Vocational Training at NTPC Limited

[National Thermal Power Corporation Limited DADRI]

AN INDUSTRIAL INTERNSHIP REPORT

submitted by

Sumit Mehenge

(16BEE1103)

in partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY

in

ELECTRICAL AND ELECTRONICS ENGINEERING

January 2019

i
 DECLARATION BY THE CANDIDATE

I hereby declare that the in-plant training report entitled “Vocational Training at
NTPC Dadri” submitted by me to VIT Chennai Campus, in partial fulfillment of
the requirement for the award of the degree of B. Tech in ELECTRICAL AND
ELECTRONICS is a record of bonafide industrial training undertaken by me
under the supervision of Mr. Sanjay Sen (AGM-EMD I/C-TH). I further declare
that the work reported in this report has not been submitted and will not be
submitted, either in part or in full, for the award of any other degree or diploma in
this institute or any other institute or university.

Signature of the Candidate

Chennai:

Date:

ii
 SCHOOL OF ELECTRICAL ENGINEERING

BONAFIDE CERTIFICATE

This is to certify that the in-plant training report entitled Vocational Training at
NTPC Dadri submitted by Sumit Mehenge 16BEE1103 to VIT - Chennai
Campus, in partial fulfillment of the requirement for the award of the degree of
B.Tech in Electrical and Electronics Engineering is a record of bonafide in-plant
training undertaken by him/her under my supervision. The training fulfills the
requirements as per the regulations of this Institute and in my opinion meets the
necessary standards for submission. The contents of this report have not been
submitted and will not be submitted either in part or in full, for the award of any
other degree or diploma in this institute or any other institute or university.

Program Chair (B.Tech EEE)

Date:

Examiner (s) Signature

1. 2.

iii
iv
 ACKNOWLEDGEMENT

The extensive training program at National Thermal Power Corporation

Limited (NTPC Ltd), Dadri was a great opportunity and an exceptional learning
experience for me. It is my first opportunity to get an exposure of practical world.

I got opportunity to work under the esteemed supervision of Mr. Sanjay Sen
(AGM-EMD I/C-Gas). It was great privilege for me to work under him. I am
thankful to him for his extremely patient gesture, to make training program fruitful
for me and for rendering every possible help to carry out this training.

I offer my gratitude to the management and staff that have spent their precious
time, expressed keen interest and given continued encouragement throughout the
study and enabled the successful completion of my vocational training at NTPC
Dadri.

I am indebted to my parents, teachers and friends who helped and encouraged me

to work hard, move ahead and inspired me with words. Their blessings made this
work possible.

Sumit Mehenge

v
 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT viii

LIST OF TABLES ix

LIST OF FIGURES x

LIST OF SYMBOLS xi

1. INTRODUCTION 1

2. Overview of NTPC 2

2.1 History 2

2.2 Installed Capacity 2-3

2.3 Coal Based Power Stations 4-7

2.4 Gas Based Power Stations 7

2.5 Hydro Based Power Projects 8-9

2.6 Renewable Energy Projects 9-10

2.7 Station at a Glance 11

3. Process/Work flow 13

3.1 Gas Power Plant 13

3.2 How does combined cycle power plant work? 14

vi
 3.3 Generators 35

3.4 Transformer 40

3.5 Protection Relays 45

3.6 Dadri Switchyard 48

3.7 Circuit Breaker 51

3.8 High-voltage direct current (HVDC) 54

4. CONCLUSION 57

vii
 ABSTRACT

This report throws light upon the task and duties performed by intern at NTPC
Dadri. A thermal power station is a power plant in which the prime mover is steam
driven. Water is heated, turns into steam and spins a steam turbine which drives an
electrical generator. After it passes through the turbine, the steam is condensed in a
condenser and recycled to where it was heated; this is known as a Rankine cycle. A
Gas turbine engines derive their power from burning fuel in a combustion chamber
and using the fast flowing combustion gases to drive a turbine in much the same
way as the high pressure steam drives a steam turbine. This is achieved by raising
the steam in the boilers, expanding it through the turbine and coupling the turbines
to the generators which converts mechanical energy into electrical energy. Gas
turbines have a very high power to weight ratio and are lighter and smaller than
internal combustion engines of the same power. Though they are mechanically
simpler than reciprocating engines, their characteristics of high speed and high
temperature operation require high precision components and exotic materials
making them more expensive to manufacture.

viii
 LIST OF TABLES
1. Table 1 Total Installed Capacity
2. Table 2 Coal Based Power Stations owned by NTPC
3. Table 3 Coal Based Joint Ventures/Subsidiaries
4. Table 4 Gas Based Power Stations owned by NTPC
5. Table 5 Gas Based Joint Ventures/Subsidiaries
6. Table 6 Hydro Based Power Projects
7. Table 7 Renewable Energy Projects
8. Table 8 Wind Energy Project
9. Table 9 Specification of ICT
10. Table 10 SPECIFICATION OF AIR BLAST CIRCUIT BREAKER
11. Table 11 SPECIFICATION OF SF6 GAS CIRCUIT BREAKER
12. Table 12 Transmission lines to locations for power distribution

ix
 LIST OF FIGURES
1. Fig.1 Growth of NTPC installed capacity and generation
2. Fig.2 Location of NTPC owned plants
3. Fig.3 . Dadri Gas Plant Parameter Display
4. Fig.4 Idealized Brayton Cycle
5. Fig.5 Rankine Cycle
6. Fig.6 Plant Layout
7. Fig.7 BOILER REPOWERING SYSTEM EXHAUST HEAT EXCHANGER

8. Fig.8 Steam Turbine Rotor

9. Fig.9 Transformer
10. Fig.10 Protection Relays
11. Fig.11 Switchyard layout
12. Fig.12 Single line diagram of a power flow
13. Fig.13 Circuit Breaker
14. Fig.14 HVDC Transmission line
15. Fig.15 Comparison of the costs of AC and DC transmission

x
LIST OF SYMBOLS, ABBREVIATION AND NOMENCLATURE

1. NTPC National Thermal Power Corporation

2. NCPS National Capital Power Station
3. DM Demineralized
4. UAT Unit Auxiliary Transformer
5. ST Station Transformer
6. ICT Inter connecting Transformer
7. CVT Capacitor Voltage Transformer
8. CT Current Transformer
9. O/H Overhead
10. EMD Electrical Maintenance Department
11. HVDC High Voltage Direct Current
12. HVAC High Voltage Alternating Current

xi
 1.
Introduction
The electric power industry provides the production and delivery of electric
energy, often known as power, or electricity, in sufficient quantities to areas that
need electricity through a grid connection. The grid distributes electrical energy to
customers. Electric power is generated by central power stations or by distributed
generation. Almost all coal, nuclear, geothermal, solar thermal electric, and waste
incineration plants, as well as many natural gas power plants are thermal. The
initially developed reciprocating steam engine has been used to produce
mechanical power since the 18th Century, with notable improvements being made
by James Watt. When the first commercially developed central electrical power
stations were established in 1882 at Pearl Street Station in New York and Holborn
Viaduct power station in London, reciprocating steam engines were used. The
development of the steam turbine in 1884 provided larger and more efficient
machine designs for central generating stations. By 1892 the turbine was
considered a better alternative to reciprocating engines; turbines offered higher
speeds, more compact machinery, and stable speed regulation allowing for parallel
synchronous operation of generators on a common bus. After about 1905, turbines
entirely replaced reciprocating engines in large central power stations.

1
 2.
Overview of NTPC

2.1. History- NTPC is India’s largest energy conglomerate with roots planted
way back in 1975 to accelerate power development in India. Since then it
has established itself as the dominant power major with presence in the
entire value chain of the power generation business. From fossil fuels it has
forayed into generating electricity via hydro, nuclear and renewable energy
sources. This foray will play a major role in lowering its carbon footprint by
reducing greenhouse gas emissions. To strengthen its core business, the
corporation has diversified into the fields of consultancy, power trading,
training of power professionals, rural electrification, ash utilization and coal
mining as well.

Fig. 1. Growth of NTPC installed capacity and generation

2.2. Installed Capacity

Present installed capacity of NTPC is 53,651 MW (including 7,551 MW through

JVs/Subsidiaries) comprising of 51 NTPC Stations (21 Coal based stations, 7
2
combined cycle gas/liquid fuel based stations, 2 Hydro based station, 1 Wind based
Station), 9 Joint Venture stations (8 coal based and one gas based) and 12
renewable energy projects.

Fig. 2. Location of NTPC owned plants

Sl.No. NO. OF PLANTS CAPACITY (MW)

NTPC Owned

Coal 21 40,355

Gas/Liquid Fuel 7 4,017

Hydro 1 800

Renewable energy projects (Solar PV) 12 878

3
Wind 1 50

Total 42 46,100

Owned By JVs/Subsidiaries

Coal & Gas 9 7,551

Total 51 53,651

Table 1. Total Installed Capacity

2.3. Coal Based Power Stations

With 21 coal based power stations, NTPC is the largest thermal power generating
company in the country. The company has a coal based installed capacity of
40,355 MW.

Sr. COAL BASED(Owned by STATE COMMISSIONED

No. NTPC) CAPACITY(MW)

1. Singrauli Uttar Pradesh 2,000

2. Korba Chhattisgarh 2,600

3. Ramagundam Telangana 2,600

4. Farakka West Bengal 2,100

5. Vindhyachal Madhya 4,760

Pradesh

4
6. Rihand Uttar Pradesh 3,000

7. Kahalgaon Bihar 2,340

8. Dadri Uttar Pradesh 1,820

9. Talcher Kaniha Orissa 3,000

10. Feroze Gandhi, Unchahar Uttar Pradesh 1,550

11. Talcher Thermal Orissa 460

12. Simhadri Andhra Pradesh 2,000

13. Tanda Uttar Pradesh 440

14. Badarpur Delhi 705

15. Sipat Chhattisgarh 2,980

16. Mauda Maharashtra 2,320

17. Barh Bihar 1320

18. Bongaigaon Assam 500

19. Kudgi Karnataka 2400

5
20. Solapur Maharashtra 660

21. Lara Chhattisgarh 800

Total 40,355

Table 2. Coal Based Power Stations owned by NTPC

Coal Based Joint Ventures/Subsidiaries:

Sr. COAL BASED(Owned by STATE COMMISSIONED

No. JVs/Subsidiaries) CAPACITY

1. Durgapur West Bengal 120

2 Rourkela Orissa 120

3 Bhilai Chhattisgarh 574

4 Kanti Bihar 610

5 IGSTPP, Jhajjar Haryana 1500

6 Vallur Tamil Nadu 1500

6
7 Nabinagar-BRBCL Bihar 500

8. Meja Uttar 660

Pradesh

Total 5,584

Table 3. Coal Based Joint Ventures/Subsidiaries:

2.4 Gas Based Power Stations

The details of NTPC gas based power stations is as follows

Sr. No. GAS BASED STATE COMMISSIONED

CAPACITY(MW)
(Owned by NTPC)

1. Anta Rajasthan 419.33

2. Auraiya Uttar Pradesh 663.36

3. Kawas Gujarat 656.20

4. Dadri Uttar Pradesh 829.78

5. Jhanor-Gandhar Gujarat 657.39

6. Rajiv Gandhi CCPP Kayamkulam Kerala 359.58

7. Faridabad Haryana 431.59

7
Total 4,017.23

Table 4. Gas Based Power Stations owned by NTPC

Gas Based Joint Ventures/Subsidiaries:

Sr. COAL BASED (Owned by STATE COMMISSIONED

No. JVs/Subsidiaries) CAPACITY

1. RGPPL Maharashtra 1967.08

Total 1,967.08

Table 5. Gas Based Joint Ventures/Subsidiaries:

2.5 Hydro Based Power Projects

NTPC has increased thrust on hydro development for a balanced portfolio for long
term sustainability. The first step in this direction was taken by initiating
investment in Koldam Hydro Electric Power Project located on Satluj river in
Bilaspur district of Himachal Pradesh. Other hydro project under construction is
Tapovan Vishnugad. On all these projects construction activities are in full swing.

Sr. HYDRO BASED STATE APPROVED COMMISSIONED

No. CAPACITY(MW) CAPACITY (MW)

1. Koldam (HEPP) Himachal 800 800

Pradesh

8
2. Tapovan Vishnugad (HEPP) Uttarakhand 520 -

3. Singrauli CW Discharge(Small Uttar Pradesh 8 8

Hydro)

4. Lata Tapovan Uttrakhand 171 -

5. Rammam West Bengal 120 -

Total 1,619 808

Table 6. Hydro Based Power Projects

2.6 Renewable Energy Projects

Solar Energy:

Sr. No. Project State/UT Capacity (MW)

1. Dadri Solar PV Uttar Pradesh 5

2. Port blair Solar PV Andaman & Nicobar Island 5

3. Ramagundam Solar PV (Phase -I) Telangana 10

4. Talcher Kaniha Solar PV Odisha 10

5. Faridabad Solar PV Haryana 5

9
6. Unchahar Solar PV Uttar Pradesh 10

7. Rajgarh Solar PV Madhya Pradesh 50

8. Singrauli Solar PV Uttar Pradesh 15

9. Ananthapuram Solar PV Andhra Pradesh 250

10. Bhadla-Solar Rajasthan 260

11. Mandsaur-Solar PV Madhya Pradesh 250

Total 870

Table 7. Renewable Energy Projects

Wind Energy Project:

Sr. No. Project State/UT Capacity (MW)

1. Rojmal Gujarat 50

Total 50

Table 8. Wind Energy Project:

10
2.7 STATION AT A GLANCE-

NTPC Dadri is a model project of NTPC. Also it is the best project of NTPC also
known as NCPS (National capital power station). Situated 60 km. away from Delhi
in the District of Gautam Budh Nagar, Uttar Pradesh. The station has an installed
capacity of 2649 MW of power-1820MW from Coal based units and 829 MW Gas
Based Station. The station is excelling in performance ever since its commercial
operation consistently in receipts of meritorious objectivity awards, the coal based
units of the station stood first in the country in terms of PLF for the financial year
1999-2000 by generating an all-time high PLF of 96.12% with the most modern O
&M practises. NTPC Dadri is committed to generate clean and green Power. The
Station also houses the first HVDC station of the country (GEP project) in
association with centre for power efficiency and Environment protection
(CENEEP) – NTPC & USAUID.

NTPC DADRI GAS POWER PLANT

The National Capital Power Station [NCPS] has the distinction of being the
country's only three in one project.. In the main plant block two modules, each
consisting of two GTGs placed on each side of 2 STGs. The central control room
is located towards west of the ST hall. The transformer yard is on the western side
of the turbine hall, with switchyard further down west. Induced draft cooling
towers have been located considering the proper flow of cooling water. Nearer to
main power house & convenient routing of open return channel to CW pump
house. The 220/400 KV switchyard has been located in front of the power station.
The 220 KV switchyard control room is accommodated in the central control room
itself. Space has been kept for liquid oil installation and oil unloading facilities.
The GAIL terminal for receiving gas is located within boundary of plant site.

11
PLANT SIZE-
Thermal (Coal) Plant – Closed Cycle Plant 840
MW

Gas Plant: Unit-1 829MW

Solar: Unit-1 5MW

Fig. 3. Dadri Gas Plant Parameter Display

Gas Source: Sources of supply GAIL. Distance of the station from the sources of
supply 1700 KM. Mode of Transport GAIL HBJ PIPELINE. APM gas is used in
the gas power station and alternative fuel now used is HSD .
Water Source: From Upper Ganges Canal and is processed into DM water for
usage.
12
 3.
Process/Work flow

GAS POWER PLANT

The power plant consists of gas turbine generating units waste heat recovery
boilers, steam turbo generator, ancillary electrical and mechanical equipments. The
power generated at this power station is fed over 220 KV AC transmission system
associated with this project to distribute the power in the various Regions.

In the Power Sector, gas turbine drive generators are used.

Gas turbines range in size from less than 100 KW up to about 140.000 KW. The
gas turbine has found increasing application due to the following potential
advantages over competive equipment.

• Small size and weight per horsepower

• Rapid loading capability

• Self-contained packaged unit

• Moderate first cost

• No cooling water required

• Easy maintenance

• High reliability

• Waste heat available for combined cycle application.

• Low Gestation Period

• Low Pollution Hazards

13
The function of a gas turbine in a combined cycle power plant is to drive a
generator which produce electricity and to provide input heat for the steam cycle.
Power for driving the compressor is also derived from gas turbine.

Combined Cycle

Combined Cycle power plant integrates two power conversion cycles namely.
Brayton Cycle (Gas Turbines) and Rankin Cycle (Conventional steam power
plant) with the principal objective of increasing overall plant efficiency.

Brayton Cycle

Gas Turbine plant-operate on Brayton Cycle in which air is compressed this

compressed air is heated in the combustor by burning fuel combustion produced is
allowed to expand In the Turbine and the turbine is coupled with the generator.
Without losses the theoretical cycle process is represented by 1’ 2’ 3’ 4’

In the actual process losses do occur. Deviation from the theoretical process,
results from the fact that compression and expansion are not performed
isentropically but polytropically which is conditioned by heat dissipation
(expansion) and heat supply (Compression) caused by various flow and fraction
by losses.

In the combined cycle mode, the Brayton Cycle is chosen as the topping cycle due
to the high temperature of the exhaust of the gas turbine (point 4 in the P.V
diagram). In modern gas turbines the temperature of the exhaust gas is in the range
of 500 to 550 0C.

14
Reference to the T.S. diagram may indicate the amount of heat that is produced,
converted into mechanical energy and extracted from this process. For the
evaluation of the cyclic process, two parameters are of greatest importance;

1) Thermal efficiency 2) Process working capacity

Thermal efficiency is obtained from chemical binding energy of the fuel and
mechanical energy available at the shaft of the gas turbine.Thermal efficiency ( th )
as follows:

th = Energy at GT shaft

Chemical Energy of fuel

= (Q Input. Q output )/ Q Input

= 1 — Q Output/ Q Input

Working capacity is also obtained from the difference between the amounts of heat
supplied and removed. This is achieved by increasing P2 that is increasing gas
inlet temperature T3.

15
 Fig.4

Rankine Cycle

The conversion of heat energy to mechanical energy with the aid of steam is
carried out through this cycle. In its simplest form the cycle works as follows
(fig.5).

The initial state of the working fluid is water (point-3) which, at a certain
temperature is compressed by a pump (process 3-4) and fed to the boiler. In the
boiler the compressed water is heated at constant pressure (process 4-5-6-1).
Modern steam power plants have steam temperature in the range of 500 0C to 550
0
C at the inlet of the turbine.

16
 Fig.5

Combining two Cycles to Improve Efficiency

We have seen in the above two cycles that gas turbine exhaust is at a temperature
of 500–550 0C and in Rankine Cycle heat is required to generate steam at the
temperature of 500-550 0C. so, why not use the gas-turbine exhaust to generate
steam in the Rankine cycle and save the fuel required to heat the water ? Combined
Cycle does just the same.

17
The efficiency of Gas Turbine cycle alone is 30% and the efficiency of Rankine
Cycle is 35%. The overall efficiency of combined cycle comes to 48%.

Types of Combined Cycles

It is basically of two types, namely Unfired Combined cycle and Fully Fired
combined cycle.

Unfired combined Cycle

The basic system is shown in figure- 3. in this system the exhaust gas is used only
for raising steam to be fed to the steam turbine for power generation.

The conventional fossil fuel fired boiler of the steam power plant is replaced with
a ‘Heat Recovery Steam Generator’ (HRSG). Exhaust gas from the gas turbine is
led to the HRSG where heat of exhaust gas is utilised to produce steam at desired
parameters as required by the steam turbine.

However, non-reheat steam turbine is the preferred choice for adopting this type of
system as usually the live steam temperature for HRSG will be solely controlled by
the gas turbine exhaust temperature which is usually around 500 0C.

18
 UNFIRED COMBINED CYCLE

FIG-6

In recent development, with the introduction of Dual Pressure Cycles more heat is
recovered in the HRSG and steam with higher pressure and temperature can be
generated. But higher capital investment and sometimes necessity of supplemental
firing system makes the system complex and costly.

19
Fully Fired Combined Cycle

Fig – 7 shows the basic schematic of this cycle. In this system the heat of

exhaust gas from gas turbine is used for two purposes as described below:

Heat contained in exhaust gas is used to heat feed water to a desire

BOILER REPOWERING SYSTEM EXHAUST HEAT EXCHANGER

Fig. 7

20
 temperature at the inlet to the boiler. This leads to the reduction or elimination of
the extraction steam requirement from the steam turbine. In case, the steam turbine
has a larger steam swallowing capacity to generate more power the amount of
steam which is being extracted from steam turbine for regenerative feed heating
could be made to expand in the turbine to increase its base load capacity and
improve the overall efficiency. In case the steam turbine does not have the capacity
to swallow extra steam available due to cutting down of extraction, the fuel being
fired in the boiler can be cut down to generate less steam by an amount equivalent
to steam required for extractions and thus improving the overall efficiency due to
less consumption of fuel.

Gas turbine exhaust contains about 14 to 16 % oxygen (by weight) and can be
used as hot secondary air in the conventional fossil fired furnaces. So the heat
required to heat the secondary air will be saved and can be used for other purposes.
FD fan power consumption will also be reduced to a great extent.

Fuels

Gas turbines are capable of burning a range of fuels including naptha, distillates,
crude oils and natural gas. Selection of fuel (s) depends on several factors including
fuel availability, fuel cost and cleanliness of fuel.

Natural gas is an ideal fuel because it provides high thermal efficiency and reliability
with a low operation and maintenance cost. Liquid fuels, particularly heavy oils,
usually contain contaminants, which cause corrosion and fouling in the gas turbine.
Contaminants, which cannot be removed from the fuel, may leave deposits in the gas
turbine, which reduce performance and add maintenance costs.

Dual fuel systems are commonly used, enabling the gas turbine to burn back-up fuels
when the primary fuel source is not available. Dual fuel systems can also be designed
to fire both fuels simultaneously.
21
Advantages of Combined Cycle Plants

Apart from the higher overall efficiency, the combined cycle power plants have
following advantages:

Low installation Cost: power from a combined cycle power plant is approximately
70% of a conventional coal based power plant of same capacity.

Low Gestation Period: Power from a combined cycle power plant can be obtained
in two phases, i.e. two third power, obtainable from gas turbines, is available
within 16-18 months and the balance in next 1 month. This is much lower than the
gestation period for conventional thermal power plants, which is around 48-60
months.

Better Reliability: Combined cycle power plants are considered to be highly

reliable with the reliability factor of 85-90% as compared to 60-65% for
conventional coal Fired Power Plants.

22
3.2 Gas Plant Operation

Gas Turbine, WHRB, Steam Turbine Starting Modes

Basic conditions for plant operation are as follows:-

• Start up or shut down of G/T, WHRB and S/T of each module is performed separately
from the other module (except for S/T gland steam back-up and heating steam back up
systems).
• Start up/shut down mode is selected freely form among those mentioned.

The start up/shut down procedure for WHRB and S/T here mainly describes operating
procedure for G/T by-pass damper, WHRB inlet damper and remote operated valve
necessary for start up and shut down from G/T exhaust gas admission to WHR till rated
load operation of S/T. For detail operating procedure for G/T WHRB, S/T auxiliaries and
remote operated valve following procedures are followed.

Start up Mode

The start up mode of G/T, S/T and WHRB shall be selected from among the following as a
rule through various other start up modes are conceivable according to power demand and
operating principle.

Outline of each start up

• Normal start up mode

This mode is two unit (2G/T’s + 2WHRB’s +1 S/T) combined cycle start up mode which,
after starting up one each of G/T and WHRB, starts up the other G/T and WHRB and
brings the output of G/T and S/T the target output of the module. In this mode, S/T is
loaded with one each of G/T and WHRB in operation, and after the initial load is achieved,
the pressure control of HP/LP by-pass valves of both WHRB’S is changed to common
pressure control and then S/T is loaded up.

23
The timing of starting up the other G/T and WHRB is left to the discretion of the operator,
and S/T is kept stand by at the initial load until the pressure control of both WHRB’S is
changed to the common pressure control.

• Rapid start up mode

This is a mode of starting up both G/T’s and WHRB’S at the same time, changing the
pressure control of HP/LP by-pass valves of both WHRB’S to the common pressure
control, then loading up and brining G/T the output of and S/T to the target output of the
module is achieved.

This mode is used only for start up after right stop or hot start up (with vacuum).

In other start up modes; in which the time from G/T start up to S/T loading is long,
simultaneous startup is not made to reduce heat lose at start up.

• G/T/WHRB additionally start up mode

This is a mode of starting up the other G/T and WHRB one until combined cycle of G/T,
WHRB and S/T is in operation. In this mode, the HP Steam pressure and temperature of the
other G/T and WHRB are raised up those of G/T and WHRB in operation, and then the
pressure control of HP/LP by-pass valves is changed to the common pressure control, and
S/T is loaded up.

• Single G/T/WHRB start up mode

This is a combined cycle start up mode of starting up S/T with only one each of G/T and
WHRB in operation. The other G/T and WHRB remain stopped.

• Individual pressure control

Individual pressure control means pressure control made automatically by using HP/LP by-
pass valves of both WHRB’s and detecting pressure before HP/LPCV so that HP/LP steam
pressure of both WHRB’S will be the same and constant respectively.

• Loading of S/T
24
S/T loading rate after HP/LP by-pass are fully closed and HP/LPCV are fully opened is
determined by the load change rate of G/T, namely S/T load change rate increases as G/T
load change rate increase. (Except for
G/T/WHRB additionally start up mode). S/T unloading rate too is determined by G/T load
change rate under HP/LP by-pass valves are fully closed and HP/LPCV are fully opened.

3.2 How Does A Combined-Cycle Power Plant Work?

Power Generation:

Air Inlet
 The amount of air needed for combustion is 800,000 cubic feet per minute. This air is
drawn though the large air inlet section where it is cleaned, cooled and controlled, in
order to reduce noise.

Turbine-Generators:

 The air then enters the gas turbine where it is compressed, mixed with natural gas and
ignited, which causes it to expand. The pressure created from the expansion spins the
turbine blades, which are attached to a shaft and a generator, creating electricity.
 Each gas turbine produces 185 megawatts (MW) of electricity.
 The blades are attached to a rotor, which spins the generator, and makes electricity.
Think of a generator as a huge spinning magnet inside a coil of wire. As the magnet
spins, electricity is created in the wire loops.

25
Heat Recovery Steam Generator (HRSG)

 The hot exhaust gas exits the turbine at about 1100 degrees Fahrenheit and then passes
through the Nooter Erickson, Heat Recovery Steam Generator (HRSG).
 In the HRSG, there are 18 layers of 100-foot tall tube bundles, filled with high purity
water. The hot exhaust gas coming from the turbines passes through these tube bundles,
which act like a radiator, boiling the water inside the tubes, and turning that water into
steam. The gas then exits the power plant through the exhaust stack at a much cooler
180 degrees, after having given up most of its heat to the steam process.
 About 1 million pounds of steam per hour is generated in this way and sent over to the
steam turbine through overhead piping.

Steam Turbine

26
  The steam turbine is a Siemens Westinghouse KN Turbine Generator, capable of
producing up to 240 MW. It is located on top of the condenser, across from the cooling
tower.
 Steam enters the turbine with temperatures as high as 1000 degrees Fahrenheit and
pressure as strong as 2,200 pounds per square inch. The pressure of the steam is used to
spin turbine blades that are attached to a rotor and a generator, producing additional
electricity, about 100 megawatts per HRSG unit.
 After the steam is spent in the turbine process, the residual steam leaves the turbine at
low pressure and low heat, about 100 degrees. This exhaust steam passes into a
condenser, to be turned back into water.
 By using this “combined-cycle” process, two gas turbines and one steam turbine, we
can produce a total of about 600 megawatts of electricity.

Emissions Control

Selective Catalytic Reduction (SCR)

 To control the emissions in the exhaust gas so that it remains within permitted levels as
it enters the atmosphere, the exhaust gas passes though two catalysts located in the
HRSG.
 One catalyst controls Carbon Monoxide (CO) emissions and the other catalyst controls
Oxides of Nitrogen, (NOx) emissions.

Aqueous Ammonia
 In addition to the SCR, Aqueous Ammonia (a mixture of 22% ammonia and 78%
water) is injected into system to even further reduce levels of NO x.

Best Available Control Technology (BACT)

 Our annual average concentration of NOx is only 2 parts per million, which is
considered the “best available control technology” or BACT by the Air Board.
 As exhaust gas passes out of the exhaust stack, it is continuously sampled and
analyzed, assuring that permit limits are being met.
 With this kind of clean, modern technology, the exhaust stack is only 145 feet high,
compared to 500 feet, the height required by older power plants that use less efficient
emission technology.
 Environmental and health organizations recognize this technology as a benefit to the
27
 community. The local chapters of the American Lung Association and Sierra Club
both support the Metcalf Energy Center.

Transmission of Generated Power Onto the Grid

Transformers

 The Gas Turbine and Steam Turbine generators produce power at 13,000 volts.
 The transformers take the generated 13,000 volts and “transform” them to 230,000
volts, which is the required voltage needed for transmission to the nearby tower that
sends power to the substation.
 A small amount of generation is directed to “Auxiliary transformers” which
“transform” the generated voltage to a lower voltage, so it may be used by the plant to
power our own pumps, fans, and motors. The Metcalf Energy Center requires 12 – 15
megawatts to operate.
Switchyard
 From each transformer, the power passes underground into our switchyard. The power
from all of the generators comes together there, where it is measured, metered and
directed onto the grid.
 The proximity of the site to a large, existing PG&E substation makes it a good place to
build a power plant and the nearest transmission tower is only about 200 feet away.
Condenser and Cooling Tower
 The purpose of the condenser is to turn low energy steam back into pure water for use
in the

Heat Recovery Steam Generator.

 The purpose of the cooling tower is to cool the circulating water that passes through the
condenser. It consists of ten cells with large fans on top, inside the cone-like stacks,
and a basin of water underneath.
 We process and treat the Title 22 recycled water after receiving it from the City, before
using it in our cooling tower. The cool basin water absorbs all of the heat from the
residual steam after being exhausted from the steam turbine and it is then piped back to
the top of the cooling tower.
 As the cool water drops into the basin, hot wet air goes out of the stacks. Normally, hot
moist air mixes with cooler dry air, and typically a water vapor plume can be formed,
one that may travel hundreds of feet in the air and be seen from miles away. The
28
 California Energy Commission considered this visually undesirable in this community
so we added a “Plume-Abatement” feature, louvers along the topsides of the tower that
control the air flow.
 The cooling tower evaporates about three-fourth of the processed, recycled water, then
we send about one-fourth of it back through the sewer lines for re-treatment by the
City.
 The Metcalf Energy Center purchases 3 to 4 million gallons per day of recycled water
from the City of San Jose. Evaporation of this water assists the City in adhering to their
flow cap limits and helps to protect the sensitive saltwater marsh habitat of the San
Francisco Bay environment from receiving too much fresh, recycled water.

Water Tanks, Natural Gas Pipeline, Control Room

Water Tanks
 The largest tank is the Service Water tank. It contains 470,000 gallons of water to be
used for drinking, fire fighting and for the high purity water train. The water from the
service water tank is pumped to the water treatment building where it then passes
through a reverse osmosis unit, a membrane decarbonater and mixed resin bed
demineralizers to produce up to 400 gallons per minute of ultra pure water.
 The pure water is then stored in the smaller 365,000-gallon tank until it is turned into
steam for making electricity.

Natural Gas

 Natural gas fuels the combustion turbines. Each turbine can consume up to 2,000
MMBTU per hour.
 The fuel comes from the major high pressure natural gas pipeline that runs along the
east side of Highway 101, less than 1 mile to the east of our site.
 During construction, “Horizontal Directional Drilling” was utilized with careful
coordination with many local authorities. The pipeline was built 60 feet underground
and passed under highways, creek, train tracks, and environmentally sensitive areas.
 The pipeline enters the site just behind the water tanks, where equipment regulates and
measures the natural gas composition, flow and pressure.
 Gas compressors pump the natural gas though the facilities’ fuel gas system where it is
delivered to the gas turbine and the HRSG duct burners at the proper temperature,
pressure and purity.
29
Control Room
 From the control room, the plant operators monitor and operate the facility, via the
plant’s “Distributed Control System”, with the click of a mouse, viewing graphic
representations of all MEC systems on various screens.
 The system gives operators both audible and visual signals to keep them informed of
plant conditions at all times and to determine when preventative maintenance is
required.

3.3 GENERATORS
Generator Components- This deals with the two main components of the
Generator Viz. Rotor (its winding & balancing) and Stator (its frame, core and
windings).

Fig. 9 Steam Turbine Rotor

1- 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 rpm. 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

30
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 problem. 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. The rotor is a cast steel ingot, and it is further forged
and machined.
Very often a hole is bored through the center of the rotor axially from one end of
the other for inspection. Slots are then machined for windings and ventilation.

2- Rotor Winding- Silver bearing copper is used for the winding with mica as the
insulation between conductors. A mechanically strong insulator such as Meccanite
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.

31
3- 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.

4- Stator- The stator is the heaviest load to be transported. The major part of this
load is the stator core. This comprises an inner frame and outer frame. The outer
frame is a rigid fabricated structure of welded steel plates, within this shell is a
fixed cage of girder built circular and axial ribs. The ribs divide the yoke in the
compartments through which hydrogen flows into radial ducts in the stator core
and circulate through the gas coolers housed in the frame. The inner cage is usually
fixed in to the yoke by an arrangement of springs to dampen the double frequency
vibrations inherent in 2 pole generators. The end shields of hydrogen cooled
generators must be strong enough to carry shaft seals. In large generators the frame
is constructed as two separate parts. The fabricated inner cage is inserted in the
outer frame after the stator core has been constructed and the winding completed.
Stator core: The stator core is built up from a large number of 'punching" or
sections of thin steel plates. The use of cold rolled grain-oriented steel can
contribute to reduction in the weight of stator core for two main reasons:
a) There is an increase in core stacking factor with improvement in lamination cold
Rolling and in cold buildings techniques.
b) The advantage can be taken of the high magnetic permeance of grain-oriented
steels of work the stator core at comparatively high magnetic saturation without
fear or excessive iron loss of two heavy a demand for excitation ampere turns from
the generator rotor.

32
5- Stator Winding- Each stator conductor must be capable of carrying the rated
current without overheating. The insulation must be sufficient to prevent leakage
currents flowing between the phases to earth. Windings for the stator are made up
from copper strips wound with insulated tape which is impregnated with varnish,
dried under vacuum and hot pressed to form a solid insulation bar. These bars are
then place in the stator slots and held in with wedges to form the complete winding
which is connected together at each end of the core forming the end turns. These
end turns are rigidly braced and packed with blocks of insulation material to
withstand the heavy forces which might result from a short circuit or other fault
conditions. The generator terminals are usually arranged below the stator. On
recent generators (210 MW) the windings are made up from copper tubes instead
of strips through which water is circulated for cooling purposes. The water is fed to the windings through
plastic tubes.

Generator Cooling System

The 200/210 MW Generator is provided with an efficient cooling system to avoid
excessive heating and consequent wear and tear of its main components during
operation. This Chapter deals with the rotor-hydrogen cooling system and stator
water cooling system along with the shaft sealing and bearing cooling systems.
 Rotor Cooling System-The rotor is cooled by means of gap pick-up
cooling, wherein the hydrogen gas in the airgap 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
33
 the deformation of copper due to varying temperatures.

 Hydrogen Cooling - 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 it’s forming an explosive mixture with oxygen, proper
arrangement for filling, purging and maintaining its purity inside the
generator have to be made. Also, in order to prevent escape of hydrogen
from the generator casing, shaft sealing system is used to provide oil sealing.
The hydrogen cooling system mainly comprises of a gas control stand, a
drier, an liquid level indicator, hydrogen control panel, gas purity measuring and indicating
instruments,
The system is capable of performing the following functions:
i. Filling in and purging of hydrogen safely without bringing in contact with
air.

ii. Maintaining the gas pressure inside the machine at the desired value at all
the times.
iii. Provide indication to the operator about the condition of the gas inside the
machine i.e. its pressure, temperature and purity.
iv. Continuous circulation of gas inside the machine through a drier in order to
remove any water vapor that may be present in it.
v. 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 demineralized 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
34
 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 210MW Generator-
Manufactured by Bharat heavy electrical Limited (BHEL)
Capacity - 247000 KVA

35
Voltage (stator) - 15750 V
Current (stator) - 9050 A
Voltage (rotor) - 310 V
Current (rotor) - 2600 V
Speed - 3000 rpm
Power factor - 0.85
Frequency - 50 Hz
Hydrogen - 3.5 Kg/cm2
Stator winding connection - 3 phase star connection
Insulation class – B
3.4 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 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.

36
 Fig. 10 Transformer
Inter Connecting Transformer (ICT)-
Power transformers are the backbone of the large grid. The power is generated at
the low voltage level and has to be carried to far away load centers. Typically, the
power is generated at the Pit heads i.e. power source like coal, water. It is
uneconomical carry the bulk power at low voltage levels. Depending upon the
requirement the voltage level is stepped up to the transmission level i.e. 220 or
400kV. At higher voltages the transmission losses are less. Similarly, at the remote
end the voltage is stepped down the distribution level. To accomplish the task
Power transformers are installed and act as bi-directional element in the system.
At NTPC Dadri this task is carried out by bank of Single Phase 400/220kV
Interconnecting transformers. Autotransformers are used when transformation ratio
is between 1 and 2 and above 315MVA, due to size and weight constraints all the
transformers are single phases. Three such single phase transformers are installed
three phases to make One bank of transformer.
Three banks of transformers are installed to evacuate power from the 220kV
switchyard generated by 4X 210MW thermal Units.

37
All these transformers are star- star connected transformers with neutral solidly
grounded. A third winding called tertiary winding at much lower voltage i.e. 33kV,
is also provide and is connected in delta to facilitate the flow of third harmonic
current to reduce the distortion in the output voltage.
To reduce the overall size of the transformer, the transformer is provided with Oil
forced and Air forced type cooling at its 100% rating. However, to save the energy,
the cooling system is controlled by the temperature of the winding. The
transformers are also equipped with On Load Tap Changer to meet the change in
voltage variation. Typically, the Tap changer provides variation between 10% of
the nominal voltage i.e. 400kV with a variation of 0.5% at each tap.
Unit Auxiliary Transformer (UAT)
The UAT draws its input from the main bus duct connecting generator to the
generator transformer. It is used for the working of large devices such as boilers,
heavy motors etc. The total kVA capacity of UAT required can be determined by
assuming 0.85 power factor and 0.9 efficiency for total auxiliary motor load. For
large units, it has become necessary to use more than one auxiliary transformer.
The maximum short circuit currents on auxiliary bus should be limited with in the
maximum switch gear rating available. The maximum permissible voltage dip
while starting the largest single auxiliary motor, usually boiler feed pump, shall
remain within acceptable limits.
Station Transformer (ST)
Station transformer is used to feed the power to the auxiliaries during the start up.
This transformer normally rated for the initial auxiliary load requirements of unit.
In physical cases this load is of order of 60% of the load at full generating capacity.
It is also provided with on load tap changer to cater to the fluctuating voltage of the
grid.

38
Make CROMPTON GREAVES Ltd.

No. 3

Rating 167*3 = 500 MVA

Tap 17

No load Voltage KV (HV side) 400/√3

No load Voltage KV (IV side) 200/√3

No load Voltage KV (LV side) 33KV

Line current Amp. (HV side) 289.25, 433.88, 723.13

Line current Amp. (IV side) 525.91, 788.87, 1314.78

Line current Amp. (LV side) 1688.48

Connection symbol YNaOd11 for 3 phase bank

Type of cooling ONAN / ONAF / OFAF

Frequency 50Hz

39
Insulation level (HV) 1450kV

Insulation level (IV) 630kV

Insulation level (LV) 250kV

Temperature rise oil deg. C 35 degrees above ambient

Table 9. Specification of ICT

COOLING OF TRANSFORMER
Heat is produced in the winding due to the current flowing in the conductors
(I^2*R) and in the core on account of eddy currents and hysteresis losses. In small
dry type transformer heat is dissipated directly to the atmosphere. In oil immersed
transformer heat is dissipated by THERMO SIPHON ACTION.
The purpose of using oil is: -
1. Cooling: Provides a better cooling and helps in exchanging heat
2. Insulation: A non-conductor of electricity so good insulator. The oil used is
such that its flash point is pretty high so that it doesn’t have any possibility to catch
fire. The oil serves as the medium for transferring the heat produced inside the
transformer to the outside transformer
There various types of cooling: -
1. AN – Air Natural
2. ON – Oil Natural
3. AF – Air forced
4. OF – Oil forced
5. ONAF – Oil natural Air forced
6. OFAN - Oil forced Air natural
40
7. OFAF – Oil forced Air forced
TRANSFORMER ACCESSORIES
Conservator: With the variation of temperature there is corresponding variation in
the oil volume. To account for this an expansion vessel called conservator is added
to the transformer with a connecting pipe to the main tank. It is also used to store
the oil and make-up of the oil in case of leakage.
Breather: In conservator the moisture from the oil is excluded from the oil
through breather it is a silica gel column, which absorbs the moisture in air before
it enters the conservator air surface.
Radiator: This a chamber connected to the transformer to provide cooling of the
oil. It has got fans attached to it to provide better cooling.
3.5 PROTECTION RELAYS
Relay is a device that detects the fault mostly in the high voltage circuits and
initiates the operation of the circuit breaker to isolate the defective section from the
rest of the circuit. Whenever fault occurs on the power system, the relay detects
that fault and closes the trip coil circuit. This results in the opening of the circuit
breaker, which disconnects the faulty circuit. Thus the relay ensures the safety of
the circuit equipment from damage, which the fault may cause.

41
 Fig. 11 Protection Relays

PURPOSE OF PROTECTIVE RELAYING

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

42
lightening and unforeseen accidental conditions.
The purpose of protective relays and relaying systems is to operate correct circuit
breaker so as to disconnect only the faulty equipment from the system as quickly
as possible, thus minimizing the trouble and damage caused by faults when they do
occur. With all other equipment it is only possible to mitigate the effects of
short circuit by disconnecting the equipment as quickly aspossible, so that the
destructive effects of the energy into the fault may be minimized.
UNDER VOLTAGE RELAY
Under voltage protection is provide for AC circuits, bus bar, transformer, motor,
rectifier etc. Such protection is given by means of under voltage relay. The relay
coil is energized by voltage to be measured either directly or via a voltage
transformer.
OVER CURRENT RELAY
If a short circuit occurs the circuit impedance is reduced to a low value and
therefore a fault is accompanied by a large current, over current protection is that
protection in which the relay pickup when the magnitude of current exceeds the
pickup level. The basic element in over current protection is an over current relay.
The over current relays are connected to the system normally by means of CTs.
EARTH FAULT RELAY
Earth fault protection responds to single line to ground fault and double line to
ground faults. The current coil of the earth fault relay is connected either in neutral
to ground relay CT circuit. Core balance CT’s are used for earth fault protection.
DIFFERENTIAL RELAY
Differential protection responds to vector difference between two or more similar
quantities. In circulating current differential protections CTs are connected on
either side of the protected equipment’s. During the

internalfaults the difference of secondary current flow through the relay coil.
43
Differential protection is used for protection of large transformer, generator,
motors feeders and bus bars.
3.6 DADRI SWITCHYARD

Fig. 13 Single line diagram of a power flow

It is a switching station which has the following credits:

(i) Main link between generating plant and Transmission system, which has a large
influence on the security of the supply.
(ii) Step-up and/or Step-down the voltage levels depending upon the Network
Node.
(iii) Switching ON/OFF Reactive Power Control devices, which has effect on
Quality of power.

SWITCHYARD EQUIPMENTS
Transformers: Transformer transforms the voltage levels from higher to lower
level or vice versa, keeping the power constant. Inter connecting transformer (ICT)
44
are used to connect 400KV switchyard to 132KV switchyard.
Circuit breakers: Circuit breakers makes or automatically breaks the electrical
circuits under loaded condition.
Isolators: Opens or closes the electrical circuits under No-load conditions.
Instrument transformers: Instrument transformers are used for stepping-down
the electrical parameter (Voltage or Current) to a lower and safe value for Metering
and Protection logics.
CTs are single phase oil immersed type. Secondary current is generally 1A, but
also 5A in certain cases.
The CVT’S (Capacitor Voltage Transformers) are used at 220KV & above. For
lower voltages electromagnetic type transformers are mostly used. The secondary
voltage is 110/sqrt(3).
Earth switch: Earth switches are device which are normally used to earth a
particular system to avoid accident, which may happen due to induction on account
of live adjoining circuits. These don’t handle any appreciable current at all.

45
Lightning arrestors: station type “lightening arresternst lightening or any surges
developing in the system, the practice is also to install lightening arresters at the
incoming terminals of the line. Shielding of substation from direct lightening
stroke is provided through earth wires located at structures ‘peaks’. Recently masts
are also used for the purpose of shielding substation.
Overhead earth wire: It protects the O/H transmission line from Lightning.
Earth switches: are devices which are normally used to earth a particular system
to avoid accident, which may happen due to induction on account of live adjoin
circuits. These do not handle any appreciable current at all.
3.7 CIRCUIT BREAKER
Types of breaker in NTPC switchyard
1- 400kv Air Blast circuit breaker
2- 220kv SF6 Filled circuit breaker

Fig. 14 Circuit Breaker

Air Blast circuit breaker:
In this the compressed air pressure around 15 kg per cm^2 is used for extinction of
46
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.
SPECIFICATION OF DLYF420 nc4
AIR BLAST CIRCUIT
BREAKER Type
Normal Voltage 420KV
Normal Current 2000A
Trip coil voltage 220V dc
Close coil voltage 220V dc
Frequency 50HZ
Short time Current 40KA 3Sec.
Breaking Current Sym. 40KA
Asym. 48 KA
R I L at 50HZ 630KV
Voltage switching impulse 1050
Operating pressure 27-31 Kg
Mass 3850 Kg
Make Hindustan Brown Boveri
Table 10. SPECIFICATION OF AIR BLAST CIRCUIT BREAKER
SF6 Filled 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 of 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.

47
 Table 11. SPECIFICATION OF SF6 GAS CIRCUIT BREAKER
SR. NO CIRCUIT BREAKER
1. CIRCUIT BREAKER ELF SL 4-1
TYPE
2. SR. NUMBER 20000070
3. Month and year of JANUARY - 2001
Mfg.
4. Voltage 245 KV
5. Normal current 1600/2500 AMP.
6. Lightning impulse 1050 KV
with stand voltage
7. Switching impulse - KV
with stand voltage
8. Short circuit breaking 40 KA
current
9. Short time with stand 40 LA 1 Sec.
current & duration
10. Line charging 125 AMP.
breaking current
11. Operating sequence 0-0 3S - CO – 3Min-
CO
12. First - pole - to - clear 1.3
factor
13. Gas pressure SF6 at 7.0 bar
200C (abs)

48
 14. Closing & opening 220 V DC
device supply voltage
15. Auxiliary circuit 240 V AC
supply voltage
16. Air pressure 20.5 bar
17. Frequency 50 Hz
18. Mass (approx.) for 3 4000 kg
Poles

Fig. 14 HVDC Transmission line

3.8 High-voltage direct current (HVDC)
This is a technological accomplishment in power by NTPC. Commissioned in
December '90, the system is the first commercial long distance HVDC link in
India, and also the largest in Asia. The basic objective of the HVDC link is to
transmit the power generated at the RhSTPP efficiently to the
northern region, with significant reduction in transmission losses. It consists of two
converter stations - one located at Rihand (RhSTPP) acting as a rectifier, and the
other at Vidyutnagar (NCPP) as an inverter, involving a distance of about 900 kms.
These stations are connected by a +/- 500 kV HVDC line for transmission of 1,500
49
MW power from Rihand to Vidyutnagar.

Fig. 15 HVDC Terminal Data

Sl.No. Line Name Capacity States

1. Panipat-1 500MW Haryana

2. Panipat-2 600MW Haryana
3. Murad Nagar 500MW Uttar Pradesh
4. Maler Kotla 500MW Punjab
5. Mandola-1 750MW Delhi
6. Mandola-2 750MW Delhi
7. Greater Noida 750MW Uttar Pradesh
8. Maharani Bagh 750MW Delhi
Table 12. Transmission lines to locations for power distribution

50
Deciding Factor for Selection of HVDC over HVAC Transmission

Fig. 31 Comparison of the costs of AC and DC transmission

From Fig. 31, we observe that the initial cost of HVDC line is high since use of
converters like rectifiers and inverters are used at the start and end of transmission
line respectively but after the breakeven distance point the DC line cost is
significantly lower than the AC line cost. So HVDC is used only for transmission
distance more than the breakeven distance (usually 200km) and if the transmission
distance is less than the breakeven point (usually less than 200 km) then HVAC is
used.

51
 4.
CONCLUSION

I went through four weeks of rigorous training under the guidance of capable
engineers and workers of NTPC Dadri and headed by Mr. Sanjay Sen (AGM-EMD
I/C-TH). It was a knowledgeable experience while taking practical training at
NTPC Dadri. It proved an opportunity for encounter with such huge machines like
tippler, turbine, boiler, and generator. But there are few factors that require special
mention. From all the study it can be concluded that NTPC Dadri is fairly
organized unit with the latest machinery available. The turbine is a very
sophisticated assembly of machinery which requires specific conditions of steam
temperature and pressure to work efficiently. Any alteration of the specific
requirements may prove hazardous to the turbine. Another interesting yet worrying
fact is the quantity of gas consumed which approximately 1004.95 MMSCM per
day. The level of pollution is always controlled according the established norms,
but still I consider it to be quite enough. Well, efforts are always underway in
reducing the pollution and improving the efficiency of the plant. All in all, a
thermal power project is very large establishment with many components.
The training was specified under the Electrical Maintenance Department(EMD).
Working under the department I came to know about the various jobs engineers do
which is to prevent breakdown of units and take preventive measures. As I was
undergoing training, I was able to know the practical application of theory what I
used to study from books. With trainings helped me understand that studies help us
to know things but practical helps to apply theories for betterment of humankind. I
would like to give special thanks to the NTPC Dadri staff for their cordial support
for making the training a success.

52