PREFACE

This report is prepared during the training period which is

one of our greatest learning experiences as it is full of
learning, analysis, knowledge & practical implementation.
This period has also provided us a chance to transform our
theoretical knowledge into a practical shape. Most
importantly we have been given exposure to the designing
and working of a thermal power plant. This report is a
result of 15 days training which we had undergone at
DSTPS, DVC, Andal at West Bengal.
Joining DSTPS as a trainee has given me a solid platform
to be exposed in the elite Government workplace at the
beginning of my professional career.
This report deals with the designing, specifications and an
overall working of a thermal power plant which plays an
important role in the electric power generation sector. Main
focus has been put on DVC Andal (DSTPS). We have also
included some photographs of the various equipments that
are used in the power plant.
 CONTENTS

1. INTRODUCTION TO DVC…………………………………………………..………………………

2. DURGAPUR STEEL THERMAL POWER STATION………………..………………………

3. THERMAL POWER STATION……………………………………………………………………..

4. BOILERS & AUXILIARIES……………………………………………………………………………

5. WATER TREATMENT………………………………………………………………………………..

6. ASH HANDLING SYSTEM…………………………………………………………………………..

7. STEAM TURBINE &AUXILIARIES……………………………………………………………….

8. TRANSFORMER………………………………………………………………………………………..

9. SWITCHYARD SECTION…………………………………………………………………………….

10.CONCLUSION……………………………………………………………………………………………
 INTRODUCTION
ABOUT THE COMPANY

The Damodar Valley Corporation (DVC) is a government organization which operated several
power station in the Damodar River area of West Bengal and Jharkhand states of India. The
corporation operates both thermal power stations and hydel power stations under the Ministry of
Power, Govt. Of India.

HISTORY
DVC emerged as a culmination of attempts made over a whole century to control the wild and
erratic Damodar River. The valley has been ravaged frequently by floods at varying intensities.
Serious floods occurred in 1730, 1823, 1848, 1856, 1882, 1898, 1901, 1916, 1923, 1935 & 1943.The
river spans over an area of 25,235 sq. km covering the states of Bihar (now Jharkhand) & West
Bengal. The catastrophe caused by the1943 flood, led to serious public indignation against the
Government. As a result, the Government of Bengal appointed a board of Enquiry titled
"Damodar Flood Enquiry committee’’ with the Maharaja of Burdwan and the noted physicist Dr.
Meghnad Saha as members for suggesting remedial measures.
The Damodar Flood Enquiry Committee suggested creation of an authority similar to the
Tennessee Valley Authority (TVA) in the USA, and recommended the construction of dams and
storage reservoirs at the sites with a total capacity of 1.5 millions acre ft. (1.850 millions cu. M)
and highlighted the possibilities of multipurpose development in the valley area. The Govt. of
India then commissioned the ‘Central Technical Power Board’ to study the proposal and
appointed Mr. W L Voorduin, a senior engineer of the TVA to study the problem at the Damodar
and to make his recommendation for comprehensive development of the valley. Accordingly, in
August, 1944 Mr. Voorduin submitted his ‘Preliminary Memorandum on the unified
Development of the Damodar River.’
Mr. Voorduin's "Preliminary Memorandum" suggested a multipurpose development plan
designed for achieving flood control, irrigation, power generation and navigation in the Damodar
Valley. Four consultants appointed by the Government of India examined it. They also approved
the main technical features of Voorduin's scheme and recommended early initiation of
construction beginning with Tilaiya to be followed by Maithon. By April 1947, full agreement was
practically reached between the three Governments of Central, West Bengal and Bihar on the
implementation of the scheme and in March 1948, the Damodar Valley Corporation Act (Act No.
XIV of 1948) was passed by the Central Legislature, requiring the three Governments, The Central
Government and the State Governments of West Bengal and Bihar (now Jharkhand) to participate
jointly for the purpose of building the Damodar Valley Corporation. The Corporation came into
existence on 7 July, 1948 as the first multipurpose river valley project of independent India.
COMMAND AREA
24,235 km2 spread across the Damodar basin. Jharkhand: 2 districts fully (Dhanbad and Bokaro)
and parts of 8 districts (Hazaribagh, Koderma, Chatra, Palamau, Ranchi, Loherdaga, Giridih and
Dumka) West Bengal: 5 districts (Bardhhaman, Hoogly, Howrah, Bankura, Purulia)
The Damodar Valley Corporation has been generating and transmitting power since 1953.
INFRASTRUCTURE
DVC developed and expanded its infrastructure to six thermal power stations' (7410 MW)'and
three hydro-electric power stations with a capacity of 147.2 MW which contribute to a total
installed capacity of 7557.2 MW. Presently DVC has 49 sub-stations and receiving stations
more than 8900-circuit km of transmission and distribution lines. DVC has also four dams,
a barrage and a network of canals (2494 km) that play an effective role in water management. The
construction of check dams, development of forests and farms and upland and wasteland
treatment developed by DVC play a vital role in eco conservation and environment management.
MISSION

 Fulfil the obligation towards stake holders and carry out the mandate of flood control,
power supply,irrigation, water supply management and soil conservation in the command
area.
 Provide quality power and best in class services at competitive rates to our consumers.
 Continue with our unending commitment towards socio-economic development and
general well-being of the people of the command area.
 Inculcate a culture of value, ethics and integrity in the organization.
DURGAPUR STEEL THERMAL POWER STATION
Durgapur Steel Thermal Power Station is a coal-based thermal power plant located
near Durgapur city in Bardhaman district in the Indian state of West Bengal. The power plant is
operated by the Damodar Valley Corporation.

CAPACITY:The plant has installed capacity of 1000 MW.

Generating
Unit No. Commissioned on
Capacity

1 500 MW 2012 May

2 500 MW 2013 March

 THERMAL POWER STATION
To generate an alternating voltage at 50 Hz, we have to run the alternator at some fixed rpm by
some external agency. A turbine is used to rotate the generator. Turbine may be of two types,
namely steam turbine (in most places) and water turbine.

The Basic Steam Cycle:

The basic steam cycle was initially developed in 1824 by Carnot and was subsequently modified
by Rankin. The basic cycle is still known as the RANKINE CYCLE in modern power
stations. Thermal power plant operates on the RANKINE CYCLE.
The main components of Rankine Cycle Steam Plant are:
 Boiler, which generates steam, usually at a high pressure and temperature;
 Turbine, which expands the steam to a low pressure and temperature thereby
producing work;
 Generator driven by the steam turbine;
 Condenser, which cools the steam to a liquid so that it may be pumped back (A feed
pump) into boiler;
 Feed heaters, which preheat the water before it enters the boiler; and
 Pre-heater, which is a part of the boiler and which reheats the steam after it has been
partially expanded.
Coal is burnt in a boiler to heat water & produce high temperature & high pressure steam. This
steam is expanded in a turbine which produces the mechanical power to produce rotational
motion. The alternator, mechanically coupled to the turbine, thus rotates producing electricity.
Chemical energy stored in coal after a couple of transformations produces electrical energy at
the generator terminals.
After steam passes through the turbine, the steam is condensed in a condenser and recycled to
where it was heated.

Elementary features of a Thermal Power Plant:-

 Thus, proximity of a generating station nearer to a coal reserve and water sources will be most
economical as the cost of transporting coal gets reduced. The greatest variation in the design of
thermal power stations is due to the different heat sources, fossil fuel dominates in our country,
and naturally thermal power plants are most popular, although nuclear heat energy and solar
heat energy are also used. However, coal thermal plants pollute the atmosphere because of
burning of coals.

Stringent conditions (such as use of more chimney heights along with the compulsory use of
electrostatic precipitator) are put by regulatory authorities to see that the effects of pollution is
minimized. A large amount of ash is produced every day in a thermal plant and effective
handling of the ash adds to the running cost of the plant. Nonetheless 57% of the generation in
out country is from thermal plants. The speed of alternator used in thermal plants is 3000 rpm
which means 2-pole alternators are used in such plants.

Generator Specifications:-
 3 parts of main generator:-
 Pilot Exciter
 Main Exciter
 Synchronous Generator

The Permanent Magnet Generator (PMG) or Pilot Exciter supplies 400 Hz AC power to the
Digital Automatic Voltage Regulator (DAVR). DAVR receives voltage and reactive current
feedback provided by potential and current transformers to provide voltage and reactive current
feedback. Comparing these signals to a reference set point in the voltage regulator, the voltage
regulator provides a controlled variable DC current to the stationary field of the rotating main
exciter. With its stationary field and rotating armature, the exciter generates three phase high
frequency AC output. This output is rectified by the rotating rectifiers. The rotating rectifier is a
three phase full wave diode bridge.
This DC current is fed via conductors to the centre of the rotor shaft and carried by a special
lead bar in the hollow shaft area under the bearing journal which is then applied to the main
generator field winding.
The stator of main generator is distilled water cooled & its rotor is hydrogen cooled.
 Power Flow from Generator

BOILERS AND AUXILIARIES

Arrangement of Boiler Auxiliaries

Fig:-Flow Chart
 From the Coal Handling Plant (CHP), coal comes through the conveyer belt to the transfer
point & from there to the travelling tripper in the bunker floor. Travelling tripper
automatically fills the coal in the 4 bunkers below as per their vacancy. Most efficient way of
utilizing coal for steam generation is to burn it in pulverized form. So, f rom the bunkers,
coal goes to the corresponding coal mills or pulverisers, where 3 crushers pulverize the coal to
fineness such that 70-80% passes through a 200 mesh sieve.
Resulting pulverised coal is blown by Primary air fan (PA fan) or Exhauster fan (measured
in tons per hour), via 4 pipes from each mill to the 4 corners of the corner fired furnace of the
water tube boiler. PA fan also dries the coal in coal mill to attain requisite pulverized coal
temperature for ready combustion at furnace.
In the boiler, water circulates in tubes heated externally by the fire. Fuel is burnt inside the
furnace, creating hot gas which heats water in the steam-generating tubes. These tubes are
attached with each other forming the closed chamber around the furnace to block any escape of
heat. Steam from here goes to the boiler drum, located outside the furnace region or flue
gas path. This stores certain amount of water and separates steam from steam-water mixture,
by the cyclone separator. The minimum drum water level is always maintained so as to
prevent formation of vortex and to protect water wall tubes (especially its corner tubes)
from steam entrapment / starvation due to higher circulation ratio of boiler. Steam from here
goes through primary superheater placed in the convective zone of the furnace, then
through platen superheater placed in the radiant zone of furnace and thereafter, through
final superheater placed in the convective zone. Superheater elevates the steam temperature
above the saturation temperature in phases; so that maximum work can be extracted from
high energy (enthalpy) steam and after expansion in t urbine, the dryness fraction does not
reach below 80%, for avoiding t urbine blade erosion/damage and attaining maximum
turbine internal efficiency. The superheated steam at requisite pressure and temperature is
taken out of boiler. Now first, it is feeded to HP turbine’s end of less volume. Then the steam
passes to its larger volume end & pressure decreases as per Boyle’s law. Next, in order to
improve the cycle efficiency, HP turbine exhaust steam is taken back to boiler to increase
temperature by reheating process. The steam is passed through Reheater, placed in between
final super heater bank of tubes & platen SH and finally taken out of boiler to extract work
out of it in the Intermediate pressure (IP) & then Low pressure (LP) turbine.
As the demineralisation is costly, so this steam is recycled. It is condensed for ease in
transportation. (Cold water supply in this surface condenser is maintained with the help of
cooling towers.)
 Fig: Surface Condenser
With help of condensate extraction pump (2 CEPs & 1 standby), this condensate goes to the
low pressure heater, & then to deaerator that removes the moisture from the steam.
Therefrom, it goes to High pressure heater via the turbine driven boiler feed (TDBFP) pump in
normal cases & by the 10 MW motor driven boiler feed pump (MDBFP along with the booster
pump to increase the pressure), when the turbine doesn’t run in emergency. The heaters consist
of plate heat exchangers. Feed water enters into the boiler through economizer. It recovers
the residual heat of flue gas before leaving boiler to preheat feed water prior to its entry into
boiler drum.

Water in boiler drum is circulated to the boiler tubes by the Boiler Circulating Water (BCW)
pumps. Any losses in this steam cycle is supplied from the DM water tank .

Bottom Ash Hopper

Ash is generated as a product of combustion of coal. The type of ash formed due to fusion
and nucleation of ash and coming out from the bottom of the furnace, is called bottom
ash. It is nearly 20% of the total ash generated. Rest 80% in the form of dust particles is called
fly ash. Bottom ash hopper is placed below boiler waterwall ring headers to receive ash
generated at boiler furnace. It is generally filled with water for cooling of deposited ash,
which is removed periodically.
Air pre-heater:
The air pre-heater absorbs waste heat from flue gas and then transfers this heat to incoming
cold air by means of continuously rotating heat transfer elements of specially formed metal
plates known as Basket (rotary re-generative air pre-heater) or through stationery tubes
(recuperative or tubular air pre-heater).
.
Furnace & combustion:
Furnace is that part of boiler where the chemical energy available in fuel is converted into
thermal energy during its combustion. Maximum heat transfer takes place in furnace.
Furnace pressure is maintained at zero or below atmospheric pressure (balanced draft
condition).
 BOILER AUXILIARIES:

Induced draft fan (ID fan):

Induced draft represents the system where air or products of combustion are driven out
after combustion at boiler furnace by maintaining them at a progressively increasing sub
atmospheric pressure. This is achieved with the help of induced draft fan and stack.
Induced draft fan is forward curved centrifugal (radial) fan and sucks the fly-ash laden gas
of temperature around 125oC out of the furnace to throw it into stack (chimney). The fan is
connected with driving motor through hydro-coupling or with variable frequency drive (VFD)
motor to keep desired fan speed.

Forced draft or Secondary Air fan (FD fan):

Forced draft represents flow of air or products of combustion at a pressure above
atmosphere. The air for combustion is carried under forced draft conditions and the fan
used for this purpose is called Forced Draft (FD) fan. It is axial type fan and is used to take air
from atmosphere at ambient temperature to supply air for combustion, which takes entry to
boiler through wind box.
 WATER TREATMENT PLANT

Raw Water Supply: Raw water received at the thermal power plant is passed through Water
Treatment Plant to separate suspended impurities and dissolved gases including organic
substance and then through de-mineralised plant to separate soluble impurities.

Water Requirement: Water is required in power plant for two basic needs, first is for steam
generation and second for is cooling purpose. Thermal power plant requires huge volume of
water, nearly of about 3 to 4 tones/hr/MW only for steam generation.
 De-Aeration: In this process, the raw water is sprayed over cascade aerator in which water
flows downwards over many steps in the form of thin waterfalls. Cascading increases surface
area water to facilitate easy separation of dissolved undesirable gases ( like hydrogen sulphide,
ammonia etc.) or to help in oxygenation of mainly ferrous ions in presence of atmospheric
oxygen to ferric ions.

Fig:Cascade Aerator
Coagulation & Filtration:- Coagulation takes place in clariflocculator. coagulant
destabilizes suspended solids & agglomerates them into heavier floc, which is separated out
through sedimentation. Prime chemicals used for coagulation are- alum, Poly Aluminium
chloride (PAC), Filters remove coarse suspended matter & remaining floc or sludge after
coagulation & also reduce the chlorine demand of the water.

Chlorination :- Neutral organic matter is very heterogeneous i.e., it contains many classes of
high molecular weight organic compounds. Humic substances constitute a major portion of the
dissolved organic carbon from surface waters. They are complex mixtures of organic
compounds with relatively unknown structures & chemical composition.

DM (Demineralised Water) Plant:- In de-mineralised water plant, the filter of water

treatment plant is passed through the Pressure Sand Filter (PSF) to reduce turbidity & then
through Activated Charcoal Filter (ACF) to absorb the residual chlorine & iron in filter water.

ASH HANDLING SYSTEM:

Ash is generated in Boiler due to combustion of pulverized coal. One ton of coal generates
0.35 to 0.45 ton of ash after combustion. A part around 20% of generated ash gets
deposited in Boiler Bottom Hopper and major part around 80% goes out as fly ash with Boiler
exhaust gases.

Bottom ash hopper (BAH)

It is a water filled hopper placed below the furnace water wall ring headers to receive
bottom ash generated out of combustion of coal.
 BAH is generally of two types – Dry Bottom and Wet Bottom. In Dry Bottom type, the
BAH is kept empty (i.e. not water filled) prior to receiving Bottom Ash and quenched by
separate spray arrangement from inside. In this system continuous ash evacuation and
disposal take place through ash handling devices like Scrapper Conveyor (Ex. DTPS unit # 4)
or Pneumatic Dry Ash conveying system. In the Wet Bottom type, the BAH is filled with
water for quenching, disintegrating and collecting the Bottom Ash in water mixed condition.
In this case ash evacuation & disposal is carried out periodically (ones in a shift of 8 hrs. Ex.
CTPS units, DTPS U#3).

Electrostatic precipitator (ESP)

A small part of fly ash gets deposited in Economizer hoppers, Air pre-heater ash hoppers
and duct hoppers before it takes entry to the Electrostatic Precipitator, where majority of
fly ash is separated out.
In Electrostatic Precipitator, there are two sets of electrodes viz. Collecting electrodes and
Emitting (discharge) electrodes. The Collecting electrode is made up of steel sheets pressed or
rolled to a special profile. The Emitting electrode is a thin wire, in helical (or spiral) form.
These two electrodes are arranged in alternate rows. A unidirectional high voltage from a
rectifier is applied between these two
Electrodes connecting its negative polarity to the emitting electrodes and positive polarity to
the collecting electrodes which are earthed.

Because of the physical configuration, the electric field in the neighborhood of the Emitting
electrode is very high. The dust laden flue gas from boiler passes between rows of collecting
and discharge electrodes. The gas molecules, which are normally neutral, are ionized in
presence of high electric field. The ionized positive charges travel towards the discharge
electrodes and the negative charges (ions and electrons) towards the collecting electrodes.
On the way to the collecting electrodes, the negative charges get attached to the dust
particles. Thus, the dust particles are electrically charged negatively. In presence of highly
 negative voltage between the emitting and collecting electrodes, the charged dust particles
experience a force which causes the particles to move towards the collecting electrodes and
finally get deposited on them. A minor portion of dust particles, which have acquired
positive charge, get deposited on the emitting electrodes also. Periodically these particles are
dislodged from the electrodes by rapping system. The particles then fall into the hopper at
the bottom from where evacuation takes place through ash disposal system.

Disposal of fly ash:

The fly ash collected in each of the electrostatic precipitator hopper, economizer hopper,
air pre-heater hoppers and the duct hopers drops continuously to a feeder ejector/flushing
apparatus provided under each hopper where fly ash gets mixed with water and the resultant
slurry drops into the ash sluice trench provided below the feeder ejectors/flushing apparatus
in case of wet disposal system. The ash slurry is then transported to the ash slurry sump by
gravity aided by high pressure jetting nozzles provided at intervals in the sluice trench. Slurry
at the sump is pumped to far off disposal area (ash pond) through cast iron or basalt lined
disposal pipe lines. The pond ash is evacuated periodically to retain its capacity for further
disposal.

STEAM TURBINE & AUXILIARIES:

In steam turbine, heat energy of steam is transformed into mechanical energy. The heat
energy content (enthalpy) of steam changes into the kinetic energy during its expansion.
The impulse or reaction of steam against blades creates centrifugal pressure normal to the
blade surface at all points and causes the rotational motion of the blades. The total motive
force acting on the blade is thus the resultant of all the centrifugal forces plus the change of
momentum. In impulse turbine, steam passing through nozzle impinges in moving blades
and the steam path turned in the opposite direction and thereby effects change in
momentum. This change in momentum produces force which drives the rotor.
 Turbine oil system:
The turbine oil system provides supply of oil to the journal bearings, maintains the
temperature of bearings at desired level and acts as operating medium for hydraulic
governor and also as sealing medium for hydrogen cooled generator.
In units 500 MW and above, the practice is to use fire resistant fluids in place of
lubricating oil for governor system to eliminate the risk of fire during oil leakage.

Turbine oil system is operated by the following pumps:

Main Oil Pump (MOP):

This pump is mounted in the front bearing pedestal and connected with turbine rotor
through gear coupling. It supplies total system oil requirement during turbine in operation.
Its discharge pressure is 20 Kg/cm2 for LMW set and 8 Kg/cm2 for KWU set at normal
turbine speed. The lubrication oil is supplied through two injectors arranged in series.

Starting oil pump (SOP) or Auxiliary oil pump (AOP):

It is a multi stage centrifugal oil pump driven by A.C. electric motor. 1 x 100% duty
 Starting oil pump for LMW set or 2 x 100% duty Auxiliary oil pump for KWU set are
provided for meeting the requirement of oil of the turbo set during start up or shut down i.e.
when Main oil pump is not in operation.

A.C. lub. oil pump (AC LOP):

This is a centrifugal pump driven by an A.C. electric motor and can meet requirement for
turbine lubrication system when the turbo-generator is on Turning Gear or under flushing of
standstill condition of the m/c. This pump automatically takes over under inter lock action
whenever the oil pressure in lubrication system falls to 0.6 kg/cm2 (gauge).

D.C. emergency oil pump (DC LOP or DC EOP):

This is a centrifugal pump driven by D.C. electric motor and automatically cuts in during
A.C. supply failure or when lubrication oil pressure falls to 0.5 kg/cm2 (gauge).

Jacking oil pump (JOP):

JOPs are positive displacement pumps that provide high oil pressure. The oil pressure lifts
the shaft slightly. This ensures no metal contact between journal and bearing. This greatly
reduces the static friction and bearings wear, also the starting torque of turning gear drive.
JOP can be stopped after the lubricating oil film is established in bearings at the time of
putting TG in turning gear.

Shaft seal oil system:

Seal oil system prevents hydrogen gas leaking out and air ingress into the hydrogen cooled
generator through the shaft glands, with the help of radial and axial oil film, the oil being
kept at higher pressure than that of hydrogen. The shaft seals are supplied with the same oil
as used for turbine and generator journal bearing lubrication. The seals used in turbo
generators are of two main types, namely Ring type (axial face type) seals and Thrust type
(radial face type) seals.

Turbine oil purifier (Centrifuge):

The centrifuge purifies turbine oil by removing water and entrained solid matter.
The centrifuge consists of a bowl which rotates on a vertical axis in an outer casing. It
draws oil from the turbine oil tank or impure oil tank through an oil pump. After removing
any water and entrained solid matter, the clean oil is returned to the oil tank or pure oil
tank. Sludge is removed from the disc of centrifuge by periodic cleaning.

Turbine glands:
Gland prevents or reduces steam or air leakage between rotor and casing of turbine
cylinder. Labyrinth glands, provided at both ends of each cylinder of turbine, are sealed by
auxiliary steam at pressure around 1.5 kg/cm2.
 Gland steam cooler:
It cools steam-air mixture sucked from turbine end gland seals. It is of vertical type and has
two sections. An ejector mounted on the cooler, maintains constant vacuum in the first
section. A part of main condensate after main ejector flows through U shaped admiralty
brass tube rolled in steel tube plate. Drain from cooler is led to condenser.

Low pressure (LP) heater:

LP heaters take extraction steam from low pressure stages of turbine.

De-aerator:
In De-aerator, condensate water is allowed to fall by gravity through steam scrubber to drive
out oxygen and other dissolved gases from condensate water. It also heats the incoming
water and acts as a reservoir to serve emergency. Pegging steam pressure, for maintaining
required NPSH at De-aerator water temperature, is also applied in the De-aerator.

Boiler feed pump:

Boiler feed pump (BFP) is a multistage pump provided for pumping de-aerator outlet water
to economizer through high pressure heaters. Generally, three pumps each of 50% of total
capacity are provided. Booster Pump, driven by the main BFP motor, is sometimes provided
before feed pp to maintain required NPSH even with lower de-aerator height. Operation of
BFP below NPSH may cause severe damage of the pump due to cavitation or vapour
bounding.

High pressure (HP) heater:

Regenerative feed heaters improve the cycle efficiency substantially. The driving force for
heat transfer in feed heaters is the LMTD (Log mean temperature difference) and TTD
(terminal temperature difference) between heater outlet drip and feed water. Tube material is
generally of stainless steel. HP heaters may be in service either individually or in group.

Stator cooling water system:

Generator (210 MW and above) stator winding is cooled by circulating DM water through
the hollow stator winding bars in a closed loop system. The circulating water is supplied
by one stator water pump with one as standby through cooler.
D.M. water before entering the windings is passed through magnetic filter to trap ferro-
magnetic (strong and average magnetic) particles, if any, flowing with water.

Hydrogen cooling System:

Hydrogen is used for cooling medium in large capacity Generator in view of its specific
gravity being only 1/14th of that of air, while its thermal conductivity is nearly seven times
higher. The lower specific gravity reduces the heat losses to be dissipated by decreasing the
windage loses of the coolant, which are always a problem with air cooled Generator. Thus,
the overall efficiency is considerably improved.
 TRANSFORMER
GENERATING TRANSFORMER (600MVA/ 21 KV/ 400 KV):

STATION TRANSFORMER (92 MVA/400 KV/11 KV)):

Station
Transformer is installed to provide power to the plant during generation is stopped. It takes
power from Grid and maintains supply to control the plant's operation.

UNIT TRANSFORMER (3phase/25 MVA/21 KV/11KV):

The Unit transformer is connected to the generator output by a tap off the Isolated Phase Bus
Duct. It has primary winding and two separate secondary at different voltages. This allows the
 station to have two different voltage levels one at 11kv and the other at 3.3 KV. The higher
voltage afforded by the 11KV windings allows for the use of similar higher voltage motors for
the large pumps or fans. The higher voltage motors offer several advantages over 3.3 KV
motors such as higher starting torques and lower full currents.
UNIT AUXILIARY TRANSFORMER (3phase/16MVA/11.5KV/3.3KV):
The unit auxiliary transformer steps down the 11 kv output from the Unit transformer to 3.3 kv
& changes the switch board to supply the various motors rated for the particular voltages. It is
also protected by medium voltage switch gear
DISTRIBUTION TRANSFORMER (3 PHASE /1000 KVA, 1600 KVA, 2000 KVA/ 11
Kv/ 415 Kv):
These transformers are used to provide 3 phase 415 v supply to low power rated motors and for
general lighting of the area & household supply, They can be of
1. Dry type
2. Oil cooled
Different Parts Of a Transformer

Radiator: The radiator of transformer accelerates the cooling rate of transformer As when transformer is in
the loaded condition, the hot oil comes up in the main tank, and enters into the radiator tank through upper
valve. As the heat transfer surface is quite large, the oil gets cooled and enters in the transformer tank via lower
value of radiator units,
 Breather:

When the temperature changes occur in transformer insulating oil, the oil expands or contrasts
and there an exchange of air also occurs when transformer is fully loaded. When transformer
gets cooled, the oil level goes down and air gets absorbed within. This process is called
BREATHING and the apparatus that pass through the air is called BREATHER. Actually the
breather is made up of Silica gel.

Conservator tank:
This is a cylindrical tank mounted on supporting structure on the roof of the roof of the
transformer's main tank. When transformer is loaded, the temperature of oil increases and
consequently the volume of oil in the transformer get increased. Again when ambient
temperature is increased, the volume of oil is also increased. The conservator tank of a
 transformer is increased, the volume of oil is also increased. The conservator tank of a
transformer provides adequate space for expansion of oil.
Buchholz Relay:
It is a safety device mounted on oil filled power transformers and reactors, equipped with an
external overhead oil reservoir called a conservator". The Buchholz relay is used as a protective
device sensitive to the effects of dielectric failure inside the equipment. If an electrical arc forms
,gas accumulation is rapid, and oil flows rapid into the conservator. This flow of oil operates a
switch attached to a vane located in the path of the moving oil. This switch normally will
operate a circuit breaker to isolate the apparatus before fault causes additional damage.
Bushing:
Transformers are connected to HV line and therefore. care is to be taken to prevent flashover
from high voltage connection to the earthed tank. Normal temperature of bushing is 60 to708 c.
Cooling System:
The different cooling schemes of transfer are oil forced air natural, oil forced air forced, and oil
natural air natural. Air is forced from two sides side forcing and bottom forcing In GT, the fans
are used in bottom and in UAT, the fans are in sides.
Meters: All the meters used are magnetically connected.
Lightning Arrester:
It is used to protect the transformer from the thunder strike. It is very low

resistance path; hence the thunder can easily get this path and pass to the ground. It is filled with
Zno. High frequency high voltage induces low resistance in Zno. So, it can conduct away the
surge.
 SWITCHYARD SECTION

400kV Switchyard, DSTPS, DVC, Andal

The switchyard is a junction connecting the Transmission &Distribution system to the power
plant.
Substation

An electrical substation is a subsidiary station of an electricity generation, transmission and

distribution system where voltage is transformed from high to low or the reverse using
transformers.
.
Bus bars are either flexible (swing) or rigid (pipe). Flexible bus bars are made of ACSR
conductors and are supported by disc insulator strings on both sides with the gantries. Rigid bus bars are made
up of Aluminium tubes and are supported on post insulators
 Andal Site :
Main bus : RigidType (4” dia Al tube)

Jack Bus : Flexible Type (ACSR Moose conductor).

The design of bus bar is done on the basis of the following points
1. The maximum amount of current to be carried.
2. Short circuit forces
3. Electrical clearances

Insulators
All the current carrying parts in a substation are supported on insulators. The insulators provide mechanical
support to the conductor sand are subject to normal operating voltage and transient over voltages. The
insulators should not fail due to mechanical load or over voltages. The insulators should have sufficient
mechanical strength to with stand the maximum wind loading, ice loading, dead load etc. and should not flash
over under any conditions of humidity, dirt, salt contaminates etc.,

Material used for Insulators :

1.Porcelain
2.Glass

Andal Site :
Tension String - Double String (2 x 30 nos.)
Suspension String- Single string (1 x 30 nos.)

Surge Arrestor/Lightning Arrestor

The surge arrestors are connected between phase and earth on the incoming side of the
transmission line. They are also connected between the transformer terminal and earth .The
function of surge arrester is to divert the lightning and switching overvoltage surges to earth
without causing drop in residual voltage. When the transient over voltage disappears, the normal
power frequency voltage and the normal healthy state is reached .A standard lightning impulse
wave is 1/50 micro seconds and a standard switching impulse wave is of 250/2500micro
seconds. Surge Arresters have two different types:-

1. Conventional Gapped Arrester having silicon-carbide resistor discs in series with the
spark gaps.
2. Metal Oxide (ZnO) Arrester having zinc-oxide discs and no gaps.
Surge Arrester used at Andal Site : Oblum make METOVER, Metal Oxide gapless type.
Isolator and Earth Switch

Isolators are disconnecting switches which are used for disconnecting of the circuit under no
load conditions,that is when no current is flowing through the circuit. An Isolator can be
opened only after opening the circuit breaker. An Isolator should be closed before closing the
circuit breaker. Circuit Breaker can make or break electric circuit under normal and fault
condition.

Isolators play an important role in substation maintenance. They are installed in such a way that
a part of substation circuit can be isolated from other live parts for the purpose of maintenance.

Earth Switch is connected between the line conductor and earth. Normally it is open. When
the line is disconnected, the earthing switch is closed so as to discharge the voltage trapped on
the line.
Though the line is disconnected, there is some voltage on the line to which the capacitance
between line and earth is charged. This voltage is significant in high voltage system.
Before proceeding with the maintenance work the voltage is discharged to earth, by closing the
earthing switch.

Circuit Breaker
Circuit Breakers are switching devices which open during fault conditions and interrupt the
short circuit currents automatically within few milliseconds.
 SF6 Circuit Breakers are now used universally for all EHV Applications.
Advantages of using SF6 Circuit breaker are :
1. Very short arcing time.
2. Can interrupt much larger currents.
3. Noiseless operation due to its closed gas circuit.
4. No moisture problem.
5. No risk of fire since SF6 gas is non-inflammable.
6. Low maintenance cost.
7. No carbon deposits so that tracking and insulation problems are eliminated.

Current Transforner
Current Transformers are used for reducing/stepping down ac current from higher value to
lower value for measurement / protection / control .The current transformer is used to measure
the very high current passing through the bus. It step downs the current and measurements are
taken in the control room the ratings of CT is based on the ampere .These CTs are connected to
the control room through cables.
CTs are either dead tank or live tank

Fig: Dead Tank CT

 Voltage Transformer
Voltage transformers are used for measurement and protection. The primary of of voltage
transformer is connected directly to power circuit between phase and ground .There are three
types of constructions :
1. Electromagnetic voltage transformer.
2. Capacitor Voltage Transformer.
3. Coupling Capacitor Voltage Transformer.

CVT consists of the capacitor voltage divider and Electro Magnetic unit. The primary voltage is
applied to a series capacitor group. The voltage across one of the capacitor is taken to auxiliary
voltage transformer. The secondary of the auxiliary voltage transformer is taken for
measurement and protection.
 Battery Room :
The storage batteries are installed in a special room. The
battery room should have adequate ventilation and
lighting. The floors and walls should have acid resistance
tiles. The battery cells are placed on racks.

Protection, Control and Automation in Substation

The following functions of protection, control,
monitoring and operation are performed by the devices in
thecontrol room automatically or semi-automatically :
1. Control
2. Monitoring
3. Protection
4. SCADA

The relay and control panels are located mainly in the

control room of the substation building from where it is
possible to supervise and monitor the substation. The control room is located at one end of the
substation area.

Protective system in a substation comprises the followings :

1. Protection of high voltage incoming and outgoing lines
2. Protection of bus bars.
3. Protection of Power Transformers.
The protective relays are mounted on the protection panes housed in the control room. The
protective relay coils or measuring circuits are connected to the secondary circuits of current
transformers and voltage transformers in the main switchyard. The control cables run between
the control room and the switchyard. The abnormal conditions such as short circuits in the
protected zone results in increase in current in the primary circuit of the CT. Thereby the
secondary current also increases and the actuating current of the relay increases. If the actuating
current is above threshold value, the relay acts and trips the circuit breaker.

The primary control in substation is of two categories :

1. Normal routine operation by operators command
2. Automatic operation by action of protective relays and control system.

The tasks of control system in a substation include data collection, event reporting and
recording, voltage control, power control, frequency control etc. The tasks of protective system
include sensing abnormal condition, annunciation of abnormal condition , alarm, automatic
tripping, back up protection, protective signaling etc.
The two systems work in close co-operation.
 CONCLUSION
Thermal Power Engineering is a very demanding at this point of time. Initial investments to
build a thermal plant are low compared to other power plants. So about 73% of electricity
generated in India is coming from coal based thermal power unit. In this 2 weeks of industrial
training in DSTPS, Andal, we ve’ gathered a lot of information regarding machines, type of work
etc. This report is mainly based on DSTPS Andal. All data and specification are gathered from
the plant.

BIBLIOGRAPHY
 Books- Electrical Machines by P.S Bimbra
 Engineering Thermodynamics By P.K Nag
 Notes taken at classes during training period.
 Photos taken by us inside the plant
 Google.com