1

INTRODUCTION:

National Thermal Power Corporation (N.T.P.C) is a major corporation of power

generation over one fourth of the total thermal power in the country.
The corporation is maintaining its impeccable record by consistently generating
reliable and quality power established in 1975. NTPCs mission has been to construct
commission and operate power projects most economically and efficiently.
NTPC Ramagundam is situated in the Godavari valley Coal fields and has one of
Indias largest thermal power stations Ramagundam is considered as Manchester of India
in light of the companies around it. Some of them are FCI- Fertilizer corporation of India,
kesoram cement, Basanth Nagar, NTPC (RSTPS- Ramagundam super thermal power
station) sourcing 2600MW of power 24/7 and APSEB unit Ramagundam. Around 24
units of coal mines belt in Godavarikhani stretching 25km) are used in these open coal
mines. (pruthvi Banjan in the name given by late shri N.T. RamaRao, the then Chief
minister of Andhra Pradesh, to the thermal station for Godavarikhani community).
Many factories around this place take the raw material from the coalmines and prepare
carbon derivatives and providing employment to more than 15,000 people. The

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temperature is hotter than most places in India. A normal temperature is 40 degrees
Celsius.
NTPC has developed a technique to reduce the temperature by reducing the carbon
dioxide in its emissions and helped reduce the average temperature by 2 degrees Celsius
from last one decade NTPC has a policy of hiring full time employer according to the
production capacity. For the records its present employers should not be more than 2600.
NTPC Ramagundam is considered one of the best in the nation. Less than 25% of the
power is provided to the state of Andhra Pradesh. Recently 7 th unit was added (August
2004) with additional capacity of 500MW. NTPC owns 89.5% of shares and remaining
25% of shares are Owen by other public sectors. NTPC is classified as a Navaratna (a
cash-rich) company, meaning it may ru8n its operations independently and rise
commercial financing without explicit government nod.
NTPC limited has been ranked 463 in the Forbes global 2000, a listing of the worlds top
public companies. It has the state of the art control room instrumentation facility. The
Ramagundam unit of the National Thermal Power Corporation (NTPC) has bagged the
Rajbhasha award for 2002-03. The station has the unique distribution of recording 93
days of trip free operation and maximum continuous run for 355 its 500MW unit VI
during the year 1994-1995.

SALIENT FEATURES:
Total land
Installed capacity :
Unit size:

10000 Acres
2600MW
3*200MW (stage -1)
3*500MW (stage-2)

Transmission system:
Sources of coal:

1*500MW (stage-3)
2400ckt kms-400KV
(i) South Godavari Coal Field of
Singareni Collieries for Stage I &

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II
(ii)
Water source:

Korba Coal Fields of SECL for

Stage III
Sri Ram Sager Dam on Godavari
River, D-83 Canal from Pochampad

Total reservoir capacity:

Beneficiary states :

reservoir
5000 acres.
ANDHARA PRADESH
TAMIL NADU
KERELA
KARNATAKA
GOA

Total investment:

PONDICHERY
Rs 2059.22 Cr. Stage I & II

Coal consumption:

Rs.1818.46 Cr Stage III

8.6 Millions tones per annum.

Water assumption:

250 cusecs

Coal transportation:

Merry go round system (MGR) of

Ash disposal:

22.4km
Ash pond kundanpally, village.

Units

Unit I 200MW November 1983

Commissioned

Unit -II 200MW May 1984

Unit III 200MW December 1984
Unit IV 500MW June 1988
Unit V 500MW March 1989
Unit VI 500MW October 1989

Transmission lines:

Unit 500MW August 2004

14 out going feeders
9-400kv lines
Hyderabad-4
Nagarjuna sagar-2

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Chandrapur-2
Khammam-1
3-220kv lines
AP Transco
2-132kv lines
International

AP Transco
IDA, IBRD loan, OPEC, KFW, SFD

Assistance
Other industries

EXIM Bank, Japan.

Kesoram Cement, Basanth Nagar

Heights of Chimney(s)

APSEB unit Ramagundam

1. Stage. I- 210m
2. Stage. II 225m
3. Stage. III 273m

Distribution Of Electricity:
Total Capacity of Ramagundam NTPC is 2600 MW of stage 1, 2 & 3 (i.e. 1, 2, 3,
& 4, 5, 6 units) distributing electricity to following states in MEGA WATT.
STATE
ANDHRA PRADESH
TAMIL NADU
KARNATAKA
KERALA
GOA
PONDICHERY

MW
610 MW
470 MW
345 MW
245 MW
100 MW
50 MW

% AGE
29 %
22 %
16 %
12 %
5%
2%

Remaining 250 MW is used to any state, now it is used for A.P.

Total capacity of stage III (unit VII) is 500 MW distributing
electricity to following states in MW:-

STATE
ANDHRA PRADESH

MW
145.86 MW

% AGE
29 %

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TAMIL NADU
KARNATAKA
KERALA
PONDICHERY

118.20 MW
86.76 MW
1.61 MW
12.57 MW

23 %
17 %
12 %
2.5 %

SCHEMATIC ARRANGEMENT OF STEAM POWER STATION

Most of the thermal plants use coal as fuel. Although steam power station simply
involves the conversion of heat of coal combination into electrical energy, yet it embraces
many arrangements for proper working and efficiency. The whole system can be dived as
follows:

Fuel Handling plant

Steam generating plant

Steam turbine

Alternator

Feed water

Cooling arrangement

FUEL HANDLING PLANT:

The coal is transported by a road or railways and stored in a coal storage
plant. From the coal storage plant coal is delivered to coal handling plant where it is
pulverized (crushed into small pieces) in order to increase its surface exposure, thus
promoting rapid combustion without using large quantity of excess air. This coal is the
boiler and ash produced after complete combustion of coal is removed to the ashhandling pump and then to the ash storage plant for disposal.
COAL MILL:
It has high transmission motor (dc motors). 20mm size of coal from coal
feeders is finally pulverized in coal mill. This finally pulverized coal has to be lifted up to
the furnace level against gravity force. as this coal mil is of heavy mass, ball bearings are
not used but sleeve bearings are used in which pressure oil is used. The temperature of
this oil should be kept optimum, which is down by separate system.

PRIMARY AIR FANS (PAF):

Primary air fan sucks air from atmosphere pressurizes it and sends it to coal
mill through primary air pre heater which heats up this pressurized air.
SEAL AIR FANS:
As to prevent the damage of sleeve bearings of coal from pulverized coal.
We use seal air fans. A SAF blows air into a pressure more than the pressure of the
coal in coal mill. Thus sealing is done by SAF. Another fuel is used in plants is oil which
is sent to the furnace to the pump tank, the burning of fuel requires air, which is called
Secondary air.

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FORCED DRAFT FAN:
This FD fan sucks the air from atmosphere pressurizes it and sends it into the
furnace. The pressurized air is heated in secondary air preheater; the source of heating in
SAPH is hot steam from low pressure turbine (LPT).
FURNACE:
Area below the boiler in which combustion of fuel takes place and from which
heat passes into the boiler proper is known as furnace. It takes coal, oil, and air from coal
mills, oil guns, and FD fans respectively and gives fire. The furnace has four walls. The
wind boxes which allow air into the furnace, coal inlets, and oil guns are all arranged at
the four corners of the walls of the furnace. They are arranged in levels (they are eight in
number for each corner). There are igniters at the corners to ignite the oil and air mixture.
The fires from the four corners are made tangential to the fireball. It provides a chamber
in which at combustion reaction can be isolated and confined so that the reaction remains
a controlled force. In addition it provides support or enclosure for the firing equipment.
The furnace has to provide

Proper installation, operation and maintenance of fuel burning equipment.

Sufficient volume for combustion requirements

Adequate refractory and insulation.

Accessibility to the boiler for maintenance and repair work that must be handled
from inside the furnace chamber.

SCANNER AIR FAN;

The furnace consists of scanners to sense the flame . Air required for
cooling the scanner is supplied by a scanner air fan, which are two in number.
AIR PREHEATERS:
Air pre-heater transfers heat from flue gases to cold primary and/or
secondary air by means of rotating heating surface elements. Beneath this regenerative
type air pre-heater, there exists a steam coil air pre-heater. These are located in secondary

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pass of the furnace at a height of around 16 M level. Each 500 MW unit is provided
with two such air pre-heaters namely Primary Air Pre-Heater (PAPH) and Secondary Air
Pre-Heater (SAPH).

STEAM GENERATING PLANT (BOILER):

The steam generating plant consisting of a boiler, for the production of
steam and auxiliaries for the utilization of flue gases.
BOILER:
The heat of combustion of coal in the boiler is utilized to convert water into
steam at high temperature and pressure. The flue gases from the boiler make their journey
through super heater, economizer, air preheater and are finally exhausted to atmosphere
through chimney.
BOILER AND ITS AUXILLARIES:
Boiler or the steam generator is the main part in the power generation process.
Boiler acts as a medium in which water is converted into steam by using the heat released
in the process of combustion of coal in the presence of oxygen. The steam generator is a
natural circulation. Single drum type, front fired, double pass and balanced draft unit
designed for various conditions
There are many mountings to the boilers, which are compulsory for the safe run
of the boilers. Also there axe accessories, which increase the efficiency of boiler.
Boiler Contains Mainly 4 Parts:
1)

Economizer

2)

Boiler drum

3)

Super heater

4)

Reheater

Economizer:
The economizer consists of the feed water through which the heat recovery takes
place in the furnace. The steam and water produced in the economizer are feed in to the
boiler drum.

Boiler Drum:
Boiler drum is the important part of the boiler. In this; steam and water are
separated. Water having more density than steam it remains in the bottom part of the
drum. The steam thus produced is of low pressure and temperature.

Super Heater:
The steams from the boiler drum of low pressure and temperature is sent into the
super heater before sending it to the turbine. Here, the steam is heated to a temperature of
545 deg.cel. And a pressure of 170 Kg/sq.cm. This is sent to high pressure turbine.

STEAM TURBINE:
The dry and super heated steam from the super heater fed to the steam turbine
through maim valve. The heat energy of the steam when passing over the blades of the
turbine is exhausted to the condenser which condensates the exhausted steam by means
of cold eater circulation.
Turbines shaft coupled to the generator turbine, is divided into three categories,
which have same shaft coupling

High pressure Turbine (HPT)

Intermediate pressure Turbine (IPT)

Low pressure Turbine (LPT)

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The dry steam entered into the super heater from the boiler drum gets heated
upto the temperature of 535 degrees and pressure of 170.5 kg/cm^2 by gaining
heat from furnace from super heater the steam is passed to the HP turbine, it is
coupled to the generator the rate of steam entered into HPT is 1590 tons per hour.
The steam leaving the HPT looses its temperature and pressure to a low value so
this steam is passed to REHEATER to increase its efficiency. This process is called
regeneration.

Reheater:
The steam sent into the high pressure turbine loses its temperature and pressure
while it rotates. So, this depleted is then again heated to the required temperature of
535deg cel and a pressure begin constant at 40 Kg/sq.cm, which was obtained at the low
pressure turbine. This steam is sent to the intermediate turbine.

Condenser:
The steam after expansion from the turbine goes to the condenser. The use of
turbine increases the efficiency of the plant by decreasing the exhaust power of the steam
below atmosphere. Another advantage of condenser is that the condensed steam can be
recovered and that provides a source of good and pure water to the boiler and noncondensable gases can also be removed from the steam by passing it through the
condenser.

Condensate Extraction Pump (CEP):

Steam after doing work in turbine is condensed in condenser so that it becomes
water. This water is stored in Hot well. CEPs are used to pump this water from Hot well
to Desecrator from where it is pump to Drum.

Low pressure heater (LPH):

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It is a three stage heater where the temperature of the water is raised to
130deg.cel. the pressurized water from the CEP passes through the coils present in the
LPH. The steam tapped from the LPT, is used to heat water.

Deaerator:
As the pressure of the steam is negative in the condenser there is a chance of
mixing atmospheric air in the steam that may react with the metal and corrode them.
Deaerator is used to separate the air from the steam or more aptly water in it. Thus pure
and gas less feed water is obtained.

Boiler Feed Pump (BFP):

The boiler feed pump takes the water from the desorator and pressurizes it to a
high pressure of 190 kg/sq.cm and feeds it to the boiler through the high pressure
heater.

High Pressure Heater:

It is a two-stage pressure heater, in which the tapped steam from turbine is used to
heat he feed water in HPH, feed water flows in a coil in which steam is sent in opposite
direction of feed water such that heat exchange takes place. Feed water regulating system
(FRS) regulator the quality of feed water to be fed into the boiler.

Electrostatic Precipitator (ESP):

This consists of alternative plates and windings that carry positive and
negative charges respectively. The positive plates are grounded. The potential that exist
between the windings is 40kv to 50 kv. With these potential; the ash gets separated from
the flue gases. The ash that accumulated on the windings is blow or is hammered by the
high forced air so that they fall down and get collected in the hopper at the bottom of the
furnace. This ash thus obtained is then removed and sent to the ash pond.

Generator:

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The generator is one of the important blocks in the power production plant.
Generator is coupled with the turbine, which rotates due to the steam. The generator
consists of two important parts namely the stator & the rotor. The stator consists of
windings to generate electric flux with the help of an excitation unit provided. The rotor
is the rotating part, which is coupled to the shaft with hearings.
The rotor is a conductor and as a conductor is cutting the flux an E.M.F. is
induced which is tapped as power supply. Thus the steam energy is converted into electric
supply. This supply is 22KV voltage is increased to 400 KV for transmission purpose by
using a step up transformer.

Cooling tower:
The cooling tower rejects waste heat from the steam cycle to atmosphere. A
cooling tower is a specialized heat exchanger in which two fluids air & water) are
brought into direct contact with each other to affect the transfer of heat. In a sprayfilled tower, this is accomplished by spraying a flowing mass of water into a rain-like
pattern, through which an upward moving mass flow of coal air induced by the action of
a fan or by natural draft.

CONDENSER CYCLE:
At the outlet of condenser is termed as condensate. This condensate is extracted
from condenser by condensate extraction pump and sent to L.P., heater. Naturally, steam
leaks at many places like joints. Also steam loss is due to steam extraction to be discussed
later. To make up this loss, make up water is added at the condenser stage of water-steam
cycle. Water collected from river, well of canal is demineralised in D.M. (demineralising)
plant and then sent to hot well f condenser as a make up water. If water is not
dematerialized, the oxidation of the impurities in water would occur in the boiler because
of high temperatures. This would result in scaling on the inner surface of water tubes in
the boiler; the consequences of which are reduced heat transfer capability of tubes,
corrosion of tubes or even bursting of these tubes.

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Feed water (condensate) heating in the L.P. heater improves thermal efficiency of
the power plant. Heating is carried out by steam extracted from I.P. stage of the turbine.
No doubt, this steam loss reduces the work done at the turbine but the overall efficiency
of power plant gets improved. There is an obvious reason for this fact. The steam
extraction is a very small percentage of the total steam being expanded in the turbine.
Had this steam been allowed to do work, it would have given only about 30% output at
the turbine shaft.
On the other hand this extracted steam gives much more work thermally by feed
water heating. The feed water heating can be fully or partially by passed as required. This
pre-heated feed water is sent to deairator located at about same height as the boiler drum.
This rise is made possible because of condensate extraction (C.E.) pump.
The air brought to feed storage tank. Water comes down at the suction of the
boiler feed pump (B.F.P) from feed storage tank. As the pressure of water at the B.F.P.
outlet is about 140kg/cm2, the suction (inlet) of B.F.P. must always be full of water at
enough pressure. This is done because of high head of feed storage tank. If this is not
done, the cavitations resulting from lack of water pressure at the inlet would deteriorate
the B.F.P. The pressurized water is heated in H.P. heaters with the help pressure water at
temperature of 250C to 300C is heated by some 20-30C more in the economizer as
already discussed. The water then goes to boiler drum to complete the water-steam cycle.

CIRCULATING WATER CYCLE :

The steam coming out from the L.P. turbine is condensed in the condenser.
There are three reasons for condensing the outlet steam. Firstly, the work done in the
turbine is maximum if the pressure difference between the inlet steam and the outlet
steam is maximum. The steam input to the turbines is at a very high pressure (120
Kg/cm2) and the outlet steam pressure is very low (nearly vacuum) due to the steam
condensation in the condenser. This is because the same amount of steam when converted
to water requires very less volume. Secondly, the feed water is dematerialized and has to

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be circulated back to the boiler and not wasted because dematerializing is a very costly
process. Thirdly, the steam if not condensed would take very large space and the
equipments succeeding the turbine stages (H.P. heaters, L.P. heaters, feed water storage
tank, etc.) would be of an uneconomically large size.
The steam in the condenser is condensed with the help of circulating cold water in
the condenser. The cold water is circulated inside thin tubes in the condenser whereas the
steam passes from outside the tubes. The temperature difference is of about 15 to 20C.
Heat transfer takes place from the steam to the cold water and the condensed steam in
form of water is collected in the hot well.
The cold circulating water coming out from the condenser is hot carrying the heat
of the steam. This water can be disposed of to the down-steam of the river, if circulating
water is available in bulk and there is a river near the power plant. The cold water to be
fed to the condenser can then be taken from the up-steam of the river. If water is not
available in excess, the hot water coming out of the condenser has to be cooled by the
cooling towers and then circulated back to the condenser.
Cooling towers are huge structures having converging-diverging shape, with a
height of about 125m and diameter of about 100m. This particular shape of cooling
towers has been provided to create a natural draught, which are mechanically coupled
with the steam turbines. A steam alternator rotates at a speed of 3000 rpm whereas a
hydro alternator rotates at a speed of 375 rpm. The d.c. excitation to the rotor of the
alternator is given from the static excitation system. The electricity produced in the stator
is taken out to the generator transformers produced in the stator is taken out to the
generator step-up the voltage and feed the high voltage(220or400KV) infinite
Transformer and Auxiliary Transformers
Approximately, 10% of power generated by alternator is consumed by auxiliaries.
6.6 KV and 415 V buses feed these auxiliaries. The power is stepped down from 15.75
KV (say) to 7 KV by the transformers known as Unit Auxiliary Transformers (UAT).
The auxiliary requirements at 415 volts are derived by Auxiliary Service Transformers.

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When the generator is required to be started, auxiliary power is made available via
Station Auxiliary Bus.
The tiebreakers between station auxiliary bus and unit auxiliary bus remain
normally open. When unit trips, tiebreaker closes. Station auxiliary bus is generally live
as it receives power from 220 KV infinite bus via station transformer (say 220/7 KV).
There are some station auxiliaries like circulating water pumps, coal handling
plant auxiliaries like circulating water pumps, coal handling plant auxiliaries etc. which
are common to a set of units. These station auxiliaries are fed from station auxiliary buses
(6.6KV and 415 volts). The unit auxiliaries like I.D. fans, F.D. fans, P.A.fans, BFP
motors, coal mills, C.E. pumps etc. are fed by 6.6 KV unit auxiliary bus. Similarly there
are many 415 volt auxiliaries like seal air fan, E.S.P. (Electrostatic Precipitator) etc.
which are fed from 415 unit service bus. There is a comprehensive protection scheme for
large induction motors, U.A.T.s, station transformer and feeders.
In the unit scheme of generators, a unit consists of one generator, its generator
transformer, circuit breaker, two unit auxiliary transformers, two unit auxiliary buses, unit
service transformers, auxiliary induction motors, 415 volts power control centers and
motors control centers etc.
A connection between an alternator and generator transformer and unit auxiliary
transformer is made by conductors enclosed in a cylindrical enclosure known as bus-duct.

HISTORICAL BACKGROUND OF GENERATOR

The generator advantages of AC over DC as a means of electricity distribution
for established towards the end of 19 th century and the rapid growthof AC systems led to
a demand for AC generators. At first these were low speed machines driven by
reciprocating engines but by 1900 generators driven directly by high speed steam turbines
were being introduced by what are recognizable the tolerance of modern machines. The
benefits are being principally in the prime movers the early turbine generators were made

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both in vertical and horizontal shaft configuration. The vertical shaft design required at
large three bearings, and was quickly abandoned. The development of the horizontal shaft
machines was rapid, unit outputs had risen from a few 100KW to 20MW by 1912. The
rates of increasing in output solved subsequently by unit outputs had risen to 50MW by
1930. The 60hz frequency standardized in the USA required a speed of USA two pole
generators to be 3600rpm and losses caused by air friction at the speed made the much
less dense gas Hydrogen acts as a polling medium.
In the UK hydrogen cooling was used in 3000rpm unit of 50MW and above from
about 1950.later the search of increase in the effective means of heat(loss) removal led
first to the use to hydrogen at higher pressure, then insulating oil and finally, pioneered in
the UK, water in direct contact with the winding conductors. By these means generators
with increasing outputs demanded were able to be manufactured transported and installed
in a power station as a single unit which was both economically and operationally
attractive. Both the phase of development and the rate of increase in the unit output have
slowed markedly in recent years, has greater emphasis has been placed on the reliability
achieved by proven designs and on the advantages of under changeability of major plant
components.

GENERATOR
Generator is a device which converts mechanical energy of the shaft into
electrical energy by electromagnetic induction. It consists of a stator and rotor & an
excitation system. NTPC generates 2600MW power of which three are 200MW & other
four are of 500MW capacity.

OPERATION
An electrical generator is machine that converts mechanical energy into
electrical energy. The energy conversion is based on the principle of production of
dynamically induced EMF, whenever conductor cuts magnetic flux, dynamically induced
EMF is produced in it according to faradays law of electromagnetic induction. This EMF
causes a current to flow if the conductor circuit is closed. Hence, the basic essential parts

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of an electrical generator are a magnetic field and a conductor(s), which can so moved as
to cut the flux.
The basic law or principle of operation of all rotating machines remains the same
ie., faradays law of electromagnetic induction. It states that whenever there is a relative
motion between a conductor & a magnet i.e., when a moving coil cuts the magnetic lines
then an EMF is induced in it. This induced EMF directly proportional to rate of change
of flux and the no. of turns thus to produce relative motion either the armature has to
rotate on the magnet.

Thus to produce relative motion either the armature has to rotate on a magnet. In a DC
generator , the armature is rotating part and in alternator, it is a stationary part. The
rotating part(rotor) produce the magnetic field and armature winding is the stator.

DESIGN FEATURES:
The construction of a generator is essentially the manufacture of component parts,
which are then assembled partly at the manufacture works and partly at the site where the
machine is to be installed. A large number of component assemblies go into making a
generator, but is usual to consider the machine into two major parts, the stator & rotor.

STATOR:
The stator core is laminated like a DC armature core. The laminations are formed
of the special magnetic iron or silicon steel having slots on the inner periphery to
accommodate armature conductors. The whole structure is held in a frame or stator
frame, which may be of cast iron or welded steel plates. Since the field rotates in the

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stator, so that flux of the rotating field cuts the core of stator continuously and causes
eddy current losses in the stator core.

To minimize the eddy current losses, the stator core is laminated. The laminations
are stamped out in complete rings for smaller machines or in segments for larger
machines & insulated from each other with varnish. The stampings also have
openings which make axial & radial ventilating ducts to provide efficient cooling.

STATOR WINDING
Stator bars, phase connectors and bushings are designed for direct water
cooling. The bars consist of hollow and solid stands distributed over entire bar cross
section to ensure good heat dissipation. Bar ends, all the solid stands into water bars from

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which the cooling water enters and leaves through a Teflon insulation houses connected
to annular manifold.
Electrical connection between top and bottom is made by bolted connection at the
connecting sleeve. The water manifolds are insulated from the stator frame permitting the
insulation resistance of the water filled winding to be measured during the operation
manifolds are grounded.

BAR SUPPORTING SYSTEM:

To protect the stator winding against the effects of the magnetic forces due to load
and ensure permanent firm seating of the bars in the slots during operation, the
bars are inserted with a side rippled spring a slot bottom equalizing strip and a top
ripple spring located beneath.

The slot edge and the gap between the bars in the stator end winding are
completely filled with insulating material cured after insulation for radial support
the end windings are clamped to a rigid support ring of insulating which in turn
fully supported by the frame

Bars are clamped to the supporting ring with pressure plates held by the clamping
poles made from a high insulating material. A ring is free to move axially within
the stator frame so that movements of the winding due to the thermal expansions
are not restricted.

ROTOR SHAFT
Slots for the insertion of the field windings are milled into the rotor body the
longitudinal slots are distributed all over circumference to obtain solid poles.

ROTOR WINDING:
The rotor winding consists of several coils, which are inserted into the slots and
series connected such that two coil groups form one pole. Each coil consists of several

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series turns,each of which consists of two halt turns, which are connected by brazing in
the end section, conductors are made of copper with about 6.1% silver contact.
RETAINING RING:
Centrifugal forces of the rotor end winding are contained by single piece rotor
retaining ring. It is made of non-magnetic high strength steel in order to reduce stray
losses.

TYPES OF GENERATOR
The CEBG (Central Electricity Generators Board ) transmission system operates
at a frequency of 50hz. So do all the generators connected synchronously to it. The large
generators are almost all directly driven by steam turbine rotating at 3000rpm;a few
operate at 1500rpm
The high-speed generators are commonly known as turbine-generators, of
cylindrical rotor generators such machine are implemented until otherwise stated.
The CEBG has for many years standardized units of 500 & 600 MW electrical
outputs. At these ratings, these have been designed in different designs of generators each
design incorporating minor charges as time progressed.
GENERATOR SPECIFICATIONS
500MW GENERATOR
Make
Type
Code
Apparent power
Active power
Power factor
Terminal voltage
Permissible variation in voltage
Speed/frequency
Hydrogen pressure
Short circuit ratio
Field current
Field voltage
Class and type of insulation
Number of terminals brought out

BHEL
THDF 115/59
IEC 34-1, VDE 0530
588MVA
500MW
0.85(lag)
21 KV
+/-5%
3000 rpm /50hz
4KG/(CM*CM)
0.58
4040 amp
340V
MICALASTIC(similar to class f)
6

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STATOR
Volts
Connection
Amps
Coolant
Winding

21KV
Y-Y
16,200A
Water & hydrogen
U-X0.001524 V-Y0.001522

ROTOR
Volts
Amps
Coolant

340V
4040A
Water & hydrogen

RUNNING UPTO SPEED

Before running up to speed, the casing and the other components will have ben
scavenged of air and filled with hydrogen to a pressure approaching the rated. Hydrogen
pressure increases with increasing temperature and the objective is to achieve rated
pressure when on steady load. The seal oil system must be operating in order to contain
the hydrogen. The stator winding water system is established taking care that the water
windings are not colder than their ambient hydrogen.
As the rated speed is approached, the voltage regulators may automatically apply
excitation by closing the exciter and main field switches. If the resulting voltage is
greater than the rated voltage/frequency control device to prevent over fluxing of the
generator transformer.

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EXCITATION SYSTEM
Basically the excitation systems are classified as DC excitation system and
AC excitation and brushless excitation system and static excitation principles.

BASIC FUNCTION:
To meet the excitation power requirements of generator under all operating
conditions i.e., to provide required DC current to the field of the generator.

TYPES OF EXCITATION SYSTEMS

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1. DC exciter either directly or gear driven.
2. AC exciter with static rectifier.
3. Brushless excitation system.
4. Static excitation system.

DC exciter is not practicable for the unit sizes under consideration.

AC exciter, response time is comparatively high, when compared with static

excitation.

STATIC EXCITATION SYSTEM

Excitation power is directly derived from generator terminals, stepped down
to required voltage through an excitation transformer rectified and controlled by an AVR
plus thyristor bridge and then fed to the generator field through slip rings and brush gear.
Static excitation system has fast response time, which will be helpful for transient
stability limit of the 400kv system. It requires high current slip rings.
Static excitation system is suitable for the 200MW generators. In NTPC, units 1,2 and 3
are used static excitation system. This can be clearly understood by the diagram shown
bellow. The diagram bellow shows the excitation loops of the stage i.e., 200MW.
However these units are three in number at this power plant.

OPERATION
Initially Turbine IS Rotated at a speed of 300rpm. When this speed is achived a
close command is fed to field breaker.
There is an interlock between field breaker and field flashing (i.e field flashing
breaker is ON)
Dc power is fed to field winding through field flashing. i.e. field winding due to
air gap flux based on flemings left hand rule.
As the current through field flashing increases the EMF induced in stator also
increases(due to increase flux)

24
When the terminal voltage is 30% of the rated voltage (18kv), thyristor gets
triggered i.e. at this voltage D.V.R starts sensing and sends pulse to thyrister gate
terminal and hence thyristor will be ON.
Now DC supply fed to field winding is due to field flashing and output of the
thyristor.
When the terminal voltage is 40% of terminal voltage (18kv), field flashing
opens
Now DC supply fed to field winding is only through the thyristor bridge and
D.V.R control.
Within 15 to 20 seconds rated terminal voltage is developed.
When generator circuit breaker is closed (i.e generator is loaded) the current
starts flowing in stator winding. Hence teminal voltage falls (rises) due to
armature reaction for lagging and leading power factor.
DVR takes care of constant terminal voltage. As the terminal voltage falls (rises)
for lagging and leading power factor DVR gets sensed through voltage
transformer(18kv/100v).
Now DVR decrease (increase) and hence EMF is adjusted to rated voltage.
Unit auxiliary Transformer UAT are direactly tapped from Generator output
terminals for auxiliary uses.

VCURVES
(235.29MVA)
0.85PF LAG 18KV
H2 COOLED (2 KG/SQ CM)

25

V-Curves is a graph armature current and field current at different power factor.
When the generator is loaded (e.g. 200MW) the active power factor delivered to
load is constant and i.e. VI cos0=constant.
As the terminal voltage V is constant current I and power factor pf are varying.
If pf decreases, leading or lagging side, armature current increases according to
the above equation.
Minimum current occurs at Unity power factor UPF.
Never the less, armature reaction varies as armature current changes. Hence the
terminal voltage changes due to variation in the armature current. To obtain
constant terminal voltage(18kv), field current should be increased(decreased) for
lagging(leading) power factor.
Different V curves can be drawn for different powers of the load for lower power
armature current decreases.

500MW BRUSHLESS EXCITATION SYSTEM

In the 500MW turbo generators, Brushless excitation system is provided. The
main advantage of rotation diode excitation system is that it dominates the use of the
rings and carbon brushes, which pose constant maintenance problems.
In this type of excitation system there are no brushes or slip rings are found
The Major Parts are

26
Pilot exciter
Main exciter
Rotating rectifier set

PILOT EXCITER:
It consists of sixteen permanent magnetic poles on the rotor. An alternating
e.m.f. (400Hz) is induced in the stator winding. This alternating current is converted
into direct current by AVR and is to the field winding of the main exciter.

MAIN EXCITER

27
It has field windings on rotor. Field winding is excited by DC received
from AVR. It has six poles on which field winding are wound. Rotor has threearmature winding. As the conductor cuts the magnetic flux, an alternating e.m.f
(150Hz) is induced which is fed red to Rectifier Bridge.

ROTATING RECTIFIVER
It consists of no. of diodes where A.C is converted to D.C this supply is fed to
field winding of generator.

GENERATOR AUXILARIES
Generator seal oil system
Hydrogen cooling system

28
Primary water system
Two poles generator uses
Water cooling for stator winding for stator winding , phase connectors
and bushings
Direct hydrogen cooling for rotor winding and also to dissipate iron
losses, windage losses and stray losses.
Hydrogen coolers are arranged vertically inside the turbine and stator
end shield

SEAL OIL SYSTEM

Generator shaft seals are suppied with pressurzed seal oil to prevent hydrogen
losses at the shaft and ingress of air into the generator.
During normal operation, shaft seals are supplied with seal oil by separate system,
consisting of hydrogen side seal oil circuit and airside seal oil circuit. The oil used
in the seal oil circuit is same as that used in the turbine generator journal bearing.
During normal operation in the air side AC pump draws seal oil from the seal oil
storage tank and feeds it to the seals via cooler and filters which drains towards
the air side and return back to the seal oil storage tank. Similarly, hydrogen side
oil pump supplies oil to seal through separate strainer and cooler.
By dividing the seal oil system into two separate circuits hydrogen losses at the
seals are kept to a minimum and good hydrogen purity is maintained. For the
airside seal, oil circuit thre seal oil pumps are provided. In the event of failure of
one pump, the second ac pump automatically takes over. If both the pumps fails,
the seal oil supply is taken over standby DC pump. On the other hand,seal oil
pump is used for oil circulation in the hydrogen side seal ol circuit.
Hydrogen side seal oil pump operating pressure 2.0bar
Airside seal oiln operating pressure 5.7bar
Air/H2 side seal oil operating temperature 40-69degreees
The schematic diagram of the seal oil system is shown in the figure above

29

HYDROGEN COOLING SYSTEM

Hydrogen is circulated in the generator interior in a closed circuit by one multistage
axial flow fan arranged in rotor at turbine end.
Hot gas is drawn by the fan from air gap and delivered to coolers it recooled and
divided into three paths.
Path I it is directed to rotor end at the turbine end bellow the fan hub for cooling of
the turbine end half of rotor.
Path II it is directed from the coolers to the individual frame compartment for
cooling of stator core.
Path III it is directed to stator end winding space .at excited end half of the rotor end
half core end portion these three flow paths mix in the air gap that returns to the
coolers through the axial flow fan.

GAS SYSTEM
It contains all equipment necessary for filling generator with CO2 , H2 or air
and removal of this media and for operation of the generator filled with H2.
The gas system consists of:

Flow meter

Hydrogen supply

Carbon dioxide supply

Nitrogen sully

Pressure reducers

Pressure gauge

Miscellaneous shut up valves

Purity metering equipment

Gas drivers

Carbon dioxide flash evaporator

HYDROGEN SUPPLY

Generator casing the heat losses arising in the

30

Generators are dissipated through hydrogen. The heat dissipating capacity of

hydrogen is 8 times higher than that of air. This is most effective cooling
system where hydrogen is pressurized inside the generator.

CARBON DIOXIDE SUPPLY

As a precaution against explosive hydrogen air mixer air the generator must
be filled with inert gas carbon dioxide prior to hydrogen filling and hydrogen
remover.

The generator must be filled with carbon dioxide until it is positively ensured
that no explosive mixer is formed duing the subsequent filling or emptying
procedure.

COMPRESSED AIR SUPPLY

To remove carbon dioxide from yhe generator the compressed air must be
admitted into the generator.

Compressed air must be clean and dry. For this reason a compressed air filter
is installed in the filter line.

NITROGEN SUPPLY
Nitrogen is used to remove hydrogen or air during primary water filling and
emptying procedure.

PRIMARY WATER SYSTEM

This system is required for cooling, in a closed circuit by a separate pump are
provided. All valves, pipes and instruments encountering primary water at\re
made from stainless material.
The primary water system consists of following components
Primary water tank
Primary water pump

31
Primary water coolers

The primary water admitted in to the pump from the tank is first passed
through the cooler& fine filter to the water manifold. In the generator interior
and then to the bushings.

After cooling, that water is returned to the primary tank and the pressure
regulater maintains pressure in the tank. The primary water tank is located on
the top of the stator frame on elastic, thus forming the highest point of the
entire water circuit.

GENERATOR PROTECTION

32

INTRODUCTION:

Since the fault current in L-G fault is low, inhibits the differential
protection.

Generator neutral is grounded by NGT & NGR to give high impedance to

fault current during L-G fault to reduce fault current 10A.
When the fault position approaches towards neutral, fault current becomes
low, not enough to operate R2 &R3 (Respond to fundamental).
When the fault is near the neutral, R1 operation, 3rd harmonic current is
short-circuited.
R2 & R3 are designed to be sensitive to the fundamental freq. voltage &
insensitive to third harmonic & zero sequence voltage that are present at
generator neutral.

33
Shunting down the generator through tripping MB, mid.BKR, FB, turbine
does not cause the fault current immediately to zero. The flux trapped in the
field will result in the fault. Current slowly delay over several seconds after
generator tripped. Substantially exacerbating damage.

UN BALANCEDLOAD/NPN/PROTECTION/UNBALANCEDARMATUR E
CURRENT WITH TIME DELAY OF 10SEC (46G)
A three phase balanced load (i.e. generator stator) produces a reaction field
which rotates synchronously with field system. Any unbalanced condition
can be resolved into positive, negative & zero phase sequence condition
The positive sequence components are similar to balanced load.
Zero phase sequence reaction produces no armature reaction, no reaction
field.
The negative sequence components are similar to positive sequence system
except that the resulting reaction field (armature reaction) rotates counter
clockwise to DC field (rotor).
Voltage inducing in the rotor at double frequency.
Eddy currents are very large and cause severe heating in the rotor, alternate
electromagnetic torque unsatisfactory vibration in stator core.
If small unbalance 10% of rated current can be reduced by reducing
reactive/active power.
I2*I2*t=k
I2=negative sequence current
t=time in sec k=proportional to the thermal capacity of the rotor.

34

35

Zero sequence currents doesnt cause heating of generator rotor, hence

this component eliminates from the measurement by delta connected
transformer.

36

GENERATOR POLE SLIPING/OUT OF STEP

GENERATOR PROTECTION
The best way to visualize and detect out of step0 generator phenomena is to
analyze apparent impedance variation with time as viewed at terminal of the
generator.

37

With advent of modern HV system as well as large conductor cooled generator,

generator and generator transformer (G.T) impedance have increased while system
impedance has decreased. Hence maximum electric power developed by machine
decreases. If it is less than mechanical power, generator goes out of synch. This requires
out of step protection on generator.

Figure bellow typical breaker and half substation with a generator and a
short circuit on transmission line near generator.

If sc is 3-phase, Mw zero MVAR more

Pm unchanged, Pa = Pm Pe accelerating machine, increasing Og. If the

transmission system fault is not cleared quickly enough, the generator
angle will advance to point that if will be driven out of synchronism.

Fault cleared by opening breakers 1,2

The resulting power transformer is reduced because of increase in

reactance x.

The time that fault can be left on the system that corresponds to the critical
switching angle is called critical switching time.

If fault is left on the system longer than fet generator will loose
synchronously by slipping pole.
Qc = 120degrees

38

CONSEQUENCES
1. Out of step condition causes.
2. high currents
3. forces generator windings
4. high level of transient shaft torque.

39
5. if slip frequency of unit with respect to power system Approaches natural torsion
frequency, the torque can be high enough to break the shaft.
6. Unit step up transformer will also be subjected to very high transient winding
currents that impose high mechanical stress on its windings.
7. High rotor iron currents, pulsating torque.

LOSS OF FIELD/LOSS OF EXCITATION IN GENERATOR:

Generator will over speed and operate as induction generator (over speeds
of order

2 to 5%)

Generator will continue to deliver power drive the excitation from the
system.

Stator current will be 200%, there will be heavy rotor currents results over
heating. Overloading stator conductor.

A loss of field condition , which is not detected, can have a drasting

impact on power system by causing a loss of reactive power support as
well as creating substantial power drain.

Loss of field relay measures the impedance as viewed from the machine
terminals it operates when impedance falls inside the circular
characteristics.

A time delay is used to provide security against tripping for stable power
swing.

CAUSES OF LOSS OF EXCITATION

1. Open circuit in the field.
2. A short circuit in the field.

40

3. A
c
ci
d
e
nt
al tripping of FB.
4. AVR control fails.
5. Loss of field to the main exciter.
6. Loss of A.C supply to the excitation system.
Under voltage is experienced by unit auxiliaries due to heavy
MVAR flow from the system. This is sensed by voltage
monitoring relay.
When field failure accompanied by U/V, it is treated class A
tripping, field fails without a serious voltage drop is treated as
class B tripping.

LOW FROMWARD POWER PROTECTION

41

Delayed tripping of generator after 2 seconds of power <0.5% of rated power to

evaluate the mechanical of steam entrapped in the turbine and eliminate the chance of
over speeding of turbine.

42

GENERATOR REVERSE POWER PROTECTION

This protection acts under the following condition of operation.

1. Turbine tripped and reverse power detected for 2 seconds.
2. Turbine stop values closed and reverse power detected 2 seconds.
3. Reverse power detected for 50 seconds.

In steam turbine under normal operation there is a continuous flow of steam through
the machine. Any losses due to turbulence will be converted into heat, which will be
continuously carried away by the steam.

If the flow of steam ceases (control valve due to any protection, generator fails to
trip on low forward power) while set continues to run at full speed, the turbulence
losses in the trapped.

43

Steam may then build up a high temperature condition in low pressure stages,
leading to softening and distortion of blades.

GENERATOR BACK UP IMPEDENCE PROTECTION

All outgoing feeders from 400KV bus bars including 220KV lines which are
connected through auto transformers are against faults through distance protection
schemes.
For all these faults the generators are the main feeding elements which are to
be protected against persistent fault.

(left uncleared by outgoing feeder

protection scheme.)
Hence generator backup protection is designed.
It is having two stage operation.
STAGE-1 time delay of 1.7 seconds.
Trip main and middle breaker leaving unit to house load protection. (this is not
the house load operation) which implemented from SWYD on frequency low.
STAGE 2(2sec)
It gives generator trip command. Normally when the first stage timer
operates and opens the generator breakers, the trip cause should cease to exist. Second
stage comes in to service if trip cause persists. This is only possible if fault lies b/w
generator and breaker.

44

GENERATOR O/V PROTECTION

This protection is targeted to guard generator stator winding against over voltages
O/v can come across generator stator winding ion case of malfunction AVR.
Voltage control in manual position coupled with heavy load thrown of etc.
Such over voltages causes damage to generator stator winding insulation where
repair is time consuming and costly.

Voltage monitored from VT1 setting 105% (of 18.7KV i.e. 19.635KV) time delay
2sec.

45

EXCITATION FAULTY-A -30F

Excitation transformer winding temperature(130 c)
D.C o/v crowbar operation.
D.V.R CHISCH2 faulty.
D.V.R o/p>90%
220V DC loss.
Thyristor temperature. H1H1 90<C
Field forcing limiter>14sec.
DVR control faulty

If any one of the above fault occurs, operate a delay 30F, that energize trip coil of
generator breaker.

46

DIFFERENTIAL PROTECTION 87G 87GT 87L

This protection operates for phase to earth and phase to phase fault within the
zone of protection.
For faults outside the zone of protection there wont be any voltage coming across
the relay, but faults within the zone, the relay picks up due to resultant voltage,
coming the relay.
The stabilizing resistor is sized to ensure the stability for external.

47

LOCAL BREAKER BACKUP PROECTION

LBB is the part of the protection schemes in 132KV, 220KV and 400KV breakers
of RSTPS.
It is targeted to come into service when the breaker has failed to open on trip
command.
If breaker doesnt open fault condition although trip command goes, breaker
causes server damage.

48

EXAMPLE

Generator has to trip as a result of its turbine/boiler trip, 752,652 breaker have to
be opened to isolate generator from the grid.
If 752 fails to open, its LBB generates a trip command to all breakers (EX1352) connected to the bus (i.e. 400KV bus-1)
If 652 fail to open, its LBB generates trip command to 552. thus isolating
GEN-II from the system hence GEN#3 trips on LBB.

ACIDENTAL OFFLINE GENERATOR ENERGING

A number of machines have been damages or in some cases, completely
destroyed when they were accidentally energized while off-line.
One method widely used to detect inadvertent energizing is the voltage
supervised over current scheme.

49
An adjustable voltage element with adjustable pick up and drop out time
delays supervise an instantaneous over current relay.
The under voltage detector will disable the over current relay when the
machine is returned to service.
Great care should be taken while implementing this protection, so that DC
tripping power is not removed when the generator is offline.
Consequences
When a off line generator is energized while on turning the gears are coasting
to a stop, it behaves as an induction motor, can be damaged within a few
seconds.
AC voltage of synchronous frequency induced in the rotor, rotor will be
overheated, thus damaging the rotor.

50

ACCIDENTAL OFF-LINE GENERATOR ENERGING

The machine impedance during this high slip interval is equilent to the generator
negative phase sequence reactance.

51

ROTOR EARTH FAULT PROTECTION

Ground leakage in the rotor circuit of the generator does not adversely effect
operation, if occurs only one point. Danger arises if second fault occurs, which causes the
change in field distribution. The distortion may cause high vibration, damage to rotor
bearings.

52

STATIC EXCITATION SYSTEM ROTOR EARTH FAULT SCHEME

The relay must not be sensitive so as to operate with the normal insulation
leakage current talking account the high voltage to earth at negative end of the
winding and any over voltages due to field forcing and so on.
The field system is not ground normally and therefore a simple line to ground
fault does not give any fault current.
A second fault to earth will short circuit a path of the winding and therefore
produces an unbalanced field forces on the rotor and results shaft distortion if
fault is not cleared quickly.
Field current and voltage increases when there is earth fault in rotor.

53

54

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s