combining four slightly modified 555s with DIS & THR
connected internally, and TR is falling edge sensitive instead of level
sensitive). There is no 557.
The NE555 parts were commercial temperature range, 0 C to +70 C,
and the SE555 part number designated the military temperature range,
55 C to +125 C. These were available in both high-reliability metal
can (T package) and inexpensive epoxy plastic (V package) packages.
Thus the full part numbers were NE555V, NE555T, SE555V, and
SE555T. It has been hypothesized that the 555 got its name from the
three 5 k resistors used within, but Hans Camenzind has stated that
the number was arbitrary.

Pin Diagram

85

The connection of the pins for a DIP package is as follows:

Pi Nam
n
1

GND

TRIG

OUT

Purpose

Ground, low level (0 V)

OUT rises, and interval starts, when this input falls below 1/2
of CTRL voltage.
This output is driven to approximately 1.7V below +VCC or
GND.

RESE
T

A timing interval may be reset by driving this input to GND,

but the timing

does not begin again until RESET

rises above approximately 0.7 volts. Overrides TRIG which overrides

THR.
5

CTRL

THR

DIS

VCC

"Control" access to the internal voltage divider (by default, 2/3

VCC).
The interval ends when the voltage at THR is greater than at
CTRL.
Open collector output; may discharge a capacitor between
intervals. In phase

with output.

Positive supply voltage is usually between 3 and 15 V.

Note-PIN 5 is also called the CONTROL VOLTAGE pin by applying a

voltage to the CONTROL VOLTAGE input you can alter the timing
characteristics of the device. In most applications, the CONTROL
VOLTAGE input is not used. It is usual to connect a 10 nF capacitor
between pin 5 and 0 V to prevent interference. The CONTROL VOLTAGE
input can be used to build an astable with a frequency modulated
output.

SPECIFICATION
86

These specifications apply to the NE555. Other 555 timers can have
different specifications depending on the grade (military, medical, etc.).
Supply voltage (VCC)

4.5 to 15 V

Supply current (VCC = +5 V)

3 to 6 mA

Supply current (VCC = +15 V)

10 to 15 mA

Output current (maximum)

200 mA

Maximum Power dissipation

600 mW

Power consumption (minimum

30 mW@5V,

operating)

225 mW@15V

Operating temperature

0 to 70 C

SINGLE PHASE AC MOTOR

An AC motor is an electric motor driven by an alternating current.
It commonly consists of two basic parts, an outside stationary stator
having coils supplied with alternating current to produce a rotating
magnetic field, and an inside rotor attached to the output shaft that is
given a torque by the rotating field.
There are two main types of AC motors, depending on the type of rotor
used. The first type is the induction motor, which runs slightly slower
than the supply frequency. The magnetic field on the rotor of this motor
is created by an induced current. The second type is the synchronous
motor, which does not rely on induction and as a result, can rotate
exactly at the supply frequency or a sub-multiple of the supply
frequency. The magnetic field on the rotor is either generated by
current delivered through slip rings or by a permanent magnet. Other
types of motors include eddy current motors, and also AC/DC
mechanically commutated machines in which speed is dependent on
voltage and winding connection

87

Induction motor has a rotating (relative to the rotor) magnetic

field on the rotor. In a squirrel cage motor, this field is created because
the motion of the stator field relative to the shorted rotor cage induces
currents in the rotor. These currents generate the rotor field, which
interacts with the stator field to create torque. A wound-rotor induction
machine has rotor windings similar to a synchronous machine, in which
currents are induced by the rotating stator field. Induction motors
always rotate in some narrow speed range that is less than
synchronous speed. This speed difference, which is necessary to
generate the rotor field, is called the "slip." Low slip machines, which
turn at very near synchronous speed, are more efficient than high slip
machines, but have lower starting torque. Induction machines can
produce some torque at zero speed, so they are capable of starting
themselves if the load torque is low enough at zero speed. The torquespeed characteristic of induction machines at rated speed has a
negative slope (as speed decreases, torque increases). As a result,
induction machines do not require controls to operate - the feedback
mechanism

is

built

into

the

machine.

The winding resistance a wound-rotor induction machine can be varied

by connecting resistors to the rotor windings via the slip rings. This
allows the torque-speed characteristics of the wound-rotor machine to
be varied as needed (e.g., high resistance and high slip for high
starting torque and then low resistance and low slip for high efficiency
at

rated

speed).

The absence of a rotor winding makes squirrel cage induction machines

significantly cheaper to manufacture than synchronous machines (or
wound-rotor

induction

machines).

Squirrel

cage

machines

are

extremely rugged because of the lack of a wound rotor (the cage is

usually cast right into the rotor laminations), and the lack of slip rings
makes them more suitable for explosive environments because there is
no arcing mechanism. The circulating currents in an induction machine

88

rotor lead to resistive losses that make induction machines less

efficient that synchronous motor.

MAIN CHARACTERSTICS OF INDUCTION MOTOR:

Wound-rotor or squirrel cage to generate the rotor magnetic field.

Rotor magnetic field rotates with respect to the rotor.

Always turn at less than synchronous speed.

Do not require control.

Much cheaper to produce (true for squirrel cage machines).

Self-starting.

Less efficient than synchronous machines.

More suitable for explosive environments.

No maintenance (for squirrel cage machines).

89

March 12
8:29:23 PM I
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90

Source of NIT

NIT Number

Document
Contract
Sale Close Classifications*
Date

Description

Farakka (West Bengal) 40034598

24/3/2015

Administrative
Procurement of Anhydrous Ammonia in 60 Kg capacity
Works & Purchases cylinder

Unchahar (Uttar
Pradesh)

40035551

31/3/2015

Work Contract

EFFECT OF STATION ACTIVITIES ON GANGA RIVER

AND OTHER WATER BODIES

Unchahar (Uttar
Pradesh)

40035550

31/3/2015

Work Contract

BRC for OH and BDM of Valves & Aux. in TG area

Stage-I, II & III

Unchahar (Uttar
Pradesh)

40035553

31/3/2015

Work Contract

Dismantling, transportation, fabrication, erection &

commissioning work of ash slurry disposal pipeline of
400NB & 350NB of St-I & II of FGUTPP, Unchahar

Unchahar (Uttar
Pradesh)

40035625

31/3/2015

Work Contract

High Pressure Water Jet Cleaning of St-I, II III

Condenser

Unchahar (Uttar
Pradesh)

40035644

31/3/2015

Work Contract

Maintenance work of Ash slurry disposal pipeline of

Stage I, II III

Rihand (Uttar Pradesh) 40023557

30/3/2015

Administrative
Supply of diesel forklift truck 5T capacity
Works & Purchases

Rihand (Uttar Pradesh) 40025090

30/3/2015

Equipment Supply
& Erection

Supply of Centrifuge Machine

Rihand (Uttar Pradesh) 40028977

30/3/2015

Miscellaneous
(Others)

Procurement of Signaling Cable for MGR

Unchahar (Uttar
Pradesh)

40035110

31/3/2015

Equipment Supply
& Erection

SUPPLY OF HIGH ALLOY PIPE & BEND FOR TG AREA

STAGE-I,II & III

Unchahar (Uttar
Pradesh)

40035401

31/3/2015

Services

CLEANING OF DRAINS IN CW AREA (PKG NO

026/2207)

Unchahar (Uttar
Pradesh)

40035432

31/3/2015

Work Contract

RUNNING AND MAINTENANCE OF ASH DYKE - II,

UMRAN AND DISCHARGE CHANNEL (PKG NO.
026/2221)

Unchahar (Uttar
Pradesh)

40035635

31/3/2015

Work Contract

Drinking water supply system in plant premises (PKG

NO 026/2218)

Unchahar (Uttar
Pradesh)

40034088

31/3/2015

Work Contract

MISCELLANEOUS JOB AT WAGON TIPPLER (185/2183)

Unchahar (Uttar
Pradesh)

40035383

31/3/2015

Work Contract

R&M of desert coolers in non O&M Plant area, Publice

buildings of T/Ship (Pkg. No. 021/2217)

Unchahar (Uttar
Pradesh)

40035384

31/3/2015

Work Contract

BMC for ACs, Water Coolers & Hydrogen Driers in O&M

area (Pkg No. 045/2198)

Unchahar (Uttar
Pradesh)

40034034

31/3/2015

Services

REPLACEMENT OF SPARES OF PERIPHERAL SYSTEM OF

ABT WITH SEPARATE OFC LAN TO INTEGRATE WITH
EXISTING ABT METERS

Unchahar (Uttar
Pradesh)

40034985

31/3/2015

Equipment Supply
& Erection

SUPPLY OF SCRAPER CONVEYOR ST-I

Unchahar (Uttar

40033148

31/3/2015

Equipment Supply

Unchahar 700036259 PROJECTORS

91

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BRBCL (Bhartiya Rail Bijalee Co. Ltd.)
Western Region Headquarters, Mumbai
Gandhar (Gujarat)
Kawas (Gujarat)
Korba (Chhattisgarh)
Sipat (Chhattisgarh)
Vindhyachal (Madhya Pradesh)
Plant Mouda (Maharashtra)
NTPC Solapur (Maharashtra)
Southern Region Headquarters, Hyderabad
Kayamkulam (Kerala)
Ramagundam (Andhra Pradesh)
Simhadri (Andhra Pradesh)
Coal Mining & Coal Washeries Headquarter
Pakri Barwadih (Bihar)
Talaipalli Coal Mining Project (Chattisgarh)
Dulanga Coal Mining Project (Orissa)
NSPCL (NTPC SAIL Power Company (P) Ltd.) - Durgapur
NSPCL (NTPC SAIL Power Company (P) Ltd.) - Rourkela
NSPCL Corporate Centre
BESCL (BHILAI Electric Supply Co. Ltd.)
BESCL Corporate Centre
Hydro Region Headquarters, NOIDA
Kol Dam (Himachal Pradesh)
Loharinag-Pala (Uttranchal)
Tapovan-Vishnugad (Uttranchal)
NESCL-NTPC Electric Supply Company Limited
NHL-NTPC Hydro Ltd., Noida
NVVNL-NTPC VIDYUT VYAPAR NIGAM LTD
Kanti Bijlee Utpadan NIGAM Limited
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Multimedia CBT.

In order to share enormous training information at the door step of Power Utilities and Engineering
Institutes as well as in house training. A Multimedia Computer Based Training (CBT) Centre has bee
established at NPTI's Corporate Office and its Regional Institute for developing Multimedia CBTs on
various Technical areas concerning Power Generation like : Thermal, CCGT/Gas, Thermal, Hydro,
Renewable Transmission & Distribution and Management Areas.

Open Learning Centres (OL Cs) have also been established at all Regional Institutes for Self Learne
at learner's own choice and pace without any help of the subject experts. CBT has been identified as
one of the most cost effective means of delivering consistent high quality training. So far NPTI has
developed more than 50 Multimedia CBTs for power professionals and has been marketing them a
reasonable prices to the Utilities and Educational Institutes.

Besides in house training in NPTI, these Multimedia CBT packages are being utilized by various Pow
Utilities / SEBs as well as Engineering Institutes for upgrading and enhancing their knowledge and
skill.
POWER UTILITIES / SEBs
BHEL, MSEB, RRVUNL, NTPC, NHPC, NPC,
PSEB, TNEB, OHPC, NLC, DVB, KLTPS, DVC,

ENGINEERING INSTITUTIONS
G.B Pant University of Agric. and Technology, NIT
NIT Durgapur, Jawaharlal Nehru Technological U

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BT and
ublicati
ns

ssociat
Links

WBPDCL, IPPGCL, BBMB, BSES, TATPOWER, (AP) Kalyani University (WB), CMERI, VNIT (Nag
THERMAX, ACC, APSEB, NDPL, UPRVUN,
College of Engineering, Bharati Vidyapeeth, Deem
BSEB, WSEB, etc.
University, Pune etc.
Advantages of Multimedia CBT
Interactive
Cost effectiveness
Provides instant feed back

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