A TRAINING REPORT ON

SURATGARH SUPER THERMAL POWER STATION

(For Fulfillment of The Requirement of Bachelor of Engineering)

15th June to 14th July 2009

Department of Electrical Engineering College of Technology & Engineering Maharana Pratap University of Agriculture & Technology Udaipur, Rajasthan.

Submitted By:

RISHABH LOHIYA B.E.- II YEAR ELECTRICAL ENGG

DEPARTMENT OF ELECTRICAL ENGINEERING

ACKNOWLEDGEMENT

I wish to acknowledge the encouragement and support received from Dr. R.R. JOSHI (HOD, Electrical department, C.T.A.E., Udaipur) & Mr. VINOD YADAV (Training incharge) for initiating my interest in training. Their mastery & work helped me in covering out this work smoothly. I am also grateful of all the workers of various departments who have helped me to improve my thinking as well as the practical knowledge. I am thankful and grateful to Mr. R.S. Mathur, SUPTDG Engineer(TM & TRG.) for giving me chance of training at their prestigious industry, which will be helpful in my progress toward bright future. I am also thankful to the executive staff, technical and non-technical staff of S.T.P.S. for extending their kind support, information and practical knowledge during my four-week practical training at their units in S.T.P.S, Suratgarh.

RISHABH LOHIYA

DEPARTMENT OF ELECTRICAL ENGINEERING

PREFACE

Practical training is a way to implement theoretical knowledge to practical use to become a successful engineer it is necessary to have a sound practical knowledge because it is only way by which one can acquire proficiency & skill to work successfully different industries.

It is proven fact that bookish knowledge is not sufficient because things are not as ideal in practical field as they should be.

SURATGARH THERMAL SUPER POWER PLANT is one of the best examples to understand the generation process of Electricity.

This report is an attempt made to study the overall generation system & related action of Power Plant. It is engaged in production of electricity using the Bituminous coal as the primary fuel & other byproducts like ash produced is used in Cement plant.

RISHABH LOHIYA

DEPARTMENT OF ELECTRICAL ENGINEERING

CONTENTS

1.

INTRODUCTION...............................................................3.

2.

SWITCHYARD....................................................................5.

3.

TRANSFORMER.................................................................9.

4.

TURBO GENERATOR.......................................................13.

5.

BOILER................................................................................20.

6.

STEAM TURBINE...............................................................30.

7.

E.S.P......................................................................................32.

8.

COAL HANDLING..............................................................33.

9.

ASH HANDLING................................................................34.

10.

COMMON AUXILARIES...................................................35.

11.

PROTECTION......................................................................36.

12. 13.

SALIENT FEATURES OF UNIT AUXILARIES................37. CONCLUSION......................................................................41.

DEPARTMENT OF ELECTRICAL ENGINEERING

1. INTRODUCTION
Suratgarh Super Thermal Power Station
Suratgarh Thermal Power Station is the First Super Thermal Power Station of Rajasthan with a total planned installed capacity of 1500 MW Presently the operational installed capacity of STPS is 1250(5x250) and one more unit of 250MW is slated for commissioning in March 2009. There are Units (6*250 MW) in 4 stages Stage I II III IV Unit No. 1 2 3 4 5 6 Capacity (MW) 250 250 250 250 250 250 Synchronizing Date 10.05.1998 28.03.2000 27.10.2001 24.03.2002 30.06.2003 31.03.2009 Cost (Rs. Crore) 2220 1900 753 1117

Location:STPS is situated near village thukrana about 27km South East of Suratgarh town is Shri Ganganagar Distt. Suratgarh was considered an ideal location for setting up a thermal power station in the state having regards to the availability of land, water, transmission network proximity to broad gauge railway and being an important load centre for North West Rajasthan. Coal:Thermal power station is based on coal. Coal is bitumen d grade coal. Coal from M.P., Bihar, Jharkhand coal mines by railway transportation with 3900 to 4200 kcal/kg.

Awards:1. Cash award of 3.75 lacks (for productivity) and Rs. 6.19 lacks for specific oil consumption 2. Golden Shield award from Union Ministry of power
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Operational Performance of Plant

The performance of Suratgarh Thermal Power Station has been exemplary right from the beginning since commissioning of Unit-I Particulars Gross Generation(MU) Plant Load Factor (%) Aux. Power Consumption (%) Sp. Oil Consumption(ml/kwh) 2004-05 9362.32 85.5 9.3 0.83 2005-06 9951.22 90.88 9.15 0.64 2006-07 10205.59 93.2 9.16 0.53 2007-08 10222.5 93.1 9.12 0.59 2008-09 9740.61 88.96 9.19 0.77

Environmental Profile Adequate measures have been taken to control pollution and ensure atmospheric emission within the prescribed limits of Environment (Protection) Act1986. 220 meter high stack have been provided to release flue gases into the atmosphere Adequate water spraying arrangements have been provided at coal unloading, transfer and conveying system to arrest and restrict Fugitive Emission. About 2.5 lacks plants of various species have been planted in STPS and ash dyke. Mobile laboratory vans are also available for regular monitoring of stack Emission, Ambient Air Quality and Trade Effluent. Regular monitoring of Stack Emission, Ambient Air Quality and Trade Effluent is carried out.

Extension Unit # 7&8( 2 x 660 MW) Two more Units of 660 MW each have been planned to add at STPS. These Units are expected to be synchronized by March 2013 and Sept. 2013 respectively.

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2. SWITCHYARD
220 KV & 400 KV SWITCHYARD AND DIFFERENT EQUIPMENTS INSTALLED AND BUS SCHEMES

BUS SCHEME
Main Function Of The Stations Is To Receive The Energy And Transmit It At The Required Voltage Level With The Facility Of Switching. At STPS Following Are The Bays: Bus Coupler 1 Sog -1 Sog -2 Generator Transformer -1 Ratangarh -1 Station Transformer -1 Bus Sectionalizer Ratangarh 2 Bus Tie Generator Transformer-2 Interlinking-1 Station Transformer-2 Interlinking -2 Station Transformer-3 Station Transformer-4 Station Transformer-5

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BUS SYSTEM
There Are Mainly Three Buses Main Bus-1 Main Bus-2 Transfer Bus Material of bus bar- Tarantull Al conductor with a capacity of 2400 amperes. Bus coupler-1 can be used as GT breaker for unit 1, 2 and 3. Only one bus coupler can be used as a GT breaker at a time.
CIRCUIT BREAKERS

SF6 GAS CIRCUIT BREAKERS

In this type of breaker quenching of arc is done by SF6 gas. The opening and closing of the circuit breaker is done by air.
TYPE DESIGNATION

E : L : F : SL: 4 : 1 :

S F 6 Gas Insulation Generation Out Door Design Breaker Construction Code BIL Rated Voltage 4 245 / 460 / 1050 kv No. of chamber

The high voltage circuit breaker type ELF SL 4-1 comprises 3 breaker poles , a common control cubicle and a pneumatic unit ( compressed air plant) a breaker pole consists of :- SUPPORT (FRAME) - POLE COLUMN - PNEUMATIC ACTUATOR (PKA) 40000 41309 N 90200

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The actuator is operated with compressed air. A pneumatic unit (97200), an air receiver and a unit compressor is installed to supply the compressed air. The compressed air stored in the air receiver is distributor to the three actuator via pipe line. If all the poles of the circuit breaker do not close simultaneously then the pole discrepancy relay will operate and trip the breaker. Also at the time of tripping, if all the breakers do not trip simultaneously, then again the tripping command through the pole discrepancy relay will initiate to trip the breaker and annunciation will appear in the sub station control room and the UCB.
ISOLATORS

Isolators are used to make or break the circuit on no load. They should never be operated on load. The isolators installed in the sub station have a capacity of 1250 amperes. They are double end break type motor operated and can be operated from local as well as remote.
CURRENT AND CAPACTIVE VOLTAGE TRANSFORMERS

These are used for metering and protection. It should always be kept in mind that a CT should never be open circuited and a PT should never be short-circuited.

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LIGHTINING ARRESTOR AND ARC HORNS

Lightning arrester is a device used on electrical power systems to protect the insulation on the system from the damaging effect of lightning. The typical lightning arrester also known as surge arrester has a high voltage terminal and a ground terminal. When a lightning surge or switching surge travels down the power system to the arrester, the current from the surge is diverted around the protected insulation in most cases to earth.

Arcing horns are projecting conductors used to protect insulators on high voltage electric power transmission systems from damage during flashover. The horns encourage flashover between themselves rather than across of the surface of the insulator they serve to protect. Horns are normally paired on either side of the insulator, one connected to the high voltage part and the other to ground. They are frequently to be seen on insulator strings on overhead lines, or protecting transformer bushings.

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4. TRANSFORMER
Transformer is made up of the following Parts: 1. Core 2. Winding 3. On Load Tap Changer 4. Tank 5. Bushing 6. Auxiliary Equipments 7. Insulating Oil 8. Cooling System In sstps there are various transformer are used for various purpose. They are: a) b) c) d) Generating Transformer Unit Auxiliary Transformer Station Transformer Instrument Transformer (A). Potential Transformer (B). Current Transformer

STATION TRANSFORMER
When the unit is to be started, power supplied to the auxiliaries is taken from the station transformer. The rating of the station transformer is 50 MVA. It takes power from the grid at 220 kV and steps it down to 6.6 kV. At the time of starting all the auxiliaries are supplied from the station transformer. When the generator is synchronized and starts producing power, about 80% of the load is shifted on to the unit auxiliary transformer. The load that requires uninterrupted supply is left connected on the station transformer. There are 6 S.Ts in the plant. One for each stage.

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Technical Data Of Transformer

HV KVA Volts (No Load) Amp (Line Voltage) NO. Of Phase & Frequency Types Of Coolant Connection Symbol Mass Of Care And WDG Mass Of Oil Total Mass Volume Of Oil Air Circulation 40000/50000 220000 105/131 3, 50 Hz ONAN / ONAF YNyno 44470 Kg 22780 Kg 86210 Kg 25600 Litre 1080 M3/min

LV 40000/50000 6900 3351/4189

UNIT AUXILIARY TRANSFORMER

Each unit has two unit auxiliary transformers. When the unit starts generating electricity these transformers are energized and then supplies power to the auxiliaries. Before starting of the unit, UAT bus is connected to the station bus. Auxiliaries of one unit takes about 20MW of power. UAT is connected between the generator and the GT. A tapping is taken from the power coming from the generator to the GT. UAT relieves GT from extra load of about 20 MW which is to be supplied to the auxiliaries via GT and ST thus increasing the efficiency. It is a step down transformer, which steps down the voltage from 16.5 kV to 6.9kV. The rating of UAT is 20 MVA. UAT bus supplies only those auxiliaries, which are not necessary to be energized in case of sudden tripping of generator.

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UNIT STATION TRANSFORMER

It is a step down transformer, which is connected to the station bus. It steps down the voltage from 6.6 kV to 0.433 kV it is used to supply the low voltage auxiliaries.

UNIT SERVICE TRANSFORMER

It is also a 66 kV/ 415 V transformer which is used to supply the auxiliaries connected to the unit secondary switchgear bus.

INSTRUMENT TRANSFORMER
Instrument transformer has very wide range in application such as measurement of voltage, current, power and energy, power factor, frequency. It is also used for protection circuit of the power system for operation of over current, under voltage, earth fault and other type of relay. According to measuring purpose, instrument transformer can be classified as: A. Current Transformer B. Potential Transformer

A. CURRENT TRANSFORMER
Current transformer is used for monitoring the current for the purpose of measuring and protection. They can be classified as Dead Tank and inverter type. The dead tank current transformer accommodates the secondary cores inside the tank which is at the ground potential. The insulated primary passes through the porcelain and the tank and the terminals into the top chamber. The primary used in such type of constructions of u type.

The inserted secondary cores are insulated to the system voltage and hence inside the top chamber which is at the line potential. Before commissioning of the current transformer,
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the earthing of the power terminal and base is essential, otherwise excessive high voltage appears at the power factor terminals and leads to heavy spark. The secondary terminal of the core should be short circuited and earthed which are not in use otherwise excessive high voltage will be develop across the current transformer secondary. The current transformer should always be in vertical position so that gas forming at the top does not enter the insulated parts.

B. POTENTIAL TRANSFORMER
The function of potential transformer is to step down the voltage so that it can be measured by standard measurement. The outlook of current and potential transformer is almost same except there is a ground terminal. They are either of 1-or 3-.in the 3- P.T. there are again three limbs and five limb core construction. The P.T. may be dry or oil field. The P.T. above 66 KV are essentially sealed with inert gas cushion provided in the top chamber to take care of expansion and construction. The transformer generally core type and form Y-Y group having the insulation as oil & paper. Every P.T. is connected to phase hence there may be three P.T.s and connected to the same bus bar coming to same meter mounted on the panel through a selector switch which can be used to measure different line voltages. As the voltage of the feeders connected to same bus bar and the same voltage and we dont use separate P.T. for each feeder.

DEPARTMENT OF ELECTRICAL ENGINEERING

3.

TURBO GENERATOR
TURBO GENERATOR manufactured by B.H.E.L. and incorporated with most modern design concepts and constructional features, which ensures reliability, with constructional & operational economy.

4.1. STATOR
The generator stator is a tight construction, supporting & enclosing the stator windings, core and hydrogen coolers. Cooling medium hydrogen is contained within frame &

circulated by fans mounted at either ends of rotor. The generator is driven by directly coupled steam turbine at a speed of 3000 r.p.m. the Generator is designed for continuous operation at the rated output. Temperature detectors and other devices installed or

connected within then machine, permit the windings, teeth core & hydrogen temperature, pressure & purity in machine under the conditions. There is a provision for cooling water in order to maintain a constant temperature of coolant (hydrogen) which controls the temperature of windings.

4.1.1 STATOR FRAME: The stator frame of welded steel frame construction, which gives sufficient & necessary rigidity to minimize the vibrations and to withstand the thermal gas pressure. Heavy end shields enclose the ends of frame and form mounting of generator bearings and radial shaft seals. Ribs subdivide the frame and axial members to form duct from which the cooling gas to & fro radial ducts in the core and is re-circulated through internally mounted coolers. The horizontally mounted water cooled gas coolers being so arranged that it may be cleaned on the water side without opening the machine to atmosphere

4.1.2 STATOR CORE: It is built up of special sheet laminations and whose assembly is supported by a special guide bass. The method of construction ensures that the core is firmly supported at a large number of points on its periphery. The laminations of high quality silicon steel which combines high permeability with low hysteresis and eddy current
DEPARTMENT OF ELECTRICAL ENGINEERING

losses. After stamping each lamination is varnished on both sides with two coats. The segment of insulating material is inserted at frequent intervals to provide additional insulation. The laminations are stamped out with accurately fine combination of ties. Laminations are assembled on guide bass of group separated by radial ducts to provide ventilation passage. The ventilation ducts are disposed so as to distribute the gas evenly over the core & in particularly to give adequate supports to the teeth.

4.1.3 STATOR BARS: Stator bars are manufactured as half bars. Each stator half coil is composed of double glass cover and bars of copper transposed in straight portion of Robill Method so that each strip occupies every radial portion in the bar. For an equal length along the bar. They are made in strips to reduce skin effect. The winding overhead is in volute shape. The overhung portion of the bar is divided into four quadrants & insulated

4.1.4 STATOR WINDINGS: Stator windings are double star layers, lap wound, three phase and short pitch type. The top & bottom are brazed and insulated at either end to form turns. Several such turns form a phase. Phases are connected to form a double star winding. The end of winding form involute shape ends, inclined towards machine axis by 20 o, thus form a basket winding with total induced conical angle of 400 End windings will be sealed against movement of short circuit by both axial & peripheral bracing. The exposed portions of windings are finally coated. Insulation of individual bars & stator windings at various stresses is tested with applied high voltages of AC of Hz.

4.1.5 TERMINAL BUSHINGS: Six output leads (3 long, 3 short) have been brought out of the coming on the exciter side. External connections are to be made to the three shorter terminals, which are phase terminals. The large terminals are of neutral & current

transformer is inserted. The conductor of Generator terminal bushing having hollow copper tubes with Copper brazed at the ends to avoid leakage of hydrogen. Hollow portions enable bushings to be hydrogen cooled. Ends of bushings are Silver-plated: middle portion of the bushing is adequately insulated & has a circular flange for bolting the stator casing. Gaskets are provided between the Flange of terminal bushings and castings to make it absolutely gas tight.
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4.1.6 BEARINGS: Generator bearings have electrical seats of consists of steel bodies with removable steel pads. The bearings are formed for forced lubrication of oil at a pressure of 2-3 ATM/ from the same pump that supplies oils to the turbine, bearings & governing gears. There is a provision to ensure & measure the rotor bearing temperature by inserting a resistance thermometer in the oil pockets.

4.1.7 VENTILATION SYSTEM: The machine is designed with ventilation system having 2 ATM rated hydrogen pressure. Two axial fans mounted on either side of the rotor to ensure circulation of hydrogen. The stator is designed for radial ventilation by stem. The end stator core packets & core clamping & plates are intensively cooled by Hydrogen through special ventilation system. Design of special ventilation is so as to ensure almost uniform

temperature of rotor windings and stator core. Rated load operating temperature is well within the limits corresponding to the Class B operation. Embedded Resistance

Temperature Detectors do continuous monitoring of Hydrogen temperature at active parts of Generator.

4.2.

ROTOR

4.2.1 ROTOR SHAFT: Rotor shaft consists of single piece alloy steel forging of high mechanical and magnetic properties performance test includes:1. 2. 3. 4. 5. 6. Tensile test on specimen piece. Surface examination. Sulfur prist tests. Magnetic crack detection. Visual examination of bore. Ultrasonic examination.

Slots are milled on the rotor gorging to receive the rotor winding. Transverse slots machined in the pole faces of the rotor to equalize the moment of inertia in direct and quadrilateral axis of rotor with a view minimizing the double frequency.

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4.2.2 ROTOR WINDINGS: rotor winding is of direct coil type and consists of parallel strips of very high conductivity Silver Bearing Copper, bent on edge to form coil. The coils are placed in impregnated glass, laminated short shells; using glass strips inter turn insulation and will be brazed at the end to form continuous winding. The complete winging will be packed at high temperature and pressed to size by heavy steel damping rings. When the windings have cooled, heavy dove tail wedges of non-magnetic materials will seal the insulation at the top of slot portion. The cooling medium hydrogen gas will be brought in direct contact with copper by means of radial slots in embedded portion. Treated glass spacers inserted between the coils and solid ring prevent lateral movement of coil overhang. The formation and description of glass spacer is such as to leave ample space for ventilation.

4.2.3 RETAINING RING: The centrifugal force of the rotor end windings are contained by single-phase rotor retaining rings. The retaining rings are made of non magnetic highstrength steel in order to reduce stray losses. Each retaining ring with its shrink fitted ring is shrunk onto the rotor body in an overhung position . the retaining ring is secures in the axial position by a snap ring.

4.2.4 FIELD CONNECTION: The field current is supplied to the rotor winding through radial terminal bolts and two semicircular conductors located in the hollow bores of the exciter and rotor shafts. The field current leads are connected to the exciter leads at the exciter coupling with Multikontakt plug-in contacts which allow for unobstructed thermal expansion of the field current leads.

4.3 BEARINGS: The bearings are self-aligned & consist of slip steel shells linked with special bearing metal having very low coefficient of friction. The bore is machined on an elliptical shape so as to increase the mechanical stability of the rotor. The bearing are pressure lubricated from the turbine oil supply. Special precautions are taken to prevent oil & oil vapor from shaft seals and bearing along the shaft. The circulation of shaft current is liable to damage. The bearing surface is protected by insulation so placed that the bearings, seals & necessary pipes are inclined from the frame.
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4.4 SLIP RINGS : The slip rings are made of forged steel. They are located at either side of Generator Shaft. The slip ring towards the exciter side is given +ive polarity initially. They have helical grooves and skewed holes in the body for cooling purpose by air. Calibrated mica is first built up to required thickness on the shaft where slip rings are located. The slip rings are insulated from the rotor shaft. Excitation current is supplied to the rotor winding. Through the slip rings which are connected to the winding. On one end and to the slip ring on the other end with insulated (terminal) studs passing though the radial holes in the rotor shaft. The terminal studs at both the ends of excitation leads are fitted gas cat seals to prevent leakage.

4.5 BUSH GEAR ASEMBLY: Generator bushes are made from the various compositions of natural graphite and binding material. They have a low coefficient of friction and are self lubricating. The brushes are provided with a double flexible copper or pigtails. A helical spring is mounted rapidly over each bush so that pressure is applied on the centerline of bush. A metal cap is riveted to the brass bead and is provided with a hole to maintain the position of the spring plug. Several brush holders, each carrying on brush in radial position are fixed to silver plated copper studs mounted on the collecting arm concentric with each slip rings. The collecting arm is made out of a copper strip. 4.6 COOLING SYSTEM: In SSTPS hydrogen cooling system is employed for generator cooling. Hydrogen is used for cooling medium primarily because of its superior cooling properties & low density. Thermal conductivity of hydrogen 7.3 times of air. It also has higher transfer co-efficient. Its ability to transfer heat through forced convection is about 75% better than air. Density of hydrogen is approx. 7/14 of the air at a given temperature and pressure. This reduces the windage losses in high speed machine like turbo-generator. Increasing the hydrogen pressure the machines improve its capacity to absorb & remote heat.

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Relative cooling properties of air and hydrogen are given below:-

1) Elimination of fire risk because hydrogen will not support combustion. 2) Corona discharge is not harmful to insula ? since oxidation is not possible. 3) Smooth operation of machine in view of vertical elimination of wind age noise & the use of heavy gas light enclosure and dirty proby casing.

GENERATOR SPECIFICATION

KVA P.F Stator Volts Amps Rotor Volts Amps RPM Frequency Coolant

: : : : : : : : :

294100 0.85 16500 V 10290 A 319 V 238 A 3000 50 Hz HYDEOGEN 3 bar Gas Pressure

EXCITATION SYSTEM

The electric power Generators require direct current excited

magnets for its field system. The excitation system must be reliable, stable in operation and must response quickly to excitation current requirements. When excitation system response is controlled by fast acting regulators, it is chiefly dependent on exciter. Exciter supply is given from transformer and then rectified.

(A)

Function of excitation system: The main function of excitation system is to supply required excitation current at rated load condition of turbo Generator. It should be

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able to adjust the field current of the Generator, either by normal controller automatic control so that for (B) All operation & between no load and rated load. The terminal voltage of the system machine (C) Maintained at its value. The excitation system makes contribution improving power system stability steady state condition. The excitation system that are commonly termed quick response system and have following principal feature :- Exciter of quick response & high voltage of not less than 1.4 times the rated filed voltage and nominal exciter response of minimum 0.5.

Type of excitation system: There have been many developments in excitation system design. There has been continuing reach among the design and the use alike from improving the excitation system performance. The ultimate is to achieve stability; accuracy etc. the modern excitation system adopted presently on BHEL make turbo-generator. I. II. Conventional DC excitation system Brushes excitation system.

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5. BOILER
It consist three different units. 5.1 Boiler Unit 5.2 Mills 5.3 Fans

5.1 Boiler Unit

The Boiler Unit comprise the following elements:Boiler Super heater Reheater Economizer Airpreheater Furnace

5.1.1 Boiler
The boiler installed in S.T.P.S. is made by M/s BHEL. Each of the boilers are single drum, tangential fired water tube naturally circulated over hanged, balanced draft, dry bottom reheat type and is designed for pulverizing coal firing with a max. Continuous steam output of 375 tons/hour at 138 kg/cm2 pressure and 5400C temperature. The thermal efficiency of each boiler at MCR is 86.8 %. Four no. of bowl mills have been installed for each boiler. Oil burners are provided for initial start up and stabilization of low load. Two E.S.P.(one for each boiler) is arranged to handle flue gases from the respective boilers. The gases from E.S.P. are discharged through 180 meters high chimney. I.D. fan and a motor is provided with a balanced draft consisting of two forced draft fans and two induced draft fans. Flue gases are utilized to heat the secondary air for combustion in the tubular type air heaters installed in the boilers. Since the boiler furnace is maintained at a negative pressure, to avoid atmospheric air entering the furnace a hydraulic pressure is maintained at the furnace bottom.
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The water filled in the stainless steel seal through the hydraulic seal between the furnace ash hoppers and the water wall ring heater. Adequate clearance is also provided for the downward expansion of the furnace. Ash is formed by the result of burning of coal inside furnace. A small quantity of ash is collected in the bottom ash hopper and considerable amount of ash is collected in the E.S.P. and magnetic separator hopper. This collected ash is extract and disposed off in a slurry form in the ash disposal arc.

5.1.2

Super Heater Superheats are meant to raise the temp. of steam, the saturation temp. By absorbing

heat from flue gases steam temp. Limiting value in the boiler is 5400C. Super heater eliminates the formulation of condensate during transporting of steam in pipelines and inside the early stages of turbine, which is harmful to the turbine blades and pipelines. Super heater section is composed of four sections viz. plates, pendant, rear, horizontal and steam cooled walls. The plates section is located just above the furnace in front of the furnace arc. The pendant section is located in the back of screen wall tubes. The rear horizontal is located in the furnace rear gas pass above the economiser and the steam cooled wall section comprises of side, front, rear and roof of the vertical real gas pass. Desuperheater is provided in between the final superheater and preheater to control the superheated steam temp. Feed water is used as a spray to control the temp. Superheated steam is led into the H.P. turbine through main steam stop valve and hydraulically operated high pressure quick closing stop valve (HPQCSV) governing valves. After doing he useful works in the H.P. turbine the steam is returned to reheater through the cold reheat lines.

5.1.3 Reheater Reheater are used to raise the temp. of steam from which point the energy had been extracted in H.P. turbine with increasing no. of reheating stages. Reheating is continuing till temp. of steam is reaches to 5400C. Reheating requires additional equipment like :(a) Heating surface (b) Boiler turbine

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Connecting pipe and safety components like safety valve non return valve isolating valve steam temp. regulating equipment etc. A reheater is composed of two sections viz. front pendent vertical spaced, rear pendent vertical spaced. The front pendent vertical section is located between the rear water wall hanger tubes and the super heater plates section. The rear pendent vertical spaced section is located above the furnace arch between the water-cooled system wall tubes and heat wall hanger tubes. 5.1.4 Economizer The function of an economizer in a steam-generating unit is to absorb heat from the flue gases and add this as sensible heat to fed water before the water enters the evaporating ckt. Of the boilers. The coils of the economizer are designed for horizontal placement which facilitates the draining of the coil and favours the arrangement in second path of boiler. Water flows bottom to the top so that steam in any from during the heat transfer can move along with water and prevent the lock up steam which will cause over heating and failure of economizer.

5.1.5 Airpreheater Air preheater is a heat exchanger in which air temp. is raised by transferring heat from other fluids such as flue gas. Since air heater can be successfully employed to reclaim heat from flue gas at lower temp. level, then it is possible with economizer the heat ejected to chimney can be reduced to a great extent thus increasing the efficiency of a boiler.

5.1.6 Furnace Furnace is the primary element part of the boiler where the chemical is obtained by combustion. Furnace is designed for maximum heat release from the face with in the combustion chamber. In water cooled chamber furnace the whole combustion region is surrounded by tubes through which water flows. These are baked by refractory walls.

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MILLING PLANT

5.2.1 5.2.2 5.2.3

Pulverized coal Systems Direct Firing System Drum/Tube mills

5.2.1 PULVERIZED COAL SYSTEMS For steam generation, there is basically system of pulverization normally in STPS plant used is Direct Firing System

DIRECT FIRING SYSTEM

Hot Primary System : In this system the fan is located before the pulverized and handles complete primary air required for drying a transporting the coal. Disadvantages are that the fan is required to handle high temperature air resulting in high a fan power. Separate sealing air fans are required to seal the mill and Journal bearings.

Cold Primary Air System : The primary air fan handles clean cold air either from FD fan discharge or taking suction from atmosphere. The advantages are saving in fan power and maintenance. The only disadvantage. Is the cost increase due to additional duct work and air heater.

Suction System : In this system the mill operates under negative pressure. Suction being created by an exhauster placed after the mill. The exhauster handles all the coal air mixture and forces it into the burners. The advantage of suction system is that the plant can be maintained clean. The disadvantage of this system id that he high speed exhauster has to handle coal air mixture and tends to wear more as the pulverized size increase.

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Pressurized Exhauster system : In this system the mills operate under positive pressure. With exhauster provided at hr exit of pulverize to boost the pulverized coal into the pressurized furnace. Since the pulverized operates with lesser pressure than forced draft fan pressure. In plant TUBE type o pulverized mill is used.

5.2.3 DRUM / TUBE MILLS

This type mills is slow speed type. They operate at a speed of 17-20 rev/min and formerly were designed as suction mills. The mill drum carrying the ball charge rotates in the antifriction bearings. Raw-coal is fed to the drum through the inlet elbow and gets crushed to powder inside the mill drum. The ball charge and the coal are carried to certain height inside the drum and slowed to fall down. Due to the impact of the balls on cola particle sand due to attrition as the particles slide over each other and also over the liners, the coal gets crushed. Hot flue gases are used for drying and transporting the pulverized coal from the mill to the classifier. Advantage : High output possible, up to 50 tones per hour. No maintenance over long periods High availability Because of high availability no stand by capacity is required No mill rejects, no problems with tramp iron Reserve of fuel within mill makes output more stable.

Disadvantage : High power consumption Some problems with control of coal level within the mill. Virtually constant power consumption at all loads; low load operation of therefore not economical. With high moisture content fuels a high primary air temperature is required because of the low air/fuel ratio
DEPARTMENT OF ELECTRICAL ENGINEERING

Unplanned stops leave the mill full of coal which, under unfavorable conditions, can ignite. This coal has to be quenched and even dug out otherwise the mill cannot be restarted.

Heat Transfer in Boiler :

In boiler heat energy is released from the combustion of fossil fuels and the heat is transferred to different fluids in the system and a part of it is lost or left out as unutilized. There are three modes of heat transfer: Conduction Convection Radiation

Heat energy is transferred from a heat source to a heat receiver by one or more of these modes for which heat source should be at a higher temperature than the receive.

In superheater tube with high temperature region but does not directly view the flam. Here the heat is transferred from flue gas to superheater tube metal by convection and by non-luminous radiation and in the tube metal by conduction and to the steam by forced convection.

The power plant boilers are large capacity steam generators used purely for the electrical power generation.

DEPARTMENT OF ELECTRICAL ENGINEERING

5.3 FANS
5.3.1 F.D. FAN (Forced fan) 5.3.2 I.D. FAN (Induced fan) 5.3.3 P.A. FAN (Primary fan)

5.3.1 FORCED DRAFT FAN

In the Axial Reaction Fans (Type AP), the major part of (about 80%) energy transferred is converted into static pressure in the impeller itself. The rest of the energy is converted into static pressure in the diffuser. These fans are generally driven at constant speed. Varying the angle of incidence of impeller blades controls the flow.

Technical Data:

Application No. off Medium handled Orientation Capacity Temp. Of medium Speed Coupling Drive motor Rating Speed Fan Weight Type of fan regulation

: : : : : : : :

Forced Draft Fan 2 Atmospheric Air Vertical Suction and Horizontal Delivery 105.2 m3/Sec 450C 1480 rpm Rigiflex coupling

: : : :

700 KW 1480 rpm 8 Tones Blade Pitch Control

DEPARTMENT OF ELECTRICAL ENGINEERING

When looking in flow direction, the fan consists of the following Components : Suction chamber Fan Housing Rotor Consisting go shaft, on impeller with adjustable blades with pitch control mechanism. Main bearings (Antifriction bearings) Outlet Guide Vane housing with guide vanes Diffuser 5.3.2 INDUCED DRAFT FAN

Radial fans manufactured are single stage, single/ double suction, simply supported/overhung centrifugal machine which can be used to handle fresh air as will as hot gases in power plant application. These fans are generally driven by constant speed motors. The output of the fan is usually controlled by inlet dampers or inlet guide vanes or by varying the speed of the fan by suitable speed control device. Technical data:

Application No. off Type Medium handled Orientation

: : : : :

Induced Draft Fan 3 NDZV 33 S Flue Gas 450 Top incl. Suction Bottom Horizontal, Delivery 250.5 m3/Sec 1540C 740 rpm Hydraulic Coupling 1750 KW 740 rpm 52.7 Tones

Capacity Temp. of medium Speed Coupling Motor Rating Speed Fan Weight

: : : : : : :

DEPARTMENT OF ELECTRICAL ENGINEERING

The major sub-assemblies of the fan are as follows : Impeller with shaft assembly Bearings and thermometers Suction chamber and spiral casing Flow regulation devices Shaft seals Couplings The fan is drive by an electric motor. The fan bearings are lubricated by means of oil lubrication. The oil must not foam during operation. Foam removing agents containing silicon must not be utilized. The oil must have good anti-corrosion properties.

5.3.3 PRIMARY AIR FAN

PA Fan is same as forced draft fan. Only the differences is that in this fan there are two stages AP fan (Axial Profiles fan), the two impellers are connected by means of a link rod, with this we can operate both the impeller blades synchronously.

Technical data:

Application No. off Type Medium Handled Speed Rating Fan wt.

: : : : : : :

Primary Air Fan 3 Ap2 17/12 Atmospheric Air 1480 rpm 1400 KW 10.8 tones

DEPARTMENT OF ELECTRICAL ENGINEERING

6. STEAM TURBINE

6.1 Introduction :Turbine is a machine in which a shaft is rotated steadily by impact or reaction of current or stream of working substance (steam, air, water, gases etc) upon blades of a wheel. It converts the potential or kinetic energy of the working substance into mechanical power by virtue of dynamic action of working substance. When the working substance is steam it is called the steam turbine.

The steam turbines and their auxiliaries installed have been manufactured by M/s BHEL. The turbines are three cylinders, compound 3000 rpm, double flow exhaust type reheat units with initial parameters of 13 kg/cm2 and 5 low pressure heaters are fed. The high pressure cylinder comprises of two curt is wheels as a regulation stage Intermediate pressure cylinders comprise of twelve stages and each of the double flow section of the L.P. cylinder consists of four stages.

6.2 Operation :There are two live steam lines connecting the boiler to the turbine. The superheated steam enters the H.P. turbine and strikes its blades hence heat energy of steam is converted into mechanical energy. The steam from H.P. turbine is reheated in reheater and reheated steam is sent to I.P. turbine through hot steam lines. Here second stage of energy conversion is takes place. Then steam is sent to L.P. turbine from where it is ejected by vacuum ejectors and condensed. Here are two cold reheat and two hot reheat lines connecting the reheater and turbine. In each of the two live steam lines one electrically operated isolation valve, one water separator and one quick closing stop valve are mounted. The direction of revolution of turbine is clock wise when looking at turbine from front bearing pedestal. For the oil lubrication of bearings and for governing, the main oil pump driven shaft is assembled into the front bearing pedestal of turbine itself.

DEPARTMENT OF ELECTRICAL ENGINEERING

6.3 Description of Steam Turbine

6.3.1 Steam flow:

Steam turbine is a tandem compound machine with HP, IP & LP parts. The HP part is single flow cylinder and HP & LP parts are double flow cylinders. The individual turbine rotors and generator rotor are rigidly coupled. The HP cylinder has a throttle control. Main steam is admitted before blending by two combined main stop and control valves. The HP

turbine exhaust (CRH) leading to reheated have tow swing check valves that prevent back flow of hot steam from reheated, into HP turbine. The steam coming from reheated called HRH is passed to turbine via two combined stop and control valves. The IP turbine exhausts directly goes to LP turbine by cross ground pipes.

6.3.2

HP Turbine:

The HP casing is a barrel type casing without axial joint. Because of its rotation symmetry the barrel type casing remain constant in shape and leak proof during quick change in temperature. The inner casing too is cylinder in shape as horizontal joint flange are relieved by higher pressure arising outside and this can kept small. Due to this reason barrel type casing are especially suitable for quick start up and loading.

The HP turbine consists of 25 reaction stages. The moving and stationary blades are inserted into appropriately shapes into inner casing and the shaft to reduce leakage losses at blade tips.

DEPARTMENT OF ELECTRICAL ENGINEERING

6.3.3

IP Turbine:

The IP part of turbine is of double flow construction. The casing of IP turbine is split horizontally and is of double shell construction. The double flow inner casing is supported kinematic ally in the outer casing. The steam from HP turbine after reheating enters the inner casing from above and below through two inlet nozzles. The centre flows compensate the axial thrust and prevent steam inlet temperature affecting brackets, bearing etc. The arrangements of inner casing confines high steam inlet condition to admission branch of casing, while the joints of outer casing is subjected only to lower pressure and temperature at the exhaust of inner casing. The pressure in outer casing relieves the joint of inner casing so that this joint is to be sealed only against resulting differential pressure.

The IP turbine consists of 20 reaction stages per flow. The moving and stationary blades are inserted in appropriately shaped grooves in shaft and inner casing.

6.3.4 LP Turbine:

The casing of double flow type LP turbine is of three shell design. The shells are axially split and have rigidly welded construction. The outer casing consist of the front and rear walls, the lateral longitudinal support bearing and upper part.

DEPARTMENT OF ELECTRICAL ENGINEERING

7. E.S.P.

7.1 E.S.P THEORY :An electrostatic precipitator (ESP), or electrostatic air cleaner is a particulate collection device that removes particles from a flowing gas (such as air) using the force of an induced electrostatic charge. Electrostatic precipitators are highly efficient filtration devices that minimally impede the flow of gases through the device, and can easily remove fine particulate matter such as dust and smoke from the air stream.

7.2 WORKING PRINCIPLE :E.S.P. can handle large volume of gases from which solid particles are to be removed Advantages of E.S.P. are:- High collection efficiency Low resistance path for gas flow Treatment of large volumes at high temp. Ability of cope with corrosive atm. An E.S.P. can be defined as a device which utilized electric forces to separate suspended particles from flue gases.

7.3 WORKING STEPS :Ionization of gases and charging of dust particles Migration of dust particles. Deposition of charge particles on collector surface. Removal of pa E.S.P. consist of two sets of electrodes, one in the form of thin wire, called discharge or emitting electrode in the form of plates. The emitting electrodes are placed in the center or midway between two plates and are connected to -ve polarity of H.V. D.C. source of order of 37 KV collecting electrodes are connected to + ve polarity. The voltage gradient between electrodes creates CORONA DISCHARGE, ionizing the gas molecules. The dust particles present in flue gases acquire ve charge and deposited on collecting electrodes. The deposited particles are removed by knocking the electrode by process called RAPPING DONE BY RAPPING MOTORS.

DEPARTMENT OF ELECTRICAL ENGINEERING

8. COAL HANDLING PLANT

Coal transferred by Railway system. One rail (Rack) consist 58-59 boxes with 60 Tons coal loaded in each box. The main equipment of coal handling plant is as-

8.1 Wagon Tripler: Tripler is equipment which the coal is unloaded from box by lifting & tilting the box. Wagon tippler has rated unloading capacity of twelve-box wagon per hour, including shunting and spotting time of haulage equipment. 8.2 Side Arm Charger: Box is placed on tripler platform and push or carries the loaded empty boxes. 8.3 Crusher: Coal is crushed in desired size by crusher. 8.4 Conveyor: A different sizes and different capacity conveyors are installed for transporting feed the coal from wagon Tripler to Bunkers. 8.5 Stacker/Reclaimer: The crushed coals are stack or reclaim the stacked coal by stacker/reclaimer. 8.6 Bunkers: Crushed coal stored in the canonical shape bunkers.

DEPARTMENT OF ELECTRICAL ENGINEERING

9. ASH HANDLING PLANT

The ash handling system provide for continuous collection of bottom ash from the furnace hearth and its intermittent removal by hydro ejectors to a common slurry sump. It also provides for removal of fly ash to the common slurry sump.

Each boiler is provided with ash precipitator for collecting the fly ash from the flue gases with high efficiency of collection to minimize the dust mains and to reduce the wear of induced draft fan. The fly ash separated from flue gases in the ash precipitator is collected in hoppers at the bottom from where it is mixed with water to form slurry and disposed off to pumping area by means of hydro ash pumps. Bottom ash from the boiler furnace is passed through slag crushers and then slurred to the chamber at the suction of the ash disposal pumps. These are high pressure and low pressure pumps for this purpose. At a time one pump is working and other two are stand by from the ash disposal pump house ash slurry is pumped through pipe lines to the ash dump area within about 1.5 km away from the ash disposal pump house.

Too separate discharge lines are provided one for each unit but only one line is used. The ash slurry from the two units is taken in one discharge line through electrically operated valves.

DEPARTMENT OF ELECTRICAL ENGINEERING

10. COMMON AUXILIARY

Common Auxiliaries Cooling Water Pump Auxiliaries Cooling Water Pump Compressor

Common auxiliaries: Common auxiliaries supply the support to run the power plant. In this cooling water and air are mainly supply.

Cooling Tower: Both CW and ACW water cooled in cooling tower by spraying and exhausting the hot air from the water.

Cooling Water Pump: This is cooling feed to condenser for condensate the exhaust steam from LP Turbine in condenser then hot well.

Auxiliaries Cooling Water Pump: By name it is supply auxiliaries cooling water to rotating equipment lub oil cooling.

Compressor: It is mainly two type . Service air Instrument air Service air: The service air are used for boiler operation Instrument air: The instrument air are used for generally for operation of the control valve, etc.

DEPARTMENT OF ELECTRICAL ENGINEERING

11. PROTECTION
A. Field Protection. B. Pole Slipping. C. Plane Overload Protection. D. Inter-turn Fault E. Negative Phase Sequence Protection. F. Reverse Power Protection. G. Forward Power Protection. H. Under Frequency & Over Frequency Protection. I. Generator Voltage Protection. J. Rotor Earth Fault Protection.

General Protection:
It is most important electrical equipment of many generating station. Tripping of even a generating unit may cause overloading of associated machines and even to system unstability. The basis function of protection applied to generator is to reduce voltage to minimum by rapid discrimination clearance of faults. Unlike other apparatus the opening of C.B. to isolate faulty generator is not sufficient to prevent future damage. Since generator would continue to supply power to stator winding fault , until its excitation is suppressed. It is, therefore, necessary to open field stop fuel supply to prime mover & in some case breaking also.

DEPARTMENT OF ELECTRICAL ENGINEERING

12. SALIENT FEATURES OF UNIT AUXILIARIES

A. BOILER AREA
I. ID FAN Rated Current RPM Discharge FD FAN Rated Current RPM Discharge PA FAN Rated Current RPM Discharge MAIN MILL MOTOR Rated Current RPM AUX. MOTOR OF MILL Rated Current RPM SEAL AIR FAN OF MILL Rated Current RPM AIR HEATER MOTOR Rated Current RPM ::::::::::::::::::::::::3,6.6 KV, 1750 KW 192.1 A 745 720.98 T/hour 3,6.6 KV, 700 KW 73.6 A 1491 408.5 T/hour 3,6.6 KV, 1400 KW 143.3 A 1400 323.4 T/hour 3,6.6 KV, 2400 KW 266.2 A 1488 3,415 KV, 30 KW 52 A 1470 3,415 V, 120 KW 198A 3000 3,415V, 11 KW 52A 1450

II.

III.

IV.

V.

VI.

VII.

DEPARTMENT OF ELECTRICAL ENGINEERING

B. TURBINE AREA
I. BFP Rated current RPM Discharge II. CEP Rated current RPM Discharge III. CVP Rated Current RPM IV. AOP Rated Current RPM V. JOP (AC) Rated Current RPM JOP (DC) Rated Current RPM EOP (AC) Rated Current RPM EOP (DC) Rated Current RPM ::::::::::::::::::::::::::3, 6.6 KV, 4600 KW 469 A 1485 720.98 T/hour 3, 6.6 KV, 325 KW 35.4 A 1466 385.00 T/hour 3, 415 V, 100 KW 142 A 588 3, 415 V, 100 KW 175 A 2980 3, 415 V, 45 KW 77 A 2960 DC 45 KW 250 A 2900 3, 415 V, 15 KW 28.5 A 1450 DC 13 KW 115 A 1420

VI.

VII.

VIII.

DEPARTMENT OF ELECTRICAL ENGINEERING

C. ELECTRICAL & CA AREA

I. GENERATOR Rated current P.F GENERATOR TRANSFORMER HV voltage LV voltage HV current LV current STATION TRANSFORMER Voltage HV current LV current CW PUMP (Stage 1) Rated current Discharge CW PUMP (Stage 2) Rated current ACW PUMP (Stage 1) Rated current Discharge ACW PUMP (Stage 2) Rated current ASH SLURY PUMP #1 Rated current RPM Discharge ASH SLURRY PUMP #2 Rated current RPM Discharge HP PUMP Rated current RPM Discharge LP PUMP :::::::::::::::::::::::::::::::::::3, 294.1MVA, 16.5 KV 10290A 0.85 (lag) 3, 315 MVA 235 KV 16.5 KV 773.9 A 11022.1 A 3, 40/50 MVA 220/6.9 KV 105/131 A 3351/41898 A 3, 6.6 KV, 1485 KW 169 A 17000 M3/hour 3, 6.6 KV, 1850 KW 209 A 3, 6.6 KV, 525 KW 60 A 3000 M3/hour 3, 6.6 KV, 500 KW 57A 3, 6.6 KV, 175 KW 21 A 988 850 M3/hour 3, 6.6 KV, 280 KW 31 A 1480 850 M3/hour 3, 6.6 KV, 710 KW 77 A 1486 1200 M3/hour 3, 415 V, 75 KW

II.

III.

IV.

V.

VI.

VII.

VIII.

IX.

X.

XI.

DEPARTMENT OF ELECTRICAL ENGINEERING

Rated current RPM Discharge XII. INTAKE PUMP Rated current RPM Discharge RAW WATER PUMP Rated current Discharge COOLING TOWER FAN Rated current DMCCW PUMP Rated current JOCKEY PUMP Rated current Discharge ASH WATER PUMP Rated current Discharge DUST SUPPRESSION PUMP Rated current Discharge HP SPRAY Rated current Discharge AIR COMPRESSOR Rated current RPM

:::::::::::::::::::::::::::::-

132 A 1483 300 M3/hour 3, 415V, 90 KW 159 A 985 1250 M3/hour 3, 415 V, 135 KW 236 A 1600 M3/hour 3, 415 V, 37 KW 62 A 3, 415 V, 140 KW 235 A 3, 415 V, 30 KW 55 A 50 M3/hour 3, 415 V, 90 KW 159 A 700 M3/hour 3, 415 V, 37 KW 66 A 200 M3/hour 3, 415 V, 180 KW 310 A 410 M3/hour 3, 415 V, 135 KW 225 A 1484

XIII.

XIV.

XV.

XVI.

XVII.

XVIII.

XIX.

XX.

DEPARTMENT OF ELECTRICAL ENGINEERING

13. CONCLUSION
The first phase of practical training has proved to be quiet fruitful. It provided an opportunity for encounter with such huge machines like wagon tippler,110 MW & 210 MW turbines and generators. The architecture of the power plant the way various units are linked and the way working of whole plant is controlled make the student realize that engineering is not just learning the structured description and working of various machines, but the greater part is of planning proper management. It also provides an opportunities to lean low technology used at proper place and time can cave a lot of labour e.g. wagon tippler (CHP). But there are few factors that require special mention. Training is not carried out into its tree sprit. It is recommended that there should be some project specially meant for students where presence of authorities should be ensured. There should be strict monitoring of the performance of students and system of grading be improved on the basis of work done.

However training has proved to be quite fruitful. It has allowed an opportunity to get an exposure of the practical implementation to theoretical fundamentals.

DEPARTMENT OF ELECTRICAL ENGINEERING

PROPERTIES OF POWER STATION COAL FROM THE IMPORTANT COAL FIELDS OF INDIA

PROXIMITE ANALYSIS NAME OF COAL FIELD/ COLLIERY G.C.V OF COAL MOIST KCAL/KG URE % 4900-5300 4--9 ASH % 10--25 25--35 15--22 28--31 21--24 25--35 16--32 10--17 2--15 VOLATI LES % 30--40 23--30 25--35 27--31 28--29 25--35 17--33 25--35 20--26 HGI

SULP HUR TOTA L% <1 <1 <1 <1 <1 <1 <1 <1 <1

G.C.V ON D.M.F BASIS KCAL/K G 8200 8000 8100 8100 8100 8000 8000 8000 7900

RANIGANJ WARDHA VALLY-KAMPTEE NORTH KARANPURA TALCHER

40--50 60-70 50-60 60-66 50-65 44-60 46-69 60-70 HIGH

4600-5000 7--10 5800-6200 4600-4900 4--6 7--9

SINGRAULI-JINGUDA SEAM(U.P) 4450-4800 9--10 SINGARENI -ANDHRA PRADESH 4000-4400 7--10 CENTRAL IDIA-PENCH CENTRA INDIA-BISRAMPUR NEYVELI-LIGNITE 4800-6200 2--9

5600-6000 9--11 2900-3300 30--60

DEPARTMENT OF ELECTRICAL ENGINEERING