Tharmal Traning Reports

CHAPTER 1
1.1 INTRODUCTION
Guru Nanak Dev Thermal Power Plant is a coal-based plant. The requirement of coal
for four units based on specific fuel consumption of 0.60 kg / kWh. The conveying and
crushing system will have the same capacity as that of the unloading system. The coal
comes in as large pieces. This coal is fed to primary crushers, which reduce the size of
coal pieces from 400mm to 150mm. Then the coal is sent to secondary crusher through
forward conveyors where it is crushed from 150mm to 200mm as required at the mills.
Then the coal is sent to boilers with the help of primary fans. The coal is burnt in the
boiler. Boiler includes the pipes carrying water through them; heat produced from the
combustion of coal is used to convert water in pipes into steam. This steam generated is
used to run the turbine. When turbine rotates, the shaft of generator, which is
mechanically coupled to the shaft of turbine, gets rotated so, three phase electric supply is
produced.
The basic requirements are:
Fuel (coal)
Boiler
Steam turbine
Generator
Ash handling system
Unit auxiliaries
MANPREET KAUR [21302101]
Page 1
CHAPTER 2
2.1WORKING
OF
THERMAL PLANT
Coal received from collieries in the rail wagon is mechanically unloaded by Wagon
Tippler and carried by belt Conveyor System Boiler Raw Coal Bunkers after crushing in
the coal crusher. The crushed coal when not required for Raw Coal Bunker is carried to
the coal storage area through belt conveyor. The raw coal feeder regulates the quantity of
coal from coal bunker to the coal mill, where the coal is pulverized to a fine powder. The
pulverized coal is then sucked by the vapour fan and finally stored in pulverized coal
bunkers.
The pulverized coal is then pushed to boiler furnace with the help of hot air steam
supplied by primary air fan. The coal being in pulverized state gets burnt immediately in
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the boiler furnace, which is comprised of water tube wall all around through which water
circulates. The water gets converted into steam by heat released by the combustion of fuel
in the furnace. The air required for the combustion if coal is supplied by forced draught
fan. This air is however heated by the outgoing flue gases in the air heaters before
entering the furnace.
.The steam after doing the useful work in turbine is condensed to water in the
condenser for recycling in the boiler. The water is pumped to deaerator from the
condenser by the condensate extraction pumps after being heated in the low pressure
heater (L.P.H) from the deaerator, a hot water storage tank. The boiler feed pump
discharge feed water to boiler at the economizer by the hot flue gases leaving the boiler,
before entering the boiler drum to which the water walls and super heater of boiler are
connected.
2.1.1 COAL MILLING PLANT
Since G.N.D.T.P. units are primarily coal fired units so each boiler is provided with
closed milling circuits to pulverize the raw coal which is received from coal conveying
system after coal crushes before it is fired in the furnace. The necessity of pulverizing the
coal is to be ensuring its maximum possible combustion in the furnace. The coal data for
units are: COAL DATA
Type of Coal
Net Calorific Value
UNITS 1 & 2
UNITS 3 & 4
Bituminous
Bituminous
4300 Kcal/kg
4727 Kcal/Kg
Moisture
10 %
7.5 %
Ash Content
30 %
32 %
2.2 SWITCHGEAR
2.2.1 INTRODUCTION
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The apparatus including its associated auxiliaries employed for switching, controlling and
protecting the electrical circuits and equipments is known as switchgear.
A tumbler switch, which is an ordinary fuse, is the simplest form of switchgear and is
generally used to control and protect the domestic and commercial appliances and
equipments. For high rating circuits, a high rupturing capacity (H.R.C.) fuse in
conduction with switch may serve the purpose. However, such switchgear cannot be
applied on power system operating at high voltages, i.e. more than 11 KV because of the
following reasons: 1. When fuse blows, it takes some time to replace it and consequently there is
interruption of power supply.
2. On high voltage system, a fuse cannot successfully interrupt large fault currents.
3. When fault occurs, fault takes some time to blow. During this time the costly
equipments e.g. generators, transformers etc. may be damaged.
Therefore in order to protect lines, generators, transformers and other electrical
equipments from damage, an automatic protective device or switchgear are required.
Automatic protective switchgear mainly consists of the relays and circuit breakers. A
circuit breaker is switchgear, which can be open or close the circuit after an operation.
Therefore, a circuit breaker is rather preferred even in the instance when a fuse is
adequate
Switch: It makes and breaks the circuit under full load or no load condition but cannot be
operated under fault conditions. It is generally operated manually.
.
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2.2.2 Isolator: It is only operated under no load conditions. Its main purpose is to isolate a portion of
the circuit from the other. Isolators are generally place on the both sides of a circuit
breaker from the other in order to make repairs and maintenance on the circuit breaker
without any danger. There are two types of isolators: TYPES OF ISOLATER:
Single pole Isolator
Double pole Isolator
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CHAPTER 3
3.1 D.C. SUPPLY SYSTEM
D.C Supply is the brain of the plant. Each unit has its own 220volts D.C system located
in the electrical bay. 48 battery of requisite rating are also being provided. Each D.C
system comprises of the following:1. Storage battery
2 Battery Charges
3. Distribution & sub-distribution boards
The batteries are of lead acid type. Battery cells have high discharge performance cell
types each of 2volts. Battery charge are static type & capable of trickle charging & boost
charging. Adequate standby provision is also made for the outage of the charger in the
form of installation of standby charges.
The D.C distribution & sub-station boards are compartmentalized; draw out type,
construction, housing switches & fuses for various feeders are as per the requirements for
the plant.
The battery rooms are well ventilated & well lighted & there is adequate provision for
expelling acid fumes & fumes h2 gas out from the battery room.
1. Dry cell batteries
2. Lead acid batteries
3. Alkaline cell batteries.
Lead acid cells are of further two types:1) Automobile battery
2) Stationary lead acid battery.
POWER REQUIREMENT
A DC source capable of delivering current as specified. The voltage required will be two
times the No. of cells in battery. The initial charging of the battery will takes approximate
55 to 90 hours.
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CHAPTER 4
4.1 BOILER SECTION
The steam generating unit is designed to meet the nominal requirements of 110MW turbo
generator set. The unit is designed for a maximum continuous rating of 375 tones/hr. at a
pressure of 139kg/cm2 and a steam temperature of 5400C. the reheated steam flows at
MCR 32H tones/hr. at the feed water temp at MCR is 2400C. The unit is a balance
draught dry bottom; single drum natural circulation, vertical water tube type, construction
with skin casing and a single reheat system. The furnace is arranged for dry ash discharge
and is fitted with burners located at the four corners. Each corner burner comprises coal,
vapour oil and secondary air compartments. The unit is provided with three ball mills and
arranged to operate with intermediate cool powder bunker. The steam super heater
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consists of 4 stages Viz. Ceiling, convection, platen and final superheated. The ceiling
super heated forms the roof of the furnace and horizontal pass and finishes as the rear
wall of the second pass. The convection super heated is made up of horizontal banks
located in the second pass. While the platens are located at the furnace exit, the portion
above the furnace nose encloses the final superheated reheated are in two stages, first
stage is the trifle heat exchangers located in the second pass, which absorbs heat from
superheated steam as well as from the flue gases. The second stage is exit reheated
located in the horizontal pass as pendant tubular loops.
(a) The flue gas for drying the cool in the mills is tapped off after the trifle heat
exchangers. The damper located in the hot flue gases pipe leading to mill controls the
quantity. Control the circulating vapour of the mill entry effect temperature control.
Immediately after the trifle heat exchanger, the air heaters and economizers are located.
The air heater is in 2 stages.
(b) The hot air for combustion from air heater stage 2 is led into the common wind box
located on the sided of the furnace. 4 cool air mixed pipes from pulverized coal bounders
are connected to 4 cool burners nozzle at the corners. There will be totally 16 coal
nozzles. 4 located in each corner. Oil guns will be located in the secondary air nozzle for
coal burning. The turn down ratio of the guns will be so selected that it will be possible to
use them also for pulverized fuels flame stabilization while operating under load below
the control point.
(c) Take into consideration the high % age of ash and the relatively poor quality of coal
due regards has been paid to wide pitching the tubes and to the gas velocity across the
heating surface areas. In order to insure reliable and continuous operation sample sot
blowing equipment is provided. There are short retractable steam root blowers provide at
the top of furnace fully retractable rotary type blowers are located for cleaning of the
secondary super heater and final heater partly retractable steam blowers are arranged for
the horizontal reheated and super heaters in the second pass. The steam root blowers are
electrically operated.
(d) Root blowing nozzles using blow down from boilers drum are provide for the
cleaning of areas around the burners nozzles zone for dislodging of slag boulder if any in
the bottom ash hopper in the furnace.
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(e) Two FD fans are provided per boiler. The FD fans are of the axial type driven by
constant speed motor. The regulation of quantity and pressure is done by inlet vane
control. The flue gases are sucked through the mechanical and electrostatic precipitators
by I.D. fans and delivered into the chimney. Two I.D. fans are provided for each boiler
and they are of the axial type driven by constant speed motors. Inlet vane control effects
the capacity change with reference to load. Both the I.D. and FD fans have been
dimensioned taking into account the minimum margins of 15% on volume and 32% on
pressure.
Specification
Manufacturer
B.H.E.L
Maximum continuous rating
375tones/hr.
Super heater outlet pressure
139kg /cm2
Reheated outlet pressure
33.8 kg/cm2
Final super heater temperature
540 digs
Feed water temperature
240deg.c
Efficiency
86% (stage-1)
87% (stage-2)
Coal consumption per day
1500 tones
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CHAPTER 5
5.1TURBINE SECTION
The turbine is the prime mover for the generator in the power plant Different types of
steam turbines used in thermal power plants, but the ones. Which are used at G.N.D.T. P.
are categorized as follows
S.No.
Type of Turbine
Turbine at G.N.D.T.P.
1.
Horizontal/vertical
Horizontal
2.
Single/multi cylinder
Multi cylinder
3.
Condensing/non condensing
condensing
4.
Reheat/ non-reheat
Reheat
5.
Regenerative/non regenerative
Regenerative
6.
With by pas/without bypass
with by pass (stage-1)

Without bypass (stage-2)
5.2 BASIC WORKING OF TURBINE

First of all the turbine is run on gear motor with the help of exciter. At that time steam is
kept on recalculating with the help of bypass valve. When the pressure of steam is
increased to an optimum level and turbine acquires a particular rpm then steam is
introduced in the H.P. (high-pressure) cylinder first. The temperature of steam at entrance
is 540C and pressure is about 139 Kg/cm2. After doing its work on the H.P. Turbine, the
steam is taken out for reheating rated temperature of steam at reheated inlet is 360C. The
temperature of steam is increased upto 535C in the boiler shell and steam is again
introduced in M.P (Medium pressure) turbine. After M.P.turbine, the steam is passed on
to L.P. (Low-pressure) turbine. This process helps the turbine to reach the speed of 3000
rpm. After L.P. turbine, the steam is condensed in condenser, build below the turbine unit.
The condenser contains a number of brass tubes through which cooling out from L.P.
turbine it comes in contact with colder brass tubes then steam get transformed into water.
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This water get collected in HOT WELL just below the condenser. From here the hot
water is again pumped with the help of condensate pumps. The cooling water is used to
condense steam gets heated up and is cooled by falling from cooling tower. This
completes the processing of steam through turbine and condenser.
5.3 ROTOR OF TURBINE
All the rotors are manually by means of rigid coupling, including the rotors of the
generator. The speed of whole system of rotor lies in the following ranges of the speed at
the operating conditions: 1900 to 2000 rpm Best noticed on the M.P. and L.P. rotors and generators.
2350 rpm Best noticed on H.P. rotor.
1. BEARING OF ROTORS
The axial load of the entire system of rotors is taken up by a double-sided axial bearing
located in the bearing stand between the H.P. and M.P casing. These are two protections
mounted near the axial bearing one hydro chemical and one electromagnetic, which fouls
the turboset during the non-permissible movement of the rotor.
The rotors are placed on radial bearing which are machined to elliptical shape. Further
scrapping operations or change top and side clearances and change in temperature of oil,
influence the oil wedge and the position of the journal bearing to maintain the same
condition as existed during the initial assembly.In the lower half of bearing a hollow
groove is provided in the babbit metal through which oil the supplied through a drilled
hole through H.P. jacking oil pumps.
The high-pressure oil rotors are lifted in the bearing so that any scrapping of the bearing
is prevented.
2. TURBINE CASING
The high-pressure part of turbine is consisted of two-concentric horizontal casing. Inner
casing is connected in such a way to the other casing that it enables to expand in all
direction. The nozzles are attached to the inner casing. The steam pipe is connected to the
condensers and the condensers are supported by springs. The casings are inter connected
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by the system of guide keys through bearing pedestals in such a way that thermal
expansion of casing does not destroy the various parts of turbine.
The displacement-bearing pedestal between M.P. and H.P parts is measured by the
electromagnetic pick up. This valve is about of 15 mm to prevent deformation at the
casing. It is very important that sliding part clean lubricated and free from hazard for
connecting parts bolts elements. The heating of bolts before tightening up and before the
locking presents. The flanges of M.P. and H.P. casings are designed to heat up by steam
during the starting up of turbo boost by which the difference in temperature between the
cylindrical position of the casing flanges and connected bolts is reduced to limited
deformation. The thermo couples are used for measuring temperatures. The thermo
couple is partially connected to the indicated apparatus. Cooling fluid is generally used
for reducing the temperature of various parts.
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3. REGULATION AND SAFETY EQUIPMENT FOR TURBINE GOVERNING

The quality of steam entering in the turbine is regulated by the four governing valves on
the inlet to the M.P. part. The amount of opening at any instant of these valves is
controlled by the pressure of secondary oil, which is indirectly depending on the primary
oil pressure and directly depending upon the spring force in the transformer during the
stand still and during starting of the turbo set. The pressure of primary oil is directly
depending on the speed of the set through the speed-sensing element. Operating the speed
changer or the normal speed changer can vary the tension in the spring in the transformer.
Thus make it possible to vary the speed before synchronizing. In case break down of any
equipment of the block the quick closing devices are provided in the regulation system of
the turbo set. H.P. quick closing valves (H.P.Q.C) M.P. quick closing valves (M.P.Q.C) at
return flap valves are operated by either directly by the tripling lever or through the relay
magnet on the main relay which creates instantaneously loss of pressure of the quick
closing oil by the change of flow of oil inside the relay.
Distribution is used for checking the function of H.P.Q.C and M.P.Q.C valves. The H.P.
and M.P quick closing valves, the non return flaps and non return extraction valves
during normal operating condition have only two positions one is fully opened another
fully closed.
4. STEAM CYCLE
The design of the power cycle based on the modern concept, where a unit consists of a
steam generator with its independent firing system tied to the steam generation. The
steam generator is designed for maximum continuous rating of 375-tonnes/hr. and steam
Pressure of 139-kg/cm2 at temperature of 540C respectively. The steam generator is
designed to supply to a single reheat type condensing steam turbine with a 8 non
regulated extraction points of steam for heading the condensate and feed water. The
steam cycle can be classified into the following three divisions: (a) Main stream (b) Reheat steam (c) extraction steam
(a) MAIN STEAM
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Saturated steam from the steam generator drum is led to the super heater bank to heat if
4up to 540C saturated steam from the drum is led to the ceiling super hearter (between
SHH1 and SHH2) from ceiling super steam goes to convection
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Super heater (between SHH2 and SHH3) the first regulated infection for at temperature
takes place after convection super heater (between SHH9 and SHH10). Before entry to
final super heater the steam is again at temperature by regulated injection. The steam is
coming out from the final super heater normally at a pressure of 139 kg/cm 2 at a
temperature of 540oC. This steam is feed to the control valve. In each of the two live
steam lines there is one turbine side main stream stop valve and one high pressure quick
closing valve along with two control valves.
(b) EXTRACTION STEAM
Steam for heating of the condenser and the feed steam is extracted from 8 non regulated
extraction points from the turbine. Heating is carried out in five stages of L.P. heaters,
one deareating heater and in two H.P. heaters extraction 1, 2, 3, is taken from L.P. turbine.
Extraction 4, 5, 6 and 7 are taken from M.P. turbine. Extraction 8 is obtained from C.R.H.
line first and second stage of heating is done by two sets of twin low-pressure heaters
mounted directly in the L.P. casing of the turbine. Extraction 3, 4 and 5 are connected to
the deaereating heater placed above feed water storage tank 7 th and 8th extraction steam is
fed to the vertical H.P. heaters respectively.
(C) REHEAT STEAM
Exit steam from the H.P. turbine is taken back to the reheater section of the steam
generating unit. Reheating is done in two stages both by flue gas and by super heated
steam. The steam to be reheated is first pass through the triple-heated exchanger, where
super heated steam is used as the heating media. The steam is finally reheated in final
reheaters (RHH3) RHH4 and RHH5) suspended in the horizontal pass of the furnace.
Reheat steam at a normal pressure of 36.4 kg/cm2 at a temperature of 540C respectively
is fed to the M.P. cylinder by two hot reheat steam pipes through strainers and combined
stop and interceptor valves. In each of the cold reheat steam lines from H.P. cylinder a
non-return valve is operated by oil pressure is provided.
5.
Turbine Accessories and Auxiliaries

I.
Surface condenser.
II.
Steam jet air ejector
III.
LP and HP heaters.
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IV.
V.
VI.
Chimney steam condenser.

Gland steam condenser.
Oil purifier or centrifuge.
VII.
Clean oil pump with clean oil tank
VIII.
Dirty oil pump with clean oil tank.
IX.
Auxiliary oil pump with auxiliary oil tank
X.
XI.
Starting oil pump.

Emergency oil pump.
(I) SURFACE CONDENSER

Two surface condensers are used for condensing the steam which has worked in the
turbine. The coolant for condensing the steam is circulating water which is inside the
condenser brass tubes and steam is outside.
Technical data of Condenser
Cooling Area
3300 msq.
Number of brass tubes
6000
Circulating water required
7500 tonnes/hr.
Vacuum in the condenser
0.90 kg/cm sq.
(II) STEAM JET AIR EJECTOR

Starting ejector is used for quick evacuation of the turbo set during starting whereas main
steam jet air ejector is used to maintain Vacuum in the condenser. It works on the
principle of VENTURI with steam working media to eject air from the condenser.
(III) LP AND HP HEATERS
In regenerative system there is a steam of 5 LP heaters, one Deaereator, 2 HP heaters. All
LP and HP heaters are of surface type i.e. condensate or feed water is inside the heater
tubes in the heater shells. L.P. heaters are of single flow whereas HP heaters are of double
flow type. Deaereator is contact type heater in which steam and condensate come in
direct contact.
(IV, V) CHIMNEY STEAM AND GLAND STEAM CODENSER: - There are
additional two heating stages provided in the regeneration system of the turbine for
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heating the condense flowing through it steam leaks off from the turbine glands is used
for heating the condensate in these heaters.
(VI, VII, VIII, IX, X) VARIOUS OIL PUMPS
Centrifuge is an oil purifier used to remove moisture and other impurities from the
turbine oil. Maximum allowable moisture content in the turbine oil is 0.2%. In case the
oil level of the main oil tank is to be made up then either oil can transferred from clean
oil tank to main oil tank with centrifuge or from dirty oil tank to main oil tank with
centrifuge.
(XI) STARTING OIL PUMPS AND EMERGENCY OIL PUMPS
Starting oil pumps supply the necessary turbine oil during starting of the turbine and upto
turbine speed of 2930 rpm till the main oil pump mounted on the turbine rotor at the HP
extension takes manually in order to provide lubrication oil for the turbo set. Emergency
oil pumps are meant to start on auto, when turbine trips and lubrication oil pressure falls
in order to provide lubrication to the turbine and generator bearings.
5.4 MAIN TECHNICAL DATA ABOUT TURBINE
a) The Basic Parameters
(a)
Rated output measured at terminal of the generator.
110,000KW
Economical output.
95,000KW
Rated speed
3,000 RPM
Rated temp. Of steam just before the stop valve.
535C
Max temp. Of steam before the stop valve
545C
Rated pressure of steam before the MP casing
31.63 ata
Max. Pressure of steam before the MP casing
35 ata
Rated temp. Of steam before the MP casing
535C
Max. Temp. of steam before the MP casing
545C
System of turbine:
Governing valves
2 interceptor valves
HP cylinder
2 Row Curtis wheel +8 moving wheels.
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Wt. of HP rotor is approx.
5,5000kg.
MP cylinder
12 moving wheels.
Wt. Of MP rotor is approx.
11,000kg
LP cylinder
4 Moving wheels of double flow design.
Wt. of MP rotor is approx.
24,000.
Direction of the turbine rotation is to the right when looking at the turbine from the front
bearing pedestal.
5.5 RELAY SECTION
Protective relay is a device that detects the fault and initiates the operation of the circuit
breaker to isolate the defective section from the rest of the system.
We have seen that whenever fault occurs on the power system, the relay detects the fault
and closes the trip coil circuit. This results in the opening of circuit breaker, which
disconnects the faulty section. Thus a relay ensures the safety of the circuit equipments
from damage which may be causes by the faulty current.
ESSENTIAL ELEMENTS OF A RELAY
All the relays have the following three essential fundamental elements as shown in block
diagram see fig.
(a) Sensing element: - Sensing or measuring element is the element which responds to
the change in magnitude or phase of the actuating quantity e.g. current in the over current
relay.
(b) Comparing element: - It is the element which compares the action of the actuation
quantity of the relay with pre-designed relay setting. The relays only pick up if the
actuating quantity is more than the relay setting.
(c) Control Element: - When a relay picks up it accomplishes a sudden change in the
controlled quantity such as closing of trip coil circuit.
1. TYPES OF RELAYS
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There are many kinds of relays applied in the power system. The relays can be designed
and constructed. To, operate in response to one or more electrical quantities such as
voltage, current, phase angle etc. The relays are classified in different ways.
According to construction and principle of operation
(i)
Thermal relays: - The heating effect of electric current is used for the operation
of these relays.
(ii)
Electromagnetic attraction relays: - The operation of these relays depends upon
the movement of an armature under the influence of attractive forces due to the magnetic
field set up by current flowing through the relay coil.
(iii)
Induction Relays: - Electromagnetic induction phenomenon is used for the
operation of these relays by induction, eddy currents are induced in the aluminum disc,
free to rotate, which exerts torque on it.
2. ACCORDING TO APPLICATION
(i) Over current, over voltage or over power relays:-These relays operate when the
current, voltage or power rises beyond a specific value.
(ii) Directional or reverse current relays: - These relays operate when the applied
current assumes a specified phase displacement with respect to the applied voltage and
the relay is compensated for fall in voltage.
(iii) Under current, under voltage or under power relays: - These relays operated
when the current, voltage or power falls below a specific value.
(IV) Directional or reverse power relays: - These relays operate when the applied
voltage and current assumes a specified phase. Displacement and no compensation is
allowed for fall in voltage.
(V) Distance relays: - The operation of these relays depends upon the ratio of the voltage
to the current.
(Vi) Differential relays: - The operation of these relays takes place at some specific
phase difference or magnitude difference between two or more electrical quantities.
3. ACCORDING TO THE TIME OF OPERATION:-
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(i)
Instantaneous relays:-In these relays, complete operation takes place
instantaneously i.e., the operation is complete in a negligibly small interval of time from
the incidence of the actuating quantity.
(ii)
Definite time lag Relays: - In these relays operation takes place after definite
time lag which is independent of the magnitude of actuating quantity.

(iii)
Inverse time lag Relays:In these relays the time of operation is inversely
proportional to the magnitude of actuating quantity.

Inverse Definite Minimum Time Lag Relays: - In these relays, the time of operation is
approximately inversely proportional to the actuating quantity, but is never less than a
definite minimum time for which relay is set.
THERMAL RELAYS
A relay in which heating effect of electric current is used for its operation is known as
thermal relays. These relays may be actuated by a.c. or d.c.
CONSTRUCTION
The schematic diagram of an indirectly heated general purpose thermal relay is shown in
fig. It has a bimetallic strip which is heated by heating element which gets supply from a
current transformer. An insulated contact arm carrying a moving contact is pivoted and is
held by a spring. The other contact of trip circuit is a fixed contact. The spring tension
can be varied by changing the position of contact arm with the help of sector plate.
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WORKING
Under normal conditions, the current flowing through the heating element is proportional
to the normal full load current of the circuit. The heat produced by the heating element,
under this condition is not sufficient to bend the bimetallic strip. However, when fault
occurs current flowing through the heating element increases which produces heat
sufficient to bend the bimetallic strip. This releases the contact arm and because of the
spring tension the relays contacts are closed which closes the trip coil circuit or the alarm
circuit once the alarm circuit or the trip coil circuit is closed; it operates the alarm circuit
or the circuit breaker to open the circuit respectively.
These over current tripping relays are use mostly for motor controls. The heating
elements of such relays are designed to with stand short time overload up to 7 times the
normal full load.
5.6 WATERTREATMENT PLANT
WATER TREATMENT PLANT

The basic requirement of Water Treatment in the thermal power station is to provide
suitable water for the boiler i.e. the water, which is free from dissolved, suspended, and
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any other type of impurities. If the water is taken as such without any treatment then this
will result in scale and sludge formation, caustic embrittlement and corrosion in the boiler
and the pipes. Water Treatment at GNDTP, Bhatinda may be broadly divided into
A)
External Water Treatment.
B)
Internal Water Treatment.
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CHAPTER
6.1SWITCHYAED
132/220KV SWITCH YARD

The electricity generated at 11 K.V. by the turbo generator sets is step up by power
transformers up to 132 KV in case of stage-1 and 220 KV in case of stage-2. For further
transmission of power from power station to grid is controlled through 7 nos 220 KV
and 15 nos 132 KV air blast circuit breakers along with their associated protective
system.
According to design substation are classified:1.
Indoor substation.
2.
Outdoor substation.
1. INDOOR SUBSTATION
In these substations the equipments are installed within the building of the substation and
hence the name indoor substation. Such substations are usually designed for 11 KV but
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can be erected for 33 KV or 66 KV, if the surrounding atmosphere is containing

impurities, which may damage the equipments.
2. OUTDOOR SUBSTATION
In these substations, the equipments are installed open and hence the name outdoor
substation. Such substation can be designed to handle low, high and extra high voltages.
The outdoor substations may be further classified as:
(I)
(I)
Pole mounted substation
(II)
Foundation mounted substation

POLE MOUNTED SUBSTATION
Such substations are designed for monthly distribution transformers of capacity unto 300
KVA. Such substations are cheapest simple and smallest of other substations. All the
equipments are of outdoor type and mounted on the supporting structure of HT
distribution line. Tripple pole mechanically operated switch is used for switching on and
off of H.T transmission line. To control L.T. side, iron clad low-tension switch of suitable
capacity with fuses is installed. Lighting arrestors are installed over the HT line to protect
the installation from the surges. Substations are earthed at two or more places. Generally
transformers of capacity upto 125 KVA are mounted on double pole structure and for
transformers of capacity above 125 KVA 4 pole structure with suitable platform is used
Page 24
such
substations
are
situated
in
very
thickly
populated
location.
(II) FOUNDATION MOUNTED SUBSTATION

These substations are built entirely in the open and in such substations all the equipments
are assembled into one unit usually enclosed by a fence from the point of view of safety.
Substations for primary and secondary transmission and for secondary distribution are of
this type.
Page 25
The major equipments installed at G.N.D.T.P. substations are

1.
Transformers.
2.
Circuit breakers.
3.
Isolators.
4.
Bus Bars.
5.
Lightning arrestors.
6.
Current Transformer
7.
Potential Transformer.
8.
Insulator.
9.
Wave traps.
Page 26
CHAPTER
TRANSFORMER
7.1 TRANSFORMER: - It is a static device which transfers a.c. electrical power
from one circuit to the other at same frequency. It is used to step up or step down the
Page 27
voltage. In all the substations except the generating station transformers are employed.
These are of following types: (A) POWER TRANSFORMER:-These are provided for stepping up the voltage. For
units 1&2 the power transformers step up the voltage from 11 KV to 132 KV and for
units 3&4 the power transformers step up the voltage from 11 KV to 220 KV. All the four
transformers have a rated capacity of 125 MVA.
Specification of power transformer
Sr. No.
6002737
Electrical specific No.
600250
Manufacturer
Heavy electrical Ltd. (Bhopal)
Year of manufacturing
1972
Insulation level :
H.V.
650 KV peak
H.V. neutral
38 KV rms
L.V.
75 KV peak
Weight of core and winding
94000 kg
Weight of oil
37200 kg.
Page 28
Total weight
188880 kg
Oil quantity
43890 liters
Oil circulation litre/min.
2 * 2724
Air circulation cubic/metre
10 * 385
(B) Inter bus linking (auto) transformer: - The auto transformers are used to balance
the load between 132 kv bus bars and 220 Kv bus bars. These transformers have a
capacity of 100 MVA each.

Specification of Inter bus linking transformer
S.No.
4137621
Electrical specification No.
410216
Manufacturer
Heavy Electrical Ltd. (Bhopal)
May, 1972
Weight of core and winding
75200 kg.
Total weight
151104 kg.
Rated capacity
100 MVA
(C) Unit auxiliary transformer: There is one unit auxiliary transformer provided on
each unit to step down the voltage from 11 Kv to 6.6 Kv, which is required to run the
major plant auxiliaries.
Page 29
Specification
S.No.
902016
Manufacturer
Heavy Electrical Ltd. (Baroda)
1972
Rated Capacity
15 MVA
Weight of core of winding
11685 Kg.
Total weight
22188 kg.
Oil in main tank
12200 litre.
Oil in cooler including pipes
2300 litre.
Total oil quantity
15620 litre.
Oil in OLTC
1120 litre.
(D) Station Transformer: There are two station transformers one for each unit is
provided to step down the voltage from 132 Kv to 6.6 Kv. These transformers have
capacity of 22.5 MVA. They serve as a stand by source of supply to auxiliaries.
Page 30
Specification
S. No.
23600
Total weight
70 tones
Manufacturer
Made in Bombay Martin Burn Ltd.
1972
Oil in main tank
14940 lt.
Oil in cooler including pipe work
4500 lt.
Oil in OLTC
1760 lt.
Total oil
21200 lt.
7.2 CIRCUIT BREAKER

Circuit breaker is a device, which may be operated under different conditions i.e. no load,
full load fault conditions. However the major duty of a circuit breaker is to operate the
circuit breaker under fault conditions under short circuit conditions, a circuit breaker
required to perform three major duties:(i)
It must be capable of opening the circuit under abnormal conditions.
Page 31
(ii)
It must be capable of classing the circuit on to a fault.
(iii)
It must be capable of carrying a fault current safely for a short time while another
circuit breaker is clearing the fault
.
OPERATING PRINCIPLE OF A CIRCUIT BREAKER

A circuit breaker is a device which.
(i)
Makes or breaks a circuit either manually or by remote control under normal

conditions.
(ii)
Breaks a circuit automatically under abnormal conditions.
(iii)
Makes a circuit manually or by remote control under abnormal conditions.
Thus, circuit breaker is just a switch which can be opened under normal abnormal
conditions both manually and automatically.
To perform the above operations, a circuit breaker essentially consists of fixed and
moving contacts, called electrodes, under normal operating conditions; these contacts
remain closed until and unless these are not operated manually or by remote control.
However when a fault occurs on the power system, the trip coil of the circuit breaker is
energized, which pulls apart the moving contracts from the fixed contacts thus opens the
circuit.
When the moving contacts are separated from the fixed contacts, an arc is struck
between them. The production of are not only delays the current interruption proxies but
is also generates enormous heat which causes damage to the equipment of the power
system or to the breaker itself. Therefore every effort is made to extinguish the arc
produced in the circuit breaker as quickly as possible.
CIRCUIT BREAKER RATINGS
According to the duties to be performed by a circuit breaker they have the following three
ratings:(i)
Breaking capacity
(ii)
Making capacity.
(iii)
Short time capacity.
Page 32
(i)Breaking capacity: - when fault occurs the contacts are separated in the circuit
breaker. The r.m.s. value of current that a circuit breaker is capable of breaking at a given
recovery voltage and under specified conditions is known as breaking capacity of the
circuit breaker.If the current is symmetrical, breaking capacity is referred to is
symmetrical breaking capacity. Whereas if the current is asymmetrical it is referred as
asymmetrical breaking capacity. Symmetrical breaking current is the r.m.s. value of the
a.c. component of the short circuit current at the instant when contacts are separated.
Whereas the asymmetrical breaking current is the r.m.s. value of the total current which
compresses of a.c. and d.c. component of current at the instant when contacts are
separated.The breaking capacity rating of a circuit breaker is generally expresses in terms
of MVA.In case of 3-phase circuit breakers breaking capacity in MVA = 3* rated
voltage * rated breaking current * 10-6.
(ii)Making capacity: - There is every possibility of closing the circuit breaker under
deed short circuit conditions. The capacity of a circuit breaker to close the circuit under
short circuit conditions depends upon its ability to with stand the effects of
electromagnetic forces. These forces are proportional to the square of the peak value of
the current on closing.
The peak value of the current during the first cycle of current wave after the circuit the
first cycle of current wave after the circuit is closed by the circuit breaker is called
making capacity. The making capacity is stated in terms of a peak value of current instead
of and r.m.s. value.
To find out the making capacity the symmetrical breaking current is multiplied by 2 to
convert the r.m.s value to peak value and then it is multiplied by 1.8 to include the
doubling effect of maximum asymmetry. Making capacity = 2 * 1.8 * symmetrical
breaking capacity = 2.55* symmetrical breaking capacity.
(iii)Short time capacity :- Sometimes fault occurs in the power system in such a way
that one circuit breaker is clearing the fault at that time the other circuit breaker
connected in series must carry the fault current safely for a short period. Moreover
sometimes the fault on the power system is of very temporary nature and presets for a
small period after which the fault is automatically cleared. In the interest of continuity of
Page 33
supply the circuit breaker should not be allowed to trip in such situations and should be
capable of carrying the fault current safely for a short period.
The period for which the circuit breaker is able to carry the fault current while remaining
closed is called short time capacity of the circuit breaker.
At G.N.D.T.P switch yard air blast circuit breakers and SF6 circuit breakers are
employed instead of oil Circuit breakers due to following reasons:(i)
There is no risk of fire hazard and explosion.
(ii)
Due to less arc duration in it as compared to that in oil circuit breakers, burning of
contact is less.
(iii)
It requires less maintenance
(iv)
They provide facility of high speed reclosure.
AXIAL-BLAST AIR CIRCUIT BREAKERS

A schematic arrangement of an axial-blast air circuit breaker is as shown in figure. The
arcing potions of the fixed and moving contacts are coated with silver tungsten alloy. The
moving contacts are coated to a piston and shaft of the contact is guided by guide spring.
Opening the lower air valve closes the circuit breaker and under normal conditions the
valve remains open. Whenever a fault occurs, the upper valve is opened and the lower
valve is closed by the mechanism not shown in figure. Air enters the upper vessel at a
high pressure, which separates the moving contacts from the fixed. An arc is struck
between the contacts, which is extinguished by the axial blast of cold air and current is
interrupted. Once the arc is extinguished, the upper valve is closed and the lower valve is
opened to close the circuit.
Page 34
SF6 CIRCUIT BREAKERS

Sulpher hexafluoride CB is shown in fig. In this the movable cylinder is coupled with the
moving contacts, whereas the piston is fixed. When fault occurs, the moving contacts are
separated from the fixed contact. Since the movable cylinder is attached with the moving
contacts, it moves against the fixed piston. Thus the gas filled in the cylinder is
compressed and released through the nozzle as shown in fig. The gas moves along the arc
and reduces its diameter by axial convection and radial dissipation. At zero current, the
diameter becomes too small and the arc gets extinguished. The gas is not exhausted to the
atmosphere; it is rather again used for arc extinction.
Advantages:
They are smaller in size because of high dielectric strength of SF6 gas.
No danger of or explosion.
They require minimum maintenance.
Since same gas is recycled, a small quantity of SF6 gas is required for long run.
They give silent operation; they do not make any sound like A.C.B. during
operation.
It requires less maintenance.
Specification
S.No.
729/13
Rated voltage
132 Kv
Rated frequency
50 Hz
Rated gas pressure
18 kg/cm2
Replaced with SF6*
7 kg/cm2
Rated current
1600 Amp.
Rated making capacity
17850 MVA
Rated breaking capacity
7000 MVA
(3) Isolator: - These are knife switches which are operated only at no-load. Their
main function is to isolate a portion of the circuit from the other. These are generally
placed on both sides of a circuit breaker in order to do repair and maintenance on the
Page 35
circuit breaker without any danger. For maintenance first of all circuit breakers are
opened then isolators are opened and properly earthed. Only then maintenance is
done. Isolators do not have the arc control devices and therefore cannot be used to
interrupt current at which an arc will be drawn across the contacts. The open arc that
would be drawn in such a case is very dangerous in that it will not only damage the
isolator and the equipment surrounding it, but will also as a rule will cause flash over
between phases. In other words results in short circuit in the installation. That is why
isolators are used only for disconnecting and connecting parts or units after first de-
energizing them by opening their circuits with respective circuit breakers.

Specifications
S.No.
09
Manufacturer
Hi-Velm industries Pvt. Ltd., Madras
Unit type
THP
Isolator
541/3
Auxiliary switch no. of pairs
12
Pressure
16 kg/cm2
Isolator kV
132 kV
Control voltage
220 V
Isolator current
800 Amp.
Page 36
(4)Bus Bars: - The thick conductors run on the towers at the generating stations, grid
stations or sub-stations operating at constant voltage required to connect a number of
generators or feeders operating at the same voltage are called bus-bars.
The bus bars are arranged in different manner. The main aim of any particular
arrangement of bus bars is to achieve adequate operating flexibility, sufficient reliability
and minimum cost. At G.N.D.T.P. there are two nos 132 kV Bus bars are made up of
aluminum. The bus coupler number two connects the 132 kV bus bars and 220 kV bus
bars with each other.
(5)Lightning Arrestor: - A lightning arrestor or surge diverter is a device which provides
an easy conducting path or relatively low impedance path for the flow of current when
the system voltage increases more than the designed value and regains its original
properties of an insulator at normal voltage.These are the arc apparatus devices designed
to protect insulators of power lines and electrical installation from lighting surges by
diverting the surge to earth and instantly restoring the circuit insulation to its normal
strength with respect to earth. These are connected between earth and line. Their purpose
is to protect the t/f winding against over voltages.
Necessity of lightning arrestors
Page 37
The ground wires and earth screens do not provide protection against the high voltage
waves reaching at the terminals of costly equipment such as transformers. These high
voltage waves may cause the following damages.
(i)
The waves may cause flash over in the internal windings of transformer and
spoils the winding insulation.
(ii)
It may cause internal flash over between turns of the same winding of transformer.
(iii)
It may cause external flash over between the terminals of electrical equipment,
which may cause damage to insulator.
(iv)
It may cause internal or external flash over causing building up of the oscillations
in the electrical apparatus. Hence it is absolutely necessary to divert this high
voltage wave to earth before it reaches at the terminals of the equipments. This is
achieved by connecting a lighting arrestor between line and earth.
(6)Current Transformers: - The current transformers are basically step up transformers.

The connections of an ammeter when used in conjunction with a current transformer for
measurement of current are shown in fig.
The primary winding having one or a few turns of thick wire is connected in series with
the line, whose current is to be measured. The secondary winding having large number of
turns of fine wire carries the instrument directly connected across it. The working of
current transformer is slightly different to that of on ordinary power transformer. In case
Of current transformer, the load impedance or burden on the secondary is very small,
therefore it is considered to be short circuited. Hence current transformer works under
Page 38
short circuit conditions. Moreover the current in secondary winding is not governed by its
load impedance rather it depends upon the current flowing through the primary.
(7)Potential Transformer:-The potential transformers are basically step down
transformers. The connection of a voltmeter is used in conjunction with a potential
transformer for measurement of high ac voltages. The voltage to be measured is applied
across primary winding, which has a large no. of turns. The secondary side, which has
much smaller number of turns, is coupled magnetically to the primary winding. The turn
ratio is so adjusted that the secondary voltage is 110V, when full rated primary voltage is
applied to primary. Potential transformers are used to operate voltmeter, the potential
coils of wattmeter and relays from high voltage lines. The design of potential
transformers in quite similar to that of a power transformer, but the loading of a potential
transformer is very small in comparison to that of a power transformer. The loading of
potential transformer sometimes is only a few volt amperes. These transformers are made
shell type because this condition develops a higher degree of accuracy. For medium
voltage i.e. unto 6.6 KV to 11 kV they may be either dry or oil immersed but for voltage
more than 11 kV they are always oil immersed type. An out door type oil immersed
voltage transformer having rating 66000/3 or 110/ 3. The working of potential
transformer is essentially the same as that of a power transformer, the main point of
difference is that the power loading of a potential transformer is very small and
consequently the exciting current is almost of the same order as that of secondary current.
Whereas in power transformers exciting current is very small fraction of secondary load
current.
(8)Insulators: - They are used to prevent the flow of current from bare conductors to
earth through line support; the conductors are secured to insulators. They provide
insulation between the conductors and earthed steel towers. The insulators are usually
placed on the cross arms which is clamped on line support. Thus the successful operation
of transmission system depends to a great extent on the quality and maintenance of line
insulators. Generally suspension and strain type insulators are employed at the
substations.
Page 39
(9)Wave traps: - These are used in carrier communication circuits and are mounted on
lines. Wave trap or line trap contains a main coil, lightning arrestor and a tuning device.
All are connected in parallel as shown in fig..
The main coil has an inductance of 0.2 MH to 2.0 MH. This inductance offers high
impedance to the frequency (50 kHz to 500 kHz) carrier signals and blocks them here. It
does not allow them to enter the power system equipment. However it offers very low
impedance to the power frequency signal (i.e. power system voltage and current). Hence
it acts as an insulator for high frequency carrier signals and a conductor for the low.
Page 40
Since the main coil is connected in series with the line, it has to carry the line current
even under fault conditions. There fore it is designed from the current rating point of
view. The current rating of the main coil may vary from 400 A to 4000 A.
The lighting arrestor is used to protect the main coil from high voltage surge whereas the
tuning device is used to block the signals of narrow band carrier frequency.
All these components of the wave trap are hanged in air through a string of insulators as
shown in fig.
Sometimes these components of wave trap are immersed in oil and are enclosed in a
drum type porcelain container having sufficient mechanical strength.
CONCLUSION
Spending my six /four weeks of training in Guru Nanak Dev Thermal Plant, Bathinda, I
concluded that this is a very excellent industry of its own type. They have achieved
milestones in the field of power generation. They guide well to every person in the
industry i.e. trainees or any worker. I had an opportunity to work in various sections
Page 41
namely switch gear, Boiler section, Turbine section, De-mineralized water plant, E.S.P,
EM-2 CELL etc. while attending various equipments and machines. I had got an
endeverous knowledge about the handling of coal, various processes involved like
unloading, belting, crushing and firing of coal. The other machines related to my field
that I got familiar with boiler, turbine, compressors, condenser etc. I found that there
existed a big gap between the working in an institute workshop and that in the industry.
Above all the knowledge about the production of electricity from steam helped me a lot
to discover and sort out my problems in my mind related to the steam turbine, their
manufacture, their capacity, their angle of blades and their manufacturing. The training
that I had undergone in this industry will definitely help me to apply theoretical
knowledge to the practical situation with confidence.
Page 42

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CHAPTER 1

Ash handling system

MANPREET KAUR [21302101]

MANPREET KAUR [21302101]

MANPREET KAUR [21302101]

MANPREET KAUR [21302101]

Single pole Isolator

Double pole Isolator

MANPREET KAUR [21302101]

MANPREET KAUR [21302101]

MANPREET KAUR [21302101]

MANPREET KAUR [21302101]

Maximum continuous rating

Super heater outlet pressure

Reheated outlet pressure

Final super heater temperature

Feed water temperature

Coal consumption per day

MANPREET KAUR [21302101]

With by pas/without bypass

with by pass (stage-1)

5.2 BASIC WORKING OF TURBINE

MANPREET KAUR [21302101]

MANPREET KAUR [21302101]

MANPREET KAUR [21302101]

3. REGULATION AND SAFETY EQUIPMENT FOR TURBINE GOVERNING

(a) MAIN STEAM

MANPREET KAUR [21302101]

MANPREET KAUR [21302101]

Turbine Accessories and Auxiliaries

Steam jet air ejector

MANPREET KAUR [21302101]

Chimney steam condenser.

Clean oil pump with clean oil tank

Dirty oil pump with clean oil tank.

Auxiliary oil pump with auxiliary oil tank

Starting oil pump.

(I) SURFACE CONDENSER

Number of brass tubes

Circulating water required

Vacuum in the condenser

0.90 kg/cm sq.

(II) STEAM JET AIR EJECTOR

MANPREET KAUR [21302101]

Rated output measured at terminal of the generator.

Rated temp. Of steam just before the stop valve.

Max temp. Of steam before the stop valve

Rated pressure of steam before the MP casing

Max. Pressure of steam before the MP casing

Rated temp. Of steam before the MP casing

Max. Temp. of steam before the MP casing

2 Row Curtis wheel +8 moving wheels.

MANPREET KAUR [21302101]

Wt. of HP rotor is approx.

Wt. Of MP rotor is approx.

4 Moving wheels of double flow design.

Wt. of MP rotor is approx.

MANPREET KAUR [21302101]

Electromagnetic attraction relays: - The operation of these relays depends upon

Induction Relays: - Electromagnetic induction phenomenon is used for the

MANPREET KAUR [21302101]

Instantaneous relays:-In these relays, complete operation takes place

time lag which is independent of the magnitude of actuating quantity.