TRAINING REPORT ON T.P.

S SIKKA

A TRAINING REPORT ON SIKKA THERMAL POWER PLANT

Prepared By:-

Ankleshwariya Siddharth

Academic Year:- 2012 College:SHEKHAWATI ENGINEERING COLLeGE DUNDLOD, JHUNJHUNU (RAJ.)

TRAINING REPORT ON T.P.S SIKKA

SHEKHAWATI ENGINEERING COLLAGE DUNDLOD, JHUNJHUNU (RAJ.)

CERTIFICATE

This is to certify that Mr. ANKLESWHARIYA SIDDHARTH D. of B.TECH 6 semester (Electrical) has satisfactorily completed his industrial project report on THERMAL POWER STATION (GENERATION 120MW X 2 UNITS) AT SIKKA during training period from 1 June 2012 to 30 June 2012 and submitted on _____________
th st th

______________ Staff in-Charge 2

_________________ Head of Department

TRAINING REPORT ON T.P.S SIKKA

ACKNOWLEDGEMENT
I am very gladly thankful to our training and placement officer and our all electrical staffs which give me a great guidance regarding training and instruct us the importance of training in electrical field. So I decide to take training in TPS and I tried for that and at last I joined Sikka TPS which is situated in Jamnagar distict. In TPS Sikka many persons help me in the duration of our training period. They give me excellent guidance regarding electricfield. So, I heartly thankful to all staff members who guided me regarding the electrical equipments used in the TPS and take deeply interest in my subject. I am especially thankful to respected Chief Engineer (Gen.), TPS, Sikka & GUJRAT STATE ELECTRICITY CORPORATION LTD (GSECL). Because he grantd me permission for taking training in this wonderful campus. Lastly I acknowledge all the respondent, well wishers who directly or indirectly helped us in completing this industrial training.

ANLESWHARIYA SIDDHARTH D. SEC-DUNDLOD, JHUNJHUNU (RAJ.)

TRAINING REPORT ON T.P.S SIKKA

INTRODUCTION
Today our life is more comfortable because of invention of modern technology. Without this technology our life becomes miserable. We cant imagine our life without electrical resources and equipments. In limited period of time there are many inventions have been done regarding engineering field. In electrical field also much improvement has been shown in this time. There is a one major factor which affects all this invention is generation of electricity. Generation is the main plinth of the electricity field. This can be approved by Thermal Power Plant. Now a days there are mainly three types of power plant are used namely Thermal Power Plant, Hydro Power Plant, and Nuclear Power Plant. Generally in Thermal power plant at first due to the combustion of coal heat energy is produced in the boiler this heat energy is converted into mechanical energy due to the steam energy by using turbine and at last mechanical energy has been converted into electrical energy by generator. This generated power is given to the grid. In India all the power plant are connected in the grid system. All the plants have been distributed in mainly four grid. These grid have been controlled by different LDC( Load Dispatch Center) which controls the generation of energy and load requirements. In all of them I selected Thermal Power Plant for improve my technical knowledge regarding it. There are many advantage have been shown in Thermal Power Plant. Basically Thermal Power Plant is operated on the base load with high load capacity and it has very high value of generation capacity. In Gujarat there are mainly nine Thermal Power Plant have been situated. They all are operated in interconnected grid system. In all of them I take my training in Thermal Power Plant at GSECL(Gujarat State Electricity Corporation Limited) Thermal Power Plant, Sikka near Jamnagar city. This highly introduced me regarding generation of electrical energy.

TRAINING REPORT ON T.P.S SIKKA

SITE REQUIREMENTS
The basic requirements of the conventional Thermal Power Plant is decided on the type, size and other essential specifications of the station to be constructed. It is necessary to know the capacity of the plant that will be required for development as well as for the period to follow thereafter. The size of the site required depends on several factors like the fuel used and its mode of delivery to the site, the area provided for the fuel storage, cooling towers, switchyards, space needs for store yards, workshop, etc.

The following factors are to be taken to consideration

.

Geology:The geology of the site should be reasonable as this affects the cost of the foundations. Modern power plants with their heavy structures impose a heavy load on the subsoil and hence are to be supported with suitable foundations.

Water for Power Station:The water requirement for thermal power station come under two main groups, the first requirement is the water required for steam generation and the second requirement is for cooling purposes. The water sources available near to thermal power station. The water sources are like canal, pond, dam, lack, bore well, sea water, etc. When we use sea water that time we require RO(Reverse Osmosis) plant to convert the sea water into potable water(Drinking water).

Coal and Power Station:In India, the principal source of commercial energy is coal amounting to over 95% of the total primary energy resources of the country. The coal resources existing in our country are of the order of 1,30,000 million tones or even more and new reserves being located. The main areas where coal mines are located are eastern region i.e., Bihar, Jharkhand, Chhattisgarh and small sources of coal are located in rest of the country as well.

TRAINING REPORT ON T.P.S SIKKA

Transport:In case of thermal power station, the problem of transport is to be considering mainly from the view point of fuel, coal economics and for initial erection of the plant. Modes of transport are also to be considered but may not be overriding factor in decision regarding feasibility. At this stage the possibility of rail and road connection capable of taking heavy and over dimensioned loads of the machines are to be considered.

Disposal of Effluents:The major effluents in case of thermal station are in ash and flu-gases. The disposal of chemically treated water generated in the water treatment plant is also an effluent, which requires attention for disposal. The disposal of gases and ash concern mainly the atmosphere and environment and that of water is concerned with the effect on marine life of the rivers and canals. The method of disposal of ash has been by converting it into slurry and pumping the same by means of ash disposal pumps or hydro aces to waste lands. It is in this connection that the requirement of large area of waste lands for effluent disposal plays a decisive factor in location. One 100 MW unit will produce about 400 to 450 tones fly ash per day on full load.

Transmission:A route must be available for the transmission lines from the site to the nearest grid system or major load point on the area board system, which can accept the station output.

Climatic Condition:Climatic condition of a place play a significant part in the economics of capital investment. The tropical climate existing in most parts of our country, calls for special attention to the ventilation and cooling arrangement.

Proximity of Airfields:Before the site is selected its proximity to air fields must be studied. The chimney height now goes up to 500-600 ft. and boiler house structure up to 200 ft. These present
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obstacles in air navigation particularly during landing and takeoff. The air safety regulation must be taken into account before locating the power house.

Fisheries and Marine Life:The intake of large volume of water from the river and consequent throw off at a higher temperature after being treated with chlorine will affect fish. On some rivers where fisheries are located, the plant site may have to be shifted through the location may be suitable on other considerations. The effluent discharge from water treatment plant has to be treated suitably before discharging it to the river.

TRAINING REPORT ON T.P.S SIKKA

INTRODUCTION ABOUT PLANT

In Gujarat there are nine Thermal Power Stations have been situated. All are under the Gujarat Government. Sikka based power plant is one of them. This plant is known as GUJARAT STATE ELECTRICITY CORPORATION LIMITED, THERMAL POWER STATION, SIKKA. This power plant is installed in Sikka near Jamnagar district in 1984. Initially it has only one unit had installed which have capacity of only 120MW. After some years for more requirement another 120MW unit has been installed for generation of electricity. So, now total capacity of power plant become 240MW of electricity generation. These units are installed of area about 280 acre land and situated at the coast of Arabian Sea. The two other unit worth each generating capacity of 250 MW. In Sikka these units are designed and monitoring has been done by GSECL engineers, TATA consulting engineers and BHEL engineers. In this plant main fuel used is bituminous coal which has been exported from another state like Jharkhand and Chhattisgarh. This coal has been taken by train. For the starting of boiler some types of oil have been necessary like FO (Furnace oil), LDO (Light Diesel Oil). Sikka thermal power plant has been situated at the coast of Arabian Sea, so there are lots of sea water is available for cooling purpose. For feed water which used in the boiler for generation of steam which has been easily available from the Sasoi Dam. Which is nearly situated at the plant. This water must be demineralised, so for that Demineralised Water Plant (D.M.PLANT) has been installed for the satisfy the availability of water. For the sea water Reverse Osmosis (R.O.PLANT) has been necessary which has been also installed in the plant campus. So the future of the Sikka power station has been quite bright.

TRAINING REPORT ON T.P.S SIKKA

Generally in Thermal Power Plant are mainly given below,

Coal Handling Plant R.O. Plant Boiler Turbine And Generator D.M. Plant Electrostatic Precipitator Unit Switchyard

Plant Capacity:-

Unit No.
1 2 Total

Installed Capacity
120 120 240

Date of Commission
26/3/1988 31/3/1993

TRAINING REPORT ON T.P.S SIKKA

COAL HANDLING PLANT

Coal Handling Plant is key plant for generation of power in a Thermal Power Station. The coal handling plant of Sikka TPS is supplied and erected by M/s ELECON Engg.co.Ltd. The daily consumption of coal for 1*120 MW units is approximate 1500 MT. The coal is transported through railway in 8 wheeler box type wagons from Jharkhand and Chhattisgarh. Average weight of coal (stack) is approximate 55 MT. As Daily approximately plant require 25 boxes to handle plant. Each boxes (Wagon) capacity is 60-70 tone and 58 wagon per train.

General Description of Coal Handling Plant

Loaded coal wagon with the help of Inhaul wagon marshalling equipment is brought on the tippler platform from where it is unloaded with the help of wagon tippler hopper. From Wagon Tippler - 1 and 2 hoppers, coal passes through Apron Feeder - 1 and 2 and Single Roll Crusher 1 and 2 to belt conveyor no. 1 and 2 respectively. Product size of single roll crusher is 200 mm. Conveyor 1 and 2 take the coal on the conveyor no. 4A and 4B. Which is turn take the coal to Junction Tower 2 where , in line Magnetic Separators are provided to remove the iron pieces from the coal and thus to safe-guard the crusher. Now the coal is taken to crusher house with the help of conveyor no. 5A and 5B . In crusher house, ring granulators receive coal from conveyor no. 5A and 5B through roller screens. The product size is 20 mm and it is fed to conveyor no. 6A and 6B through Belt feeder 3A and 3B. The crushed coal is taken to Bunkers via Junction Tower no. 1 where again in line magnetic separators are provided for removing the iron pieces/particles from the crushed coal. The crushed coal is brought to JT 1 with the help of conveyor no. 6A and 6B. From here the coal is fed to bunkers by travelling trippers, through Belt feeders 4A and 4B and conveyor no. 7A and 7B. Conveyor 4A and 4B can also receive coal from manual unloading hopper via conveyor no. 3. The coal is fed on to the conveyor no. 3 through motorized rack and pinion gates RPG 1A and 1B, 1B and 1C, and with the help of Belt feeder BFD 1A, 1B and 1C. When coal is required in boiler house coal bunkers, crushed coal would be fed to conveyor 6A and 6B. When crushed coal is not required in coal bunkers, the same would be fed to conveyor no. 8A and 8B for stacking. In no wagon period, whenever required the coal is reclaimed by bulldozers and fed to reclaim hoppers from where it is fed to conveyor no. 6A and 6B via conveyor no. 9A and 9B.The coal from bunkers are fed to crushing mill via coal feeders. There are two types of mill are used in the Unit 1 and 2.
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Photo of a wagon

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The Unit 1 uses bowl mill and Unit 2 uses tube mill of 6 nos. for pulverizing the coal. The coal is pulverizing in the size of micron and this coal is fed the boiler furnace. Coal dust arising from various feed point in bunker floor, Junction Tower 1 and crusher house would be extracted by dust extraction system, while coal dust arising at wagon trippers, and manual unloading hoppers would be suppressed by dust suppression system, thus keeping the coal handling system free from dust. Each belt conveyor stream is having a normal capacity of 500 MTPH. Also the crusher is having a normal capacity of 500 MTPH. The coal handling system is designed to handle coal normally having the following properties: a) Moisture b) Bulk Density c) Maximum Size - 20% - 0.85 tones/m3 - 200 mm after single roll crusher - 20 mm after crusher house

Following equipment are used in to the coal handling plant. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. RPG BFD CONV IMS FG DC SRS CR TC CS MD TT B AF WT JT CH :- Rack And Pinion Gate :- Belt Feeder :- Conveyor :- Inline Magnetic Separator :- Flap Gate :- Dribble Conveyor :- Screen Roller Screen :- Crusher :- Telescopic Chute :- Conveyor Scale :- Metal Detector :- Travelling Tippler :- Breaker :- Apron Feeder :-Wagon Tipplers :- Junction Tower :- Crush House

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OPERATION OF THERMAL POWER PLANT

Coal is conveyed at coal conveyor from an external stack and ground to a very fine powers by large metal sphere in the pulverized fuel mill. Then it is mixed with preheated air driven by the forced draught fan. The hot air fuel mixture is forced at high pressure into the boiler where it rapidly igniters. Water of a high purifier flows vertically up the tube line walls of the boiler drum, where it turns into the steam is separated from any remaining water. The steam is passes through a manifold in the roof of drum into the pendent superheated where its temperature and pressure increase rapidly to around 200 bar and 570C sufficient to make the tube walls glow a dull red. The steam is piped to the high pressure turbine, the first of a three stage turbine process. The steam is exhausted from the high pressure turbine and reduced in both pressure and temperature and is returned to boiler reheater. The reheated steam is then passed to the intermediate pressure turbine and from there passed directly to the low pressure turbine set. The existing steam now a little above its boiling point, is brought into thermal contact with cold water in the condenser, it is condensed rapidly from steam to water. The condensate water then passes by a feed pump. Through a deaerator and pre warmed, first in the feed heater powered by steam drawn from the high pressure set and then in the economizer, before being returned to the boiler drum. The cooling water from the condenser is sprayed into the cooling tower, creating a highly visible plume of the water vapor, before being pumped back in to the condenser in cooling water cycle. The three turbine sets are sometimes coupled on the same shaft as the three phase electrical generator which generates an intermediate level voltage. This is stepped up by the unit transformer to a voltage more suitable for transmission and is sent out onto the three phase transmission system. Exhaust gas from the boiler is drawn by induced draught fan through an Electrostatic Precipitator (ESP) and is then vented through the chimney.

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BOILER
General Description
A boiler is a closed vessel, which is used to generate the steam under pressure at some rate. Type : Tangentially Fired, Balanced Draught (F.D. & I.D. Fans) Make : Bharat Heavy Electrical Limited (India) Fuel : Indian Bituminous Coal The boiler is designed to meet the nominal requirement of 120MW turbo generator set. The unit is designed for maximum continuous rating of 383 T/hr of steam flow at pressure of 135 kg/cm2 and steam temperature of 540C. The main function of boiler in Thermal Power Plant is that the heat of combustion of coal in the boiler is utilized to convert water into steam at high temperature and pressure. The flue gases from the boiler make their journey through super heater, economizer, and air pre-heater and are finally exhausted to atmosphere through the chimney. The unit is of natural circulation type with complete water cooled furnace, tangentially fired, balanced draught radiant reheat type, dry bottom with direct fired pulverized coal with bowl mills. In Sikka based thermal power plant boiler used is water tube type with maximum steam temperature is 2000C. In natural circulation boiler the water flow from drum to down comer and from water wall to drum is established by a force created by different in specific weight of cold and hot water. The furnace is burner arranged for dry ash discharge and is fitted with Nos. of coal burners located at different elevation at each four corners. The Nos. of oil burners with capacity to maintain MCR of boiler are also located at different elevation at each four corners sandwiched between coal nozzles. The unit is provided with 6 Nos. of coal mills. Fire of which are capable to take load up to MCR. Two Nos. of FD (Forced Draught) fans are provided per boiler to provide sufficient air required for proper combustion at MCR (Max. Continuous Rating). Two Nos. of ID (Induced Draught) fans are provided for each boiler to maintain the furnace draft at MCR.

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The main parts of the Boiler are:1. 2. 3. 4. 5. 6. 7. 8. Drum Super heaters Preheaters Economizer Air Preheater Furnace Burners Igniters

1. DRUM:The boiler drum is made of Alloy steel plate. The drum dished ends are provided with manholes covers. Welded studs are provided for all connection including large bore down corners, CBD, EBD, chemical dozing etc. The drum internal consists of an internal feed distribution system. The water in the furnace side walls and the extended side walls absorbs heat. The resulting mixture of water and steam is collected in the outlet headers and discharged into the steam drum through a serried of riser tubes. Steam generated in the front and rear walls is supplied directly to the steam drum. In the steam drum, separation of water and steam takes place. The boiler water mixes with the incoming feed water. The saturated steam is led to the superheater via the superheater connecting tubes. More over level controller, level indicator and gauge glasses are fitted with drum. Level should be maintained to normal. If level rises, the carry over to turbine increases. If level low, The water walls starve and fail due to overheating. Two nos. of safety valves are provided on the drum, one on left hand side and the other on right hand side. The set values of these safety valves are 158 kg/cm2 and 162 kg/cm2. The safety valves when opens can handle fall steaming capacity of boiler. 2. SUPERHEATER:The steam produced in the boiler is wet and is passed through a superheater where it is dried or superheated by the flue gases on their way to chimney. Superheating provides two principal benefits. Firstly, the overall efficiency is increased. Secondly, too much condensation in the last stage of turbine is avoided. The superheated steam from the superheater is fed to steam turbine through the main valve.

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The superheater is composed of four basic stage or sections Platen section, a pendant section, a rear horizontal section and the steam cooled wall and roof section. The platen section is located directly above the furnace in front of the furnace arch. The Pendant section is located in back of the screen wall tubes. The horizontal section of the superheater is located in the rear vertical gap pass above the economizer. The steam cooled wall sections from the side, front and rear walls and roof of the vertical gas pass. 3. REHEATER:Type : Pendant Total H.S. in M2 : 1260 Control : Burner Tilt The reheater is composed of two stages or sections, the front pendant section and the rear pendant section. The rear Pendant section is located above the furnaces arch between the water-cooled screen wall tubes and the rear water wall hanger tubes. The front pendant section is located between the rear water-fall hanger tubes and superheater platen section. 4. ECONOMISER: An economiser is essentially a feed water heater and derives heat from the flue gases for this purpose. The feed water is fed to the economiser before supplying to the boiler. The economiser extracts a part of heat of flue gases to increase the feed water temperature. Type : Bar tube Total H.S. in M2 : 3890 No. of blocks : Three The purpose of economiser is to preheat the boiler feed water before it is introduced into the steam drum, and to recover some of the heat from flue gases leaving the boiler. The economiser is located in the boiler rear gas pass below the rear horizontal superheater. Feed water is supplied to the economiser inlet header via the feed stop and check valves. The feed water flow is upward through the economiser, that is in counter flow to the hot flue gases. Most efficient heat transfer is here by accomplished. Any difficulty with steam generation within the economiser is eliminated by the upward water flow. From the outlet header the feed water is led to the drum via the economiser outlet links.

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5. AIR PREHEATER: An Air Preheater increase the temperature of the air supplied for coal burning by driving heat from flue gases. Air is drawn from the atmosphere by a forced draught fan and is passed through Air Preheater before supplying to the boiler furnace. The Air Preheater extracts heat from flue gases and increases the temperature of air used for coal combustion. The principal benefits of preheating the air are increased thermal efficiency and increased steam capacity per square meter of boiler surface. 6. FURNACE: The furnace of boiler of completely water cooled. The furnace is enclosed in a skin casing which is placed directly behind the furnace tubes. Skin casing is provided with suitable insulation and exterior of furnace is finished off with casing of ripped aluminium sheets. The front and rear water wall of the furnace are tapered at the bottom to form a hopper with suitable manhole door. The construction of furnace bottom depends on fuel and a conditions. Bottom designed most commonly used for coal fired units are of the open hopper type, often referred to as the dry bottom type. For gaseous and oil fuels, closed bottoms are generally utilized. In the bottom type construction two furnace water walls, usually the front and rear walls, slope down toward the centre of the furnace of from the inclined, sides of the bottom. Ash and slag from the furnace is discharged through the bottom opening into the ash hopper directly below it. Depending the height of the furnace, 6 to 14 inches clearance between the furnace and ash hopper us allowed for downward expansion of the furnace walls. 7. BURNERS: There are total 24 pulverized coal burners for corner fired and 12 oil burners provided each in between two pulverized fuel burner. The pulverized coal burners are arranged in such a way that six mills supply the coal the burners at 4 corners, of the furnace. All the nozzles of the burners are interred linked and can be tilted as a single unit from +30 to -30. The oil burners are fed with heavy fuel oil till boiler load reaches to about 25%. 8. IGNITERS: There are 12 side eddy plate oil igniter per boiler. The atomizing air for igniters is taken from plant air compressors at 7 kg/cm2. The burner is located at three elevations. Each elevation has four oil burners and igniters. These elevations are normally known as AB elevation, CD elevation and EF elevation. Igniters are used for lighting the main oil for combustion of igniter oil. Mainly two types of igniters are used. Eddy Plate Igniter High Energy Arc Type Igniters

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BOILER AUXILIARIES
The different boiler auxiliary equipments are as given below. 1. Coal Bunker: These are in process storage silos used for storing crushed coal from the coal handling system. Generally, these are made up of welded steel plates. Normally, there are six such bunkers supplying coal of the corresponding mills. These are located on the top of the mills so as to aid in gravity feeding of coal. 2. Coal Feeder Each mill is provided with a drag link chain/rotary/gravimetric feeder to transport raw coal from the bunker to the inlet chute, leading to mill at a desired rate. 3. Mills: There are six mill of 25% capacity each, for every 200 MW unit, located adjacent to the furnace at oM level. These mills pulverize coal to the desired fineness to be fed to the furnace for combustion. 4. P.A.Fan: The primary air fans (2 per unit and 50% capacity each) are designed for handling atmospheric air up to a temperature of 50C. these fans are located at oM level near the boiler. 5. Air Pre-Heater: Air Pre-Heater transfer heat from flue gases to cold primary and secondary air by means of rotating heating surface elements. These regenerative type air pre-heater, there exists a steam coil sir pre-heater. These are located in the secondary pass of the furnace at a height of around 16 M level. Each 200 MW unit is provided with two such air pre-heater. 6. Burners: As evident from the name itself, these are used for burning pulverized coal or oil. Every unit has a set of such burners located at different elevations of the furnace.

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7. F.D.Fan: The forced draught fan (2 per unit and 50% capacity each) are designed for handling secondary air for the boiler. These fan are located at oM level near the PA Fan. 8. Wind Box These act as distributing media for supplying secondary air to the furnace for combustion. These are generally located on the left and right sides of the furnace while facing the chimney. 9. Electrostatic Precipitator These are generally two plate type located between boiler and the chimney. The precipitator is arranged for horizontal gas flow and is constructed with welded steel casings. 10. ID Fan There are two induced draught fans per boiler located between the Electrostatic Precipitator and the chimney. These fans are used for sucking flue gas from furnace. 11. Chimney These are tall RCC structure with single or multiple flues. The height of these chimneys vary depending on the location considerations anywhere between 150 m to 220 m.

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BOILER OPERATION
The boiler is a rectangular furnace about 50 feet (15m) on a side and 130 feet (40m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (58mm) in diameter. At starting boiler fired by using LDO (Light Diesel Oil) and FO (Furnace Oil). Light Diesel Oil and Furnace Oil are heavy oil. LDO flow by using air where as FO flow using steam. Pulverized coal is air-blown into the furnace from fuel nozzles at he four corners and it rapidly burns, forming a large fireball at the center. The thermal radiation of the fireball heats the water that circulates through the boiler tubes nears the boiler perimeter. The water circulation rate in the boiler is three to four times the throughout and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700F (371C). It is separated from the water inside a drum at the top of the furnace. The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam us superheated to 1000F (500C) to prepare it for the turbine. Plants designed for lignite coal are increasingly used in location as varied ad Germany, Victoria and North Dakota. Lignite is a much younger form of coal than black coal. It has a lower energy density than black coal and require a much larger furnace for equivalent heat output. Such coals may contain up to 70% water and ash, yielding lower furnace temperature and requiring larger induced draft fans. Plants that use gas turbines to heat the water for conversion into steam use boilers known as heat Recovery Steam Generator(HRSG). The exhaust heat from the gas turbines is used to make superheated steam that is then used in a conventional water-steam generation cycle, as described in gas turbine combined-cycle plants section below. Maximum operating life of boiler is 25 year.

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FEED WATER HEATING AND DEAERATION

The feed water used in the steam boiler is a means of transferring heat energy from the burning fuel to the mechanical energy of the spinning steam turbine. The total fees water consists of re-circulated condensate water and purified makeup water. Because the metallic materials it contacts are subjects to corrosion at high temperatures and pressure, the makeup water is highly purified before use. A system of water softness and ion exchange demineralizers produces water so pure that it coincidentally becomes an electrical insulator, with conductivity in the range of 0.3-1.0 microsiemens per cm. The makeup water in a 500 MW plant amount to perhaps 20 US gallons per minute (1.25 L/s) to offset the small losses from steam leaks in the system. The feed water cycle begins with condensate water being pumped out of the condenser after travelling through the steam turbines. The condensate flow rate at full load in a 500 MW plant is about 6000 US gallons per minute (400 L/s).

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Diagram of boiler feed water with vertical, domed aeration section and horizontal water storage section. The water flows through a series of six or seven intermediate feed water heaters, heated up at each point with steam extracted from an appropriate duct on the turbines and gaining temperature at each stage. Typically, the condensate plus the makeup water then floes through a deaerator that removes dissolved air from the water, further purifying and reducing its corrosively. The water may be remaining oxygen in the water to below 5 parts per billion(ppb). It is also dosed with pH control agents such as ammonia or morph line to keep the residual acidity low and thus non-corrosive.

1. STEAM CONDENSING
The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be pumped. If the condenser can be made cooler, the pressure of the exhaust steam is reduced can be made cooler, the pressure of the steam is reduced and efficiency of the cycle increases.

Diagram of a typical water cooled surface condenser. The surface condenser is a shell and tube heat exchange in which cooling water is circulated through the tubes. The exhaust steam from the low pressure turbine enters the shell where it is cooled and converted to condensate by flowing over the tubes as shown in the adjacent diagram. Such condensers use steam ejectors or rotary motor-driven exhausters for continuous removal of air and gases from the steam side to maintain vacuum.

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For beat efficiency, the temperature in the condenser must be kept as low as practical in order to achieve the lowest possible pressure in the condensing steam. Since the condenser temperature can almost always be kept significantly below 100C where the vapor pressure of water is much less than atmospheric pressure, the condenser generally works under vacuum. Thus leaks of non-condensable air into the closed loop must be prevented. Typically the cooling water causes the steam to condense at a temperature of about 35C (96F) and that creates an absolute pressure in the condenser of about 2-7 Pa, i.e., a vacuum of about -95Pa (Template: Convert/in Hg) relative to atmospheric pressure. The large decrease in volume that occurs when water vapor condenses to liquid creates the low vacuum that helps pull steam through and increase the efficiency of the turbines.

2. CONDENSER
When steam exhaust from the turbine it exhaust in the condenser. Which is exhausted with high temperature and low pressure. Condenser is made up of copper tubes which are in large sizes. Generally two types of condenser are used one way and two way types of condensers. In Sikka thermal power station two type circulating tubes are used. When water passes through the tubes and steam exhaust at the condenser it contacted with the outer surface of the tube. Cooling water passes through the tubes. When this steam connected with the water it becomes cooled. In Sikka thermal power plant cooling water is taken from the sea. Which passed through the copper tubes. Which cooled the steam hence steam cooled and become water which collected in the storage tank and further taken by the boiler feed pump. Due to the condenser water is circulating in cyclic process. So the efficiency of the plant become quite high. In Sikka thermal power plant sea water is used as cooling water so no need of cooling tower for cooling the condensate cooling water. This technique is quite cheap in the processing.

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LDO PUMP HOUSE

When the plant has been start up after the shut down position so at first boiler is taken to at some rated temperature range than the coal have been used in it. So at first LDO oil have been used in this RFO and LFO type oil have been used for the lighting the unit. In this thermal power plant there are two sections of LDO pumps have been used. This oil is quite thick so it cant pass through the tubes of boiler so it is heated by one heater at rated temperature of oil. This oil has been stored in a large tank at about 60C temperature. This oil has been taken in the heater by using oil pump. In this pump house a 3 phase Induction motor has been used. In heater oil has been heated through the steam which exhaust by the turbine. Oil has been heated up to 130C temperature and at last is given to the turbine at high temperature and pressure. Due to the high pressure oil has been injected in the boiler furnace which makes one boll of fire which called the fire ball. So at last the oil has been ignited and the water has been boiled through it.

ID AND FD ( INDUCED DRAFT AND FORCED DRAFT )FANS

In past the draught system which used in the factories for the cooling purpose or for the air circulation. This type of circulation is called the natural air circulation but it is not more effective. In the power plant this type of circulation is not more effective hence mechanical draught system have been used. In this system ID fan and FD fan are used. Forced draught fan is used to connect with the Air Preheater in which is forced air is taken by the fan. One highly rated motor is connected with the fan which operate fan. ID fan is used to exhaust the flue gases in to the boiler furnace and this fan flow out these in to the atmosphere through the chimney. ID fan is very useful for the power plant to control the flue gases in to the boiler furnace. FD fan is also very useful for power plant for boiler furnace. This fan useful to the maintain the temperature of the coal powder in to the boiler furnace. It is also produce very hot air in to the boiler furnace to make properly fire of coal. Plant used only 15% to 40% air of this fan first air is stored in to the wind box and than flow in to the boiler furnace by four corners.

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ELECTROSTATIC PRECIPITATOR

Due to combustion of coal ash particles are produced are produced in the steam which passed through the turbine than exhaust in the chimney. If these dust particles directly disposed to the atmosphere hence it is quite dangerous for the human health and produced major pollution in the air. So it is quite necessary to remove these particles from the gas which is done by the electrostatic precipitator which is one type of electrode. There are two electrodes have been used in it. Both are positively charged so when dust particles pass through it hence the negatively charged dust particles attract with the positive charged plate and stick with the plate. At last these all particles have been collected from the bin. Remaining gas has been exhaust in the air which is not as much effective than the first. Which is discharged through the ID fan. The ash content in the Indian coal is of the order 30% to 40%. When coal is fired in the boiler, ashes are liberated and about 80% of ash is carried along with the flue gas. If these ashes are allowed to atmosphere, it will create an air pollution thereby resulting in health hazards. Hence it is necessary to precipitate the dust from the flue gases and in this process electrostatic precipitator finds a place in boiler . In this 120 MW boiler, burning about 100 tons of coal per hour gas will be of the order of 27 tons/hr. The additional advantages obtained because of the installation of precipitator is that the wear of the ID fan blades are reduced due to precipitation of dust, resulting in reduced maintenance work in ID fan. The electrostatic precipitator is efficient in precipitation of particles from submicron to large sizes of particles and hence they are preferred to mechanical precipitators. The efficiency of modern ESP is of the order of 99.9%.

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R.O. PLANT (REVERSE OSMOSIS PLANT)

In Reverse Osmosis Plant the process of osmosis is reversed by the applying the some external force. This plant converts the sea water into the drinking sweet water. In this plant various processes used are explained below. R.O.Plant has been used when shortage of water in the plant. In Sikka thermal power plant large amount of cooling water has been necessary so for this sea water has been used for cooling purpose. This has been fulfilled by R.O.Plant. When the sea water has been passing through the inlet of membranes it is still salty so it is passing through the R.O. streams which are imported from the USA. In each stream there are 24 lines and in each line there are 6 membranes are arranged horizontally, so there are total 144 membranes arranged for purification of the sea water. In the membranes there is no. of CPA (Composite Poly Amide) stages. These stages of CPA are arranged around the pipe line. After passing through the membranes now the water divided in to two tubes. One tube is of clean water which stored in the storage tank which is placed outside of the R.O.Plant. Sikka based R.O.Plant is biggest plant in Gujarat State at the side of sea-sore.

This water is given to the Row water house where the water is supplied for the different purposes in the plant. The efficiency of this plant is about 30% if we inlet 100 liters water we get 30 liters of sweet water and remaining 70 % of the water is returned to the sea. By using this plant we can fulfill the requirement of water of water which used in the plant or in a colony for drinking purpose.

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D.M. PLANT (DEMINERALISED PLANT)

In the boiler the feed water is used demineralised water only. This DM plant takes water from the Sasoi dam. The water which used in the boiler must be totally demineralised. Process of working of this plant is given below. Figure shows complete cycle of D.M. Plant. In this plant water has been taken from Sasoi dam than it is taken into the reservoir via clarifier. Because in dam water there are large amount of ion, silicon and sand all are removed here. In clarifier aluminum spate has been used to remove chlorides from water. At last it clarifies the water. After clarifier it has been taken in the contact tank in which water is alumdizing takes place. After that it has been taken in the PSF (Pressure Sent Filter) in which all sand particles small as well as big has been removed. There are 4 no. of PSF tank, two in service where as other two for spare. Time period of clearing PSF tank every 12 hours. PSF tank remove florin by using Na2so3 (Sodium Sulfite) dosing than after it is given to the SAC. SAC (Strong Acid Citation) contain citation resin in which all positive ions like sodium, potassium and magnesium have been absorbed and give H+ water as output. The capacity of SAC tank is 3200 liter. After this water have been passed through WBA. WBA (Weak Base Anion) contain caustic soda in which all negative ions like sulfide, carbonize and chloride have been absorbed and give OH water as output. The capacity of WBA tank is 2100 liter. So from SAC and WBA all the ions have been removed than SBA (Strong Base Anion) removed all silica particles from water because 0.02 ppm water density increase from DM plant to boiler at the rate of 1 ppm. So that steam entering in the turbine and particles of silica deposit on the turbine and damages the turbine blade. Because silica increased with high temperature and high pressure. To remove silica caustic soda is used in SBA. At last water passes through the MB (Mixed Bed) where all remaining dissolved particles from the SAC, WBA, SBA have been polished by this system. Storage capacity of MB is 10 times higher than that of the WBA and SBA. In between WBS and SBA degasser tank is connected which remove the Co2 from the water by using blower. The water without Co2 is collected at bottom of the tank and Co2 in upward then in atmosphere. Collected water then passes through the SBA by using pump. At the last of this process this water has been stored in the storage tank which is called DM storage tank and this water is taken in the boiler. Due to demineralization this water cant damage the boiler tubes. The pH of water stored in the storage tank is 0.9 to 7 and its conductivity is less than 1 mass and containing of silica is 0.02 ppm.
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In this plant one lab has been worked which tested pH of water at every stage of filtration and other impurities of the time interval of one hour. The DM plant is very useful for the power plant. We can use dematerialize water in to the boiler also this type of water is very costly so this plant make the sea water and this DM water and this also effect the economic features of the plant.

CW PUMP HOUSE
This is the cooling water pump house where the steam become cooled down which is the outlet of the turbine. The cooling water from the steam is fed to the boiler and turbine auxiliary for cooling purposes. This water is goes to the condenser to condensate the steam. Moreover all the cooling system of the auxiliary cooled by the cooling water. The cooling water is taken from the channel made in the sea about 2 km distance. This cooling water is clean up in two stages like 1. Through section gate 2. Water traveling screen Section gate is one type of the gate which prevents the bigger impurities to run the water than this water traveling screen in the way of water which prevent from small impurities. Now this cleaned water is gathered in sump and from sump the water is pumped to the condenser by using C.W. pump. So in the thermal power plant C.W. pump is the most necessary part. There are 5 no. cooling water pumps are installed for supplying water to condenser and different auxiliaries.

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TURBINE

INTRODUCTION
The turbine is horizontal tandem compounded, reheat, impulse type three cylinder machine, with continues maximum economical mating of 120 MW at the generator terminal at a speed of 3000 rpm make by AEI (Associated Electrical Industries) UK supplied by BHEL. The design inlet conditions are 127.6 kg/cm2 and 538C fro main steam and 26.2 kg/cm2 and 538C for reheat steam. Provision is made for steam extraction from the turbine for 6 stage regenerative feed heating system. The high pressure steam chests are located one on the either side of the high pressure cylinder. Live steam from the boiler is admitted into the high pressure steam cheat which contains two combined isolating and emergency stop valves and one governor valve. This steam chest is interconnected with the second with high pressure steam containing only one governor valve by means of cross under pipes. Steam from these chests is supplied to the high pressure cylinder by means of 4 Nos. of high pressure loop pipes. Steam after expanding through the high cylinder is passed through the reheater section of the boiler. Reheat steam is supplied to two interceptor emergency stop valves ant two interceptor governor valves. From the interceptor steam chests steam is supplied through two intermediate pressure loop pipes welded to the bottom half of the inlet end of intermediate pressure cylinder. Steam after expanding through the intermediate pressure cylinder. Steam after expanding through the cross over pipes to a double flow pressure cylinder. Finally steam from low pressure cylinder is exhausted to the condenser. The flow of steam in the high pressure cylinder and intermediate pressure cylinder are opposite directions. The low pressure cylinder is of a double flow design. This arrangement ensures minimum axial thrust. Each flow to the low pressure cylinder is provided with a multi exhaust.

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1. HIGH PRESSURE CYLINDER

It is a double shell construction split horizontally and bolted firmly to avoid any leakage of steam. The double shell construction reduces the thermal stress to a minimum. High pressure cylinder consists of 11 impulse stages through which steam flows towards the front pedestal. The design of the turbine balding provides a high efficiency of energy conversion. A central pedestal is provided between the high pressure and intermediate pressure cylinder. The pedestal houses the combined thrust and journal bearing and coupling between the high pressure and intermediate pressure cylinder and IP inlet journal bearing. Two high pressure steam chests the provided one an each side of the HP cylinder with necessary piping, connecting chest and cylinders. One chest contains two combined isolating and emergency stop valves and one governor valve. The other chest contains one governor valve only.

2. INTERMEDIATE PRESSURE CYLINDER

Associated with the intermediate pressure cylinder will be two interceptor steam chests, one on each side of the turbine and necessary interconnecting piping between chests and cylinder. Each interceptor chest consists of one emergency valve and one governor valve. The intermediate pressure cylinder consists of 13 stages through which steam flows towards the low pressure end. Two tap offs are provided for feed heating. The opposite direction of steam flow in the high pressure and intermediate pressure cylinder tougher with the double flow arrangement of the low pressure cylinder reduces the axial thrust to a minimum. Further, this type of arrangement will ensure that the difference in the thermal expansion between the temperature stationary and rotating elements is reduced to a minimum.

3. LOW PRESSURE CYLINDER

It is a double flow arrangement with two openings. Each flow comprises six stages and includes amulet exhaust. Integral pedestal are provided for the bottom half casing of the low pressure cylinder. The pedestal is used for housing the journal bearings at either and of the low pressure cylinder. The generator side pedestal is also used for housing the turbine generator coupling and the turning gear. The rotating part of the turbine consists of a high pressure, intermediate pressure and low pressure rotors rigidly coupled so as to form a single rotor. The alternator rotor coupled to the relative to the stationary components by the trust bearing provided in the center pedestal. The direction of rotation of the rotor will be clock-wise when the machine is viewed from the turbine front pedestal.

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4. STEAM TURBINE TECHINCAL DATA

1. 2. 3. 4. Maximum Continues Rating Number of stages HP cylinder Number of stages IP cylinder Number of stages LP cylinder : : : : 120 MW at 3000 RPM 11 13 6 Double Flow

5. No. of extraction for regenerative feed heating system 6. Main steam Inlet pressure 7. Main steam Inlet Temperature 8. Reheat steam Inlet pressure 9. Reheat steam Inlet Temperature 10. Condensate back pressure

: : : : : :

6 127.6 kg/cm2 538 C 26.43 kg/cm2 538 C 74 mm hg. Abs.

15.8 TURNING GEAR

A turning gear, for slowly rotating the turbine rotor during starting and shutting down, is mounted on the rear end pedestal between the turbine and generator. It consists of two AC motors and the appropriate reduction gearing. The high torque motor stars the rotor from rest while the second motor increase the speed of the rotors to bearing speed so as to maintain oil film lubrication of the journal bearing and internal ventilation of the turbine casings, to some extent.

TURNING GEAR SPECIFICATION

1. Type 2. Method of Engagement 3. Motor 4. Type 5. Voltage 6. Phase 7. Frequency 8. Insulation 9. Main Motor 10. Auxiliary Motor 11. Turbine rotor bearing speed : : : : : : : : : : : Double Speed Clutch 2 Nos. Induction 415 V 3 50 Hz Class B 15 KW, 970 rpm 6.7 KW, 960 rpm high torque 2.5/33 rpm

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GENERATOR
Alternator is coupled to a steam turbine and converts mechanical energy of the turbine into electrical energy. The alternator may be hydrogen or air cooled. In Sikka plant hydrogen cooling is used for the alternator. The necessary excitation for the alternator is provided by means of main exciter. This is one type of D.C generator. Pilot exciters directly coupled to the main exciter through the shaft and both are coupled with generator. Pilot exciter is permanent magnet type D.C generator, which provided the excitation for the main exciter.

18.1 Specification of Generator :

1. KW 2. KVA 3. Stator Voltage 4. Stator Current 5. Rotor Voltage 6. Rotor Current 7. RPM 8. Pole 9. Frequency 10. Phase 11. Power Factor 12. Connection 13. Cooling 14. Insulation Class : : : : : : : : : : : : : : 20000 Watt 150000 V 10500 V 8248 Amp 179 V 2253 Amp 3000 6 50 Hz Three 0.8 Star H2 B (130 C)

18.2 Specification of Main Exciter :

1. KW 2. KVA 3. Voltage 4. Current 5. RPM 6. Pole 7. Frequency 8. Power Factor 9. Phase 10. Connection : : : : : : : : : : 993 Watt 1045 V 382 V 1945 Amp 3000 6 50 Hz 0.95 Three Star
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TRAINING REPORT ON T.P.S SIKKA

11. Excitation Voltage 12. Excitation Current 13. Max Inlet air temp 14. Insulation Class

: : : :

55 V 31.4 Amp 50 C B (130 C)

18.3 Specification of Pilot Exciter :

1. KW 2. KVA 3. Voltage 4. Current 5. RPM 6. Pole 7. Frequency 8. Power Factor 9. Phase 10. Connection 11. Insulation Class : : : : : : : : : : : 11.2Watt 12.5 V 450-380 V 0.18 Amp 3000 6 400 Hz 0.9 Three Star B (130 C)

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GENERATOR COMPONENTS
1. Stator Frame
The stator is the heaviest load to be transported. The major part of the load is the stator core. This comprises an inner frame and outer frame. The outer frame is rigid fabricated structure of welded steel plates, within this shell is fixed cage of girder built circular and axial ribs. The ribs divide the yoke in the compartments through which hydrogen flows into radial ducts in the stator core and circulate through the gas cooler housed in the frame. The inner cage is usually fixed into the yoke by an arrangement of springs to dampen the double frequency vibrations inherent in 2 pole generator. The end shields of hydrogen cooled generators must be strong enough to carry shaft seals. In large generator the frame is constructed as two separate parts. The fabricated inner cage is inserted in the outer frame after the stator core has been constructed and the winding completed.

2. Stator Core
The stator core is built up from a large number of punching or sections of thin steel plates. The use of cold grain-oriented steel can contribute in the weight of core for two main reasons: a) There is an increase in core stacking factor with improvement in lamination cold rolling and in cold building techniques. b) The advantage can be taken of the high magnetic of grain-oriented steels of work the stator core at comparatively high magnetic saturation without fear or excessive iron loss of two heavy a demand for excitation ampere turns from the generator rotor.

3. Stator Winding
Each stator conductor must be capable of carrying the rated current without overheating. The insulation must be sufficient to prevent leakage currents flowing between the phases to earth. Windings for the stator are made up from copper strips wound with insulated tape which is impregnated with varnish, dried under vacuum and hot pressed to form a solid insulation bar. These bar are thin place in the stator slots and held in with wedges to form the complete winding which is connected together at each end of the core forming the end turns. These end turns are rigidly braced and packed with blocks of insulation material to withstand heavy forces which might result from short circuit or other fault conditions. The generator terminals are usually arranged below the stator.

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4. Rotor
The electrical rotor is the most difficult part of the generator to design. It revolves in most modern generators at a speed of 3000 rpm. The problem of guaranteeing the dynamic strength and operating stability of such a rotor is completed by the fact that a massive non-uniform shaft subjected to multiplicity of differential stresses must operate in oil lubricated sleeve bearings supported by the structure mounted on foundations all of which posses complex dynamic be behavior . The passage of the current through the winding generates heat but the temperature must not be allowed to become high, otherwise difficulties will be experienced with insulation. To keep the temperature down the cross section of conductor could not be increased but this would introduce other problems. In order to make room for large conductors, body and this would causes mechanical weakness.

5. Rotor Winding
Silver bearing copper is used for the winding with mica as a insulation between conductors. A mechanically strong insulation such as micanite is used for lining the slots. Later design of winding for large rotor incorporate combination of hollow conductors with slots or holes arranged to provide for circulation of the cooling gas through the actual conductor when rotating at high speed. Centrifugal force tries to lift the winding out of the slots and they are contained by wedges. The end rings are secured to a turned recess in the rotor body by shrinking or screwing and supported at the other end by fitting carried by the rotor body. The two end of the windings are connected to slip rings, usually made of forged steel and mounted on insulated sleeves.

6. Temperature Monitoring:Temperature detector of the thermocouple type are provided for measuring temperature throughout the generator. A few of the couples are provided in the stator winding situated between the coil and separator inside the slots. Couples are provided for the gas inlet and outlet temperature and shaft seat.

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SWITCHYARD

One of the important unit and part of the thermal power plant is switchyard. In Sikka thermal power plant there are two generating units of 120MW so from this generating voltage which are step up and step down by the switch yard. In Sikka thermal power station there are two switch yard one of 132KV and another one is 66 KV. 66 KV switchyard connected through Interconnected Transformer with 132 KV switchyard. At a time of shut down or tripping time electricity is not generated in the plant so for starting of plant auxiliaries it must necessary of auxiliaries supply. So for that time power supply is taken from the grid. In Sikka thermal power plant there are two bus bars of grid. One bulbar is charged and take supply from it. When the unit is in starting condition hence from generator 11kv power generated at the output side which is step-up by step-up transformer which is known as generating transformer. There are two units of generating transformers. This voltage has been furthered step-down at 6.6kv which is given to the station auxiliaries which is known as unit auxiliary transformers. In 132kv switchyard there are six outgoing lines. One line is given to the step-down transformer which stepped down the voltage at 66kv which also have been six outgoing lines. Both busbars of 132 KV switchyard are connected with different types of transformer and lines. BUSBAR 1 Generating Transformer 1 Station Transformer 1 Jamnagar Naghedi Bhatia Interconnected Transformer 1 BUSBAR 2 Generating Transformer 2 Station Transformer 2 Ranavav Reliance Petrochemical Limited (R.P.L) Dhrol

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66 KV switchyard are connected with different types of lines. 1. 2. 3. 4. Gujarat State Fertilizer Corporation (GSFC) - 1 & 2 Sikka 1 & 2 Vadinar Maghpar

o There are some different type of equipments have been used which is given below.
1. High Voltage Transformer :Mainly two types of transformers are used in the plant one of the step up and step down. Another classification has been done by using its applications there are station transformer, auxiliary transformer, unit station transformer. They all are of high capacity about 500MVA to 50MVA capacities. Cooling of these transformers are must necessary. So there are different media of cooling have been used in the transformer. In 500MVA transformer oil has been circulating around the core of the surface which take heat of the core of the transformer. This oil has been colled out by the exhaust fan which given outside of the transformer body. Still the temperature of transformer is not controlled and its become high than the transformer will automatically tripped.

2. Circuit Breaker :In Sikka thermal power station there are generally two types of circuit breaker have been used. Circuit breaker is a protecting device. Which protects the transmission line in the faulty condition. When fault occurs circuit breaker operated and tripped hence protect from the accident. Circuit breakers are classified as per its uses and fuel used in it for protection. There are three types of circuit breakers are generally used in the switchyard. it.

3. Current Transformer and Potential Transformer (CT and PT) :In switchyard CT and PT is the most necessary equipments. Current transformer is used for measuring the current in ampere which is located at incoming and outgoing lines in the substations. Secondary of the CT never be opened because if it is opened hence very high earth fault current passes through it and it invites an accident. Potential transformer has been widely used for the measurement of the potential of voltage. When at high or low value of voltage means in darkness condition it tripped the transmission line.

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4. Lightning Arrestor :-

Lightning arrestor is located at the outgoing side of the switchyard or substation. It used for the protection from the lightning surges. When lightning surges passed through it a very high voltage passed through it. It earthed all the surge voltages and protect all the switchyard instruments from the lightning surges.

5. Wave Trap and Coupling Capacitor :Wave trap has been a simple one type of coil and coupling capacitor is the one type of the capacitor which use with the very high freq operation. Wave trap and coupling capacitor have been used for the carrier communication which has the intercommunication between the grid system.

6. Isolator :It is the manually operated switch when fault occurs in the line hence the circuit breaker tripped. Due to tripping of circuit breaker the line will disconnect from the healthy line. Some times due to the high inductance the faulty line will be charged and circuit breaker will be operated hence it invite a dangerous accident. So at the time of maintenance circuit breaker as well isolator is also used to isolate the line from the other healthy line. When line will be cleared than first circuit breaker is closed and isolator become closed manually.

7. Insulators :Insulators are used to insulate the live line from the tower or pole contact. Generally pin type of insulators are used in the switchyard. Where in transmission line pin type or suspension type insulators are used. In Sikka thermal power plant, 1. Total two generating transformer (GT-1 & GT-2 ) with capacity of 150 MVA, 11 KV / 138 KV. 2. Total six unit auxiliary transformer, three for unit-1 (1A,1B,1C)and other three for unit-2 (2A,2B,2C) with capacity of 1250 KVA and 1600 KVA respectively. 3. Total two station transformer (ST-1,ST-2) capacity of 25 MVA, 132 KV / 7 KV.

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8. SPECIFICATIONS :1. Generating Transformer 1 & 2 a) Rating b) c) d) e) f) g) h) i) j) k) l) m) No load Voltage Current Phase Frequency Cooling Impedance Voltage Connection Weight of core and winding Weight of oil Oil Oil Temperature Winding Temperature HV LV HV LV HV LV 150 MVA 150 MVA 132 KV 11 KV 628 Amp 8258 Amp Three 50 Hz OFAF 13.57 % Star 95000 kg 32670 kg 36300 ltr 50 C 55 C

2. Unit Auxiliary Transformer 2A,2B,2C a) Rating b) c) d) e) f) g) h) i) j) k) l) m) No load Voltage Current Phase Frequency Cooling Impedance Voltage Connection Weight of core and winding Weight of oil Oil Oil Temperature Winding Temperature HV LV HV LV HV LV 1600 KVA 1600 KVA 6.6 KV 433 KV 140 Amp 2133 Amp Three 50 Hz ONAN 8.50 % Star 2310 kg 1175 kg 1320 ltr 50 C 55 C

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3. Station Transformer 1 & 2 a) Rating b) c) d) e) f) g) h) i) j) k) l) No load Voltage Current Phase Frequency Cooling Impedance Voltage Connection Weight of core and winding Weight of oil Oil Temperature Winding Temperature HV LV HV LV HV LV 25 MVA 25 MVA 132 KV 7 KV 110 Amp 2062 Amp Three 50 Hz ONAF 13.13 % Star 37500 kg 14000 kg 50 C 55 C

4. SF6 Circuit Breaker a) b) c) d) e) f) Voltage Current Lightning impulse Air pressure Frequency Mass 145V 2500 A 650 KV 20.5 bars 50Hz 1750 kg.

5. Transformer a) b) c) d) e) Rating Volts No load Full load Current 37500/50000 V 132000 V 66000 V 164/218.07 328/437.04

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6. Oil Circuit Breaker a) b) c) d) e) f) g) h) Voltage Insulating level Frequency Normal current Braking current Mass of oil Closing of coil Tripping of coil 72.5 KV 140 KV 50 Hz 1600 A 20 kA 1380kg. D.C. 110V D.C. 110V

7.Current transformer
a) b) c) d) e) Rated primary current Frequency Type Weight of oil Total weight 600/300/1-1A 50Hz Dead tank 70kg. 275kg.

8.Potential Transformer a) b) c) d) Outer potential H.S.V. Type Frequency 66kv 75 V-7 50Hz

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PROTECTION IN THE ELECTRICAL EQUIPMENT

1. GENERATOR PROTECTION There are different types of protection have been used in the electrical equipment in the power plant. which are given below: (1) Generator Differential Relay For protection against phase to phase faults in the generator windings. (2) Generator Stator Main Earth Fault Relay For 100% protection of generator stator windings, the relay will give trip command for earth faults up to 95% of the windings and a time delayed alarm for 100% of the winding. (3) Generator stator back-up Earth Relay Neutral voltage displacement relay connected to the residual voltage derived from the generator VTs for standby earth fault protection. (4) Generator Negative sequence Relay Relays for protection of the generator against high unbalanced current as follows: Initiate alarm after a time delay if the negative sequence current exceeds the generator maximum continuous withstand rating. Trips the unit for negative phase sequence currents exceeding the continuous withstand rating with inverse time characteristic. (5) Generator Low Forward Power Relay Power relay with a sensitive setting of about 0.5% of rated power. For certain faults, the turbine is tripped first. This relay initiates an alarm when the electrical output has fallen down to a value below 0.5% of the voltage. (6) Generator Back-up Protection relay Impedance relay to provide back-up protection to the generator for multi phase faults in the system up to the end of outgoing lines.

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(7) Generator Overload Alarm relay Over current relay which gives alarm after a time delay when the generator current exceeds the present value. (8) Loss of Excitation Relay For alarm on loss of excitation and trip if the loss of excitation is accompanied by under voltage. (9) Generator pole slipping Relay For the protection to the generator when it is running out of synchronism with the system due to excessive load or insufficient excitation. (10) Generator overvoltage Relay For the protection to the generator against over voltage after a time delay. (11) Generator Under frequency Relay For protection against sustained low frequency operation beyond the capacity of this protection will be set to operate when frequency falls below a value injurious to the turbine or generator as the manufacturer's recommendation. (12) Generator VT fuse failure Relay Voltage balance relays connected on the generator VT secondary side to detect loss of potential. These will give annunciation and block operation of automatic voltage regulator and voltage operated relays. 2. TRANSFORMER PROTECTION There are different types of protection used in the transformers which are given as below: (1) Differential Relay High speed biased differential relay with second harmonic restraint. The protection zone will cover the generator, generator transformer and tap off to the unit auxiliary transformer.

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(2) Over fluxing Relay This relay operates on voltage and frequency ratio and protects the generator transformer against over fluxing, due to undue rise in voltage with the normal frequency or fall o frequency with normal voltage. This operates in two steps: To block raising of voltage by AVR and to lower voltage. To trip this unit after a time delay. (3) Over current Relay Inverse time over current relay to provide back up over current protection for the generator and transformer. (4) Earth fault Back up Relay Inverse time over current relay to provide backup earth fault protection.

(5) Buchholz, winding temperature and oil temperature Protection Relays Alarm will be initiated by Buchholz relay on slow collection of gas due to incipient faults or when the winding temperature or oil temperature exceeds the lower preset value. Tripping will be initiated by Buchholz relay for heavy faults in transformer or where winding temperature of oil temperature exceeds preset high value. Auxiliary relays have been used for multiplication of instrument contacts.

22.3 132KV LINE PROTECTION The following protection are provided for the lines: The main protection will be connected to independent CT core and separately fused VT supply. The main protection is a three phase, three zone, non switched static distance scheme with carrier link to the remote end, power swing blocking, single and three phase tripping and VT fuse failure protection. The backup protection is by directional inverse time over current relays for the both phase and earth faults.

22.4 HV BUS COUPLER PROTECTION

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The following protections are provided for HV bus coupler. Over current relay for phase to phase faults and three phase faults. Earth fault relay for phase to ground faults. 22.5 HV BUS BAR PROTECTION Bus differential relay Tuned high impedance instantaneous bus fault relay for protection against faults on HV bus. Independent bus bar protection relays are provided for each of the HV buses with common check relays. Bus wire supervision relays to guard against faults in the CT secondary bus wire on fault are also provided. Individual hand reset high speed tripping relays are provided for each circuit. Electrical reset relays operated by isolator auxiliary contacts for switching CT secondary circuits to appropriate bus differential relay when bus connection is changed, are also provided. 22.6 INDUCTION MOTORS PROTECTION Following protections are provided for the 6.6kv motors which are used in the unit auxiliaries which are given below. (1) Thermal overload relay Relay characteristics are selected to match with the motor thermal withstand characteristics and starting characteristics. The relay is set to trip the motor on overload. (2) Overload alarm relay Over current relay to give alarm after a time delay when the motor is overloaded. (3) Instantaneous over current relay Over current relay with low transient over reach to trip the motor against short circuits. (4) Locked rotor relays Over current relay with a time delay relay to trip against locked rotor conditions. If the locked rotor withstand time of the motor is less than the starting time of the motor, this protection will be through speed switch to monitor locked rotor condition. In this case, additional over acceleration time protection shall be provided. (5) Differential relay For motors of rating 1500kw and above, 3 phase terminal brought out on the neutral side also. The relay strips the motor.
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TRAINING REPORT ON T.P.S SIKKA

(6) Earth fault relay Current operated relay connected to core balanced CT for tripping motor. (7) Bus under voltage relay Under voltage relay connected to each bus section with definite time delay to trip the motors during sustained under voltage condition. This timing will be selected such that none of the motors will trip when started at 80% v. (8) Bearing temperature indicator Bearing temperature details are provided on both the bearings with a contact for alarm purpose. A second contact set for higher temperature is used for tripping the motor wherever so recommended by motor manufacturer. (9) Water flow monitor for CACW motors Where the motor is water cooled, a flow switch is provided to initiate an alarm and trip the motor after a time delay when water flow is less. Adequate water flow is used as permissive condition to start the motor. (10) Lube oil pressure monitor where forced oil lubrication is provided Motor closing circuit has permissive interlock for normal lube oil pressure. Low lube oil pressure gives an alarm and starts the standby lube oil pump after a short time delay and trips the motor after a longer time delay.

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