AMBUJA CEMENT LTD.

RABARIYAWAS

TRAINING REPORT ON GENERATION, TRANSMISSION & DISTRIBUTION OF ELECTRICAL POWER

Submitted in partial fulfillment for the award of the degree of

Bachelor of Technology In Electrical Engineering 2013-14

Submitted to: Dept. of Electrical Engineering

Submitted By: Mr. Pikesh Jain B. Tech. 4th year, 7thsem. Electrical Engineering, JECRC Jaipur

Pikesh Jain

Acknowledgement
I am thankful to Mr. S.N. Jhanwar Sir (Head, EE Dept.) under whose guidance I have timely completed the report. It is my proud privilege to express my profound sense of gratitude to Mr. Sachin Singhal (HEAD, Power Plant) for his constant guidance and encouragement throughout the training period. I am indebted to Mr. Jai singh Shekhawat (Section head, Powerplant),Mr R.P tak(asst. manager) for sharing their vast experience as well as providing me with priceless study materials and photographs. I also express my deep gratitude to Mr. Ritesh Dhuria,Mr. Grijesh, Mr. Mohd. Arif, Mr.Ashok Sharma, Mr. Praveen Sharma, Mr. Mukesh Saxena, Mr. Sujeet for sharing their knowledge patiently. I am also thankful to Mr. Mangu Singh Shekhawat, Mr. Anil Sharma for providing all facilities and ensuring all my requirements were attended to. I will now conclude by thanking my parents, without whose care and assurance, I would not have been able to accomplish this. Pikesh Jain

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Preface
Practical knowledge means the visualization of the knowledge, which we read in books. For this we perform experiments and get observations. Practical knowledge is very important in every field. One must be familiar with the problems related to that field so that he may solve them and became successful person. After achieving the proper goal of life an Engineer has to enter in professional life. According to this life he has to serve an industry, may be public or private sector or self-own. For the efficient work in the field he must be well aware of practical knowledge as well as theoretical knowledge. To be a good Engineer, one must be aware of the industrial environment & must know about management, working in industry, labor problems etc., so he can tackle them successfully. Due to all the above reasons & to bridge the gap between theory and practical, our engineering curriculum provides a practical training course of 30 days. During this period a student in industry and gets all type of experience and knowledge about the working and maintenance of various types of machinery. I have undergone by 30 days of training ( after III yr.) at AMBUJA CEMENT LTD. RABARIYAWAS. This report has been prepared on the basis of the knowledge which I acquired during my 30 days (01-06-2013 to 030-06-2013) training at Captive power plant.

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Introduction of Power Plant

Power plant is a process unit where by means of consumption of energy from various fuels (i.e. coal, compressed gas, and nuclear energy, hydro) energy is created and by which electricity is generated. In Rabriyawas, we have two thermal power plants: 1. 2. 15 MW 18.7 MW

In these power plants we are using F-grade coal, Lignite, Pet coke & biomass as fuel. The steam is produced with the help of Atmospheric Fluidized bed combustion Boiler having a pressure & temperature of 65Kg/sq.cm & 495 +/5 deg. C respectively. This pressurized steam is then used to run a Turbine which in turn rotates the Generator & produces the power.

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Various Circuits of Thermal Power Plant

The thermal power plant can be divided into following circuits :1. Coal & Ash Handling Circuit: This circuit describes the total loading of coal and how it is used for burning in boiler, there handling and conversion into fly ash and how fly ash handling is done. 2. Air & Flue Gas Circuit This circuit describes the uses of atmospheric air in the process of power generation. How air intake is done and how it is converted in the flue gas. 3. Water & Steam Circuit This circuit describes the uses of water in the plant. It also describes the importance of water in thermal power plant and its conversion in to steam. Use of the steam in power generation process. 4. Steam Condensing Circuit. This circuit describes the conversion of steam into the water. This circuit is used where there is scarcity of water. This circuit also reduces the wasting of water as the cycle is the closed cycle.

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Description of Thermal Power Plant: 15 MW

COAL & ASH HANDLING CIRCUIT :

COAL CIRCUIT: In Rabriyawas unit, various type of coals are brought by the road transportation. The trucks are emptied with the help of Coal Tippler, from where it is feeded to a Reciprocating Feeder and is supplied to YC-1 belt. A stacker is provided on YC-1 belt which is used for stacking the coal when the Bunker levels are full. The coal from the pile is reclaimed with the help of loader and feed to belt no. YC2. The coal from YC1 & YC2 is fed to BC1 belt. As shown in the chart The further sequence of the coal handling is as follows: BC1 BC2 BC7 BC4 VIBRATING SCREEN CRUSHER VIBRATING SCREEN 2 BC3 BC5 BC6A & BC6B There is one metal separator near the tail pulley of BC2. From BC2 the material is feed to vibrating screen, this contain two meshes of size 50 sq mm and 9X 12 mm sq. The material which can pass through this screens will directly fed to BC3 and rest will go to the crusher. After this the coal is crushed into the hammer crusher. Again the crushed coal passes through the vibrating screen2, where the mess size is 9X12 mm sq. The size of the coal is -6mm. this coal is fed to belt no. BC3 and from here it is fed into the bunker via BC5, BC6A and BC6B. The coal above 6mm size is consider as reject and fed again into the crusher via BC7, BC4, BC1 and BC2. From bunker, the coal is fed to the furnace through pocket feeder. In this way the coal is feed to the furnace from the coal yard.

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ASH CIRCUIT: After the coal is burnt, the ash is formed. This ash is carried with the Flue gases and sticks to the economizer tubes, Air preheater tubes & ESP plates. This ash is extracted from the economizer tubes, Air preheater tubes & ESP plates by soot blowers and is conveyed to the fly ash Silos with the help of compressed air.

AIR & FLUE GAS CIRCUIT :

In this plant we have two Induce Draft fan, Forced Draft fan, and Primary Air fans for air & flue gas circuit. F.D. fan takes the air from the atmosphere and is fed to the Air preheater. In Air preheater the fresh air gets heat from the flue gases & thus becomes hot i.e. it attain a temperature of about 140 deg C. 30% of this hot air is then fed to the P.A. fan . The primary air from P.A. fan is used for conveying coal to the furnace, while the remaining hot air i.e. secondary air is used for fluidizing the bed. The used air in the furnace is known as the Flue gas. This flue gases consist of fly ash as well as high heat it have a temperature of approx 291.1 deg C. therefore for utilizing this heat energy we passes it through the economizer (to raise the temperature of feed water), Air Preheater (to raise the temperature of fresh air), ESP (to collect dust & fine particles in order to decrease the pollution rate). As this hot flue gas is passing through the economizer it heat the incoming feed water. The exhaust flue gas from the economizer has sufficient heat i.e of temperature 226 deg C. As mentioned that this hot gas is used for heating the fresh air while its passage through the APH. While its flow through the ESP, fly ash are separated. And it is exhausted in the atmosphere with a temperature of around 130 deg C. In order to maintain a proper flow of flue gases from the furnace, a device is needed for creating the suction and it is accomplished by the I.D. fan i.e. induced draft fan.

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I.D. fan create the suction in the system and that take off the flue gases and exhaust it into atmosphere via chimney.

WATER & STEAM CIRCUIT :

Water required for the various processes in this plant is obtained from the under ground sources like bore wells. This water contains many impurities & Minerals Presence of impurities in feed water can causes scaling, corrosion and problem related to the material. The impurities present in the feed water can be categories as: a) SUSPENDED SOLID Suspended solid present in water are clay , silt, organic matter and microorganism. Effect :- Scaling, deposition and it also accelerate corrosion. b) DISSOLVED SOLID Dissolved solid includes i) ii) iii) calcium salt: calcium carbonate, calcium sulphate etc. magnesium salt: magnesium carbonate, magnesium sulphate etc. sodium salt: sodium carbonate, sodium bicarbonate etc.

Presence of these minerals can caused temporary and permanent hardness Temporary hardness: this is caused by the presence of the calcium sulphate and magnesium salt. Permanent hardness: this is caused by the presence of the calcium sulphate and magnesium salt. Effects: it has a greater effect on scale deposition c) DISSOLVED GASES

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Dissolved gases includes oxygen, carbondioxide and hydrogen sulphate etc. Effect:- It has invariably influence on corrosion.

PROCESS OF DEMINERALIZATION OF FEED WATER

The sequences by which we perform the demineralization is as follows 1. Water sources the water source generally we are using is ground water. 2. Raw water tank after pumping the ground water, we store this water in raw water tank. From here, the water is divide in two part i.e. for cement plant and power plant. 3. Raw water pump two pump of centrifugal type are used for carring the water from the raw water tank for processing in power plant. This pump has a max flow of 12 cu. M / hr with a pressure of 4 kg/cu cm 4. Chlorination by hypo chloride dosing chlorination is done to prevent fouling micro-organisms chlorine gas is dosed in solution upto 1-3 ppm. 5. Multi Grade Filter (MGF) it is 3 in no.(one operating at a time) remove turbidity and suspended particle it have steel vertical rubber line pressure vessel, 2 grade of silica quartz for charging water passes from top to bottom while in operation MGF unit gets isolated when pressure drop across bed is increases from 0.8 to 1 kg/cu cm 6. Activated Carbon Filter (ACF) it is 2 in no. Pikesh Jain

purpose- dechlorination, removal of color, odour and organics construction- steel vertical rubber line vessel. On top it has distributor and at bottom it has plate type strainer. Charging- granular activated carbon made of coconut shells and supported by layer of siles and peeble. Recharging pressure exceed 0.8 1 kg/ cu cm

7. Sodium Metabisulfate dosing system(SMBS) it is 1 in no. Purpose- remove free chlorine It effect the process of R.O. i.e effecting the R.O. membrane 8. Acid dosing system it is 2 in no. to avoid scaling because it filtered water contain bicarbonate and CO3. Hence dosing is done by HCl to make ph between 5-6 9. SHMP dosing system(sodium hexa meta biphosphate) To remove hardness salt of calcium and magnesium To improve quality of RO 10. Micron Cartilage Filter It is two in no. Used to remove particle upto the size of 5 micron One MCF has 8 cartilage of cylindrical shape 11. High Pressure Pump it is used to increase pressure which is needed for carrying RO process i.e.12-16kg/sq.cm 12. Desalination by reverse osmosis it is 2 in no. it is used for removing solid particle it has the efficiency of 97% 13. Degasification system purpose- remove free carbon dioxide system consist of o degasses tower o degasses air blower o degassed water tank 14. Mixed bed polisher unit with regeneration system(MB) Pikesh Jain 10

R.O. water contain many cation and anion To remove this we used the M.B. system. It contain the bed of resin of cation and anion exchanger Regeneration- In codirection of flow with 5% HCl and NaOH.

15. PH correction dosing system R.O. water has ph between 6.0-6.5 It is more acidic in nature and it cause corrosion . So we have to increase ph It is done by morphine dosing system. This increase the ph to 8.5

In this way water is ready to use in the plant. The D.M. water is fed into the deaerator where the dissolved oxygen is removed from the water. The boiler feed pump, pumps all the incoming or stored water in the tank to the boiler drum via economizer with a operating pressure of 86.9 kg/sq.cm.

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While passing through the economizer it get heated to a temperature of 225.6 deg C, with the help of flue gasses. This warm water is feed to the boiler drum. From here it goes in the furnace for further heating. With the help of down comer line the water passes through the water tube and get start converting in the steam. The saturated steam formed is separated in the boiler drum and pas through the primary super heater where it attains a temperature of 453.5 deg C After primary super heater there is a provision of cooling down the temperature of steam by desuperheater. Desuperheater make the superheat steam to a temperature of 374.7 deg C. In desuperheater there is a spray of water which lower the temperature of superheated steam. After this, it passes through a radiant superheater, where the steam is heated to a temperature of about of 472.5 deg C This super heated steam is finally pass to the turbine for generation of electricity having a pressure of 64.2 kg/sq.cm and temperature of 472.5 deg C. From turbine, the steam is extracted only at one place i.e. for deaerator. The steam at the end of turbine is extracted at a pressure of 0.2 kg/cm.sq and temperature of 60.3 kg/cm sq. As this power plant runs on a closed circuit phenomenon. Therefore the steam is condensed with the help of air cooled condenser. The condensing of steam is explained in next section.

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 STEAM CONDENSING CIRCUIT :

The steam once used to run the turbine losses its pressure but contains some amount of temperature which can be used in various ways. The steam from turbine enters into the Air Cooled Condenser where the steam gets condensed into water by losing heat to the atmosphere. The condensed water from the ACC goes to condenser tank from where it is feed into VSC, GSC & deaerator through condensate extraction pump. A part of the steam is extracted from the main steam line for gland sealing and is given to vent steam condenser(VSC) & gland steam condenser(GSC). In these condensers this steam losses heat to the condensate water & makes it warmer while this steam gets condensed into water. This condensed water is then supplied to the waste heat recovery system where it gains heat from the exhaust gases of the Kiln and gets warmer. This warmer water is then feed into the deaerater and the cycle repeats.

Temperature at various points: Temperature and pressure after CEP (Condensate Extraction Pump): 13.5 to 14 kg/sq.cm and 50 deg C Temperature after ejector: 60 deg C Temperature after VSC (Vent Steam Condenser): 70 deg C Temperature after GSC(Gland Steam Condenser): 82 deg C Temperature after WHR(Waste Heat Recovery):120 deg C At 120 deg C the water is fed again to the deaerator and the cycle repeats.

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Description of Thermal Power Plant-2: 18.7 MW

COAL & ASH HANDLING CIRCUIT :

For this unit of Rabriyawas , the coal handling system is as similar as the that of unit-1. The only difference lie is that after the vibrating screen the coal goes on to the belt BC8 instead of BC3 . Here the flow of coal is as follows: BC1 BC2 VIBRATING SCREEN CRUSHER VIBRATING SCREEN 2 BC8 BC8ABC9BC10BC 11A And the number of bunker is 2 with five hopper, with a capacity of 220 tons. The conveying of coal and discharging of fly ash is similar to that of unit1.

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 AIR & FLUE GAS CIRCUIT :

In this plant we have only one Induce Draft fan, Forced draft fan, Primary Air fans for air & flue gas circuit. All the process are same as that of unit-1. F.D. fan takes the air from the atmosphere and is fed to the Air preheater. In Air preheater the fresh air gets heat from the flue gases & thus becomes hot i.e. it attain a temperature of about 140 deg C. 30% of this hot air is then fed to the P.A. fan . The primary air from P.A. fan is used for conveying coal to the furnace, while the remaining hot air i.e. secondary air is used for fluidizing the bed. The used air in the furnace is known as the Flue gas. This flue gases consist of fly ash as well as high heat it have a temperature of approx 291.1 deg C. therefore for utilizing this heat energy we passes it through the economizer (to raise the temperature of feed water) , Air Preheater(to raise the temperature of fresh air), ESP (to collect dust & fine particles in order to decrease the pollution rate). As this hot flue gas is passing through the economizer it heat the incoming feed water. the exhaust flue gases from the economizer has sufficient heat i.e. of temperature 226 deg C. As mentioned that this hot gas is used for heating the fresh air while its passage through the APH. While its flow through the ESP, fly ash are separated. And it is exhausted in the atmosphere with a temperature of around 130 deg C. In order to maintain a proper flow of flue gases from the furnace, a device is needed for creating the suction and it is accomplished by the I.D. fan i.e. induced draft fan. I.D. fan create the suction in the system and that take off the flue gases and exhaust it into atmosphere via chimney.

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 WATER & STEAM CIRCUIT :

The D.M. water is fed into the deaerator where the dissolved oxygen is removed form the water. The water level in the deaerator tank is maintained at 1956 mm The boiler feed pump, pumps all the incoming or stored water in the tank to the boiler drum via economizer with a operating pressure of 84.3 kg/sq.cm. While passing through the economizer it has initial temperature of 175 deg C and get heated to a temperature of 282.6 deg C, with the help of flue gasses. This warm water is feed to the boiler drum. From here it goes in the furnace for further heating. With the help of down comer line the water passes through the water tube and get start converting in the steam. The saturated steam formed is separated in the boiler drum and pass through the convective superheated where it is attain a temperature of 475.5 deg C After convective super heater there is a provision of cooling down the temperature of steam and i.e. by desuperheater. Desuperheater makes the superheated steam to a temperature of 374.7 deg C. In desuperheater there is a spray of water which lower the temperature of superheated steam. After this, it passes through a radiant superheater-1, where the steam get more superheated by radiant method of heat transfer. Again there is desuperheater for lowering the steam temperature. And after this it passes through the radiant superheater-2, where it attains the temperature and pressure according to the load.

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This super heated steam is finally pass to the turbine for generation of electricity having a pressure of 64.2 kg/sq.cm and temperature of 472.5 deg C.

STEAM CONDENSING CIRCUIT :

From turbine, the steam is extracted from three places that are: 3. to HP heater, 4. to Deaerator, 5. to LP heater, and the final one is the main extraction line. HP HEATER The first extraction of steam from the turbine has a pressure and temperature of 13.34 kg/cm sq and 321.36 deg C respectively. This steam is condensed by the water coming from the deaerator via BFP and this condensed steam is fed to the flash tank and deaerator. On the other hand, the water(139.66 deg C) from deaerator get heated to a temperature of 190.04 deg C and this water is fed to the economizer.

SPECIFICATION OF HP HEATER SHELL SIDE 24 kg/cm.sq TUBE SIDE 120 kg/cm.sq 17

DESIGN PRESSURE Pikesh Jain

DESIGN TEMPERATURE SURFACE AREA WEIGHT

215 kg/cm.sq 85 m sq 7300 kg

235 kg/cm.sq

DEAERATOR: The second extraction is for the deaerator which is done at the temperature and pressure of 335.9 deg C and 6.18 kg/cm sq. This steam is used for the process of deaeration of incoming water, going to the boiler. The deaerated water is stored in the deaeration tank. The deaerator tank level is maintained at 13 75 mm. This water is extracted from the tank by BFP and passed to the HP heater from where it goes to boiler. LP HEATER The steam extracted from the turbine in the third stage is fed into the LP heater at pressure and temperature of about 1.18kg/sq.cm and 129.90 deg C. This steam is condensed with the help of cold water coming from the GSC. The condensed steam is passed to the hot well via drain cooler. On the other hand, the condensed water (61.48 deg C) from GSC get heated to a temperature of 108.17deg.C and fed to the deaerator.

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SPECIFICATION OF LP HEATER SHELL SIDE 3.5 kg/ sq.cm 150 C 75 sq.m 4000 kg U-Tube Horizontal TUBE SIDE 20 kg/sq.cm 150 C

DESIGN PRESSURE DESIGN TEMPERATURE SURFACE AREA WEIGHT TYPE

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Main Components Of Thermal Power Plant

BOILER
The type of boiler in ACL Rabriyavas is of atmospheric fluidized bed combustion type. FLUIDISED BED COMBUSTION FLUIDISED BED When air or gas is passed through an inert bed of solid particle such as sand supported on a fine mesh, the air initially will seek a path of least resistance and pass upward through the sand. Which further increase in the velocity, the air bubbles through the bed and particle attains a state of high turbulence. In such condition the bed assumes the appearance of a fluid and exhibits the properties associated with the fluid and hence the name fluidized bed. MECHANISM OF FLUIDISED BED COMBUSTION The sand in a fluidized state , is heated to the ignition temperature of the fuel and the fuel is injected continuously into the bed, the fuel will burn rapidly and the bed attains a uniform temperature due to effective burning. This, in short, is called fluidized bed combustion. Thus it is essential that temperature of bed temperature should be atleast equal to ignition temperature of fuel and it will never be allowed to approach ash fusion temperature (1050 deg C to 1150 deg C) to avoid melting of ash. This is achieved by extracting heat from the bed by conductive and convective heat transfer through tubes used in the bed.

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If velocity is to low, fluidization will not occur & if the gas velocity becomes too high, the particles will be fed in the gas stream and lost. Hence to sustain stable operation of the bed, it must be ensured that the velocity is maintained between minimum fluidization velocity and particles entrainment velocity. ADVANTAGES OF FBC BOILERS The Considerable reduction in boiler size is possible due to high heat transfer rate over a small heat transfer immersed in the bed. Low combustion temperature of the order of 750 900 deg C facilitates burning of coal with low ash fusion temperature, prevents NOx formation, reduces high temperature corrosion and erosion, and minimizes accumulation of harmful deposits due to low volatilization alkali components. Such sulphur coals can be burnt efficiently without much generation of SOx by feeding limestone continuously with the fuel. These unit can be designed to burn a variety of fuels including low grade coals like floatation slimes and periphery rejects without much sacrifice in operation efficiency, because only about 1% by weight of carbon content in the bed can sustain the fluidized bed combustion. The formation of sticky deposits on the fire side of the tubes because of lowering temperature by sodium components in ash is avoided due to low bed temperatures. Lower coal crushing cost due to higher particle size. Using FBC, the plant efficiency goes to 80%

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STARTING OF ALL INDIVIDUAL EQUIPMENT:

The sequence of starting of the equipments is as follows: 1. 2. 3. 4. Pikesh Jain check water level gauge for water in shell/drum start the ID fan start the FD fan start the PA fan

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5. start the fuel feeding Starting the ID fan Before starting the fan close the damper on the suction side of the fan. If the fan is started with damper in partially open condition, the fan may trip due to overload or the fuses may get blown off. The fan may also fail to start, if the water level in the drum is less then the trip level. Starting of FD fan It is to be carried out similar to that of ID fan by keeping the inlet damper close. FD fan can be started only if the ID fan is running. Starting of PA fan PA fan should be started after the ID and FD fan have been started. Starting of the fuel feeder In FBC boiler, the fuel should not be fed when the bed material is cold and bed temperature is less than 600 deg C in case of coal as fuel. Hence before taking the trial run of the feeder care should be taken so that fuel does not enter the furnace during the trial run. This can be done in two ways: The fuel between the gate and the feeder can removed after closing fuel chute gate before taking the trial run. The chain can be removed and the system can be checked upto the output shaft of gear box.

Starting of Feed Pumps: Ensure that the suction valve is open and water is available in the tank. Also ensure that the valve in the min. recirculation line is open and the discharge valve or the feed control valve including the bypass valve is closed. Then start the feed pump. Do not close the suction valve, when the pump is running. The min. recirculation valve to be opened at the time of starting the pump and immediately closed, after outlet valve is open. Do not run the feed pump without suction filter. During normal running of boiler the pump can be started/stopped with discharge valve open, since the feed line is under pressurized condition. Pikesh Jain 23

BOILER LIGHT UP:

The light up is done using charcoal and diesel as explained below: A fixed quantity of dry charcoal is spread uniformly over the startup compartment A fixed quantity of diesel mixed charcoal is spread uniformly over the dry charcoal The fire is initiated using a burner. Further by proper air flow control fire can be spread and the heat released by the charcoal is utilized to heat the bed material to a temp above the ignition temp of the fuel In the process of preheating bed material the required fluidization velocity is maintained in the bed by suitably opening the FD fan inlet damper Further the fuel feed rate is adjusted to maintain a bed temp of 800 to 850 deg C The charcoal of size below 15mm shall not be accounted for the above quantity Keep the ID fan damper open at the time of lighting up. This would reduce the possibility of furnaces puff. Initiate the fire busing no. of swab. Throw the swab in such a way that fire spread uniformly over the entire surface.

The lighting of the boiler is to be done with the help of charcoal and diesel. The light up is to be done only for a single compartment. After stabilizing with a single compartment fire is transferred to the other compartment as per the procedure explain separately. COMPARTMENTAL TRANSFER The start up with one compartment is recommended for the following reasons: 1) Gradual loading of pressure parts 2) Reduction of charcoal for startup 3) Load variation The compartment transfer means activating a static compartment of the furnace adjacent to the activated compartment. This is done just by admitting the fluidizing air to the compartment to be activated and mixing the cold material with hot material of the operating compartment. Before activating a static compartment the air flow in the fluidizing compartment shall be increased to 120% of the MCR air flow, and a fuel feed rate should be correspondingly increase to maintain the bed temp of 900 degC.

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Now open a compartment air damper of the adjacent compartment which is to be activated. The cold bed material in this compartment would begin to mix up with hot bed material in the operating compartment. The bed temp in new compartment would begin to rise. The bed temperature in operating compartment shall be once again brought up to 900 deg C before another attempt is made. By following the process of mixing the bed material of the compartment to be activated with that of the operating compartment, on one or many attempts, the activation can be completed. The bed temperature of any compartment shall be brought to at least 600 deg C before fuel feeding is commenced. The primary air line in the new compartment shall be opened and the fuel feeding can be commenced and the bed temperature shall be brought to 800 deg C MCR fluidizing air flow condition. Care shall be taken not to drop the temperature of the operating compartment below 600 deg C in the process of activating adjacent compartment. If by mistake, the temperature of the operating compartment drops below 600 deg C it becomes necessary to raise the temperature using charcoal. NORMAL OPERATION LOAD CONTROL: The steam generation needs to be matched with that of demand to avoid venting of the steam. If the steam drawn from the boiler is less compared to the steam generated and then the pressure would rise and thus resulting in the lifting of the safety valve. Frequent lifting of safety valve will damage the safety valve seat. Steam generation can be varied by slumping compartments or by varying the fluidization air flow or by varying the bed temperature or by varying the bed height. Load variation of 70% to 100% may be obtained by varying the bed temperature. The bed temperature can be reduced to 700 degC and can be increased to 900 degC based on demand. For this purpose the fuel feed rate needs to be varied. Further turndown is also possible by reducing the fluidization air flow but not to the extent of defluidization of the bed. In such case the air flow through primary air line should never be reduced. Only the fluidizing air flow should be reduced. Further load controlling is done by slumping the compartment. The compartment can be slumped only from either end of the bed. in case of three compartment only first or third compartment is to be slumped before the middle compartment is slumped.

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Slumping of the compartment is to be done as explained here. Bring down the fuel rate to minimum and switch off the feeder. Wait till the bottom bed temp comes around 850 deg C and then closed the fluidizing air damper of the compartment. Then closed the fuel transport air line damper. When the fluidizing air through a compartment is cut off, the air through the other compartment could increase. This air flow shall be adjusted by throttling inlet damper of FD fan. Further draft in the furnace shall be adjusted by throttling of ID fan inlet damper. Reactivation of the compartment shall be done in the following sequences. Open the fuel transport air line valve first and ensure the required air pressure is available in the PA fan header. If the line is chocked, chokes shall be removed by use the drain gate, of the fuel transport line. Then open the fluidizing air damper and set the FD fan inlet damper for the required flow. If the bed temp is above 600deg C fuel feed shall be initiated and the bed temp shall be brought to the required operating temperature. SLUMPING SEQUENCE After running all the compartment at least once, the following philosophy shall be adopted for meeting the load throw off. 75% LOAD 75% load can be achieved either by operating all the compartments under reduced bed temperature. When the steam demand comes down to around 75%, then the air flow has to be correspondingly reduced. To prevent the bed temperature from shooting up. Fuel feed rate also has to be reduced thereby reducing the total heat input to the boiler. Thus the reduced steam demand can be met. Alternatively 75% Load can be met by slumping compartment 1 or 2 and reducing the air flow to the level specified for remaining compartments operation. During slumping of a compartment proper sequence has to be followed as given below 1. stop the fuel feeder of the compartment to be slump 2. after two min stop the air flow to the compartment to be slump 3. reduce the air flow to the specified level for five compartment operation it is not advisable to keep particular compartment slump for a long duration. Hence it is suggested to activate the slump compartment after certain interval and slump the other compartment 60% LOAD

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60% MCR load can be achieved by slumping one compartments and reducing the air flow and fuel feed rate. A lower bed temperature than 900 degC may have to be maintained by adjusting the fuel feed rate to meet the steam demand. 50% LOAD 50% MCR load can be achieved with 3 compartments. With this combustion, though the steam flow can be matched, there may be a shortfall in superheated steam temperature when the feed water temperature is more than 105 deg C. in this arrangement one FD fan can be stopped in 15 MW plant. If compartments 3, 4 &6 or 4,5 & 6 are run then superheated steam temperature can be achieved . however both the FD fan have to be operated. 40 % LOAD 40 %MCR load can be achieved by keeping the 3 compartments in operation (indicated for 50 % MCR operation) and reducing the air flow and fuel feed rate. However at high feed water temperature there will be shortfall in superheated steam temperature while only 3 compartments are in operation. IMPORTANT NOTE 1. During cold start compartment which are having the bed superheated should be activated only after stabilizing other compartment or after ensuring that 30% MCR steam is generated or vented. 2. During hot restart, if the compartments which are not lighted directly by burners, have to be restarted after a long gap it is preferable to cool down the entire bed and start from compartment 1 & 2 to avoid overheating of bed super heater coil. ASH REMOVAL The ash should be drained from all collecting point. Failure to remove the gas will result in choking of the flue gas path. BOILER TRIPING DUE TO POWER CUT In this case immediately close the inlet dampers of the FD, ID fan. In the event of power availability and if the boiler is required to be started immediately switch on the fan. Establishing the air flow and start fuel feeding. Otherwise if the boiler is to be boxed up, close the main steam stop valve. Close the compartment damper also. INGRESS OF FOREIGN MATTER IN FUEL: Pikesh Jain 27

Ingress of cotton waste, cloth, coconut shell etc. will block the fuel flow from the chute into the feeder. This is indicated by the drop in bed temperature provided the fed rate of feeder is not increased. The above mentioned problem can be eliminated if a screen is provided in the fuel handling system. At times it may so happen that the foreign matter may block the fuel transport line when there is no air flow in the fuel transport line, the bed material from the bed enter the fuel fed nozzle leads to choking of the line. The choking should be removed by slumping the bed and by opening the drain gates. NORMAL SHUT DOWN TO COLD During shut down of boiler to the cold condition, the following steps are followed: Reduce the fuel feed rate Stop the fuel feeder Maintain the same air flow to cool the bed faster

For slow cooling: In this condition switch off the FD, ID fan when the bed temperature fall below 500 deg.C

For fast cooling In this condition, keep the fan open till the temperature come down to 100 deg C

In both condition the blow down valve should be open. NORMAL SHUT DOWN TO HOT STAND BY: If boiler has to be put on standby for several hour like 2hrs, then following procedure has to follows: Switch off the fuel feeder Switch off the FD, PA and ID fan Do not reduce boiler pressure line. Keep the boiler pressure at desired pressure at which it can withstand by closing main steam valve.

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HOT RESTART OF BOILER For starting the boiler from standby, then following operation has to be followed: Open the air vent and fluidizing air damper Open FD, PA damper Start ID, FD & PA fan Start the fuel feeder

SPECIFICATION OF BOILER MAKE TYPE CAPACITY PRESSURE TEMPERATURE FUEL FIRING FEEDER TYPE BED SIZE EXPANDED BED HEIGHT HEAT INPUT EXISTING BOILER HEATING SURFACE AREA BOILER DRUM Boiler drum is the equipment used for storing the water as well as for separation of steam from water. Cethar Vessel Pvt. Ltd Single Drum Water Tube Boiler(FBC) 80 TPH 65 kg/cm.sq 495+/-10 deg. C Coal Drag Chain(new plant) and Pocket Feeder(old plant) 5105 X 8950 mm sq 998 mm 68027637 Kcal/hr 2285 m sq

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Water from the economizer is fed into the boiler drum. Through down comer tubes it is fed in the furnace via water tubes, where this water start converting in the steam and start rising in the boiler drum via riser tube. In this way, steam is produced. Now the saturated steam is separated from the water by turbo separator and fed to the convective superheater for superheating of the steam.

SPECIFICATION OF BOILER DRUM

MAKE CAPACITY MAX. WORKING PRESSURE SUPERHEAT OUTLET PRESSURE SUPERHEAT OUTLET TEMPERATURE Cethar Vessel Pvt. Ltd. 80,000 kg/hr 78 kg/cm.sq 66 kg/cm.sq 495+/-5 deg. C

BURNER
Burners play an important role in the combustion process i.e. during the cold startup. It is used for burning the fuel to light up the boiler. The burner have following characteristics:

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Make Application Fuel Type Oil through out Oil pressure Atomizing air pressure Combustion Air pressure Fixing arrangement Combustion air temperature Furnace back pressure Type of ignition Type of atomization Location

Wesman Startup of boiler Light diesel oil(LDO) Air atomized 20 lt/hr 3 kg/sq cm 800 mmWC 400 mmwc Inclined 40 deg C -5 mmWC Manual By air Furnace refractory wall

FANS:
In power plant, HA series fans are used which have been designed for medium and heavy duty application. The fan are available with backward curve, backward inline and straight radial blade. These fans are of single inlet and single width type. Static Parts Of The Fans: 1. Casing: single or impart casing is provided with inspection door, drain plug and sealing plates 2. Inlet Cone: it is space from where the air enter 3. Pedestal Rotating Parts Of The Fans: 1. 2. 3. 4. Impeller: it is made of high tensile steel and mounted on the main shaft. Shaft fitted with bearing and housing Flexible coupling with guard Cooling disc with guard, if required.

Accessories of Fans:

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1. Flexible connections: it is provided between the fan and the ducts. It protect fan from the damage caused due to expansion in the duct system. If fan is mounted on anti vibration mounting then this connection must be provided in order to have complete vibration isolation. 2. Cooling Disc: it is mounted on fan shaft. It is supplied incase the air or gas temperature handle by the fans exceed 100 degC. Cooling is made up of halves. Additional Accessories & Features: Inlet multi louver damper Inlet guide vane Inlet box Sound absorber Vibration isolator Damper actuator Bearing temperature indicator Vibration monitor Shock pulse monitor.

In plant we have three types of fans for operation, namely: INDUCED DRAFT(ID) FAN FORCED DRAFT (FD) FAN PRIMARY AIR (PA) FAN

Specifications of these fans are as follows: FD FAN : The purpose of force draft fan is feed the air in the system. The specification of this fan is given below Type Medium Flow cu.m/sec Pressure mmWC Temperatue degC Type of drive Speed Casing orientation Centrifugal Ambient Air 17.4 835 40 Direct coupled 1480 rpm ACW-10(FD-1)

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Motor rating Motor make Bearing Bearing make Coupling

CW-2(FD-2) 200kw/270 hp ABB 22226EK/C3 SKF A236

PA FAN:

The function of primary air fan is to feed the air for carrying the coal to the furnace. The specification of this fan is given below: Type Medium Flow Pressure Temperature Type of drive Speed Casing orientation Motor rating Motor make Bearing Bearing make Coupling Centrifugal Hot air 3.23 cu.m/sec 715mmWC 150 degC Direct coupled 2940 rpm ACW-10 (PA-1) CW-2(PA-2) 37 kw/50 hp ABB 22226EK/C3 SKF A236

TURBINE
FUNCTION The function of the turbine is to drive an A.C. generator at a speed of 3000 R.P.M. CONSTRUCTION OF TURBINE The principle component part of the outer casing of the turbine are front section, the exhaust section and middle section whose length depends on required no. of stages The front and the middle section are made up of cast steel and are single casing. The welded exhaust section is bolted to the middle section.

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The outer casing is horizontally split and the top and together by a bolted flange. FRONT SECTION The front section can be subdivided into 3 parts:1. The Admission 2. The Control Valve Chest 3. The Front Bearing The Admission:-

bottom halves are held

It incorporates a horizontally split inner casing in order to achieve a good efficiency and simultaneously reduce the pressure on the outer casing. The inner casing is supported in the outer casing so that it is free to expand in all the directions. In the inner casing there are four nozzle groups which admit the steam to the control stage & then into the wheel chamber of the inner casing. There are sealing strips in the inner casing which mess with sealing strips in the turbine rotor to form a labyrinth seal in which there are no physical contact. The main steam enters the inner casing through inlet connections bolted to the outer casing. In addition to the four nozzle groups there is an extra bypass inlet connection for the direct admission of the initial steam into the wheel chamber of the inner casing. Steam Flow:-The steam passes through two inlet branches, emergency stop valves of the control valve chest. When these control valves lift, the steam flows into the inner casing. The inlet connections of the initial steam lines run towards the middle of the turbine, which means that at first the steam flows away from the exhaust section. The exhaust steam cools the inner wall of the casing admission section so that it cannot be heated to the temp. of the initial steam by either the inlet connection or the radiated heat from the inlet section of the inner casing. Then the steam flows into the middle portion and then to the exhaust portion after expanding to the condenser pressure. Thrust Balance:The axial thrust produced in the moving blades is balanced by the dummy piston near the nozzle chambers. The leakage steam from the dummy piston flows directly from the labyrinth seal to the second drum stages in the middle portion whose direction of flow is opposite to that of the first drum stages. Since the dia of the dummy piston can not be normally made as large as really necessary. A second piston Is provided near the front gland bush. It is exposed to Pikesh Jain 34

the pressure of the steam after the inner casing. The leakage steam from this large piston has already given up the power in the first drum stages which reduces the loss of efficiency. Control Valve Chest The characteristic feature of this range of turbine are the control valve chest placed at the side of the turbine. This reduces the overall height and allow the outer casing to the symmetrical in the radial section. Also there is no contact between initial steam and the outer casing. Each control valve chest contain an emergency stop valve and two or three control valve. Since the casing admission has four inlet connection for the nozzle group and one for the bypass in to wheel chamber and the control valve chest on the one side of the turbine has three control valve and that on the other two valve. Whenever there is no bypass valve, both the valve chest shall have two control valve each. Each control valve chest has its own actuator which operates the 2 or 3 control valve stems through a lever. Each control valve has a separate packed steam gland. The body of the emergency stop valve for each group of the control valve is welded to the control valve chest. The hydraulic part of the emergency stop valve incorporating the actuating piston is flange mounted on the valve body. The emergency stop valve is the main shut off device b/w the steam supply system and the turbine. A drop in pressure in the trip oil circuit causes the valve to interrupt the steam supply to the turbine very rapidly. Front Bearing It comprises the pedestal, bearing housing and the main oil pump. The pedestal support the front paw as well as the bearing housing. This construction safely avoid any tilting of the bearing house as a result of thermal movement of the outer casing. The bearing housing is aligned parallel to are the turbine axis on a centralizing key in the pedestal. This guide permits free movement in the axial direction and is aligned transversely by adjusting devices. The bearing housing is freely supported on adjusting devices in the pedestals. It is constrained by stud to prevent lifting. This Pikesh Jain 35

stud allow clearance of few hundredth of mm b/w the bearing housing and the pedestal in the vertical direction in order to ensure unrestricted sliding. The sliding surface of the adjusting devices are coated with a special sliding substances. The main oil pump is driven directly from the turbine rotor through an oil lubricated toothed coupling. The pump is mounted solidly on the bearing pedestal. This means that the toothed coupling accommodates any displacement b/w the turbine rotor and pump shaft due to thermal expansion of the turbine casing. MIDDLE SECTION It provides space for blading after balanced piston gland to exhaust portion. Turbine Rotor And Bearing The turbine rotor is a single forging incorporating the thrust bearing collar and coupling flange. It is supported in two pressure lubricated journal bearings. The bearing have a shaft lift oil system which enables the rotor to be raised from contact with the bearings while at rest. This ensures minimum wear during start up and permit warming up and cooling down at low revolutions. The thrust bearing is of the double sided type with tilting segmental pads. It locates the rotor relative to the casing and absorbs any residual steam from the balding. It also formed the fixed point of the rotor in the front bearing housing which means that , as the temperature of the turbine casing rises, the rotor is carried forward by the bearing housing. Since the rotor temp rises at the same time causing expansion, the end result for the coupling flange at the rear of the rotor is only a small movement relative to a fixed point of the turbine. Casing Shaft Gland Where the rotor shaft penetrates the turbine casing the internal steam space is sealed to the atm. By the gland bushes. These bushes have caulked in sealing strip which mesh with similar strips caulked in to the shaft to form a sealing in which there is no metal to metal contact. The rows of sealing strip from a labyrinth gland which drives its sealing effect from the conversion of pressure energy into kinetic energy with subsequent conversion of heat through the eddying of flow. The pressure is reduced to the point where , at the final row of strip, there is only a very small excess pressure remaining. Most of the leakage steam is bleed off from the center of the gland bush & therefore only a very small portion of the total steam reaches the vapour pipe at the end of gland bush and escapes to the atmosphere. Blading Pikesh Jain 36

The turbine contains fixed and moving blades. Two different types of moving blades are used: impulse blades for the control stage & reaction blades for the drum balding. A control stage is needed if nozzle group control of the steam flow is employed. It must be an impulse stage because of the possible use of partial admission. The nozzles of the control stage are machined and mounted in slots in the inner casing; therefore they can be changed individually if necessary. The moving blades of the control stage are also machined and have a twin lug straddle root with integral shrouding. Apart from the last three rows the moving blades employed of the drum balding have inverted T roots & integral shrouding. The inverted T roots are inserted into grooves in the rotor and caulked with sectional strip to secure them. The roots of the blades are sized so that when the blades lined up they produce passage of the required size without the need for spacers. A gate blade fills the point of entry to the groove so that there is no gap in the ring of blades nor any sudden change in the pitch. The gate blade is secured to the rotor by grub screws. Unlike the remainder of the drum balding, the moving blades of the last 3 rows have no shrouding. The third from last rows has inverted T roots. The last row have twisted moving blades which have been drop forged. These blades have fir tree roots which are inserted into appropriate grooves in the rotor. Blade Tip Sealing The radial tip clearance of all fixed and moving blades with shrouding is several mm. Therefore stationary & moving parts cannot come into contact with each other even when distortion of the rotor & casing occurs. The large radial clearance is sealed by shrouding in order to keep the power losses due to tip losses to minimum. In the case of the fixed blades the sealing strips are caulked into the turbine rotor and for the moving blade, into the guide blade carrier. The thin sealing strips leave only a few tenths of a mm. clearance b/w the shrouding & the rotor, guide blade carrier. If the sealing strips touch, the amount of heat generated is so slight that no dangerous distortion of the guide blade carrier of rotor can result. Guide Blade Carrier Function Pikesh Jain 37

Its function is to support the fixed guide blades in the turbine. The use of guide blade carriers enables damage guide blades to be changed without having to dismantle the bottom half of the outer casing & its pipe work connections. Construction The guide blade carrier is of horizontally split design with a bolted flange. it is supported and located axially in the outer casing by the means of a circumferential groove which engages with a cast projection. The paws of the bottom half of the carriers are supported in recesses in the bottoms half of the outer casing. Adjusting devices enable it to lined up level with the turbine axis. Side alignment is provided by an eccentric pin which engages in a slot in the bottom half of the outer casing at right angles to the joint faces. The support surfaces of the carrier paw and the eccentric pin lie in symmetrical planes in order to prevent any distortion arising from thermal expansion. Steam Labyrinth Gland Purpose The packing gland shell carries on the periphery of the inner surface caulked in sealing strip which together with the edges of the corresponding sealing strips of comb like projection on the rotor shaft, are forming a seal without mechanical contact b/w the moving rotor and stationary turbine casing. A seal of the labyrinth type act on the principle of transforming potential energy into kinetic energy and subsequently dissipating the kinetic energy by the formation of eddies. Packing glands for sealing against Positive Pressure With packing glands intended for sealing against a higher pressure prevailing in the turbine casing, the major part of the leak steam flow will be exhausted from the middle section of the gland shell. Only a very small part of the leak steam flow is thus allowed to penetrate into the collecting groove provided at the downstream end of the gland from where it will escape via the gland steam stack into the atmosphere. A disk shaped annular fin on the turbine shaft, which extends into the collecting groove, aspirates air by centrifugal action from the atmospheric end of the packing gland and delivers it into the gland steam stack. This is an effective means for preventing the sealing steam which may be leaking out of the packing gland from blowing against adjacent bearing sections and heating them up. Packing glands for sealing against Negative Pressure

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Packing glands for sealing against negative pressure reigning in the turbine casing have to block the penetration of air into the casing. The respective passage of the packing gland, instead of serving for sucking off leak steam, will be connected to a steam supply of slight positive pressure. The flow of this sealing steam will be split into two parts. One part of the steam goes into the turbine casing, other to the gland steam stack from where it escapes into the atmosphere. This latter part of the leak steam prevents the penetration of air into the portion of packing gland, which is situated b/w the gland steam stack and the sealing steam connection.

CONDENSATE DRAIN
Condensate accumulating in those passages of the packing gland, where the gland steam is flowing, will be effectively drained through a hole drilled at lowest point of the gland. STEAM STRAINERS Functions: Steam strainers are initiated in the main steam lines and in the reheat lines from the boiler to protect the admission elements of the HP and the LP turbines from foreign objects which could be picked up in the boiler or associated piping. Construction: the strainer is made of corrugated strip wound on a frame. This design offers a high degree of resistance even to particles impenging at high velocity. The frame consists of two rings and number of rods welded b/w the rings. The rods additionally braced by reinforcing rings welded inside them. The strainer is designed for a single direction of flow the outside inwards. For longer strainers the screen is made up of several parts. The end turns of the corrugated strip are then tacked to the T section intermediate rings. The maximum mesh size of the strainer which is determined by the height of that corrugation is 1.6 mm. the effective area is made at least 3 times the cross section area of the pipe. The strainer may be used for both initial commission of the turbine and for regular operation. CONTROL VALVES Function: the control valves are opened and closed in order to adjust the throughput of steam to give the required power out put from the turbine. Depending upon the power requirement the control valves are opened or closed in the specific sequence. The valve seats are in the form of diffusers in order to keep flow losses to a minimum.

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Construction: The steam chest contains a valve cross bar in which the actual control valve are suspended loosely. The cross bar is connected to the arm through two stems and the pivoted links. The arm is operated by the actuator which is flexibly mounted on the bracket attached to the steam chest. The steam chest has two bonnets in which the valve stems are guided by two rings. The rings also form the top and bottom stem glands. Each stem head is loaded by a compression spring, so that the control valves are held closed when the turbine is stationary. Operation: when the turbine is at rest the springs keep the cross bar in its lowest position and the cons of the control valves are forced on to their seats by the pressure of steam. A control pulse from the governor causes the actuator to pull the arm downwards, thus raising the stems and lifting the cross bar. The valves then lift in a sequence determined by the different lengths of the spacer bushes in the cross bar. GOVERNING SYSTEM Introduction: The turbo generator set is equipped with electro hydraulic governing system. The system offers the advantages of electronic methods for measurement and signal processing and use of hydraulic devices for control of large positioning drives. The advantages of this combination are Better integration capability High quality steady state and dynamic response Facility for implementation of complicated function. The signal processing, control function and inter locks are incorporated in the electronic controlled cubicle, which is placed in the control room. An electro hydraulic converter provides the link b/w electronic and hydraulic section. Electro hydraulic turbine controller: Controls speed, load and inlet pressure. Additionally the system incorporates protective devices like emergency trip device, emergency stop valve, remote trip solenoid valve, over speed governor, thrust bearing safety device. Purpose: Starting a turbine from the control room requires, remote control of the emergency trip gear. Such control will be achieved by the following devices: 1) Solenoid valve Pikesh Jain 40

2) An automatically control switch with interlocking mechanism which will block the switch in open position. Operation: After the starting device has been brought into the starting position the solenoid valve will be moved through the action of the control switch. This will allow pressure oil to flow via the solenoid valve to the auxiliary piston of the emergency trip gear. The described position of the control elements allows the building up of the system oil pressure in the emergency tripping and starting oil circuits, thus enabling the emergency trip gear to hold itself in the operating position. To the extent as these pressures arising , the pressure switch is going to be actuated. SPECIFICATION OF TURBINE TYPE MAX OUTPUT POWER DESIGN RATING SPEED INITIAL STEAM PRESSURE PREMISSIBLE DEVIATION IN PRESSURE INTIAL STEAM TEMPERATURE PESSURE AT HP WHEEL CHAMBER EXHAUST PRESSURE NK-40/56-3 18.7 MW 19.6 MW 7700 rpm 64 ata 67.3 ata 490 C 47 ata 0.2 ata

PROTECTIVE EQUIPMENTS FOR TURBINE Types: 1) Emergency Stop Valve: Purpose: The emergency stop valve serve as the principal shutting off device b/w steam system and turbine. Under ordinary operating as well as under emergency conditions it causes instantaneous interruption of the steam supply to the turbine. The emergency stop valve is horizontally mounted to the steam chest of the outer turbine casing ; it consists of steam section and an oil section with hydraulic servo cylinder.

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Mode of operation: Steam Section Live steam, after having passed through strainer, arrives at valve cone which has been provided with a relief cone owing to its considerably smaller area in comparison to the area of the main cone, the relief help in reducing the forces when the emergency stop valve is been opened, because it tends to balance the pressure differential existing b/w the upstream and the downstream side of the main cone. a bushing in the valve hub carrying a knife edge which acts as an additional seal for the space behind the valve hub against the pressure of the live steam as long as emergency stop valve is opened. In this way , the lost steam, which otherwise may leak out along the valve steam is precluded all the time stop valve remain in the open position. In closed position any leak steam which happened to seep out b/w valve stem and the bushing will be drained off through the line the major part of the steam pressure force acting upon the valve hub is transmitted directly to the outer casing surrounding the steam section of the stop valve. 2) Speed Monitoring: Function: Convenience of operation or local site condition of a turbine plant sometimes warrant the accurate measuring of remote reading of the turbine speed. To this effect, the speed will be measured by electromagnetic pick up which does not require mechanical contact with rotating part. This signal may also be used as input for supplementary governor and control equipment. Operation: when the perforated disc rotating the front of the pick up this produces a frequency proportional to the speed of turbine rotor. The pick up frequency is converted into the speed proportional current in a converter and measured on an indicating instrument. 3) Vibration Monitoring: Function: Vibration of turbine, originates from the rotor and is transmitted to the external bearing housings through the bearing oil fill which has both spring and damping effect. When measuring the absolute bearing housing vibration, only secondary effect of the vibrations is detected. The vibration can be measured at the surface of housing can only give a general indication of the vibration behavior of a turbine. The measurement do not have the same validity as measurement of the shaft vibration Pikesh Jain 42

because the rotating mass is usually relatively small compared with the stationary mass and the vibration is not transmitted fully. Vibration measurement directly from the rotor of the turbine has proved in practices to be the best form of the monitoring. By connecting dotted line or continuous line recorders to the output of measuring device it is possible to connected to detect changes in the vibration level which provide an early warning of damage. For simple monitoring measurement of the vibration (peak value) in the one direction can be adequate depending upon the specified requirement. For complete acquisition of the vibration behavior according to VDI 2059 it is usually necessary to provide 2 sensors at 90degree to each other at each measuring point.

SHAFT VIBRATION (PEAK TO PEAK) IN MICRONS

OPERATING PARAMETER (micron) TURBINE Front A VYX101 Front B VYX101B Rear A VYX102 Rear B VYX102B GEAR BOX HSS A VYX103 HSS B VYX103B LSS A VYX104 LSS B VYX104B GENERATOR FRONT A VYX105 FRONT B VYX105B REAR A VYX106 REAR B VYX106B 29.7 34.4 35.2 46.2 5.6 6.0 26.3 23.1 44.1 53.9 48.8 50.3

INTERLOCK PARAMETER (micron) 170 170 170 170 160 160 160 160 200 200 200 200

LUBE OIL SYSTEM

A satisfactory & continuous supply of oil is essential for the safe & reliable running of a turbine & its driven equipments. The Oil supply system includes the following equipments: MAIN OIL TANK:- Housing the oil volume required for lubricating oil & governing system. 43

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LUBE OIL PUMPS:- It is a single stage centrifugal pump driven by A.C. motor. The pump delivers the total oil required for the governing & lubricating oil systems. EMERGENCY OIL PUMPS:- During coasting down of turbine when lube oil pump is not available lubricating oil is provided by emergency oil pump. It is operated by a D.C. source. OVERHEAD OIL TANK:- When emergency oil pump also fails as a last option to protect bearing, an overhead oil tank is provided. This tank is kept at an elevation so that oil flows through gravity. TWIN OIL COOLERS:- The heat absorbed in the bearing is dissipated in the oil cooler which is of shell & tube design. The system consists of two oil coolers each of 100% capacity. DUPLEX TYPE OIL FILTERS:- The Duplex type oil filter with disposable cartridge type with filtration of 10 microns is provided to supply clean oil to the bearings. Adjustable bearing oil throttles, which permit adjustment in the oil quantity required for respective bearings. OIL VAPOUR EXTRACTION FANS:- To remove oil vapors settled over the oil surface in oil tank.

TURNING DEVICE:During turbine start up & shut down operations the rotor has to be turned. If a hot turbine is shut down & the turbine rotor is not turned, distortion of the rotor will occur after sometime & of high significance. If any immediate restart is required the resultant eccentricity of the rotor can cause serious damage to the blade tip sealing or to the blade themselves due to rubbing. In addition, the excessive vibration due to unbalance of the rotor can lead to wearing of the bearings. During the turning operation an A.C. motor drives the turning gear. For starting turning operation, the Clutch has to be engaged manually when shaft train is in standstill condition. As the turbine picks up the speed, the shaft train tends to overtake the turning drive, the clutch is disengaged automatically. The turning gear is provided on extension of input shaft of gear box. The turning gear is also provided with hand wheel to turn the rotor when A.C. power is not available.

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JACKING OIL SYSTEM:Function:Before a turbine is started up the shaft journals are in contact with the white metal of the bearings due to its own weight. In order to prevent the metal to metal contact b/w journal & bearing shell during startup & shut down, which is damaging in the long term, an oil pocket machined into the bottom shell of the journal bearing is supplied with oil under high pressure. This lifts the shafting system slightly & it floats on a film of oil. Now the break away torque (frictional torque required to overcome the metal to metal contact during starting) depends on shear stress in the oil film, so the torque exerted by the turning gear is less and hence the oil required for lifting the shaft is less. TURBINE INTEGRAL STEAM FLOW SYSTEM Live Steam System: The turbine is supplied with live steam from a steam source of 64 ata , 490 deg C. During start up steam is admitted steadily for warming up the live steam piping upto the turbine. During this period steam is vented to the atmosphere. Any condensate formed shall be drained initially through the drain valves. Turbine: The steam from live steam system is admitted into the turbine through emergency stop valve and governing valves. The balance piston leak off line is connected to second extraction line to deaerator. Turbine Extraction System: The turbine is a single cylinder machine with 3 uncontrolled extractions: 1) HP heater 2) Deaerator 3) LP heater Power assisted check valves are provided one in each line, to prevent back flow of the steam and causing over speeding of turbine. The valves are hooked up to the turbine governing system to make them close with every trip of the turbine. Extraction Drain System: All the extraction lines are provided with drain points to drain condensate during warming up of the pipes, during heated out conditions and during turbine trip conditions. It is recommended to keep all the drain valves open up to 10% of block load on turbine to avoid any accumulation of drain in the piping. This drain valve shall be Pikesh Jain 45

closed after attainment of above conditions. The drains upstream of extraction NRV are connected to condenser surge pipe and downstream drains connected to drain flash tank. GLAND SEALING SYSTEM: It is necessary to seal the gland steam of condensing turbine to maintain the vacuums in turbine and condensing system. The vacuum in the system is maintained by supplying steam at 1.1 ata . Through a source of 11 ata, 350 deg. C continuously to turbine glands. The pressure controller is set at 1.1 kg/cm2 and the steam is supplied from the auxiliary steam header to gland steam header through the control valve. Chimney Steam: The steam from turbine gland is evacuated to gland steam condenser. This shall prevent steam oozing out from the gland and heating the bearing pedestals. 2 ejectors are mounted on the GSC for evacuation. Exhaust Hood Spray System: It may necessary to run the turbine in no load condition for prolonged periods. During this period, the exhausted hood temperature will rise beyond safe limits, especially from material strength point of view. Hence it is necessary to limit the exhaust hood temperature by cooling the exhaust steam by spraying condensate through spray nozzle fitted in the exhaust. The spray water is taken from condensate extraction discharge. The spray water is supplied to spray nozzle via a solenoid operated valve. This valve opens automatically by means of the temperature switch mounted on the exhaust hood whenever temp. exceeds the preset limit. Whenever the temp. return to a safe limit the solenoid valve closes automatically. Thus stopping the spray water supply. Turbine Drain: The drain from all spaces of turbine which are under vacuum during start up are connected to condenser. The drains are led to drain pot to air cooled condenser. The drains should be connected to drain manifold in the correct sequence i.e. the drain from HP spaces must be farthest from the drain pot of ACC and followed by the drain from the LP spaces. The pipeline riding from the turbine main steam stop valve should be drained to atmosphere. The inlet of the drain to the surge pipe must be at the min. of the 250 mm above the maximum water level in the drain pot. Vacuum Breaking System: In case of turbine trip (for reason of low lubricating oil pressure) vacuum is broken in the condenser by admitting atmospheric air into the condenser through a motor Pikesh Jain 46

operated valve that opens in such case. This is provided to shorten the coasting down time. The valve is sealed with condenser water against ingress of air into the condenser during normal running of set. STARTING AND SHUTDOWN The stating operation may have an impact influence on the possible curtailment of turbine life because major thermal and mechanical stresses will be experienced in the course of starting. This hazard may be particularly enhanced with start from the cold. The most favorable condition can therefore be expected when the temperature of the live steam during the starting period can be matched as closely as possible to the actual temperature of the turbine. For starting a cold turbine or one which has cold down to below 230 deg C , it is recommended to use the live steam temperature to the casing temperature as the limit set by the requirement after boiler or of the elements of the entire turbine will permit. However the temperature of the live steam must exceed by at least 30 deg C the saturation temperature of the steam at the chosen live steam pressure. Oil Supply The oil pump employed for starting should have been switched on some time before in order to carry out the preparatory starting operation that can be performed during standstill, the check for proper function of governor system and also to achieve a certain pre warming of the oil. Where a hydraulic jacking pump is provided for lifting the rotor off its bearing, it should be taken into operation by opening the respective valves in the pressure oil live as soon as turbine have achieved a speed of 80 120 rpm the jacking oil pump can be switched of again. Condensing System The cooling water supply for the condenser should be taking into operation in accordance to the local requirement of the site. It is to ensure that all other element requiring water for cooling can be supplied with cooling water as and when necessary. Open the delivery valve fully. Open the maximum flow valve to the condenser to the extent permitting the steady and adequate circulation of condensate. Start the water level regulating system of the condenser. Also make sure that the collected amount of condensate is returned to the feed water tank after passing such intermediate apparatus like economizer, deaerator etc.

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Start the air extraction system in order to ensure the proper evacuation of the condenser. Opening the Live Steam Valve: After through draining on the line ahead of the live steam valve, open that valve so that live steam line up to the turbine will gradually be pressurized and warmed up. If the live steam valve is equipped with the bypass, this should be opened first in order to relieve the pressure on the valve. In order to achieve satisfactory evacuation of the condensing system, steam must be admitted to the shaft seal at a pressure exceeding the atmospheric by about 6 mbar. This prevents air from entering into the turbine casing along the rotor shaft. Open the suction valve 1 to 2 turns and the seal steam valve to the point where light wisps of steam emerge at the steam vents. Opening of Emergency Stop Valve: After having sufficiently drained the live steam line, turn the hand wheel of the starting device in the opening direction. This will cause trip oil pressure to build up behind the piston disc of the emergency stop valve. Check the oil pressure prevailing in the space behind the piston, the condition at which the emergency stop valve begins to open. The movement, the emergency stop valve, starts with its opening movement, pause either further turning the starting device hand wheel until the oil pressure behind the piston has definitely collapsed. Only after having made sure that this has been the base, open the starting device to max. position to open the emergency stop valve fully. Next, through electronic governor speed raise push button built secondary oil pressure and speed start increasing. Bringing the Turbine up to the Speed: The turbine will be brought up to speed through further raising of speed reference in electronic governor in accordance with the instruction of the test report and while paying particular attention to the prohibited speed ranges and to smooth running behavior of the entire machine set. Automatic Oil Pumps Control: When the auxiliary oil pump is not operating, make sure that automatic oil pump control continues to be switched on. In the event of failure of the main oil pump, it

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will ensure that following a major drop in the system oil pressure, the existing auxiliary oil pump will take over the supply immediately and maintain it at the required level. Oil Cooling: If the temperature of the oil cooler outlet exceeds 40 deg C, the cooling water inlet valve has to be open to the point at which a constant oil temperature of 45 deg C is maintained. The oil outlet temp at the individual turbine bearing are not identical and may vary enter a range of 50 deg to 65 deg for an inlet temp of 45 deg C. If a temperature of 120 deg C is reached the turbine must be shut down immediately.

UNLOADING THE TURBINE:

Regular Unloading: For unloading the turbine, the hand wheel of the speeder gear has to be turned slowly in the counter clockwise direction. This should result in a continuous decrease of secondary oil pressure so that the control valves are going to close. The possible effect of the unloading operation on the boiler control, on other auxiliary apparatus and on turbine dependent element of the power plant should be taken into account as far as possible. Prior to unloading all personnel involved has to be contact and mutual understanding be reached about the measure to be taken. Unloading after a Disturbance: In this case the machine may be shut down by releasing the automatic trip gear, regardless of its actual load. Closing the Valves for Uncontrolled Extraction: Where uncontrolled extraction is provided, make sure that at decreasing load the extraction valve will not be closed before secondary oil pressure has dropped below the assigned value. In case of spontaneous unloading, all extraction valves are going to close simultaneously, even if the ESV remains open. The extraction valve can also be closed by arranging small hand wheel on the change over valve, to be turned clockwise. Subsequently the main hand wheel should be turned into the stop. Under no circumstances the main hand wheel be forcibly tighten because this would risk the entire valve mechanism. Pikesh Jain

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Opening the Drains In installation equipped with extraction stop valve, the drain provided in the lines b/w these valve and the turbine have to be opened immediately after the extraction stop valve are closed, if it is intended to operate the turbine plant in that condition for some time. All supplementary shutting off the device in the extraction lines have to be closed. Extraction Pressure Regulator: Where an extraction pressure regulator is installed and the turbine is to be operated at low load for a prolonged period, the regulator has to set to the zero extraction. This will eliminate possible fluttering in the governing system. Such instabilities may arise from the fact that the extraction pressure regulator attempts to maintain the pressure at the extraction point constant. DEAERATOR DM water used for thermal power plant as heating fluid contains dissolved gases (mainly oxygen and co2). These gases attack on metals at a high temperature causing corrosion. So it is important to remove all these dissolved gasses before using in boiler. This is achieved by heating the water at its saturation temperature. The unit used for removing there dissolved gases is called deaerator. In addition to removal of dissolved gases in feed water, the other functions of deaerator are as follows. 1. It acts as surge tank to meet varied demand of boiler. 2. It increases the NPSH of feed water pump. 3. It forms a part of the regenerative cycle. PRINCIPLE OF OPERATION If the partial pressure of dissolved gases can be reduced by any method, then the dissolved gas will escape from the water. Based on the principle the water is heated up to its saturation temperature by using oxygen free steam. Steam also acts as a carrier medium to carry the liberated gases to atmosphere. DESCRIPTION: From the principle of deaeration it is clear that heating of feed water and scrubbing of water have to take place in the shortest possible time to achieve optimum deaeration. For this purpose the feed water is broken in droplets to increase the contact area and to facilitate better heat exchange and fast deaeration.

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The deaerator supplied is a tray cum spray type. It comprises of a) A Deaerating header b) A Storage tank. The condensate enters the deaerating header. Deaerating header comprises of number of nozzles and trays stacked one above the other. The trays are sieve type. Condensate collected in the tray trickles down to the next tray. Likewise flows to the bottom most tray and then into storage tank. Steam enters storage tank at one end travels over feed water and enter the deaerating header. The steam heats up the condensate flowing downward and apart of a steam is condensed back during this process. Remaining steam gas is vented to atmosphere. The condensate is collected in the storage tank provided below the deaerating header. The storage water in the storage tank and the system control helps meeting varying demand of boiler. VENT STEAM CONDENSER The gland steam which vents from gland finally to atmosphere is called vent steam. This vent steam is discharged either through chimney to atmosphere or it can be discharged to a heat exchanger which is called vent steam condenser (VSC). VSC is a shell and tube type heat exchanger. Condensate flows through the tube while vent steam after releasing heat condenses at shell side. The inlet condensate temperature increases taking the heat of steam and by this way it forms a part of regenerative cycle. CONSTRUCTION VSC is fitted with the following mounting and fitting. 1. 2. 3. 4. 5. 6. 7. steam line and ejectors vent steam line condensate inlet and outlet line level gauge and level switches drip drain line with trap pressure gauge in shell side temperature gauges in condensate inlet/outlet line and drip drain line

OPERATION Condensate from CEP discharge flows through the tube while the vent steam condenses outside the tube. The drip thus formed is discharge at surged pipe through trap. The non condensable gas which remains in the condensate is Pikesh Jain 51

discharge to atmosphere by vapor extraction fan. Due to any leakage in condenser, the GS condenser can be bypassed from condensate. In that case the vent steam can be discharged directly to atmosphere. GLAND STEAM CONDENSER INTRODUCTION It is a shell and tube heat exchanger. Gland leak off steam is gradually over pressurized due to the gradual load. To maintain the gland steam pressure the excess steam is condensed in the gland steam condenser. During lower load or any tube leakage GSC can be bypass and gland steam can be dumped into the condenser after desuperheating.

CONSTRUCTION The GSC comprises mainly shell, tubes, water box. The shell is made of boiler quality carbon steel. The GSC is fitted with the following fitting and mountings and connections 1. 2. 3. 4. 5. 6. 7. condensate inlet outlet line connection steam inlet connection drip drain connection level gauge connection level switch pressure indicator in shell side temperature gauges in i/l and o/l condensate line and drip drain line EVACUATION SYSTEM (STEAM JET AIR EJECTOR) Heat transfer action in surface condenser is impaired by the non condensable gas which mixes with the film of condensate on the tube surface. The source of air and other non condensable gases may come with the steam or leakage through turbine gland. Air ingress is a serious factor and should be kept down as much as possible. Since it is not possible to eliminate it entirely, Pikesh Jain 52

arrangements are made for continuously drawing it out of the condenser and compress it up to atm. Pressure where it can be released. The steam jet air ejector is widely used to continuously draw the non condensable gases from the surface condenser. The steam jet air ejector used for evacuation may be categories into following type: 1. hogging or starting ejector 2. main or running ejector HOGGING EJECTOR It is used for quick evacuation of the condenser from atm. Pressure to around 0.6 kg/m.sq by 30 min before putting main ejector in line. It is essentially consist of 1. steam nozzle 2. mixing chamber 3. diffuser The ejector work on the principle of conversion of pressure energy into kinetic energy in an expansion nozzle. The steam air mixture from condenser is sucked mainly by viscous drag of high velocity of steam jet. The resultant K.E. of the mixture is converted into the pressure energy in a diffuser and finally let out to the atmosphere. No ejector condenser is provided for hogger ejector. MAIN EJECTOR The main ejector is used for holding the vacuum in the condenser. The suction air and vapour mixture is compressed into atmospheric pressure in two stages and finally vented to the atmosphere. Ejector condensers are provided at the end of each stage to condense the steam in the mixture. The cooling medium for ejector condenser is condensate from CEP. The condensate of the motive steam is drain to the flash tank or condenser through U-leg and steam traps. Generally two sets of ejector are supplied for the purpose. While one set is in service the other set is kept as a stand by. Pikesh Jain 53

AIR COOLED CONDENSER Air cooled condenser is a finned tube condenser cooled by forced draft air. Exhaust steam from turbine exchanges heat to the air and gets condensed. ACC is used in those places where there is scarcity of water needed for cooling the turbine exhaust steam. The ACC provided for the power plant to serve the following function 1. to condensate the turbine exhaust steam 2. to deaerate the air from the condensate ACC has three modules. Each modules is having two cooling fans. Two modules from the condensing zone and the other module which is placed in between the condensing zone is called the dephlegmator zone. ACC is constructed in two number of A type frame. Each frame consists of 20 number of condensing and 4 no. of dephlegmator tube bundle. In the condensing tube bundle the exhaust steam coming out from turbine get condensed whereas air line for ejector has been tapped from dephlegmator tube bundle. Each frame is connected with a steam header fixed at the apex and two condensate headers at the bottom. Steam from apex header enters the condensing zone through the tube bundle and after getting condensed the condensate is collected at tube bottom condensate header. The cooling medium that is air which is supplied by the FD fan flow crosswise to the tube bundles. Each tube bundles is fabricated from fine tube and arranged in triangular pitch for better heat transfer. A frame structured ACC has the following advantages 1. Because of inclined tube bundle the condensate drainage is easier 2. Because of entry steam header is at the apex the steam distribution is optimum. 3. Pressure drop across cooling tower is very less

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BOILER FEED PUMP.

These pumps are horizontal, multistage centrifugal pumps designed for boiler feed and other high pressure applications. The pumps are suitable for pumping clean liquid. This liquid is pumped with a liquid velocity up to 2 m/s in the suction pipe and up to 3 m/s in the discharge pipe. Specifications: Medium delivered Capacity Minimum capacity Differential head Differential pressure Suction pressure Discharge pressure Pumping temperature Pump input Speed Impeller diameter Lubricating Oil Oil temperature Cooling Cooling water Pressure normal/max Temp outlet max. Allowable working pressure Allowable working temp Boiler feed water 48.7 cu.m/hr 12 cu.m/hr 900 m 79.7 bar 8.7 bar 88.4 bar 164 deg C 161.6 kw 2975 rpm 218 mm ISO VG 46 >40-65 deg C 0.3 cu.m/hr 2/10 bar 40 deg Suction side : 20 bar Discharge side: 120 bar 185 C

OTHER AUXILIARIES
ECONOMIZER In boilers, economizers are heat exchange devices that heat fluids, usually water, up to but not normally beyond the boiling point of that fluid. Economizers are so named because they can make use of the enthalpy in fluid streams that are hot, but not hot

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enough to be used in a boiler, thereby recovering more useful enthalpy and improving the boiler's efficiency. They are a device fitted to a boiler which saves energy by using the exhaust gases from the boiler to preheat the cold water used to fill it (the feed water). In thermal power plant, water passes through an economizer, then to a boiler and then to a superheater. The economizer also prevents flooding of the boiler with liquid water that is too cold to be boiled given the flow rates and design of the boiler. A common application of economizers in steam power plants is to capture the waste heat from boiler stack gases (flue gas) and transfer it to the boiler feed water. This raises the temperature of the boiler feed water thus lowering the needed energy input, in turn reducing the firing rates to accomplish the rated boiler output. Economizers lower stack temperatures which may cause condensation of acidic combustion gases and serious equipment corrosion damage if care is not taken in their design and material selection. AIR PREHEATER An air preheater is a device designed to heat air before another process with the primary objective of increasing the thermal efficiency of the process. The purpose of the air preheater is to recover the heat from the boiler flue gas which increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas. As a consequence, the flue gases are also sent to the flue gas stack (or chimney) at a lower temperature, allowing simplified design of the ducting and the flue gas stack. It also allows control over the temperature of gases leaving the stack (to meet emissions regulations, for example).

ELECTROSTATIC PRECIPITATOR
It consists of a steel air tight chamber housing the collecting and discharge electrodes. The discharge electrodes are usually suspended from the top through support insulators. Collecting electrodes are connected to ground and emitting electrodes are supplied with a high negative voltage, in KV. Raping system periodically cleans the dust is collected on the collecting electrodes. Dust is collected in trough type hoppers before they are discharge pneumatically or through their combination of rotary air lock valve and dust

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conveying system. Inlet and outlet cones ensure gradual drop in velocity till it retains the design velocity on reaching the collecting plates. Gas distribution plates at the inlet and outlet ensures uniform gas distribution across the length and width of ESP. collecting electrodes are usually spaced at 300mm or 400mm. Emitting electrodes are of various types: Some type of sharp point, which are corona generating sources. Sections or fields to reduce the effect of electrical disturbance called sparking of ESP

There are 2-3 fields in series for smaller quantity of gas. 5- 7 field in series for larger quantity of gas Rapping which is usually either top rapping using MIGI rappers or side rappers using rotating hammers driven by geared motors. Inlet field naturally collects more dust as compared to outlet field. In three field ESP Inlet field collect 80% dust, Second field collect 16% dust, Third field collect 4% dust. Inlet rappers are cleaned faster as compared to outlet rappers. Current increases as we go from inlet field to outlet field and voltage reduces from inlet field to outlet field. SPECIFICATION: ESP Gas volume Am/ hr Operating temperature Operating pressure Design pressure Design temperature Inlet dust load Outlet dust concentration 147024 Am / hr 150 C - 170 mmWC - 225 mmWC 250 C 48.29 gm / Nm 30 mgm / Nm with all fields operation 100 mgm / Nm with one TR set out of service 25-30MMwc 19 no. 400mm 4

Pressure drop across ESP No of gas chamber Collecting surface spacing Total no. of field

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DISCHARGE ELECTRODE Type Material Total no of electrodes COLLECTING ELECTRODES Material No of electrodes per field Collecting electrodes Total no of electrodes CE to CE spacing RAPPING ARRANGEMENT Type No of collecting electrodes rapper No of discharge electrode rapper Rapper controller type HOPPER Type No of hopper

Rigid pipe & spiker IS 513 684 no IS 513 20 nos 7.3+9(40+40)nos 80 400mm MIGI 40nos 16nos PLC based Pyramid 4

SILENCER
While steam blowing (for wet steam) the steam is exhausted in the atmosphere with a very high velocity via a small duct and this result in generation of very high noise. To have a control on this, we are using silencer. Silencer is a device that is used for decreasing the noise level of the blowing off steam The silencer used have following characteristics: Application Medium Flow Steam pressure Temperature Sound level No. of inlet Position Materials (internal) Steam line start up vent Superheated steam 24000 kg/hrs 68 kg/sq.cm 495+/-10 deg C <85db at 1m distance of silencer 1 Vertical Stainless steel (304)

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GENERATOR
ELECTRICAL DATA Output rating Rated voltage Rated frequency Rated current Power factor Rated speed Type of duty Excitation method Full load excitation voltage Full load excitation current Phase sequence Insulation class for windings 23375 KVA 11 KV 50 -5 % to +3% Hz 2045 amp 0.8 over excited 1500 rpm Continuous duty Brushless excitation 151.0 V 476.0 amp ABC for clockwise rotating field Stator F Rotor F

MECHANICAL DATA Type of construction Protection class Machine suitable for Direction of rotation Moment of inertia (GD^2 / 4) Brush holders Earthing brush Bearings Horizontal, foot mounted with two bearings IP54 Installation indoor Clockwise rotation 1400 kg per sq mtr approx Qty type Qty 2 type grate Size : 10* 20* 25 Size 315 dia lubrication : closed circuit oil content 74 cub dm per min 59

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Rate of oil required for bearings at an oil Temperature rise of 10 deg C Maximum oil pressure at bearing inlet

: lube DIN CL 32 OIL 51517 TS 37 DM^3 Per min ES 37 DM^3 Per min 0.6 Bar

VENTILATION DATA VENTILATION Cooling air flow rate Intake air temperature Pressure drop on air side mm of water cold Altitude above sea level AIR COOLERS Heat duty Quantity of cooling water Air outlet temperature Cooling water inlet temperature Pressure drop on air side Pressure drop on water side Tube material Fin material No. of elements BRUSHLESS EXCITER Type Serial no. Year of manufacture Output rating Rated voltage Pikesh Jain EAR 60/9- 15/16 -2 10738 2007 Continuous duty 130 kw 210 V 60 510 kw 100 cu. m ./ hr 39 deg C 32 deg C 15 mm of WCL 7 m of WCL Adm. Brass Copper 5 +1 Generator closed circuit air cooling 19 cubic mtr per sec 42 deg C 15 Above 1000

Rated current Rated exciter voltage Rated exciter current Type of construction Degree of protection Speed Direction of rotation viewed from drive end Ventilation MACHINE TYPE TYPE Rating Power factor Speed Voltage stator Current stator Frequency Type of construction Degree of protection machine WEIGHTS Stator of generator Rotor of generator Base frame Generator weight with brushless exciter Max. transport weight Brushless Excitation

620 amp 29.6 V 10.74 amp Horizontal shaft Overhang type IP 54 1500 rpm Clockwise rotation Tapped from generator

TALL 1240-12N-15 synchronous generator 23375 KVA 0.8 lag 1500 rpm 11 KV 2045 amp 50 Hz Horizontal shaft, foot mounted with two bearings IP54

240000 17600 5800 50600

Kg Kg Kg Kg

Auxiliary exciter 15/16

506000 Kg Type of machine Ear 80/9 15/16 Type of protection IP54 Type of machine Ear 11/16 Type of protection IP54

BRUSHLESS EXCITATION Main exciter Pikesh Jain Type EAR 80/9 15/16 -2 61

S1 / 10s

Weights

Pilot exciter

Degree of protection Voltage Current Output Excitation Rotor Stator Pilot exciter Total weight Type EAP 11/16 -15/6 Degree of protection Voltage Current Output

IP54 210/ 295 V 620/868 amp 130/ 255 Kw 29.6V / 10.74 amp 1050 Kg 350 Kg 131 Kg 1530 Kg IP54 221 V 3.94 V 1.5 KVA

DESCRIPTION OF MACHINE CONSTRUCTION

ROTOR The rotor consists of the shaft, the rotor core, the field winding, the damper winding, the fans, the slip rings or the rotor of the brushless exciter. The shaft transmits the torque to the machine. The rotor is carried by two bearings. The field winding is inserted in the slot group of the rotor core, connected and linked to the terminals of the direct coupled exciter by lead runs through the bore in the shaft. The bars of the damper winding are driven into the slots at the periphery of the core and are connected to an end disc at the other end. STATOR The stator consists of the yoke core and the stator winding and parts of the enclosure. The stator is secured to the base frame by means of holding down bolts with washers. The slots of the stator core accommodate a double layer coil winding. The terminals ABC are installed in a terminal board. Their location is selected to suit the conditions at the suite the conditions at the site. The star point leads Ao Bo Co can be arranged in the form of an open star point inside the outer casing. Certain machines have the winding end leads connected to a terminal board at the lower part of the stator. BEARINGS The rotor runs in two floating type guide bearings, designed as pedestal bearings, with forced oil and the bearings are of the self aligning type. The non drive end Pikesh Jain 62

bearing pedestal is secured to the base frame and insulated from the later. All the connections are arranged to prevent short circuiting of the insulation. ENCLOSURE The enclosure consists of the inner and outer compartments. The inner compartments comprise the winding shields which from an annular enclosure of the end turns of the stator winding and are also used as air guides. The outer enclosure is designed as required for the particular degree of the protection, as indicating in the dimension drawing or in Terminal data. The ventilating circuit is of the double ended symmetrical arrangement. EXCITATION: Depending on the service conditions involved, the synchronous machine may be excited from a THYRIPART excitation system, a rotating exciter e.g brushless excitation system or another external excitation system. In this case a brushless exciter is employed, the excitation power is supplied to the field circuit through rotating rectifier, and through brushless and slip rings with all the other excitation systems. BASE FRAME The base frame carries the stator, the bottom section of the outer casing, the sleeve bearings and the exciter. The base frame transmits the forces occurring the machine to the foundation. Depending on the mounting conditions at the site, the base frame is installed on soleplates by means of anchoring bolts. ACCESSORIES The fixing accessories include shims and leveling plates. Various instruments e.g for measuring pressure and temperature, fittings, space heaters and anchoring accessories. THERMAL PROTECTION STATOR WINDING The description of the stator winding is monitored by resistance thermometer embedded in the stator winding to protect the winding against thermal overloads. Thermal overloading means a prolonged excess temperature which may destroy the winding insulation or considerably reduce the life of the insulation. If the winding temperature at the points reaches or exceeds the permissible limit value, an alarm signal is given or the machine shut down automatically, depending on the temperature attained. The bifilar thermometer resistor is wound on a core covered with a glass fibre tape and potted in cast resin, and thus has a high mechanical strength. The temperature sensors are installed in separators of the stator winding. Pikesh Jain 63

BRUSHLESS EXCITER CONSTRUCTION The exciter is brushless and takes the form of a stationary field generator. Its rotor is mounted on the overhang of main machine shaft end. The stator may be fixed either to be base frame of the main machine or to a separate steel or concrete foundation. A permanent magnet three phase pilot exciter driven directly by the common shafting or a static auxiliary excitation unit is used for exciting the field of the stationary field generator via a voltage regulator. The three phase current flowing in the rotor winding is rectified by silicon diodes in the rotating rectifier and fed into the field winding of the main machine. ROTOR The rotor is fitted on the shaft extension of the main machine and locked to it in the circumferential direction by parallel keys which are capable of accepting shock loads caused by short circuit in the main machine without being over stressed. The rotor hub is of welded construction and carried the laminated core which is compressed axially by means of a clamping ring welded to the hub. ROTOR WINDING The three phase rotor winding inserted in the slots of the laminated core is connected in the star. It is a two layer winding to insulation of class F. The end leads of the individual windings are on the A end and connected to the U, V, W and neutral bus rings arranged at the same end. Both winding overhangs are bound with heat setting glass-fiber tapes to afford protection against centrifugal forces. RECTIFIER It comprise of 6 diodes assemblies and the protection circuit. The code assemblies each consist of a light metal heat sink with integrally formed cooling fans containing one end disc type diode secured by means of a clamping plate. A contact face provided on the A side of each heat sink is connected by means of links to the appropriate bus ring on the three phase side. Diode assemblies situated on the opposite sides of the rotor spider have opposite polarities. The dc bus rings carry the protective varistors are screwed to the B end of the rotor spider by means of insulating mounts. The two bus rings are connected to Pikesh Jain 64

the excitation cable, which are lead through the insulated hollow shaft of the main machine. VARISTORS To protect the rectifier bridge against over voltages occurring during starting or during fault conditions, a non linear resistor is provided. This protective resistor consists of 12 varistor discs parallel connected between the positive and negative bus rings. The varistor discs are clamped between the bus rings by means of insulated screws. STATOR The stator frame of the brushless exciter consists of a roller yoke ring with welded on mounting feet. The pole pieces carrying the exciter winding are bolted to the inside of the yoke ring. The coils would on the pole pieces are of insulted copper wore and the impregnated with resin. They are connected in series in such a way that the leads of the north poles are crossed over while those of the south poles are uncrossed. The excitation winding end leads are led to the terminal box which is screwed to the outside of the stator frame and contains the terminal block. The terminal box is fitted with the two cable glands for the entry of the external connections. An earthing terminal is provided on the stator frame at the point below the terminal box. The stator frame of the B.L. exciter is fixed by means of hexagon bolts to either the base frame of the machine or independent of the machine on separate foundation blocks anchored in the concrete. Taper dowels are used for locating the exciter. END SHIELDS Depending on the degree of protection of the machine, these end shields have either ventilating slots or welded on connection pieces for ventilating ducts. The end shield on the A end is of the split type construction and has a split sealing ring screwed to its inner diameter and embracing the sleeve of the rotor hub with title clearance. The end shield on the B end of the exciter is unsplit. VENTILATION The B.L. exciter uses closed circuit cooling the air inlet being on the A end and the outlet on the B end. The stator spider is provided with the openings, permitting the passage of cooling air past the rectifier heat sinks and also over the bus ring together with the varistor and the carrier storage effect circuit. To intensify the cooling air circulation, an additional fan impeller can be screwed onto the end clamping ring. With open machines the cooling air flows through inlet & outlet slots provided in the end shields. Pikesh Jain 65

With enclosed machine, the end shields are provided with the welded-on connecting pieces which permit the installation of ducts that may be connected to the cooling circuit of the main machine, if required. The connecting pieces may alternatively be designed so as to be connected via gaskets with the air passages in the base frame supporting the main machine thus integrating the cooling circuit of the B.L. exciter with that of the main machine. MAINTENANCE The brushless exciter requires only a minimum of maintenance. The machine should be inspected for the dust deposits at the suitable intervals and to remove them, specially in the region of the heat sinks. A suitable method is blowing out with the compressed air at a pressure not exceeding 4 bars after first removing the end shield.

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SINGLE

LINE

DIAGRAM

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SEQUENCE OF EQUIPMENTS IN SWITCHYARD ARE AS :

Lightning arrestor Isolator 1 Current transformer 1 Potential transformer Circuit breaker cb 1 Isolator 2 Isolator 3 Current transformer Circuit breaker cb 2 Lightning arrestor Transformer

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VARIOUS EQUIPMENTS IN SWITCHYARD 1. ISOLATOR : It differentiates the electrical equipment from the main line during fault condition. RATING: 132 KV 800 AMP Motor 0.5 HP Current ckt voltage 110 V dc Rating of motor 3 phase 514 V ac Heater voltage 240 V ac Auxiliary contacts no. 6 2. CIRCUIT BREAKER : Circuit breaker is an electromagnetic devices that opens a circuit automatically when current exceeds a predetermined value. It consists of current carrying contacts called electrodes which, under predetermined conditions, separate to interrupt the circuit. An arc is struck between them when the contacts are separated. This arc is extinguished either by lengthening the arc or splitting the arc.

RATING : 145 KV Normal current 1250 KV Lightning impulse withstand voltage 650 KV Switching impulse withstand voltage 650 KV S.C breaking current 31.5 amp Line charging current 50 amp Short time withstand current and duration 31.5 KA 3. LIGHTNING ARRESTOR :

& 3 sec

A lightning arrestor or surge diverters is a device that that is connected between line and earth, i.e., in parallel with the equipment to be protected.

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When a traveling waves reaches the diverter, it sparks over at a certain prefixed voltage and provides a conducting path of relatively low impedance between the line and ground.

The surge impedance of the line restricts the amplitude of current flowing to ground. 4. TRANSFORMER : This step downs the incoming 132 KV voltage into 66 KV and feds into the grid bus line. RATING : KVA 22500 / 28000 Volts at no load HV 13.2 KV LV 6.6 KV Amperes HV 98.4 / 122.5 LV 1883 / 2343 Types of cooling ONAN / ONAF

5. CURRENT TRANSFORMER: This is used for measuring the high current from the line. This measures the current the high voltage side of transformer during on load condition.

6. REACTORS : Reactors are used to limit the short circuit current flowing to a safe value. They consist of large coils of high self inductance and very low resistance.

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Conclusion:
The training at Ambuja Captive Power Plant was very helpful to me. It has improved my theoretical and practical concept of electrical power generation, transmission & distribution and also improvised my knowledge about protection of various electrical equipments. This training also helped me in understanding the importance of Safety while working. So the training was more than helpful to me understanding every aspect related to Generation, Transmission and Distribution of Electrical Energy

References
1. B.R. Gupta 2. J.B. Gupta 3. Manuals of Ambuja Captive Power Plant

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