WANAKBORI THERMAL POWER

STATION (GSECL)

AN INTERNSHIP REPORT
Submitted by

PRAJAPATI VIVEKKUMAR MANIBHAI

210600109517

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING OF

8th SEMESTER

ELECTRICAL ENGINEERING DEPARTMENT

STUDYING AT
GOVERNMENT ENGINNERING COLLEGE
GODHRA

Gujarat Technological University, Ahmedabad

402032

GOVERNMENT ENGINEERING COLLEGE,

GODHRA

CERTIFICATE

This is to certify that the internship report submitted along with the internship
entitled Wanakbori Thermal Power Station has been carried out by
PRAJAPATI VIVEKKUMAR MANIBHAI under my guidance in partial
fulfillment for the degree of Bachelor of Engineering in Electrical, 8th Semester of
Gujarat Technological University, Ahmadabad during the academic year 2023-24.

Prof. A. N. BHRAHMBHATT Prof. N. S. DESAI

Internal Guide Head of Department

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GOVERNMENT ENGINEERING COLLEGE , GODHRA

DECLARATION

due reference We hereby declare that internship report submitted along with the
internship entitled Wanakbori Thermal Power Station submitted in partial fulfillment
for the degree of Bachelor of Engineering in Electrical to Gujarat Technological
University, Ahmedabad, is a bonafide record of original internship work carried out by
me at Wanakbori Thermal Power Station, GSECL under the supervision of Prof. A. N.
BRAHMBHATT and that no part of this report has been directly copied from any
students reports or taken from any other source, without providing.

Name of the student Sign of student

1. PRAJAPATI VIVEKKUMAR MANIBHAI __________________

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ACKNOWLEDGEMENT

I wish to express my sincere gratitude to the Chief Engineer for granting me the permission
to pursue an internship at the GSECL Wanakbori Thermal Power Plant. I am in great debt
of my Industry guides the staff member of EMD-I, TESTING, EMD-III and TRAINING
CENTER for continuously guiding me at the company and answering allmy doubts with
patience. I would also like to thank my Internal Guide Prof. A. N. BRAHMBHATT for
helping me through my internship by giving me the necessary suggestions and advices
along with their valuable co-ordination in completing this internship.

I also thank my parents, friends and all the members of the family for their precious support
and encouragement which they had provided in completion of my work. In addition to that,
I would also like to mention the company personals who gave me thepermission to use and
experience the valuable resources required for the internship.

Thus, in conclusion to the above said, I once again thank the staff members of GSECL
Wanakbori Thermal Power Station for their valuable support in completion of the
project.

Thankyou

PRAJAPATI VIVEKKUMAR MANIBHAI

(210600109517)

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ABSTRACT

Thermal power plant is a major source of electricity production by coal . We learned

about Boiler auxiliary , PA Fan , FD – ID Fan , Turbine , Generator , Electrostatic
precipitator , Economizer , Air preheater , Boiler feed pump and many components in
power plant .Typically fuel is used to boil water in a large pressure vessel to produce
high-pressure steam , which drives a steam turbine connected to an electrical generator .
The low-pressure exhaust from the turbine passes through a steam condenser and is
recycled to where it was heated . this is known as a Rankine cycle .

The WTPS (GSECL) is located near Wanakbori Dam located on the Mahi river in Kheda
District of Gujarat . It is Coal based power station . There are 7 units of 210MW each with
a total installed capacity of 1470MW . All the above units are of BHEL made ; the 1x
800MW coal based super critical unit no 8 & the Station capacity has increased to
2270MW .

I was Good learning and experience for me to work with their technical knowledge . This
internship has an important role in exposing the real-life situation industry .

The training is planned in 3 departments during entire Internship:

1. EMD 1 From 15/01/2024 to 14/02/2024

2. TESTING From 15/02/2024 to 14/03/2024
3. EMD 3 From 15/03/2024 to 15/04/2024

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LIST OF FIGURES

Fig 2 Layout of 210MW plant ............................................................. 4

Fig 2.1 Layout of plant ........................................................................ 4
Fig 2.2 Rankine cycle .......................................................................... 5
Fig 2.3 Graph of Rankine cycle ........................................................... 6
Fig 2.4 Working components ............................................................... 6
Fig 2.5 Coal & Ash cycle ..................................................................... 9
Fig 2.6 Air & Gas cycle ....................................................................... 10
Fig 2.7 Feed water & Steam flow… ..................................................... 10
Fig 2.8 Cooling water cycle ................................................................. 11
Fig 3 Water / Steam cycle .................................................................... 14
Fig 3.1 Combustion System ................................................................. 14
Fig 3.2 Tangential Firing… ................................................................. 15
Fig 3.3 Top view of Tangential Firing… .............................................. 15
Fig 3.4 Economizer ............................................................................. 18
Fig 3.5 Superheater.............................................................................. 19
Fig 3.6 Air Preheater ........................................................................... 20
Fig 3.7 Boiler Drum ............................................................................ 21
Fig 3.8 Boiler Feed Pump… ................................................................ 22
Fig 3.9 Coal Mill ................................................................................. 22
Fig 3.10 Flame Scanner ....................................................................... 25
Fig 3.11 DM Plant ............................................................................... 26
Fig 3.12 Condenser.............................................................................. 26
Fig 3.13 Cooling Tower....................................................................... 27
Fig 3.14 Deaerator ............................................................................... 28
Fig 3.15 Electrostatic Precipitator ........................................................ 29
Fig 3.16 Turbine .................................................................................. 30
Fig 3.17 Cooling… .............................................................................. 32
Fig 3.18 Generator Cooling… ............................................................. 33
Fig 3.19 Barringgear Motor ................................................................. 33
Fig 3.20 H2 Dryer ............................................................................... 34
Fig 3.21 Seal Oil System ..................................................................... 34
Fig 3.22 Excitation System .................................................................. 35
Fig 4 Relay Test Kit ............................................................................ 40
Fig 4.1 Transformer Turns Ratio Test .................................................. 41
Fig 4.2 Current Transformer Test Kit ................................................... 41
Fig 4.3 Vibration Tester ....................................................................... 42
Fig 4.4 Generating Transformer ........................................................... 43
Fig 4.5 Single Line Diagram of UAT ................................................... 44
Fig 4.6 6.6KV Bus Bar Tie Diagram Unit 1 to 7… .............................. 45
Fig 4.7 PT ........................................................................................... 47
Fig 4.8 CT ........................................................................................... 48
Fig 4.9 CVT ........................................................................................ 48
Fig 4.10 Lightning Arrester ................................................................. 49
Fig 4.11Circuit Breaker ....................................................................... 50

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Fig 4.12 Wave Trap… .......................................................................................... 51

Fig 4.13 Working of Wavetrap… ......................................................................... 51
Fig 5 layout of ash handling plant ......................................................................... 52
Fig 5.2 Dm water plant ........................................................................................ 54

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LIST OF ABBREVIATIONS

GT – Generating Transformer

ST – Station Transformer

UAT – Unit Auxiliary Transformer

CT – Current Transformer

PT – Potential Transformer

BFP – Boiler Feed Pump

FD Fan – Forced Draft Fan

ID Fan – Induced Draft Fan

PA Fan – Primary Air Fan

ESP – Electrostatic Precipitator

HPT – High Pressure Turbine

IPT – Intermediate Pressure Turbine

LPT – Low Pressure Turbine

OCR – Over Current Relay

OLR – Over Load Relay

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TABLE OF CONTENTS

Acknowledgement .......................................................................... iv
Abstract .......................................................................................... v
List Of Figure ................................................................................. vi
List Of Abbreviation ....................................................................... viii
Table Of Content ............................................................................ ix
Chapter 1 ...................................................................................... 1
1 About GSECL ...................................................................... 1
1.1 About Wanakbori Thermal Power Station… ...................... 2
Chapter 2 ...................................................................................... 4
2 Operation of 210MW Thermal Power Plant .......................... 4
2.1 How does Thermal Power Plant Work…............................ 5
2.2 Rankine cycle .................................................................... 5
2.3 Working Components of Thermal Power Plant .................. 6
2.4 Water Treatment Plant ....................................................... 7
2.5 Main four circuits of Coal Based Plant ............................... 9
Chapter 3… .................................................................................. 12
3 Boiler Turbine & Generator .................................................. 12
3.1 Boiler and Auxiliary .......................................................... 13
3.2 Tangential Firing… ............................................................ 15
3.3 Boiler Auxiliary ................................................................. 16
Chapter 4… .................................................................................. 39
4 Electrical Testing… ..................................................................... 39
4.1 Scope of Work… ............................................................... 39
4.2 Testing Equipment ............................................................. 39
4.3 Transformer Details ........................................................... 43
4.4 15.75KV / 7KV Single line diagram (UAT) ....................... 44
4.5 6.6KV Bus Bar Tie diagram Unit 1 to 7… ......................... 45
4.6 Types of Equipment In Switchyard .................................... 45
Chapter 5 ...................................................................................... 52
5 EMD – 3… ........................................................................... 52
5.1 Ash handling plant ............................................................. 52
5.2 Layout of Ash handling plant ............................................. 52
5.3 DM Water Plant… ............................................................. 54
5.4 CW Water Pump House ..................................................... 55
5.5 Ash Water pump House ..................................................... 55
Conclusion .................................................................................... 57
Reference ...................................................................................... 58

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402032 INTRODUCTION

CHAPTER – 1

1. ABOUT GSECL
Gujarat State Electricity Corporation Limited (GSECL) is a wholly owned subsidiary of
the Gujarat Urja Vikas Nigam (GUVN), which came into existence in August 1993 after
the unbundling of the GEB. It is a power generation company working in the territory of
Gujarat, India. It delivers electricity through four distribution companies – DGVCL,
MGVCL, PGVCL and UGVCL.

PROFILE: - Gujarat State Electricity Corporation Limited was incorporated in August

1993 with the objectives to mobilize resources from the market for adding to the
generating capacity of Gujarat and improving the quality and cost of existing the
generating capacity of Gujarat and improving the quality and cost of existing generation.

GSECL is involved in a wide spectrum of activities to improve the electricity

infrastructure and generation of power in Gujarat and has the status of Independent Power
Producer (IPP) with approval to undertake new power projects. The Company
commenced its commercial operation in the year 1998.

As a part of the reform process, the Government of Gujarat has unbundled the various
functions of GEB and GSECL was given responsibility of electricity generation.

GSECL was notified as State Generating Power Plant by Government of Gujarat on 29

May 2004 with the purpose of improving efficiency in the state’s electricity generation
activities.

OPRATIONAL POWER STATIONS

Sr no Name Type of Fuel

Fuel Capacity
(MW)

1. Ukai Thermal Power Station Coal 1350

2. Gandhinagar Thermal Power Station Coal 630

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3. Bhavnagar Lignite Thermal Power Plant Coal 500

4. Wanakbori Thermal Power Station Coal 2270

5. Sikka Thermal Power Station Coal 540

6. Kutch Thermal Power Station Lignite 290

7. Dhuvaran Gas Based CCPP Gas 219

8. Utran Gas Based Power Station Gas 510

9. Ukai Hydro Power Station Hydro 300

1o. Kadana Hydro Power Station Hydro 242

11. Panam Canal Mini Hydro Power Station Hydro 2

Table 1

GSECL is also serving Sardar Sarovar Narmada Nigam Limited Hydro-Electric project
by O&M contract.

1.1 .ABOUT WANAKBORI THERMAL POWER STATION

WTPS is the biggest Thermal Power Plant of GSCEL in Gujarat. Wanakbori Thermal
Power Plant is a coal-fired power station in Gujarat, India. It is located on the bank of
Mahi River in Mahi Sagar (Kheda) district

Wanakbori Thermal Power Station in ISO 9001:2008 & ISO 14001: 2004 & OHSAS
18001- 2007 certified power station and CEA Accredited Training Centre.

There Are 7 Turbo-Generator Sets Each Of 210 MW Out of Which 3 Units Are
Equipped with Russian Turbines (LMW Leningrad Machine Works) And 4 Units Are
Equipped with German Turbines (KWU) Unit No 7 Is Entirely Computerized & Linn
e Is Proposed Of 800 MW And Well Advanced. All Above Units Are Made by BHEL
American Combustions Engg. Designed High Pressure Boilers Are Provided in All
These Units .

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The Turbo Generator Sets Having Capacity Of 210 MW, 3000 R.P.M. 15.75KV,247
MVA AI 0.85 P. f Are Connected to Generator Transformers Of 250 MVA 15.75/220
KV In Stage -1; In Stage-2And3 .G.Ts Of 250MVA, 15.75/400KV In Stage 4 to 7 .

The interconnection Transformer of 500 MVA, 220/400KV is located in switch yard

between 220KV & 400KV power system.

Stage Unit Installed Capacity Commissioning date

(MW)
Stage-1 1 210 March 1982
2 210 January 1983
3 210 March 1984
Stage-2 4 210 March 1986
5 210 September 1986
6 210 November 1987
Stage-3 7 210 December 1998
Stage-4 8 800 October 2019
Table 1.1
Total Capacity of Power Generation Unit Operational 7*210MW And 1*800
Nameplate

Capacity 2270 MW

The switch yard is connected to transmission lines as per following

belowdetails

400KV Lines

 Asoj
 Dehgam
 Soja
220KV lines
 Godhra
 Yankatpura
 Asoj
 Kapadvanj-1 & 2
 Dhansura-1 & 2
Grid system/Frequency is control held by state load dispatch center (SLDC), Gotri,
Vadodara .

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-CHAPTER – 2
2 OPERATION OF 210MW THERMAL POWER PLANT

FIG . 2 LAYOUT OF 210MW PLANT

FIG . 2.1 LAYOUT OF PLANT

Thermal Power Plants also called Thermal Power Generation Plant or Thermal Power
Station. A thermal power Plant / Station is used to convert heat energy to electric
power/Energy for household and commercial applications in the process of electric
power generation, steam-operated turbines convert heat in to mechanical power and
then finally electric power.

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2.1 HOW DOES THERMAL POWER PLANT WORK?

 In thermal power plants, the heat energy obtained from combustion of solid
fuel (mostly coal) is used to convert water into steam, this steam is at high
pressure and temperature
 This steam is used to rotate the turbine blade turbine shaft is connected to the
generator. The generator converts the kinetic energy of the turbine impeller
into electric energy.

2.2 RANKINE CYCLE:

The Rankine cycle or Rankine Vapor Cycle is the process widely used by
power plants such as coal-fired power plants or nuclear reactors. In this
mechanism, a fuel is used to produce heat within a boiler, converting water
into steam which then expands through a turbine producing useful work. This
process was developed in 1859 by Scottish engineer William J.M. Rankine.
This is a thermodynamic cycle which converts heat into mechanical energy
which usually get transformed into electricity by electrical generation

FIG .2.2 RANKINE CYCLE

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FIG . 2.3 GRAPH OF RANKINE CYCLE

2.3 WORKING COMPONENTS OF THERMAL POWERPLANT

FIG . 2.4 WORKING COMPONENTS

The fuel is transported from mines via trains to the fuel storage facility in a power
plant. The fuel transported to the plant is generally bigger in particle size and before
it is fed to the boiler furnace it is broken down into smaller pieces using crushers. The
fuel is then fed to the boiler generating a large amount of combustion heat

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- On the other hand, treated water free from impurities and air is fed to the boiler
drum where the combustion beat from the fuel is transferred to water to convert it
into high pressure and temperature steam.

Generally, flue gases from the boiler exhaust are at high temperature and if this heat
is not utilized will lead to a large number of losses resulting in reduced boiler
efficiencies

So generally, this waste heat is recovered by heating either air required for
combustion or preheat water before sending it into a boiler.

Flue gases are then allowed to pass through a dust collector or a bag filter to arrest dust
particles so as to prevent air pollution before sending it to the atmosphere through a
chimney. Fuel storage and handling plant.

The most essential part of any power plant is to store the fuel safely in an appropriate
amount so that the plant can run smoothly in normal days in well es when de supply
of fuel from mines is improper. So, a fuel storage facility is defined an adequate
amount of fuel

In a thermal power plant process, the first step in process of power generation is that
the fuel is brought to breaker house with the help of belt conveyor, here light dust is
separated with the help of rotary machine through the action of gravity

It further goes to the crusher where it is crushed to a size of about 50mm

2.4 Water Treatment Plant:

In thermal power, plant water is used in large quantity this water is converted into
steam and used to rotate the turbine so this water and steam come into direct contact
with the boiler, boiler tubes, boiler accessories, and turbine blades.

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Normal water is taken from the river, well contains a lot of dirt, suspended particulate
matter (SPM), dissolved minerals and dissolved gases such as air etc. If the water fed
to the boiler is not treated then it will reduce the life and efficiency of equipment by
corroding the surfaces and scaling of equipment which may lead to overheating of
pressure parts and explosions.

Suspended matter from the water is removed by adding alum into the water tank
through gravity separation. Addition of alum coagulates the suspended particles and
due to an increase in the density, it settles at the bottom of the tank through gravity.

After gravity separation, water softening is done by ion exchange process. As the
hardness comes through the carbonates and bicarbonates of sodium and magnesium,
these salts are removed from water anion exchange and cation exchange process.

Water also contains dissolved oxygen and this leads to corrosion and fouling of boiler

tubes and surfaces when it comes in their contact. So removing dissolved oxygen
from water is done by adding oxygen scavengers and by using a Deaerator tank .

Deaerator tank also acts as a feed water tank to store the feed water. On heating feed
water in a deaerator tank decreases the solubility of air in water, thereby removing the
dissolved air from the water.

"Thermo dyne supplies both Water Softeners and Deaerator tanks to improve the
quality of your feed water to the boiler as this improves the life and efficiency of your
boiler and its equipment."

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2.5 The coal based thermal power plant comprises of four main
working circuits:

1. Coal and ash cycle

2. Air & gas cycle
3. Feed water and steam flow cycle
4. Cooling water cycle

1. COAL AND ASH CYCLE:

Coal arrives at the coal handling plant and after necessary handling, passes on
the furnace through pulverized & fuel feeding device. Ash resulting from the
combustion of coal collects at the back of the boiler and is removed to the ash
storage through ash handling plant

FIG . 2.5 COAL &ASH CYCLE

2. AIR AND GAS CYCLE:

Air is taken from atmosphere through the action of forced draught (FD) fan and passes
on the furnace through air preheater. Flue gases are produced when coal is combusted
in the boiler. The flue gases after passing around boiler tubes and superheater tubes in
the furnace pass through an economizer and finally through the air preheater before
being exhausted to the atmosphere via electro precipitator (ESP) & chimney

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FIG . 2.6 AIR & GAS CYCLE

3. FEED WATER AND STEAM FLOW CYCLE :

In the water and steam circuit condensate leaving the condenser is passes through the
deaerator and water heaters before going the boiler through
economizer.

FIG .2.7 FEED WATER & STEAM FLOW

In the boiler drum and tubes, water circulates due to the difference between the density of
water in the lower temperature and the higher temperature section of the boiler. Wet
steam from the drum is further heated up in the superheater before being supplied to the
turbine. After expanding in turbine steam is condensed in the condenser. The condensate
leaving the condenser is circulated to boiler. A part of steam and water is lost while
passing through different components and this compensated by supplying additional feed
water. This feed water is purified & softened before going the boiler, to avoid the

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scalingof the tubes of the boiler. The purification and softening of water are done in
water treatment plant.

4. COOLING WATER CYCLE:

The cooling water supply to the condenser helps in maintaining a low pressure in it.
The cooled water extract heats from turbine exhaust steam in the condenser and
become hot. Hot water gets cooled after passing through cooling tower and again
circulated to condenser through circulating water pump. A part of water is lost in the
cooling tower and this compensated by supplying the water from a natural source
such as river, lake or sea.

FIG 2.8 COOLING WATER CYCLE

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402032 BOILER , TURBINE & GENERATOR

CHAPTER 3

3 BOILER , TURBINE & GENERATOR

ELECTRICALMAINTANANCEDEPARTMENT

TURBINE-GENERATOR

 HT MOTOR 6.6KV  TURBINE

 LT MOTOR 415V  EMERGENCY STOP SUPPLY
 BFP  SPEED GOVERNING SYSTEM
 ESP 1. HPT
 ID FAN 2. IPT
 FD FAN 3. LPT
 GENERATOR
 PA FAN
 EXCITATION SYSTEM
 DEARATOR TANK
 COOLING SYSTEM
 BOILER
1. H2 DRYER
 ECONOMIZER 2. HYDROGEN COOLING
 AIR PREHEATER 3. STATOR WATER
 COAL MILL AND FEEDER COOLING
 FLAME SCANER  SEAL OIL SYSTEM
 IGNITER  BARRINGGEAR MOTOR
 DM PLANT  CONDENSOR
 EMERGENCY SUPPLY

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3.1 BOILER AND AUXILIARY

What is Boiler?

It is an enclosed pressure vessel in which water is converted into steam by gaining

heat from any source (coal, oil, gas etc.). Boiler in thermal power plant accumulates
the steam and build up a pressure to expend it in turbine and convert thermal energy
to mechanical energy. The generator which is connected to turbine converts the
mechanical energy into electric energy.

BOILER DETAILES:

 Stage 1 & 2: Tangentially fired, Balance draft Natural circulation, Radiant

Reheat type
 Stage 3: Vertically suspended water tubes,
 Height of boiler: 64 m
 Capacity: 700 Tones/hour
 Feed water Temp: 241°c
 Steam Temperature: 540°c
 Force Draft fan: 2 Nose
 Induced Draft fan: 2 Nose
 Primary Air fan: 2 Nose
 Coal mill: 6 Nose
 Steam pressure at boiler outlets: -
SH: 137 Kg/cm²
RH: 25.8 Kg/cm²
 Height of chimney: - Stage-1 & 2 = 150 m Stage-3 = 220 m

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FIG . 3 WATER/STEAM SYSTEM

FIG . 3.1 COMBUSTION SYSTEM

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3.2 Tangential firing :

The most effective method for producing intense turbulence is by the impingement of
one flame on another. This action is secured through the use of burners located in
each of the four corners of the furnace, close to the floor or the water-screen. The
burner nozzles are so directed that the streams of coal and air are projected along a
line tangent to a small circle, lying in a horizontal plane, at the center of the furnace.
Intensive mixing occurs where these streams meet.

A scrubbing action is present which assures contact between the combustible and
oxygen, thus promoting rapid combustion and reducing carbon loss. A rotative
motion, similar to that of a cyclone, is imparted to the flame body, which spreads out
and fills the furnace area. The ignition at each burner is aided by the flame from the
preceding one.

FIG . 3.2 TANGENTIAL FIRING

FIG . 3.3 TOP VIEW OF TANGENTIAL FIRING

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Igniter Gun Oil and Spark :

An ignition, warm-up and low-load-stabilization system for furnaces fired by

pulverized coal is described. In conjunction with a system in which pulverized coal is
sent directly from a coal mill to a load-bearing nozzle and in which combustion air is
brought to the nozzles from an air preheater that uses hot furnace gases to warm the
combustion air, igniter nozzles are provided that are supplied by pipes bearing coal
from which the drying air has been separated. Combustion air for the igniter nozzles
is heated by an independent heat source that heats the combustion air or a portion
thereof to a temperature higher than that of the air supplied by the air preheater. Such
a coal-fired igniter burner can replace oil or gas-fired igniters and warm-up guns and
thereby reduce the amount of oil or gas used in ignition, warm-up, and low-load
stabilization.

3.3 BOILER AUXILIARY:

1 .COAL BUNKER:
Many plants like coal fired power plants, cement facilities and cogeneration
industries employ coal bunkers to store coal and coal mills to crush the raw material
into fine particles before being injected into the boiler.

2 .RAW COAL FEEDER:

Coal Feeder is a device that regulates the amount of coal to be supplied into the Coal
Mill. The amount of coal is regulated according to the needs in the boiler combustion
chamber (furnace).

Coal that has been crushed with a Crusher will be transported by belt conveyor to
Coal Yard for stock and Coal Bunkers. From the Coal Bunker then the upper
strobe/damper is opened, the coal from the bunker enters the loading area of the coal
feeder, then the belt conveyor runs at a speed set by Variable Speed Drive (VFD).

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Coal is carried along through the weighing area for load weighing/measurement.
Flow settings are generated from load calculations detected by load cells at the speed
of the conveyor belt which is detected by speed sensors. The coal that has been set
flow in the coal feeder goes into the mill to be smoothed

3 .COAL PULVERIZER:

The main Function of the Pulverizer in thermal power plant is to crush/grinding the
raw coal coming from coal handling system through coal feeder into a pre-
determined size in order to increase the surface area of the coal. If the coal is not
pulverized, the coal might not burn completely, thus resulting in wastage of fuel Also,
pulverization of coal helps the boiler to respond to load variations more promptly.

There are four primary principle involved in pulverization:

1. Drying
2. Grinding
3. Circulation
4. Classification

4 .COAL MILL:

The main function of the pulverize in thermal power plant is to crush gridding the
raw coming from coal handling system through coal feeder into a pre-determined size
in order to increase the surface area of the coal. If the coal is not pulverized, the coal
might not burn completely, thus resulting in wastage of fuel. Also, pulverization of
coal helps the boiler to respond to load variations more promptly.

In coal mill number of input is 1 pipe and output side 4 pipe used, and that pipe was
going to boiler.

In thermal power plant 6 coal mill used. Mainly 4 coal mills are running and 2 coal mills
is spare.

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5 .ECONOMIZER:

The feed water from the high pressure heaters enters the economizer and pick up heat
from the flue gases after the low temperature super heater.

The boiler designer always keeps the economizer water outlet temperature to about
25-35

degrees below the drum saturation temperature.

Economizer tubes are commonly 38.1*4 mm in OD and made in vertical section of

continuous tubes between inlet and outlet headers with each sections formed into
several horizontal paths connected by 180° bend for proper drainage.

Economizer is generally placed between the last super heater reheated and the air
preheater.

Chemical and water washing when cleaning the economizer in shut down time of the
station.

FIG . 3.4 ECONOMIZER

6 . SUPER HEATER :

A superheater is a device used to convert saturated steam or wet steam into

superheated steam or dry steam. Superheated steam is used in steam turbines for
electricity generation, steam engines, and in processes such as steam reforming.

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There are three types of superheaters: radiant, convection, and separately fired. A
superheater can vary in size from a few tens of feet to several hundred feet (a few
meters to some hundred meters)

FIG . 3.5 SUPERHEATER

7. AIR PREHEATER :

An air preheater is any device designed to heat air before another process (for
example, combustion in a boiler With the primary objective of increasing the thermal
efficiency of the process. They may be used alone or to replace a recuperative heat
system or to replace a steam coil.

The purpose of the air preheater is to recover the heat from the boiler flue gas which
increases the thermal efficiency of the boiler by reducing the useful heat lost in the
flue gas. As a consequence, the flue gases are also conveyed to the flue gas stack (or
chimney) at a lower temperature, allowing simplified design of the conveyance
system and the flue gas stack. It also allows control over the temperature of gases
leaving the stack (to meet emissions regulations, for example). It is installed between
the economizer and chimney.

The rotating-plate design (RAPH) consists of a central rotating-plate element

installed within a casing that is divided into two (bi-sector type), three (tri- sector

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type) or four (quad-sector type) sectors containing seals around the element. The
seals allow the element to rotate through all the sectors, but keep gas leakage between
sectors to a minimum while providing separate gas air and flue gas paths through
each sector.

FIG . 3.6 AIR PREHEATER

Tri-sector types are the most common in modern power generation facilities. In the
trisector design, the largest sector (usually spanning about half the cross-section of
the casing) is connected to the boiler hot gas outlet. The hot exhaust gas flows over
the central element, transferring some of its heat to the element, and is then ducted
away for further treatment in dust collectors and other equipment before being
expelled from the flue gas stack. The second, smaller sector, is fed with ambient air
by a fan, which passes over the heated element as it rotates into the sector, and is
heated before being carried to the boiler furnace for combustion. The third sector is
the smallest one and it heats air which is routed into the pulverizes and used to carry
the coal-air mixture to coal boiler burners. Thus, the total air heated in the RAPH
provides: heating air to remove the moisture from the pulverized coal dust, carrier air
for transporting the pulverized coal to the boiler burners and the primary air for
combustion.

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The rotor itself is the medium of heat transfer in this system, and is usually composed
of some form of steel and/or ceramic structure. It rotates quite slowly (around 1-2
RPM) to allow optimum heat transfer first from the hot exhaust gases to the element,
then as it rotates, from the element to the cooler air in the other sectors.

8 . RE-HEATER :

Reheater is a part of the boiler which to reheat steam output from the first level of the
steam turbine. Reheated steam will again absorb the heat energy from the boiler to be
used in the next level steam turbine. Reheater is one way to improve the thermal
efficiency of the Rankine Cycle.

9 . BOILER DRUM :

A steam drum is a standard feature of a water-tube boiler. It is a reservoir of

water/steam at the top end of the water tubes. The drum stores the steam generated in
the water tubes and acts as a phase-separator for the steam/water mixture. The
difference in densities between hot and cold water helps in the accumulation of the
"hotter"-water/and saturatedsteam into the steam-drum.

FIG . 3.7 BOILER DRUM

10 .WATER WALLS:

Water Walls furnace wall that is comprised of refractory and tubes in a water-tube
boiler her tubes are evenly spaced and generally connect to headers which in turn are
connected back to the main generating bank of the boiler.

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11 .BOILER FEED PUMP:

Boiler feed pump is a multi-stage pump provided for pumping feed water to
economizer.

BFP is biggest auxiliary equipment after boiler and turbine. It consumes about 4 to 5
MW electricity. By using booster pump we can increase pressure about 35 Kg/cm2
Then BFP increase the pressure about 150 Kg/cm2. And this high-pressure water
again fed into the economizer.

FIG . 3.8 BOILER FEED PUMP

12 . COAL MILL :

Coal mills are mainly used to crush the coal. It crushed the coal in powder form. In
the Unit-1, 6 coal mills are present in the unit. In which 4 are working & 2 is standby.
IN Coal Mill 1 incoming and 4 outgoing lines, Is There coal mill, inner side 3 rod is
mounted in 120 degree. 200 mm Coal powder. Coal feeder to coal mill

FIG . 3.9 COAL MILL

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Capacity 400KV

Voltage 6.6KV
Speed 992 RPM
Insulation Class F
Stator AMP 39.8A
TABLE 3

13 .PRIMARY AIR FAN:

Main function of PA fan is to carry from pulverize to furnace and also heating of coal so that
moisture present in coal can be removed and coal can be easily burnt out in furnace.
Discharge of PA fan divided into two parts first one is cold PA and second one is hot PA after
passing through air preheater which is utilize for transformation of coal from pulverize to
furnace.

Make BEAL

Speed 1480 RPM

Voltage/amp 6.6 KV/152 A

Output (KW) 1450KW

Type HT switchgear VCB

Full load current 152 amp

Weight 7.8 ton

Table 3.1
14 .DRAUGHT OR DRAFT SYSTEM:

The difference between tam pressure and pressure existing in furnace is termed as
draft.

In a power plant large amount of air are needed for combustion of fuel. And huge
amount of combustion products (flue gases, ash) has also removed from boiler so that
pressure differential is needed. Draught is used to define static pressure in furnace,
ducts.

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15 .FORCED DRAUGHT FAN:

Function of the FD fan is to supply secondary air to the wind box. Forced draught
fans are installed at inlet to air preheater. They handle cold air or say atmosphere air.
FD fan forcing air into the furnace and ductwork. Air is often passed through an air
heater, which heats the air going into the furnace in order to increase the overall
efficiency of the boiler. Dampers are used to control the quantity of air admitted to
the furnace. Forced draught furnace usually has a positive pressure. Two FD fans are
used in parallel say A and B. Centrifugal fans with background- curved blading type
is used in power plant

Make BEAL
Speed 1490 RPM
Voltage/amp 6.6 KV/86 A
Rating 820KW
Weight 6 ton
Table 3.2
16 .INDUCED DRAUGHT FAN:

ID fans are generally located at the end of ESP (Electro static precipator). Induced
draught fan (ID fan) which removes flue gases from the furnace and forced the
exhaust gases up to the chimney. Induced draught furnaces usually have a slightly
negative pressure. Two ID fans are used in parallel (say A and B) for better reliability.
Centrifugal fans with forwardcurved or flat blading is used in pp. Id fan creates
negative draft inside furnace-5 to 10 mm WC.

Type SCIM
Make BHEL
Speed 1490 RPM
Voltage/amp 6.6 KV/86 A
Rating 820KW
Weight 6 ton
Table 3.3

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17 .FLAME SCANNER:

Boilers need heat. More often than not, that means some sort of flame is involved.
Where there's fire, there needs to be some sort of monitoring system in place. That's
where flame scanners come in. Basically, flame scanners do what the name implies:
they check for the presence of flame. If a flame should happen to go out for some
reason, that could not only shut down the boiler or greatly reduce its capacity, it could
also create a potentially explosive environment as unburned fuel builds up.

FIG . 3.10 FLAME SCANNER

18 . DEMINERALIZATION (DM) PLANT :

Demineralization is the process of removing mineral salts from water by using the action
process

Basic process:

1) Distillation

2) Membrane filtration

3) Deionizing

4) Degasser

In the context of water purification, ion exchange resin. The impurity ions are taken
up by the resin.

The following ions are widely found in raw water.

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Cation: calcium (Ca+2), Magnesium (Mg+2), Sodium (Na+2), potassium(K+)

Anions:

chlorine (cl-) bicarbonate (HCO3-), Nitrate (NO3-)

FIG . 3.11 DM PLANT

19 .CONDENSER:

The surface condenser is used in WTPS .

A Surface condenser is a commonly used term for a water-cooled shell tube beat
exchanger which is installed on the exhaust steam from a steam turbine.

The primary purpose of a surface condenser is to condense the exhaust steam from a
steam turbine to obtain maximum efficiency and also convert in pure water.

These condensers are heat exchanger which converts steam from its gaseous to its
liquid state at a pressure below atmospheric pressure

FIG . 3.12 CONDENSER

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20. COOLING TOWER:

Cooling tower are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of the water to remove
process heat and cool the working fluid. The towers vary in size from small roof top
units to very large hyperboloid structures.
• Cooling tower is one of type of heat exchanger
• Type: Natural Draft Cooling Tower
• Cooling Tower Height, Stage 1 & 2:112 m Stage 3 & 4.118 m
By using CEP (Condensate Extraction Pump) cold fluid is again fed into condenser
and from condenser to cooling tower cycle is again repeated.

FIG 3.13 COOLING TOWER

21 .DEAERATOR:

Function of deaerator is to remove the dissolved gamed (Oxygen & carbon Dioxide)
in water

Presence of oxygen in water reacts with metal and to form iron oxide,

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To Provide net positive suction head (NPSH) for pump. Deaerator located sufficient
height. When water sucked by pump pressure does not fall PSAT and no flashing of
water into vapor which protects BFP from damage & cavitation.

FIG 3.14 DEAERATOR

22 .ELECTROSTATIC PRECIPITATOR:

Electrostatic precipitator, also called electrostatic air cleaner, a device that uses an
electric charge to remove certain impurities either solid particles or liquid droplets-
from air or other gases in smokestacks and other flues. The precipitator functions by
applying energy only to the particulate matter being collected, without significantly
impeding the flow of gases. Originally designed for recovery of valuable industrial-
process materials, electrostatic precipitators are used for air pollution control,
particularly for removing harmful particulate matter from waste gases at industrial
facilities and power-generating stations. If released into the atmosphere, such
particulates reduce visibility, can contribute to climate change, and lead to serious
health problems in humans, including lung damage and bronchitis. Electrostatic
precipitators can capture fine particles (i.e., those that are smaller than 2.5 microns
[0.0001 inch] in diameter), which are especially dangerous if released because they
can be drawn deep into the lungs and can trigger inflammatory reactions.

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FIG . 3.15 ELECTROSTATIC PRECIPITATOR

23.STEAM TURBINE :

The steam turbine is a prime mover that converts the stored mechanical energy in
steam into rotational mechanical energy. A turbine pair consists of a ring of fixed
blade and a ring of moving blades. The blades are so designed that the steam glides
overt eh blade surface without striking it. As the steam floes over the covered surface
of blade, it exerts a pressure on the blade along its whole length owing to its
centrifugal force. The motive force on the blade will be the resultant of the
centrifugal pressures on the blade length plus the effect of change of the steam as it
flows over the blade.

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FIG . 3.16 TURBINE

1. High pressure (HP): Turbine (first cylinder) - Steam inlet Temperature - 540°C
Steam inlet pressure - 130 Kg/cm2

2. Intermediate Pressure (IP): Turbine (second cylinder) Steam inlet Temperature

- 540°C Steam inlet Pressure - 35 Kg/cm2

3. Low pressure (LP): Turbine (Third cylinder) - it used steam of very low
pressure and temperature. Steam inlet Temperature - 325°C Steam inlet Pressure-7
Kg/cm2

24. TURBO GENERATOR:

A turbo generator is an electric generator connected to the shaft of a steam turbine or

gas turbine for the generation of electric power large steam powered turbo generators
provide the majority of the world's electricity and are also used by steam- powered
turbo- electric ship .

25 .CONSTRUCTION FEATURES:

Turbo generators are used for high shaft rotational speeds, typical of steam and gas
turbines. The rotor of a turbo generator is a non-salient pole type usually with two
poles. The normal speed of a turbo generator is 1500 or 3000 rpm with four or two

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poles at 50 Hz (1800 or 3600 rpm with four or two poles at 60 Hz). The rotating parts
of a turbo

generator are subjected to high mechanical stresses because of the high operation
speed. To make the rotor mechanically resistant in large turboalternators, the rotor is
normally forged from solid steel and alloys like chromium-nickel-steel or chromium-
nickel- molybdenum are used. The overhang of windings at the periphery will be
secured by steel retaining rings. Heavy nonmagnetic metal wedges on top of the slots
hold the field windings against centrifugal forces Hard composition insulating
materials, like mica and asbestos, are normally used in the slots of rotor This material
can withstand high temperatures and high crushing forces

The stator of large turbo generators may be built of two or more parts while in
smaller turbo-generators it is built up in one complete piece

26 .GENERATOR DETAILS :

Type: THW-210-2B (water & hydrogen turbo generator)

Rated capacity: 210 MW, 247 MVA
Power factor. 0.85 lag
Stator: 15.75-volt, 9050 A
Rotor. 310 V DC, 2600 A
Excitement system: static used dry transformer
Type of cooling: water, hydrogen
Hydrogen pressure: 3.5 kg/cm2

27 .COOLING SYSTEM:

1. Hydrogen Cooling

2. Water Cooling

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1 .HYDROGEN COOLING

Many power generators over 150 MW in capacity utilize hydrogen as a cooling

method to transfer heat from the power generating winding enclosure to the heat
exchanges known as H2 coolers.

Hydrogen cooled power generators are more efficient and have less mass of materials
of construction than their air-cooled cousins.

Hydrogen gas is 7 times more effective as a heat transfer medium than air and 1/14th
the density, resulting in less friction losses and more fuel converted to electricity.

The losses occurring in the generator stator winding components via stator winding,
main brushes & phase connectors are dissipated directly through water. The cooling
water being in direct contact with voltage winding, must have an electrical
conductivity of order of 0.5 to 1 μΩ . 4500 holes in rotor for hydrogen cooling.

FIG 3.17 HYDROGEN COOLING

2 .WATER COOLING:

Stator winding is cooled by closed circuit circulation of low conductivity water

(Demineralized water) through the hollow rectangular conductors which from the
cooling system for higher rating (200 MW & above) Generator.

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The cooling water from the expansion tank is circulated by two 100% duty AC motor
driven centrifugal pumps, one working and the other standby. The pump are
electrically interlocked between each other in such a manner that the standby pump
automatically starts up in case of water drops in the circuit. In case of the pressure is
still less, an alarm signal appears and machine should be tripped.

Figure 3.18 GENERATOR COOLING

28. BARRING GEAR MOTOR :

Barring gear system is a mechanism in turbines to rotate the turbine at constant speed
during cooling down period. When the turbine is tripped/stopped the cooling of rotor
takes place. In order to have even cooling of the rotor the machine 51 is not brought
back to zero speed immediately. The constant speed is maintained with the help of
barring gear mechanism. It may be achieved with the help of hydraulic motor, electric
motor or manual. Here Barring gear motor has rotate the shaft in 3 RPM

FIG . 3.19 BARRINGGEAR MOTOR

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29. H2 DRYER :

A H2 dryer is apparatus designed to adsorb and remove water through hydrogen-

oxygen reaction, using a desiccant in the absorber. The hydrogen is heated up to
about 100°C for easy reaction in the pre-heater and the heated hydrogen gas flows
into the catalyst tower filled with palladium.

FIG . 3.20 H2 DRYER

30. SEAL OIL SYSTEM:

A seal oil system for the generator was developed to keep the hydrogen from leaking
along the rotor shaft, The seal ring floats on the shaft and does not rotate. It receives
makeup oil from the bearing lubricating oil system. Seal oil pressure is 0.6 to 09 Kg
of hydrogen pressure. For Seal system two motor are used, one AC & One DC.

FIG 3.21 SEAL OIL SYSTEM

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31. EXCITATION SYSTEM:

The excitation system provides direct current for windings of generators rotating
magnetic field.

Two types of excitation systems are in use:

1. Brushless, i.e. an exciter machine coupled to the generator

2. Static that means outside the generator alternating current is rectified. Direct
current is supplied to the rotor excitation winding via two brushes Both systems
perform the same function.

Excitation systems can be defined as the system that provides field current to the
rotor winding of a generator. An Excitation System Required a DC supply which is
obtained through thyristor control panel. Dry type transformer supplies the thyristor
control panel. Here 120 Carbon Brush used in Exciter, and used 310 V DC supply for
generator rotor for excitation.

FIG 3.22 EXCITATION SYSTEM

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32. STATIC EXCITATION:

In order to maintain system stability, excitation system should have superior dynamic
performance (fast response) means the field current must be adjusted extremely fast to
changing operational conditions. In this system, all components are solid state & no
moving parts & thus its response is high & thus, static excitation system is more
preferable. The required excitation power is taken from the generator output itself & fed
to the excitation transformer which steps down to the required voltage & then it is given
to Thyristor converter & that controlled DC o/p given to the field winding of the
generator via field breaker.

The static excitation system consists of the following equipment:

1. Rectifier Transformer.
2. SCR bridge Thyristor Converter.
3. Field Flashing Equipment.
4. Field Breaker and Field Discharge Equipment.
5. Automatic Voltage Regulator.

1 .RECTIFIER TRANSFORMER:

Transformer is a electrical static device which transforms, not converts electrical

voltage, current, power from one level to another level without changing its
sinusoidal waveform & frequency. Excitation transformer is also known as rectifier
transformer from its function

point of view. It is dry type cast coils transformer & is most suitable for static
excitation system. It is provided with CT for over current protection & temperature
surveillance

device for over temperature protection. Rating: 15.75 KV/575 V step down
transformer. The transformer must supply rated excitation voltage/ current
continuously and is capable of supplying ceiling currents at the ceiling excitations for
a short period of 10 seconds.

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2 .SCR BRIDGE THYRISTOR CONVERTER:

The Thyristor Bank consists, suitable nos. of bridges connected in a parallel. Each
Thyristor bridge consists six Thyristor (3 phase full wave rectification). fuses &
snubber circuit for protection. Where snubbed ckt is a RC combination is used to
suppress the rate of rise of forward voltage i.e. dv/dt otherwise thy gets damaged.
Thyristor SCR Silicon controlled rectifier is made with Anode, Cathode & Gate, &
by giving pulses, Thyristor can be conducted & by changing the firing angle, variable
output of thyristor can be obtained. Each bridge is controlled by one final pulse stage
& is cooled by a fan. This arrangement provides fast control of DC excitation current.

3 .FIELD FLASHING EQUIPMENT :

Field Breaker is a device which is used to give the DC supply to the field winding of
the Generator with the help of carbon brush & slip ting assembly. Generally made
from combination of carbon & copper having Grade of HM 6R

Generally, 112 (28 X 4112 nos.) carbon brushes are used in 210 MW Generator.
Slipring is made up by copper material

4 .FIELD BREAKER AND FIELD DISCHARGE EQUIPMENT :

As residual magnetism of generator is not sufficient to start voltage-built process, a

separate equip for excitation is required. The field flashing is done by external source
like station battery or rectified AC from station bus AC supply

Filed flashing is used to build up voltage up to 30%. And after words pulses are
generated/released to fire/trigger to Thyristor bridge. From 30 to 70% both flashing
and regulation remains in circuit. The Field Flashing breaker will automatically
switch off as soon as voltage reaches to 70% of the generator rated o/p voltage.

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The FDR Field Discharge Resistor is normally of non-linear for medium large
machines, i.e. voltage dependent resistor. A over voltage protection employed to
protect the field winding of generator against over voltages Operates on the insulation
break over principle.

5 .AUTOMATIC VOLTAGE REGULATOR (AVR) :

This is the heart of the system. This regulates the generator terminal voltage by
controlling the firing angle to the thyristor Its response is very high (High control
speed) as there is no any rotating part

Inertia free control). (Actual output of the generator is sensed by the installed CT &
PT & those signals are given to the AVR

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CHAPTER – 4
4 ELECTRICAL TESTING
An electrical test is an evaluation of the parametric, functional, or timing performance of
a component when electrical power is applied. Parametric tests typically involve dc or
analog measurements of current or voltage. Functional tests usually have Boolean test
patterns applied to the inputs (the logic stimulus) and the Boolean outputs are evaluated
(the logic response). The set of applied stimuluses and expected response conditions for
all the component's primary input and output pins for each logic state is referred to as a
test vector. Timing tests measure the rising and falling edges of signals, usually the
primary outputs, to determine the time required for output changes to occur as a result of
input stimulus changes. Timing tests are often used to measure the time that the
component takes to propagate a change through a critical logic path.

Failure of electrical or electronic components usually involves electrical malfunction or

operation outside of the desired electrical limits. Therefore, failure analysis typically
requires performing electrical tests to duplicate or reproduce the incorrect operation of
the component.

Electrical tests are performed by applying voltage and/or current to the component and
observing its voltage and/or current responses. Tests can range from simple, manual
measurements of electrical continuity for the component's inputs or outputs to complex
functional tests using hundreds of thousands of vectors at test rates greater than 100 MHz
the measurement equipment can range in sophistication from simple, inexpensive hand-
held volt ohm meters to complex, digital test systems costing more than one million
dollars.

4.1 SCOPE OF WORK

Relay Testing
CT Testing
Testing of various switchyard equipment
Transformer Testing
Generator panel testing
Testing of LT and HT circuit breaker
HT and LT Panel testing
Equipment Protection checks

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4.2 TESTING EQUIPMENT

4.2.1 MULTIMETER
Also known as a VOM (Volt-Ohm meter), a multi-meter is a handheld device that
combines several measurement functions (such as voltage, current, resistance and
frequency) into a single unit.

Multi-meters are mainly used to troubleshoot electrical problems in a wide array of

industrial and household devices such as electronic equipment, motor controls,
domestic appliances, power supplies, and wiring systems.

Digital multi-meters are the most common form of meter used today; however
analog multi-meters are still preferable in some cases, like when monitoring a
rapidly changing value or sensitive measurements, like testing for CT polarity.

4.2.2 MEGOHMMETER
Most commonly referred to as simply a "megger", a megohmmeter is a special type
of ohmmeter used to measure the electrical resistance of insulators.
Resistances values by megohmmeters may range from several megohms to several
million megohms (tera-ohms). Megohmmeters produce high voltages via battery
powered internal circuitry or a manually operated generator with outputs ranging
from 250 to 15,000 volts. Megohmmeters are one of the most frequently used
pieces of test equipment and can be used to measure the insulation of various
types of apparatus such as circuit breakers,transformers, switchgear and cables.

4.2.3 RELAY TEST SET

FIG. 4 Relay Test Kit

These are power system simulators used for testing protection devices used in
industrialand power systems. Relay test sets are fitted with multiple sources to
test solid-state and multi-function numerical protection, each voltage and current
channel is operated independently to create different power system conditions.

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High end relay test equipment can test not only simple voltage, current, and
frequency relays but also complex protection schemes, such as communication-
assisted line protection, and protection schemes that use IEC61850-compliant IEDs
(intelligent electronic devices).

4.2.4 TRANSFORMER TURNS RATIO (TTR) TEST SET

The TTR test set applies voltage to the high-voltage winding of a transformer and
measures the resulting voltage from the low voltage winding, this measurement is
known as the turns ratio. In addition to turns ratio, the units measure excitation
current, phase angle deviation between the high- and low-voltage windings and
percent ratio error.
Transformer turns ratio test sets come in a variety of styles and test connections,
however all turns ratio testers have at least two high leads and two low leads. The
excitation voltage of a TTR test set is generally less than 100V.

HIGH VOLTAGE TEST LEAD

LOW VOLTAGE LEAD
TEST

FIG . 4.1 Transformer Turns Ratio Test Set

4.2.5 CURRENT TRANSFORMER TEST SET

FIG 4.2 Current Transformer Test Kit

CT test sets are small, multi-function units designed to perform demagnetization,

ratio, saturation, winding resistance, polarity, phase deviation, and insulation tests
on current transformers. High-end CT test equipment can directly connect to multi

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ratio CT's and perform all tests on all taps with the push of a button and without
changing leads.
Current transformers can be tested in their equipment configuration, such as being
mounted in transformers, oil circuit breakers or switchgear. Modern CT with
multiple voltage and current outputs can double as a relay test set when operated
with a laptop & computer.

4.2.6 VIBRATION TESTER

FIG . 4.3 Vibration Tester

Vibration analyzers are used to identify and locate the most common mechanical
faults (bearings, misalignment, unbalance, looseness) in rotating machinery. As
mechanical or electrical faults develop in motors, vibration levels increase. These
increases in vibration and noise levels occur at different severity of a developing
fault.
Accelerometers are used to take vibration measurements with the equipment in
service and data is loaded into software for analysis. As the machine under test
operates, the accelerometer detects its vibration along three planes of movement
(vertical, horizontal and axial).

4.2.7 HIGH CURRENT TEST SET

A high current test set may consist of two pieces known as a "control unit" and an
"output unit", or these functions may be combined in a single package. Low
voltage, high current outputs are used for primary-injection testing of low voltage
circuit breakers.
The high current or "primary-injection" test set consists of large transformers that
step down line voltage (ex. 480V) to a very low level, such as 2-15 V. The large
reduction in voltage allows for a large increase in available current output
(15kA+), especially for a short duration.
Current output is controlled by a tap changer and variable resistor. Integrated
timers display the period between current on and current off to indicate how long
it takes for a circuit breaker to trip.

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Circuit breakers may be connected directly to the high current test set via bus or
cable. Depending on the size, this type of test equipment can also use to test
ground fault and other current relays by connecting directly to switchgear bus.

4.3 TRANSFORMERS DETAILS

Generator transformers:stage
1: 250 MVA, 15.75/220 KV

stage 2: 250 MVA,

15.75/400 KV

Interconnection transformer :500 MVA (167*4,3+1, stand by), 220/400 KV

Station transformers: 25 MVA, 220/07 KV
Unit auxiliary Transformers: 15 MVA,
15.75/07 KV

Unit service Transformers 07 KV /433 volts

Station service transformer: 02 MVA, 07 KV /433v

4.3.1 Generating Transformer

FIG . 4.4 GENERATING TRANSFORMER

Transformer is a static machine, which transforms the potential of alternating current at same
frequency. It means the transformer transforms the low voltage into high voltage & high voltage
to low voltage at same frequency. It works son the principle of static induction principle.

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The Generating transformer serves as step up transformer it consists of transformer tank in which
the windings are placed mounted on the core which is further attached to the sets of bushes there
is an oil tank which is filled with transformer oil (mineral oil) the tank serves for the cooling
purposes. The Buchholz relay is provided for the protection. The oil-filled tank often has radiators
through which the oil circulates by natural convection; some large transformers employ forced
circulation of the oil by electric pumps, aided by external fans or water-cooled heat exchangers.
Oil-filled transformers undergo prolonged drying processes to assure that the transformer is
completely free of water vapor before the cooling oil is introduced. This helps in preventing
electrical breakdown under load. Oil filled transformers may be equipped with Buchholz relays,
which detect gas evolved during internal arcing and rapidly de-energize the transformer to avert
catastrophic failure (permanent failure). Oil-filled transformers may fail, rupture, and burn, causing
power outages and losses. Installations of oil-filled transformers usually include fire protection
measures such as walls, oil containment, and fire- suppression sprinkler systems.

4.3.2 STATION TRANSFORMERS

The Station Transformers are employed to supply auxiliary loads to the power plant for
starting the plant when generating unit is not in operation. There transformers are
connected to the switchyard bus. LV side of the station transformer is connected to the
auxiliary buses.

4.3.3 UNIT AUXILIARY TRANSFORMER

Unit Auxiliary Transformer is nothing but a step-down transformer, which is connected

parallel to the generator before the generator circuit breaker. Unit Auxiliary Transformer
Is used to deliver the power to the motor, fans, pumps, lightings etc.

4.4 15.75KV / 7KV SINGLE LINE DIAGRAM (UNIT

AUXILIARY)

FIG . 4.5 SINGLE LINE DIAGRAM OF UAT

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4.5 6.6 KV BUS BAR TIE DIAGRAM UNIT 1 TO 7

210 MW

FIG . 4.6 6.6 KV BUS BAR TIE DIAGRAM UNIT 1 TO 7

4.6 TYPES OF EQUIPMENT IN A SWITCHYARD

1. GENERATING TRANSFORMER
2. BUS BAR
3. POTENTIAL TRANSFORMER
4. CURRENT TRANSFORMER
5. LIGHTENING ARRESTER
6. CIRCUIT BREAKER
7. ISOLATOR
8. POWER LINE COMMUNICATION EQUIPMENTS
9. WAVE TRAPS

1. GENERATING TRANSFORMER

Transformer is a static machine, which transforms the potential of alternating current

at same frequency. It means the transformer transforms the low voltage into high

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voltage & high voltage to low voltage at same frequency. It works son the principle
of static induction principle.

The power transformer serves as step down transformer it consists of transformer

tank in which the windings are placed mounted on the core which is further attached
to the sets of bushes there is an oil tank which is filled with transformer oil (mineral
oil) the tank serves for the cooling purposes. The Buchholz relay is provided for the
protection. The oil-filled tank often has radiators through which the oil circulates by
natural convection; some large transformers employ forced circulation of the oil by
electric pumps, aided by external fans or water-cooled heat exchangers. Oil-filled
transformers undergo prolonged drying processes to assure that the transformer is
completely free of water vapor before the cooling oil is introduced. This helps in
preventing electrical breakdown under load. Oilfilled transformers may be equipped
with Buchholz relays, which detect gas evolved during internal arcing and rapidly de-
energize the transformer to avert catastrophic failure (permanent failure). Oil-filled
transformers may fail, rupture, and burn, causing power outages and losses.
Installations of oil-filled transformers usually include fire protection measures such
as walls, oil containment, and fire-suppression sprinkler systems.

2. BUS BAR

In electric power distribution, a busbar (also bus bar) is a metallic strip or bar,
typically housed inside switchgear, panel boards, and busway enclosures for local
high current power distribution. They are also used to connect high voltage
equipment at electrical switchyards, and low voltage equipment in battery banks.
They are generally uninsulated, and have sufficient stiffness to be supported in air by
insulated pillars. These features allow sufficient cooling of the conductors, and the
ability to tap in at various points without creating a new joint.

3. POTENTIAL TRANSFORMER
There 2 sets of the PT of 132KV and 1 sets of 66kv is installed at the substation. Potential
transformers are instrument transformers. They have a large number of primary turns and
a few numbers of secondary turns. It is used to control the large value of voltage. These
are used for the metering purposes

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The potential transformer works along the same principle of other transformers. It
converts voltages from high to low. It will take the thousands of volts behind power
transmission systems and step the voltage down to something that meters can handle.

These transformers work for single and three phase systems, and are attached at a
point where it is convenient to measure the voltage. Potential Transformer is designed
for monitoring single-phase and three- phase power line voltages in power metering
applications.

Theprimaryterminalscanbeconnectedeitherinline-to-lineorinline-to-
neutralconfiguration.
Fused transformer model shared signate dye suffix of "Forgone fuse or "FF" fortwo
fuses.

A Potential Transformer is a special type of transformer that allows meters to take

readingsfromelectricalserviceconnectionswithhighervoltage(potential)thanthemeteris
norm ally capable of handling without at potential transformer.

FIG 4.7 PT

4. CURRENT TRANSFORMER

Also known as CTs, current transformers are devices that measure alternating current.
They are widely used to measure high magnitude currents.

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A current transformer essentially lowers (steps down) a high current to a lower, safer
level that you can manage properly. It steps down the current to be measured so that
you can measure it with an average range ammeter. Functions of a current
transformer include:

Converting large primary currents into small 1A/5A current Providing the current for
the coil of measuring device and protective relaying It separates primary voltage from
secondary voltage.

FIG 4.8 CT

5. CAPACITANCE VOLTAGE TRANSFORMER (CVT) & PT

Voltage transformers (VT), also called potential transformers (PT), are a

parallelconnected type of instrument transformer. They are designed to present a
negligible load to the supply being measured and have an accurate voltage ratio and
phase relationship to enable accurate secondary connected metering.

FIG . 4.9 CVT

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A capacitor voltage transformer (CVT), also known as capacitor-coupled

voltage transformer (CCVT), is a transformer used in power systems to step
down extra high voltage signals and provide a low voltage signal, for metering
or operating a protective relay.

6. LIGHTNING ARRESTER
A lightning arrester is a device used on electric power transmission and
telecommunication systems to protect the insulation and conductors of the system
from the damaging effects of lightning. The typical lightning arrester has a high-
voltage terminal and a ground terminal. When a lightning surge (or switching surge,
which is very similar) travels along the power line to the arrester, the current from the
surge is diverted through the arrester, in most cases to earth.

A non-linear heavy duty lightning arrester has been set up for ICT and generator
transformer circuits on all lines to protect valuable equipment in the switchyard from
electric shock. An emitter measuring continuous leakage current and a discharge
counter recording electric shock are also arranged.

FIG . 4.10 LIGHTNING ARRESTER

7. SF6 CIRCUIT BREAKER

In Sulphur Hexafluoride or SF6 Circuit Breaker, Sulphur hexafluoride (SF6) gas is

used as an insulating and arc quenching medium. SF6 gas has many superior
properties which makes it perfect for are quenching. Sulphur Hexafluoride or SF6
Circuit Breaker is most popular and

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widely used breaker. This type of breaker is mostly used for EHV systems like 220
kV, 400 kV and 765 kV.

 Single Break SF6 Circuit Breaker

In Single Break Circuit Breaker, only one moving and fixed contacts are present. This
means that, there will only be one interrupter unit in such breaker. Single break SF6
circuit breaker is used for 220 kV applications.

 Double Break SF6 Circuit Breaker

In such type of breaker, there are two set of moving and fixed contacts connected in
series. Therefore, to enclose two set of contacts, there must be two interrupt unit in
series. This type of breaker is used in 400 kV applications. In double break circuit
breaker, grading capacitors are used to equalize the voltage distribution across each
contact. Thus for 400 kV application, the voltage across each contact will be 200 kV.
Therefore, it is logical to use SF6 gas at a pressure same as used in 200 kV
application.

FIG . 4.11 CIRCUIT BREAKER

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8 .Wave Trap

A line trap, also known as wave trap, or high-frequency stopper, is a maintenance-

free parallel resonant circuit, mounted inline on high-voltage (HV) AC transmission
power lines to prevent the transmission of high frequency (40 kHz to 1000 kHz)
carrier signals of power line communication to unwanted destinations. Line traps are
cylinder-like structures connected in series with HV transmission lines. A line trap is
also called a wave trap.

The line trap acts as a barrier or filter to prevent signal losses. The inductive
reactance of the line trap presents a high reactance to high-frequency signals but a
low reactance to mains frequency. This prevents carrier signals from being dissipated
in the substation or in a tap line or branch of the main transmission path and grounds
in the case of anything happening outside of the carrier transmission path.

WavetrapComponents:
1. Main coil
2. Terminal
3. Coronaring
4. Coronacap
5. Birdbarrier
6. Tuning pack
7. Surge arrester
8. Windingspider(crossarm)
FIG .4.12 WAVE TRAP

FIG . 4.13 WORKING OF WAVE TR

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CHAPTER 5
EMD – 3
ASH HANDLING PLANT
What is ash handling plant or ash handling system?

Ash handling plant or ash handling system in thermal power plant are used to cooled
down the ash to manageable temperature, transferred to a disposal area or storage
which is further utilized in other industries.

General description of ash handling plant

The design of the ash handling plant is dependent upon the method of ash disposal. It
may pump into a disused quarry or transported from the power station for processing
into building materials. A typical system, outlined below, includes both facilities.

Ash from the boiler is collected in a hopper directly below the furnace, whence it is
removed by high pressure water jets and discharged, via sluice ways, into ash crushers.
The crushed ash falls into ash tanks, and is then projected by water-jet pumps supplied
by HP sluice pumps through discharge pipelines to ash pits, where it is allowed to
settle. After settlement and drainage, the ash is removed by grabbing crane for
disposal by road vehicles or by conveyor to a disposal pit.

In thermal power plants, coal is used as a fuel for generating electricity. After burning
of coal, 40 % of total coal consumption is converted into ash which need to be properly
disposed-off from the thermal power plant.

Layout of Ash Handling Plant or Ash Handling System in Thermal

FIG 5.1 LAYOUT OF ASH HANDLING PLANT

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EQUIPMENT'S USED IN ASH HANDLING SYSTEM IN THERMAL POWER
PLANT

1. ELECTROSTATIC PRECIPITATOR (ESP)

2. FEED DISCHARGE SLUICE GATE

3. CLINKER GRINDER OR CRUSHER

4. JET PUMP

5. DEWATERING BIN

6. TRANSFER BAI

7. STORAGE BIN

8. DRY BOTTOM ASH CONVEYOR

9. CLINKER COOLING CONVEYOR

10. DRY BOTTOM ASH SYSTEM

11. SHURY PUMP

WORKING OF ASH HANDLING SYSTEM IN THERMAL POWER PLANT

Ash handling system are generally divided into three types fly ash handling
system, bottom ash handling system and ash slurry disposal system.

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DM WATER PLANT:

Generally, in water ions like ca, mg, na, hcos', etc. Are presents and cat and
mg are responsible for making water heavy.

O it is necessary to supply light water in very high- pressure type boilers,

otherwise it can lead to corrosion and damages to our costly equipment's like
turbine etc.

In WTPS per 02 unit it having 1 DM plant in operation

FIG 5.2 DM WATER PLANT

IMPORTANT COMPONENTS OF DM PLANT LISTED

BELOW:

O DEGASSER PUMP:

It blows air from the bottom to top side and water sprinkles from
top side and it releases carbonate or dissolved gases.

Total 6 degasser pumps (4 running 2 spare) having ratings of

18.5kw (25 hp) and 2900 rpm.

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CW WATER PUMP HOUSE:

Cooling water house pumps water from cooling tower's water to the plant's
condenser below the turbine for condensing the steam.

98% of water in the pond comes from cooling tower and 2% water from make-
up from canal or well, here from mahisagar canal..

01 cw plant operates between 3 units.

Each cw plant having 09 motor pumps having capacity of 6.6kv of operating

voltage and manufactured by jyoti ltd. And kirloskar. So, here 3 motor pumps
operate per one unit.

Each motor has mechanical locking mechanism so that it can't spin to the
opposite direction DURING ITS OPERATION PERIOD OR ITS STARTUP.

ASH WATER PUMP HOUSE

Plants are in operation.

Ash water plant equipped with 06 no. Of hp (high pressure) motor pumps
rating of 6.6kv of operating voltages.

Hp water supply per 03 unit wtps have 01 ash water plant and total 02 no. Of
ash water pumps are used to extract bottom ash from the furnace

Or economizer.

O in ash handling plant hp pumps supply water for quenching, trench jetting.
Seal trough flushing, gate cooling, sump stirring etc.

Ash water pump house also equipped with 03 no. Of lp (low pressure) motor
pumps which having ratings of 13.5 kw and 415v of operating voltage

Olp pump motors are used for systems with jet pumps for refractory cooling.
Hopper cooling water to maintain hopper temperature at 60 °c, make up or fill
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of hopper water, seal trough, slurry pump, etc. Ashon during its operation
period or in startup.

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CONCLUSION: -

An internship at "wanakbori thermal power station" enabled me to understand the overall

function of various department of the industries. As an intern, i was a great opportunity
to know the working environment. I have gained knowledge about the industrial and
study deal with the welfare schemes and incentives that are given to the workers to
improve the production capacity of the organization and the process of power generation
and distribution and its stages in detail. To conclude from this internship, i gained
practical knowledge, regarding the functions under taken by different departments in the
company. This internship also helped me to see the quality control and other evidence
maintained by each department in the company rather than studying theoretically.

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7 . REFERENCE

 HTTPS://WWW.G

SECL.IN/

 PRACTICAL BOILER OPERATION ENGINEERING AND POWER

PLANT BOOK BY AMIYA RANJAN MALLICK

 HTTPS:/LEN.WIKIPEDIA.ORG/WIKITHERMAL POWER. STATION

 AN INTRODUCTION TO THERMAL POWER PLANT ENGINEERING

AND OPERATION FOR POWER PLANT PROFESSIONAL BY P. K. DAS

& A. K. DAS

 ELECTRICAL ENGINEERING BOOKS

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