REPORT ON STUDY OF POWER

GENERATING SYSTEM AND

DISTRIBUTION IN CAPTIVE
POWER PLANT
PROJECT SUBMITTED TO
TRAINING AND DEVELOPMENT CENTR
RASHTRIYA ISPAT

NIGAM LIMITED

VISAKHAPATNAM STEEL PLANT

PROJECT SUBMITTED BY
PAKKI YAMINI SRI
CHAKRADHARI.TAMMINANA

K.HEMA VARA LATHA

SATYA PRASAD NAYAK
D.LAKSHMI SAI
PRASANNA

UNDER THE ESTEEMED

GUIDANCE OF
MR.SARAT KUMAR TRIPATHY
ASSISTANT GENERAL MANAGER (ELECTRICAL)

Electrical Department
Thermal power plant
Visakhapatnam Steel
Plant

Department of electrical and electronics engineering

Vignans Institute of Information

Technology
Beside VSEZ,Duvvada,Visakhapatnam - 530046

Certificate
This is to certify that the Industry-Oriented Mini Project entitled on the REPORT
ON STUDY OF POWER GENERATING SYSTEM AND DISTRIBUTION IN
CAPTIVE POWER PLANT has been jointly carried out by

NAME OF THE STUDENT

PAKKI YAMINI SRI

REGD.NO
08L31A0258

CHAKRADHARI.TAMMINANA

09L35A0208

K.HEMA VARA LATHA

09L35A0202

SATYA PRASAD NAYAK

D.LAKSHMI SAI PRASANNA

08L31A0279
08L31A0295

Under my guidance in partial fulfillment of the requirements for the Award of the
Degree of Bachelor of Technology in Electrical and Electronics Engineering of
Jawaharlal Nehru Technological University, Kakinada during the academic year 20112012.

Mr.SARAT KUMAR
TRIPATHY
Assisant
General manager(TPP,VSP)
External Guide

ACKNOWLEDGEMENT
The mini project on Study of power generating system and
distribution in capititive power plant carried out in Visakhapatnam
steel plant for duration of 2 weeks dated from 23.05.11 to 04.06.11.
We would like to thank our guide Mr.Tripathy garu, Assistant General
Manager[Electrical] who extended his full support in the completion of
this report successfully.
We would like to thank the management of Visakhapatnam
Steel Plant who has extended their support in completing our mini
project. We would like to extend our thanks to the heads of all
departments who have given their support. Our special thanks to
Mr.Prabhakar garu[T&DC] who made this all happen.

PREFACE
The Visakhapatnam Steel Plant was designed way back in
late 1960s but by the ime its
chief Consultants MN Dastur & companys - report and revised
reports were accepted in
1984 to start construction, it had become the most expensive steel
plant ever to be
constructed, designed to produce about 3.4 million tones (Mt) of
processed steel per year.

The plant is s[pread across a sprawling 19,000 acres (77

km)of which only 5,000
acres (20 km) are used so far. The rest is still pristine shrub forest
land. The company also has
a blast furnace grade lime stone captive mine at jaggayyapeta, a
captive mine for dolomite at
madharam, a manganese ore captive mine at Cheepurupalli. It has also
got a mining lease for
river sand in River Champavati.
Two blast furnaces Godavari and Krishna with an
effective volume of 3200m3 one
of the largest in the country are built with Russian collaboration. These
blast furnaces produces
about 6000 tonnes of molten iron per day. Its novel circular cast house
with four tap holes
ensures continuous tabooing of hot metal. The annual production
capacity of these blast
furnaces is 3.4 million tones of liquid iron.
Three top-blown LD converters,each of 133m3 volume in
steel melt shop, produce a
total of 3.6 million tones of liquid steel per annum. This liquid steel
thus produced is cast in six,
4 strand bloom casters. A special feature in energy conservation is the
collection of converter
gas to be used as a fuel in the plant. The entire molten steel at VSP is
continuously cast at the
radial type continuous casting machines resulting in significant energy
conservation and better
quality steel.

CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.

Abstract 01
Thermal Power Plant Introduction02
Power Requirement...04
Sources of Power..06
APSEB supply network.07
Boilers13
Turbo-Generators...15
Auxiliaries of TPP..24
Power Generation and Distribution
25
10. Islanding of Power Plant29
11. Conclusion..3
1

ABSTRACT
The project titled Study of power Generating system and Distribution
in Capititive Power Plant at Vishakapatnam Steel Plant is carried out at Thermal
Power
Plant. It covers the complete generating system of the Plant and power distribution in
Vishakapatnam Steel Plant. The main objective of the project is to study the various
equipments
provided for generation and distribution of power and the process underneath it.
A generating station which converts heat energy obtained by the combustion
of coal
into electrical energy is known as Thermal Power Station. A Thermal power plant
basically
works on the principle as seen in Rankine cycle. Steam is produced in the boiler by
utilizing the

heat obtained by combustion of coal. This steam is used to run the prime movers where it
gets
expanded. This expanded steam is then condensed in a condenser to be fed into the boiler
again. The prime mover,here the steam turbine drives the alternator which converts the
mechanical energy of the turbine into electrical energy. Such types of power stations are
generally commissioned where its main source coal and in abundance water are
available.

THERMAL POWER PLANT-AN

INTRODUCTION
The fact that thermal energy is the major source of power generation itself
shows
Thermal power plants importance in India. More than 60% of electrical power is
produced by
Thermal powered steam plants in India. The steep rise in the demand for power demands
a
larger unit setup which requires the use of more fuel. These plants are trying to keep the
overall cost of power generation low using modern techniques and devices.
In steam power plants the heat obtained by the combustion of fossil fuels
(coal, oil or
gas) is utilized by the boilers to raise the steam to a high pressure and temperature. The
steam
so produced is used in driving the steam turbines and sometimes steam engines coupled
to

generators and thus in the generation of electrical energy. The steam turbines or steam
engines
thus used not only act as prime movers but also as drives for auxiliary equipments such as
pumps, fans etc.
The steam power plants may be installed either only to generate electrical
energy or
electrical energy generation along with steam generation for industrial purposes such as
paper
mills, sugar mills, chemical works, plastic manufacture, food manufacture etc.
Generally Thermal power plants are categorized as

Utility Power Plant- Power is produced solely for the purpose of generation and
supplied to the various kinds of customers through grid.

Captive Power Plant- Power is produced for supplying quality power for the
effective
functioning of the actual plant. Import and export of power takes place in
accordance
with the load.

The Thermal power plant seen in Vishakapatnam Steel Plant is a captive power plant. The
power requirement of VSP is met through captive generation as well as supply from
APSEB
grid.
Captive capacity of TPP in VSP : 286.5 MW

3 units of 60 MW generation capacity.

1 unit of 67.5 MW generation capacity.
2 units of 7.5 MW capacity at Back Pressure Turbine Station (BPTS).
2 units of 12 MW capacity at Gas Expansion Turbine Station (GETS).

The speciality of this power plant is that the energy from the waste heat is not wasted.
The

Heat of hot coke from cokeovens are used in BPTS and the gases from blast furnace are
used in
GETS to generate power.

POWER REQUIREMENT
Integrated Steel Plants are major consumers of electricity, with specific
consumption
of power at around 600-650 kWh/Ton of liquid steel. The estimated annual power
requirement
of Visakhapatnam Steel Plant, at full level of production in each shop, is 1932 million
kWh.
This corresponds to an average demand of 221 MW. The demand is found to be 227 MW
on an
average and 260 MW peak value.
The estimated energy consumption and average demand of major shops is given below:

SHOP

RMHP
CO & CCP
SINTER PLANT

Annual Energy
(106 kW Hrs.)
35
171
254

AverageDemand (MW)

4.0
19.5
29.0

BLAST FURNACE
SMS & CCM
LMMM
WRM
MMSM
CRMP
TPP
ASP
COM. STATION & CWP
AUXILIARY SHOPS
WATER SUPPLY
TRAFFIC & OTHERS
TOWNSHIP
LOSSES

210
126
100
118
100
35
310
258
131
20
15
7
28
14

24.0
14.5
11.5
13.5
11.5
4.0
35.0
29.5
15.0
2.5
2.0
1.0
3.0
1.5

TOTAL

1932

221.0

SOURCES OF POWER
Power requirement of VSP is met through captive generation as well as
supply from
APSEB grid. The captive capacity of 270 MW is sufficient to meet all the plant needs in
normal
operation time. In case of partial outage of captive generation capacity due to
breakdown,
shutdown or other reasons, the short fall of power is availed from APSEB grid. Turbo
Generators of VSP normally operate in parallel with state grid. Excess generation over
and

above plant load is exported to APSEB.

The agreement with APSEB provides for a contract demand of 150 MVA and permit
export of
power. Tariff for import, export, demand charges, penalties etc. are stipulated. For
purpose of
billing, import and export energy is separately metered at Main Receiving Station.

APSEB SUPPLY NETWORK

The Power Grid Corporations Sub-station adjacent to Ukkunagaram is connected to
Vijayawada by a 400 kV line. It is also being connected to Jaipur, Orissa (Eastern Grid)
through
DC back to back arrangement of 500 MW capacity and by 400 kV AC double circuit
line.
Power is stepped down through a 315 MVA, 400/220 kV auto transformer at Power Grid
Corporation Sub-station and is fed to the adjacent APSEB switching station. This
switching
station is also connected to Bommuru and Gajuwaka sub-stations by 220 kV double
circuit lines.
Bommuru sub-station is connected to generating stations at Vijayawada, Lower Sileru,
Vijjeswaram, Kakinada and Jegurupadu. Gajuwaka sub-station is connected to Upper
Sileru.
Two 1000 MW Thermal Power Stations are expected to come up in the next few years at

Visakhapatnam and close to steel plant.

Power is supplied to VSP from APSEB switching station over two 220 kV lines on
double
circuit towers. Power is received at the Main Receiving Station (MRS) located near
Main gate
and further distributed to various units within the plant.

EXTRA HIGH VOLTAGE DISTRIBUTION

(220 kV)
Power from APSEB is received at Main Receiving Station (MRS). The entire
plant is
configured as five electrical Load Blocks and Step down sub-stations are provided in
each block
(designated as LBSS 1 to 5) with 220 kV transformers to step down power to 33/11/6.6
kV and
for further distribution as indicated below:

STATION
DESIGNATION
LBSS1 (220/11/6.6 kV)
LBSS2 (220/11/6.6 kV)

AREAS COVERED

(220/33 kV)
LBSS3 (220/11/11 kV)
LBSS4 (220/11/11 kV)

Ladle furnace in SMS

MMSM
LMMM, WRM, Aux. Shops, Adm. Building and
Kanithi reservoir pump house.
TPP, Plant essential category loads, KBR &
Township pump houses & hospital.
Plant, Township and construction network.

LBSS5
(220/11&220/11/11 kV)
MRS (220/33 kV)

RMHP, CO & CCP, Sinter Plant, BF

BF, SMS, ASP, CRMP, Comp. House-1

HIGH VOLTAGE DISTRIBUTION

(33/11/6.6 kV)
Two 220/33 kV Transformers installed at MRS feed power to Township step
down
Station through 33 kV cables. Here the voltage is further stepped down to 11 kV by two
nos. of
33/11 kV transformers. Out going feeders from this station supply power at 11 kV
through
cables to township net work. 11 kV overhead construction power lines are connected to
this
sub-station.
Electric power at 11/6.6 kV stepped down at above LBSS stations is distributed
to
smaller Load Block Distribution Station (LBDS) located in each unit. Power supply to
essential
category loads of various zones is extended form TPP directly from Generator Switch
Board
(GSB) at 11 kV. Cross-linked Poly Ethylene (ELPE) cables are used for 11 kV
distribution.
6.6 kV supply is mostly used for motors (of rating >200 and <200 kW generally).
Crosslinked poly ethylene cables are used for 6.6 kV distribution. Appropriate protective relays
provided to quickly isolate faulty feeders/apparatus with suitable discrimination. All
varieties of
breakers such as Bulk Oil/MOCB/VCB/SF6/Air Blast are used.

MEDIUM VOLTAGE DISTRIBUTION

(BELOW 650 V)
In each shop, to cater to Medium and Low voltage load, 11 kV/415 V LCSS
are

formed. Power is fed from LCSS to motors, MCC, Power Distribution Boards (PDB),
Lighting
Distribution Boards (LDB), ESP transformers etc. and for further distribution. The 3
phase 415
V distribution is solidly earthed neutral system. PVC cables are used for medium voltage
distribution generally.

LOW VOLTAGE DISTRIBUTION (250 V &

BELOW)
Low voltage distribution consists of power supply on single phase to lighting
equipment,
ceiling fans, portable hand tools and domestic appliances etc. For safety reasons, 24 V
distribution is also provided to cater to hand lamps etc. in some areas. PVC cables are
used.

SCADA
The 220 kV, 11 kV and 6.6 kV distribution system is monitored by a
centralized
Supervisory Control And Data Acquisition system. The plant generation, import/export
and
consumption in each unit are monitored through SCADA.

MAIN EQUIPMENTS IN TPP

The following are the equipments involved in TPP

Boilers
Turbo-generators
Transformers
Turbo-blowers
Chemical water treatment plant

Coke Dry Cooling Plant (CDCP) boilers

Back Pressure Turbine Station(BPTS) and Cooling Water Plant (CWP) -1 and 2
Gas Expansion Turbine Station (GETS)

PROCESS FLOW CHART OF TPP &

BH
BOILERS
No. of boilers

: 5 (4 working+1 standby)

Steam capacity

: 330Tons/Hr

Pressure

: 101 ata
: 540oC

Temperature
Fuel

: Pulverized coal, BF Gas, CO Gas,

Furnace oil/LSHS
Type
circulation,

: single drum, natural

suspended type, radiant,
multiple fuel, corner fired.

Coal for the plant is obtained from Talcher, Orissa. Lignite coal is obtained.
Lignite is
porous, has 30-50% moisture, light weight. It is stored in coal bunkers (Immediate stock
bins)
and then ground in coal mills i.e. pulverized to increase the surface area of combustion.
Then

Primary Air fan sweeps the pulverized coal for combustion to occur. The heat resulting
due to
this combustion is used to raise the steam in boiler to the required temperature and
pressure.

FUEL COMPARISON
Fuel

Calorific Value

Coal
3200 4500 KCal / KG
Coke-Oven gas
4425 KCal / NM3
Blast Furnace Gas
800 KCal / NM3
Fuel Oil 10000 KCal / KG

The water input given to the boiler is demineralized before sending into the
boiler, to
prevent the corrosion and damage of boiler tubes and turbine blades. There are superheaters
which are used to increase the steam temperature to 540oC. The heat from flue gas is used
for
the same.

TURBO-GENERATORS
GENERATOR (60 MW)- TG#1,2,3
No. of units
Make

:3

: BHEL

Type & description

: TARI 930-36P

Rated power Active

: 60000 kW

Rated power Apparent

Power factor

: 75000 kVA

: 0.8

Rated stator voltage

: 11000 5% Volts

Rated stator current

Rated rotor voltage

: 300 Volts DC

Rated rotor current

: 596 Amp

Rotational speed

: 3000 RPM

Frequency cycles

: 50 HZ

Critical speed

3936 Amp

: 1765 n1, >4500 n2

Class of insulation of winding : F

Air gap between stator and rotor : 55 mm
Type of cooling

: Air cooling indirectly

Maximum temp. rise of stator winding : 120O C

Maximum temp. rise of rotor winding : 130O C
Winding type
Turbine type

: double layer-with 36 slots

: impulse-reaction (1:40)

GENERATOR(67.5 MW)- TG#4

No. of units
Make

:1

: BHEL

Type & description

: TARI 930-36P

Rated power Active

: 67500 kW

Rated power Apparent : 84375 kVA

Power factor

: 0.8

Rated stator voltage

: 11000 5% Volts

Rated stator current

: 4429 Amp

Rated rotor voltage

: 300 Volts DC

Rated rotor current

: 625 Amp

Rotational speed

: 3000 RPM

Frequency cycles

: 50 HZ

Critical speed

: 1765 n1, >4500 n2

Class of insulation of winding : F

Air gap between stator and rotor : 55 mm
Type of cooling

: Air cooling indirectly

Maximum temp. rise of stator winding : 120O C

Maximum temp. rise of rotor winding : 130O C

SYNCHRONISATION
A generator requires to be synchronised if it is to be run in parallel with
others.
Before it is connected electrically to energised busbar, the following conditions must be
satisfied.
a. Equality of voltage
b. Equality of frequency
c. Synchronisation of phases
With these requirements fulfilled, there will be no voltage difference between any
corresponding pairs of terminals of machines and busbars, so that points can be
electrically

connected without disturbance.

ASYNCHRONOUS OPERATION
Asynchronous operation of the generation on field failure is allowed depending
upon
the permissible degree of the voltage dip and acceptability of the system from the
stability
point of view. During field failure there are important points to be noted.

Field failure with under-voltage

Field failure without under-voltage

Field failure with under voltage will be sensed and the machine will get tripped
without
any delay.
During field failure without under voltage, active load on the generator shall be
decreased to 40% of rated load immediately. The generator can operate at 40% of the
rated
load asynchronously for a total period of 15 minutes from the instant of failure of

excitation.
Within this period, steps should be taken to establish the reasons of field failure to restore
normalcy. If it cannot be restored then the set has to be switched off. Then the set should
switched over to the reserve excitation.

TURBO BLOWERS
BLOWERS

3 (2 Working + 1 Standby)

CAPACITY

6067 m3 /min

SPECIAL FEATURES

Constant Speed with EHTC (Electro Hydraulic Turbine Governing system)

Inlet Guide Vane Control
Axial type largest blowers in India.

VSP has 2 blast furnaces. To meet the blast air requirement, 3 turbo blowers, each of
6067 nm3/min capacity, are installed at TPP. These blowers are of axial type and are the
largest blowers installed in India.
These blowers are provided with suction filters, pre-coolers and inter-coolers.

AUXILIARIES OF TPP
These include coal conveyors, cooling towers and pump house#4 for cooling
water
system, pump house for ash water, ash slurry, fire water and fuel oil and emergency diesel
generators, electric switch gear for power distribution, ventilation and air conditioning
equipment etc. The entire power generated at Back Pressure Turbine Station (BPTS) and
Gas
Expansion Turbine Station (GETS) is transmitted over 11 kV cables to power plant,
stepped up
through a 220 kV transformer at LBSS5 and transferred to plant grid.

TRANSFORMERS
TRANSFORMERS CONNECTED TO 60 MW GENERATORS

Type Of Cooling

Vector group

: YNd11

Class of insulation
Power rating

ONAN

:F

: 63 MVA

Primary voltage
Secondary voltage

: 11 kV
: 220 KV

TRANSFORMERS CONNECTED TO 67.5 MW GENERATORS

Type Of Cooling

: ONAN

Vector Group

Class of insulation
Power rating

YNd11

:F

: 90 MVA

Primary voltage
Secondary voltage

: 11 kV
: 220KV

There are 2 main types of transformers present in a Thermal Power Plant viz.

Generator transformer
Auxiliary transformer

A Generator Transformer is one which steps up the voltage to the grid for the
purpose of
distribution. There are 5 generator transformers of 50,63,90MVA,220/11KV rating.
An Auxiliary transformer is one which steps down the voltage for the plant
purposes. The
auxiliary transformers include 32 LT transformers of 1.6MVA,11KV/415V rating and 6
LT
transformers of 20MVA,11/6.6KV rating.

CHEMICAL WATER TREATMENT PLANT

The Chemical Water Treatment Plant located in TPP produces high quality
purified
Demineralised Water and soft water. There are 6 streams of de-mineralising units each
capable
of producing 125 m3/hr. 2 softening units of 125 m3/hr each is present. Demineralisation
is

done by the Cation and Anion Exchange process. This DM water is supplied to TPP, Steel
Melt
Shop (SMS), CDCP Boilers at Coke Ovens and Rolling mills. Soft water is supplied to
Chilled
Water Plant-I, II and SMS mould cooling.

BACK PRESSURE TURBINE STATION (BPTS)

BPTS GENERATOR (7.5MW)
No. of units
Make

:2

: BHEL

Type & description

: TGN 218226/2

Rated power Active

: 7500 kW

Rated power Apparent

Power factor

: 9375 kVA

: 0.8 lag

Rated stator voltage

: 11000 5% Volts

Rated stator current

: 492 Amp

Rated rotor voltage

: 140 Volts DC

Rated rotor current

: 596 Amp

Rotational speed

: 3000 RPM

Frequency cycles

: 50 HZ

Critical speed

: 1900 n1

Class of insulation of winding : B(Stator &Rotor)

Type of cooling

: Closed Circuit Air cooling

Short Circuit Ratio

: 0.610

Generator field Resistance : 0.334 at 20C

Moment of Inertia of Rotor : GD = 101tm

Max. Short Circuit Torque(for Coupling) : 15368 kg-m
No. of Generator Terminals

:6

Generator Phase Connection

Generator Brushes
Size

: Star

: 4 for Ring (2 Rings)

: 32 x 32 mm

Grade

: HM6R

Minimum Permissible dia of Slip Ring : 370mm

Max. out put with one cooler out of service : 6562 kVA
Volume of cooling Air : 28800m/hr
Designed for

: Tropical Climate

GETS GENERATOR (12MW)

TG-1
Make : RUSSIA

TG-2

RUSSIA

Type & description : T-122-3

T-12-2T3

Rated power Active : 12000 KW 12000KW

Rated power

: 15000 KVA 15000KVA

Power factor : 0.8 lag

0.8 lag

Rated stator voltage : 6300/10500 Volts 11000 Volts

Rated stator current : 1375/825 Amp

787Amps

Rated rotor voltage : 230/232 Volts DC 232 Volts DC

Rated rotor current : 268/270 Amps 270Amps
Rotational speed : 3000 RPM

3000 RPM

Frequency cycles : 50 Hz

50Hz

Critical speeds : 1720 n1, 4720 n2

Efficiency : 97.6

1700n1, 4800n2

97.6

Type of cooling : Closed Circuit Air cooling

Mass of Rotor

: 6980kg

7500kg

Stator Mass : 14500/15300kg

Rotor fly wheel Moment : 1.42 tm

15300kg
1.42tm

POWER GENERATION AND DISTRIBUTION

Each generator of group 1, 2 and 3 is connected to one section of Generator
Switch
Board (GSB). Each section of GSB-1 is in turn connected with each other by a bus
coupler with
reactor and without reactor scheme.
The TG#4 which was added later on to augment power position of the plant and
to
utilize full capacities of 4 running boilers, is connected through a power transformer to
220 kV
side of the Load Block Sub-Station (LBSS)-5.In addition, the plant has got total of 4
small
generator sets (2 at coke ovens [CO] and 2 at blast furnaces) which utilize the waste heat
and

blast furnace top pressure respectively to produce power.

Sets operating at CO area have a capacity of 7.5 MW each and at BF area have a
capacity of 12.5 MW each. One set each from CO and BF areas are connected to GSB-2
and
GSB-3 respectively.
GSB-1 is connected to the plants 220 kV circuit at LBSS-5 with 3- 11/220 kV,
50/63
MVA transformers. GSB-2 and GSB-3 are connected to plants 220 kV circuit at LBSS-5
via a 3
winding 11/11/220 kV transformer. Power requirement of power plant is et by 2 switch
boards
namely 5LBDS7 and 05HVLC-1 connected to 3 section of GSB-1.
5LBDS-7is mainly a 11 kV switch-board with 3 sections and caters to the need of
various load centres throughout TPP. 05HVLC1 is a 6.6 kV load centre which meets the
requirement of HT drives.

ISLAND OPERATION SCHEME

A scheme has been envisaged at TPP to get isolated from the grid in case of
system
disturbance or low frequency condition with ABB make relay type FCX 103b relay for
some
conditions. Frequency is considered as the main parameter for this operation as it is
highly
reliable compared to voltage and current.
The conditions are

When a frequency of 47.5 Hz or goes above 51.5 Hz is sustained for 0.5 seconds,
the mainline breaker will trip, isolating the plants 220 kV from grid. This is
called first stage of isolation.
When the frequency further drops down to 46.9 Hz and is sustained for 1 second,
the 11 kV section is cut off from the grid. This is called second stage of isolation.

If the rate of change of frequency is 2 Hz/second, sustained for 100 ms, isolation
occurs.

POWER DISTRIBUTION OF
THERMAL POWER PLANT
To meet power requirement of its auxiliaries any power plant relies on station
auxiliary
transformer in case of outage of its generation. But in the case of TPP whenever such
situation
occurs, power requirement of its auxiliaries are met by the same power transformer
(which are
used for power evacuation in case of normal generation) through Generator switch
board.

GENERATOR SWITCH BOARD

Generator switchboard, GSB-1 supplied by Hitachi, Japan is a 11 kV, 4500 A, 78.8
KA, 3
section board, in AA bay. Each 60 MW set is connected to one section of the board. The
bus is
provided with a bus coupler and a B/C with 4500 Amps reactor between section-1 & 2 as
well
as between section-2 & 3. With all 3 generators in service, the bus can be operated only
if B/Cs
with reactors are in service. Power is evacuated through 63 MVA transformer-1, 2 & 3
which
are connected to section-1 & 3 of the board on 11 kV side.
All category-I loads of the steel plant i.e. Water supply, BF, SMS & CO are
connected to

the GSB through link, reactor and MOCB in addition to earth switches.
There are 3 nos. of earthing transformers, which are used to provide earthing for 11
kV
system at TPP. As TG-1,2 & 3 are having floating neutral, two out of three earthing
transformers will be kept in service. The Earthing transformer is of zigzag type
connection with
the neutral grounded by 14 resistance. Each resistance is capable of handling 500
Amp. The
system is designed in such way that with two earthing transformers in service the earth
fault
current will not exceed 1000 Amp.
The switch board is provided with all type of operative safety interlock which are
being
checked regularly whenever shutdown is taken in any of the feeder, generator and bus.
SF6 gas monitors are provided for all SF6 breakers (3 TGs, 4 transformers and 4 Bus
couplers). Any abnormality in SF6 gas system, annunciation is initiated in ECR.
Air pressure is also being monitored and alarms systems are connected to ECR.
Separate compressors are provided for supplying required air in the above SF6 breakers.
= 15 Kg/cm2

Normal value of Air pressure at breakers

Normal value of SF6 pressure at breakers = 5 Kg/cm2

Normal value of air pressure at compressor

30 Kg/cm2

5LBDS7 SWITCH BOARD

5LBDS7 , BHEL make switch-board is 11 kV distribution station located in
AA bay of
annexure building. This board is divided in 3 section. Each section is connected to
respective
section of GSB-1 through 11 kV feeder. There is a provision of bus coupler between
section 1 &

2 as well as between section-2 & 3 as well as between Section-2 & 3 of 5LBDS-7 switch
board,
which can be put in service in case of necessity. From this board 11 kV feeders are
distributed
to various transformer substations 57LC1 to 57LC13 and 57HCLC1. These substations
cater to
power supply requirements of various auxiliary units of power plant. All the breakers are
of
MOCBs except Incomers , Buscouplers , LC 13 feeders, Station Service transformers of
TG-4 &
57 HVLC-1 feeders which are vacuum breakers.
Different substations fed from 5LBDS-7 are listed below.
01 57LC1

Boiler LT auxiliaries, TG, TB auxiliaries

02 57LC2

Coal handling, ACDB, Ventilation, air-conditioning & cranes

03 57LC3

Ash water pump house

04 57LC4

Cooling towers

05 57LC5

Chemical water treatment plant and dewatering plant

06 57LC6

Pump house & LT auxiliaries

07 57LC7

Chilled water plant-2

08 57LC8

Ash slurry pump house

09 57LC9

ESP-1 & ESP-2

10 57LC10

ESP-3 & ESP-4

11 57LC11

ESP-5

12 57LC12

Lighting

13 57LC13

Cooling tower (extension)

14

Station auxiliary transformer feeder for TG-4

15 57HVLC1

Cooling water pumps in PH-4.

05HVLC1 LOAD CENTRE

This is a 6.6 kV switch board located in AAA bay of annexure building. This is a high
voltage transformer station provided with 3 numbers of 11 kV/6.6 kV, 16 MVA/20 MVA
transformers. These transformers designated as Transformer-1, Transformer-2 and

Transformer-3 are getting their incoming 11 kV supply from GSB-1 Section-1, Section-II
and Section-III respectively.
This substation is a triple ended substation with 4 bus section. Section-1 is fed from
secondary of transformer-1, Incomer-2 & Incomer-3. There is a bus coupler between
Section-1 and Section-II and another bus coupler between Section-III and Section-IV as
shown in single line diagram.
This substation caters to HT auxiliaries of all 5 boilers and 7 BFPs distributed over HT
MCCs of 5 Boilers. This switchboard is very critical for very survival of power plant.

ELECTRICAL SHOCK
Electricity is an ideal form of energy which is efficient, economical, clean and
quick,
available at the touch of finger. However, it is quicker and more efficient in causing
damage if
safety aspects are not properly followed. To those who are unskilled and inexperienced
in
electrical work, electricity is a serious source of potential danger. Electrical hazards are
not
usually obvious. For instance, a live conductor does not differ in appearance from a dead
conductor, or the lack of grounding of a metal casing may pass unnoticed until it is too
late
when it is touched and found to be dangerously live.
An electrical shock causing 10mA of current to pass through the heart will stop
many
human heart beats. Voltage as low as 25V DC/ AC RMS should be considered dangerous
and
hazardous since it can produce a fatal current under certain conditions. Higher voltages
are
even dangerous.

Hazards from electricity are classified into two categories, primary and secondary. In the
first group are:
o
o
o
o

Electric shocks
Burns-Joule's burns
Flash over burns
Fire due to spark

In the second category are:

o
o

Person falling from height

Dropping of objects

SHOCKS: We experience an electric shock when the body's nervous system is

suddenly and
accidentally stimulated by electric current that will flow due to difference in voltage.
Shocks
occur when the body becomes part of an electric circuit. The current enters the body at
one
point and leaves at other. It may occur in one of the following three ways:
o
o
o

With both wires of an electric circuit

With one wire of an energised circuit and the ground.
With a metallic part that is in contact with an energised wire.

The severity of shock depends on the following factors:

o
o
o
o

The flow of current through the body(magnitude)

The path of current through the body(resistance)
The length of time the body is in the circuit(duration)
The body resistance lies in the skin. It is about 500 for a large and wet skin
surface and more than 10000 for thick & calloused skin.

1 mA

: Causes no injury but sensation and varies from 0.6 mA and 1.5 mA.

10 mA
: Causes tingling, heat and pain. Adult is unable to let it go. Forearm
muscles are
held in tight contraction.
20-40mA : Chest muscles held in contraction and respiration ceases to function. This
may

cause death. If the current is interrupted within 2-3 minutes, respiration

might
restart spontaneously and recovery is usually rapid.
100 mA

: Heart action ceases, pulse is absent and blood circulation is arrested.

CONCLUSION
We had made a thorough study regarding the generating system and distribution in
captive
power plant. We studied the process of generating power which starts from dumping the
raw
material into the boiler and ends at the generators where the power is generated. The
generated power is then distributed to various loads depending on their requirement.
Thus, this project is the result of our study on the generating system and distribution
of
electrical power in captive power plant. The whole generation and distribution process is
thoroughly studied and the report is presented.