Chhattisgarh State Power Generation Company Limited

2014
Deepak Raj Kurrey

APG10910313003
7/7/2014
Chhattisgarh State Power
Generation Co. Ltd.
Chapter 1: Chhattisgarh State Power Generation Co. Ltd.

Communication Skills Report Page 5

Acknowledgement

This is chapter 1 of the report on Chhattisgarh State Electricity
Board. The data presented inside the report can be used for information
and Industrial Report data.

There may be Compilation Error.


Introduction
Chhattisgarh State Power Generation Co. Ltd. (CSPGCL) is the
most important unit of the organization which gives the
organization its identity. CSPGCL is the unit which generates
electricity for CSEB. It became functional w.e.f. 01.01.2009. This
company generates electricity which is further transmitted and
distributed.
The company generates electricity by the following
Thermal Power Plant (TPP)
Hydel Power Plant (HPP)
The company has Thermal Power Plants and Hydel Power
Plants which provides electricity by means of Coal and Water, the
list is given below as on 11-10-2010

Projects Units & Capacity
Korba Thermal Power Station (East) 4x50MW
2x120MW
Dr. Shyama Prasad Mukherjee Thermal
Power Station
2x250MW
Hasdeo Thermal Power Station, Korba
(West)
4x120MW
Korba West Extension Thermal Power Plant 1x500MW
Bhoramdev Co-Generation Plant, Kawardha 1x6MW
Mini-Mata Hasdeo Bango Hydel Power
Station
3x40MW
Gangrel Hydel Power Station 4x2.5MW
Sikasar Hydel Power Station 2x3.5MW
Mini/ Micro Hydel Power Station, Korba
(West)
2x0.85MW
Total Generation 2424.7MW


The major of electricity generation is done by Thermal Power
Plant (TPP), and Hydel Power Plant shares a small portion of it.
One of the TPP is Korba West Extension (1x500MW), which
has 4 turbine units to generate 480MW of electricity, but has found
that it is generating 20MW more electricity than the actual plan and
design. Here is a short technical overview of the plant.



Hasdeo Thermal Power Plant 4x120MW, Korba (West)

Thermal Power Plants generates electricity by the
means of coal as its main energy generating fuel and water
as a major driver and controller in electricity generation. We
will little introduction of the power plants major
machineries used in Hasdeo Thermal Power Plant.



The Major organs of the TPP are as a follows
Boiler
Turbine
Generator
Water Treatment Plant
Coal Handling Plant
Ash Handling System
Heavy Fuel Oil Handling System
Compressed Air System
Equipments Cooling System (Water)
Diesel Generating Set
Fire Fighting System
Air Conditioning System
Interlocking & Protection

Here is a short briefing of all the above
COAL HANDLING PLAN In a TPP, the initial process in
the power generation is Coal Handling the overall
processes carried out at a CHP in a coal based thermal power
generating station or TPP is given in short here.
Major Factors
o Coal Companies
o Transport
o CHP Equipment Suppliers and Contractors



Major Issues
o Coal Quality
o Coal Transportation
o Coal Stock
o Component Contractors

Schematic cum Block Diagram of a CHP



The basic layout of Coal Handling Plant is shown by block
diagram. The coal is unloaded at various unloading station and
transported by conveyors to crushing and screening plant via transfer
house. After crushing required quantity of coal is transported to bunker
via transfer house and remaining coal is stored in stockyard. This coal is
reclaimed as per requirement. From the bunker the coal flows through
coal mills to boiler furnace. The main aim of CHP to maintain level of
coal in bunkers for smooth coal supply to boiler
There are different streams for transporting of coal. For caring out
preventive maintenance schedule one of the stream kept under
shutdown. If at the same time breakdown occurs in a machine in other
stream, which interrupt the coal supply to boilers. Due this loss of
generation will occur.
A plant, which supply of coal to boilers having capacity of 750
tons per hour failed to fulfill need will loss generation of 0.6 MU for one
hour. This cost 1.20 Crore of Rupees.
Technical Details
CRUSHER HOUSE
No. of Crusher Four (4) Nos.
Type of Crusher Ring Hammer Type
Capacity 1000 MTPH
Max. Coal size at inlet 200 mm
Motor Rating 750 KW
Belt feeder Nos./capacity 4 Nos./1000 MTPH
Vibrating feeder Nos./capacity 4 Nos./1000 MTPH
Feeder size (MM) 7000 x 1600
TRIPPER
Total Number 6 Nos.
Capacity of tripper conveyer 2000 MTPH (each).
Travel of tripper 165 M.
Travelling speed 0.3 M/sec.
Belt speed 3.15 M/sec.
Motor of tripper 2x5.5 kW


SILOS
Total Nos. 18 Nos.
Cylindrical portion 9.2 M.
Conical 3.485 M
Hyperbolic 3.3 M
Dia. (internal) 7.0 M (cylindrical)
TRACK HOPPERS
No. of Hopper One
Max. Coal lump size 200 mm
Paddle feeder capacity 100 MTPH
CONVEYORS
Conveyor capacity T/hr. 2000 MTPH
Belt speed M/Sec. 2.8/3.15 M/Sec.
Belt Width (Min) 1600 mm

Boiler In this section, Crushed Coal coming from coal
handling plant are burnt and water is converted into steam
of certain pressure which is capable of rotating the turbine
at 3000 rotation per minute and that is standard speed for
electricity generation in Indian Standard. Detail of boiler
used here:
General Specification
Manufacturer M/s BHEL (C.E. Design)
Type Balanced Draft, Dry bottom, Single drum Controlled
Circulation plus.
Type of Firing - Oil Ignition
Tilting Tangential
Minimum load at which steam generator can be operated
continuously with complete flame, stability without oil
support (& MCR) 2 Adjacent, Mills at 50% capacity



Minimum load at which the steam generator can be operated
continuously with complete flame stability with oil support
(% MCR) 20%
Maximum load for which individual mill beyond which no oil
support is required 50%

Furnace Specification
Type Controlled Circulation
Wall Water Steam cooled
Bottom Dry
Draft Balanced
Tube Arrangement Membrane
Explosion/Implosion With stand capacity at 67%
Yield point +/-660 mm/wc
Residence time for fuel particles in the furnace 3 seconds
Effective volume used to calculate the residence time (M
3
)


- 14790
Height from furnace bottom ash hopper to furnace roof (M)
- 62. 735
Depth (M) - 15.289
Width (M) - 18.034
Furnace projected area (M2) - 7610
Furnace volume (M3) - 14790
Super Heaters
LTSH pendant Panel 1
Platen Horizontal Stage I Type Convection Radiant
Stage II Stage III
Radiant Platen (Drainable/Non- drainable) Non --- Non----
Pendant (Drainable/Non-drainable) Drainable -----------
Horizontal LTSH (--do--) <----------- drainable ----------->
Effective heating surface area (m
2
)/Modified
5903/12500 1350/1660 1465/1730
Total circumferential heating surface area (m
2
)
5703 ----------- -----------
Total Number of Tubes, Tube pitch (mm)
708 444 408
Parallel to gas flow 101.6 54.00 63.5
Across gas flow 152.4 254.00 762

Method of Joining long tube
<----------------------- Butt weld --------------------------->
Total wt. of tubes (T)/modified
<-------------------------1130/919 --------------------------->
Reheat Emergency temp. Control attemperator
Type - Spray
No. of stages of attemperator - One
Position in the steam circuit - Cold reheats lines
Specification of the Material - SA - 106 Gr - B
Spray nozzle Material - SA- 213T & SS Tips



Economizer
Type - Non Steaming
Water side effective heating - 7810 / 8903.4
Surface area (M
2
)/ Modified
Gas side effective heating/Modified - 10210/14204.4
Surface area (M
2
)
Gas flow path area (M
2
) - 128
Design pressure of tubes Kg/Cm
2
- 209.8
OD of Tubes (MM) - 51.00
Actual thickness tubes (MM) - 5.6
Length of Tubes (MM) (approx.) - 2, 15,000/2, 45, 100
Pitch (MM) - 101.6
Total Wt. of Tubes (Kg.) - 4, 82, 200
PRESSURES (STEAM & WATER)
HP Heaters in
Description Unit ----------------------- HP Heaters
MCR 88.72% 70.84% 53.59% out
MCR MCR MCR NCR
Pressure
Superheater Outlet kg/cm2 178 176.08 173.5 171.6 176.4
LTSH Outlet kg/cm2 188.3 184.4 178.9 174.9 185.0
Drum kg/cm2 193.4 188.4 181.6 176.4 189.3
Economizer Inlet kg/cm2 197.2 191.9 184.6 179.1 192.9
Reheater Outlet kg/cm2 43.46 41.05 32.93 24.99 46.60
Reheater Inlet kg/cm2 45.85 43.20 34.66 26.31 49.00



Pressure Drop
Superheater System kg/cm2 15.4 12.3 8.1 4.80 12.9
Reheater kg/cm2 2.39 2.15 1.73 1.32 2.40
Economizer kg/cm2 1.60 1.30 0.80 0.50 1.4
Excluding static head

FUEL
The fuel data on which the guarantees given are as follows:
Description Unit
Fuel Design Coal
Proximate Analysis
Fixed Carbon % 25.00
Volatile Matter % 19.00
Moisture % 12.00
Ash % 44.00
Grind ability Index HGI 58
Higher Heating Value kcal/kg 3500
Size of coal to mill mm 25

Turbine In this section, the Heat energy is converted
into Mechanical Energy (Rotational Energy). The water
converted into steam is used to rotate the turbine which is
coupled with a large Alternator.
Manufacturer : KRAFTWERK UNION, WEST GERMANY
Type : Three Cylinder, Reheat, Condensing Turbine
Stages : HP 18 Nos. IP 14x2 Nos. LP 6x2 Nos.
Nominal Rating : 500 MW
Peak Loading : 536.7 MW


Rated Speed : 3000 rpm
Max/ Min Speed : 3090 / 2850 rpm
Speed exclusion range 400 to 2850 rpm.
Weight (in ton)
HP IP LP
a) Rotor : 11.6 21.8 84.6
b) Cylinder Assembled : 80.0 32.5 86.0
c) Main stop & control valve : 10
d) Reheat stop & control valve : 17
Moments of Inertia (kg/m2)
a) Rotor of HP Cylinder : 713.0
b) Rotor of IP Cylinder : 2145.6
C) Rotor of LP Cylinder : 22981.0

Shaft Lift pump
a) Safety Valve Setting : 200/ 180 ata
b) Pressure limiting valve setting : 180/ 140 ata
c) Pump starts at a turbine speed of : <510 rpm
d) Pump stops at a turbine speed : > 540 rpm

TURBINE OIL PURIFIER SYSTEM
Centrifuge.
Max Capacity : 12500 Liters/hr.
Rated capacity : 8100 liters /hr.
Speed of bowl : 7605 R.P.M.
Oil temp. inlet to electric heater : 55
0
C(through regenerative heat
exchanger)


Oil temp. at outlet to electric heater : 65
0
C
Water temp. in the heater tank. : 90

0
C

GENERATOR In this section, Mechanical energy given
to the turbine is converted into Electrical Energy. Here,
Turbine rotates the Alternator at 3000 rpm. And electricity
is generated of High Ampere. This is later stepped up to high
voltage for Transmission using a step-up transformer.

Make BHEL (KWU)
Type THDF 115/59
Code IEC 34-1, VDE 0530
Cooling, stator winding Directly water cooled, Stator core , rotor
Directly hydrogen cooled.


RATING
Apparent power 588 MVA
Active Power 500 MW
Power factor 0.85 (lag)
Terminal voltage 21 kv
permissible variation in + 58 %
Voltage. Speed/ Frequency rpm/Hz 3000/50
Stator corrent 16200 Amps.
Hydrogen pressure kg / cm
2
4
Short Circuit Ratio 0.48
field current ( Calculated value) 4040 A
Field Voltage 340V
Class and type of Insulation MICALSTIC (Similar to class F)
No. of terminals brought out 6
Resistance in ohms at 20
o
C
Stator winding between terminals u-x 0.001414
v-y 0.0014 17
w-z 0.001420
Rotor winding F1- F 2 0.068293
MAIN EXCITER
Active Power 3780 KW
Current 6300 A
Voltage 600 V
Speed 3000 rpm.
Voltage Regulating System
Type Thyristor 04-2
Maximum output voltage 250 V
Output current for field forcing 152 A
Output current for rated Generator load 88A
Auxiliary Voltages from three phase supply. 220 V
Pilot exciter for thyristor sets 400 Hz.
D. C. Voltage From station for contactors & drives 220V
Power input continuously < O.1 KW


Power input, short time < 1 kw
DC Voltage from Station battery 2x24 for controls Max. 15 A Positive,
and regulation Max. 6A negative
Rated secondary voltage 120v
Power input of Voltage transformer per phase 2 VA
Rated secondary current 5 A
Power input of current transformer per phase 6.5 VA (Plus losses in
connecting lead)
Accuracy of control Better than + - 0.5%
Setting range of voltage point potentiometer +58 - 15% of nominal
generator voltage.
Setting range of drop compensation or compounding + 0-10% dependent on
the and proportional to reactive current* setting of the potentiometer

------------------------------------------------------------------------------------------------
* Direction of reactive current compensating depend on the phase relation which is determined by
connection of CT's to TVR terminals.



TORQUE, CRITICAL SPEEDS

Maximum short circuit torque of stator at line to line single phase short circuit
1488 kpm
Moment of inertia of generator shaft 10,000 kgm
2

Critical speed (Calculated) nk1 14.4 S
-1
(V-GEN)
nk2 30. 1 S
-1
(V-EXC)
nk3 39.8 S
-1
( S-GEN)
GENERATOR VOLUME AND FILLING QUANTITIES
Generator volume (Gas Volume) 80 m
3

CO2 filling quantity *** 160 M
3

(STP) *
H2 filling quantity ** (to 4 bar) 520 M
3
(STP) *
* STP = Standard temperature and pressure. 0
0
C and 1.013 bar to DIN 1343.
** Volume required with unit at stand still with the unit on turning gear, the volume will be higher.
*** CO
2
quantity kept on stock must always be sufficient for removal of the existing Hydrogen
filling. All values are approximate.

GENERATOR PROTECTIONS
Generators are high quality machines for securing the best possible continuity
of power supply. In addition to a suitable technical design and responsible mode of
operation, provision has therefore been made for automatic protection facility the
following protections have been provided in the 500 MW T. G.
1. Generator Differential protection (87G)
2. Generator Low forward power protection ( 37G )
3. Negative phase sequence protection (46G)
4. Pole slipping protection (98G)
5. Under frequency protection (81G)
6. L.B.B. Protection (50G)
7. Gen field failure protection (40G)
8. Stator Earth fault protection (64 G1 & 64G2)
9. Inter turn fault protection (95 G)
10. Over load protection (51G)
11. Over Voltage protection (59G)
12. Gen. Back up impedance protection (21G)


Specification of Transformer
Generator Transformer
Manufacturer TOSHIBA
Nos. of units 10 Nos. (1 0)
Rating HV & LV (MVA) 200 MVA
Rated Voltage, HV 420 KV
Rated Voltage. LV 21 KV
Rated current, HV 825 Amps
Rated current, LV 9520 Amps
No. of phases 1
Frequency 50 Hz
Type of cooling OF AF
Connection symbol when formed a bank YD5
Impedance at principal tap (75
o
C) 12.5%
OFF CKT Tap Changer Tapping in 5 equal steps of 2.5% each
provided on HV winding to give +5%
to 5%
Temperatures rises Variation of high voltage
o Oil, by thermometer 50
o
C
o Winding, by resistance 55
o
C
CTI and WTI, auxiliary contacts settings
o OTI Alarm 85
o
C
Trip 90
o
C
o WTI Alarm 105
o
C
Trip 115
o
C
Station Transformer
Manufacturer HHE
Nos. off 3
Capacity 20/35/50 MVA
Voltage Ratio 33/11.5/6.9 KV
Vector group DY/nY/n
Unit Auxiliary Transformer
Manufacturer HHE
Nos 6
Capacity 20/25 KVA
Voltage Ratio 21/6.9 KV
Cooling ONAN/ONAF


Percentage impedance 8.5%
C.T. Transformer
Manufacturer HHE
Nos. 2
Capacity 20/25KVA
Voltage Ratio 33/6.9
Vector group DY/n
Percentage impedance 8.5%
Cooling ONAN/ONAF
Ash Water Transformer
Nos. off 2
Capacity 1250 KVA
Voltage Ratio 11KV/433V
Percentage impedance 0.06
Station Service Transformer
Make M/s. ASGM Gmbh
Nos. off 6
Capacity 1600 KVA
Voltage Ratio 6.6 KV/0. 433 KV
Vector group Dynl
Percentage impedance 0.08 + 10%
Unit Service Transformer
Nos. off 6
Capacity 1600 KVA
Voltage Ratio 6.6 KV/433 V
Vector Group DY 1
Percentage impedance 0.08 + 10%
TIE TRANSFORMER
Manufacturer TOSHIBA
Nos of units ONE
Rating 55/75 MVA (30)
Rated Voltage, HV 400 KV
Rated Voltage. LV 34.5 KV


Rated current. HV 1260 Amps
Rated current, LV 108 Amps
No. of phases 3
Frequency 50 Hz
Type of cooling ONAN/ONAF
Connection symbol YND11
Impedance at principle tap 11.74% @75
0
C
Fuel Oil Service Transformer
Manufacturer M/s. Ingra
Nos. off 2
Capacity 1250 KVA
Voltage Ratio 11/0. 433 KV
Vector group DYnl
Percentage impedance 6%
WATER TREATMENT PLANT Water quality within
powers is of critical importance in maintaining efficient
operation and in limiting downtimes due to corrosion or
maintenance. The major phases and stages where water
quality is measured are discussed in this application note
along with the parameters measured. Raw water contains
organic matter, inorganic salts, bacteria which need to be
removed before being fed to the boiler. It follows the three
major steps for the purification of raw water
Disinfection by Chlorination In this stage, microbiological
organism is removed from the water before it is further
purified or processed.
Softening of Water In this stage, the hardness producing
inorganic materials like Calcium and Magnesium are
removed from the water. Because these substance can
cause more consumption of fuel, caustic embrittlement of
the boiler leading to blast of boiler. Here Lime soda
process is followed where calcium is precipitated into


carbonates and Magnesium into magnesium hydroxide.
These are then settled and filtered.
Dechlorination of Water It is the process of removing
residual chlorine from disinfected wastewater prior to use
it. Sulfur dioxide is most commonly used for
dechlorination. This is done either by
o Carbon bed which is not that much effective, or
o Addition of bisulphate, later removed by Anion
exchange process.

Block Diagram of a Water Treatment Plant

The water treatment plant here is established by Driplex
Water Engineering.



Technical Specification of the Plant as well as its auxiliaries
Pre-treatment Plant
Clarifier-cum-Flocculate:
No. and type One (1)
Rated effluent flow 3000m
3
/hr.
Effluent Turbidity 20 NTU
Retention Time at rated speed
Floculation Zone 30 min.
Classified Zone 2 hrs. 30 min
O.D. at top 20.6
Bridge revolving Speed 0.038
Gravity Filter
Nos. 2
Flow rate per filter 300 M
3
/hr.
Surface flow rate 4.845 M
3
/hr/m
2

Filter water reservoir and transfer pump:
Reservoir Capacity 450 M
3

Nos. of pump 3 working+1
Standby Capacity of pump 150 M
3
/hr.

CHEMICAL DOSING SYSTEM
Alum Dosing Pump
Nos. of Tanks 3
Capacity 8 Hrs. each to clarify
Strength of solution 10%
Alum Dosing System
Type Positive displacement
Control 0-100% automatically by pneumatic stroke positioned


Nos. 2 each of 100% cap.
Lime Slaking Tank
Capacity 12 hrs. consumption of clarifiers at 10% strength.
Nos. 2
Lime Slurry Transfer Pump
Nos. 2
Capacity 4M
3
/hr.
Lime Solution Preparation Tank
Capacity 6 hrs. consumption of clarifier at 6% strength w/v
strength of solution 6%
Nos. 4.
Lime Solution Dosing Pump
Type positive displacement
Control 0-100% automatically by pneumatic stroke positioned
No. 2 each of 100% cap.
Coagulant aid preparation Tank
Nos. 2 each of 100% cap.
Control 0-100% manually by micrometer dial.
Type Positive displacement type.
Chlorination System
Nos. of chlorinators 4
Capacity 10 Kg/hr
Type of Injector Vacuum type
Water Booster pumps 3 Nos. (2 w+1 s) Horizontal, centrifugal type

DEMINERALIZATION PLANT
GENERAL
Nos. of stream 3
Normal Flow through one stream 130m
3
/hr
D.M. water storage tank 3 Nos. of 2000 m
3
each


ANION EXCHANGER
No. off/stream 2
Design flow rate 130 m
3
/hr.
Shell lining 4.5 mm thick
Shell Material IS - 226
Size WBA 2100 x 4688, SBA 2100 x 5320
Qty. WBA 4.4 m
3
- IRA - 93 RE, SBA 5.17 m
3
-IRA-40 RC
Regeneration NAOH
MIXED BED UNITS
No. off 3
Design flow 130 m
3
/hr.
Surface flow rate 40 m
3
/hr/m
2

Material IS-226 shell.
Resin Cation + Anion 2 M
3
+ 2m
3
, IR-120 = MB + IR 402 MB
REGENERATION SYSTEM
Storage tanks Acid Alkali
No. 4 4
Size Dia & Length 3200 x 6766 mm 3200mm/6760 mm
Capacity 50 M
3
50 M
3

Lining RL-4.5 mm RL 4.5 mm
Concentration of chemical 30% 48%
UNLOADING PUMP
Acid Alkali
Nos. 2 2
Type Horizontal Horizontal
Centrifugal Centrifugal
Capacity 20 M
3
20M
3

TDH MWC 10 10
Neutralization System:
No. of pits 2
Capacity 450 M
3



Recirculation cum disposal pump :
Nos. 2/pt (Total 4 nos.)
Capacity 150 M
3
/hr/at 15 mwc
Duty 3 hrs. every shift
D.M. Tanks:
No. 3
Capacity 2000 M
3
each
Size 14 M x 14.M - Ht.
Material MS I. S. - 226.
Activated Carbon Filter :
No per stream 1
Design Flow rate 145 M
3
/hr.
Design Surface flow rate 15 M
3
/hr/m
2

Filled Ht. 1200 MM
Supporting Material Graded Gravel- 225 mm (Ht.)
Material of shell IS 2002 Gr. II
Internal painting epoxy.
Cation Exchanger:
No per stream 2
Design Flow rate 130 M
3
/hr.
Design surface flow rate 35 M
3
/hr/M
2

Filled Ht. WAC-1.00 m, SAC 1.610 M
Qty. of resin WAC -3.46 M
3
m3-IRC-84RF, SAC 5.54 M
3
-IR-120 RF
Regeneration by Hydrochloric Acid
Shell size 2100 mm
2
(wac)
Material of shell IS -226 Rubber Lined.
Degasser System:
Nos. of 3
Type Forced draft type
Normal Flow rate 130 M
3
/hr
Filled Material P.P.N.
CO
2
content in effluent 5 PPM (Max.)


Shell material IS 226
Rubber Lining 4.5 mm thick
Size 2000 x 5575 ht (Degasser tower)

Ash Handling Plant Ash is the residue left after the coal is
incinerated. In Thermal Power Plants coal is generally used as fuel
and hence the ash is produced as the byproduct of Combustion. Ash
generated in power plant is about 30-40% of total coal consumption
and hence the system is required to handle Ash for its proper
utilization or disposal.
Ash generated in the ESP which got carried out with the flue
gas is generally called Fly ash. Around 80% is the value of fly
ash generated. It also consists of Air pre heater ash &
Economizer ash (it is about 2 % of the total ash content).
Ash generated below furnace of the steam generator is called
the bottom ash. Bottom ash (Bottom ash is 20% of the ash
generated).

Schematic Diagram of an Ash Handling Plant



The ash handling system handles the ash by bottom ash handling
system, coarse ash handling system, fly ash handling system, ash disposal
system up to the ash disposal area and water recovery system from ash pond
and Bottom ash overflow. Description is as follows:
Bottom Ash Handling System Bottom ash resulting from the
combustion of coal in the boiler shall fall into the over ground,
refractory lined, water impounded, maintained level, double V-
Section type/ W type steel- fabricated bottom ash hopper
having a hold up volume to store bottom ash and economizer
ash of maximum allowable condition with the rate specified.
The slurry formed shall be transported to slurry sump through
pipes.
Coarse Ash (Economizer Ash) handling System Ash
generated in Economizer hoppers shall be evacuated
continuously through flushing boxes. Continuous generated
Economizer slurry shall be fed by gravity into respective
bottom ash hopper pipes with necessary slope.
Air Pre Heater ash handling system Ash generated from APH
hoppers shall be evacuated once in a shift by vacuum
conveying system connected with the ESP hopper vacuum
conveying system.
Fly Ash Handling System Fly ash is considered to be collected
in ESP Hoppers. Fly ash from ESP hoppers extracted by
Vacuum Pumps up to Intermediate Surge Hopper cum Bag
Filter for further Dry Conveying to fly ash silo. Under each
surge hopper ash vessels shall be connected with Oil free
screw compressor for conveying the fly ash from Intermediate
Surge Hopper to silo. Total fly ash generated from each unit
will be conveyed through streams operating simultaneously
and in parallel.
Ash Slurry Disposal System Bottom Ash slurry, Fly ash slurry
and the Coarse Ash slurry shall be pumped from the common
ash slurry sump up to the dyke area which is located at a
distance from Slurry pump house.



Technical Description of Ash Handling System
HOPPER SPECIFICATION

S. No. Description Units
Provided
per Boiler
Ash Collection Rate per
Boiler, Kg/Hr ( Max @
100% BMCR)
Holding
Capacity in
Hrs.
1 Furnace bottom ash hopper 1 32800 Not less than
2 hrs.
2 Economizer 4 8190 8
3 A. H. Hopper
a) Primary
b) Secondary

4
4

2800
5310

8
8
4 E. P. Hopper
1
st
Row
2
nd
Row
3
rd
Row
4
th
Row
5
th
Row
6
th
Row

16
16
16
16
16
16

103000
17560
6210
2555
1170
570

8
8
8
8
8
8

PUMPS SPECIFICATIONS
L. P. Fly Ash water Pumps
No. of Pumps : 4
Location : Ash water pump house
Capacity : 1100 M3/Hz
Head : 65 MWC
Suction : Submerged
RPM : 1500
H. P. Fly Ash Water Pump
No. of Pumps : 3
Suction : Submerged
Capacity : 300 M3/Hr
R.P.M. : 1500 rpm
Head : 95 MWC


Location : Ash water pump house
Motor : 110 KW
Seal Water Pump
Units : 2
Stand-by : 1 Unit
Capacity : 100 M
3
/hr
Head : 160 MWC
Type : Centrifugal Pumps
Location : Inside Ash Slurry Pump House
R.P.M. : 3000 rpm
Suction : Flooded
Motor : 90 KW
Fly Ash Slurry pump (Refer item for Bottom Ash Slurry Pump)
No. of pumps Ten (10) size streams (each stream having two pumps in series)
No. of Unit operation Three (3) streams working and two (2) stand by
Type Horizontal single stage centrifugal with non-clog impeller
Location Inside Ash Slurry pump house
Capacity 1300 M
3
/Hr
Head 40 MWC
Motor 330 KW
Heavy Fuel Oil Handling System This is the Heart of
the boiler of the plant or we can say it is the heart of any fuel
based power generation station around the globe. Fuel
handling and storage problems can limit the efficiency of the
entire boiler.
SOLID FUELS
Solid fuels (including coal, wood, and solid waste) present
some of the same handling difficulties. Problems occur unless a
free-flowing, continuous supply of fuel that is properly sized for the
specific type of combustion equipment is provided. The problems
include sizing, shredding or pulverizing, consistency of moisture
content, freezing or lumping, dusting, fires in storage due to


spontaneous combustion, and fires in the feed or ash handling
systems.
Most problems can be minimized or eliminated through proper
selection of fuel handling equipment. Specific types of equipment
for handling, storage, and preparation depend on the characteristics
of the solid fuel used.
Because the proper equipment is not always available, fuel
additives or aids have been used in the attempt to minimize
problems. These additives include grinding aids, moisture
improvers, dusting aids, freezing inhibitors, and catalysts to
minimize combustibles in ash and fly ash handling systems.
LIQUID FUELS
Liquid fuels include waste oils, light oils, heavy oils, and other
combustible liquids. Because of the problems of liquid residue
disposal, an increasing variety of combustible liquids is being
considered and tested. Figures 20-1 and 20-2 illustrate key
components found in a typical liquid fuel handling system and fuel
oil storage system, respectively.
Problems encountered in the handling, storage, and
preparation of liquid fuels include water contamination, sludge
formation, resistance to flow, biological growths, instability, and
corrosiveness. Generally, these conditions are manifested as
excessive strainer plugging, poor flow, increased loading on the fuel
pump, heater deposits, fuel line deposits, loss of storage space,
burner tip deposits, burner fouling, leakage due to storage tank
corrosion, poor atomization, and other combustion problems. Table
20-1 summarizes the nature and cause of problems associated with
key liquid fuel handling system components.
Compressed Air System Air compressors are used to
supply process requirements, to operate pneumatic tools
and equipment, and to meet instrumentation needs. Only 10-
30% of energy reaches the point of end-use, and balance 70-


90% of energy of the power of the prime mover being
converted to unusable heat energy and to a lesser extent lost
in form of friction, misuse and noise.
Compressors are broadly classified as: Positive
displacement compressor and Dynamic compressor.
o Positive displacement compressors increase the
pressure of the gas by reducing the volume.
Positive displacement compressors are further
classified as reciprocating and rotary
compressors.
o Dynamic compressors increase the air velocity,
which is then converted to increased pressure at
the outlet. Dynamic compressors are basically
centrifugal compressors and are further classified
as radial and axial flow types.
COMPRESSED AIR SYSTEM
Manufacturer : Kirloskar Pneumatic
Model Number : T-BTD-BM
Type of compressor : Horizontal Balanced Opposed
Numbers : Eight Units
Instrument Air : 4 Units.
Plant Air : 4 Units
Actual capacity of each compressor : 30.0 Nm
3
/min
Discharge pressure Kg/cm2 gauge : 8.0
Design ambient temperature : 50 deg C
Design ambient pressure : 0.99753 Kg/cm
2

Design ambient humidity : 100%
Exact capacity considering worst : 39.05(at45 deg.C&75%RH)



EQUIPMENT COOLING SYSTEM Thermoelectric
power plants boil water to create steam, which then spins
turbines to generate electricity. The heat used to boil
water can come from burning of a fuel, from nuclear
reactions, or directly from the sun or geothermal heat
sources underground. Once steam has passed through a
turbine, it must be cooled back into water before it can be
reused to produce more electricity. Colder water cools the
steam more effectively and allows more efficient
electricity generation.
ECW Pumps (D.M. Water)
Nos : 3 (1 standby)
Flow : 2140 M
3
/hr
Suction Head : 30 MWC
Discharge Head : 50 MWC
MOTOR Rating : 400 KW
Speed : 985 RPM
Plate Type Heat Exchanger
Nos : 2 (1 standard)
Fluid : Primary - Secondary
: D.M. Water - Raw water
In/Out let temp 0C : 44.5/38 - 35/40.92
Flow rate (M
3
/hr) : 2140 - 2350
Equipment Cooling Water Storage Tank
Elevation : 24.0M
Capacity : 60 M3 for unit No. 4, 50 M3 for unit 5 & 6

Diesel Generator Set After a blackout (a near total
loss of generation and load) takes place, efforts have to
be taken to bring back the system to a normal state at


the earliest. It may surprise you to know that this (black
starting!) is not an easy task. Once a generator is
tripped, restarting it requires a significant amount of
power. Power is required for 2 types of activities:
o Survival Power: For emergency lighting,
battery chargers etc. Usually the requirement
is 0.3% of the generator capacity.
o Startup Power: For starting power plant
auxiliaries (pumps etc.) Interestingly, nuclear
and thermal units require approximately 8 %
of the unit capacity for auxiliaries alone!
Therefore, a 500 MW generator requires
approximately 40 MW for running its
auxiliaries.
Technical Specification
Manufacturer
Engine : Kirlosker Cummins
Alternator & Exciter : NGEF
Control panel : Control & Switchgear Co. Pvt. Ltd.
Battery : Exide
Charge : Logic stat
Engine
Rating at site condition : 750 KVA
Engine type : KTA 3067 G
RPM : 1500 rpm
No. of Cylinders arrangement : 16 cylinder 60
0
Vee.
Starting time : 30 Sec from Cold
Governor : PSG Motorised
Fuel Oil : HSD as per IS: 1460 grade
Lube Oil : MIL IS2104 C
Guaranteed fuel oil Consumption at 100% : 150 gms/BHP/hr
Lub. oil consumption : 0.62 lit/hr


Mech. Efficiency : 38%
Total Weight : 6 Tons
Alternator
KW : 600
KVA : 750
PF : 0.8
Stator Current : 1043 A
Speed : 1500 rpm

Fire Fighting System Fire is big threat and cause loss to
human life and property. However, disasters due to fire normally
remains localized to a particular installation until and unless
tripping of the entire power plant causes disturbance in the
transmission grid by way of over loading and leading to tripping of
other power stations/ transmission lines connected with the grid.
The most common cause of the fires is known to be electrical short
circuits and fire triggered by the inflammable materials. The
damages caused by the fire accidents generally take excessive time
for restoration. Analysis of causes of fire incidents reveal that
majority of the fires could perhaps be prevented and extent of
damage minimized, if fire safety measures were strictly enforced.
Early detection of fire and swiftness in fighting it can definitely turn
major disaster to minor accidents. In power sector accidents taking
place on account of human error or due to malfunctioning of any
equipment are also causes of crisis situations. In this plant the
following equipments are installed for fire-fighting
Sprinkler System
Jockey Pump
Hydrant System with Booster Pump
Air Condition System It is another method
equipment cooling in the power station. The major function
of air-condition is to optimize the temperature and control


the humidity of the Major components as well as of its
auxiliaries.
Compressor
Main Control Room Esp Control Room
Maker Kirlosker Pheumatic Co. Kirlosker Pheumatic Co.
No. off Six (6) Six (6)
Model AC - 1670 AC - 470
No. of Cylinders 16 4
Type Reciprocating Reciprocating
Refrigerant R-22 R-22
Type of Cooling Air Cooling Air Cooling
Condensing temp 2
0
C 4.44
0
C
Operating RPM 1450. 1250 1000
Capacity (TR) 136.96,117.19 25.86
Drive KW at 50
0
C 128.99,111.18 23.27

Condenser
No. off Six (6) Six (6)
make Kirlosker Pneumatic Co. KirloskerPneumatic Co.
Model 500-9, 500-8 250-70
Over all size OD 640X3419, 640x3114 340 x 2275(MM)
Shell Thickness mm 8 6.35
Tube Mat. Copper Copper
tube Size dia mm 19 19
Tube Thickness mm 1.41 1.41

Interlocking & Protections
Air PreHeater Interlocking
FD Fan Interlocking
ID Fan Interlocking
PA Fan Interlocking
Scanner Fan Logic
Seal Air Fan Logic
PUL Reviser
CC Pump Protection


MFT Conditions
Boiler Flame Failure Protection
Turbine Protection
Generator Protection
Earthling and Lightning Protection



Introduction: The Hasdeo Bango Hydel Electric Project
is situated at village Machadoli, Katghora, Korba at left bank
of Hasdeo River. This Project is designed for multipurpose
use. The Project was sanctioned by Planning Commission in
March 1984. Hasdeo Bango Dam meets the water
requirement of Aluminum Plant, SECL, NTPC, CSPGCL, Korba
Town and other industrial units.
Geographical Location: The Hasdeo Bango Hydro
Electric Plant is situated at Hasdeo River, the geographical
location is at Latitude 223613.69 N & Longitude
823549.95 E [Turbine Floor is at 302.44 Meters from
MSL]
Capacity: Three units of 40 MW each.
Commissioning dates:
Unit I - March 1994
Unit II - July 1994
Unit III - November 1994


Salient Features:

Project Cost: Project Cost of Bango Hydel Station was
105.39 Crores (Civil Works: 33.70 Crores, Electrical &
Mechanical Works: 71.69 Crores)
Power Evacuation: The Power is evacuated through
132 KV Korba East, Jamnipali, Manendragarh and
Bishrampur feeders.
Achievements: National Award with Gold Shield by
Ministry of Power, Govt. of India in recognition of
outstanding performance during the year of 2006-07.

Chhattisgarh State Power Generation Company Limited

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Deepak Raj Kurrey

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