A TRAINING REPORT ON PRACTICAL TRAINING TAKEN AT

KOTA SUPER THERMAL POWER STATION KOTA

From: 16-07-08 to 30-08-08

Session: 2008-2009

Submitted to: Mr. Ram Singh Chowdhary (Seminar Coordinator)

Submitted By: Gaurav sharma (IV BE Electrical Engg.)

DEPARTMENT OF ELECTRICAL ENGINEERING,

JAIPUR ENGINEERING COLLEGE AND RESEARCH CENTRE, TONK ROAD, SITAPURA,
JAIPUR- 303905

CONTENTS
SERIAL NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 Introduction Coal handling plant Mills Boilers & its auxiliaries Cooling system Excitation system Transformer Auxiliary system Protection Relays Water clarification cum filteration plant Electrostatic precipitator Control & instrumentation Control room

TOPIC
1 3 5 6 12 13 16 23 27 29 34 38 40 43

PAGE NO.

1. INTRODUCTION

INTRODUCTION
The KOTA SUPER THERMAL POWER STATION is ideally located on the left bank of Chambal River at the upstream of KOTA BARRAGE. Thermal power station to produce electrical power for supply undertakings K.S.T.P.S. is designed for ultimate capacity of 1045 MW. First two unit of 110MW each, another three units of 210MW each and further the sixth unit of 195MW has been completed. The state Rajasthan is predominantly rural and agricultural .While Rajasthan mineral sources are immense, its sources for power generation werent commensurable with its requirements. The large expense of water, stored by the barrage provides, as efficient direct circulation cooling system for the power station thus avoiding installation of cooling towers. For bringing in coal for power station and machinery and equipment etc. a 15Km long private siding from the Gurla Railway Station on Delhi-Bombay broad gauge line has been laid-up to the power station. Keeping in view the higher demands of power, it was decided to house initially a 2 x 200 MW thermal power station at Kota on techno-economical reasons as follows Availability of clean water required for station. Location of station on Broad gauge main railway line. Proximity to Madhya Pradesh Coal fields. Concentration of load in Kota region due to large No. of industries located. The coal linkage for the power station is brought from Dudhichua mines of Singrauli coal field which is about 800 km from Kota. The source of Water (cooling for the P.S.) is the reservoir formed by Kota Barrage on the Chambal River. The water is drawn from this reservoir and after use released near the left main canal of the barrage. The comparative use of water from barrage by the P.S. is 2.75 cusec for each 110 MW unit. A single chimney of 180 Meters height with two separate flues for the two units each of 110 MW is provided. Similarly another chimney with three separate flues is also provided for another three units of 210 MW each. The disposal for fifth unit till now is also through the second chimney.

For Thermal power station the other advantage for choosing Kota are: Availability of station amount of clean cooling water required for the station. Location of station on broad gauge main Delhi- Bombay Railway line. Concentration of load in Kota city and Kota region. Constant power supply. Proximity to M.P. coal fields. Transmission and Grid substation quite nearer to the site.

INSTALLATION AND COMMISSIONING OF UNITS:Construction work for stage-I started in 1977 and first unit of 110 MW was commissioned on 17th Jan. 1983.The second 110 MW unit was firstly synchronized in July 1983. The second stage units are synchronized in 1989. The second unit of second stage was commissioned in Oct. 1989. After that unit of 210 Mw was started in April 11, 1984. The commencement of unit VI, in Stage IV started in July, 2001 and the synchronization of the unit was done in July, 2003.

Thus the units in K.S.T.P.S. are as: Stage I - (Two units each of 110 MW) Stage II- (Two units each of 210 MW) Stage III- (one unit of 210 MW) Stage IV- (one unit of 195 MW)

NEED FOR POWER STATION:Rajasthan is the largest state in the country. About 30% population lives in villages which are local point of development while Rajasthan mineral resources are immense. But its resources for power station generation not upto requirements.Moreover the state government has drawn up a rural electrification program with a large demand on agricultural load with rapid adoption & modern method of agricultural and industrialization of towns. The mode of living of people in rural and urban areas is changing rapidly with requirement of more power. The hydro potential available on the Chambal has already has nested fully by the construction of Gandhi Sagar Dam, Rana Pratap Sagar Dam, Jawahar Sagar Hydro P.S. It is because lack of adequate resources for power development that a Nuclear Power Plant has been established at Rana Pratap Sagar Dam for meeting the anticipated demands of Rajasthan. The feasibility report for K.S.T.P.S. was prepared by central Electrical authority, in April 73, envisaged an installed Capacity of 2 x 210 MW units and 1 x 200 MW units. The planning commission declared the project in Sep 76 for installation of 2 x 110 units at estimated cost of Rs. 8160 Lakhs. In Aug. 77 M/C Design (New Delhi) Pvt. Ltd., were appointed as consultants for carrying out designing and detailed Engineering of project. Land measuring 235.5 Hct. was required for the project in 1976-77 for disposal of the ash; a tank very near to power station measuring 157.26 Hct has been acquired, where ash in slurry form is disposed through ash disposal pipe lines. Rajasthan State Electricity Board (RSEB)completed the construction which is done by Raj. Bridge construction corporation (RBCC) and other auxiliaries are supplied by Bharat Heavy Electrical Limited (BHEL) & Instrumentation Limited (IL), Kota.

ENERGY GENERATED IN KSTPS

Total generation Capacity = (2 x 210+2 x 210+1 x 210+ 1 x 195) = 1045MW Total generated Electricity (in one hour) = 1045MW x 1=10.45Lakh units Total generated Electricity (in 24hours) = 10.45 x 24= 250.8 Lakhs units Amount of Coal required (per day) in KTPS is = 0.5 x 250.8 x 100000 Kg. = 125.4 x 100000Kg. = 125.4 million Kg. This amount of coal is supplied by 5 trains of coal.

2. GENERATOR

GENERATOR
Generator is the main part of thermal power station or any power plant. A generator is a machine which converts mechanical energy into electrical energy. The generator has gas cooling construction enclosing the stator winding, core and hydrogen coolers .The cooling medium hydrogen is contained within the frame and circulation by fans mounted on either ends of the rotor .The generator is driven by directly coupled steam turbine at a speed of 3000 rpm. Provision has been made for circulating the cooling water in order to maintain a constant temperature of the coolant i.e. H2 as measured at the fan section side which is in touch with the temperature of the winding, core and other parts as per load. Each of the 2 units under stage-1 have been provided with BHEL make 3-phase turbo generator rated 137.5 MVA, 11KV, 0.8 pf, 7220 Amp, 3000 rpm and 50 cycles/sec .The generator has closed loop of hydrogen gas system for cooling of the stator and rotor at a pressure of 2.0 atm. is filled in a gas tight outer casing of the generator. H2 gas circulates inside the casing by two single stage rotor mounted fans on either side of the rotor .The heated H2 is in turn cooled by six surface type water coolers axially mounted inside the generator casing .The cooling water is supplied to H 2 coolers from the BCW over head tank. Each generator has terminal led out of its casing and a star point is formed by sorting the neutral side terminals by a sorting bar. The neutral is grounded by a 1-phase 11000/220V, 37.5 KVA. Neutral grounding transformer, whose secondary coil is laminated by laminated strip with mechanical ventilating holes, is connected across a 650V, class 0.4 ohm, 50 kW neutral grounding resistors and relays for protection of generator against stator earth faults and stator in turn faults (rating 1 amp). The H2 gas inside the generator casing is prevented from leaking in between the rotor and shields, by a continuous oil film maintained between the rotor and sealing rings .The shaft sealing system have two independent oil sources associated pumps, regulators, coolers filters, electrical controls and alarm system. Two independent oil sources are provided for air side and H 2 side sealing rings. The oil circuit of the H2 side of the shaft seal is closed and the oil is vacuum treated.

TURBO GENERATOR SPECIFICATIONS:(a) STAGE I Make Manufacturer Type Apparent Output Active Output Power factor Rated voltage Rated current Rated speed Frequency Russian BHEL T.G.P. 137.5MVA 110 MW 0.8 lagging 11 KV 7200 Amp. 3000 rpm 50 Hz

Phase connections No. of generator terminals Max. Output with air cooling 230V (b) STAGE II & III

Double gen. star 6 68.75MVA Excitation voltage

Make Manufacturer Rated capacity Rated Output Rated current Rated terminal voltage Rated speed Power factor Excitation voltage Phase sequence Insulation class No. of turns per phase/pole Short circuit ratio

KWVC Craftworks,Germany BHEL 247 MVA 210 MW 9050 Amp. 15.75 KV 3000 rpm 0.8 lagging 310V Double star B 10 0.49

(c)

STAGE IV Make Manufacturer Rated Capacity Rated Output Rated Current Rated Terminal Voltage Rated Speed Power Factor Excitation Voltage Phase Sequence Insulation Class No. of Turns per Phase/Pole Short Circuit Ratio KWVC Craftworks,German BHEL 247 MVA 210 MW 9050 Amp. 15.75 KV 3000 Rpm 0.8 Lagging 310 V Double Star B 10 0.49

DESCRIPTION OF THE GENERATOR PARTS:-

1. STATOR BODY:Armature of a generator formed of laminations having slots on its inner periphery to accommodate armature conductors and is known as stator .The stator body is a totally enclosed gas tight fabricated structure suitably internally to rigidity .It is designed mechanically to withstand internal pressure and forces as an event of unlikely event of explosion of hydrogen & oil mixture withstand pressure .The function of stator frame is to contain and support the stator core winding , hydrogen coolers and also path for distribution of cooling hydrogen through the generator . 2. STATOR CORE:The rotating magnetic field flow with the core .In order to reduce the magnetizing (eddy) current losses in the active portion of the stator core due to rotation of field structure in between the stator the entire core is built up of thin laminations .The segments are stamped out from CRGO .The core contain several pockets separated by steel spaces for radial cooling of the core by hydrogen. 3. STATOR WINDING:The stator has 3 phase double layer, short pitched and bar type of winding having two parallel paths .Each slot accommodates two bars .The lower and upper bars are displaced from each other by one winding pitch and connected at their ends so as to form coil groups .Each bar consists of solid as well as hollow conductors with cooling water passing through the later alternator. Arrangement of hollow and solid conductors ensures an optimum solution for increasing current and losses. The high voltage insulation is provided by thermo setting insulator using Mica paper type (Resin Rich). 4. DISTILLATE HEADER:Ring type header, made up of copper are provided separately for distillated inlet and outlet min the stator of turbine side .The headers are support on insulator and insulated from stator body .At turbine side each individual bar is connected with inlet/outlet header .The vent pipe connection are at the top of the both inlet and outlet header .The vent pipes are connected to gas trap desire to measure the extent of hydrogen leakage into water circuit. 5. TERMINAL BUSHING:Three phases and six neutral terminals are brought out from the stator through bushings which are capable of withstanding high voltage and provided with gas tight joints .The bushing is assembled and tested for flow, leakage to ensure tightness and continuous flow of water. 6. END SHIELD:To make the stator body air tight the end shield are fitted .Gas tightness is achieved by putting a rubber sealing cord .The end shields are made3 in two halves convenience during erection and installation. 7. ROTOR:The field structure is the largest & heaviest component of generator and is called the rotor. The rotor houses the static excitation winding and the exciting current is supplied to the rotor through the slip rings & brushes. The rotor shaft is a single piece forging the longitudinal slot for inserting the field winding. The slots are distributed over the circumference so that two field solid poles are obtained .After completion of rotor assembly the rotor is balanced at different speeds in various planes and then to an over speed test at 120% of rated speed for 2-minutes .The rotor conductor is of

silver bearing copper. The field copper current is supplied to the rotor wdg. , through two semiconductor copper bars arranged in hollow bars of rotor through radial current carrying bolts. 8. BEARINGS:The generator bearings are of pedestal type with spherical seating. It allows self alignment and is supported on a separate pedestal on slip ring side. The bearing has a provision of hydraulic shaft lifting during start up and turning gear operation to eliminate shaft current. Shaft bearing and its pipes are insulated from earth. The current carrying gear assembly is rigidly fixed on the extent part of the bearing pedestal on the exciter side. There are two brushes gear stand for (+) ive and (-) ive supply. The field to stator wdg. Provide the brush gear. The brushes are spring loaded to maintain required contact pressure of 0.2 kg/sq.cm and the brush pressure can be adjusted individually. The designs of brushes during normal operation condition have low coefficient of friction and are self lubricating. 10. STATIC EXCITATION SYSTEM The static excitation systems mainly consist of the following: A rectifier transformer 6 Nos. Thyristor converters An Automatic Voltage Regulator Field Suppression Equipment Field Flashing Equipment In the static excitation system power required for excitation of generator is tapped from 11 kV bus ducted through after a rectification in Thyristor converters the dc power is fed to the generators field winding through a field breaker. The AVR controls the o/p from Thyristor converters by adjusting the firing angle depending upon the generator voltage. The field flashing circuits facilitates initial build up of generator voltage from the station ac or dc supply. A RECTIFIER TRANSFORMER:This transformer steps down the generated voltage from 11KV to 640V & has a rating of 1360kVA.It is a dry type naturally cooled transformer with resin cast coils. THYRISTOR CONVERTERS:The Thyristor converters are housed in a thysert panel & are connected in parallel and they take ac into power supply from the secondary winding of rectifier transformer and feed the rectified o/p to the field winding of the generator through a field breaker. Each Thyristor converter is rated for a continuous current o/p of 1/5 th of the rated capacity of the generator. Thus 20% of rated capacity will always be available to meet the emergency. Each Thyristor converter consists of 6 in no. Thyristor connected in 3 phase full wave six pulse bridge form & they are cooled by fans. AUTOMATIC VOLTAGE REGULATOR(AVR):It is transistorized Thyristor controlled equipment with very fast response. It has two channels auto & manual. Auto channel has closed loop regulation while manual has open loop regulation. FIELD SUPPRESSION EQUIPMENT:They consist of the field breaker with a discharge resistor. It has 4 main breaking contacts & 2 discharge contacts which close before the main contact breaks.

BRUSH GEAR:-

 FIELD FLASHING EQUIPMENT:For initial build up of generated voltage, a field flashing circuit with a power transformer (415V/42V, 4kVA) and a rectifier (full wave bridge type construction) is provided. Field flashing circuits take power from station. 220V dc system is also provided for building up generated voltage in case of ac auxiliary power supply is not available.

3. TRANSFORMER

TRANSFORMER
Transformer is made up of following parts:1. Core 2. Winding 3. On load tap changer 4. Tank 5. Bushing 6. Auxiliary equipment 7. Insulating Oil 8. Cooling system An on load tap changer is a device used for changing the tapping connection of winding suitable for operation while the transformer is energized on load .The tap changer is operated by a motor operated driving m/c by load or remote control and a handle is fined for manual operation in any emergency. Tank bodies for transformer are made from rolled steel plates which are fabricated to form the container. In KSTPS there are various transformers for various purposes. They are:1. Generating Transformer 2. Unit auxiliary Transformer 3. Station Transformer 4. Instrument Transformer 5. Capacitor voltage Transformer 1. GENERATING TRANSFORMER:In KSTPS, there is one generating transformer for each unit of it. There rating are different depend upon capacity of each unit. The generated electricity from main generator is being feed into transformer, so it is known as generating transformer. It is three phase power transformer. This converts generated electrical power of low voltage into high voltage for better transmission purpose .It is also known as main transformer. There is a provision of movement of transformer on rail in the power station premises during erection and for repair and maintenance.

SPECIFICATIONS:Unit 1 & 2:Manufacture No. /unit Type of construction No. of phases Type of connections No. of Taps Rating Type of winding

BHEL One Core type 3 HV star, LV delta 9 125 MVA, 11/240 KV HV Shielded multilayer LV helical

Type of cooling Rated data On load losses Maximum efficiency Oil Temp. Rise Core lamination material Core to LV wdg. HV to LV wdg. Insulation Vol. of Air for initial Unit 3,4,5 &6:Manufacture No. /unit Rating Bushing voltage Transformer Ratio Type of cooling Rating Percentage impedance Winding Temp. Rise Line Current

ON/OB/OFB ON cooling 62500KVA OB cooling 87500KVA OFB cooling 125000KVA 78KW 99.72 40oC Cargo sheet steel Insulation Bakelite Paper, press board 5750 Lt. BHEL One 250 MVA 240KV 15.75/220KV ON/OF/AF OF Cooling 250MVA AF Cooling 175MVA ON Cooling 125MVA 14% 50oC HV 602.12A LV 9175.15A

Marshalling Box:In every electrical equipment, there is an arrangement of signal in case of overloading, temp. Rise above permissible range, short ckt. Etc. In Xmer there is also some arrangement. The limiting temp. as follows: 1. Oil temp. Indicator:Signal temp. Setting Alarm Trip 2. Winding temp. Indicator:Fan on Pump on Alarm Trip 95oC 100oC 85oC 95oC 115oC 125oC

2. UNIT AUXILLIARY TRANSFORMER:Power required for all units auxiliary are met by UAT, one for each unit and there are

five units, so five UATs are for five units. This transformer normally needs the power requirement for all units auxiliary when the unit is synchronies with the grid and has become stable. It works when load is 40% or more. UAT gets power by tapping from bus bars of primary wdg. Of generating transformer. It's primary winding are connected to 11KV bus and secondary are connected to 6.6KV switch gear. UAT is provided with over load tap changer on high voltage side which permits variation of voltage up to 10% in 16 steps connected to UAT1 & UAT2 6.6KV bus duct. Its primary is Delta connected & secondary is Star connected. In addition of these, this Xmer can take the load of C.H.P, D.M. plant, E.S.P. & hydrogen unit. SPECIFICATIONS:Unit 1 & 2:Manufacture Type Type of cooling Rating Rated Primary Voltage Rated Secondary voltage Phases Rated Current Frequency Impedance ratio Oil Temp. Rise Winding Temp. Rise Core & Winding weight Weight of Oil Oil quantity Unit 3 & 4:Manufacture Type Type of cooling Turns Ratio Oil Temp. Rise Winding Temp. Rise Phases Rated Current Frequency Connection symbol Customer

BHEL Oil filled natural cooled step down transformer ON/AN 15 MVA 11 KV 6.6 KV 3 HV-787 A, LV-1237A 50 Hz 7% 40oC 50oC 18320 Kg 8220 Kg 9670 liters BHEL Oil filled natural cooled step down transformer ON/AN 15.75 KV/ 7 KV 40oC 50oC 3 HV-550.51A, LV-1238.65A 50 Hz Dd R.S.E.B

3. STATION TRANSFORMER:The power requirement of the unit auxiliaries during unit start up or shut down and of all auxiliaries is met by two stations transformer of Crompton Greaves make. The station transformer is rated for 50 /25/ 25MVA, 220/7/7MVA, Yd1d1 and is provided with an on load tap changer on HV winding. This permits a voltage variation of up to 10% in 16 equal steps of 1.25% each. SPECIFICATIONS:-

Manufactured Total no. provided Type of construction Type of cooling Rated output Rated voltage at no load Frequency Oil Temp. Rise Winding Temp. Rise Type of HV winding Type of LV winding Type of main contact

Crompton Greaves Ltd,Bombay 2 Core type with three limbs ON/AN,ON/AF ON/AF 50/25/25 MVA ON/AN 36/18/18 MVA HV side 220 KV LV side 7KV 50 Hz 40oC 50oC Disc Helical Plug & socket

4. INSTRUMENT TRANSFORMER:In KSTPS instrument transformer have wide range in application such as measurement of voltage, current, power & energy power factor, frequency. It is also used for protection circuit of the power system for operation of over current, under voltage, earth fault and other type of relays. In all above applications the transformer is put for measurement purpose in low voltage conversion. The actual measurement is being done by measuring instrument. According to measuring purpose instrument transformer can be classified as (a). Current Transformer (b). Potential Transformer (a). Current Transformer:Current transformer is used for monitoring the current for the purpose of measuring and protection. They can be classified as Dead tank & Inverter type. The dead tank current transformer accommodate the secondary cores inside the tank which is at ground potential. The insulated primary passes through the porcelains and the tank and the terminals into the top chamber. The primary used in such type of construction is of U type. The inserted secondary cores are insulated to the system voltage and hence inside the top chamber which is at the line potential. Before commissioning of the current transformer, the earthing of the power terminal and the base is essential otherwise excessive high voltage appears at the power factor terminals and leads to heavy spark. The sec. terminal of the core should be short circuited and earthed which are not in use otherwise excessive high voltage will be developing across the current transformer sec. The C.T. should always be in vertical position so that gas forming at the top does not enter the insulated parts. The C.T. actually step downs the current so that it can be measured by standard instrument. There are 3 C.T. in each feeder. The C.T. is inserted into energy incoming and outgoing feeder from 220 KV systems for measurement and protection purpose. The 220 KV C.T. are oil filled nitrogen sealed BHEL made out door type.

SPECIFICATIONS:Type Rated voltage

Outdoor oil filled Nominal 220KV Maximum 243KV

Class of insulation Quantity of oil required Weight

A 300 liters Without oil 772 Kg With oil 1030 Kg

(b). Potential Transformer:The function of P.T. is to step down the voltage so that it can be measured by standard measurement. In three phases P.T. there is 3&5 limbs core construction. The P.T. may be dry or oil field. The P.T. above 66KV is essentially sealed with inert gas cushion provided in the top chamber to take care of expansion & construction. The transformer is generally core type and form Y-Y group and having the insulation as oil and paper. Every P.T. is connected to phase hence there may be 3 P.T.s and connected to the same bus bar coming to same meter mounted on a panel through a selector switch which can be used to measure different line voltages. As the voltage of the feeders connected to same bus bar and same voltage and we do not use separate P.T. for each feeder. The P.T. installed are single phase type oil filled nitrogen sealed electromagnetic type. Each 220KV P.T. has two windings on secondary side and is rated for 220 KV. We use two winding to reduce load on the side winding making maintenance easy and making transformer not so bulky in nature. One is used for metering and the other is used for protection. SPECIFICATIONS:Type Outdoor oil filled Rated voltage Nominal 220KV/110KV Maximum 245KV/110KV Class of insulation A Quantity of oil required 298 liters Weight Without oil 1183 tons With oil 1437 tons

5. CAPACITOR VOLTAGE TRANSFORMER:Each of the four line feeders are provided with three capacitor voltage transformer for metering and synchronizing. SPECIFICATIONS:Manufacture Type Rated voltage No. of phases Rated primary voltage Rated secondary voltage

W.S. Insulators of India Ltd.,Madras CVE 245/1050 Nominal 220KV Maximum 245KV 1 220/sqrt 3 KV 110/ sqrt 3 KV

SWITCH YARD

SWITCH YARD

The 220KV switch yard has conventional two buses arrangement with a bus coupled breaker. Both the generator transformer and line feeder taking off from switch yard can be taken to any of the two buses, similarly two station transformer con be fed from any two buses. Each of these line feeders has been provided with by pass isolators connected across line isolators and breaker isolators to facilitate the maintenance of line breaker. Each 220KV line has provision of local break up protection. In event of breaker which corresponding to bus bar differential protection scheme and trips out all the breakers and connected zone bus bars differential protection scheme for bus I & II. All the breaker of the connected zone and bus coupler, breaker will trip in event of fault in that zone. Each of the two bus bars has one P.T. one for each phase connected to it. Potential Transformer are make in BHEL oil filled, nitrogen sealed have two core rated for 220KV /110KV. One cores each for metering & protection. Each time line feeders has three nos. Core for each phase capacitor voltage Trans. for metering and protection are multicored single phase, oil filled, nitrogen sealed and are provided at rate of one per phase. A described of electrical equipment at 220KV system are as follows: 1. Circuit Breaker(MOCB & SF6) 2. Isolators 3. Current Transformers(C.T.) 4. Potential Transformers(P.T.) 5. Lighting Arresters 6. Earthing Arresters 7. Capacitor Voltage Transformers(C.V.T.)

CIRCUIT BREAKER:A circuit Breaker is a piece of Equipment which can:1. Make or break a circuit either manually or by remote control under normal conditions. 2. Break a circuit automatically under fault condition. MOCB provided for each stage are BHEL made and rated for 245KV, 2500A , 134MVA. Each pole has three interrupters which are oil filled with nitrogen gas at 7.5 Kg/sq. cm. The three pole of MOCB are designed for single phase individual operation of any pole. Breaker operate can be done only from respective pole operating mechanism by putting selector switch on local. And now a days SF6 Circuit Breakers are also used.

Interlock Scheme of Circuit Breaker: 1. Generator Breaker 2. Station Transformer Breaker 3. Line Feeder Breaker 4. Bus Coupler Breaker Breakers are used to break the circuit either in load condition or in the no load condition.

220 KV MOCB SPECIFICATIONS:Make Type Voltage Frequency Mass of Current Breaker (with oil) Normal Current Gas Pressure Melting Current Tripping Coil Closing Coil Operating Mechanism Type

BHEL, Hyderabad HLR 245 / 250 2E 245 KV 50 Hz 3720 Kg. 2500 Amp. 0.3 to 0.7 KG. / Sq. cm. 100 K Amp. DC 220 V DC 220 V BLG-3520

ISOLATERS:It is essentially a knife switch and is designed to open a circuit under no load. Its main purpose is to isolate one portion of the circuit from the other and is not intended to be opened while current is flowing in the line. Such switches are generally used on both sides of circuit breakers in order that repairs and replacement of circuit breakers can be made without any danger. They should never be opened until the circuit breaker in the same circuit has been opened and should always be closed before the circuit breaker is closed. LIGHTENING ARRESTER:An electric discharge between cloud and earth, between clouds or between the charge of the same cloud is known is as Lightening. A Lightening Arrester or a surge diverter is a protective device which conducts the high voltage surges on the power system to the ground. For protection against each of the line feeder, Generator Transformer and Station Transformer have been provided with three lightening arresters, which are outdoor type and are rated for 198 KV. The lightening arresters of the line feeders are located in the switch yard and those of GTs and STs are located near respective Transformers.

SPECIFICATIONS OF LIGHTENING ARRESTER:Type Maximum Voltage Maximum Current No. of Units CPC-II 198 KV / unit 10KA 6

EARTHING ISOLATORS:The term Earthing means connecting of the non-current carrying parts of the electrical equipment or the neutral point of the supply system to the general mass of earth in such a manner that all times an immediate discharge of electrical energy takes place without danger. An Earthing isolator is a large value of capacitance. This can be charged up to line voltage. Earthing isolator is used to discharge the line capacitance and work on it.

SWITCH GEAR

SWITCH GEAR
The apparatus used for switching, controlling and protecting the electrical circuits and equipment is known as switchgear. A switch gear is one which makes or breaks electric circuit. Numerous problems arise in erection, testing and commissioning of switch gear and various precautions are to be made in operating and maintenance of switch gear. Essential Features of Switch Gear:1. Complete Reliability 2. Absolutely certain discrimination 3. Quick operation 4. Provision for manual control 5. provision for instruments The Switch Gears used at KSTPS are indoor types. The main components of indoor switchgear are given below:1. Bus-Bars 2. Isolating Switches 3. Current Transformers 4. Potential Transformers 5. Circuit Breaker 6. Earthing arrangement 7. Relays 8. Inter-Locking arrangements

BUS-BARS:Bus bars are defined as the conductors to which several incoming and outgoing lines are connected. They are essential component of Switchgear. They are made up of Cu. and Al. The type and designers of Switchgear depends upon rated normal current and short circuit capacity. The Bus bars are enclosed in bus bar chamber. The bus bar of neighboring link units is connected by Al links. The incoming and outgoing cables are provided for metering purposes. The C.T. normally of ring type is fitted on insulated primary. The insulation is provided by cast resin fittings. In KTPS there are two types of indoor type switch gear: 1. 6.6 KV or High tension 2. 415 KV or Low tension

ISOLATING SWITCHING:1. They are capable ofa. Interrupting the Transformer Magnetizing Current. b. Interrupting line charging Current. c. Interrupting load Transformer Switching. 2. The main application is in connection with feed or bank Transformer feeders & there units make it possible to switch out one Transformer while the other is still on load.

CIRCUIT BREAKER:They are capable of breaking the circuit on faults. It is heavy duty equipment mainly utilized for protection of various circuit and separation of loads. The Circuit Breaker uses on a relay or by manual signal. The Circuit Breakers which are used in Switchgear are MOCB type.

EARTHED SWITCHES:-

Earthed switch is connected between line conductor and earth. Normally it is open when line is disconnected. The Earthing switched is closed so as to discharge the voltage trapped on line for high voltage and so the capacitor between line and earth is charged to high voltage. For maintenance work their voltage are discharged to earth by closing the earth switch.

INTER-LOCKING:The following type of inter- locking are provided 1. The Circuit Breaker must be in open position before it is lowered in this position. 2. The Circuit Breaker can be closed only raising the final plug in position. 3. The Circuit Breaker can be closed before raising plug in position. 4. Inter-locking between isolators, Earthing switches and Circuit Breakers are provided.

RELAYS:A Protective Relay is a device that detects the fault and initiates the operation of the circuit breaker to isolate the defective element from the rest of the system. Fundamental required of protective Relaying:1. Selectivity 2. Speed 3. Sensitivity 4. Reliability 5. Simplicity 6. Economy

PROTECTION

PROTECTION

The fault, which may occur in stator winding are1. Phase to phase fault. 2. Phase to ground fault. 3. Short circuit between lines. 4. Over heating. These faults are due to1. Over voltage is because of system transients, lightening switching surges or sudden loss of load. 2. Insulation deterioration due to any matter, moisture, corona discharge, Hardening of solid and vibration. It is very necessary to minimize the tripping time during any fault so that the lamination is not damaged. The repairing being affected by replacing the faulty stator bar. A delayed clearance may damage the lamination, so fire may be caused and partial reinsulation of core may be necessary.

PROTECTION OF ROTOR:Fault which may occur in the rotor winding are1. First rotor fault. 2. Second rotor fault. 3. Inter turn fault. Alternator is not earthed therefore a single earth fault is not itself dangerous. However its present increase the change of further more fault, due to increase of stress between earth and other parts of the winding. When rotor voltage are induced by stator transient. A stator earth fault may result in part of rotor winding being short circuit and may cause serious and permanent damage. The magnetic unbalance consequence can produce serious vibration and distortion of rotor shaft. So for the protection there is alarm in case of frost rotor fault. After first rotor fault, monitoring instrument is provided to trip the unit in case of second rotor earth fault.

GENERATOR PROTECTION:The Generator is required to be tripped or isolated on following types of fault: 1. Failure of generating insulation. 2. Failure of prime mover turbine or boiler. 3. Failure of generating auxiliaries such as hydrogen gas system, seal oil system, cooling system, and cooling water system. 4. Failure of grid. The tripping command to the GT breaker is given by master trip relay 866, 86GT, and 86GB. To make it feasible the master trip relay is connected to a common bus. All the protection relays are connected in between the position of 220V.

D.C. PROTECTION AND THIS COMMON BUS:-

Protection device are that detect abnormal condition in electrical circuit by measuring the electrical quantity which are different under normal and fault condition. The basic electrical quantities are voltage, current, phase angle and frequency. The relay doesnt operate for normal voltage, normal current, normal phase angle and normal frequency. Different type of protection can be listed as: 1. Current operated protection. 2. Different protection. 3. Voltage operated protection. 4. Impedance type protection. 5. Frequency type protection.

1. CURRENT OPERATED PROTECTION:a. Generated differential protection. b. Generative negative sequence protection. c. Generator output current protection. d. Generator stator earth fault protection. e. Generator REF protection. f. Generator standby earth fault protection. g. UAT o/c protection. h. Generator o/c and short circuit protection. i. L.B.B. protection. j. Bus Bar protection. 2. DIFFERENTIAL PROTECTION:a. Generator overall differential protection. b. UAT differential protection.

3. VOLTAGE OPERATED PROTECTION:a. Generator over voltage protection. b. Generator stator E/F protection. c. GT over voltage protection. d. PTs voltage supervision protection. e. Generator inter-turn fault protection.

4. IMPEDANCE TYPE PROTECTION:a. Generator back up impedance protection. b. Generator loss of exact protection. c. Generator pole slip protection.

5. FREQUENCY TYPE PROTECTION:a. Generator under protection Frequency.

SEQUENTIAL EVENT RECORDER

In sequential event recorder information is formatted to aid the user /reader in quickly locating needed information at the desired level. It monitor the operational of equipment requires recording that provides an accurate detailed and permanent record of the function of all system

components. Particularly during start up and shut down of generating station or extensive switching operation in substations and process plant. An equipment failure or other distribution in plant usually results in the operation of relays, breakers and other equipment without adequate recording equipment, it is impossible to determine what happened first and the sequence of event that followed required for analysis management needs the complete history of events provided by the recorder for an explanation to higher authorities. SER/SOR/Digital event recorder etc. basic purpose is to sequentially record events that occur in a plant or process and print out each event with real time of its occurrence. It continuous scans the status of field, contacts sensing and remembering all changes and transmits any change along with its time of occurrence to printing device. SER has ability to record sequences of events occurring at intervals greater than one milli seconds. The SER fulfills the basic requirement of high speed recording as follows:(1) The equipment provide for monitoring the status of all function. (2) It must have ability to indicate the correct sequence and actual time of occurrence. (3) It is used to monitor the status of processing plants generating stations, power transmission substation. (4) The purpose is to detect the numerous and often rapidly occurring events in process operations and transmit this critical data to plant personnel.

CONTROL ROOM

CONTROL ROOM
Various measurements can be taken at the control room simultaneously. The second important part of the control room is relay part. Various relays are provided here. I.L. Kota provides the instruments for control rooms. There is one control room from which two adjacent units of 100 MW each can be controlled. In addition there are local panel at the boiler, turbine set and boiler feed pump. The operation of the unit is basically controlled from the unit control room. The operations from various vents and chains are doing not locally as per the requirement. The unit control room has a set of vertical panel for indicating or recording the parameters of boiler and turbine. The parameters which are recorded in the unit control board include pressure and temperature of line steam, reheated steam, feed water and fuel oil, drum level, flue gas, oxygen content, air flow mill, outlet temperature, turbine speed, control valve operation, back pressure in condenser, metal temperature etc. The control panel for generator datas and exciter synchronizing arrangement are also provided. Announcement facility is also available in the control room. The unit control room also houses most of electronic regulators, relays, recorders, and other devices in the rear side of the room. The room is provided with air conditioning arrangement. The scheme of control and instrumentation is designed to control the parameters and operation of equipment. Automatic control is provided for combustion for feed water regulators, super heaters, and reheaters etc. The ratio of steam flow is maintained automatically. The feed water regulation is based on impulse from drum level.

CONTROL ROOM PANELS:CP-I:-

1. FAN CONTROL DESK: a. ID Fan (Induced draft fan, 3 nos.) at full load. b. FD Fan (Forced draft fan, 2nos.) at full load. c. PA Fan (Primary air fan, 3 nos.) at full load. 2. PRESSURE CONTROL DESK: a. Furnace pressure (5-10mm.) b. Primary air header pressure (750-800mm.) 3. FO: a. Wind box pressure or wind box differential pressure. CP-II:1. FUEL CONTROL DESK:a. Coal oil flow. b. Oil pressure. c. Temperature of mill (inlet or outlet) d. Flow of air (54 tones per hour) e. Differential pressure of mill. CP-III:a. Drum level control.

b. Flow of steam and water. c. Pressure of steam and water. d. Temperature of steam and water. CP-IV:1. TURBINE DESK:a. Pressure control, load mode control. b. Speed control. c. Ejector, control valves, stops valves and deviators. CP-V:1. GENERATOR CONTROL PANEL:a. Voltage, current, MVAR. b. Stator, rotor temperature. c. For stator cooling. (i). Hydrogen pressure control. (ii). Water pressure control. In case of any defect or the unusual behavior of any of the equipment, the alarm rings and the light on the control panel indicates the problem. The plant or the unit trips if the problem is raised above the permissible range. The unit 1 and 2 (stage-1) control room has a panel to control the switchyard also.

AUXILIARY SUPPLY

AUXILIARY SUPPLY
Electrical supply system is the most important part of the thermal power station. The failure of even comparatively small equipment could result in the losing of load or being put out of commission. So reliability of the station can be no better then reliability of its auxiliary. Therefore it is essential that: 1. To use the most suitable equipment available. 2. To use the best and most reliable method of power supply to the auxiliary and other components. 3. To use simple layout with minimum no. of interconnections, and it gives reliability and flexibility. 4. SOURCE OF SUPPLY: 1. URGENT AUXILLARY: Those are associated with running of units whose loss would cause an immediate reduction unit output. SERVICE AUXILLARY: These are common auxiliaries associated with one or more units. There loss would not affect the output of the unit after considerable time of interval.

SELECTION OF SERVICE VOLTAGE: The selection of service voltage at which the large number of auxiliaries in a station to be supplied has to be made at very early stage in the design. Accordingly the rating of the unit service voltages is selected. These service voltages for different ratings are: (1)Above 210 MW There service voltage may be required 415V, 6.6KV and 11KV (2) Upon 210 MW two auxiliary voltages of 415V and 6.6KV are required.

ELECTRICAL AUXILLARY SYSTEM: The KSTPS auxiliaries are operated at two voltages that are 6.6KV and 415V. In respect of 6.6KV system, auto change over facility is provided for change over of source of supply from unit station in the case of unit trip out. The station is having the following auxiliary system: 1. Three phase, 6.6KV, 50 HZ. Underground system for motors rated above 170 KW. 2. Three phase, 4-Wire, 415V, 500HZ. Solidly grounded system for motor rated up to 170 KW. 3. Single phase, 240 V, 50 HZ. System for single phase motors, AC control circuits and space heaters for motors above 37.5 KW and all switch gear /MCC panels. 4. 220V D.C. underground system for use in control and protection system.

3- , 6.6 KV SYSTEM: For the running unit, the unit auxiliaries are normally fed from genr itself through 11/7 KV, 15 MVA unit auxiliary transformers, which is, connected to the unit switchgear viz. USA and

USB. Power to station auxiliaries and by unit auxiliary is fed from 220/7 KV, 50 MVA station transformers through two switchgear viz. 55-1A and 55-1B. Besides feeding the station and standby unit auxiliaries, the station switchgear play a vital role as a source of power supply to unit auxiliaries during start up and shut down. Connecting the 6.6 KV unit buses with station buses makes this provision. 55-1A bus feeds buses US1B and US2B. Each unit and switchgear bus is provided with a potential transformer. Separate 6.6kv switchgear has been provided for C.H.P. loads. It has two incomers. One from 55-1A and other from 55-1B. The 6.6 KV C.H.P. switchgear has a bus P.T. cubical comprising of three P.T.s are connected in Y-Y configuration with an output of 100 VA.

415 V SYSTEMS: For driving ten 100W motors and other accessories, we need 415V supply. For this purpose various transformer are used to step down 6.6 KV to 415V at various places. Oil circuit breaker is provided between 6.6 KV bus and primary winding of transformer. This system is three phase, 4-wire solidly grounded system is made available for 1000 KVA, 6.6 KV/ 433V transformer. All 415 circuit breakers are Air Circuit Breaker (A.C.B.). Separate switchgear for emergency purpose has been provided for metering the load requirements of all emergency purpose lubricating pumps (AC), emergency axillaries of the station that is turbine bearing gear, jacking oil pump etc. Standby source of power to emergency switchgear is provided by two auto-starting diesel generating set each rated for 3-, 415 V, 50 HZ., 250 KVA.

240 V SYSTEMS: -

Single - , 240 V, 50 HZ. System is provided for control circuits of contactors modular of all 415 V switchgear or MCC space heating of various switchgears and space heating of all motor above 37.5 KW rating. Each of modules with power contactor in 415 V switchgear is provided with a single-phase 240-isolating transformer for 240 V control panel (distribution load). Ten distribution boards are provided to supply various panels.

24 V SYSTEMS: Single - , 24 V, 50 HZ. Supply is used for winding heating of motors up to 37.5 KW. This is made available by one or more 1- 415 V/24 V, 4 KVA transformers. Three transformers are provided with 415 V switchgear/MCB.

220 KV SYSTEMS: Two 220 KV buses have been provided in switchyard and are inter connected through a bus coupler. Each of the 2X110 MW generators are connected to this system through a step up 125 MVA 240/11 KVYDI (10% taps of 2.5/. 5 taps of 8 n0.) generator. These are two-step down station transformer which feeds the two 6.6 KV station switchgear viz. 55-1A and 55-1B each station transformer has two winding on secondary side of 50/25/25 MVA. 220/7/7 KV YN did of 10 % 16 equal tapes of 1.25 % each 4 line feeders take-off from 220 KV switch yard, 2 of Sakatpura GSS and 2 of Heerapura (JPV) GSS.

220 V A.C. SYSTEMS: 1- 24 V, 50 cycles supply is used for winding heating of motors up to 37.5 MW. This is made available by 415V/24 V, 4KVA transformer provided for each 415 V switchgear /MCC. The control circuitry of the motors feeders up to 37.5 KW ensures that the winding heating supply in switch head off before the main power supply to motor is switched on.

220 V D.C. SYSTEMS: The station 220V D.C. system is used for control, interlocks, and protection indication and annunciation circuit of various equipments. In addition some critical unit and station auxiliary also operate on 220 V D.C. e.g. D.C. emergency oil pump for turbine lubrication D.C. SOP D.C. lightning etc. The station 220V D.C. system has two sections via A and B each connected to a battery bank and a float battery charger. One float cum boost battery charger has been provided for boost charging of exhausted battery bank and for acting as a stand by to both float chargers both section of D.C. system have bus coupler. 220 V D.C. super distribution cabinets have been provided that is two in control room and 2 in 6.6KV switch gear rooms. Each has two I/C from main 220V D.C. bus. Each battery bank comprising of 110 numbers 2V each lead died cells and has a capacity of 600 amps. Hour at 10-hour rate of discharge and electrolyte temp. Of 27.C. Each float charger is rated for 8.5 KW, 264V and 32 amperes and boost chargers is rated for 175 KW, 291 V and 60 amperes.

5. TURBINE

Turbine
Turbine is an m/c in which a shaft is rotated steadily by the impact of reaction of steam of working substance upon blades of a wheel. It converts the potential energy or heat energy of the working substance into mechanical energy. When working substance is steam it is called steamTurbine In the steam turbine the pressure of the steam is utilized to overcome external resistance and the dynamic action of the steam is negligibly small.

PRINICIPLE:Working of the steam turbine depends wholly upon the dynamic action of steam. the steam is caused to fall with pressure in a passage of nozzle, due to this fall in pressure, a whole amount of heat energy is converted into mechanical energy & steam is set moving with the reactor velocity. The rapidly moving particle of steam enter the moving part of turbine and here suffers a change in the direction of motion which gives rise to change of momentum and therefore to a force. This constitutes a driving force to a machine. The passage of the m/c through the moving part of the turbine commonly called the blade, may take place in such a manner that the pressure at the outlet sides of the blade is equal to that of the inlet side. Such a turbine is broadly termed as outlet turbine or Impulse Turbine. On the other hand, the pressure of the steam at outlet from the moving blade may be less than that at type inlet side of the blade. The drop of pressure suffered by the steam during its flow through the moving blades causes a further generation of kinetic energy within the blades and adds to the propelling force which is applied to the turbine rotor, such a turbine is broadly termed as Reaction Turbine. The majority of the steam turbine has therefore two important elements; these are:-

NOZZLE: - In which the steam expands from a high pressure and a state of comparative rest to the
lower pressure and a state of comparatively rapid motion.

BLADE: - In which the steam of turbine particle changes its direction and here its momentum
changes. The blades are attached to the stationary element of the m/c or rotor whereas in general the nozzles are attached to the stationary part of the turbine which is usually termed as stator casing.

DESCRIPITION: -

There are two turbines for 110MW generation and four turbines for 210MW generation in KSTPS. The 110 MW steam turbine is a three cylinder impulse reaction turbine, which once reheat

and 8 non regulated extractions for regeneration heating of feed water. The turbine offers high operational flexibility coupled with quick loading capacity. The three cylinder containers of turbine are high, medium/ intermediate and low pressure parts. There are two sets of stop and governing values assembled in series. The steam is exhausted out from the HP casing through both of the stop and governing valve seats. The steam is exhausted out from the HP casing and admitted to reheaters where it is reheated to original temp. The reheated steam is taken to the MP casing through combined stop and antercoupler valves arranged at either side of the casing. The exhaust from the MP casing is taken directly to the LP casing. The steam after expansion in the LP casing condensate in two condensers.

TURBINE SPECIFICATION: Rated output Economic output Rated speed Direction of rotation viewing front pedestal Maximum pressure of steam before the stop valve Maximum temperature of steam before the stop valve Maximum pressure of steam before MP Casing Maximum temperature of steam before MP Casing 110 MW 95 MW 3000 rpm. Clockwise 145atm. 5450C 35atm. 5450C

4.

BOLIER

Boiler
Water tube tangential firing with burner fitting pulverized coal fired natural circulation. Bhel made boiler
A boiler is an enclosed that provides a means for combustion heat to be transfer into water until it becomes heated water or steam. Its volume increases 1600 times. The process of heating a liquid until reaches its gaseous states its called evaporation. The boiler system comprises of 1. feed water system 2. steam system 3. Fuel system

1. Feed Water system:It provides water to the boiler and regulate feed according to demand.

2. Steam system:It collects and controls the steam produced in the boiler steam are directed through a piping system to a point of use. Steam pressure is regulated using valves and checked with pressure gauges.

3. Fuel system:Fuel system includes all equipments used to provide fuel to generate the necessary heat for higher boiler efficiency feed water is preheated by economizer using the waste heat in the flue gases.

ECONOMIZER:The purpose of the economizer is to preheat the boiler feed water before it is introduced into the steam drum, and to recover some of the heat from the flue gases leaving the boiler. The economizer is located in the boiler near gas pass below the rear horizontal super heater. Each section is composed of a number of parallel tube circuits. All tube circuits originate from the inlet header and discharge into the outlet header and economizer header tubes. Feed water is supplied to the economizer inlet header via the feed stop and check valves. The feed water flows upward through the economizer i.e. in counter flow to the hot flue gases from the outlet header the feed water is laid to the drum via the economizer outlet links.

SUPER HEATER:1. 2. 3. 4. 5. 1. Pendant Section:2. Platen Section:The super heater is composed of 5 basic stages of sections: Pendant Section Platen Section Rear Horizon Section Steam Cooled Wall Roof Section It is located directly behind the screen tubes. It absorbs heat by convection.

It is located directly above the furnace in front of the furnace or arcs. It absorbs heat mainly by radiation.

3. Rear Horizon Section:It is located in the rear vertical gas pass above the economizer. It is the primary super heater of the convulsive counter flow type.

4. Steam Cooled Wall Section:It is from the side front and rear walls and roof of the vertical gas pass.

REHEATER:It is composed of two stages or sections the front pendant vertical spaced and the rear spaced. Rear pendant is located above the furnace arcs between the water cooled screen tubes and the rear water wall hanger tubes. The front pendant vertically spaced section is located between the rear water wall hanger tubes of super heater plates section.

AIRPREHEATER:The function of an air preheater is similar to that of an economizer. It recovers some portion of heat of flue (exhaust) gases and transfers the same to the air before it passes into the furnaces for combination purposes. Air preheater is generally placed after the economizer, so that the flue first pass through the economizer and then to the air preheater. Air preheater is of two types, recuperative and regenerative type. In recuperative type air and hot gases passages are different, both being separated by a metal wall. In regenerative type and flue gases are made to pass through the matrix. It receives heat from the hot gases and transfers it to the cold when it passes.

TANGENTIAL FIRING SYSTEM:In the tangential firing system the furnace itself constitutes the burner. Fuel and air are introduced to the furnace through four windows assembly located in the furnace corners. The fuel and air steams from the wind boxs nozzles are directed to a firing circle in the centre of furnace. The rotative or cyclonic action that is characteristic of this type of firing is most effective in turbulently mixing the burning fuel in a constantly changing air and gas atmosphere.

DRAUGHT SYSTEMS:In a boiler the combustion of fuel requires supply of sufficient quantity of air and removal of exhaust gases and this is achieved by Draught system. The circulation of air is caused by a pressure, known as draught. The draught may be produced either naturally or artificially (Mechanical). Natural draught is produced thermally and the mechanically draught is produced by means of a fans. Natural Draught:The natural draught is provided by the action of chimney or stack and is used only in small boilers. Its intensity depends upon the average temp. Difference between the flue gases within the chimney and the outside air and also on the height of the chimney above the level of the furnace grate. Its weather conditions and boiler operating conditions. Chimney, in addition of providing natural draught, helps in reducing air pollution too, as it delivers the products of combustion and fly ash to a high altitude. The height of chimney is 180 meters. Mechanical Draught:-

Artificial or mechanical draught is provided when the natural draught caused by a chimney is not sufficient or where a certain draught is required to be maintained irrespective of whether condition or boiler operating conditions. In a mechanical draught system, the movement of air is due to the action of a fan. In an Induced draught system, the blower is installed near the base of the chimney and the burnt gases are sucked out of the boiler, reducing the pressure inside the boiler to less than atmosphere one. In case of a forced draught system, the blower is installed near the base of the boiler. In this system of draught the air pressure throughout the system is above the atmospheric pressure and air is forced to flow through the system. In the most of the cases, a forced or induced draught alone is not sufficient and to achieve advantages of both the systems a balanced draught system (combination of induced draught and forced draught systems) is used. Rating of fan:ID fan : FD fan : PA fan : 850 KW 300 KW 820 KW

COMPRESSED AIR SYSTEM:The following are: 1. Intake air fillers:In take air filler is used to prevent dust from entering compressors. 2. Inter stage coders:Reduce the temp of air before it enters the next stage to reduce the work of compression and increase work efficiency. They are normally water Cooled. 3. After coolers:The objective is to remove the moisture in the air by reducing the temp. is water cooled heat exchanger. 4. Air Dryers:The remaining moisture is removed by using air dryers as air forged instrument & pneumatic equipments has to be relatively free from any moisture. The moisture is removed by using adsorbent like silicon gel activated carbon or refferigerent dryers or heat of compression dryers. 5. Moisture Drain traps:It is used for removal of moisture in the compressed air. 6. Receivers:Air receivers are provided as storage and smoothing pulsating air output and reducing pressure variations from compressors.

EMERGENCY SWITCHGEAR: All the emergency auxiliary of the station e.g. Turbine A.C. emergency Lops, bearing gear JOP, AC emergency lighting etc. connected to station service switch gears (SSSG) and stand by

source of power to D.G sets 12 nos. distribution boards (D.C.) has been provided for supply to various control panels and circuit isolators etc.

3. WATER TREATMENT PLANT

(W.T.P.)

Water Treatment Plant (W.T.P.)

The principal problem in high pressure boiler is to control corrosion and steam quality. Internal corrosion cost power station crores of rupees. In repair without strict control impurities in steam also from deposit over turbine blades and nozzles. The impurities are present in water as follows Undissolved and suspended solid materials Dissolved salts and minerals Dissolved gases Other minerals like coal, acids etc. 1. (a) Turbidity and sediment (b) Silica (c) Microbiological (d) Sodium and Potassium salt (e) Dissolved salts and minerals. 2. (a) O2 gas (b) CO2 gas

WATER TREATMENT STAGE:River (raw water) Clarification Filtration Demineralization

CLARIFICATION AND FILTERATION OF WATER:River water contains different impurities i.e. Suspended impurities Biological impurities Soluble impurities Colloidal impurities Suspended impurities are removed by Al and Cl 2 and Ca (OH) 2 where alum is used as coagulate. Colloidal impurities are removed by alum and filtration of water. Water after filtration contain soluble impurities like Na2CO3, Si, NaCl, sulphite, chlorides and other minerals, nitrates etc. These are removed in D.M. plant where these reactions occur on anion and caution.

WORKING:The raw water enters through valve and than chemicals is added. Chlorine and alum are added. Chlorine is added to remove bacteria etc. Alums are added to make the impurities heavier, once the impurities become heavier than a no. of flocs are formed. By mixing the alums, heavy impurities are settle down due to gravity and later removed. The time required for the formation of floc is called retention time which is generally 3 hours but this cant

be achieved as it require large tank. In order to cope up the limitation CLARRIFOCCULATOR TANK is used. This flocculator tank is consist of 1. Clarification zone 2. flocculation zone After the addition of chemical the basic requirement arises is of mixing. Thus flash mixers are used. Normally the chemicals mix naturally but when the raw water contains much impurity than agitators are used to mix them. Clarrifocculator tank has a central pillar which has four windows at 90 degree. The outer circle is half of windows so that level of water is arise then it flows down through these windows into overflow channel. After mixing from flash mixer, the water passes on to central pillar and follows the path as shown in fig. i.e. it moves to max. Floc area and comes out from window at 3.5 m height. The downward flow is through perforated wall which sinks the raw water. Due to the long path a retention time of 4 hour is easily available. The capacity of water in this plant is 1000*1000 lt. /hr. In flocculation zone max. Floc is formed and after removing it, the clear water moves into clarifier. Some impurities are weightless and do not settle down so they are passed through filter beds. There are two types of filter beds. 1. Gravity filter bed. 2. Forced filter bed. In FORCED FILTER BEDS raisins are added to settle down the impurities. In GRAVITY FILTER BEDS graded gravels are arranged. At bottom gravels of big size are there and above other gravels are arranged according to size. Above it grit and most of the above is sand. The clarified water enters into sump. Sump is fully closed leaving one window to see the level. Since it is fully closed hence no foreign matter can enter into it.

DISADVANTAGE OF ALUM:1. Reduces the water of the pH. 2. Solubility of alum is very difficult.

REPLACEMENT OF ALUM:The pH level of the water should remain between 7.5 to 8.5 but alum drops the pH level to 4.5. Thus lime is added to maintain pH level. It increases cost so we use PAC (poly aluminum chloride) as it is available in liquid form and the quantity can be easily controlled in case of emergency. PAC also does not affect pH.

OPTIMIZATION:The water coming from clarification zone is divided in two parts i.e. one of the part is isolated from other. One of the used for potable purpose while the other goes to D.M. plant. The one going to D.M. plant is better purified so that no chance of any impurities appears so PAC and Cl2 are more added but for water to be parted has less PAC and Cl 2 too. This optimum use of chemical is called process of optimization. The capacity of PAC tank is 40 tones. The one tank which regularly supplies PAC is called PAC day tank.

CHLORINE SUPPLY: Chlorine more than 3 ppm is harmful. Thus chlorine is taken in liquid form but given out in gaseous form. The regular contains 3 safety devices. One to see level of Cl2 being supplied and other to create vacuum and maintain pressure.

 One Cl2 tank has two valves. The upper valve is to get 6 Kg Cl2 in gas form and lower valve is to get 15 Kg Cl2 in liquid form. Cl2 destroys every metal hence its all work is done in silver pipe. In the room exhaust fan is downward because Cl2 is heavier thus it first flows on floor and thus it blown out.

SILICA TEST:For silica test following chemicals are mixed with sample. Ammonium molybdate Oxalic acid HCl ANS Its color is observed spectrometically @ 810 mm. If blue color than it shows presence of the silica. 1. 2. 3. 4.

Demineralizing Plant
Water mainly used for cooling purpose of different parts like bearing winding etc. in KSTPS. For this water should be Demineralized (D.M. water). Dissolved salts in water exist in ionic form. They are basically two types of impurities like 1. Cation impurities: Ca, Mg, Fe etc. (+ve charges) 2. Anion impurities: CO3, SO4, Cl2, NO3, Fluorides, CO2, SiO2 etc. (-ve charges) In natural water equal numbers of cations and anion are formed. Except it only CO2 and SiO2 are found which are to be measured or removed. Concentration of ion is measured in terms of ppm. Ion exchange rasin (made of porous hydrocarbon solid phase) is available in vessels. (Cation and Anion or mixed bed vessels).

WORKING:Clarified water enters through pipes. One of them is soft water which comes through 350 mm diameter pipe (N.B.) while water to be de mineralizes comes through 250 mm dia. (N.B.) pipe. Then the water is stored in D.M. Storage plant having capacity of 500 m 3 /hour. There are four series available A, B, C, D. Only one series is operated at one time while the other is for emergency purpose. All three are kept in stand by position. Water is further supplied by feed water pump (6 in no.) to Activated Carbon filter.

ACTIVATED CARBON FILTER:In this filter carbon is supplied to remove Cl2 content which is mixed into water in the clarifier. If Cl2 content is still more than Na2SO3 is added to remove it. The impurities become heavier and settle down. These impurities are removed through BACK WASH PUMP.

STRONG ACID CATION EXCHANGER:-

Now Cl2 free water reaches to SAC where Zeolite is used as a cation exchanger. One zeolite ion catches no. of H + ion. There are different impurities in water e.g. CaCl 2, MgSO4, Mg (HCO3), NaCl etc. In SAC following reaction are takes place. Ca+Cl2- + 2Z-H+ MgSo4 + 2ZH Z2Ca+ + 2HCl Z2Mg + H2So4 2NaZ + H2SiO3

Na2SO3 + 2ZH

Low Ph acidic water goes to degasser form and than cation exchanger. H2CO3 H2O + CO2

When SAC rasin exhausts than cation rasin is recharged through HCl. Z2Ca ZNa + 2HCl + HCl 2ZH + CaCl2 + NaCl

2H

Now water is moved to degasser (It retains 5000-6000 pbc. Rcags) to some height and than flown downwards in pipe and at the same time air is blown from bottom in upward direction through Air Blower. Thus CO2 from the upper opening is exhausted.

WEAK BASE ANION EXCHANGER AND STRONG BASE ANION EXCHNGER:The water is now supplied to weak base anion exchanger and then to strong base anion exchanger. Weak Base Anion removes the lower valences anions like dioxides and hydrides etc. Rasin used as zeolite which contain OH- ions. In WBA and SBA following reaction takes place. HCl H2SO4 H2CO3 H2SiO3 + + + + ZOH 2ZOH ZOH ZOH ZCl + H2O Z2So4 +2H2O Z2CO3 + 2H2O ZHSiO3 + H2O

The pH value decreases from 7 to 9 and the conductivity of water is measured from instrument which is 0.2 to 0.4 mho. Anion rasin once exhausted is again regenerated with caustic soda dosing. ZCl + Noah ZOH + NaCl Na2SO4

Z2SO4 + 2NaOH

2ZOH +

These acids may destroy the material of pipe hence they are first made to flow through rubber tubes coated with metal.

MIX BED:-

In this both cation and anion exchanger are used simultaneously. Now the water is stored into storage tanks and are further distributed to various units to boiler feed pump, cooling tower pump etc. Each series supply water at a rate of 80*1000 lt. \hour. In mix bed since the rasin is lighter hence comes upwards while the other one becomes heavy and comes downwards.

DM WATER QUALITY:Ph Iron Free CO2 Conductivity Total Silica Total electrolyte between 6.0 and 8.0 Not traceable Not traceable Less than 0.3 siemens /cm at 20 degree Centigrade Less than 0.020 ppm Less than 0.1 ppm as CaCO3

DOIZING SYSTEM:1. Hydrazine (to remove oxygen intake) Dozing at CEP header N2H4 + O2 H2O + NH3

2. Dozing at BFP Header (ammonia to remove oxygen) NH3 + O2 NH4OH

3. Dozing at boiler drum: PO4- directly to boiler drum to remove only Ca- Mg hardness. Also at fuel place continuous blow down is also carried out and precipitate Ca-Mg impurities. Capacity of each series is 80 m3 /hr. Silica is maintained to less than 0.02 ppm as if remains, than cause problems in boiler. Hence silica tests are performed to remove it. All the acids are taken in dilute form like HCl (33% dilute) After the whole process the pH of the water to be drained is checked and than through effluent water pump it is drained into river.

PH VALUE OF WATER:This is recommended to feed the water in the boiler at 25 degree centigrade and pH value is 8.2 to 9.2 up to 28 days and the pressure is 59 Kg \cm2.

2.COAL HANDLING PLANT

Coal handling plant

1. INTRODUCTION:The term coal handling plant means to store and to handle the coal which is transported by the train and convey to the bunkers with the help of belt conveyers. Through the bunkers coal is transferred to the coal mill and drifted to the furnace. The coal handling plant includes wagon trippler, conveyer belt, crusher house, stacker & reclaimer, bunkers & coal mill. Coal Supply in KSTPS:The coal for KSTPS is received from BHARAT COKING COAL, DHANBAD & SOUTH EASTERN COAL FIELD LTD. BILASPUR by train.

Koria rao:Brusher Badgamia Kunda Bijuri Vishrampura Chirimiri Kunshiya Dumanhill Kiovinda Jamuna OCM Norajabad

Korba area:Deepka (f) grade Zebra Juna (d) grade Kushmanda (f) grade Manikpura (f) grade Surkanchar (f) grade

Technical Data:Wagon Trippler:Nos. Capacity Two 12 box/hr

Trippler motor:Make Type Output Siemens Slip ring induction motor 71 K W Type Capacity Method of operation Belt weightier type Magnetic separator type Electro magnet 350 T /hr Pulsating direct current Electromagnetic D.C operated electro-magnet

Vibrating feeders:-

Metal Detector:Type Two channel power unit

Power supply

230 V

Bunker level indicator:Nos. Type 4 per bunker Mechanical

Crusher:Type Capacity Feed size to crusher Type of crusher cleaning Motor rating Direct drive ring granulator 550 T/hr 300 mm Water jet cleaning 500 H P

Vibrating screens:Type mechanical Location Capacity Stacker type Effective stack pile height Travel speed Location crusher house vibrating screens crusher house 675 T P H Reversible stacker 9 met. 7.5 to 15 m/min (a) at loading & discharge point (b) At vibrating ends (c) At ring granulator

2. STAGES OF COAL HANDLING PLANT: Wagon Trippler:The term Wagon Trippler contains two words WAGON & TRIPPLER .Wagon means the compartment of train which is just like a container which is used to carry the coal from mines to generating stations & the word Trippler means a machine, which is used to unload the wagon into the hopper. Hopper is just like a vessel which is made of concrete & it is covered with a thick iron net on its top. Here big size coal pieces are hammered by the labors to dispose it into the hopper. There are two processes to clamp the wagon to the trippler. These are Bittle system Side arm charger method Bittle system:Bittle system is the oldest system to clamp the wagon to the trippler, it is an Electrical system. In this there is a Bittle which moves on a track i.e. Bittle track, which is installed in between the main track (rail track).Movement of Bittle is done with the help of wire rope which is connected to the pulley of electrical motor. Motor is operated by an operator. The Bittle has the wheel locking system which locks the wheel of the wagon with

carrying coal and then pulls this wagon to the trippler. When the wagon is hold on the trippler then whole is known as a WAGON TRIPPLER .After reaching to the trippler, the wagon is unloaded in the hopper.

Side arm charger method:Side arm charger is a hydraulic system. The system hydraulic means a machine which operated on an oil pressure .There is a hydraulic motor in which the oil filled into the oil tank which is first sucked by oil pump and distributed to the motor pipes. First the side arm charger move towards the wagon and clamp it from its knuckle and then pull it to the trippler. The trippler is operated when the wagon is on the trippler at that time it is known a Wagon Trippler. After reaching to the trippler, the wagon is unloaded in the hopper.

Convey of coal to crusher house:After unloaded the coal wagon into the concrete hopper, the supply of coal is control by Appron Feeder and Scrapper. Appron feeder is made of iron .After passing through the scrapper conveyor the coal is fed into the Roll Crusher where the crushing of coal takes place. In the roll crusher there are two shafts on which metal hammer are mounted, these two rollers rotates in opposite direction to each other. When the coal comes in between these two rollers it gets crushed into small pieces and then convey to the separator through belt conveyor. In Pent house there is a belt weightier which is used to weight the belt which carry the coal and feed into the separator with the help of Flap Gate .The heavy coal pieces and stones are fed into the "Rotary breaker" where the heavy stone pieces are crushed into small pieces by the blades which are on fixed on the rotary net and this net is used to separated the heavy stone pieces from the coal and conveyed to the Dispose House. There is a refuse disposal hopper which collects stones and iron pieces and disposes it outside the plant. There is another path in the separator which is used to pass the small coal pieces directly to the crasher house with the help of belt conveyor. Primary Crusher house:Coal crusher house is a part of coal handling plant where the coal is crushed with the help of a crusher machines .In crusher machine there is pair of two shafts on which hammer are fixed. Both shafts rotates in opposite direction due to which when coal comes between the two shafts crushed into the small pieces and conveyed to the bunkers or open storage (stacker) according to the requirement through the belt conveyor.

Stacker & reclaimer:Stacker is a place where the open storage of a coal takes place. Reclaimer means the unloading of coal from the stacker. Coal Mill:In coal mill, coal is pulverized or crushed properly into the powdered form. Hot air is mixed with powdered coal to remove the moisture from the coal, which increases the efficiency of plant. Pulverization is done to increase the surface area of coal. From coal mill coal is drift to the furnace with the help of air. There are four main equipment of coal mill, which are as follows: Bunkers:These are basically used to store crushed coil which comes from crusher house. Feeders:-

These are used to control the supply of crushed coal to the mill depending upon load condition. Feeder pipe:Feeder pipe are used to convey the crushed coal to the Tube mill or Bowl mill.

Tube mill / Bowl mill:In unit 1 & 2 Bowl mill is used while in unit 3 to 6 Tube mill is used. Tube mill:Tube mill is used to pulverize the crushed coal. In the tube mill there is a cylinder which continuously rotates with 17 to 20 rpm. Around the cylinder there are steel balls which are around of 70 tones in weight and 50 mm in diameter. These balls are known as thicrome grinding media ball. Coal is pulverized when it comes between the stationary surface of the shell & the steel ball. Then this pulverized coal is drifted to classifier where filterization of coal takes place. Bowl mill:It is also used to pulverize the crushed coal .In bowl mill there is a rotor and four bowls. When the coal comes between the rotor and three moving bowl it become pulverized. In bowl mill there is no classifier. In both the mill powdered form coal is drifted to the furnace with the help of mixture of hot &cold air through Primary air fans.

7. COOLING SYSTEM

COOLING TOWER DEAREATER CONDENSER H2 GENERATING PLANT

Cooling Tower
It is used to reject heat into the atmosphere. There are two types of the cooling tower. (1) Natural draft (2) Mechanical draft Natural draft tower used vary large concrete chimney to introduce air through the media. They are generally used for water flow rate about 45000 m3 /hour. It is used in utility power station. Mechanical draft tower utilize large fans to force or suck air through circulating water. The water falls downward over fills surface which helps in increase the contact time between the water and air. This held maximize heat transfer between two media. Cooling rates depend upon fan diameter and speed. This type of tower much wider used. Mechanical draft towers are available in a capacity from approximately 10 tones, 2.5 m3/hour flow to several thousands tones and m3/hour. Many towers are constructed so that they can be grouped to achieve the desired capacity. Fills may be horizontal. Water falls over successive layers, splash bars continuously breaking into smaller droplets. Plastic is better than wood splash filling. Circulating water pump house has pumps for condensing the steam for condenser. Five pumps are used for condensing unit no. 1 & 2 and after condensing this water are discharged back into river. Each pump has capacity of 8275vcubic m/hr. develop the pressure about 1.94 kgf/sq.cm. Three seal water pumps are used sealing CW pumps shaft at pressure 4.5 kg/sq.cm. Two pumps for unit 1 and 2 with one stand is used for supplying raw water to clarified chemical dosing is done in between and clarified water is taken through main line. From main line water passes through filter bed to filter the water. Clarified water is pumped to 42 m. elevation by two pump of capacity 270 cubic m/hour at the discharge pressure of 6.9 kg/sq.cm. At 42 meter elevation the water is stored in tank and used for cooling the oil coolers and returned back to river. Oil coolers are situated at ground and are three in no. each unit.

Bearing Cooling Water

Water from river comes in plant heat exchanger, where its temperature cools down and that goes in AHP to make slurry. There are 480 plates exchangers. BCW requirements of boiler and turbine auxiliaries of both the units is meet from BCW soft water overhead tank with the capacity of 2000 cubic meter. The cooling system is closed circuit except for some unit auxiliaries drains and coal handling plant requirement all the BCW drains are connected back to soft water pump. There are 4 vertical pumps in BCW plant to supply water to PHE. These pumps known as fair banks have discharge capacity of 1100 cubic m/hour pressure of 73 kg/sq.cm. and power of 40 kW and its motor is made by graves cotton. BCW pump is used for cooling down the temperature of

water to 36 degree centigrade from 40 degree centigrade. These are 3 PHE with 480 plates. Cooled water from PHE also goes to BCW tank. The height of BCW tank is so high (48 meters) to maintain the gravity head so that water can easily flow to different parts like turbo generator, PA fans, FD fans, ID fans, mills, Airpreheater, boiler etc. without using motor. This cooling water is known as bearing cooling water because it is mainly used for cooling purpose of bearing of different motors.

SOFTENING PROCESS (BCW WATER):In B.E. the resin available; Ca+Cl2MgCl2 + + 2Z-Na+ Ca (Z) 2 2ZNa + 2NaCl

Mg (Z) 2 + 2NaCl

In softing process Ca, Mg, Fe, etc. are removed and absorbed by sodium Zeolite resin. Mg (HCO3) or Ca (HCO3) Mg (SO4)2 or Ca (SO4)2 Regeneration of resin, CaZ or MgZ + + Na2Z CaZ + 2NaHCO3 CaZ + Na2SO4

+ Na2Z

2NaCl Na2Z +MgCl2 or CaCl2 Brine solution Inject in B.E. Deareater

DEAREATION OF FEED WATER:In deareation dissolve gases such as oxygen & CO2 are expelled by preheating the feed water before it enters the boiler. All natural water contains dissolve gases in solution (i.e. oxygen + CO2) are released when water heated. Deareation can be done by two methods:(1) Mechanical (2) Chemical

1. Mechanical:It operates as a boiling point of water at the pressure in a deareater. That can be of vacuum gauge pressure type. Vacuum type operation below atmospheric pressure at about 82 degree centigrade. Pressure type deareater by allowing steam in feed water at desired operating pressure and hence temperature of minimum 105 degree centigrade. It releases oxygen and CO 2 and vented form the system in the atmosphere.

2. Chemical:By adding sodium sulphite or hydrogen reacts with oxygen to form sodium sulphite and H2O.

Condenser
In condenser steam changes into water. The basic requirement is to remove latent heat from the steam which is removed by another water (clarified water) when it accepts the latent heat and becomes hot, than it is passed to cooling tower. In cooling tower the water is cooled and then mix with river water.

PUMPS
The entire green colored instrument is pumps which are 18 in no. to further pass the water. 1. FILTER WATER TRANSFER PUMP:It is soft section consisting two types:-

(a)

BEARING COOLING WATER PUMP:-

All the bearing temperature is controlled through oil bath and filter water is used. Oil is used to cool the supplied water. Here doesnt used raw water because at the time of puncture it enters in the machinery part and small impurity may stop the operation.

(b)

CONDENSATE WATER PUMP:-

This pump is coupled with blue colored motor. In order to couple it with motor a little opening is left through which water leaks out when pumped. This leakage is avoided by sealing it. If not sealed than whole unit can trip. Sometimes sand remains in water and when it passes in asbestos sheet, it rubes the material again and again and thus destroy it. This action is called Amory action. This action is avoided by sending filtered water at a pressure more than that of pump pressure.

2. FILTER WATER TRANSFER PUMP:This pump transfers water to D.M. plant. These pumps are in D.M. section.

3. POTABLE WATER PUMP:These pump pumps clear water for potable purpose for whole plant.

4. BACK WASH PUMP:-

It is used to remove the dirt collect from sump. Water collected in surge tanks and than cleared and is than dumped into river. The sludge is collected by a steel structure which rotates on rail track. This structure has steel arms which has rubber. Sweeper at bottom called scratches than sludge is brought to drain channel.

\ H2 GENERATING PLANT
Hydrogen gas is used for cooling purpose for rotor of the generator. For cooling purpose we have to use 99.9% pure hydrogen. To avoid fire so we have to apply Hydrogen cooling. It is very difficult to generate and store the Hydrogen gas because it is very explosive.

GENERATING PLANT:Hydrogen gas is produced by electrolytic dialysis by mixing KOH in D.M. water. This reaction is done in electrolyser where Anode and Cathode are applied. Anode plate is used for collecting H2 and Cathode plate is used for collecting O2. For electrolytic dialysis 3000 Ampere current is passed into electrolyser. O 2 is released to atmosphere and H2 is sent to next machinery for further treatment.

COLLECTING PROCESS:H2 Gas from electrolyser Refrigerator for cooling Separator to separate the moisture Compressor Catalytic purifier Dryer (Al2O3) H2 cylinder In compressor H 2 is treating in three steps where pressure is raised up 2 to 130 Kg/cm . In dryer Alumina is used to absorb moisture.

CAPACITY:In KSTPS the full day capacity of H 2 generating is 40 cylinders per day. But in plant per day utilization are of 15 cylinders. Per cylinder capacity is 200-250 kg and stored H2 is 99.8% pure.

PRECAUTION:H 2 is very explosive gas so we have to take precautionary steps in order to avoid any accident these steps are as follows 1. To avoid any accident plant timing is fixed 9 A.M. to 5 P.M. 2. In generating plant underground wiring is used and spark proof lamination bulbs are employed. 3. Siren:-H2 ppm is kept maintain if it has some variation than Siren will start. 4. Special roof is made for H2 plant so if gas is leakage than it will escape out easily.

HYDROGEN COOLING:Large rating turbo generators require compactness from the view point of economy and transportation. For such generators, closed air circuit ventilation system is not

sufficient to cool the machine effectively. Hydrogen has been found a well suited cooling medium and is more common in the totally enclosed ventilating system of large turbo generator. Hydrogen as a coolant has the following advantages over air: 1. EFFICIENCY AND NOISE. Hydrogen density is only about 0.07 that of air at the same temperature and pressure so less windage and ventilation losses. As a result, machine efficiency is more. Due to low density, the noise produced is less.

2. COOLING. On an equal weight basis, specific heat of hydrogen is about 14.5 times of air. Heat storing capacity is given by = m*s* If heat stored in air is given by m*s* then heat stored in hydrogen is given by (0.07m)*(14.5s)*=m*s* heat stored capacity is same for per unit volume but heat transfer between hot parts of the machine and cooling gas is 1.5 times with hydrogen than air. 3. LIFE. In high voltage machines, air is producing corona discharge. In air O 2, N2 will form ozone, nitric acid and other organic compound which may harm insulation. Hydrogen as a coolant, ozone and other chemical compounds due to corona discharge cannot be formed because of the absence of oxygen. The life of insulation is increased and maintenance expenses are reduced. 4. FIRE HAZARD. Fire hazard inside the machine is minimized because hydrogen air mixture does not explode so long as the hydrogen content is more than 70%. 5. RATING. Hydrogen pressure inside the machine system is maintained at a pressure above atmospheric. With this, the air cannot leak into hydrogen circuit to form an explosive mixture. Hydrogen cooling at 1, 2 and 3 times the atmospheric pressure can raise the rating of the machine by 15, 30 and 40% respectively above its air cooled rating. The stator of hydrogen cooled machine must be gas tight and explosion proof. For this purpose, oil filled gas seals at the rotor shaft ends are necessary.

COMMON AUXILIARY

ASH HANDLING PLANT (A.H.P) ELECTROSTATIC PRECIPITATOR (E.S.P.) SOOT BLOWING

SUPPLY

Electrostatic Precipitator (E.S.P.)

If suspended particles are not removed from the flue glass, and it is allowed to be released in environment, then it would cause a serious threat to the environment, so it becomes necessary to extract suspended particles from the flue glass and for this purpose ESP is widely used.

WORKING PRINCIPLE:An electrostatic precipitator is defined as a device which utilizes electrical forces to separate suspended particles. The electrostatic precipitator consists of two sets of electrodes , one in form of thin wire called discharge or emitting electrode and other set is called collecting electrode in there form of plate . The emitting electrodes are placed in the center of two plates and are connected usually two negative polarity of high voltage D.C. source of 37kV. Collecting electrodes are connected to the positive polarity. The voltage gradient b/w the two electrodes create corona discharge, ionizing the gas molecules. The dust particles present in the flue gas acquire negative charge and experience a force which drives them towards the collecting electrodes where they get deposited. The deposited particles are removed by knocking the electrode by a processor or manually. This process is known as Rapping. In KSTPS rapping is done by rapping motor operated hammer.

CONSTRUCTION: The main parts of ESP are as follows:Casing Hoppers Collecting system Emitting system Rapping mechanism for collecting system Rapping mechanism for emitting system Insulator housing

CASING:It is designed for horizontal gas flow to provide for heat expansion, the casing is supported by roller bearing support.

HOPPERS:-

They are of pyramidal shape .Angle between hopper corner and Hz is never less than 55 degree.

COLLECTOR SYSTEM:The profiled collecting electrode is based on the concept of dimensioned electrode stability .The upper plates have hooks and lower edge has a receiving plate.

EMITTING SYSTEM:The framework is thoroughly braced and forms a rigid box like structure, the emitted electrode is made of hard stainless steel wires.

RAPPING MECHANISM FOR COLLECTING SYSTEM:The system employs fumbling hammer which are mounted on an Hz. Shaft in a staggered fashion .A uniform rapping effect is provided for all collecting plates in one row .Rapping frequency is very low to minimize the dust loss. The hammers are operated by motor, so that they strike the plate at fixed frequency.

RAPPING MECHANISM FOR EMITTING ELECTRODES:During electro-precipitation a fraction of the dust will be collected on the emitted electrodes and corona will gradually be suppressed as the dust quantity grows .It is therefore necessary to rap the emitting electrodes occasionally .This rapping is done with a rapping system employing Tumbling Hammer, which are mounted on a horizontal shaft in a staggered fashion.

POWER SUPPLY SYSTEM:For optimum functional efficiency of the precipitator, supply voltage should be maintained near about the flush level between the precipitator electrodes, which is obtained by an electric control system which raises the output voltage to flush level and reduce it automatically by a small amount in the event of flash over. An additional increase in voltage produces a disproportionate increase in current accomplished by heavy sparking and a rapid reduction in dust collecting efficiency.

Ash Handling Plant (A.H.P)

The complete ash handling plant is supplied, erected and commissioned by M/s INDORE PVT.LTD.DELHI on a turn key basis .The ash handling system is provided for continuous collection of bottom ash from the furnace hearth and its intermittent removal by hydro ejectors to a common slurry sump .It is also provided for removal of fly ash to the common slurry sump. Each boiler is provided with ash precipitator for collecting the fly ash from the flue gases with high efficiency of collection to minimize the dust mains and to reduce the wear of induced draft fan .The fly ash separated from flue gases in the ash precipitator is collected in hoppers at the bottom from where it is mixed with water to form slurry, and disposed off to pumping area by means of hydro ash pumps .Bottom ash from the boiler furnace is passed through slag crushers and then slurred to the slurry chamber at the suction of the ash disposal pumps .These are high pressure and low pressure pumps for this purpose .At a time one pump is working and other two are stand by .

From the ash disposal pump house ash slurry is pumped through pipe lines to the ash damp area within about 1.5 km away from the disposal pump house .two separate discharge lines are provided one for each unit but only one line is used .The ash slurry from the two units is taken in one discharge line through electrically operated valves.

Soot Blowing
Soot blowing is the process by which we clean the boiler tubes with the help of steam .A large number of tubes are present inside the boiler .Slowly the fine ash particles get collected on the tube surface and form a layer, this layer of ash particles is called soot .Soot reduces the thermal conductivity. When flue gases temperature rises above normal temperature i.e20C then we have to remove the soot deposits .3 mm of soot can cause an increase in fuel consumption of 2.5% due to increase in flue gas temperature .Thats why periodic off line cleaning is required .Steam used for this process is at a pressure of 22kg/cm2 and temperature of 540 C. Mainly three types of soot blowers are used in KSTPS. 1. Water wall 2. Super heater soot blower (S.H.S.B) 3. Airpreheater soot blower (A.P.S.B)

1. WATER WALL:They are 40 in no. and have travel time of 1.5 minute .Initially these are outside the boiler ,when soot blowing process start ,the glance of the soot blower enter inside the boiler and then rotate and come outside again .

2. SUPER HEATER SOOT BLOWER:They are 28 in no. and travel time 6 minute .It has transverse of 5 m inside the boiler .It enters and come out in rotated motion ,so it rotates in both the cases . 3. AIRPREHEATER SOOT BLOWER:There are only 2 A.P.H.S.B and has 55 minute traveling time .It is like a disc ,and have only rotary motion and takes 55 minute for completing the cycle .

10. EFFCIENCY

Efficiencies
In KSTPS we convert potential energy or chemical energy of the fuel into heat by the process of combustion. The heat is given to the water and it converts its form into steam. The pressure of steam rotates the turbine, which is now in the form of kinetic energy. Generator producing electrical energy, which is sand to different localities for utilization, consumes this kinetic energy. Enthalpy is defined as the thermodynamic property of a system, is equal to the sum of the sum of its internal energy and the product of its pressure and volume. Enthalpy is an ancient Greek word meaning evolution and many eminent scholars have been attempted to define it. It is a mathematical concept of available energy in the steam. Efficiency in the case of electrical generator process can be expressed as the amount of heat energy librated in the boiler compared with the amount of electrical energy generated with it.

PLANT EFFICIENCY: We will divide whole plant efficiency in four-component efficiency: (1). Cycle efficiency (2). Turbo genr efficiency (3). Boiler efficiency (4). Auxiliary power efficiency Overall = Boiler x Turbine x Cycle x Genr CYCLE EFFICIENCY: Cycle efficiency being the maximum possible heat energy that could be obtained from any particular set of steam conditions employed. The operation of heat reduction of condenser, which is almost 50% of the total available heat, makes ranking cycle relatively inefficient.

Cycle = energy available for conversion in work Energy given in boiler as heat
In can be controlled by: (a). Condenser vacuum. (b). Steam conditions of CV and LV (c). Regenerative feed heating.

2. ALTERNATOR EFFICIENCY: The alternator is a very efficient machine at about 98 % efficiency. The losses can be categorized as: (a). Copper and iron loss

(b). Wind age losses Operationally the plant is governed by the grid requirements. For voltage we use the set out from generator transformer.

3. BOILER EFFICIENCY: It depends upon: (a). Dry flue gas loss: Increase by excess air in boiler. (b). Wet flue gas loss: Moisture in coal. (c). Moisture in combustion loss: Hydrogen loss. (d). Radiator and in accounted loss.

4. TURBINE EFFICIENCY: It means the efficiency of steam turbine in converting the heat energy made available in the cycle into actual mechanical work. Turbine losses falls into one or two groups either losses external to the turbine or losses directly related to the expansion of the steam in the cylinder.