Académique Documents
Professionnel Documents
Culture Documents
PROJECT REPORT
AT
CHANDRAPURA THERMAL
POWER STATION
-BY
Page 1 of 47
ABHILAS
BANERJEE
KIIT
UNIVERSITY
PREFACE
This Project Report has been prepared in fulfilment of industrial training
to be carried out in third year of our four year B.TECH course. For
preparing the Project Report, we have visited Chandrapura Thermal
Power Station under Damodar Valley Corporation during the suggested
duration for the period of 21 days, to avail the necessary information.
The blend of learning and knowledge acquired during our practical
studies at the company is presented in this report.
The reasons behind visiting the power plant and preparing the project
report is to study the mechanical overview, electrical overview, various
cycles and processes of power generation and details of control and
instrumentation required in thermal power plant.
We have carried out this training under well experienced and highly
qualified engineers of CTPS, DVC of various departments viz.
Mechanical, Electrical, Chemical and Control & instrumentation depts.
We have taken the opportunity to explore the Electrical Department, its
use, necessity in power plant and maintenance of various instruments
used for monitoring and controlling the numerous process of power
generation. We have tried our best to cover all the aspects of the power
plant and their brief detailing in this project report.
All the above mentioned topics will be presented in the following pages
of this report. The main aim to carry out this training is to familiarize
Page 2 of 47
ourselves with the real industrial scenario, so that we can rotate with our
engineering studies.
ACKNOWLEDGEMENT
I AM EXTREMELY GRATEFUL TO THE MANAGEMENT
OF D.V.C. ESPECIALLY TO THE CHIEF ENGINEER
AND HOP CTPS CHANDRAPURA FOR ACCEPTING ME
FOR
VOCATIONAL
TRAINING
AT
CTPS
CHANDRAPURA.
I AM ALSO VERY MUCH THANKFUL TO DEPUTY
CHIEF ENGINEER (E&I) MR.R.B.SINGH FOR
FACLITING MY TRAINING IN ELECTRICAL
AND
MECHANICAL MAINT. DEPT.
I WILL ALSO LIKE TO EXTEND MY SENSE OF
GRATITUDE
TO
DR.
G.P.RAUT(FQA),MR.S.KUMAR(M),MR.P.J.CHOW
DHURY(EE), MR R.KUMAR(C&I),D.V.C. CTPS FOR
FACULTING MY TRAINING UNDER THE DIFFERENT
SECTION OF ELECTRICAL AND MECHANICAL MAINT.
DEPT.
I AM ALSO HIGHLY OBELIGED TO VARIOUS
OFFICERS AND STAFFS OF CTPS WHO ALWAYS
Page 3 of 47
CONTENTS
1.
2.
3.
4.
Introduction
Details of CTPS Generating Units
Overview of a Thermal power plant
Mechanical operation
a. Coal handling Plant
b. Water Treatment Plant
c. Water De-mineralization Plant
d. Boiler System
e. Ash handling plant
f. ESP
g. Boiler auxiliaries
h. Steam Turbine
i. Condenser Cooling System
j. Chimney
5. Electrical operation
a. Generator
b. Transformers
c. Excitation system
Page 4 of 47
Page No
5
5
6
7
9
10
11
15
15
17
19
21
23
24
26
28
30
31
33
36
41
42
43
46
47
INTRODUCTION
Damodar Valley Corporation was established on 7th July 1948. It is the most
reputed company in the eastern zone of India. DVC is established on the Damodar
River. The company operates both thermal power plant and hydel
power dams under the Indian Ministry of Power. DVC is
headquartered in the city of Kolkata, West Bengal, India
Chandrapura Thermal Power Station is a thermal power plant located in
Chandrapura Town in the Indian state of Jharkhand. The power plant is
operated by the Damodar Valley Corporation. It has 5 units with a total
installed capacity of 890 MW. All of the units are coal-based.
Page 5 of 47
Gen.
Unit
Name of Manufacturers
Boiler
Original
capacity
(MW)
Present
capacity (MW)
Year of commissioning
TG
Combustion
General
Engineering Inc, Electric
USA
Co., USA
140
140
Combustion
General
Engineering Inc, Electric
USA
Co., USA
140
140
Combustion
General
Engineering Inc, Electric
USA
Co., USA
140
140
October,1964
May 1965
July,1968
November,2011
7
BHEL
BHEL
250
250
BHEL
BHEL
250
250
July,2011
Page 6 of 47
1. Cooling tower.
8. Condenser.
9. Intermediate pressure turbine.
10. Steam governor valve.
11. High pressure turbine.
12. De-aerator.
13. Feed heater.
14. Coal conveyor.
MECHANICAL OPERATION
COAL HANDLING PLANT
In a coal based thermal power plant, the initial process in the power generation
is Coal Handling. The huge amount of coal is usually supplied through
railways. A railway siding line is taken into the power station and the coal is
delivered in the storage yard. The coal is unloaded from the point of delivery by
means of wagon tippler. It is rack and pinion type. The coal is taken from the
unloading site to dead storage by belt conveyors. The belt delivers the coal to 0m
level to the pent house and further moves to transfer point.
The transfer points are used to transfer coal to the next belt. The belt elevates the
coal to breaker house. It consists of a rotary machine, which rotates the coal and
separates the light dust from it through the action of gravity and transfer this dust
to reject bin house through belt.
The belt further elevates the coal to the transfer point and it reaches the crusher
through belt. In the crusher a high-speed 3-phase induction motor is used to
crush the coal to a size of 50mm so as to be suitable for milling system. Coal
rises from crusher house and reaches the dead storage by passing
through transfer point.
Page 8 of 47
Page 9 of 47
Magnetic Separator
Page 10 of 47
Page 11 of 47
BOILER SYSTEM
BOILER:
Working principle of Boiler:
In Boiler, steam is generated from demineralised water by the addition of heat.
The heat added has two parts: sensible heat and latent heat. The sensible heat raises
the temperature and pressure of water as well as steam. The latent heat converts
water into steam (phase change). This conversion is also known as boiling of
water, which is dependent on pressure and corresponding temperature. Boiler is an
enclosed vessel in which water is heated and circulated until the water is turned in
to steam at the required pressure. Coal is burned inside the combustion chamber of
boiler. The products of combustion are nothing but gases. These gases which are at
high temperature vaporize the water inside the boiler to steam.
BOILER OPERATION:
Page 12 of 47
Page 13 of 47
Superheater:
Superheaters (SH) are meant for elevating the steam temperature above the
saturation temperature in phases; so that maximum work can be extracted from
high energy (enthalpy) steam and after expansion in Turbine, the dryness fraction
does not reach below 80%, for avoiding Turbine blade erosion/damage and
attaining maximum Turbine internal efficiency. Steam from Boiler Drum passes
through primary superheater placed in the convective zone of the furnace, then
through platen superheater placed in the radiant zone of furnace and thereafter,
through final superheater placed in the convective zone. The superheated steam
atrequisite pressure and temperature is taken out of boiler to rotate turbo-generator.
Reheater:
In order to improve the cycle efficiency, HP turbine exhaust steam is taken back to
boiler to increase temperature by reheating process. The steam is passed through
Reheater, placed in between final superheater bank of tubes & platen SH and
finally taken out of boiler to extract work out of it in the IP and LP turbine.
De-superheater (Attemperator):
Though superheaters are designed to maintain requisite steam temperature, it is
necessary to use de-superheater to control steam temperature. Feed water,
generally taken before feed water control station, is used for de-superheating steam
to control its temperature at desired level.
Drain & Vent:
Major drains and vents of boiler are
(i)
Boiler bottom ring header drains,
(ii) Boiler drum drains & vents,
(iii) Superheater & Reheater headers drains & vents,
(iv) Desuperheater header drains & vents etc.
Drains facilitate draining or hot blow down of boiler, as and when required;
while vents ensure blowing out of air from boiler during initial lighting up as
well as facilitate depressurizing of boiler.
Page 14 of 47
Technical data
of the Boiler
Type
Furnace
Width
Depth
Volume
Fuel heat input per hour
Designed pressure
Superheater Outlet pressure
Low temperature SH (horizontally spaced)
Final superheater (vertically spaced)
Platen SH (Pendant platen)
15240mm
11506mm
5240m3
692Mkcal
182.5kg/cm2
155kg/cm2
7955m2
2110m2
1341m2
Attemperator
Type
No. of stages
Spray medium
Spray
Two
Feed water from boiler feed pump (BFP)
Reheater
Type
Total H.S. area
Control
Spaced
3790m2
Burner tilt & excess air
Economiser
Type
Total H.S area
No of blocks
Plain tube
5517m2
Two
Page 15 of 47
Page 16 of 47
Page 17 of 47
EERM
BOILER AUXILIARIES
1. Coal Bunker:
Coal bunker supplies coal to pulverizing fuel mills.
Each bunker can hold 1,000 tons of coal, and there
may be six to eight bunkers per unit. Power station
coal is not as lumpy as coal used in the home.
Typically around half of it is less than 12.5
millimeters across and 95% is less than 50
millimeters. This when powdered is called 200
mesh cleared. It is better than the face powder in
terms of size.
CCoal Bunker
2. Coal Feeder:
In this arrangement consist two method, volumetric and gravimetric method.
When gravimetric method does not work, then by volumetric method we can
measure the weight of the coal by spring balance. There is long belt to move
coal into the coal mill.
3. Coal Mill or Pulversior:
Each of unit may have six to eight pulverizing fuel mills, each capable of
pulverizing 40 tons of coal per hour. Inside the mills, ten giant hollow steel
Page 18 of 47
rollers crush the coal into a fine powder. Crushing the coal into a fine powder
makes it easier to burn it more completely. In other words, due to the
increased surface area, the combustion efficiency increases
4. Draught Fans:
All these fans are operated at 6.6kv for unit 7&8. For unit 1,2,3 these fans
operated at 3.3kv.
Primary Air Fan:
Air to blow the coal from the mill to the boiler, called the primary air, is
supplied by a large fan driven by a variable speed motor. When mixed with a
stream of air the powdered coal behaves more like a gas than a solid. Primary
air does two jobs heating the coal powder and secondly lifting it into the
furnace through pipelines.
Page 19 of 47
In a coal fired boiler, oil firing is adopted for the purpose of initial ignition of
coal during introduction of coal mill or imparting stability to the coal flame
during low boiler load condition. Efficient or complete combustion of the fuel
oil is best achieved by atomizing oil by compressed air for light oil (LDO).
Use of HFO is beneficial with respect to LDO in view of its lower cost. Heavy
furnace oil used to heat up the boiler during mill exchange.
Air Preheater:
The air heaters use the remaining heat energy in the flue gas to heat up the
combustion air for the boiler. Efficiency is increased by using this heat that
would otherwise go through the chimney. The air temperature leaving the air
heaters is at 300C.
Page 20 of 47
turbine exhaust to the reheater to prevent hot steam from the reheater flowing back
into the HP turbine.
The steam coming from the reheater is passed to the IP turbine via two
reheater stop and control valve combinations. Cross around pipes connect the IP
and LP cylinders . Connections are provided at several points of the turbine for
feedback extraction purpose.
140 MW (KWU) Steam turbine (Chandrapura TPS U # 1,2&3)
Steam from Super heater enters the HP turbine at 1800 psi and 1000 F through two
Main Stop Valves(MSV).There are eight control valves, four are connected on top and
four on the bottom. The governing system works in the principle of nozzle control
governing. The first stage is velocity compounded called Curtis Wheel. Rotation is
clockwise in the direction of the steam flow. There are 9 HP stages, 12 IP stages and 5
stages on either side in LP turbine. Reheated Steam at 1000 F and 350 psi enters into
the IP turbine through two Interceptor Valves (IV) connected in series with two
reheat stop valves. The HP-IP rotor system is housed in a common outer casing
connected with the exhaust hood in vertical plane. The exhaust hood has internal
cross over duct that takes the steam from IP exhaust for feeding to LP turbine
through middle. The HP-IP turbine rotor is mono block and made from a single
forging.
250 MW (KWU) Steam turbine (Chandrapura TPS U #7&8)
HP turbine inlet steam: 147.10 kg/m^2 & 537C. Steam entry to HP turbine
through two combined main stop& control valves and to IP turbine through two
combined reheat stop and control valves. Reheated steam pressure and
temperature: 34.95 kg/m^2 & 537C. 250 MW KWU turbine is a tandem
compounded, three cylinders, single reheat, condensing turbine provided entirely
with reaction blading.
Number of stages: HPT single flow with 25 stages, IPT single flow with 17
stages and LPT double flow with 8 stages per flow. Six steam extractions for
feed/ condensate water heating have been taken from HPT exhaust & 11th stages of
IPT for high pressure heaters, from IPT exhaust for de-aerator and from 3 rd, 5th &
6th stages of LPT for low pressure heaters. The individual turbine rotors and the
generator rotor are connected by rigid couplings.
Turning gear is providing to rotate turbine shafts slowly during the pre-run up
operation and after shut down to prevent uneven heating or cooling of the shafts.
The uneven heating or cooling would lead to bending and misalignment of shafts
with possible fouling of stationary parts. Use of turning gear during starting
eliminates the necessity of admitting suddenly a large flow of steam to rotate the
turbine from rest.
Condenser
Condenser is a huge heat exchanger and is located at the exhaust of LP
turbine. The steam after driving turbine is dumped into condenser for
recycling. The dumped steam is cooled by circulating water flowing through
the tubes of condenser. The cooling takes place where the steam comes into
contact with condenser cold water tubes through which cooling water is
circulated with the help of Circulating Water Pumps. The steam is thus
condensed into water and is taken into the system for reuse. The hot
circulating water on absorption of heat in condenser is taken in top of
cooling towers where it is allowed to fall under gravity for lowering its
temperature for recycling.
Cooling Tower
Each cooling tower consists of independent cells, each with its own induced
draft fan, water supply and distribution grid. Each cell is fitted with closely
spaced PVC fins to promote the formation of a massive eater film. Beneath
the cells are a common collection basin and a single outlet for cooled water.
The constant speed fan discharges warm saturated air through a kinetic
energy recovery stack from each cell and the hot circulating water is
cooled by upward draft of air generated by cooling tower fans.
The hot circulating water from condenser rises at the top of the tower
through two number mild steel distribution pipe and flows out into a
horizontal concrete trough on the top floor of the tower through flow control
valves. The trough is perforated with small holes into which plastic nozzles
are inserted to break the streams into umbrella shaped sprays. The tower is
provided with drift eliminator to minimize drift losses.
The cold water is collected in the basin of cooling tower and flows to the
CW pump through a trapezoidal section canal for further circulation through
condenser. The tower basin is provided with sluice gate vales which are
operated periodically to flush the basin water to reduce turbidity. The
flushed water is drained to waste.
Page 23 of 47
COOLING TOWER
CHIMNEY
A chimney may be considered as a cylindrical hollow tower made of bricks or
steel. In CTPS the chimneys of five units are made of bricks. Chimneys are used to
release the exhaust gases (coming from the furnace of the boiler)high up in the
atmosphere. So, the heights of the chimneys are made high.
The height of a chimney influences its ability to transfer flue gases to the external
environment via stack effect. Additionally, the dispersion of pollutants at higher
altitudes can reduce their impact on the immediate surroundings. In the case of
chemically aggressive output, a sufficiently tall chimney can allow for partial or
complete self-neutralization of airborne chemicals before they reach ground level.
The dispersion of pollutants over a greater area can reduce their concentrations and
facilitate compliance with regulatory limits.
Page 24 of 47
Chimneys in CTPS
ELECTRICAL OPERATION
The electrical operation of a power plant comprises of generation, transmission and
distribution of electrical energy. In a power station both distribution and
Page 25 of 47
transmission operation can take place. When power is sent from power station to
all other power station in the grid, it is known as distribution of power. When
power plant is driving power from other power station it is known as transmission
of power/electrical energy.
TURBO GENERATOR
In C.T.P.S. there are 5 electric generators for units 1 to 3 and 7,8. These are 3 phase
turbo generators, 2 pole cylindrical rotor type synchronous machines which are
directly coupled to the steam turbine. The generator consist of 2 parts mainly the
stator and the rotor.
Stator:
The stator body is designed to withstand internal pressure of hydrogen-air mixture
without any residual deformation. The stator core is built up of segmental punching
of high permeability, low loss CRGO steel and are in interleaved manner on spring
core bars to reduce heating and eddy current loss. The stator winding has 3phase
double layer short corded bar type lap winding having 2 parallel paths. The
winding bars are insulated with mica thermosetting insulation tape which consists
of flexible mica foil, fully saturated with a synthetic resin having excellent
electrical properties. Water cooled terminal bushings are housed in the lower part
of the stator on the slip ring side.
Page 26 of 47
Stator
Rotor:
Rotor is of cylindrical type shaft and body forged in one piece from chromium
nickel molybdenum and vanadium steel. Slots are machined on the outer surface to
incorporate windings. Winding consists of coil made from hand drawn silver
copper with bonded insulation. Generator casing is filled up with H2 gas with
required pressure, purity of gas is always maintained>97%. Propeller type fans are
mounted on either side of the rotor shaft for circulating the cooling gas inside the
generators.
Rotor
Page 27 of 47
Data
Rated kW capacity
250,000 KW
294,117 KVA
16,500 V
0.85 lag
10,291 A
Rated speed
Rated frequency
3000 RPM
50 Hz
Coolant
Hydrogen
Page 28 of 47
TRANSFORMER
The electricity thus produced by the generator then goes to the generator
transformer where the voltage is increased for transmission of electricity with
minimized copper losses.
In general a transformer consists of primary and secondary windings which are
insulated from each other by varnish.
In C.T.P.S. all are oil cooled and air cooled. Some of the transformer accessories
are:
1. Conservator tank 2. Buccholz relay 3. Fans for cooling 4.Lightning arrestors 5.
Transformer bushings 6. Breather and silica gel.
GENERATOR TRANSFORMER
In CTPS each unit has one generator transformer. All generator transformers are
step up transformers. Primary winding is delta and secondary winding star. For
7&8 unit transforms 16.5 to 220KV.
Page 29 of 47
AUXILIARY TRANSFORMRERS
Station Service Transformers
Normal source to the station auxiliaries and standby source to the unit auxiliaries
during start up and after tripping of the unit is station auxiliary transformer.
Quantity of station service transformers and their capacity depends upon the unit
sizes and nos. Each station supply transformer shall be one hundred percent
standby of the other. Station service transformers shall cater to the simultaneous
load demand due to start up power requirements for the largest unit, power
requirement for the station auxiliaries required for running the station and power
23 requirement for the unit auxiliaries of a running unit in the event of outage of
the unit source of supply. The no. and approximate capacity of the SST depending
upon the no. and MW rating of the TG sets are indicated below.
Page 30 of 47
Unit Auxiliary
Transformer
EXCITATION SYSTEM
The purpose of excitation system is to continuously provide the appropriate
amount of D.C. field current to the generator field winding. The excitation system
is required to function reliably under all conditions of the generator and the system
to which it is connected.
Functional components of an excitation system:
A good excitation system consists of properly coordinated functional components
which are
a) Excitation Power source
b) Semiconductor Rectifier
c) Voltage controller
d) Protective, limiting and switching equipment
e) Monitoring, Metering and indicating equipment and
f) Cooling system
Types of Excitation System:
In earlier days DC excitation system was in use. Increase in generator capacity in
turn raised the demand of excitation power which was not achievable by the DC
exciters.
Page 31 of 47
Page 32 of 47
SWITCHYARD SECTION
A switchyard is essentially a hub for electrical power sources. For instance, a
switchyard always exists at a generating station to coordinate the exchange of
power between the generators and the transmission lines in the area. A switchyard
also exists when high voltage lines need to be converted to lower voltage for
distribution to consumers. Here in CTPS there is a big switch yard section for the
Page 33 of 47
units one to six, and also for seven & eight there also a switch yard. Some of the
operation of the components of the switch yard is sometimes done from the control
rooms of respective units.
220KV Switchyard of CTPS
A switchyard may be considered
as a junction point where
electrical power is coming in from
one or more sources and is going
out through one or more circuits.
This junction point is in the form
of a high capacity conductor
spread from one end to the other
end of the yard. As the switchyard
handles large amount of power, it
is necessary that it remains secure and serviceable to supply the outgoing
transmission feeders even under conditions of major equipment or bus failure.
There are different schemes available for bus bar and associated equipment
connection to facilitate switching operation.
The Basic Components of a Switchyard:
Bus Bar: The conductors to which several incoming and outgoing lines are
connected. They are made up of Cu & Al.
Circuit Breaker: A circuit breaker is equipment that breaks a circuit either
manually or automatically under all conditions at no load, full load or short
circuit. Oil circuit breakers, vacuum circuit breakers and SF6 circuit breakers
are a few types of circuit breakers. SF6 circuit breakers have been used in both
220kv and 400kv switchyard.
Isolator: Isolators are switches which isolate the circuit at times and thus serve
the purpose of protection during off load operation.
Switchyard of unit#7,8
Page 34 of 47
Potential transformers:
In any electrical power system it is necessary to
a) Monitor voltage and power factor,
b) Meter power consumption,
c) Feed power to control and indication circuit and
d) Detect abnormalities (i.e. under/over voltage, direction of power flow
etc.) and feed impulse to protective device/alarm circuit.
Potential transformers therefore play a key role by performing the following
functions.
a) Electrically isolating the instruments and relays from HV side.
Page 35 of 47
SWITCHGEAR
RELAY:
THE TYPE OF RELAYS USED IN CTPS FOR PROTECTION OF POWER
SYSTEM COMPONENTS AT 220KV SWITCHYARD
Page 36 of 47
relay
protection relay
differential protection
multiplier relay
healthy relay
Numerical LBB protection relay
Mechanical Relay
HV Switchgears:
Indoor metal clad draw out type switchgears with associated protective
and control equipments are employed. Air break, Air Blast circuit
breakers and Minimum Oil circuit breakers could still be found in some
very old stations. Present trend is to use SF6 or vacuum circuit breakers.
SF6 and vacuum circuit breakers requires smaller size panels and
thereby reasonable amount of space is saved. General arrangement of
6.6 KV Switchgear panels. The main bus bars of the switchgears are
most commonly made up of high conductive aluminum or aluminum
alloy with rectangular cross section mounted inside the switchgear
cubicle supported by molded epoxy, fiber glass or porcelain insulators.
For higher current rating copper bus bars are sometimes used in
switchgears.
HV Switchgears
Page 37 of 47
LV Switchgears:
LV switchgears feed power supply to motors above 110 KW and
upto160
KW rating and to Motor Control Centers (M.C.C). LV system is also a
grounded system where the neutral of transformers are solidly connected
to ground. The duty involves momentary loading, total load throw off,
direct on line starting of motors and under certain emergency condition
automatic transfer of loads from one source of supply to the other. The
switchgear consists of metal clad continuous line up of multitier draw
out type cubicles of simple and robust construction.
Each feeder is provided with an individual front access door. The main
bus bars and connections shall be of high grade aluminum or aluminum
alloy sized for the specified current rating. The circuit breakers used in
the LV switchgear shall be air break 3 pole with stored energy, trip free
shunt trip mechanism. These are draw out type with three distinct
positions namely, Service, Test and Isolated. Each position shall have
mechanical as well as electrical indication. Provision shall be there for
local and remote electrical operation of the breakers. Mechanical trip
push button shall be provided to trip manually in the event of failure of
electrical trip circuit. Safety interlocks shall be provided to prevent
insertion and removal of closed breaker from Service position to Test
position and vice versa.
LV Switchgears
Page 38 of 47
PROTECTION
GENERATOR PROTECTION:
The purpose of generator protection is to provide protection against abnormal
operating condition and during fault condition. In the first case the machine and the
associated circuit may be in order but the operating parameters (load, frequency,
temperature) may go beyond the specified limits. Such abnormal running condition
would result in gradual deterioration and ultimately lead to failure of the generator.
Protection under abnormal running conditions
a) Over current protection: The over current protection is used in generator
protection against external faults. Normally external short circuits are cleared by
protection of the faulty section and are not dangerous to the generator. If this
protection fails the short circuit current contributed by the generator is normally
higher than the rated current of the generator and cause over heating of the stator,
hence generators are provided with back up over current protection which is
usually definite time lag over current relay.
b) Over load protection: Persistent over load in rotor and stator circuit cause
heating of winding and temperature rise of the machine. Permissible duration of
the stator and rotor overload depends upon the class of insulation, thermal time
constant, cooling of the machine and is usually recommended by the manufacturer.
Beyond these limits the running of the machine is not recommended and overload
protection thermal relays fed by current transformer or thermal sensors are
provided.
c) Over voltage protection: The over voltage at the generator terminals may be
caused by sudden drop of load and AVR malfunctioning. High voltage surges in the
Page 39 of 47
system (switching surges or lightning) may also cause over voltage at the generator
terminals.
Modern high speed voltage regulators adjust the excitation current to take care
against the high voltage due to load rejection. Lightning arresters connected across
the generator transformer terminals take care of the sudden high voltages due to
external surges. As such no special protection against generator high voltage may
be needed. Further protection provided against high magnetic flux takes care of
dangerous increase of voltage.
e) Unbalance loading protection: Unbalance loading is caused by single phase
short circuit outside the generator, opening of one of the contacts of the generator
circuit breaker, snapping of conductors in the switchyard or excessive single phase
load. Unbalance load produces (ve) phase sequence current which cause
overheating of the rotor surface and mechanical vibration. Normally 10% of
unbalance is permitted provided phase currents do not exceed the rated values.
For (ve) phase sequence currents above 5-10% of rated value dangerous over
heating of rotor are caused and protection against this is an essential requirement.
g) Loss of prime mover protection: In the event of loss of prime mover the
generator operates as a motor and drives the prime mover itself. In some cases this
condition could be very harmful as in the case of steam turbine sets where steam
acts as coolant, maintaining the turbine blades at a constant temperature and the
failure of steam results in overheating due to friction and windage loss with
subsequent distortion of the turbine blade. This can be sensed by a power relay
with a directional characteristic and the machine can be taken out of bar under this
condition. Because of the same reason a continuous very low level of output from
thermal sets are not permissible.
Page 40 of 47
Page 41 of 47
TRANSFORMER PROTECTION:
Although transformers are generally provided with both electrical and mechanical
protection schemes, our services are related to the protection against the electrical
disturbances. The general electrical protection provided to a transformer are related
to the following
Overload protection
Protection against short circuits (internal / external)
Protection against ground faults
Transient over voltages (switching, lightning)
V/f protection
Protection against overload is achieved using over current relays and details of
thermal with stand capability curves of the transformer. Protection against external
short circuit condition is achieved by fuses, over current relays with are without
instantaneous settings. Protection against internal short circuit is achieved by
proper application of differential protection. Suitable protections are needed
separately for phase and ground faults. Protection against over voltages due to
switching, lightning, switching of capacitor banks or other system disturbances is
achieved by proper insulation coordination.
NEUTRAL GROUNDING TRANSFORMER (NGT): -The NGT is used to detect
earth faults. It comprises of primary winding and secondary winding, the
secondary winding is connected with a low value resistance. Whenever earth fault
arises heavy current flows to the primary winding and as a result an e.m.f is
induced in the secondary winding. The voltage drop across the resistance is sensed
by the E/F relay and it actuates to actuate the Generator Circuit Breaker (GCB) and
thus the generator is tripped.
Page 42 of 47
Stator Winding:
Rotor winding:
Hydrogen
Page 43 of 47
DIESEL GENERATOR
A diesel generator is the combination of a diesel engine with an electrical
generator (often an alternator) to fed power supply to emergency 415V
drives during total station power supply failure.
Diesel
Generator
BATTERY BANK
Normally D.C. power is supplied by the float charger and the batteries are kept in
float condition at 2.15 V per cell to avoid discharging. The charger consists of
Page 44 of 47
General Instrumentation in a
Power Plant
Page 45 of 47
Page 46 of 47
Pressure Measurement:
Temperature Measurement:
Like pressure, temperature is also a most important process
parameter of a thermal power plant. Temperature is also
measured at many points. Depending upon the importance of the
parameter, which is to be measured, either Expansion
Thermometers or Electrical type thermometers are widely used.
Parts which are less important and where only indication is
required Expansion Thermometers are used. And for
measurement of parts which are critical and remote and require
accuracy, precision and remote transmission.
Page 47 of 47
Measurement of level:
In thermal power plant, measurement of level is essential for the
purpose of safe and efficient operation of the plant. For the
purpose of co-ordination and control, level measurement is also
required. In thermal power station, measurement of level is
carried out for liquid and solid. The coal level in the pulverize coal
bunkers are measured, which are the example of measurement of
level of solid. Measurement of Boiler drum water level, Deaerator
water level, Condenser Hot well level, etc is the example of
measurement of level of liquid. When liquid level is monitored for
the purpose of guidance for operating personnel, level is
measured by sight glass method. These are normally known as
Direct Gauge Glass. Local gauges of Deaerator water level,
Condenser Hot well level, Boiler Drum water level, HP heaters &
LP heaters shell water level (HPHs & LPHs drip level), Lube oil
tank level, etc falls under this category. In thermal power plant,
liquid level is also measured to generate audiovisual alarm signal
as well as protective signal when the measured level falls below
or raises above a preset value (level). Normally, float & switch
type level sensor, which works on buoyancy method, is used for
this type of level measurement. In some cases, level is measured
for remote indication and for control. For this type of level
measurement differential pressure transmitters (dp transmitter)
are normally used. The dp transmitter may be of LVDT type,
Reluctance type or Capacitance type.
Measurement of Flow:
Page 48 of 47
CONCLUSION
The practical experience that I have gathered during the overview
training of large thermal power plant having a large capacity of 920 MW
for Unit#1,2,3,7,8. It gave me large spectrum to utilize the theoretical
knowledge and to put it into practice. The trouble shooting activities in
operation and decision making in case of crisis made me more confident
to work in the industrial atmosphere. Moreover, this overview training
has also given a self-realization & hands-on experience in developing
the personality, interpersonal relationship with the professional
executives, staffs and to develop the leadership ability in industry
dealing with workers of all categories.
I would like to thank everybody who has been a part of this project,
without whom this project would never be completed with such ease.
Page 49 of 47
BIBLIOGRAPHY
*WEBSITES
http://en.wikipedia.org
http://www.google.co.in
*BOOKS
Page 50 of 47
Page 51 of 47