A Training Report

For Partial Fulfillment B.E Electrical Engineering from MSIT, Janakpuri

ON National Fertilizers limited, Panipat Unit

Presented By guidance of:-

Under

Harshal Kumar Johnson Oram B.Tech (EEE) 00315004911

Mr.

Acknowledgement
It is a matter of great pleasure for me acknowledging me with profound sense of gratitude, the invaluable help & worth guidance rendered by my project guide Mr. Johnson Oram .Their innumerable suggestions which served as the material source & the motivational force for the successful completion of the training. At last, I am thankful to all those who helped me in any way, in achieving my goal of successful completion of the training. It is my pleasure to thank my father Mr.R.K.Sonkar for his constant encouragement and valuable advice during the whole training period.
[2]

Harshal Kumar

COMPANY PROFILE

[3]

National Fertilizers Limited was established in August, 1974 to set up two fuel oil based plants at Bathinda (Punjab) and Panipat (Haryana). Both of them were commissioned in 1979. The Nangal Fertilizer plant of Fertilizer Corporation of India (F.C.I) has been merged with National Fertilizer Limited (NFL) in 1978 on the reorganization of FCI and NFL group of companies. Later, NFL executed its gas based plant at Vijaypur (Madhya Pradesh) on HBJ gas pipe line. Vijaypur plant had gone in commercial production in July, 1988. The National Fertilizers Limited is now operating three fuel based plants located at Nangal, Bathinda and Panipat and a gas based plant at Vijaypur. The of three fuel based plants is 900 TPD of ammonia, 1000 TPD of urea at Nangal and 1550 TPD of urea at Bathinda and Panipat. The capacity of gas based plant at Vijaypur is 700 TPD of Ammonia and 400 TPD of Urea with the addition of the gas based plant in the family of National Fertilizers Limited, the Company now occupies the position of largest producer of nitrogenous fertilizers in the country.

PLANTS AND CAPACITIES

CAPTIVE POWER PLANT AMMONIA PLANT UREA PLANT SULPHUR RECOVERY PLANT
[4]

2X15MWH 900MT/DAY 1550MT/DAY 26.5MT/DAY

 STEAM GENERATION PLANT COAL HANDLING PLANT DM WATER PLANT RAW WATER PLANT

3X150MT/DAY 150&250MT/HR 400MT/HR 2400M

Training Report

CAPTIVE POWER PLANT

[5]

Captive power plant has been installed to meet the total power requirement of the plant. The turbo generators of 15MW each generate power at 11KV. Power plant can be run in parallel and in isolation with the grid. Boiler of 210T/hr has been provided to supply stream to turbo generators. Boiler is designed to operate on coal with support of oil and or fully on fuel oil.

It was commissioned in 1988 with the basic purpose of serving Panipat unit independent from HSEB grid so that performance does not have any adverse effect.

Three main actions of plant are:[6]

 Steam generation plant Turbo generator set Transformer

STEAM GENERATION PLANT

Coal from material handling plant is taken to six bunkers through conveyer belts. Coal from six bunkers are fed to 3 ball mills through six coal feeder for controlling the flow of controlling the flow of coal according to the boiler demand. Each ball mill is connected to two coal feeders through six coal crusher.

[7]

Major sections of SGP are: Boiler Super heater Economiser Air preheater Electrostatic precipitator Forced shaft fans &induced shaft fans

BOILER:
Boiler in the CPP is multi relay RX type from fixed boiler. Normal capacity of boiler is 210T/hr. Boiler is designed to run on pulverized coal supported by oil. Plant can take full load on any type of fuel.

SUPER HEATER:
Basic function of super heater is to raise the temperature of steam above the boiling point of water which increases the overall efficiency of the plant. It consists of groups made up of several alloy steels such as chromium molybdenum. There are three types of super heaters namely: radiant, convection, and separately fired. Super heaters increase the efficiency of the steam engine, and were widely adopted. Steam which has been superheated is logically known as superheated steam; nonsuperheated steam is called saturated steam or wet steam. Super heaters
[8]

were applied to steam locomotives in quantity from the early 20th century, to most steam vehicles, and to stationary steam engines. This equipment is still an integral part of power generating stations throughout the world.

ECONOMISER:
It heats the feed water on its way to boiler. It consists of large number of closely spaced large parallel tubes connected by the header of the drum. Economizers are commonly used as part of a heat recovery steam generator in a combined cycle power plant. 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.

AIR PREHEATER:
Heat absorbed from flue gas is transferred to incoming cold air by means of continuously rotating heat transfer elements of specially formed metal plates. An air preheater or air heater is a general term to describe any device designed to heat air before another process (for example, combustion in a boiler) 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.
[9]

ELECTROSTATIC PRECIPITATOR:
Its basic function is to free the gas from ash and minimize the pollution. Each ESP has 10 electrodes and 18 plates. 60 KV (DC) is fed by the help of transformer and rectifier assembly. Following is the process taking place in the electrostatic precipitator:-

Dust laden flue gases from the boiler passes between rows of two electrodes. Neutral gas molecules get ionized due to the process of electronic field. Positively charged ions travel towards emitting electrodes and negatively charged ions get attached to dust particles. Dust particles get electrically charged and deposited on collecting electrodes.

TURBO GENERATOR SET

[10]

Fig. Turbo generator

SPECIFICATION:

NUMBER

[11]

OUTPUT 15MW RATED POWER FACTOR RATED VOLTAGE RATED FREQUENCY SPEED DEGREE OF PROTECTION INSULATION CLASS ROTOR-F TEMPRATURE ROTOR-B 0.8

18750KVA,

11000V 50Hz 3000RPM IP-54 STATOR-F

STATOR-B

EXCITATION CHARACTERISTICS:

[12]

AT NO LOAD V=55V AT MAXIMUM RATED CURRENT V=163V AT 125% MAX RATED CURRENT V=189V

I=276A,

I=580A,

I=672A,

EFFICIENCY AT POWER FACTOR 0.8:

100% LOAD 75% LOAD 50% LOAD 97.53% 97.25% 96.49%

[13]

DESCRIPTION
GENERAL:

Three phase alternator set has: Totally enclosed self ventilated with two lateral air to water cooling. Horizontal shaft Two enshield sleeve bearing with forced lubrication. Six stator leads consisting of copper bars arranged vertically at the bottom frame.

Rated output is given for continuous running at 50 Hz frequency, power factor 0.8, 36C inlet temperature of fresh cooling water and altitude above sea level exceeding 1000m.

[14]

STATOR CONSTRUCTION:
FRAME: The frame has parallelepiped form. It is made
of welded steel and designed to ensure the best mechanical holding.

CORE: The core is built of low losses electrical sheet

lamination insulated in accordance with insulation process and can be clamped between two plates; the whole is divided in to elementary stacks separated by steel insulation which form ventilation canal for cooling of coil.

STATOR WINDING: Stator wedge consist of identical

coils. The alternator is insulated in accordance with our epoxy process which is an insulating system based on mica tape with paper or Dacron support and wrapped in multiple layer around the coil. After impregnation the complete stator is subjected to heat treatment that allows a compact homogeneous supervious insulated structure to be obtained.

TERMINALS: The six main leads which consist of

copper strip are arranged vertically at the bottom of frame.
[15]

SPACE HEATER: One space heater is located at the

base of stator to avoid humidity when the generator is running.

ROTOR CONSTRUCTION:
SHAFT: Shaft end and rotor bodies are integrally forged
of high mechanical quality steel that has undergone a no. of tests.

ROTOR WINDING: Wedge is made of cold drawn

rectangular of high conductivity. The turns are framed on mandrel and lead into the slots. The turns are stratified glass fiber insulation.

RETAINING RING: These are fixed to the rotor body.

In this way the shaft end are free to bend without touching the retaining ring. The rings have great number of radial holes which permits evacuation of the end turned air.

VENTILATION: The ventilation system is designed to

provide maximum efficiency and prevents hot spots. The art is drawn at each end of the generator by the two helicoidally fans. After cooling the active parts of the
[16]

machine, the air is discharged at the periphery of the stator core and then in the coolers located on either side of the frame.

COOLERS: The two air to water coolers are located in

either side of frame. They are formed by the nest of round cupronickel tubes on which aluminum cooling fins are fixed.

EXCITER
DESCRIPTION: Total enclosed cooled with cold air
supplied by the main generator inverted alternators with stationery field and rotating armature. It feeds the generator through a rectifier mounted on shaft connection between the rectifier bridge and main generator field are made by hole drilled in shaft.

ROTATING ARMATURE: The lamination cut in one

piece insulated after puncturing. The slots are scrunch on the rim that has to be keyed on the shaft. The armature winding is installed in the open slots, secured in position and connected to the rotating rectifier bridge.

STATOR: The frame consist of laminated magnetic ring

on which the main hole cores are bolted. The field coils are secured on the hole cores.

RECTIFIER

The rectifier bridges are mounted in GRAETZ Bridge and are two types of cells.
[17]

BRIDGE:

Each arm of the bridge uses 3 cells in parallel and elementary rectifier bridge is protected by fuses. The size of cells and their charge to avoid all the possibility of overload or over voltage when the alternator is running in following conditions: Three phase fault at the generator terminals. Over voltage of the network. None synchronized running.

GENERATOR EXCITATION:In both automatic and manual operation with excitation by taping the generator must be started until a voltage of 0.1Un is reached. The stator is cut off by a voltage threshold relay which they release the controller. In automatic operation the generator is excited so that rated voltage is reached immediately a variation of du being then possible by external control.

OVERLOADING: When load current increases, generator speed decreases, now reading increases. Signal sent to control panel from where it is sent to governing valve that in turn governs the steam in flow of the turbine. Valve opens accordingly and steam in flow increases. Collaterally, now reading goes to neutral.
[18]

DE-EXCITATION:
Whether manual or following activation of a protection device, de-excitation occurs after the coupling circuit breaker has opened following the rapid cut off of the excitation current, the transformer/thruster set will operate as inverter. On a de-excitation order, thruster clock pulses are locked in the minimum position (inverter mode) excitation contactor being then de-energized.

GENERATOR PROTECTION:
1. FREQUENCY RELAY

Solid state frequency relay with high accuracy and stability are used:(a) For splitting up a grid system opening transmission lines to prevent complete system collapse. (b) For isolating small systems having their own generation from the main system. (c) For the protection of generators and auxiliary where frequency suppression can avoid damage to turbines and auxiliary drives.

2. ACTIVE OR REACTIVE POWER RELAYS

[19]

The WTG 7100 relays have been developed in order to provide a static solution to the various problems of protection requiring real measure of active power (as well as energy flow direction supervision), a solution offering the following advantage: Unbalanced power in case of 3-wire,3-phase

networks, measured by two wattmeter method. Great directional stability. Active power relay is totally unaffected by current and voltage harmonics. Operating threshold continuously adjustable. Low burden on current and voltage transformer.

3. OVER CURRENT PROTECTION RELAY

The ITG relay of the 7200, 7300, 7400 series provides a complete range of phase or earth fault protection relays inverse time extremely inverse time type with or without instantaneous high set units. The ITG relay of the 7200, 7300, 7400 series have specifically designed or the protection of the networks and substations against fault between phases or from phase to earth.

4. ALTERNATOR LOSS OF FIELD PROTECTION RELAY

[20]

The YTM 7111 is an admittance relay, specifically designed for the detection by using the electrical quantities available in its stator circuit of the loss of field of an alternator connected to a network. To perform this detection, the relay is supplied from two phase circuit and corresponding phase to phase voltage. If the field current of alternator is interrupted either by a short circuit or by accidental opening of the rotor circuit, after a short period the machine will loose synchronism. The rotor will accelerate slighter and the alternator will operate as asynchronous generator continuing to supply active power required for its magnetization from the network to which it is connected. The rotor motor may go above nominal due to reactive power absorbed and low frequency currents are induced in the damper winding and on rotor surface causing abnormal heating of the later if asynchronous operation continuous for too long period.

5. ROTOR EARTH FAULT RELAY

The first fault should however be first eliminated without delay, because it allowed to remain a second fault of the same type that would immediately put the machine out of service and could cause very serious damage to rotor.

[21]

The object of TTE 7015 and TTE 7017 is to detect immediately any fault on the rotor winding of a synchronous machine in order to give an alarm and if required to separate the machine from network.

TRANSFORMER

[22]

RATING

MVA FREQUENCY TYPE OF COOLING

31.25/24 50 Hz ONAF/ONAN

VOLTAGE AT NO LOAD

[23]

H.V. (STAR) L.V. (STAR) T.V. (DELTA)

132KV 11KV 6.6KV

NORMAL AMPERES AT 31.5 MVA BASE

H.V. A L.V. A

137.8 1653.3

INSULATION LEVEL

H.V. 650KVP L.V. 75KVP

[24]

H.V.NEUTRAL 95KVP

DESCRIPTION OF TRANSFORMER
GENERAL:
The transformer is oil immersed with double rating of 31.5 MVA and 24 MVA under oil natural air forced and oil natural air natural type of cooling respectively. The transformer is the most convenient and economical device for transfer of power from one voltage to another voltage(low or high) at the same frequency. It works on the principle of electromagnetic induction. There is hardly any installation without a transformer. Due to this equipment, it has been possible to transmit bulk power to load centers from far off power houses and to various machineries and switchgears of the power plant.

Transformers are of two types:-

STEP-UP TRANSFORMER: The transformer which steps up the voltage at the secondary side is called step-up transformer.
[25]

 STEP-DOWN TRANSFORMER: The transformer which step down the voltage at secondary side are called step-down transformer.

MAIN PARTS OF POWER TRANSFORMER:

Primary winding Secondary winding Oil tank Conservator Breather Explosion vent Temperature gauge Tap changer Tubes for cooling Transformer oil Earth point Primary terminals Secondary terminals

[26]

ACCESSORIES OF TRANSFORMER

1. OIL CONSERVATOR:
Oil conservator is a short of drum mounted on the top of transformer. A level indicator is fixed to it, which gives alarm at low level. Conservator is connected through a pipe to the transformer tank containing oil. This oil expands or contracts depending upon the heat produced and so the oil level in conservator is left open to the atmosphere through the breather so that the extra air may go out or come in.

2. BREATHER:
The breather is a box containing calcium chloride or silica gel to absorb moisture that entering the conservator. Silica gel is having a property absorbing the moisture or humidity, so it is used as breather. It is well known fact that the insulating property of the

[27]

transformers oil is lost if a small amount of moisture enter in it, so dry air is passed through the breather.

3. EXPLOSION VENT:
It is also a safety device of the transformer which protects the transformer tank from gases induced by and any type of short circuit in the transformer. This consists of a vertical pipe closed by diaphragm made of thin Bakelite sheet. This diaphragm bursts or slides out in case of abnormal pressure inside the tank.

4. TEMPRATURE INDICATOR:
It is also a protective device fitted to the transformer to indicate temperature of transformer oil. For measuring temperature of the oil, bulb of the vapour pressure type thermometer is placed in the hot oil and dial of the thermometer is mounted outside the tank. Two indicating pointers black and red are provided. Alarm contacts are also provided which come into action when predetermined permissible higher temperature is reached under abnormal operating conditions. Temperature indicator indicates the temperature of both i.e. the winding temperature as well as of oil temperature.

5. BUSHINGS:
The bushing serves as supports and insulation of the bus bars and transformer terminal. The bushing consist of porcelain shell body, upper and lower locating washer
[28]

used for fixing the position of bush bar and mounting flange with the hole drilled for fixing bolt and it is supplied with an earthing bolt.

Fig. Bushing

7. MAGNETIC OIL GAUGE:

The magnetic oil gauge supervises the level of oil in the conservator tank. The oil level gauge is provided on the transformer are of dial type with minimum and maximum level marking and pointer which indicate the level of oil in the conservator. Sometimes the scale is also graduated for oil temperature on the basis of its level

8. TAP CHANGER:
The voltage control of transmission and distribution system is obtained by tap changer. Tap changer are either on load or off load tap changer. Tap changer is fitted with transformer for adjusting secondary voltage.

[29]

The voltage control of the range of 16% can be achieved by tap changing transformers.

MAIN RECEIVING SUBSTATION

Total factory load is around 23.5 MW, 2 lines from HSEB (Haryana State Electricity Board) and 2 lines from CPP are taken to receiving towers with the help of insulator arrangement. For the protection of switchyard, shielding wires are also provided on receiving towers. 3 transformers step down 132KV to 11KV.

Normally 3 kinds of supply are available:

NORMAL SUPPLY:
[30]

It is given by generator and grid. Supply levels of 132KV, 11KV, 3.3KV and 415V are available.

EMERGANCY SUPPLY:
It gets operated when there is failure of normal supply. It is given from DG set. Generally it comes in act after 2 minutes of failure of normal supply.

CRITICAL SUPPLY:
It gives to those motor operated valves, whose non functioning could result in blockage of pipelines carrying poisonous gases which could lead to serious accidents.

The protective equipments switchyard are:-

present

in

132KV

LIGHTNING ARRESTOR:
They are used to protect the electrical system against direct lightning strokes. It conducts the high voltage surges on the power system to the ground. Each lightning arrestor is connected in parallel to one phase wire.

ISOLATOR:
Isolator opens a circuit under no load. The main purpose of an isolator is to isolate one portion of circuit from other and is not intended to open while current is flowing in the
[31]

line. They are used in both sides of the circuit breaker in order that repair work can be performed on circuit breaker without any damage.

CIRCUIT BREAKER:
It can open a circuit under any condition i.e. under load as well as no load conditions. It is so designed that it can be operated manually under normal condition and automatically under faulty condition with the help of the relay circuit. They are used to open circuit or break the circuit. Minimum Oil Circuit Breaker (MOCB) are used in the switchyard.

CURRENT TRANSFORMER:
They are used to measure the current flowing in the system. They are connected in series with each phase wire. In case of overcurrent they operate a relay which in turn disconnects all the links to faulty area.

POTENTIAL TRANSFORMER:
They are used to measure the voltage through the system. They are also connected in parallel to each phase wire, in case of overvoltage they operate a corresponding relay which in turn send signal to disconnect link to the faulty area.

RATING OF SYNCHRONOUS GENERATOR AT CPP

OUTPUT 18750KVA
[32]

VOLTAGE 11000V CURRENT R.P.M. P.F. EXCITATION VOLTAGE EXCITATION CURRENT 984A 3000 0.8 163V 580A

RATING OF DIFFERENT THREE PHASE INDUCTION MOTORS INSTALLED AT CPP

1. ASH HANDLING MOTOR

VOLTAGE KW RPM PF FREQUENCY INSULATION CLASS 2. ASH WATER PUMP-A

3300V 180 1486 0.82 50 Hz F

VOLTAGE
[33]

3300V

KW RPM FREQUNCY P.F. IP HP INSULATION CLASS

250 1488 50 Hz 0.86 55 340 B

3. ASH WATER PUMP

VOLTAGE KW RPM CURRENT HP INSULATION CLASS

3300V 200V 1486 45A 270 F

Bibliography
From Daily Dairy From engineeringfundamentals.com
[34]

 From electric M\c by J.B Gupta.

[35]