Ravi Singh completed an industrial training at NTPC Badarpur power station. He thanks the staff who provided guidance during his training, particularly Mr. Mahendra Singh Chabra and Mr. Anant Kumar Varshney. NTPC was established in 1975 and has expanded significantly, with plans to reach 75,000 MW of capacity by 2017. Badarpur power station meets over 24% of Delhi's electricity needs with its 720 MW installed capacity. The report provides overviews of the basic principles of thermal power generation, control and instrumentation labs, distributed control systems, and other key components and processes at NTPC power stations.

1. INDUSTRIAL TRAINING
REPORT
NTPC BADARPUR
SUBMITTED BY:
RAVI SINGH
ELECTRONICS AND INSTRUMENTATION
NIT AGARTALA

2. ACKNOWLEDGEMENT
With profound respect and gratitude, I take the
opportunity to convey my thanks to complete the
training here.
I do extend my heartfelt thanks to Mr
MAHENDRA SINGH CHABRA (A.G.M
ELECTRICAL) for providing me this opportunity
to be a part of this esteemed organization.
I convey my gratitude and sincere thanks to Mr
ANANT KUMAR VARSHNEY for guidance and
kind help extended to me in order to successfully
complete my training by providing with adequate
information required.
I am extremely grateful to all the technical staff of
BTPS/NTPC for their co-operation and guidance
that helped me a lot during the course of training. I
have learnt a lot working under them and I will
always be indebted of them for this value addition
in me.

3. Overview of NTPC
 NTPC was set up in the central sector in the 1975.
 NTPC has installed capacity of 29,394 MW. It plans to be a 75,
MW company by 2017.
 NTPC Badarpur station has also bagged ISO 9001/ ISO 14001
certification.
 Today NTPC contributes more than 3 / 5th of the total power
generation in India.


4. Overview of BTPS
 BTPS MEETS MORE THAN 24% OF DELHI’S
ELECTRICITY
CONSUMPTION
 INSTALLED CAPACITY 720 MW
 DERATED CAPACITY 705 MW
(3x95 + 2x210MW)
 OWNED BY GOVT. OF INDIA, MINISTRY OF
POWER
 BEING MANAGED BY NTPC FOR THE LAST 26
YEARS SINCE 1st APRIL 1978
 NTPC adjudged as the 3rd best employer in India

5. Basic Principle
There are basically three main units of a thermal power plant:
1. Steam Generator or Boiler
2. Steam Turbine
3. Electric Generator

6. C&I LABS
Control and Instrumentation Department ha
following labs:
1. Manometry Lab
2. Protection and Interlocks Lab
3. Automation Lab
4. Electronics Lab
5. Water Treatment Plant
6. Furnaces Safety Supervisory
System Lab

7. Distributed control system
A distributed control system (DCS) refers to a control system usually of a
manufacturing system , process or any kind of dynamic system, in which
the controller elements are not central in location (like the brain) but are
distributed throughout the system with each component sub-system controlled
by one or more controllers.
DCS (Distributed Control System) is a computerized control system used to
control the production line in the industry
The entire system of controllers is connected by networks for communication
and monitoring.
DCS is a very broad term used in a variety of industries, to monitor and control
distributed equipment.
 Electrical power grids and electrical generation plants
 Environmental control systems
 Traffic signals
 Radio signals
 Water management systems
 Oil refining plants
 Metallurgical process plants
 Chemical plants
 Pharmaceutical manufacturing
 Sensor networks
 Dry cargo and bulk oil carrier ships
 A DCS typically uses custom designed processors as controllers and uses
both proprietary interconnections and communications protocol for
communication. Input and output modules form component parts of the
DCS. The processor receives information from input modules and sends
information to output modules. The input modules receive information
from input instruments in the process (or field) and transmit instructions
to the output instruments in the field. Computer buses or electrical buses
connect the processor and modules through multiplexer or
demultiplexers. Buses also connect the distributed controllers with the
central controller and finally to the Human–machine interface (HMI) or
control consoles. See Process automation system.
 The elements of a DCS may connect directly to physical equipment such
as switches, pumps and valves and to Human Machine Interface (HMI)
via SCADA. The differences between a DCS and SCADA is often subtle,
especially with advances in technology allowing the functionality.

8. Flow measurement
Flow measurement is the quantification of bulk fluid movement. Flow can be
measured in a variety of ways. Positive-displacement flow meters accumulate a
fixed volume of fluid and then count the number of times the volume is filled to
measure flow. Other flow measurement methods rely on forces produced by the
flowing stream as it overcomes a known constriction, to indirectly calculate
flow. Flow may be measured by measuring the velocity of fluid over a known
area
Venturi meter
A Venturi meter constricts the flow in some fashion, and pressure
sensors measure the differential pressure before and within the constriction.
This method is widely used to measure flow rate in the transmission of gas
through pipelines, and has been used since Roman Empire times.The coefficient
of discharge of Venturi meter ranges from 0.93 to 0.97. The first large-scale
Venturi meters to measure liquid flows were developed by Clemens
Herschel who used them to measure small and large flows of water and
wastewater beginning at the end of the 19th century
Orifice plate
An orifice plate is a plate with a hole through it, placed in the flow; it constricts
the flow, and measuring the pressure differential across the constriction gives
the flow rate. It is basically a crude form of Venturi meter, but with higher
energy losses. There are three type of orifice: concentric, eccentric, and
segmenta
Level to flow
The level of the water is measured at a designated point behind weir or
in flume a hydraulic structure using various secondary devices (bubblers,
ultrasonic, float, and differential pressure are common methods). This depth is
converted to a flow rate according to a theoretical formula of the
form where is the flow rate, is a constant, is the water
level, and is an exponent which varies with the device used; or it is converted
according to empirically derived level/flow data points (a "flow curve"). The
flow rate can then integrated over time into volumetric flow. Level to flow
devices are commonly used to measure the flow of surface waters (springs,
stream, and rivers), industrial discharges, and sewage. Of these, weirs are used
on flow streams with low solids (typically surface waters), while flumes are
used on flows containing low or high solids contents

9. Pressure measurement
Many techniques have been developed for the measurement of pressure and vacuum.
Instruments used to measure pressure are called pressure gaugesor vacuum gauges.
A manometer could also refer to a pressure measuring instrument, usually limited to
measuring pressures near to atmospheric. The term manometer is often used to refer
specifically to liquid column hydrostatic instruments.
A vacuum gauge is used to measure the pressure in a vacuum—which is further divided into
two subcategories, high and low vacuum (and sometimesultra-high vacuum). The applicable
pressure range of many of the techniques used to measure vacuums have an overlap. Hence,
by combining several different types of gauge, it is possible to measure system pressure
continuously from 10 mbar down to 10−11
mbar.
Bourdon
The Bourdon pressure gauge uses the principle that a flattened tube tends to straighten or
regain its circular form in cross-section when pressurized. Although this change in cross-
section may be hardly noticeable, and thus involving moderate stresses within the elastic
range of easily workable materials, the strain of the material of the tube is magnified by
forming the tube into a C shape or even a helix, such that the entire tube tends to straighten
out or uncoil, elastically, as it is pressurized. Eugene Bourdon patented his gauge in France in
1849, and it was widely adopted because of its superior sensitivity, linearity, and accuracy;
Edward Ashcroft purchased Bourdon's American patent rights in 1852 and became a major
manufacturer of gauges. Also in 1849, Bernard Schaeffer in Magdeburg, Germany patented a
successful diaphragm (see below) pressure gauge, which, together with the Bourdon gauge,
revolutionized pressure measurement in industry.[6]
But in 1875 after Bourdon's patents
expired, his company Schaeffer and Budenberg also manufactured Bourdon tube gauges
DPharp Digital Transmitters
a new standard for accuracy, stability and robustness.
Yokogawa has more than 45 years' experience in the development, design, and manufacture
of pressure sensors and pressure transmitters and differential pressure transmitters. The
DPharp series of digital pressure transmitters use a differential pressure high accuracy
resonance (DPharp) sensor that represents one of the most revolutionary advances in
transmitter technology.

10. Resistance thermometer
Resistance thermometers, also called resistance temperature
detectors ('RTD's), are sensors used to measure temperature by correlating
the resistance of the RTD element with temperature. Most RTD elements
consist of a length of fine coiled wire wrapped around a ceramic or glass core.
The element is usually quite fragile, so it is often placed inside a sheathed
probe to protect it. The RTD element is made from a pure material, typically
platinum, nickel or copper. The material has a predictable change in resistance
as the temperature changes; it is this predictable change that is used to
determine temperature.
They are slowly replacing the use of thermocouples in many industrial
applications below 600 °C, due to higher accuracy and repeatability
Two-wire configuration
The simplest resistance thermometer configuration uses two wires. It is only
used when high accuracy is not required, as the resistance of the connecting
wires is added to that of the sensor, leading to errors of measurement. This
configuration allows use of 100 meters of cable. This applies equally to
balanced bridge and fixed bridge system.
Three-wire configuration
In order to minimize the effects of the lead resistances, a three-wire
configuration can be used. Using this method the two leads to the sensor are
on adjoining arms. There is a lead resistance in each arm of the bridge so that
the resistance is cancelled out, so long as the two lead resistances are
accurately the same. This configuration allows up to 600 meters of cable.
Four-wire configuration
The four-wire resistance thermometer configuration increases the accuracy and
reliability of the resistance being measured: the resistance error due to lead
wire resistance is zero. In the diagram above a standard two-terminal RTD is
used with another pair of wires to form an additional loop that cancels out the
lead resistance. The above Wheatstone bridge method uses a little more
copper wire and is not a perfect solution. Below is a better configuration, four-
wire Kelvin connection. It provides full cancellation of spurious effects; cable
resistance of up to 15 Ω can be handled.

11. Electricity generation
Turbo generator
Electricity generation is the process of generating electrical power from other
sources of primary energy.
The fundamental principles of electricity generation were discovered during
the 1820s and early 1830s by the British scientist Michael Faraday. His basic
method is still used today: electricity is generated by the movement of a loop
of wire, or disc of copper between the poles of a magnet.[1]
For electric utilities, it is the first process in the delivery of electricity to
consumers. The other processes, electricity transmission,distribution, and
electrical power storage and recovery using pumped-storage methods are
normally carried out by the electric power industry.
Electricity is most often generated at a power station by
electromechanical generators, primarily driven by heat engines fueled by
chemical combustion or nuclear fission but also by other means such as
the kinetic energy of flowing water and wind. Other energy sources include
solar photovoltaics and geothermal power.

12. With the massive expansion of power generation, there is also growing awareness among
all concerned to keep the pollution under control and preserve the health and quality of
the natural environment in the vicinity of the power stations. NTPC is committed to
provide affordable and sustainable power in increasingly larger quantity. NTPC is conscious
of its role in the national endeavour of mitigating energy poverty, heralding economic
prosperity and thereby contributing towards India’s emergence as a major global
economy.
Lay out of Employee’s
Overall Power Generation
The table below shows the detailed operational performance of coal based stations over the years.
The energy conservation parameters like specific oil consumption and auxiliary power
consumption have also shown considerable improvement over the years.
THERMAL POWER PLANT
A Thermal Power Station comprises all of the equipment and a subsystem required to produce
electricity by using a steam generating boiler fired with fossil fuels or befouls to drive an electrical
generator. Some prefer to use the term ENERGY CENTER because such facilities convert forms of
energy, like nuclear energy, gravitational potential energy or heat energy (derived from the
combustion of fuel) into electrical energy.
Unit 1997-98 2006-07 % of increase
Installed Capacity MW 16,847 26,350 56.40
Generation MUs 97,609 1,88,674 93.29
No. of employees No. 23,585 24,375 3.34
Generation/employee MUs 4.14 7.74 86.95
OPERATIONAL PERFORMANCE OF COAL BASED NTPC STATIONS
Unit 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06 06-07
Generation BU 106.2 109.5 118.7 130.1 133.2 140.86 149.16 159.11 170.88 188.67
PLF % 75.20 76.60 80.39 81.8 81.1 83.6 84.4 87.51 87.54 89.43
Availability
Factor
% 85.03 89.36 90.06 88.54 81.8 88.7 88.8 91.20 89.91 90.09

13. , POWER PLANT is the most common term in the united state; While POWER STATION prevails in
many Commonwealth countries and especially in the United Kingdom.
Such power stations are most usually constructed on a very large scale and designed for
continuous operation.
Typical diagram of a coal fired thermal power station
1. Cooling water pump
2. Three-phase transmission line
3. Step up transformer
4. Electrical Generator
5. Low pressure steam
6. Boiler feed water pump
7. Surface condenser
8. Intermediate pressure steam turbine
9. Steam control valve
10. High pressure steam turbine
11. Deaerator Feed water heater
12. Coal conveyor
13. Coal hopper
14. Coal pulverizer
15. boiler steam drum
16. Bottom ash hoper
17. Super heater
18. Forced draught(draft) fan
19. Reheater
20. Combustion air intake
21. Economizer
22. Air preheater
23. Precipitator
24. Induced draught(draft) fan
25. Fuel gas stack
The description of some of the components written above is described as follows:
1. Cooling towers
Cooling Towers are evaporative coolers used for cooling water or other working medium to near
the ambivalent web-bulb air temperature. Cooling tower use evaporation of water to reject heat
from processes such as cooling the circulating water used in oil refineries, Chemical plants, power
plants and building cooling, for example. The tower vary in size from small roof-top units to very
large hyperboloid structures that can be up to 200 meters tall and 100 meters in diameter, or
rectangular structure that can be over 40 meters tall and 80 meters long. Smaller towers are
normally factory built, while larger ones are constructed on site.
The primary use of large , industrial cooling tower system is to remove the heat absorbed in the
circulating cooling water systems used in power plants , petroleum

14. refineries, petrochemical and chemical plants, natural gas processing plants and other industrial
facilities . The absorbed heat is rejected to the atmosphere by the evaporation of some of the
cooling water in mechanical forced-draft or induced draft towers or in natural draft hyperbolic
shaped cooling towers as seen at most nuclear power plants.
2.Three phase transmission line
Three phase electric power is a common method of electric power transmission. It is a type of
polyphase system mainly used to power motors and many other devices. A Three phase system
uses less conductor material to transmit electric power than equivalent single phase, two phase, or
direct current system at the same voltage. In a three phase system, three circuits reach their
instantaneous peak values at different times. Taking one conductor as the reference, the other two
current are delayed in time by one-third and two-third of one cycle of the electrical current. This
delay between “phases” has the effect of giving constant power transfer over each cycle of the
current and also makes it possible to produce a rotating magnetic field in an electric motor.
At the power station, an electric generator converts mechanical power into a set of electric
currents, one from each electromagnetic coil or winding of the generator. The current are
sinusoidal functions of time, all at the same frequency but offset in time to give different phases.
In a three phase system the phases are spaced equally, giving a phase separation of one-third one
cycle. Generators output at a voltage that ranges from hundreds of volts to 30,000 volts. At the
power station, transformers: step-up” this voltage to one more suitable for transmission.
After numerous further conversions in the transmission and distribution network the power is
finally transformed to the standard mains voltage (i.e. the “household” voltage).
The power may already have been split into single phase at this point or it may still be three phase.
Where the step-down is 3 phase, the output of this transformer is usually star connected with the
standard mains voltage being the phase-neutral voltage. Another system commonly seen in North
America is to have a delta connected secondary with a center tap on one of the windings supplying
the ground and neutral. This allows for 240 V three phase as well as three different single phase
voltages( 120 V between two of the phases and neutral , 208 V between the third phase ( known
as a wild leg) and neutral and 240 V between any two phase) to be available from the same supply.
3.Electrical generator
An Electrical generator is a device that converts kinetic energy to electrical energy, generally using
electromagnetic induction. The task of converting the electrical energy into mechanical energy is
accomplished by using a motor. The source of mechanical energy may be a reciprocating or turbine
steam engine, , water falling through the turbine are made in a variety of sizes ranging from small
1 hp (0.75 kW) units (rare) used as mechanical drives for pumps, compressors and other shaft
driven equipment , to 2,000,000 hp(1,500,000 kW) turbines used to generate electricity. There are
several classifications for modern steam turbines.
Steam turbines are used in all of our major coal fired power stations to drive the generators or
alternators, which produce electricity. The turbines themselves are driven by steam generated in
‘Boilers’ or ‘steam generators’ as they are sometimes called.
Electrical power station use large stem turbines driving electric generators to produce most (about
86%) of the world’s electricity. These centralized stations are of two types: fossil fuel power plants
and nuclear power plants. The turbines used for electric power generation are most often directly
coupled to their-generators .As the generators must rotate at constant synchronous speeds
according to the frequency of the electric power system, the most common speeds are 3000 r/min
for 50 Hz systems, and 3600 r/min for 60 Hz systems. Most large nuclear sets rotate at half those
speeds, and have a 4-pole generator rather than the more common 2-pole one.

15. Energy in the steam after it leaves the boiler is converted into rotational energy as it passes
through the turbine. The turbine normally consists of several stage with each stages consisting of a
stationary blade (or nozzle) and a rotating blade. Stationary blades convert the potential energy of
the steam into kinetic energy into forces, caused by pressure drop, which results in the rotation of
the turbine shaft. The turbine shaft is connected to a generator, which produces the electrical
energy.
4.Boiler feed water pump
A Boiler feed water pump is a specific type of pump used to pump water into a steam boiler. The
water may be freshly supplied or retuning condensation of the steam produced by the boiler.
These pumps are normally high pressure units that use suction from a condensate return system
and can be of the centrifugal pump type or positive displacement type.
Construction and operation
Feed water pumps range in size up to many horsepower and the electric motor is usually separated
from the pump body by some form of mechanical coupling. Large industrial condensate pumps
may also serve as the feed water pump. In either case, to force the water into the boiler; the pump
must generate sufficient pressure to overcome the steam pressure developed by the boiler. This is
usually accomplished through the use of a centrifugal pump.
Feed water pumps usually run intermittently and are controlled by a float switch or other similar
level-sensing device energizing the pump when it detects a lowered liquid level in the boiler is
substantially increased. Some pumps contain a two-stage switch. As liquid lowers to the trigger
point of the first stage, the pump is activated. I f the liquid continues to drop (perhaps because the
pump has failed, its supply has been cut off or exhausted, or its discharge is blocked); the second
stage will be triggered. This stage may switch off the boiler equipment (preventing the boiler from
running dry and overheating), trigger an alarm, or both.
5. Steam-powered pumps
Steam locomotives and the steam engines used on ships and stationary applications such as power
plants also required feed water pumps.
6. Control valves
Control valves are valves used within industrial plants and elsewhere to control operating
conditions such as temperature,pressure,flow,and liquid Level by fully partially opening or closing
in response to signals received from controllers that compares a “set point” to a “process variable”
whose value is provided by sensors that monitor changes in such conditions. The opening or
closing of control valves is done by means of electrical, hydraulic or pneumatic systems
7. Deaerator
A Dearator is a device for air removal and used to remove dissolved gases (an alternate would be
the use of water treatment chemicals) from boiler feed water to make it non-corrosive. A dearator
typically includes a vertical domed deaeration section as the deaeration boiler feed water tank. A
Steam generating boiler requires that the circulating steam, condensate, and feed water should be
devoid of dissolved gases, particularly corrosive ones and dissolved or suspended solids. The gases
will give rise to corrosion of the metal. The solids will deposit on the heating surfaces giving rise to
localized heating and tube ruptures due to overheating.

16. 8. Feed water heater
A Feed water heater is a power plant component used to pre-heat water delivered to a steam
generating boiler. Preheating the feed water reduces the irreversible involved in steam generation
and therefore improves the thermodynamic efficiency of the system.[4] This reduces plant
operating costs and also helps to avoid thermal shock to the boiler metal when the feed water is
introduces back into the steam cycle.
In a steam power (usually modeled as a modified Ranking cycle), feed water heaters allow the feed
water to be brought up to the saturation temperature very gradually. This minimizes the inevitable
irreversibility’s associated with heat transfer to the working fluid (water). A belt conveyor consists
of two pulleys, with a continuous loop of material- the conveyor Belt – that rotates about them.
The pulleys are powered, moving the belt and the material on the belt forward. Conveyor belts are
extensively used to transport industrial and agricultural material, such as grain, coal, ores etc.
9. Pulverizer
A pulverizer is a device for grinding coal for combustion in a furnace in a fossil fuel power plant.
10. Boiler Steam Drum
Steam Drums are a regular feature of water tube boilers. It is reservoir of water/steam at the top
end of the water tubes in the water-tube boiler. They store the steam generated in the water tubes
and act as a phase separator for the steam/water mixture. The difference in densities between hot
and cold water helps in the accumulation of the “hotter”-water/and saturated –steam into steam
drum. Made from high-grade steel (probably stainless) and its working involves temperatures
390’C and pressure well above 350psi (2.4MPa). The separated steam is drawn out from the top
section of the drum. Saturated steam is drawn off the top of the drum. The steam will re-enter the
furnace in through a super heater, while the saturated water at the bottom of steam drum flows
down to the mud-drum /feed water drum by down comer tubes accessories include a safety valve,
water level indicator and fuse plug. A steam drum is used in the company of a mud-drum/feed
water drum which is located at a lower level. So that it acts as a sump for the sludge or sediments
which have a tendency to the bottom.
11. Super Heater
A Super heater is a device in a steam engine that heats the steam generated by the boiler again
increasing its thermal energy and decreasing the likelihood that it will condense inside the engine.
Super heaters increase the efficiency of the steam engine, and were widely adopted. Steam which
has been superheated is logically known as superheated steam; non-superheated steam is called
saturated steam or wet steam; Super heaters were applied to steam locomotives in quantity from
the early 20th century, to most steam vehicles, and so stationary steam engines including power
stations.

17. Conclusion
The BTPS IT has come a long way from lagging to leading in IT enablement
among NTPC power stations. IT Vision realized, making BTPS highly information
enabled plant.
Reference
• TRAINING REPORTS OF PAST YEARS AT NALANDA LIBRARY
• INTERNET
• DOCUMENTS OF C&I DEPARTMENT

18. C&I Lab
In C&I Lab parameters to be monitored are:
1. Speed
2. Temperature
3. Current
4. Voltage
5. Pressure
6. Flow of Gases
7. Vibration

19. Electricity from Coal
OPERATION AND MAINTAINANCE
This control & instrumentation is the brain of the plant because from
relays to transmitters followed by the electronic computation chipsets a
recorders and lastly the controlling circuitry, all fall under this.
A View of Control Room at BTPS