Training

Report

This report is about overview of the thermal power plant of ESSAR

industries,which I visited and completed vocational training of fifteen
days.

Name :Vivek C. Trivedi

Enroll no :100010109024
Institute :A.D.Patel Institute Of Technology,Vidhyanagar
Duration :10/06/2013 to 25/06/2013
 Introduction

Essar Power, amongst Indias largest power generation companies in the private sector, has a total
installed generation capacity of 3,910 MW.

Essar Power is one of India's leading private power producers with a 14-year operating track record. The
company's power business currently has seven operational power plants in India and one operational
power plant in Algoma, Canada, with a total installed generation capacity of 3,910 MW.

This capacity is increasing to 6,700 MW by March 2014.

Salaya I Gujarat (1,200 MW)

The Salaya I power plant, located near Essar Oil's refinery complex at
Vadinar, Jamnagar district, Gujarat, is an imported coal-fueled thermal power plant with two 600-MW
generation units. Salaya I Unit 1 (600 MW) started commercial operations from April 2012.

Coal for the plant will be extracted from Essar Energy's captive coal mine in Indonesia.

Vadinar Power Jamnagar (120 MW)

The Vadinar Power power plant, located at the Vadinar refinery
complex, is one of the Vadinar refinery's captive power and steam co-generation plant. The plant is a 120 MW
refinery residue-based multi-fuel, captive, co-generation plant, with capacity to generate 77 MW of power and 230
tph of steam.

Essar Oil provides the fuel required at the power plant to generate the power and steam for the power plant's
operations.
 Electrical Section of Power Plant
Following are the different parts located in power plant-

1. Switchyard
2. Transformer yard
3. Switchgear room
4. Battery room
5. A.C. Generator (Alternator)
6. Motors of plant
7. ESP building
8. Testing Lab
 Description of switchyard

Output of GT-1/2 that is 400kv is given to the switchyard arrangement.

Switchyard is divided into four major parts:
1. Bay-1
1. Bay-2
2. Bay-3
3. Bay-4

Through bay1&2 power is transmitted to Amreli(line 1&2) and through bay3&4 to

Hadala(line 1&2).
 Switch yard is the important part of a thermal power plant from where the electrical transmission
begins and it distributed electric power to other districts and some parts of its generation it uses itself.

For the transmission of electrical power by the switch yard following equipment are used.

1. Bus bar I and II

2. current transformer (C.T.)

3. Potential transformer (P.T.)

4. Electromagnetic voltage transformer(EMVT)

5. Capacitance voltage transformer

6. Isolator

7. Circuit breaker

8. A.C.S.R. conductor

9. Wave trap

The generated power is transmitted by transfer bus in the condition of fault in bus bar first and second
for the transmission of first unit there are three current transformers.

Three potential transformer and three capacitance voltage transformer one air blast circuit breaker one
isolator in a switch year one C.T. and one P.T. and one C.V.T. is used for per phase RYB. Use of current
transformer and potential transformers is helpful to measure.

By the help of these transformers the high range of current andvoltage are minimized otherwise it is
harmful for the measuring instruments.

The capacitance voltage transformer is used for control unit to communicate at the station. Its work is to
check the low frequency and to pass high frequency for communication to send massage and for gaining
message it check to low frequency and pass high frequency to control unit.

In switch yard they use SF6 circuit breaker and before it is isolated by isolator.

Isolator is also a type of breaker into which there is no medium where in circuit breaker there is any
medium air oil gas (SF) for are distinguishing into switch yard.

They use 6mm ACSR conductor for it is power cable and is suitable for the transmission.
 Wave trap

Wave trap is used detects the distance of fault. In switch yard stock bridge damper is used to stop
vibration of transmission line produced by strom and speedy air blow.

1. For any power sector to carryout efficient and quick operation and load generation management
dedicated communication network is most essential.

2. In present day scenario numbers of communication facilities are available such as DOT P&T lines,
UHF/MW radio links, Optical fiber, Satellite link, etc,.

3. Since each having some drawbacks for its reliability. So PLCC is a need for any power sector as
dedicated communication

4. PLCC network is laid throughout the state to meet Load Dispatch Center requirement of speech and data
communication.

5. At LDC data is received from all power stations, 400/220/132 kv s/s, interstate lines which is having
updated information of generation, load & line position.

6. THUS DEDICATED COMMUNICATION NETWORK PLAYS IMPORTANT ROLE FOR

LDC OF ELECTRCIITY BOARD.
INSTRUMENT TRANSFORMERS:-
Instrument transformer are used to measure
high current and high voltage in A.C. circuit. While instrument transformer used to measure high current
in current circuit is called as current Transformers and Transformers used to measure high voltage line is
called as potential transformers there are following types of instruments transformers.

CURRENT TRANFORMERS:-
It is called as CT also. In these transformers the primary
winding is made of thick insulated conductor by 1 to 50 turns and is connected into the series of main
current circuit. Secondary winding is made of proper insulated conductor by giving more turns and short
circuited by ammeter of 5 Amp.

Current transformers are also used for street lighting circuits. Street lighting requires a constant current
to prevent flickering lights and a current transformer is used to provide that constant current. In this case
the current transformer utilizes a moving secondary coil to vary the output so that a constant current is
obtained

POTENTIAL TRANSFORMERS:-
In potential Transformers there are more turns in primary
winding and it is connected in parallel to the main operated high voltage line which is measured by
potential transformers. There are less turns in secondary winding and are connected in the parallel of low
voltage range voltmeter. I fact potential transformer is a step down transformers of proper ratio. In the
view of protection secondary winding is separated by high insulated material from primary winding of
transformers.
CAPACITANCE VOLTAGE TRANSFORMERS :-
It is called as C.V.T. the C.V.T. is used for control unit to
communicate in the station. It is work to check low frequency and
to pass high frequency for communication to send massage and for
gaining massage it check to low frequency and pass high
frequency to control unit.

BUS BAR:-
Bus Bars are the common electrical component
through which a large no of feeders operating at same voltage have to be connected.

If the bus bars are of rigid type (Aluminum types) the structure height are low and
minimum clearance is required. While in case of strain type of bus bars suitable ACSR conductor are
strung/tensioned by tension insulators discs according to system voltages. In the widely used strain type
bus bars stringing tension is about 500-900 Kg depending upon the size of conductor used.

Here proper clearance would be achieved only if require tension is achieved. Loose bus
bars would effect the clearances when it swings while over tensioning may damage insulators. Clamps or
even effect the supporting structures in low temperature conditions.

The clamping should be proper, as loose clamp would spark under in full load condition
damaging the bus bars itself.

BUS BAR ARRENGEMENT MAY BE OF FOLLOWING TYPE:-

1) Single bus bar arrangement:-

2) Double bus bar arrangement:-

3) Double bus bar arrangement with auxiliary bus:-

PROTECTION TO ELECTRICAL EQUIPMENTS:-

 Necessary protective
system will be provided to protect the electrical equipment when subjected to abnormal conditions.
These will be mounted on a panel and installed in the centralised control room almost of the protection
relays are now manufactured in the country and a few might have to be imported.

ISOLATORS:-
Isolator" is one, which can break and make an electric circuit in no load
condition. These are normally used in various circuits for the purposes of Isolation of a certain portion
when required for maintenance etc. Isolation of a certain portion when required for maintenance etc.
"Switching Isolators" are capable of

1. Interrupting transformer magnetized currents

2. Interrupting line charging current
3. Load transfer switching

Isolator

Its main application is in connection with transformer feeder as this unit possible to
switch out one transformer, while the other is still on load.

The most common type of isolators is the rotating centre pots type in which each phase has three
insulator post, with the outer posts carrying fixed contacts and connections while the centre post having
contact arm which is arranged to move through 90` on its axis.

The following interlocks are provided with isolator:

a) Bus 1 and2 isolators cannot be closed simultaneously.

b) Isolator cannot operate unless the breaker is open.

c) Only one bay can be taken on bypass bus.

d) No isolator can operate when corresponding earth switch is on breaker.

CIRCUIT BREAKER:-
The function of relays and circuit breakers in the operation of a power system is to prevent or limit
damage during faults or overloads, and to minimize their effect on the remainder of the system. This is
accomplished by dividing the system into protective zones separated by circuit breakers. During a fault,
the zone which includes the faulted apparatus is de-energized and disconnected from the system. In
addition to its protective function, a circuit breaker is also used for circuit switching under normal
conditions.

Each having its protective relays for determining the existence of a fault in that zone and having
circuit breakers for disconnecting that zone from the system. It is desirable to restrict the amount of
system disconnected by a given fault; as for example to a single transformer, line section, machine, or
bus section. However, economic considerations frequently limit the number of circuit breakers to those
required for normal operation and some compromises result in the relay protection.

Some of the manufacturers are ABB, AREVA, Cutler-Hammer (Eaton), Mitsubishi Electric,
Pennsylvania Breaker, Schneider Electric, Siemens, Toshiba, Konar HVS and others.

The circuit breaker must detect a fault condition; in low-voltage circuit breakers this is usually done within the
breaker enclosure. Circuit breakers for large currents or high voltages are usually arranged with pilot devices to
sense a fault current and to operate the trip opening mechanism. The tripsolenoid that releases the latch is usually
energized by a separate battery, although some high-voltage circuit breakers are self-contained with current
transformers, protection relays, and an internal control power source.
Once a fault is detected, contacts within the circuit breaker must open to interrupt the circuit; some mechanically-
stored energy (using something such as springs or compressed air) contained within the breaker is used to separate
the contacts, although some of the energy required may be obtained from the fault current itself. Small circuit
breakers may be manually operated, larger units have solenoids to trip the mechanism, and electric motors to
restore energy to the springs.

Various types of circuit breakers:-

 1) SF6 Circuit Breaker

2) Air Blast Circuit Breaker

3) Oil Circuit Breaker

4) Bulk Oil Circuit Breaker (BOCB)

5) Minimum Oil Circuit Breaker(MOCB)

SF6 CIRCUIT BREAKER:-

Sulphur hexafluoride has proved its-self as an excellent insulating and
arc quenching medium. It has been extensively used during the last 30 years in circuit breakers, gas-
insulated switchgear (GIS), high voltage capacitors, bushings, and gas insulated transmission lines. In
SF6 breakers the contacts are surrounded by low pressure SF6 gas. At the moment the contacts are
opened, a small amount of gas is compressed and forced through the arc to extinguish it.

Working of SF6 Circuit Breaker

The working of SF6 CB of first generation was quite simple it is some extent
similar to air blast circuit breaker. Here SF6 gas was compressed and stored in a high pressure reservoir.
During operation of SF6 circuit breaker this highly compressed gas is released through the arc and collected to
relatively low pressure reservoir and then it pumped back to the high pressure reservoir for reutilize.
The working of SF6 circuit breaker is little bit different in moder time. Innovation of puffer type design makes
operation of SF6 CB much easier. In buffer type design, the arc energy is utilized to develop pressure in the
arcing chamber for arc quenching.

Here the breaker is filled with SF6 gas at rated pressure. There are two fixed contact fitted with a specific contact
gap. A sliding cylinder bridges these to fixed contacts.

The cylinder can axially slide upward and downward along the contacts. There is one stationary piston inside the
cylinder which is fixed with other stationary parts of the SF6 circuit breaker, in such a way that it can not change its
position during the movement of the cylinder.

As the piston is fixed and cylinder is movable or sliding, the internal volume of the cylinder changes when the
cylinder slides.

PROTECTIVE RELAYS:-
 Relays must be able to evaluate a wide variety of parameters
to establish that corrective action is required. Obviously, a relay cannot prevent the fault.

Its primary purpose is to detect the fault and take the necessary action to minimize the damage to the
equipment or to the system.

The most common parameters which reflect the presence of a fault are the voltages and currents at the
terminals of the protected apparatus or at the appropriate zone boundaries. The fundamental problem in
power system protection is to define the quantities that can differentiate between normal and abnormal
conditions. This problem is compounded by the fact that normal in the present sense means outside the
zone of protection.

This aspect, which is of the greatest significance in designing a secure relaying system, dominates the
design of all protection systems.

Distance Relays:-
Distance relays respond to the voltage and current, i.e., the impedance,
at the relay location. The impedance per mile is fairly constant so these relays respond to the distance
between the relay location and the fault location. As the power systems become more complex and the
fault current varies with changes in generation and system configuration, directional over current relays
become difficult to apply and to set for all contingencies, whereas the distance relay setting is constant
for a wide variety of changes external to the protected line.

Types of distance relays:-

1) Impedance Relay
2) Reactance Relay
3) Admittance Relay

Transformer yard
 Transformer is a static electrical device. Who change low voltage electrical power into high voltage
power or high voltage power into low voltage power at the same frequency on the basic of electro
Magnetic induction concept.

1. Mainly there are two transformer yards available for individual units of plant.
2. TRAFO-1 is for unit-1 and same way TRAFO-2 is for unit-2.
3. The arrangement and construction of both TRAFOs are identical.

4. As known that voltage generated by each generator of each unit is 20kv,so this voltage is
suppplied to transformers located in TRAFO via generator circuit breaker(GCB) and then given
back to different units as per requirement.

Description of TRAFO-1/2:-
There are mainly four types of transformers available in trafo,they are as follows:-
At a first time the 20kv supply generated by generator comes to generated transformer and from there it
first goes to unit Auxiliaries transformer. Where it stepped down to 3.3KV.

The unit auxiliaries i.e. (Motor Pump) are operated b y this power and further it is stepped down to 415 v
to operated small auxiliaries of the unit.

1.)Generating transformer(GT)-
In this three 1-ph transformers are connected with
each other to form 3-ph transformer.
Input is 20kv from generator to the primary side marked as terminals 2.1 and 2.2
Output is 400kv,which is used as transmission voltage,terminals are 1.1 and 1n

RATINGS OF GT-1/2:-
Capacity :250 MVA,
Voltage Ratio :420/20kv,
Connection :star/delta
Winding :Ynd1
No of taps :17
Type of cooling :OFAF(oil forced air forced)
Frequency :50Hz

2.) Station transformer(ST): They are used to supply common loads of both the
units.
These are 3winding transformers.

The station transformer(s) cater for start-up power requirement, station auxiliary load requirement during
normal operation of the units(s) and outage of UAT.

RATINGS OF ST-1/2:
Capacity :70/45/25 MVA
Voltage ratio :20/11.5/34.5kv
Winding type :Dyn11yn11
No of tapings :5

3.) Unit transformer(UT): There are two transformer UT 1-A & UT 1-B.
They are used to supply equipments of unit-1 only.and same way there is UT 2-A
and UT-2B for supplying unit-2.

Ratings of UT:
Capacity :45 MVA
Voltage ratio :20/11kv
Winding type :Dyn11
No of tapings :5
Connection :delta/star
Type of cooling :ONAN/ONAF

4.) Unit Auxillary transformer(UAT):

The bus leading from generator to generator Transformers will be tapped of conveniently for connection
to high voltage side of the unit Transformers. Auxiliary Transformers used for stepping down the voltage
3.3 KV for supplying power to the unit auxiliary loads of the power station.

RATINGS OF UAT-1/2:
Capacity :16 MVA
Voltage ratio :11/3.3kv
Winding type :Dyn11
No of tapings :5
Connection :delta/star
Type of cooling :ONAN

Power supply system:

1. All auxiliaries dedicated to the unit is fed from the unit bus connected to UAT(s).During start up and shut
down of the unit, the unit auxiliaries shall be supplied power from the station bus connected to station
transformer(s).

2. All the loads pertaining to balance of plant facilities are fed from station bus connected to station
transformers. Station bus shall also be capable of supplying power to largest unit in the station during
start up and shut down.

3. Power supplies, buses, switchgears, interlocks and standby supply systems foe station and unit auxiliaries
are designed in such a way that the main equipment and auxiliaries are not endangered under all
operating conditions. Trafo. voltage ratios, type of tap changers and tap ranges and impedances there on
are optimized that the auxiliary sys. Volt. Under various grid and loading conditions are always within
permissible limits and equipment are not subjected to unacceptable voltages during operation and
starting of motors. Further, the vector group of other auxiliary trafos shall have identical vector groups.

Bus Duct:

1. Bus duct 2. IPBD

3. Nominal service voltage 4. 21KV

5. Frequency 6. 50Hz

7. Rated voltage 8. 24KV

9. Continuous rating current 10. 22000A

11. Basic impulse insulation level 12. 125KV peak

13. Bus bar conductor material 14. Aluminum

A.C. GENERATOR or ALTERNATOR

The Generator complies with the relevant IS/IES standard. The efficiency of generator is more than 98%
at rated load.

Rated apparent power 705.88MVA

Rated voltage at generator terminals 20KV

Rated generator O/P current 20377K

Generator cooling(stator core, Rotor) H2 cooling

Power factor 0.85

Resistance temperature detectors (RTDs) and thermocouples are provided at suitable location for
monitoring the temperatures of stator core, stator windings and bearings.

The star point of generator would be connected to the earth through an earthing transformer.

GENERATOR EXCITATION SYSTEM

Generator excitation system as well as automatic voltage regulator (AVR) is provided with the generator
as per central electricity authority (technical standards for connectivity to the grid) regulations 2007.
Power system stabilizer (PSS) is provided in AVR.
 The rated current of excitation system is 110% of machine excitation current at the rated output of the
machine. The rated voltage is 110% of machine excitation voltage.

MOTORS of Power Plant

Fault
S. No. Name of Motor Quantity Power Rating Voltage FLC Current CT ratio
Nos. (KW) (KV) Amps Amps
TURBINE AREA
1 MDBFP motor 1 13000 11 803 4818 1000/1
2 TDBFBP Motor 2 710 3.3 150 900
3 CEP Motor 3 1120 3.3 233 1398
4 CCCWP motor 2 400 3.3 82 492
5 OCCWP motor 2 250 3.3 51 306

BOILER AREA
1 ID fan motor 2 3100 11 191 1146 250/1
2 PA fan motor 2 2200 11 136 816 160/1
3 FCP motor 3 400 3.3 82 492
4 Mill motor 6 750 3.3 178 1068
5 FD fan motor 2 1400 3.3 288 1728

1 CWP motor 3650 11 241 1446 250/1

Testing Laboratory

The TESTS performed in the lab are as follows:

1. Transformer testing
2. Relay testing
3. Battery testing
4. C.T. and P.T. testing
5. Motor testing

TRANSFORMER TESTING
1. Insulation resistance test.
2. Winding Resistance Test.
3. Voltage Ratio Test.(only 415 V Transformer).
4. Magnetisation Current Measurement Test.
5. Magnetic Balance Test.
6. Tan-delta Test.

RELAY TESTING
1. Differential Protection Relay.
2. Distance Protection relay.
3. Generator Protection Relay.

C.T. and P.T. TESTING

C.T. tan delta testing.
MOTOR TESTING
1. Insulation Resistance Test.
2. Winding Resistance Test.
3. Polarity Test.
4. Differential Relay Stability Test.
5. Tan Delta Test.

Electroststic Precipitator(ESP)
Electrostatic precipitation is a method of dust collection that uses electrostatic forces, and consists of
discharge wires and collecting plates.
A high voltage is applied to the discharge wires to form an electrical field between the wires and the
collecting plates, and also ionizes the gas around the discharge wires to supply ions.
When gas that contains an aerosol (dust, mist) flows between the collecting plates and the discharge
wires, the aerosol particles in the gas are charged by the ions.
The Coulomb force caused by the electric field causes the charged particles to be collected on the
collecting plates, and the gas is purified.
This is the principle of electrostatic precipitation, and Electrostatic precipitator apply this principle on an
industrial scale.

The particles collected on the collecting plates are removed by methods such as

(1) dislodging by rapping the collecting plates,

(2) scraping off with a brush, or
(3) washing off with water, and removing from a hopper.

Why do we use rectifier transformers for ESP(electrostatic precipitator) in

thermal power plant?

An ordinary transformer will produce AC voltage to the ESP fields.

You do not want the voltage to drop off because it will release the ash particulate when you do not want
to as it goes through the zero point and then it would reverse charge and repel the ash!

The rectifiers change the AC voltage into DC to feed to the fields to keep the voltage constant and in the
right direction to capture particulates.

Battery room
 A battery room is a room in a facility used to house batteries for backup or uninterruptible power
systems. Battery rooms are found in telecommunication central offices, and to provide standby power to
computing equipment in datacenters.

Batteries provide direct current (DC) electricity, which may be used directly by some types of
equipment, or which may be converted to AC by uninterruptible power supply (UPS) equipment.

The batteries may provide power for minutes, hours or days depending on the electrical system design,
although most commonly the batteries power the UPS during brief electric utility outages lasting only
seconds.

In industrial applications mainly three types of batteries are used namely:

1. Vented / Flooded Lead Acid batteries

2. Sealed maintenance free batteries/Valve Regulated Lead Acid
3. Nickel Cadmium (Ni-cd) batteries

CONCLUSION
The phase of practical training has proved to be quite faithful. It proved an opportunity to encounter

with such transformer ,generator, circuit breaker etc.

It also provides an opportunity to learn technology used at proper place can save a lot of labour.

The architecture of the power plant, the various component linked with it, the way the whole power plant

is controlled make the student realised that engineers is not just learning the structured description and

working of various machines but the proper planning of the management.

Training is carried out into its true sprit, It is recommended that there should be some project especially

meant for student where the presence of authorities should be ensured.

However, training has proved to be quite faithful. It has allowed us an opportunity to get an exposure of

the practical implementation to theoretical fundamentals.