POWER GENERATION AND DISTRIBUTION IN VIZAG STEEL PLANT

N.SANTOSH SUSHMITA DAS K.KIRAN KUMAR J.SURESH KUMAR V.UMA SOUJANYA B.BHARATH KUMAR P. V. JAGADEESH BABU

VIZAG STEEL PLANT

Visakhapatnam Steel Plant (VSP), the first coast based Steel Plant of India is located, 16 KM South West of city of Destiny i.e. Visakhapatnam. VSP has an installed capacity of 3.3 million Tonnes per annum of liquid steel which will be doubled by 2012. VSP has become the first integrated Steel Plant in the country to be certified to all the three international standards for quality (ISO-9001), for Environment Management (ISO-14001) & for Occupational Health &

INTRODUCTION TO THERMAL POWER PLANT

Thermal power plant in VSP is a captive power plant which is established in the year 1988. It is established mainly to reduce the cost of power consumption. TPP covers an approximate area of 20 acres. The fuel input of TPP is imported from Bailadilla ores located in Chattisgarh and

OBJECTIVES OF TPP
To

Supply uninterrupted Cold Blast to Blast Furnaces as per Furnace requirements . supply uninterrupted Essential Power. supply 13 ata process steam for other units of Steel Plant.

To To

To

supply quality De Mineralised water to meet both internal and plant needs.

POWER GENERATION & DISTRIBUTION

Constituent departments Thermal Power Plant Distribution Networks

ENERGY CONSUMPTION
SPECIFIC

POWER CONSUMPTION 600-650 kwh /Ton of steel

AVERAGE

POWER DEMAND :

227 MW

POWER REQUIREMENT

Average Load : 227 MW Peak Load : 260 MW

SOURCES OF POWER

CAPTIVE

POWER PLANT

STATE

ELECTRICITY GRID

CAPTIVE GENERATION SOURCES

Thermal Power Plant Back Pressure Turbine Station

Gas Expansion Turbine Station

MAIN EQUIPMENTS OF TPP

Chemical Water Treatment Plant Boilers Turbo-Generators Turbo-Blowers CDCP Boilers Back Pressure Turbine Station Gas Expansion Turbine Station

Chemical Water Treatment Plant (CWTP)

Water to the boilers and other departments is fed from kanithi balancing reservoir. Boilers require soft water failure of which forms scales and sludges. CWTP produces high purity demineralized water and soft water. It has a total 6 De-mineralizing units of125 cu m/hr each and 2 softening units of 125 cu. m/hr each.

BOILERS
Boiler is an enclosed vessel in which water is heated and circulated until the water is turned in to steam at the required pressure.

BOILERS

5(4 working +

1Standby) CAPACITY 330 Tons/ Hr PRESSURE 101ata TEMPERATURE 540o C

All the boilers in VSP are of water tube type and of BHEL make. Boiler coal is imported from Bailadilla ores in Chattisgarrh and also from Orissa. Coal is crushed and stored in RMHP. Soft water is provided to the boilers which is treated at chemical water treatment plant and fed to the boilers through 7 boiler feed pumps each of 2.4MW. Boilers outlet flue gas is passed through electro static precipitators to control air pollution.

TURBO GENERATORS
4 TGs : ( 360MW + 167.5MW )
Special features:

Electro Hydraulic Turbine Governing System. Controlled extraction at 13ata and 4ata for process steam needs. (Only in TG 1,2 & 3) Central admission of steam to reduce axial thrust.

Steam is admitted at 90 ata pressure and 500O C. Steam extracted at 13ata is used for valve operations of the different equipments and 4ata is used for instrumentation purposes. Each turbo generator generates power at 11KV. All the power generated from TG-1, 2 and 3 is directly distributed at 11 KV for essential category loads of VSP.

Excess power from TG- 1, 2 and 3 is transferred to 220 KV plant grid through three 50/63MVA step up transformers at LBSS-5. Turbo generators of VSP operate in parallel with state grid. Excess generation over and above plant load is exported to APTRANSCO. The short fall of power under certain conditions is availed from APTRANSCO.

TURBO BLOWERS
Turbo blowers are blowers which produces compressed air with the help of a steam based turbine.

BLOWERS CAPACITY

3( 2 Working + 1 Standby ) 6067 M3 /min each

These blowers are of axial type and are the largest blowers installed in India. To meet the varying needs of Blast Furnace, the blowers are provided with adjustable stator guide blades.

Special Features :
- Constant Speed with EHTC

- Inlet Guide Vane Control

- Axial type Largest blowers in India

AUXILLIARY UNITS OF TPP

CDCP (COKE DRY COOLING PLANT) BOILERS 16nos Back Pressure Turbine Station 2 x 7.5 MW Gas Expansion Turbine Station 2 x 12 MW

COKE DRY COOLING PLANT (CDCP) BOILERS

Hot coke produced in the Coke Oven Batteries is cooled by circulating Nitrogen.

Hot circulating nitrogen gas is passed

through Waste Heat Boilers in which steam

is produced at 40ata pressure and 440OC

temperature.

BACK PRESSURE TURBINE STATION

The 40ata steam generated in CDCP

Boilers is utilized for driving 2 Nos. of 7.5 MW Back Pressure Turbines for generation of Power.

Steam is admitted at 40ata pressure and

440OC temperature and exhausted at 2.5ata pressure.

It has a controlled extraction of 7ata

pressure.

The turbine and alternator are of BHEL

2.5ata exhaust steam is utilised for production of chilled water in CWP-1. 7ata extraction steam for process requirements of CO & CCP zone. These alternators run in synchronous with the main generators and are connected to LBSS-5 through a 220KV 31.5/40/50MVA three winding step up transformer.

GAS EXPANSION TURBINE STATION (GETS)

Hot flue gases from the blast furnaces is utilised as input to drive turbines in GETS. The gas is first cleaned and heated to 140 OC before using it. Each BF is connected to a turbine of 12MW capacity. 7.5MW of power is expected at full production level.

Special features First of its kind in India. Motor mode operation. At very low pressure or during shutdown of blast furnaces, the alternator takes input from the supply lines and acts as a synchronous motor (condenser) which helps in improving the power factor of the grid. Water washing of stator & rotor blades. Variable stator vanes.

POWER DISTRIBUTION IN VSP

Power distribution in VSP is categorized as four types:

Extra High Voltage Distribution (220Kv)

High Voltage Distribution (33/11/6.6kv)

Medium Voltage Distribution (Below 650 V) Low Voltage Distribution (250 V And Below)

EXTRA HIGH VOLTAGE DISTRIBUTION (220 KV)

Power from APTRANSCO is received at Main Receiving Station (MRS). The entire plant is configured as five electrical Load Blocks and Step down Sub-Stations (LBSS 1-5) with 220 KV transformers to step down for further distribution. LBSS1 is connected to LBSS5 by two radial lines. LBSS 2,3&4 are connected to MRS by

POWER NETWORK
EASTERN BUS 400 Kv TO JAIPUR (ORISSA) DC BACK TO BACK

POWER GRID SUB STATION

TO VIJAYAWADA (NUNNA)

SOUTHERN BUS 400 Kv

315MVA 400/220 Kv AUTO XMER

220 Kv

APSEB SWITCHING STATION

TO BOMMURU TO PENDURTHI TO GAJUWAKA

- BREAKER

AL1

AL2

BUS 1

MRS 220 Kv

MRS
BC

VSP
TO CPRS

BUS 2 LBSS 3 LBSS 4

LBSS 2
ML1 ML2 ML3

12.5 MVA 220/33 Kv XMER

LBSS 1

BUS 1
BUS 2 T1 50/63 MVA T2 50/63 MVA

TPP 220 Kv BC T4 31.5/40/50 MVA

LBSS 5

T3 50/63 MVA

T5 90 MVA

GSB 1

GSB 2
11 Kv

GSB 3

TG 1 60 MW

TG 2 60 MW

TG 3 60 MW

TG 4 67.5 MW

BPTG 1 7.5 MW

GETG 1 12 MW

BPTG 2 7.5 MW

GETG 2 12 MW

LOAD BLOCK AND STEPDOWN SUB-STATIONS

STATION DESIGNATION LBSS1 (220/11/6.6 kV) LBSS2 (220/11/6.6 kV) (220/33 kV) LBSS3 (220/11/11 kV) AREAS COVERED RMHP, CO & CCP, Sinter Plant, BF BF, SMS, ASP, CRMP, Comp. House-1 Ladle furnace in SMS Medium Merchant Structural Mill LMMM, WRM, Aux. Shops, Adm. Building and Kanithi reservoir pump house. TPP, Plant essential category loads, KBR & Township pump houses & hospital. Plant, Township and construction network.

LBSS4 (220/11/11 kV)

LBSS5 (220/11&220/11/11kV) MRS (220/33 kV)

HIGH VOLTAGE DISTRIBUTION (33/11/6.6KV)

220KV Power is stepped down to 11/6.6 KV at each LBSS station. This power is distributed to smaller Load Block Distribution Station (LBDS) located in each unit. Cross-linked Poly Ethylene (XLPE) cables are used for 11 KV distribution. 6.6 KV supply is mostly used for motors of rating 200 to 2000 KW.

 Medium

Voltage Distribution(Below

650v) For medium and low voltage loads of 11KV/415 V Load Centre Sub-Stations (LCSS) are formed. Power is fed from LCSS to Motor Control Centre, Power Distribution Boards, Lighting Distribution Boards. PVC cables are used for medium voltage distribution generally.
Low

Voltage Distribution (250 v and below) Consists of power supply on single phase

ESSENTIAL CATEGORY LOADS

Some of the technological process/ equipment requires all time availability of electricity. These include exhausters in BF, SMS, rolling mills, kanithi reservoir pump house, TPP auxiliaries, hospital etc. which accounts to a total of 70MW. Disturbance of supply may involve dangerous situation to equipment/ heavy losses to the plant. Power is supplied to them from TPP generator 11kv switch board and also from

LOAD BLOCK STEP DOWN SUBSTATION 5

This 220 KV Sub station serves as outdoor switch yard for TPP. This substation consists of 5 in no. 220 KV/11 KV transformers connected to the 11 KV generated switch board of TPP. MRS and LBSS-5 are interconnected with three numbers of 220 KV tie lines. The TPP is synchronized with APTRANSCO grid, supply at 220 KV/11 KV and

Power is fed from LBSS-5 to LBSS-1 at 220

GENERATOR SWITCH BOARD (GSB-1)

GSB-1 is a 11 kV, 4500 Amp, 3 section board located in ECR. Each 60 MW generator is connected to one section of the board. GSB-1 is provided with a normal bus coupler and also a reactor bus coupler of 4500 Amp reactor between section 1 & 2 as well as between Sections 2 & 3. Reactor bus couplers are employed to oppose sudden changes in current while coupling the buses. All essential category loads of plant are served directly from GSB-1.

GSB-2 & GSB-3 11kV SWITCH BOARD

GSB-2 is connected to BPTS and GETS generators-1 where as GSB-3 is connected to the generators-2. No outgoing feeders are connected in both these board. These generators are connected to system through a three winding 220/11/11KV 31.5/40/50MVA Transformer

SWITCH GEAR IN LBSS-5

CIRCUIT BREAKERS: A circuit breaker is a piece of equipment which can make or break a circuit either manually or by remote control under normal conditions break a circuit automatically under fault conditions All the incoming feeders are provided with 4500A SF6 gas type and outgoing feeders are provided with 2000A MOCB type circuit breakers.

INSTRUMENT TRANSFORMERS: The function of these instrument transformers is to transform voltages or currents in the power lines to values which are convenient for the operation of measuring instruments and relays. There are two types of instrument transformers Current transformer (C.T.) Potential transformer (P.T.)

The use of instrument transformers permits the following advantages: They isolate the measuring instruments and relays from high-voltage power circuits. The leads in the secondary circuits carry relatively small voltages and currents. This permits to use wires of smaller size with minimum insulation. All the PTs and CTs of LBSS-5 are of BHEL make.

LIGHTNING ARRESTER A lightning arrester or a surge diverter is a protective device which conducts the high voltage surges on the power system to the ground. Under normal operation, the lightning arrester is off the line i.e. it conducts no current to earth or the gap is nonconducting. On the occurrence of overvoltage, the air insulation across the gap breaks down and an arc is formed, providing a low resistance path for the surge to the ground.

In LBSS-5 lightning arrestors are of MACHAS make. These are heavy duty station class type. A total no. of 24 lightning arresters are provided each has rated voltage of 198KV and rated current 10KA. ISOLATOR Isolator is a switch used to make sure that an electrical circuit can be completely deenergized for service or maintenance. Isolator is an off-load device intended to be opened only after current has been

FREQUENCY BASED ISOLATION OF TPP

To isolate the plant from over/under frequency conditions of the AP Transco grid, three frequency relays are provided in each section of GSB-1 Each relay has four frequency based operation elements. Rate of change of frequency(df/dt) with a starting under frequency of 47.7 Hz and sustained over frequency of 51.5 Hz for 0.15 sec are the extremities for isolation of load.

Frequency based isolation scheme is provided in three stages:

Stage-I

Frequency isolates plant form Grid at 220 kV after a sustained under frequency of 47.5 Hz for 0.5 sec.

Stage-II Frequency isolates the GSB from 220 kV network by tripping the 63 MVA transformers after a sustained under frequency of 46.9 Hz for 1 sec.

Stage-III Frequency isolates some of the selected loads from GSB-1 after a sustained under frequency of 46.0 Hz for 0.15sec.

POWER TARIFF
The APTRANSCO Power tariff for VSP is a two part tariff. Contracted Maximum Demand =135MVA Energy charges are divided into i. General industrial load ii. Lighting & fan load Where lighting & fan load cannot be segregated, 15 % of total energy accounted as lighting & fan load. Power factor of VSP shall not be less than 0.95 lag.

CONCLUSION
We had learnt about the process of generation of power in a thermal power plant and also using a gas expansion turbine, which is a useful recovery of waste energy. The applications of various electrical equipments used in sub-stations for safe transmission of power are clearly observed. The overall plant line diagram has helped

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