1

ABOUT THE COMPANY

NTPC, the largest power Company in India, was setup in 1975 to accelerate power development in the country. It is among the worlds largest and most efficient power generation companies. In Forbes list of Worlds 2000 Largest Companies for the year 2007, NTPC occupies 411 th place. NTPC has installed capacity of 29,394 MW. It has 15 coal based power stations (23,395 MW), 7gas based power stations (3,955 MW) and 4 power stations in Joint Ventures (1,794 MW). The company has power generating facilities in all major regions of the country. It plans to be a75, 000 MW Company by 2017.NTPC has gone beyond the thermal power generation. It has diversified into hydro power, coalmining, power equipment manufacturing, oil &gas exploration, power trading & distribution. NTPC is now in the entire power value chain and is poised to become an Integrated Power Major .NTPC's share on 31 Mar 2008 in the total installed capacity of the country was 19.1% and it contributed 28.50% of the total power generation of the country during 2007-08. NTPC has set new benchmarks for the power industry both in the area of power plant construction and operations. With its experience and expertise in the power sector, NTPC is extending consultancy services to various organizations in the power business. It provides consultancy in the area of power plant constructions and power generation to companies in India and abroad. In November 2004, NTPC came out with its Initial Public Offering (IPO) consisting of 5.25% afresh issue and 5.25% as offer for sale by Government of India. NTPC thus became a listed company with Government holding 89.5% of the equity share capital and rest held by Institutional Investors and Public. The issue was a resounding success. NTPC is among the largest five companies in India in terms of market capitalization. INTRODUCTION TO NTPC VINDHYANAGAR: Singrauli Region is very aptly called the Power Capital of India due to large concentration of power generating units set up around Govind Vallabh Pant Sagar (popularly known as Rihand Reservoir). Apart from three Super Thermal Power stations of NTPC i.e. Singrauli, Rihand & Vindhyachal, Power Houses of UPSEBs are also located nearby in Anpara and Obra and a Power House of Birla Group at Renu Sagar. Altogether, the region has a capacity of generate more than 10,000 MW. Out of which, around 9,000 MW is being generated presently, which is approximately 10% of the total installed capacity in the country. The Singrauli Region feeds power to Northern & Western Grids. NTPCs Singrauli & Rihand Projects belong to the Northern Region where as Vindhyachal project belongs to the Western Region and feeds power to the States and Union Territories of Madhya Pradesh, Maharashtra, Gujarat, Goa, Dadra and Nagarhaveli, Daman & Diu. The power flows out from Vindhyachal through 400 KV Transmission System. A Transmission Line of 132 KV is also available. At Vindhyachal, countrys first High Voltage Direct Current (HVDC) Back to Back Station linking power transmission systems between Western and Northern Grids has also been installed with capacity 250 MW each, which is being operated now by Power Grid Corporation Limited Vindhyachal Super Thermal Power Project has been developed in two stages. The first stage comprising of six Units of 210 MW set up with Technical & Financial Assistance from erstwhile USSR. Government approval was accorded in 1982 for setting up of Stage-I. The foundation stone for Vindhyachal was laid on 12th November 1982 by the then Prime Minister Late Smt.

2 Indira Gandhi. The first Unit of 210 MW was put in to Commercial Operation in the year 1989 and the last Unit in February 1992. Today Vindhyachal is among the top ten performing stations of the country. Approved Capacity 3260 MW (Stage-I 1260 MW + Stage-II 1000 MW + Stage-III 1000MW) Installed Capacity 3260 MW Location Sidhi, Madhya Pradesh Coal Source Nigahi Mines Water Source Discharge canal of Singrauli Super Thermal Power Station. Beneficiary States Madhya Pradesh, Chattisgarh, Maharashtra, Gujarat,Goa, Daman & Diu and Dadar Nagar Haveli Approved Investment Stage I & II- Rs.4053.42 Crore + Stage-III Rs. 4201.5 crs. Unit Sizes Stage I: 6x 210 MW + Stage-II: 2x500 MW + Stage III: 2x 500 MW Units Commissioned Unit -I: 210 MW October 1987 Unit -II: 210 MW July 1988 Unit -III: 210 MW February 1989 Unit -IV: 210 MW December 1989 Unit -V: 210 MW March 1990 Unit -VI: 210 MW February 1991 Unit -VII: 500 MW March 1999 Unit -VIII: 500 MW February 2000 Unit -IX: 500 MW July 2006 Unit -X: 500 MW March 200

A graph showing NTPC s capacity and power output

EVOLUTION:
NTPC was set up in 1975 with 100% ownership by the Government of India. In the last 30 years, NTPC has grown into the largest power utility in India 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. NTPC became a listed company with majority Government ownership of 89.5%.NTPC becomes third largest by Market Capitalization of listed companies The company rechristened as NTPC Limjh

ited in line with its changing business portfolio and transforms itself from a thermal power utility tan integrated power utility National Thermal Power Corporation is the largest power generation company in India. Forbes Global 2000 for 2008 ranked it 411th in the world. NTPC is the largest power utility in India, accounting for about 20% of Indias installed capacity.

COAL AND ELECTRICITY : Coal is a combustible black or brownishblack sedimentary rock normally occurring in rock strata in layers or veins called coal beds or coal seams. The harder forms, such as anthracite coal can be regarded as metamorphic rock because of later exposure to elevated temperature and pressure. Coal is composed primarily of carbon along with variable quantities of other elements, chiefly hydrogen, with smaller quantities of sulfur, oxygen and nitrogen In addition to other uses, coal is primarily used to generate electricity in places called power stations. Sources of electricity refer to the inputs used to generate electricity. Coal refers to all coal and brown coal, both primary (including hard coal and lignite-brown coal) and derived fuels (including patent fuel, coke oven coke, gas coke, coke oven gas, and blast furnace gas). Peat is also included in this category

INTRODUCTION TO THEMAL POWER PLANT:

Introduction Classification Functioning

INTRODUCTION:
Power Station (also referred to as generating station or power plant) is an industrial facility for the generation of electric power. Power plant is also used to refer to the engine in ships, aircraft and other large vehicles. Some prefer to use the term energy center because it more accurately describes what the plants do, which is the conversion of other forms of energy, like chemical energy, gravitational potential energy or heat energy into electrical energy. However, power plant is the most common term in the U.S., while elsewhere power station and power plant are both widely used, power station prevailing in many Commonwealth countries and especially in the United Kingdom. A coal-fired Thermal Power Plant At the center of nearly all power stations is a generator, a rotating machine that converts mechanical energy into electrical energy by creating relative motion between a magnetic field and a conductor. The energy source harnessed to turn the generator varies widely. It

6 depends chiefly on what fuels are easily available and the types of technology that the power company has access to. In thermal power stations, mechanical power is produced by a heat engine, which transforms thermal energy, often from combustion of a fuel, into rotational energy. Most thermal power stations produce steam, and these are sometimes called steam power stations. About 80% of all electric power is generated by use of steam turbines. Not all thermal energy can be transformed to mechanical power, according to the second law of thermodynamics. Therefore, there is always heat lost to the environment. If this loss is employed as useful heat, for industrial processes or district heating, the power plant is referred to as a cogeneration power plant or CHP(combined heat-and-power) plant. In countries where district heating is common, there rededicated heat plants called heat-only boiler stations. An important class of power stations in the Middle East uses byproduct heat for desalination of water.

CLASSIFICATION:
BY FUEL : Nuclear power plants use a nuclear reactor's heat to operate a steam turbine generator. Fossil fuelled power plants may also use a steam turbine generator or in the case of natural gas fired plants may use a combustion turbine. Geothermal power plants use steam extracted from hot underground rocks.

Renewable energy plants may be fuelled by waste from sugar cane, municipal solid waste, landfill methane, or other forms of biomass. In integrated steel mills, blast furnace exhaust gas is a low-cost, although low-energydensity, fuel. Waste heat from industrial processes is occasionally concentrated enough to use for power generation, usually in a steam boiler and turbine. BY PRIME MOVER: Steam turbine plants use the dynamic pressure generated by expanding steam to turn the blades of a turbine. Almost all large non-hydro plants use this system. Gas turbine plants use the dynamic pressure from flowing gases to directly operate the turbine. Natural-gas fuelled turbine plants can start rapidly and so are used to supply peak" energy during periods of high demand, though at higher cost than base-loaded plants. These may be comparatively small units, and sometimes completely unmanned, being remotely operated. This type was pioneered by the UK, Prince town being the worlds first, commissioned in 1959. Combined cycle plants have both a gas turbine fired by natural gas, and a steam boiler and steam turbine which use the exhaust gas from the gas turbine to produce electricity. This greatly increases the overall efficiency of the plant, and many new base load power plants are combined cycle plants fired by natural gas. Internal combustion Reciprocating engines are used to provide power for isolated communities and are frequently used for small cogeneration plants. Hospitals, office buildings, industrial plants, and other critical facilities also use them to provide backup power in case of a power outage. These are usually fuelled by diesel oil, heavy oil, natural gas and landfill gas. Micro turbines, Sterling engine and internal combustion reciprocating engines are lowcost solutions for using opportunity fuels, such as landfill gas, digester gas from water treatment plants and waste gas from oil production. Renewable energy plants may be fuelled by waste from sugar cane, municipal solid waste, landfill methane, or other forms of biomass. In NTPC Vindhyachal we generate electricity by coal.

FUNCTIONING:
Functioning of thermal power plant: In a thermal power plant, one of coal, oil or natural gas is used to heat the boiler to convert the water into steam. The steam is used to turn a turbine, which is connected to a generator. When the turbine turns, electricity is generated and given as output by the generator, which is then supplied to the consumers through high-voltage power lines. Process of a Thermal Power Plant DETAILED PROCESS OF POWER GENERATION IN A POWER PLANT: 1) Water intake: Firstly, water is taken into the boiler through a water source. If water is available in a plenty in the region, then the source is an open pond or river. If water is scarce, then it is recycled and the same water is used over and over again.2) Boiler heating: The boiler is heated with the help of oil, coal or natural gas. A furnace issued to heat the fuel and supply the heat produced to the boiler. The increase in temperature helps in the transformation of water into steam. 3) Steam Turbine: The steam generated in the boiler is sent through a steam turbine. The turbine has blades that rotate when high velocity steam flows across them. This rotation of turbine blades is used to generate electricity.4) Generator: A generator is connected to the steam turbine. When the turbine rotates, the generator produces electricity which is then passed on to the power distribution systems.5)

Special mountings: There is some other equipment like the economizer and air pre-heater. An economizer uses the heat from the exhaust gases to heat the feed water. An air pre-heater heats the air sent into the combustion chamber to improve the efficiency of the combustionprocess.6) Ash collection system: There is a separate residue and ash collection system in place to collect all the waste materials from the combustion process and to prevent them from escaping into the atmosphere. Apart from this, there are various other monitoring systems and instruments in place to keep track of the functioning of all the devices. This prevents any hazards from taking place in the plant.

10

COAL:Coal that we use in NTPC Vindhyanagar for electricity generation is

transported from the Nigahi mines under Northern Coal Limited NCL.NTPC makes an agreement with NCL The coal that is used is not used directly but undergoes a large number of processes. This is called coal processing. In coal-fired power stations, the raw feed coal from the coal storage area is first crushed into small pieces and then conveyed to the coal feed hoppers at the boilers. The coal is next pulverized into a very fine powder. The pulverizers may be ball mills, rotating drum grinders, or other types of grinders. Some power stations burn fuel oil rather than coal. The oil must kept warm (above its pour point) in the fuel oil storage tanks to prevent the oil from congealing and becoming unpumpable.The oil is usually heated to about 100C before being pumped through the furnace fuel oil spray nozzles. Boilers in some power stations use processed natural gas as their main fuel. Other power stations may use processed natural gas as auxiliary fuel in the event that their main fuel supply (coal or oil) is interrupted. In such cases, separate gas burners are provided on the boiler furnaces. The coal used in NTPC is processed and finished under coal handling department. It involves various operations .They are listed below. Stackers and Reclaimers were originally manually controlled manned machines with no remote control. Modern machines are typically semi-automatic or fully automated, with parameters remotely set. RECLAIMING: Tunnel conveyors can be fed by a continuous slot hopper or bunker beneath the stockpile to reclaim material. Front-end loaders and bulldozers can be used to push the coal into feeders .Sometimes front-end loaders are the only means of reclaiming coal from the stockpile. This has a low up-front capital cost, but much higher operating costs, measured in dollars per tonne handled. High-capacity stockpiles are commonly reclaimed using bucket-wheel reclaimers. These can achieve very high rates. COAL SAMPLING: Sampling of coal is an important part of the process control in the CHP. A grab sample is a one-off sample of the coal at a point in the process stream, and tends not to be very representative. A routine sample is taken at a set frequency, either over a period of time or per shipment. SCREENING: Screens are used to group process particles into ranges by size. These size ranges are also called grades. Dewatering screens are used to remove water from the product. Screens can be static, or mechanically vibrated. Screen decks can be made from different materials such as high tensile steel, stainless steel, or polyethylene. Screening and Separation Unit MAGNETIC SEPERATION: Magnetic separators shall be used in coal conveying systems to separate tramp iron (including steel) from the coal. Basically, two types are available. One type incorporates

11 permanent or electromagnets into the head pulley of a belt conveyor. The tramp iron clings to the belt as it goes around the pulley drum and falls off into a collection hopper or trough after the point at which coal is charged from the belt. The other type consists of permanent or electromagnets incorporated into a belt conveyor that is suspended above a belt conveyor carrying coal. The tramp iron is pulled from the moving coal to the face of the separating conveyor, which in turn holds and carries the tramp iron to a collection hopper or trough. Magnetic separators shall be used just ahead of the coal crusher, if any, and/or just prior to coal discharge to the in-plant bunker or silo fill system. COAL CRUSHER: Before the coal is sent to the plant it has to be ensured that the coal is of uniform size, and so It is passed through coal crushers. Also power plants using pulverized coal specify a maximum

Coal crusher plant

coal size that can be fed into the pulverizer and so the coal has to be crushed to the specified size using the coal crusher. Rotary crushers are very commonly used for this purpose as they can provide a continuous flow of coal to the pulverizer. PULVERIZER:

12 Most commonly used pulverizer is the Boul Mill. The arrangement consists of 2 stationary rollers and a power driven baul in which pulverization takes place as the coal passes through the sides of the rollers and the baul. A primary air induced draught fan draws a stream of heated air through the mill carrying the pulverized coal into a stationary classifier at the top of the pulverizer. The classifier separates the pulverized coal from the unpulverized coal. An external view of a Coal Pulverizer ADVANTAGES OF PULVERIZED COAL:

Pulverized coal is used for large capacity plants. It is easier to adapt to fluctuating load as there are no limitations on the combustion capacity. Coal with higher ash percentage cannot be used without pulverizing because of the problem of large amount ash deposition after combustion. Increased thermal efficiency is obtained through pulverization. The use of secondary air in the combustion chamber along with the powered coal helps in creating turbulence and therefore uniform mixing of the coal and the air during combustion. Greater surface area of coal per unit mass of coal allows faster combustion as more coal is exposed to heat and combustion..

STEAM GENERATOR OR BOILER:

The boiler is a rectangular furnace about 50 ft (15 m) on a side and 130 ft (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (60 mm) in diameter. Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the center. The thermal radiation of the fireball heats the water that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the boiler is three to four times the throughput and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700 F (370 C) and 3,200 psi (22.1MPa). It is separated from the

13 water inside a drum at the top of the furnace. The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to 1,000 F (540 C) to prepare it for theturbine.The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. The generator includes the economizer, the steam drum, the chemical dosing equipment, and the furnace with its steam generating tubes and the superheated coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include: forced draft(FD) fan, air preheater (APH), boiler furnace, induced draft (ID) fan, fly ash collectors(electrostatic precipitator or baghouse) and the flue gas stack. For units over about 210 MW capacity, redundancy of key components is provided by installing duplicates of the FD fan, APH, fly ash collectors and ID fan with isolating dampers. On some units of about 60 MW, two boilers per unit may instead be provided.

BOILER FURNACE AND STEAM DRUM:

Once water inside the boiler or steam generator, the process of adding the latent heat of vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical reaction of burning some type of fuel .The water enters the boiler through a section in the convection pass called the economizer. From the economizer it passes to

14 the steam drum. Once the water enters the steam drum it goes down the down comers to the lower inlet water wall headers. From the inlet headers the water rises through the water walls and is eventually turned into steam due to the heat being generated by the burners located on the front and rear water walls (typically). As the water is turned into team/vapor in the water walls, the steam/vapor once again enters the steam drum. The steam/vapor is passed through a series of steam and water separators and then dryers inside the steam drum. The steam separators and dryers remove the water droplets from the steam and the cycle through the water walls is repeated. This process is known as natural circulation. The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot blowers, water lancing and observation ports (in the furnace walls) for observation of the furnace interior. Furnace explosions due to any accumulation of combustible gases after a trip-out are avoided by flushing out such gases from the combustion zone before igniting the coal. The steam drum (as well as the superheater coils and headers) have air vents and drains needed for initial startup. The steam drum has an internal device that removes moisture from the wet steam entering the drum from the steam generating tubes. The dry steam then flows into the superheater coils.

Geothermal plants need no boiler since they use naturally occurring steam sources. Heat exchangers may be used where the geothermal steam is very corrosive or contains excessivesuspended solids. Nuclear plants also boil water to raise steam, either directly passing the working steam through the reactor or else using an intermediate heat exchanger

15

FEEDWATER HEATER:
A Rankine cycle with a two-stage steam turbine and a single feedwater heater. In the case of a conventional steam-electric power plant utilizing a drum boiler, the surface condenser removes the latent heat of vaporization from the steam as it changes states from vapour to liquid. The heat content (btu) in the steam is referred to as Enthalpy. The condensate pump then pumps the condensate water through a feed water heater. The feed water heating equipment then raises the temperature of the water by utilizing extraction steam from various stages of the turbine. A Rankine cycle with a two-stage steam turbine and a single feed water heater Preheating the feed water reduces the irreversibilitys involved in steam generation and therefore improves the thermodynamic efficiency of the system. [9] This reduces plant operating costs and also helps to avoid thermal shock to the boiler metal when the feed water is introduced back into the steam cycle

16

17

SUPERHE ATER:
As the steam is conditioned by the drying equipment inside the drum, it is piped from the upper drum area into an elaborate set up of tubing in different areas of the boiler. The areas known as superheater and reheater. The steam vapor picks up energy and its temperature is now superheated above the saturation temperature. The superheated steam is then piped through the main steam lines to the valves of the high pressure turbine.

DEAERATOR:
A steam generating boiler requires that the boiler feed water should be devoid of air and other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the metal. Generally, power stations use a deaerator to provide for the removal of air and other dissolved gases from the boiler feedwater. A deaerator typically includes a vertical, domed deaeration section mounted on top of a horizontal cylindrical vessel which serves as the deaerated boiler feedwater storage tank.

18 Boiler Feed Water Deaerator (with vertical, domed aeration section and horizontal water storage section) There are many different designs for a deaerator and the designs will vary from one manufacturer to another. The adjacent diagram depicts a typical conventional trayed deaerator. If operated properly, most deaerator manufacturers will guarantee that oxygen in the deaerated water will not exceed 7 ppb by weight (0.005 cm/L).

TURBINE:
Turbines are used to rotate the shaft of the generator which is coupled to it. An electric generator converts mechanical energy to electrical energy. Turbines can be condensing or non-condensing design typically with large mass flows and comparably low output. Traditionally, pressures were 6.21 MPa and below with temperatures441 C or lower, although the trend towards higher levels of each continues. There are now a considerable number of co-generation steam turbines with initial steam pressures in the 8.63 to 10 MPa range and steam temperatures of 482 to 510 C.

LUBRICATION BEARINGS AND LUBRICATION:

19 Two types of bearings are used to support and locate the rotors of steam turbines Journal bearings are used to support the weight of the turbine rotors. A journal bearing consists of two half-cylinders that enclose the shaft and are internally lined with Babbitt, a metal alloy usually consisting of tin, copper and antimony; and Thrust bearings axially locate the turbine rotors. A thrust bearing is made up of a series of Babbitt lined pads that run against a locating disk attached to the turbine rotor. Highpressure oil is injected into the bearings to provide lubrication. The oil is carefully filtered to remove solid particles. Specially designed centrifuges remove any water from the oil.

SHAFT SEAL:
The shaft seal on a turbine rotor consist of a series of ridges and groves around the rotor and its housing which present a long, tortuous path for any steam leaking through the seal. The seal therefore does not prevent the steam from leaking, merely reduces the leakage to a minimum. The leaking steam is collected and returned to a low-pressure part of the steam circuit. TURNING GEAR: Large steam turbines are equipped with "turning gear" to slowly rotate the turbines after they have been shut down and while they are cooling. This evens out the temperature distribution around the turbines and prevents bowing of the rotors.

VIBRATION:
The balancing of the large rotating steam turbines is a critical component in ensuring the reliable operation of the plant. Most large steam turbines have sensors installed to measure the movement of the shafts in their bearings. This condition monitoring can identify many potential problems and allows the repair of the turbine to be planned before the problems become serious

ELECTRIC GENERATOR:
The basic function of the generator is to convert mechanical power, delivered from the shaft of the turbine, into electrical power. Therefore a generator is actually a rotating mechanical energy converter. The mechanical energy from the turbine is converted by means of a rotating magnetic field produced by direct current in the copper winding of the rotor or field, which generates three-phase alternating currents and voltages in the

20 copper winding of the stator (armature). The stator winding is connected to terminals, which are in turn connected to the power system for delivery of the output power to the system. he class of generator under consideration is steam turbine-driven generators, commonly called turbo generators. These machines are generally used in nuclear and fossil fueled power plants, co-generation plants, and combustion turbine units. They range from relatively small machines of a few Megawatts (MW) to very large generators with ratings up to 1900 MW. The gener at orsparticular to this category are of the two- and four-pole design employing round-rotors, with rotational operating speeds of 3600 and 1800 rpm in North America, parts of Japan, and Asia(3000 and 1500 rpm in Europe, Africa, Australia, Asia, and South America). At Badarpur Thermal Power Station 3000 rpm, 50 Hz generators are used of capacities 210 MW and 95 MW .As the system load demands more active power from the generator, more steam (or fuel in a combustion turbine) needs to be admitted to the turbine to increase power output. Hence more energy is transmitted to the generator from the turbine, in the form of a torque. This torque is

Electric generator mechanical in nature, but electromagnetically coupled to the power system through the generator. The higher the power output, the higher the torque between turbine and generator. The power output of the generator generally follows the load demand from the system. Therefore the voltages and currents in the generator are continually changing

21 based on the load demand. The generator design must be able to cope with large and fast load changes, which show up inside the machine as changes in mechanical forces and temperatures. The design must therefore incorporate electrical current-carrying materials (i.e., copper), magnetic flux-carrying materials (i.e., highly permeable steels), insulating materials (i.e., organic), structural members(i.e., steel and organic), and cooling media (i.e., gases and liquids), all working together under the operating conditions of a turbo generator Since the turbo generator is a synchronous machine, it operates at one very specific speed to produce a constant system frequency of 50 Hz, depending on the frequency of the grid to which it is connected. As a synchronous machine, a turbine generator employs a steady magnetic flux passing radially across an air gap that exists between the rotor and the stator. (The term air gap is commonly used for air- and gas-cooled machines). For the machines in this discussion, this means a magnetic flux distribution of two or four poles on the rotor. This flux pattern rotates with the rotor, as it spins at its synchronous speed. The rotating magnetic field moves past a three-phase symmetrically distributed winding installed in the stator core, generating an alternating voltage in the stator winding. The voltage waveform created in each of the three phases of the stator winding is very nearly sinusoidal. The output of the stator winding is the three-phase power, delivered to the power system at the voltage generated in the stator winding .In addition to the normal flux distribution in the main body of the generator, there are stray fluxes at the extreme ends of the generator that create fringing flux patterns and induce stray losses in the generator. The stray fluxes must be accounted for in the overall design Generators are made up of two basic members, the stator and the rotor, but the stator and rotor are each constructed from numerous parts themselves. Rotors are the high-speed rotating member of the two, and they undergo severe dynamic mechanical loading as well as the electromagnetic and thermal loads. The most critical component in the generator are there taining rings, mounted on the rotor .These components are very carefully designed for high-stress operation. The stator is stationary ,as the term suggests, but it also sees significant dynamic forces in terms of vibration and torsional loads, as well as the electromagnetic, thermal, and high-voltage loading. The most critical component of the stator is arguably the stator winding because it is a very high cost it demand it must be designed to handle all of the harsh effects described above. Most stator problems occur with the winding.

STATOR:
The stator winding is made up of insulated copper conductor bars that are distributed around the inside diameter of the stator core, commonly called the stator bore, in equally spaced slots in the core to ensure symmetrical flux linkage with the field produced by the rotor. Each slot contains two conductor bars, one on top of the other. These are generally referred to as top and bottom bars. Top bars are the ones nearest the slot opening (just under the wedge) and the bottom bars are the ones at the slot bottom. The core area between slots is generally called a core tooth. Stator of a Turbo Generator The stator winding is then divided into three phases, which are almost always wye connected .Wye connection is done to allow a neural grounding point and for relay protection of the winding. The three phases are connected to create symmetry between them in the 360 degree arc of the stator bore. The distribution of the winding is done in

22 such a way as to produce a 120degree difference in voltage peaks from one phase to the other, hence the term three-phase voltage. Each of the three phases may have one or more parallel circuits within the phase. The parallels can be connected in series or parallel, or a combination of both if it is a four-pole generator. This will be discussed in the next section. The parallels in all of the phases are essentially equal on average, in their performance in the machine. Therefore, they each see equal voltage and current, magnitudes and phase angles, when averaged over one alternating cycle. The stator bars in any particular phase group are arranged such that there are parallel paths which overlap between top and bottom bars. The overlap is staggered between top and bottom bars. The top bars on one side of the stator bore are connected to the bottom bars on the other side of the bore in one direction while the bottom bars are connected in the other direction on the opposite side of the stator. This connection with the bars on the other side of the stator creates a reach or pitch of a certain number of slots. The pitch is therefore the number slots that the stator bars have to reach in the stator bore arc, separating the two bars to be connected. This is always less than 180 degrees .Once connected; the stator bars form a single coil or turn. The total width of the overlapping parallels is called the breadth. The combination of the pitch and breadth create a winding or distribution factor. The distribution factor is used to minimize the harmonic content of the generated voltage. In the case of a two parallel path winding, these may be connected in series or parallel outside the stator bore, at the termination end of the generator. The connection type will depend on a number of other design issues regarding current-carrying ability of the copper in the winding. In a two-parallel path, three-phase winding, alternating voltage is created by the action of the rotor field as it moves past these windings. Since there is a plus and minus, or north and south ,to the rotating magnetic field, opposite polarity currents flow on each side of the stator bore in the distributed winding. The currents normally flowing in large turbo generators can be in the order of thousands of amperes. Due to the very high currents, the conductor bars in a turbo generator have a large crosssectional area. In addition they are usually one single turn per bar, as opposed to motors or small generators that have multiple turn bars or coils. These stator or conductor bars are also very rigid and do not bend unless significant force is exerted on them

The steam turbine-driven generators have auxiliary systems enabling them to work satisfactorily and safely. The steam turbine generator being rotating equipment generally has a heavy, large diameter shaft. The shaft therefore requires not only supports but also has to be kept in position while running. To minimize the frictional resistance to the rotation, the shaft has a number of bearings. The bearing shells, in which the shaft rotates, are lined with a low friction material like Babbitt metal. Oil lubrication is provided to further reduce the friction between shaft and bearing surface and to limit the heat generated.

ROTORS

23 The rotor winding is installed in the slots machined in the forging main body and is distributed symmetrically around the rotor between the poles. The winding itself is made up of many turns of copper to form the entire series connected winding. All of the turns associated with a single slot are generally called a coil. The coils are wound into the winding slots in the forging, concentrically in corresponding positions on opposite sides of a pole. The series connection essentially creates a single multi-turn coil overall, that develops the total ampere-turns of the rotor (which is the total current flowing in the rotor winding times the total number of turns). There are numerous copper-winding designs employed in generator rotors, but all rotor windings function basically in the same way. They are configured differently for different methods of heat removal during operation. In addition almost all large turbo generators have directly cooled copper windings by air or hydrogen cooling gas. Rotor of a Turbo Generator Cooling passages are provided within the conductors themselves to eliminate the temperature drop across the ground insulation and preserve the life of the insulation material. In an axially cooled winding, the gas passes through axial passages in the conductors, being fed from both ends, and exhausted to the air gap at the axial center of the rotor. In other designs, radial passages in the stack of conductors are fed from sub slots machined along the length of the rotor at the bottom of each slot. In the air gap pickup method, the cooling gas is picked up from the air gap, and cooling is accomplished over a relatively short length of the rotor, and then discharged back to the air gap. The cooling of the end-regions of the winding varies from design to design, as much as that of the slot section. In smaller turbine generators the indirect cooling method is used (similar to indirectly cooled stator windings), where the heat is removed by conduction through the ground insulation to the rotor body.

24

Rotor of a generator The winding is held in place in the slots by wedges, in a similar manner as the stator windings. The difference is that the rotor winding loading on the wedges is far greater due to centrifugal forces at speed. The wedges therefore are subjected to a tremendous static load from these forces and bending stresses because of the rotation effects. The wedges in the rotor are not generally a tight fit in order to accommodate the axial thermal expansion of the rotor winding during operation. There are also many available designs and configurations for the end-winding construction and ventilation methods. As in the rotor slots, the copper turns in the end-winding must be isolated from one another so that they do not touch and create shorts between turns. Therefore packing and blocking are used to keep the coils separated, and in their relative position as the rotor winding expands from thermal effects during operation. To restrain the end winding portion of the rotor winding during high-speed operation, retaining-rings are employed to keep the copper coils in place.

25

BEARINGS:
All turbo generators require bearings to rotate freely with minimal friction and vibration. The main rotor body must be supported by a bearing at each end of the generator for this purpose. In some cases where the rotor shaft is very long at the excitation end of the machine to accommodate the slip/collector rings, a steady bearing is installed outboard of the slip-collector rings. This ensures that the excitation end of the rotor shaft does not create a wobble that transmits through the shaft and stimulates excessive vibration in the overall generator rotor or the turbo generator line. There are generally two common types of bearings employed in large generators, journal and tilting pad bearings. Journal bearings are the most common. Both require lubricating and jacking oil systems, which will be discussed later in the book, under auxiliary systems. When installing the bearings, they must be aligned in terms of height and angle to ensure that the rotor sits in the bearing correctly. Such things as shaft catinery must be considered and p re-loading or shimming of the bearings to account for the difference when the rotor is at stand still and at speed. Getting any of these things wrong in the assembly can cause the rotor to vibrate excessively and damage either the rotor shaft or the bearing itself. Generally, a wipe of the bearing running surface or babbitt result

TRANSFORMER:
A transformer is a static device consisting of a winding, or two or more coupled windings, with or without a magnetic core, for inducing mutual coupling between circuits. When an alternating current flows in a conductor, a magnetic field exists around the conductor. If another conductor is placed in the field created by the first conductor such that the flux lines link the second conductor, then a voltage is induced into the second conductor. The use of a magnetic field from one coil to induce a voltage into a second coil is the principle on which transformer theory and application is based

26 :

A transformer at NTPC Vindhyanagar ANSI/IEEE defines a transformer as a static electrical device, involving no continuously moving parts, used in electric power systems to transfer power between circuits through the use of electromagnetic induction .The transformer is one of the most reliable pieces of electrical distribution equipment. It has no moving parts, requires minimal maintenance, and is capable of withstanding overloads, surges, faults, and physical abuse that may damage or destroy other items in the circuit. Often, the electrical event that burns up a motor, opens a circuit breaker, or blows a fuse has a subtle effect on the transformer. Although the transformer may continue to operate as before, repeat occurrences of such damaging electrical events, or lack of even minimal maintenance can greatly accelerate the eventual failure of the transformer. The fact that a transformer continues to operate satisfactorily in spite of neglect and abuse is a testament to its durability. However, this durability is no excuse for not providing the proper care. Most of the effects of aging, faults, or abuse can be detected and corrected by a comprehensive maintenance, inspection, and testing program.

Transformers are exclusively used in electric power systems to transfer power by electromagnetic induction between circuits at the same frequency, usually with changed values of voltage and current. There are numerous types of transformers used in various applications including audio, radio, instrument, and power. In Badarpur Thermal Power

27 Station, we deal exclusively with power transformer applications involving the transmission and distribution of electrical power. Power transformers are used extensively by traditional electric utility companies, power plants, and industrial plants .The term power transformer is used to refer to those transformers used between the generator and the distribution circuits, and these are usually rated at 220 kVA and above. Power systems typically consist of a large number of generation locations, distribution points, and interconnections within the system or with nearby systems, such as a neighboring utility. The complexity of the system leads to a variety of transmission and distribution voltages. Power transformers must be used at each of these points where there is a transition between voltage levels. Power transformers are selected based on the application, with the emphasis toward custom design being more apparent the larger the unit. Power transformers are available for step-up operation, primarily used at the generator and referred to as generator step-up (GSU)transformers, and for step-down operation, mainly used to feed distribution circuits. Power transformers are available as single-phase or three-phase apparatus WINDINGS: The windings consist of the current-carrying conductors wound around the sections of the core, and these must be properly insulated, supported, and cooled to withstand operational and test conditions .Copper and aluminum are the primary materials used as conductors in power-transformer windings. While aluminum is lighter and generally less expensive than copper, a larger cross section of aluminum conductor must be used to carry a current with similar performance as copper. Copper has higher mechanical strength and is used almost exclusively in all but the smaller size ranges, where aluminum conductors may be perfectly acceptable. In cases where extreme forces are encountered, materials such as silver-bearing copper can be used for even greater strength. The conductors used in power transformers are typically stranded with cross section, although some transformers at the lowest ratings may use sheet or foil conductors. Multiple strands can be wound in parallel and joined together at the ends of the winding, in which case it is necessary to transpose the strands at various points throughout the winding to prevent circulating currents around the loop(s) created by joining the strands at the ends. Individual strands may be subjected to differences in the flux field due to their respective positions within the winding, which create differences in voltages between the strands and drive circulating currents through the conductor loops. Proper transposition of the strands cancels out these voltage differences and eliminates or greatly reduces the circulating currents. A variation of this technique, involving many rectangular conductor strands combined into a cable, is called continuously transposed cable (CTC)

CONTROL AND INSTRUMENTATION:

The entire plant of NTPC Vindhyanagar is controlled centrally by a software called DDCIMS. Here we use various instruments for measurement of various parameters such a s temperature, pressure, flow etc

28

TEMPERATURE MEASUREMENT: Temperature measurement is generally done by: THERMOCOUPLES RESISTANCE THERMOMETERS THERMISTORS BIMETTALIC THERMOMETERS ACCOUSTIC PYROMETERS LOCAL INSTRUMENTS. RESISTANCE TEMPERATURE DETECTORS (RTDs): THERMOCOUPLES: It is based on seeback effect which says that when heat is applied to a junction of two dissimilar metals an emf is generated which can be measured at the other junction RESISTANCE THERMOMETERS: The resistance of a conductor changes when its temperature is changed .this property is utilized to measure the temperature. rt = ro (1+dt) where = temp co- efficient of resistance dt = temperature difference THERMISTORS: Thermistors are generally composed of semiconductor materials .they have a negative coefficient of temperature so resistance decreases with increase in temp BIMETALLIC THERMOMETERS Bimetallic devices are extensively used in process industries for local temperature measurements also used as overload cutout switch in electrical apparatus by monitoring current flow. ACOUSTIC PYROMETERS The velocity of sound in a medium is proportional to the temperature. gas temperature =[(distance) / (time * b)] 2 b is an accepted constant PRESURE MEASUREMENT :Pressure is measured by special pressure gauges . They are binary pressure transmitters that indicate whether a pressure is high or low by the use of binary signals Flow can also be measured with the help of pressure as

29 Flow is directly proportional to change in pressure SOFTWARE APPROACH: The plant is controlled by software called DDCIMS. Here as we give commands they are connected to electronic panels that are connected to the local bus and through them the commands are connected The wires of the bus are made of fire resistant material Whole plan of the map can be seen on the computer screen Whenever an alarming condition is encountered, alarms start buzzing As soon as the alarms are acknowledged they start glowing

A c&I lab CONCLUSION: NTPC Vindhyanar is the power capital of the nation. It provides power to all the parts of the nation .Its total output is 3260 MW with one stage under construction. It is a very big milestone in the history of technological advancement of the nation Approved Capacity 3260 MW (Stage-I 1260 MW + Stage-II 1000 MW + Stage-III 1000MW) Installed Capacity 3260 MW Location Sidhi, Madhya Pradesh Coal Source Nigahi Mines Water Source Discharge canal of Singrauli Super Thermal Power Station. Beneficiary States Madhya Pradesh, Chattisgarh, Maharashtra,Gujarat, Goa, Daman & Diu and Dadar Nagar Haveli Approved Investment Stage I & II- Rs.4053.42 Crore + Stage-III Rs. 4201.5 crs. Unit Sizes Stage I: 6x 210 MW + Stage-II: 2x500 MW + Stage III: 2x 500 MW

30 Units Commissioned Unit -I: 210 MW October 1987 Unit -II: 210 MW July 1988 Unit -III: 210 MW February 1989 Unit -IV: 210 MW December 1989 Unit -V: 210 MW March 1990 Unit -VI: 210 MW February 1991 Unit -VII: 500 MW March 1999 Unit -VIII: 500 MW February 2000 Unit -IX: 500 MW July 2006 Unit -X: 500 MW March 2007