The document summarizes the 4 week industrial training that the author completed at NTPC Limited Badarpur Thermal Power Station from June 3rd to July 4th, 2013. The training involved visiting various divisions of the power plant including the Electrical Maintenance Department I (EMD-I), Electrical Maintenance Department II (EMD-II), and Control and Instrumentation Department (C&I). The document then provides details on the basic process of electricity generation from coal, the major components of a power plant, electrical equipment, and laboratories in the Control and Instrumentation Department.

1. INDUSTRIAL TRAINING
2013
NTPC LIMITED
BADARPUR THERMAL POWER STATION
MADE BY :
Jatan Singh Soni
11BEE0061

3. Training at BTPS
I was appointed to do 4 week training at this esteemed
organization from 3rd June to 4th July, 2013. I was
assigned to visit various divisions of the plant, which
were:
Electrical Maintenance Department I (EMD-I)
Electrical Maintenance Department II (EMD-II)
Control and Instrumentation Department (C&I)
It was really amazing to see the power plant and learn
how electricity, which is one of our daily requirements of
life, is produced.

4. INDEX
• OPERATION OF POWER PLANT
• PARTS OF A POWER PLANT
• VARIOUS CYCLES AT POWER
STATION
• ELECTRICAL MAINTENANCE
DEPARTMENT-I
• ELECTRICAL MAINETNANCE
DEPARTMENT-II
• CONTROL AND
INSTRUMENTATION

5. The basic steps in the generation
of electricity from coal involves
following steps:
• Coal to steam – Steam Generator
or Boiler
• Steam to mechanical power -
Steam Turbine
• Mechanical power to electrical
power – Electric Generator

6. BASIC POWER PLANT CYCLE

7. PARTS OF A POWER
PLANT
1. Cooling tower
2. Cooling water pump
3. Transmission line (3-phase)
4. Unit transformer (3-phase)
5. Electric generator (3-phase)
6. Low pressure turbine
7. Condensate extraction pump
8. Condenser
9. Intermediate pressure turbine
10. Steam governor valve
11. High pressure turbine
12. Deaerator
13. Feed heater
14. Coal conveyor
15. Coal hopper
16. Pulverized fuel mill
17. Boiler drum
18. Ash hopper
19. Super heater
20. Forced draught fan
21. Reheater
22. Air intake
23. Economizer
24. Air preheater
25. Precipitator
26. Induced draught fan
27. Flue Gas

20. THE EQUIPMENTS THAT NORMALLY FALL IN
THIS CATEGORY ARE:-ISOLATOR
• Isolator cannot operate unless breaker is open
• Bus 1 and bus 2 isolators cannot be closed simultaneously
• The interlock can be bypass in the event of closing of bus coupler breaker.
• No isolator can operate when the corresponding earth switch is on
SWITCHING ISOLATOR
• Switching isolator is capable of:
• Interrupting charging current
• Interrupting transformer magnetizing current
• Load transformer switching. Its main application is in connection with the transformer feeder as the unit
makes it possible to switch gear one transformer while the other is still on load.
CIRCUIT BREAKER
• One which can make or break the circuit on load and even on faults is referred to as circuit breakers. This
equipment is the most important and is heavy duty equipment mainly utilized for protection of various
circuits and operations on load. Normally circuit breakers installed are accompanied by isolators.
LOAD BREAK SWITCHES
• These are those interrupting devices which can make or break circuits. These are normally on same
circuit, which are backed by circuit breakers
EARTH SWITCHES
• Devices which are used normally to earth a particular system, to avoid any accident happening due to
induction on account of live adjoining circuits. These equipments do not handle any appreciable current
at all. Apart from this equipment there are a number of relays etc. which are used in switchgear.

23. OIL CIRCUIT
BREAKERS
AIR CIRCUIT
BREAKERS
SF6
CIRCUIT
BREAKERS

26. RATINGS OF THE GENERATORS USED
• Turbo generator 100MW
• TURBO GENERATOR 210 MW
•
• The 100 MW generator generates 10.75 KV and
210 MW generates 15.75 KV. The voltage is
stepped up to 220 KV with the help of generator
transformer and is connected to the grid.
• The voltage is stepped down to 6.6 KV with the
help of UNIT AUXILLARY TRANSFORMER (UAT)
and this voltage is used to drive the HT motors.
The voltage is further stepped down to 415 V and
then to 220 V and this voltage is used to drive Lt
Motors.

28. COOLING OF TRANSFORMERS
OF LARGE MVA
As size of transformer becomes large, the rate of the oil circulating becomes insufficient to dissipate
all the heat produced & artificial means of increasing the circulation by electric pumps. In very large
transformers, special coolers with water circulation may have to be employed.
TYPES OF COOLING:
Air cooling
Air Natural (AN)
Air Forced (AF)
Oil immersed cooling
Oil Natural Air Natural (ONAN)
Oil Natural Air Forced (ONAF)
Oil Forced Air Natural (OFAN)
Oil Forced Air Forced (OFAF)
Oil immersed Water cooling
Oil Natural Water Forced (ONWF)
Oil Forced Water Forced (OFWF)

29. UNIT AUXILIARY TRANSFORMER (UAT)
Unit I & V- 12.5 MVA
The UAT draws its input from the main bus-ducts. The total KVA capacity
of UAT required can be determined by assuming 0.85 power factor & 90%
efficiency for total auxiliary motor load. It is safe & desirable to provide
about 20% excess capacity then circulated to provide for miscellaneous
auxiliaries & possible increase in auxiliary.
STATION TRANSFORMER
It is required to feed power to the auxiliaries during startups. This
transformer is normally rated for initial auxiliary load requirements of the
unit in typical cases; this load is of the order of 60% of the load at full
generating capacity. It is provided with on load tap change to cater to the
fluctuating voltage of the grid.
NEUTRAL GROUNDED TRANSFORMER
This transformer is connected with supply coming out of UAT in stage-2.
This is used to ground the excess voltage if occurs in the secondary of
UAT in spite of rated voltage.

31. BUS BAR
Bus bars generally are of high conductive aluminum conforming to IS-5082 or copper
of adequate cross section. Bus bar located in air insulated enclosures & segregated from all
other components .Bus bar is preferably cover with polyurethane.
BY PASS BUS
This bus is a backup bus which comes handy when any of the buses become faulty. When any
operation bus has fault, this bus is brought into circuit and then faulty line is removed there
by restoring healthy power line.
LIGHTENING ARRESTOR
It saves the transformer and reactor from over voltage and over currents. It grounds the
overload if there is fault on the line and it prevents the generator transformer.
WAVE TRAP
WAVETRAP is connected in series with the power (transmission) line. It blocks the high
frequency carrier waves (24 KHz to 500 KHz) and let power waves (50 Hz - 60 Hz) to pass-
through.
BREAKER
Circuit breaker is an arrangement by which we can break the circuit or flow of current. A
circuit breaker in station serves the same purpose as switch but it has many added and
complex features. The basic construction of any circuit breaker requires the separation of
contact in an insulating fluid that servers two functions:
• extinguishes the arc drawn between the contacts when circuit breaker opens.
• It provides adequate insulation between the contacts and from each contact to earth.

32. EARTHING ROD
Normally un-galvanized mild steel flats are used for earthling. Separate earthing electrodes are
provided to earth the lightening arrestor whereas the other equipments are earthed by connecting
their earth leads to the rid/ser of the ground mar.
CURRENT TRANSFORMER
It is essentially a step up transformer which step down the current to a known ratio. It is a type of
instrument transformer designed to provide a current in its secondary winding proportional to the
alternating current flowing in its primary.
POTENTIAL TRANSFORMER
It is essentially a step down transformer and it step downs the voltage to a known ratio.
RELAYS
Relay is a sensing device that makes your circuit ON or OFF. They detect the abnormal conditions in
the electrical circuits by continuously measuring the electrical quantities, which are different under
normal and faulty conditions, like current, voltage frequency. Having detected the fault the relay
operates to complete the trip circuit, which results in the opening of the circuit breakers
and disconnect the faulty circuit.
There are different types of relays:
Current relay
Potential relay
Electromagnetic relay
Numerical relay etc.
AIR BREAK EARTHING SWITCH
The work of this equipment comes into picture when we want to shut down the supply for
maintenance purpose. This help to neutralize the system from induced voltage from extra high
voltage. This induced power is up to 2KV in case of 400 KV lines.

34. INTRODUCTION
This division basically calibrates various instruments and
takes care of any faults occur in any of the auxiliaries in
the plant.
“Instrumentation can be well defined as a technology of
using instruments to measure and control the physical and
chemical properties of a material.”
C&I LABS
Control and Instrumentation Department has following
labs:
• Manometry Lab.
• Protection and Interlocks Lab.
• Automation Lab.
• Electronics Lab.
• Water Treatment Plant.
• Furnaces Safety Supervisory System Lab

35. THANK YOU