Performance Improvement of Electrostatic Precipitator: Analysis and Improvement

PROJECT REPORT
(Project Semester January-June 2016)
Performance Improvement of Electrostatic Precipitator:

Analysis and Improvement
Submitted by
Loveneet Saini
BE13104023
Under the Guidance of
Dr. Jagdish Kumar Er. Naveen Malhotra

Associate Professor Addl. Superintendent Engineer
PEC University of Technology Thermal Training cell
Faculty Coordinator Industry Coordinator
Department of Electrical Engineering

PEC University of Technology, Chandigarh
25 January to 25 May,2016
PEC University of technology Page0

DECLARATION
I hereby declare that the project work entitled Performance Improvement of Electrostatic
Precipitator: Analysis and Modification is an authentic record of my own work carried out at
Thermal Training Institute, GGSSTP, Roopnagar as requirements of 17 Weeks project
semester for the award of degree of B.E. (Electrical Engineering), PEC University of
Technology, Chandigarh, under the guidance of Er. Naveen Malhotra and Dr. Jagdish Kumar,
during 25th January 2016 to 25th May2016.
(Signature of student)
Loveneet Saini
13104023
Date: ___________________
Certified that the above statement made by the student is correct to the best of our knowledge
and belief.
(Name & Designation) (Name & Designation)

Faculty Coordinator Industry Coordinator

ACKNOWLEDGEMENT
It gives me immense pleasure to take this opportunity to thank GGSSTP Ropar along with its
Stafffor giving me such a great opportunity to do project work under this North Indias
Largest Capacity Thermal Power Plant (1260 MW). It gave me opportunity to learn the work
carried out here, got a glimpse of the new environment and hard work of power sector. I
would like to express my sincere gratitude to Er. Naveen Malhotrafor his invaluable
guidance and enormous help, encouragement and comforting behaviour, which helped me to
complete my internship successfully.
I would also like to acknowledge Mr. Satwinder Singh, Mr. Manjeet Singh, Mr Kulwant
Singh, Mr Puri who helped me in one way or other with their constant involvement during
my training.
I would also like this opportunity to express my sincere gratitude to my faculty coordinator,
Dr. Jagdish Kumar for his constant guidance, valuable suggestions and moral support. I
acknowledge gratefully the help of GGSSTP Ropar staff and members who were always eager
to help me with their warm attitude and technical knowledge. Finally, no word will be enough
to express my deepest reverence to family and friends without whom enthusiasm and support
I wouldnt have been able to pursue my goals.

CONTENTS
S.No. TOPIC PAGE

NO.
1. Declaration 1
2. Acknowledgement 2
3. Summary 5
4. Introduction to GGSSTP 6-8
5. Working of Thermal Plant 9-10
6. Coal Handling Plant 11-14
7. Boiler & its Auxiliaries 15-21
8. Turbines 22-25
9. Generator and its Auxiliaries 26-33
10. Draft Fans 34-36
11. LT Switchgear 37-39
12. HT Switchgear 40-42
13. Transformer Yard 43-54
14. 220 KV Grid 55-64
15. Protection & Protection System 65-68
16. Electrostatic Precipitator Analysis 69-80
17. Practical Application of Theory 81-84
18. Advanced Microprocessor control 85-94
19. Conclusion 95

20. References 96
Table of Figures
Figure No. Description Page no.

1. Plants Water and Air Cycle 10
2. Stacker and Reclaimer in GGSSTP 12
3. Power station Steam Turbine and Its External Equipment 22
4. View of Internals of a Power Station Steam Turbine 25
5. Generator in GGSSTP 26
6. PA Fan Induction Motor 36
7. Part Cross Section of a Transformer 44
8. Station Transformer in GGSSTP 46
9. Generator Transformer in GGSSSTP 47
10. Bus Bar System in Substation in GGSSTP 55
11. Air Blast Circuit Breaker 57
12. SF6 Circuit Breaker 58
13. Isolators 59
14. Current Transformers 60
15. Potential Transformers 60
16. Lightning Arrestor 61
17. Line Traps 62
18. Electrostatic Precipitator at GGSSTP 69
19. Tubular Collection Electrode 70
20. Corona Formation 71
21. Particle Charging 72
22. Migration Velocity vs Treatment Time 73
23. Comparison of Potential in clean and dust laden plate 77
24. Skewed Gas Flow Distribution 79
25. Precipitator Power Optimization 87
26. Back Corona Current and Voltage Waveform 88
27. Normal and Intermittent Energization 90
28. Performance Comparison visualization of Analog controls v/s 94
Microprocessor through Stack Opacity

SUMMARY
As Student Intern in the Guru Gobind Singh Super Thermal Power Plant, I got the
opportunity to explore the ideas of the modern electrical engineering which forms the
backbone of the very power system, which lights up the world we live in. I got the
opportunity to reconcile the knowledge of theoretical framework with its actual practical
realizations.
My training was divided into five modules:
1.Generation
2.Protection
3.LT Switchgears
4.HT Switchgears
5.Analysis of Electrostatic Precipitator
Initial stage of my training involved getting a thorough knowledge of how the process of
generating electricity begins and the subsequent steps necessary to make electricity available
to the consumer. During my analysis I found that, Electrostatic Precipitator (ESP) of stage 3
of the planthas poor precipitation efficiency, hence posed a menace to surrounding
environment.This motivated me to work on ways to resolve this menace. To resolve this, I
carried out analysis of electrostatic precipitator and the fundamental principles of electro
physics on which precipitator works.
Finally using the extensive research of Mr. Frederick cottrel and others I presented the use of
advance microprocessors to boost stage 3 ESP efficiencies so as to meet the pollution control
norms of the Ministry of Forest and Environment, India.
The project report begins with introduction to the working of power plant with the overview
of the Thermal power plant. Mechanical aspects of coal and ash handling are also presented.
Then is the brief overview of the analysis that have been followed for the completion of the
project.
In order to have a better look into the project flowcharts, snapshots, Graphs have been
supplemented wherever necessary. It gives the insight of the theoretical framework presented
and outlines the fundamental ideas used for modification of electrostatic precipitator
The report concludes giving the final results and future scope of the work done followed by
references.

About Powercom and Transcom
Govt. of Punjab unbundled Punjab State Electricity Board into two companies
Punjab State Power Corporation Ltd. (POWERCOM)

Punjab State Transmission Corporation Ltd. (TRANSCOM)
In exercise of the Power conferred by article -45 of the Articles of Association of Punjab State
Power Corporation Limited and Punjab State Transmission Corporation Ltd.and all other
Powers enabling him on this behalf, Governor of Punjab is appoint the following Chairman
cum Managing Directors and Directors of the above Corporations with immediate effect. The
appointment will be initially for a period of one year from the date of joining:-
POWERCOM
1. Er.K.D.Chowdhry Chairman cum Managing Director

2. Sh.G.S.Bachi Director/Administration
3. Er.Arun Kumar Director/Distribution
4. Er.G.S.Chhabra Director/Generation
5. Sh.S.C.Arora Director/Finance
6. Sh.H.C.Seth Director/H.R
TRANSCOM
1. Sh.Anurag Agarwal Chairman cum Managing Director

2. Er.Ravinder Singh Director/Technical
3. Sh.Uma kanta Panda Director/Finance
Prior to this unbundling the organization was PSEB.
The Punjab State Electricity Board (PSEB) was a statutory body formed on 1-2-1959 under
the Electricity Supply Act.1948. Subsequently with the re-organization of the erstwhile State
of Punjab under the Punjab Re-organization Act 1966 this form came into existence w.e.f. 1st

May, 1967. Starting with the modest installed capacity of 62 MW, the PSEB grew up by leaps
and bounds with generating capacity 6841 MW as on 31-3-2009 from all sources,
including share from Central Sector Projects. The Board's gross generation during the
year2008-09 was 38880 Million Units. PSEB operated its own Generation Power Plants and
also got power as its share from BBMB. The PSEB also constructed and maintained its
Transmission and Distribution system for providing efficient services to the various categories
of electricity consumers in the state. PSEB proudly serving more than 66.31 lakhs consumers
comprising of approximate 54.86 lakhs. General, 1.12 lakhs Industrial and 10.33 lakhs
Agricultural connections till 31.3.2009
Introduction to GGSSTP, ROPAR
Plant the ever increasing gap between power demand and its availability was one of the main
reasons for envisaging the Guru Gobind Singh Super Thermal Power Plant for the state of
Punjab after Guru Nanak Dev Thermal Power Plant, Bhatinda.
Salient Features of GGSSTP, Ropar: -
1. Location ROPAR, about 50 km from Chandigarh on

Chandigarh Nangal Highway no.21 Near
Ghanauli Village railway station.
2. No. of Houses 6
3. No. of Units 6
4. Total Generator Capacity 6210 MW = 1260 MW
5. Source of Water Supply From Nangal Hydel Channel
6. Fuel used Coal from coal fields of Bihar, West Bengal
& Madhya Pradesh more than 50 sources
calked Collieries. Distance of these sources
is between 1417 Km & 1560 Km.
7. Turbine 210 MW 3 Cylinder mixed flow tandem
coupled 3000 rpm BHEL make.
8. Generator 247 MVA, 15.75 KV, 9050 A at 0.82 lag, 50
Hz, double star two pole

9. Commissioning Unit 1 = 26.9.84
Unit 2 = 29.3.85
Unit 3 = 31.3.88
Unit 4 = 29.1.89
Unit 5 = 29.3.92
Unit 6 = 30.3.93
10. Cost of project Stage-I Rs 380 Crores
Stage-II Rs 438 Crores
Stage-III Rs 599 Crores
11. Total energy contribution annually 6942 Mus
12. Cost per unit Rs 1.84

WORKING OF THERMAL PLANT
Thermal power station burn fuels and use the resultant steam to drive the turbo generator. The
object is to convert heat into mechanical energy in the. turbine and to convert mechanical
energy into electrical energy by rotating magnets inside a set of magnets. The coal brought to
the station by means of trains travel from the coal handling plant by conveyor belts to the coal
bunkers. From where it is fed to pulverizing mills which grind it to a ne powder. Finely
powdered coal mixed with preheated air is blown into the boiler by primary air fan where it
burns more like a gas than as a solid with additional amount of air called the secondary air
supplied by the secondary draft fan. As the coal has been ground nely the resultant ash is ne
powder. Some of its contents bind together to form lumps which fall in ash pits at the bottom
of the furnace. The ash mixed with water is then taken to the pits for subsequent disposal. The
electrodes charged by high voltage electricity in the electrostatic precipitator trap most of the
ash. The dust is then conveyed by water to the disposal area or to the bunkers while the
cleaned ue gases pass on through the ID fan to discharge through the chimney. Meanwhile
the heat released from the burning of coal has been absorbed by many kms of tubing which
line the boiler. Inside these tubes is water, which takes the heat and is converted into steam at
high temperature and pressure. This steam at high temperature and pressure is sent to the
turbine where it is discharged through the nozzles on to the turbine blades. The energy of the
steam striking on the blades makes the turbine to rotate. Coupled to the turbine is the rotor of
the generator. So when the turbine rotates the rotor of the generator turns. The rotor is housed
inside a stator having heavy coils of copper bars in which electricity is produced through the
movement of magnetic eld produced by the rotor. Electricity passes from stator winding to
the transformer, which increases its voltage level so that it can be transmitted over the lines to
far off places.
The steam, which has given away its energy, is changed back into water in the condenser.
Condenser contains many kms of tubing through which cold water is continuously pumped.
The steam passing over the tubes continuously loses heat and is rapidly changed back into
water. But the two waters i.e. the boiler feed water and cooling water must never mix. Boiler
water must be absolutely pure otherwise the tubing of the boiler may get damaged due to the
formation of salts inside the tubes due to the presence of different impurities in water.

To condense large quantities of steam huge and continuous volume of water is required. In
some power stations same water has to be used again and again because there is not enough
water. So the hot water extracts are passed through the cooling towers. The cooling towers are
simply concrete shells acting as a huge chimney creating a draught of air. The design of
cooling towers is such that a draught of air is created in the upward direction. The water is
sprayed at the top of the tower. As it falls down the air owing in the upward direction cools
it. The water is collected in a pond from where the water is recirculated by the pumps to the
condenser. inevitably, however some of the water is taken away by the draught of water in the
form of vapours and it is this water with familiar white clouds emerging from the cooling
towers.
Figure1: Plant Water and Air Cycle
LPH-Low Pressure Heater Mills HPT-High Pressure Turbine

BFP-Boiler Feed Pump Furnace IPT-Intermediate Pressure Turbine
HPH-High Pressure Heater Deaerator LPT-Low Pressure Turbine
RH-Reheater ECO-Economizer ESP-Electrostatic Precipitator
CRH-Cold Reheat Line AH-Air Preheater FD Fans-Forced Draft Fans
HRH-Hot Reheat Line DRUM-Boiler Drum ID Fans-Induced Draft Fans
G-Generator Chimney Condenser

COAL HANDLING PLANT
The coal handling plant is that unit of thermal plant which involves complete processing of
coal from the moment it arrives in the coal yard to the time it is fed to the boiler. The coal is
transported to the coal yard from the coal mines through railways. A rake: is a train containing
about 58-60 wagons. Each wagon contains about 58 tons of coal.
HOW COAL HANDLING PLANT FUNCTIONS

Coal handling plant has the following basic functions to perform:
1. Unloading of coal wagons.
2. Reclaiming of crushed and uncrushed coal.
3. Coal crushing.
4. Removal of unwanted particular from the coal.
5. Coal feeding to the raw coalbunkers of running units.
WAGON - Shunters are used for placing the wagons on rail table. Shunter or loco has the hp.
of 450h.p. and 650h.p. the whole wagon get unload in 4 minutes (app). The weight of wagon
is measured with the help of electronic motion wave bridge. Approximately weight of wagon
is 82 ton. Each wagon contains 58 tons of coal. The types of wagon are ntype and c-type.
During measuring of wagon, the speed of train should be 5km/hr l 0km/hr and weight is
measured with electronics motion wave bridge.
COAL WAGONS ARE UNLOADED IN 2 WAYS
Wagon tippler
These are 5 in no. & is used for unloading of the coal wagons. Tippler consists of rail table
(the rail table is turned at an angle of 135), tracks, pits (in pit, there is suspension), at the top
of wagon tippler, there is holding beam for holding the wagon.
The wagon is unloaded on grating. The ac. motor is of 95 hp. The whole process is
mechanical.
MUTH- (manual unloading track hopper) when there is fault in wagon tippler, it is
used. Coal is unloaded manually on grating.

SCR (stacker cum reclaimer) when coal size is reduced to 25mm. The coal is in
large quantity, then crushed coal is stacked and when necessary is reclaimed.
ERH- (emergency reclaimer hopper) when there is emergency coal is reclaimed.
MANUAL UNLOADING
Manual unloading is done by the labour itself by using the suitable equipments. The wagon
capacity is 58 ions and it itself weights 2 ions. The capacity of bunker hall is 660 tons, which
is sufficient for 22 hours. The raw coal has a size of the order of 500 mm approx. This coal is
sent to the primary crusher on conveyor belts and reduced to a size of 125 mm. This coal from
primary crusher is sent to secondary crusher. Secondary crusher further reduces the size of the
coal to 25mm. This coal from secondary crusher is sent to coal mills on the conveyor belts.
CHP also has stackers and reclaimer.
COAL PULVERISING SYSTEM

In RTP, bowl mills have been installed for pulverizing the raw coal. Designed mill capacity is
39.7tonnes/hr. But it depends on the hard glove grind ability index (HGI), the moisture
content of coal and neness requirement of pulverized coal.
Figure 2: Stacker and Reclaimer in GGSSTP

STACKER AND RECLAIMER
This machine can do the combined function of making the stockpile on either side of the track
and also reclaim them. The required switches for stacking operation will closed during
stacking operation and similarly for the reclaiming operation. The smelting and reclaiming
should be done in auto-manual mode. Total stacking area is divided into four zones on either
side. In manual mode stacking and reclaiming operation of machine will be started from
control desk located in the operators cabin sequentially. Stacking-cum- reclaiming operation
mode is selected from control room.
RAIL WAGON
The rail mil track gauge is 1676m and the provision is made for the passage though the
installation of all standard Indian rolling stock of this size. The tippler will accept the
following for any one operation. One standard boxcar wagon 8 wheeler orlow 4 wheeler 0
type wagons handled in pair.
CONVEYER
The conveyors are rubber type and usually 1250 or 1500 mm wide. It is a rubberized belt with
nylon ply. The belt is braided. This combination of plies is a carcass. Four plies comprise one
carcass. The conveyor belt capacity is 1250t/hr.
PRIMARY CRUSHER
Primary crusher reduces the size of coal to 125 mm. It is a hollow shell with diameter 12 and
length 22. It is a hollow shell supported on tie rods connected with perforated plates to make a
circle. On these dewing, perforated plates are present with holes of diameter 125mm.
SECONDARY CRUSHER
Coal for further reduction of size is fed from primary crusher to the secondary crusher
bymean of a screen, which is not stationary but vibrates. The secondary crusher is a ring
granulator system; its design is different from the primary crusher.
There are two types of hammers:
1. Ring-type hammers
2.Tooth-type hammer

TRIPPLER TROLLEY
It is located in bunker halls. There are 6 tippler trolleys. The function is to pour coal to the
bunkers. Each unit has 6 bunkers and the trolleys moves along conveyors on rail
TRAVEL SYSTEM
The total system makes the stacker to move to and fro along the conveyor. The total track
length is 750 m. The speed of travel system is 7.1 m/s in slow mode and 14.16 in fast mode
COAL MILLS AND MILLING SYSTEM

Mechanical energy is created from thermal energy in this plant. 3000 'l' of coal is being
consumed for one unit of plant per day. Each raw coalbunker has capacity of 680 tons.Raw
coal is milled and pulverized and then is fed to the furnace. The coal mills pulverize the coal
before feeding in the furnace. In RTP there are three stages for six units.
TYPES OF MILLS
1. Low speed mills: they have a speed of rotation of 10 to 15 rpm. These mills have a
cascading system. The coal gets pulverized due to cascading of valves and balls and then coal
gets sucked.
2. Medium speed mills: the speed of rotation is 50 rpm.
3. High speed mills: the high-speed mills have a speed of rotation 80 to 85 rpm. The wear and
tear being very high, these mills are not installed in RTP.
Each unit has six bowl mills. There are total 36 bowl mills. For generating power of 210mw, 4
bowl mills are sufcient. Each mill capacity is 39.6Usec. The coal mills are designed for
performance coal. But coal we get is performance coal HGI - 55 with following
specications.
volatile matter - 4500 kcal/kg.
ash contents - 28%.
The hgi being high, the coal is hard to mill and more is of stone type. There are 3 no. Of
grinding rolls, which grind coal before it, is fed to the furnace.

BOILERS AND ITS AUXILIARIES
Introduction to Boiler
A boiler is a combination of systems and equipment in which chemical energy is converted
into thermal energy, which is then transferred to working uid, so as to convert it into steam at
high temperature and pressure.
In GGSSTP, there are six boilers for six units. A boiler is a 210 MW Radiant Reheat, Natural
Circulation, Single drum, Semi-outdoor, Dry bottom, Water Tube and designed for coal as
principle fuel. The Heavy Fuel Oil (HFO) ring capacity is equivalent to 22.5% boiler
Maximum Continuous Rating (MCR). Four burners are capable for 7.5% boiler MCR heat
input. A layout arrangement is of conventional type that is with the mills in front of the boiler.
The complete furnace section is of fusion welded wall type, arranged as a gas and pressure
tight envelop. The extended sidewall section (where re-heaters are located) is covered with
water-cooled n welded walls. The maximum ue gas velocity in the pressure part system is
limited to 10-12 m/sec at 100% boiler MCR load. All headers are located outside the gas path,
except for the economizer inlet header; intermediate headers and LTSH inlet header are
located in the low gas temperature section. Two numbers of Reheater De-super heater are
provided at the inlet of the reheater for emergency control of nal reheated steam.
In a boiler, there are Down Comers, Super heaters, Re-heaters, Ring heaters, Economizers,
Air Pre-heater, Steam Cooled Walls. All the four walls of furnace consist of pipes in which
water ows and is connected to the drum by Down Corners. This arrangement of boiler avails.
Cold water to come down and Hot water to rise through risers. The complete pressure parts
are suspended from the boiler steel roof structure and arranged for free expansion downwards.
Salient Features of Boiler have been given below:
Drum
The boiler drum is made of alloy steel plate of 97mm thickness and has an outside diameter of
1800mm. The drum is fusionwelded type with welded-on hemispherical dished ends. The
drumdished ends are provided with manholes and manhole covers. Drum is welded with

down comers tubes, return tubes, saturated steam outlet tubes feed water inlet tubes. The drum
is designed for two -stage evaporation. The rst stage evaporation takes place in CLEAN
compartment which occupies the major part of the drum. The second stage evaporation takes
place in SALT compartment which occupies remaining portion of drum. The evaporation in
the salt compartment is approx. 6-7% of the total evaporation.
Furnace Walls
The combustion chamber is formed of water wall tubes of outside diameter of 60mm and is
placed at a distance of 125mm in front and rear waterwalls. On the sidewalls the water-wall
tubes are set at a distance of 65mm.In the region above the burners of front and rear water
walls, radiation wall superheater tubes are arranged in between the widely pitched water-walls
tubes. The lower parts of the front and rear water wall tubes are provided with at ns to
cover the entire combustion chamber. In the corner where the pulverized coal burners are
located, the tubes are bent suitably to provide opening for the setting of the tilting comer
burners.
The seam less water-wall tubes is welded to the bottom and top headers by means of Stubs.
Adequate dimensioning of downcomers ensures perfect natural circulation of water in the
various circulation contours. The guides and springs supporting suspensions are so designed
and dis-positioned so as to ensure proper expansion and contraction of the tubular system
without occurrence of any undue stresses.
There are four furnace walls consisting of re tubes fabricated from seamless carbon steel and
fusion welded. These four walls are front, rear, right and left water walls.
Down Comers
These are six numbers of down comer pipes, connecting the steam drum and water wall lower
ring header.
Riser Pipes
118 numbers of riser pipes are rolled upward to take the steam water mixture from the outlet
of the water-wall header to the steam drum.

Economizer
It absorbs heat from the ue gases and adds it mainly as sensible heat to the feed water. It
preheats the feed water before it enters the drum. The work in the evaporative section of the
plant is reduced due its heat contribution. It has a heating surface of 49301112 and is made of
seamless tubular loops. The tubes have diameter of 32mm are welded with by means of stubs
to the inlet and outlet headers. Usually blowing of economizer tubes is necessary for blowing
away the deposits. But it necessary for Indian coal.
Super Heaters
Steam coming out of the drum is circulated through a number of superheaters. There is 14
number of super heater headers. The steam superheater has a total heating surface of 3782m 2.
It consists of six stages between which two regulating injections controlled by automatic
regulator of superheater steam temperature are arranged. The tubular pendent loops are
arranged across the full width of the boiler.
Saturated steam from the boiler drum is led to the wall superheater I located in the upper part
of the front and rear water walls of the furnace. From there it is led through the tubes which
from the ceiling of the horizontal pass to the convection horizontal superheater II located in
the second pass of the boiler. The rst auxiliary regulating injection is arranged at the end of
the superheater II before the inlet of the steam to the radiant platen type superheater III and
superheater IV. The final outlet superheater IV is also arranged in horizontal pass of the boiler.
The regulating injection is suspended between the fifth stage and sixth stage of the superheat.
The final superheater is suspended between the rows of the grid tubes in the horizontal pass of
the boiler. The second regulating injection is suspended between the fifth and sixth stage of
superheat. The final superheater is suspended between the rows of the grid tubes in the
horizontal pass of the boiler. The superheater tubes are welded to the inlet and outlet headers
by means of stub. the flow of steam in superheater is as follows:
Steam cool wall roof tubes (SCW) -> SCW side tubes -> Extended SCW side tubes->
Front SCW tubes->SC roof and rear wall tubes-> Super heater rear horizontal
Assemblies->LTSH-> SHDESH platen super heater-> Pendant super heater.

Re-Heaters
From pendant vertically spaced plate section located between rear window hanger and super
heater plates. Rear pendant vertically spaced plate section located above furnace arch between
the water, cooled screen tubes and rear water wall hanger tubes. Approximate heating surface
is about 3366 m2 and is made of pendant and horizontaltubular loop. The steam from
superheater ows through the tube of outside diameter of 32mm, while the steam to reheater
flows through a bigger tube of outside diameter or 60mm. The superheated steam for the tri-
flux is drawn through a three-way valvearranged in a connecting pipe between the inlet and
external platen superheaters before injecting stage I.
The reheater II is suspended in the horizontal pass of the boiler and the tubular loops are
arranged after the pendant coils of the convection superheater V. The reheatertubes are welded
to the inlet and exit headers by means of stubs. The material is carbon molybdenum and
chromium molybdenum. Austentine Stainless Steel temperature are controlled by spraying
water coming out of boiler feed pump discharge.
Air Pre-Heaters
They are trisected types as they are the last stage in the heat recovery cycle. It preheats the
primary air and secondary air with ue gases. There are two numbers of air pre heaters and
contain heating elements in three layers. These are hot, intermediate and cold layers. Its
heating surface is about 1900 sq.
Flue Gas Path

Flue gases travel upward in the furnace and downward through the rear gas pass to the
economizer and air heaters. In the economizer, some heat of ue gases is utilized to heat the
feed water before it goes to drum. Further in the air heaters, the residual heat of the flue gases
are utilized to pre-heat the secondary and primary air. From the air heaters the gases pass
through the electrostatic precipitators and induced draft fans to the stacks.Interconnections of
the gas ducts at inlet and outlet of electrostatic precipitators are provided.
Furnace (11560C) > Platen SH (10260C) > Reheater (920C) > Final SH (6660C) >
LTSH (346C) > Economizer(140C) > APH > ESP > Induced Daft Fan > Chimney.

Primary Air Path
A Primary Air fun injects air from atmosphere into the air pre-heater. At the outlet of an pre-
heater temperature of the air is raised above the initial temperature. This air is then introduced
into the bowl mills, here air is thoroughly mixed with finely crushed coal. This mixture is then
fed in the wind box hence to the furnace. The function of primary air is to transfer pulverized
coal to the furnace and also to provide sufficient air air required for combustion of the coal.
PA. Fan >APH >Bowl Mill>Furnace.
Secondary Air Path

Air from atmosphere is forced into the air pre heater with the help of Forced Draught. Air
coming out of air pre heater has high temperature with respect to initial value. This air is then
supplied directly into the wind box and then to the furnace. The function of secondary air is to
provide an extra amount (Le. 30% extra) of air to facilitate complete combustion. Its main
advantage is that very less amount of ash is left after combustion.
FD. Fan > Air Pre-Heater >Furnace.
Wind Box Assembly

The fuel ring equipment consist of four wind box assembles located in the furnace corner.
Each wind box assembly is divided in its height into number of sections. The coal
compartment contain a coal nozzle, the top, bottom and intermediate compartments and each
fuel compartments are used for the admission of secondary air. Combustion air (secondary
air) is admitted to the intermediate air compartments and each fuel compartments through sets
of lower dampers. A damper drive cylinder located at the side of wind box operates each set
of dampers. Secondary air damper Operates the 4 cylinders at each elevation either manually
or automatically. Some of the intermediate air compartments between coal nozzle contains a
rectangular oil gun. Optical ame scanners are installed in ame scanner guide pipe
assemblies in the auxiliary air compartments. The scanner pick up Visible light given off by
the ame and thereby detects the ame.

Details of Boilers
Type Water tube, Single

Make BHEL
Capacity 680 tons/hr.
Steams pressure 155 atm
Steam temperature 540C
Cooling and Circulating Water

Technique Once through cooling
Actual Discharge 26400 1113/ Hr.
Cooling Pump3 Nos.
Capacity8800 m3
Boiler Parameters
Superheater outlet steam flow 690T / hr.
Steam pressure at SH outlet 155kg/cm2
Steam temperature at SH outlet 540C.
Re-heater outlet steam ow 597.5T/Hr
Steam pressure at RH inlet 37.6kg/cm2
Steam pressure at RH outlet 36. l k g/cm2
Steam temperature at RH outlet 5400C
Steam temperature at RH inlet 3420C
Feed water temperature 2430C
entering economizer
Ambient air temperature 400C
Tangential Firing System

In the tangential firing system, the furnace itself constitutes the burner, Fuel and air are
admitted into the furnace through four wind box assemblies located in the furnacecorners. The
fuel and the air streams from wind box nozzles are directed. to firing Circle at the center of
the furnace. The rotating action that is characteristic of this type of firing is most efcient in
turbulently mixing the burning fuel in a constantly changing an and gas atmosphere.
Heat Igniter
The equipment gives the high intensity electrical spark which immediately ignites the oil
articles surrounding the spark, thus creating a ame pocket in the oil spray. The ame
propagation into the oil spray from this pocket gives the successful ignition. The igniter works
in combustion with the discriminating ame scanner, which is capable of sensing the

associated ame only. The discriminating ame scanner senses the ame immediately after
the ignition and permits to continue.
Boiler Auxiliaries
ID Fans 3 Nos.
FD Fans 2 Nos.
PA Fans 2 Nos.
ESP 28 Nos.
Ash Handling Plant
Fuel Oil System
Scanner Air Fan
Soot Blowers 56 Nos.
Fuel Oil System

To lower the ignition temperature of coal Heavy Fuel Oil (HFO) or Heavy Petroleum Stock
(HPS) is sprayed on the pulverized coal so that it ignites quickly and also completely.
Soot Blower
Soot blowers have been provided for cleaning and soot blowing the water walls, super heater,
and reheater tubes for efcient heat transfer in both radiation and convection Zones. Soot
blowers are operated to keep the external heating surfaces clean. Recording and comparing
the exit gas temperature at various loads and furnace condition can establish proper soot
blowing schedule. Abnormal low steam temperature may be due to a fouled SH/RH externally
or internally and abnormal high steam temperature may be due to a dirty furnace.
TURBINES
Steam Turbines
The steam turbine is a prime mover that converts the stored mechanical energy in steam into
rotational mechanical energy. A turbine pair consists of a ring of fixed blade and a ring of
moving blades. The blades are so designed that the steam glides over the blade surface
without striking it. As the steam ows over the covered surface of blade, it exerts a pressure

on the blade along its whole length owing to its centrifugal force. The motive force on the
blade will be the resultant ofthe centrifugal pressures on the blade length plus, the effect
ofchange of the steam as it flows over the blade.
Figure 3: A Typical Power Station Steam Turbine and Its External Equipment
Specications
Type 3Cylinder Mixed Flow Tandem Coupled

Make BHEL, KWU Design
Capacity 210 Mw
Speed 3000 rpm
Stages Nos. (HP, IP, LP)
Efficiency 43%
Inlet Steam Pressure 150 Kg / cm2
Inlet Steam Temperature 535C
Overall Length 16.975 m. -

Overall Width 10.5 m.
General Design Features

The turbine is of tandem compound design with separate High Pressure (HP), Intermediate
Pressure (IP) and Low Pressure (LP) Cylinders. type while IP and LP turbines are The HP
turbine is of Single Flow of Double Flow type. The turbine is condensing type with single
reheat. It is basically engineered on reaction principle with throttle governing. The stages are
arranged in HP, IP and LP turbines driving alternating current full capacity turbo generator.
The readily designed HP, IP and LP turbines are combined and sized to required power output,
steam parameters and cycle conguration to give most economical turbine set. The design and
constructional features have proved their reliability in service and ensure trouble free
operation over long operating periods and at the same time ensuring high thermal efciencies.
Barrel Type High Pressure (HP) Turbine

The outer casing of the HP turbine is of barrel type construction without any massive
horizontal ange. This unique construction permits rapid startup from any thermal state and
high rates of load changes of the turbo set. The steam and metal temperature matching
requirements are also less stringent as there is no asymmetry of mass distribution in traverse
or longitudinal planes.
The barrel type outer casing does not cause any problems during over hauls and capital
maintenance as the assembly and disassembly of the turbine can be done in a relatively short
time as compared to the conventional design. The HP turbine is of single flow type with 25
reaction stages.
Inlet Temperature 5400C
Outlet Temperature 3430C
Inlet Pressure 155 Kg/cm2
Outlet Pressure 49 Kg/cm2
Intermediate Pressure (IP) Turbine

The IP turbine is double ow type with a horizontal split, inner casing being kinematically
supported within the outer casing. It has 20 reaction stages. IP inner and outer casings as well
as LP inner casing are suspended from top halves to totally eliminate the effect on TG centre
line with the heating of the anges. Although the casings are of horizontal split design yet
these do not impose any constraints in start-up timings and rapid load uctuations.

Outlet Pressure 7Kg/cm2
Low Pressure (LP) Turbine

LP turbine is also double ow type with exhaust area optimally selected for the expected
vacuum conditions. It has 8 reaction stages per flow. Special design measures have been
adopted to remove the moisture from the last stages by reducing the thickness of water lm on
the guide blades.The axial clearances between the guide blades and the moving blades have
been so chosen so as to reduce the droplet sizes and attendant erosion of leading edges. Low-
pressure extraction has been optimized not only from thermodynamic considerations but to
effectively drain out moisture also. The casing of LP turbine is connected with IP cylinders by
two crosses around pipe, one on either side of the machine and level with the oor. The
horizontally split, fabricated LP casing is comprised of three shells. The bearing pedestals are
mounted on the foundation. Freestanding blades have been envisaged. The blades are
designed to operate in the speed range corresponding to 47.5 Hz to 51.5 Hz grid frequency.
Outlet Pressure 0.85Kg/cm2

Figure 4: View of Internals of a Power Station Steam Turbine

GENERATOR AND ITS AUXILLERIES
Figure 5: Generator in GGSSTP
The Electric Generator is the most important part of the power station. All other units in the
power station are installed to drive the alternator. Generator uses the principle of
electromagnetic induction to generate electric power. In the simplest form, generator consists
of a revolving rotor and fixed stator. The stator carries a three-phase winding, in which
alternating emf is induced when shaft of rotor is moved with the help of prime mover. Rotor
carries field magnet and coils, which provide the magnetic flux of the machine. Current
brought into field circuit by means of two rotor slip rings and set of brushes on them excites
the field. The magnitude of induced emf in winding of stator depends upon the strength of
magnetic field, the speed of rotation and number of stator coils in series.
Salient Features of Generator

The 210 MW turbo generators have been designed with the latest and most effective method
of cooling of the windings, which enables a low value of weight per KW ratio to be achieved.
Its modem excitation and control systems are a great asset to the plant.

Make &Type BHEL & THW-210
Maximum Continuous 247000 KVA
KVA Rating
Maximum Continuous 210000 KW
KW Rating
Rated Terminal Voltage 15750 V
Rated Stator Current 9050 A
Rated Power Factor 0. 85 Lag
Excitation Current at
MCR Condition 2600 A
Excitation Voltage at
MCR Condition310 V
Rated Speed 3000 rpm
Rated Frequency 50 Hz
Efficiency at full load 98. 55%
Short Circuit Ratio 0. 49
Direction from Slip Ring Side Clockwise
Phase Connection Double Star
No. of Terminals Brought Out 9{3Ph & 6N)
No. of coil slots per pole 12
No. of turns per phase 10
Capacitance of 3-Phases 0. 72mf
W. r. t. Earth
Hydrogen Pressure 3. 5 Kg/cm2
Rotor
Material of Shaft (Chromium, Nickel,Vanadium Steeland Molybdenum).

Overall Diameter 6580 mm
Length of rotor 9770 mm
No. of Brushes 112
Generator Cooling
Cooling of rotor Hydrogen (Purity99.95 %)

Cooling of stator D.M. Water
Temperature of Hydrogen44C
Purging of the generator Instrument air, CO2, (in order) H2

Stator Frame
It is totally enclosed in a gas tight fabricated structure made up of high quality mild steel and
austenitic steel. It is suitably ribbed with annular rings called inner walls to ensure are high
rigidity and strength. Size of inner walls is selected on the basis of vibration considerations
resulting partly in greater wall thickness than required from the point of view of mechanical
strength. The natural frequency of stator body is well away from any of the exciting
frequencies. Inner and SideWalls are suitably blanked to house four longitudinal hydrogen
gas coolers inside the stator body.
Terminal Box
The beginnings and the ends of the stator winding are brought out to the slip ring side ofthe
stator body and brought out through 9 terminal bushings in the terminal box. Three phases
and six neutral terminals are brought out from the stator frame through bushings, which are
capable of withstanding high voltage and provided with gas tight joints. The terminal box is a
welded construction of (Non-Magnetic) Austenitic Steel Plates to eliminate Stray losses due
to eddy currents, which causes excessive heating.
Stator core
A rotating magnetic ux threads with the core. In order to minimize the magnetizing and eddy
current losses in this active portion of the stator, the entire core is built up of thin laminations.
For reasons of manufacture, each lamination layer is made up of a number of
individualsegments.
The segments are stamped out with accurately nished die from sheets of cold rolled
highquality silicon steel. Before insulating with varnish each segment is carefully debarred.
The stator body is turned on end while the core is stacked with lamination segments in
individual layers. The segments are assembled in an interleaved manner from layer to layer so
that a monolithic core of high mechanical strength and uniform permeability to magnetic ux
is obtained. The stampings are held in position by twenty core bars having dovetail section.
Insulating paper pressboard are also put between the layers ofstampings to provide additional
insulation and to localize short-circuit, which may occur due to failure of varnish insulation of
sheet stamping.
To ensure tight monolithic core the stampings are hydraulically compressed during the

stacking procedure at different stages when a certain heights of stack are reached forming
different pockets. Between two packets one layer of ventilating segments is provided.
The steel spacers are spot welded on stamping. These spacers form ventilating duets
fromwhere the cold hydrogen from gas coolers enters the core radially inward there-by
takingaway the heat generated due to eddy current losses.
The pressed core is held in pressed condition by means of two massive non-magneticSteel
castings of Press Ring. The Press Rings are bolted to the ends of core bars. Thepressure of
pressing is transmitted to stator core stumpings through press ngers of Non-Magnetic Steel
and Duralium placed adjacent to press rings.
Stator Winding
The stator has a threephase, double layer, short pitch and bar type of winding; havingtwo
parallel paths. Each slot accommodates two bars. The slot lower bars and slot upperbars are
displaced from each other by one winding pitch and connected at their ends so asto formring.
Conductor Construction
Each bar consists of solid as well as hollow conductors with cooling water passingthrough the
latter. Alternate arrangements of hollow and solid conductors ensure anoptimum solution for
increasing current and to reduce losses.
The conductors of small rectangular cross-section are provided with glass lapped
strandinsulation. These are arranged side by side in two layers. A separator insulates
theindividual layers from each other. In the straight slot portion the strands are transposed
by360 degrees to reduce the eddy losses. The transposition provides for a
mutualneutralization of voltages induced in the individual strands due to the slot cross-eld
andend winding eld and ensures that no circulating currents will arise.
The current owing through the conductor is thus uniformly distributed over the entirebar
cross section so that the current dependent losses are reduced. At the crossover pointsputting
insulating strips of thermosetting tape reinforces the insulation. To ensure thatstrands are
rmly bonded together and to give dimensional stability in slot portion, alayer of glass tape is
wrapped over the complete stack. After that the stack is pressed andcured in steam-heated
hydraulic press. Prior to applying the bar insulation, overhangs onboth ends of the bar is
formed as an involute in hydraulic press. Coil plugs for electricaland water connections are
brazed at both the ends.

Bar insulation is done with epoxy mica thermosetting insulation. This insulation is voidfree
and possesses better mechanical properties. Thermosetting epoxy insulation is morereliable
winding insulation, especially for high-voltages. The insulation is appliedcontinuously to the
slot and end turn connections right up to the end connection.
The Rotor Shaft is a long forging measuring about 9 meters in length and one meter
indiameter and on 2/3rd of its circumference the rotor body is provided with longitudinalslots
to accommodate eld winding. High quality heat-treated steel is used whose mainconstituents
are chromium, molybdenum, nickel and vanadium. The shaft and body areforged integral to
each other by drop forging process. Slot pitch is selected in such a waythat the displacement
between two solid poles is 180 degrees. The solid poles areprovided with additional slots in
short lengths of two different conguration, one slot actsas an outlet for the hydrogen, which
cools the overhang and the other is used toaccommodate damper segments acting as damper
windings.
Within the barrel portion therotor slot wedges behave as damper winding bars during
unbalanced operation. In theLongitudinal slots of the rotor the field winding of several coils is
inserted. The coils arewound around the poles so that one north magnetic and one south
magnetic pole areobtained on the shaft.
The conductors are made up of hard drawn silver bearing copper. It has low
electricalresistance and high creep resistance so that the coil deformation due to thermal
cycling atthe start operation is minimized. Layer of glass laminates insulates the individual
turnsfrom each other. This laminate is built by glass strips on the tum of copper and
bakedunder temperature and pressure. Coils are insulated from the rotor body by U-
shapedglass laminate moulded slots troughs made of glass cloth impregnated with epoxy
varnish
The rotor winding is cooled by means of direct cooling method or gap pick- up
method.Hydrogen in the gap is sucked through elliptical holes serving as scoop on the
rotorwedges and is directed to ow along lateral vent ducts on rotor. The gas picked-up by
thewedge scoop in the inlet zones due to pressure created under the scoops by
rotationcorresponding ducts on the other side and ows outwards and thrown into the gap
intothe outlet zones.
Slip Rings and Brush Gear

The Slip rings consist of helical grooved alloy steel rings shrunk on the rotor body Shaft.Both
slip rings are mounted on single bush and are connected to the eld windingthrough a semi
exible copper leads and current carrying bolts. Two semicircular copperbars insulated
from each other and from shaft are placed in a central bore of rotor joiningtwo Sets of current
carrying bolts. The rotor shaft is supported on pedestal type ofhearing. A brush gear provides
Field current to the rotor winding. Brush gear is rigidlyxed on the exciter side. Two brush
gear stands each made of two symmetrical SiliconBrass casting half rings. The brushes are
spring-loaded types to maintain required contactpressure of 0.2 kg/cm2. Brushes have low
coefcient of friction and are self-lubricatingprovided with double exible copper leads.
Before lling brushes are rubbed withmedium and ne sandpaper in the direction of rotation
to obtain equal currentdistribution. Excessive pressure causes chattering and bouncing of
brushes. Insufcientpressure tends to cause sparking.
Bearings
Generator bearings are of pedestal type with spherical seating to allow self-alignment andare
supported on a separate pedestal on slip ring side and in the L-P casting on the turbineside.
The pedestal is massive steel casting providing high rigidity. Bearing bush is also ofsteel lined
with high quality white metal. Oil under pressure is supplied to bearingthrough a diaphragm
that is pre-selected to regulate the ow so as to get temperature risewithin the limit. Oil
catcher and deectors are provided to check the axial leakage of oil.Thrust bearings are
provided to control radial alignment.
Synchronizing Conditions
Phase sequence should be same.
Generator and system voltage should be in phase.
Effective value of voltage should be same.
Frequency should be same.
Generator can be synchronized in auto as well as manual mode.
Unloading and Shutdown
Reduce the load on unit by operating the turbine side controls.Simultaneously, reduce the
reactive load by de-exciting the machine.Open the generator line circuit breaker.
Cut out the auxiliary to manual mode.
Seal oil supply should be kept ON as long as gas is under pressure.
Bearing oil supply should also be kept in operation.

Cooling water to gas cooler may be stopped. For prolonged shutdown dry compressed airis
blown into winding at 850m3/hr. to drain the distillate.
To achieve uniform cooling during shut down, the machine is put on barring speed forsome
time. Even after shut down the rotor is to be turned through 180 periodically toavoid thermal
deection of rotor.
During shut down all excitation should be removed at the time speed reaches 2000 rpm.If not
done temperature of the rotor will increase as ventilation decreases due to decreasein speed.
Generator Auxiliaries
Seal Oil System

Generator shaft seals are supplied with pressurized seal oil to prevent hydrogen escape atthe
shaft. As long as seal oil pressure in an annular gap exceeds the gas pressure insidethe
generator, no hydrogen will escape from the generator housing. The shaft seals aresupplied
with required seal oil from exclusively closed loop oil circuit.
During normal operation AC seal oil pump draws seal oil from oil tank and feeds it to theshaft
seals through coolers and lters. Oil supplied to seals is drained towards the hydrogen and
airside through annular gap between the shaft and the seal ring. The seal oil in seal tank is
kept under vacuum to prevent deterioration of hydrogen purity in thegenerator housing. For
oil circulation, two 100% capacity screw type pumps, one AC driven and other DC motor
driven are provided. Vacuum pump is provided to maintain the specied vacuum inside the
seal tank. On failure ofA.C pump, the standby D.C pumpautomatically takes over the supply.
On failure of both the pumps seal oil is taken over bythe turbine governing oil system.
Stator Water Cooling System

One of the efcient ways of taking away the losses due to heat from the winding of
anymachine is by direct cooling using water. High quality de-mineralized water is
circulatedthrough the hollow conductor of the stator winding. The cooling water must
haveconductivity less than 2.5micro mho/cm.
Static Excitation System (High Frequency AC System)

This system is developed to avoid commutator and brush gear assembly. In this systemthere is
a shaft driven A.C pilot exciter, which has rotating permanent magnetic eld andstationary

armature. DC current is fed to the high frequency exciter through a controlledrectier. High
frequency output is rectied by stationary diodes and is fed via slip ringsto the eld winding.
Static System
In order to maintain system stability, it is necessary to have fast excitation system,
whichmeans that the eld current can be adjusted extremely fast according to the
changingoperating conditions. Because of these reasons, static excitation system is preferred
toconventional excitation systems.
In this system the AC power is tapped off from the generator terminals, stepped
down,rectied by fully controlled thyristor bridges, and then fed to the generator eld
winding.Any deviation in the terminal voltage is sensed by an error detector and causes
thevoltage regulator to advance or retard the ring angle of the thyristors thereby keepingthe
terminal voltage.
Components of the Excitation System

Rectier Transformer
SCR Output Stage
Excitation Startup and Field Discharge Equipment
Control Circuit
Technical Data for Static Excitation system

Excitation Current at No-Load 917A
Excitation Current at Full-Load 2600A
Excitation Voltage at NoLoad 102V
Excitation Voltage at FullLoad 310
DRAFT FANS
When combustion takes place in the furnace, then the draft fans are used. There are threetypes
of drat fans.
1) ID fan induced draft fan
2) FD fan forced drat fun
3) PA fan primary air fan

I.D.FAN (INDUCED DRAFT FAN)
a) FUNCTION
(1) To remove flue gases from the furnace and throw in it atmosphere-
(2) It maintains negative pressure in furnace.
b)SPECIFICATIONS
(I) TypeAN25E6 with an axial non prole bladed fan expeller
(2) No. Of fans 3 per boil (2 running, 1 standby)
(3) Medium handled ve gases at 150C
(4) Fan capacity 230m3/sec
(5) Total head 350mmwc
(6) Fan speed 990 rpm
(7) Motor rating 1300 kw, 6.6 KV, 990 rpm.
(8) Type of fan regulation inlet guide vane control
(9) Type of lubrication -
I) fan bearing grease
II) motor bearing- forced
F.D. FANS
A) FUNCTION
i) To supply air at required pressure to furnace for proper combustion.
ii) To control the quality of air furnace.
B) SPECIFICATION
1) Type - AP-118/11
Where;
AP-I-single stage axial profane bladed fan
18-nominal tip diameter of impeller in decimeter
11- nominal hub diameter of impeller in decimeter
2) No. Of fans: 2 per boiler (both running)

3) Medium handled atmosphere air at normal temperature.
4) Fan capacity 110m3 /sec.
5) Total head developed: 520mmwc
6) Fan speed 1480 rpm
7) Motor rating 750 kw, 6.6 KV, 1480 rpm, squirrel cagemotor.
8) Type of fan regulation Variable pitch fan.
9) Type of lubrication:
(i)Fan forced lubrication oil system
(ii) Motor grease
10) Fan weight 8570 kg
P.A. FAN
A) FUNCTION
1)Pa fan is a part of FD fan system i.e. it also supplies air in the furnace forcombustion air
supplied by PA fan and FD fan combine together to make total airow in furnace.
2)Air supplied by PA fan is used to dry and transport the pulverized coal from coalmill to
furnace and referred to as primary air.

Figure 6: PA Fan Induction Motor
B) SPECIFICATIONS
1)Type NDV 22 tie stuck
Where NDV-radius single own switch
22-nominal tip diameter of impeller in diameter
tie stack- type of diffuser.
2) No. Of fans two per boiler (both running)

3) Medium handled atmospheric air
4) Fan capacity 70m3/sec
5) Total head developed 210 mm wc
6) Fan speed 1435 rpm
7) Motor rating 1250 kw, 6.6 kv, 1435 rpm
8) Type of regulation inlet damper control
9) Type oflubrication
a) Fan bearing -forced hub oil system
b) Motor bearing -grease
10) Type of coupling hydraulic coupling

LTSWITCHGEAR
The 415V LT supply is mostly used to run various LT motors (Wagon Tippler, BeetleCharger,
Scanner Fan, Conveyor Belt, LOP, JOP, Sump Pump, Tippler Trolley and SCRMotor) or
equipment and lighting loads at GGSSTP, Ropar. These supplies are availableat number of
Low-Tension Switchgear situated at different locations depending upon theservice required
for various equipments. There are also 415V LT buses situated atdifferent locations to run
auxiliaries for each unit. The various Low-Tension Switchgearsystems are as follows:
Unit Service Switchgear.

Station Service Switchgear.
Normal cum Emergency Switchgear.
Unit Service Switchgear Buses

In every unit there are two-unit service buses i.e. USSA and USS-B. These 415V unitbuses
are energized independently from two-unit service transformers, each having acapacity of
1600KVA and 6.6 KV/433 V voltage ratio. There is a bus coupler breakerbetween the two
sections. Under the normal conditions, both USSA and USS-B shouldbe independently
charged through USTA and UST-B respectively and bus couplerbreaker should be open. In
case of any one of the UST Incomer Breaker trips, bus couplerautomatically closes down.
Station Service Switchgear Buses

There are two 415V Station Service Switchgear buses, which are energized through
twoStation Transformer (2,000KVA, 6,600/433V). There is a bus coupler 10F between
twoBuses. 11F is the Tie isolator, which is always kept closed. In case any of the
SSSGincomer Breaker trips, bus coupler 10F will close automatically. These feed the
common415V auxiliaries of unit 5 and 6. Under normal conditions both 415V SSSG buses A
andB should be independently charged from SST A and B respectively. Bus coupler 10F
(OnSSSG-A) should be OFF and isolator 11F (On SSSG-B) should be in closed position.
Normal cum Emergency Switchgear Buses

415V Normal cum Emergency buses of one stage (say stage-3) is normally energizedfrom
Emergency Transformer (say 3 & 4). These buses can be alternatively charged fromUSSG

buses 5B or 6B also.In case of 9F i.e. EST-3 Incomer trips, USSG 8F will close automatically.
Give tripcommand to 9F.
However, if 8F trips, 9F will come on Auto-mode. Give trip command to SF.
In case of Grid failure, the emergency bus supply is charged through the DG Set. Thereare
three DG-sets per stage. DG set 7 is for the unit5 and DG sat 9 is for unit-6 and DGset 8 is
standby set and is common to both unit Sand 6.
Under Normal Conditions

NE Bus is charged from EST (Breaker 9F is ON).
Breaker 8F (EM Bus) is OFF.
Breaker 10F (EM Bus) is OFF.
Breaker 6F (DG Bus) is OFF.
Breaker 5F (DG Bus) is OFF.
Breaker 4F (DG Bus) is ON.
Breaker 9F and 7F (DG Bus) is OFF.
In Case of Grid Failure

DG set 7 and 9 start due to under voltage on EM bus.
Check the breaker 8F, 9F and 10F on the EM bus are OFF.
Trip breaker 4F (DG bus).
Close breaker 10F (DG Bus).
In case 5F do not close or DG set 7 does not
To Normalize the EM Bus Supply

When grid supply has been restored and stabilizes, the EM bus should be energized from the
natural source i.e. EST as explained below:
Switch OFF breaker 5F and 6F (DG bus) or 7F (DG bus) as the casemaybe.
Switch OFF breaker 10F (EM bus).
Close 6.6KV breaker of EST-3.
Give trip command to 8F and 9F on EM bus.
Close breaker 9F (EM bus).
In case EST-3 is not available, close breaker 8F (EM bus).
Close breaker 4F (DG set).
Note:
1. When breaker 8For 9F (EM bus) trip on automode, give trip command to thesebreakers.

2. When breaker 8For 9F (EM bus) close on auto-mode, give close command to
thesebreakers.
220V DC Buses
Unit DC buses feed the control and protection system of the unit. DC seal oil pump,
FOP(DC), LOP (DC) and JOP(DC) ofthe are also fed from unit DC buses. Control
andprotection supplies of common auxiliaries and common 415V/6.6KV buses are fed
fromstation DC bus.
Unit DC buses 5 and 6 have been divided into two sections with provision of a buscoupler
within the two sections. One section of unit DC buses is energized from. Thenormal source
i.e. from the respective battery charger while the Second section lsenergized from station DC
bus. Bus-Coupler of unit DC buses is kept open: Normalsources of control and protection
supplies of the unit are fed from rst section of unit DCbuses while the standby sources of
control or protection supplies of unit are fed from thesecond section of the unit DC buses.
Common Switchgear for Two Units of Each Stage

Cooling Water Pump House (CWPH) Switchgear.
Fuel Oil Pump House (FOPH) Switchgear.
DM Plant Switchgear.
Ash Handling Plant Switchgear.
Coal Handling Plant Switchgear.
415V A.C Supply for 220 KV Substation.
220V D.C Unit Board.
220V D.C Station Board.
220V D.C MCC at 220 KV Substation.
HIGH TENSION (HT) SWITCIHGEARS

(6. 6 K V)

The 6.6KV switch gear for stage 1 of GGSSTP Ropar comprise of station board C I Aand C I
B and Unit Boards 1A, 1B and 2A, 2B apart from CWPH, coal handling and coalhandling/
ash handling switch boards. In addition, there are station boards C II A and C IIB. Station
boards C I A & C I B are being fed from 50 MVA, 220/6.6 KV stationtransformer no.1 and
station boards C II A & C II B are fed up from 50 MVA,220/6.6KV station transformer no.2.
There is provision for feeding C 1 A and C 1 B busesfrom C II A and C II B buses
respectively through tiebreakers.
For stage 2, station buses C II A & C II B are fed from station transformer no.3, unitbuses 3A
and 3B are from unit 3, 4A and 4B are from unit 4. When unit is not running,unit buses 3A &
4A are fed from C II A and 3B & 48 from UAT transformer no. 3A &3B respectively and 4A
and 48 from UAT transformer no.4A & 48 respectively.
Stage 3 buses C IV A, C IV B are fed from station Transformer no.4. The buses C IV Aand C
IV B can be fed from station transformer no.2 also. Making an extension bus at CIII A & C III
B bus has made this arrangement. The 6.6 KV system has following feedingtransformer and
buses:
Feeding Transformers
Electrostatic Precipitator Transformer.
Ash handling Transformer.
CWP Transformer.
Unit Service Transformer.
Station Service Transformer.
Buses
Station Bus
The sources of rst 6.6 KV supply is from station transformer, which is 50 MVA,220/66 KV,
step down transformer. And takes power from 220 KV grid and feed it tostation bus of
respective stage. There are two buses per station transformer. There is onestation transformer
for each stage and the station transformer no.2 is standby for all thethree stages.
When the fault occurs in any one of the three transformers, supply is taken from thestation
transformer no.2 through the tiebreakers.
At Stage-I, Cooling Water Pump House, Coal Handling Plant, Coal Handling cum
AshHandling Bus section are fed from the station bus.

At Stage-II, Fuel Oil Pump House Transformer and Water Treatment Plant Transformerare
also fed from station bus along with CWPH, CHP and CHP/AHP bus section.
At Stage-III, ESP transformer is also fed from the station bus. Station service
transformer,which is 2 MVA, 6.6 KW 415V step down transformer is used to supply low
tensionpower to MCC, and lighting system of the plant is fed from station bus.
Unit Bus
The second source from which the 6.6 KV supply is taken is the Unit AuxiliaryTransformer
which is 15 MVA, 15.75 KV/6.6 KV step down transformer, which takespower from its
respective generator. There are two UAT per unit. Unit buses are fed fromthese UATs through
tiebreakers. The main load on the unit bus is the motors of the boilerfeed pump, condensate
extraction pumps, induced draft fans, forced draft fans, primaryair fans, bowl mills etc.
There is an interconnection between the unit bus and the station bus through thetiebreakers
and isolators. When unit is not running or the UAT is faulty, this breakerautomatically closes
and the breaker between the unit bus and the station bus openautomatically. In case the UAT
is faulty, the unit bus is changed over to the station bus inthe auto mode.
The load fed by HT buses (6.6KV) are as follows:
Primary Air Fan.
Induced Draft fan.
Forced Draft fan.
Coal Mills.
Boiler Feed Pumps.
Condensate Extraction Pump.
Electrostatic Precipitator Transformer.
Cooling Water Pump.
Conveyor Belts (6.6KV only).
Crushers.
Unit Service Transformer.
Station Service Transformer.
The arrangement of station and unit buses of Stage 2 & 3 is same as in the stage 1. Butthe
additional load of BCW system has come up. The load of CWP and BCW has beendivided on
the station and unit buses.
Circuit Breakers used in HT Switchgear (6.6KV)

Basically two types of circuit breaker used for the protection of HT buses are:
Vacuum Circuit Breaker
Minimum Oil Circuit Breaker.

Vacuum Circuit Breaker
Vacuum circuit breaker installed at High-Tension (HT) Switchgear section is 3-, IndoorType,
Single Break and Motor Operated Closing and Opening type.
Specifications
Make ABB
MVA Rating 150MVA
Voltage 6.6KV
Breaking voltage capacity7.6KV
Current 1200A
Rated Frequency 50-60 Cycles/Sec
Minimum Oil Circuit Breaker

Minimum oil circuit breaker installed at High-Tension (HT) section is 341), Indoor MetalClad
Draw Out Type and Motor Operated Closing and Opening type.
Specifications
MakeJoyti Ltd.
MVA Rating 145MVA
Voltage 6.6KV
Breaking voltage capacity 7.2KV
Current 1250A
Rated Frequency 50-60 Cycles/Sec.
TRANSFORMER YARD
Transformer yard is the area where different kinds of transformers have been installedwith
different functioning. Here 15.75kv generated by the generator is stepped-up to220kv for the
primary transmission, with the help of generator transformer(GT).With thehelp of unit
auxiliary transformers (UAT)the 15.75kv is steppeddown to the 6.6kv forproviding supplies
to the different unit auxiliaries. Station transformed (ST) have beeninstalled, which step down
the 220/6.6 KV is used to charge the station buses in the HTswitchgears.Unit service
transformers(UST) have been installed to step down the 6.6kvto 415v for the It auxiliaries,
like this station service transformers(SST) have beeninstalled to charge 415 volt buses for It
auxiliaries. Moreover, neutral groundingtransformers (NGT) are also there for grounding the
neutrals of the star side of thegenerator transformer, station transformer etc.

A special earthing scheme has been adopted for the whole yard, moreover the panels ofthe
transformers are also there to keep a watch on the parameters of the transformersalong with
the protections.
INTRODUCTION TO TRANSFORMER
Transformer is a device, or a machine that is used to step up or down the input voltageusing
electro -magnetic induction without change in supply frequency. It consists ofprimary
winding and secondary winding. Primary winding is used as an input power totransformer
while secondary winding acts as output terminal. The step up and step downtransformer are
categorized on the basis of the turns on primary and secondary side. Ifprimary winding is
having more turns than secondary winding than it is called step downtransformer and step up
in opposite case.Actually, the transformer is an electromagnetic energy conversion device,
since theenergy received by the primary is rst converted to magnetic energy and it is
thenreconverted to useful electrical energy in the other circuit (secondary winding circuitthird
winding circuit etc.) Thus primary and secondary windings of a transformer are notconnected
electrically, but are coupled magnetically. This coupling magnetic eld allowsthe transfer of
energy in either direction, from high voltage circuits. If the transfer ofenergy occurs at the
same voltage, the purpose of the transformer is merely to isolate thetwo electric circuits and
this use is very rare in power application

Figure 7: Part Cross Section of a Transformer
PRINCIPLE OF WORKING
A transformer works on the principle of electromagnetic induction. According to thisprinciple,
an e.m.f. is induced in a coil if it links a changing flux. In a transformer electrical
energytransfers from one circuit to another circuit talus place without the use of moving part
It has therefore, thehighest possible efficiency out ofall the electrical machines and requires
almost negligible amount ofmaintenance.
In core-type transformer, half of the l.v. (and h.v.) winding is on one limb and the otherhalf is
on the second limb. In shell-type transformer, the LV. and h.v. windings aresandwiched.
TYPE OF TRANSFORMERS
There are six types ofTransformers: -
l. Generator transformer (l for each unit).
2. Unit auxiliary transformer
3. Station transformer (1 for two units).
4. Unit service transformer
5. Service station transformer

6. Neutral grounding transformer
ST (STATION TRANSFORMER) 220/6.6KV

It is connected to grid. It is step down transformer which step downs 220 KV of grid to6.6kv,
which is given to SST.
SST (STATION SERVICE TRANSFORMER) 6.6/.433 KV
It is a step down transformer which is energized from grid supply and feeds the 215V Station
bus.
UST (UNIT SERVICE TRANSFORMER) 6.6/.433 KV
It is also step down transformer which is energized from unit supply throughUAT.
EST (EMERGENCY SERVICE TRANSFORMER) 6.6/.415 KV
This transformer feeds emergency bus through ST and it is a stepdown transformer.
UAT (UNIT AUXILIARY TRANSFORMER)15.75/6.6 KV
This transformer step downs the generated 15.75 kV of each unit and feeds UST.
STATION TRANSFORMER
When unit is not operational then, unit buses can be fed from station transformer
busesthrough the breakers and on synchronization of unit, unit board can be fed from
15mva,15.75kv/6.6kv unit auxiliary transformer. On tripping of unit. supply of respective
unitbuses, is automatically switched over to station buses, coal handling and ash handling
bussections.
SPECIFICATIONS
Made AEG ELEFUNKEN
Type of cooling ONAF/ONAN
Rated (volts) HV50000 40000
LV131500 26000
LV231500 26000
Rated current HV13.2 105
LV1 2636 21755
LV2 2636 2175.5
Frequency 50 Hz

Top oil temperature rise 45c
Winding temperature rise 50c
Figure 8: Station Transformer in GGSSTP
Input to station transformer is fed from 220kv switchyard. There are two outputs of station
transformer each of 6.6kv. Normally for load beyond 45mw station transformers feeds the
auxiliaries. Above transferred to the UAT and a few one remains operating on station
transformer.
Cooling system for station transformer is oil natural air forced at 50 kva and oil natural air
natural (onan) at 40 kva and below. Oil cooling is done with the help of oil radiators an oil
pumps. Forced air cooling is done by providing the air fans on the radiators fms. There are
two sections of air fans each having 6 fans. For protection of system there are lightning
arresters at the input as well as outputs of the transformer. A lightning arrester is connected
between the phase and ground near the transformer to protect its insulation from lightning
surges and switching surges. Lightning arrester discharges the current

GENERATOR TRANSFORMER
Input bus-bars to generator transformer are laid through insulating ducts. These ducts are
made up of aluminum and have diameter of 1000 mm. Conductors are placed in these ducts
with the help of space insulators. There are 48 support insulators per conductor. Ducts are
filled with instrument air at a very low pressure of about 50 mm to 250 mm of water column.
Ducts are lled with instrument air to avoid moisture.
Figure 9: Generator Transformer at GGSSTP
SPECIFICATIONS
Type of cooling ONAN ONAF OFAF

Rating hv and lv (MVA) 125 180 250
Rating 1v (MVA) 125 180 250
No load voltage hv 230 KV
lv 15.75 KV
Line current at
lv (amp) 313.79 451.86 627.57

Temperature rise of oil (c) 45 45 45
Phase 3
Frequency 50 Hz
UNIT AUXILIARY TRANSFORMER

Input for l5MVA, 15.75kv/6.6kv unit auxiliary transformer is taken from the input busbar of
the generator transformer. There are two unit auxiliary transformers for eachgenerating
transformer. When the load increases above 45 MW unit auxiliary transformertakes the load
from the station transformer. Output of the unit auxiliary transformer is fedto drive boiler feed
pump. Forced draught fan, induced draught fan, mill drive,electrostatic precipitator other
equipments installed in the thermal plant. Cooling used forunit auxiliary transformer is oil
natural air natural. Local control panel is installed nearthe unit auxiliary. Both manual as well
as remote control from ucb is possible. There aretwo temperature gauges that measure the
winding and oil temperature. On load tapchanger is provided for the control of output voltage.
Tap changer has 17 taps. Hencevoltage control up to 17 different voltages is possible.
Installation of on load tap changeris possible because output current is small. Hence danger of
sparking is not there.
Specications of unit auxiliary transformer
Make EMCO LTD. TRANSFORMER,
KVA1500
No load voltage (KV) HV 15750
LV 6900
Amperes(A) HV 549.9
LV 1255.15
Phases HV 3
LV 3
Maximum temperature
Rise in oil 45C
Maximum temperature
Rise in winding50C
Type of cooling ONAN
Frequency 50HZ
Total weight (in kg) 29472kg.

THE MAIN COMPONENTS INSTALLED AT G.T.
i. Transformer core
ii. Transformer oil
iii. Conservator tank
iv. Pressure relief valve
v. Bushing
vi. Buchholzs relay
vii. Radiator
viii. Oil pumps
ix. Cooling fans
x. Tap changer
xi. Dehydrating breather
xii. Control panel
TRANSFORMER CORE
The core of the transformer is made up of magnetic material made from cold rolled
grainoriented sheet steel to reduce losses. Lower voltage winding is placed near the core
andafter placing the insulation higher voltage winding is placed. This is done to minimize
theinsulation requirements
TRANSFORMER OIL
For high voltage transformers lapthanic base oil is used and for low voltagetransformer
parafnic base oil is used. Cost of lapthanic base oil is near to Rs. 30 perliter and for
lapthanic base oil it is around Rs. 25-26 per liter
Specications:
1. Break down voltage in KV: approximately 240 KV.
2. Resistivity: - the required value is around 0.1 x 102 Q cm.
3. Dissipation factor: - it is higher above 145 KV and has lower value below 145 kv.
4. Flash point: - as per pseb instructions, it should be above 140C.
5. Foam point: ~ as per pseb instructions, it is around 30C.

CONSERVATOR TANK
The purpose of conservator tank is to maintain a proper level of oil in the
transformerwinding.Conservator is used on transformer for providing adequate space for
expansion of oilwhen t/f is loaded or when ambient temperature changes substantially. It
alsoconserves the insulating property of oil from deterioration and protects the t /f
againstfailure on account of bad quality of oil.Conservator mainly consists of a cylinder
closed from both ends by flat plates to form acontainer. Large conservator is provided with
detachable end plate on one side tofacilitate cleaning and maintenance.
Breather xing pipe enters the conservator cylinder from bottom and is extended up to thetop.
This arrangement ensures that oil does not enter the breather even at highestoperating level.
Even the lowest oil level in conservator ensures that all live pans insidethe transformer are
always immersed under oil and that the oil is there in buchholz relay. Oil level indicator is
marked with minimum and lling level ofoil at 35 degreesCelsius.When the ambient
temperature around the transformer rises or when the transformer isloaded, the oil inside the
transformer expands towards the conservator pushing awaycorresponding quantity of air
through breather. Similarly, when ambient temperaturelowers or when load on transformer is
reduced or switched off, oil in the tank contracts.The oil in conservator ows towards the tank
and outside air is then breathed in throughthe breather, to take place of oil going in the tank.
PRESSURE RELIEF VALVE

Pressure relief valve is mounted on top of transformer tank. It releases gas or thetransformer
oil pressure to atmosphere during large duration overloads and faults or anyash inside the
tank. PRV has a diaphragm which can bear up to certain pressure of 5kg/sq.cm, if pressure
rises above the set value then it releases the over pressure into theatmosphere.
BUSHING
Bushings are placed on the outer side of the transformer for bringing out the conductingwires
from the winding. These are required as they help to maintain an insulation levelbetween
conductor and transformer body. The conducting wires from the bushing comeoutside for
further connections.
BUCHHOLZ RELAY

Buchholz relay is a very sensitive, gas and oil operated instrument which detectsformation of
gas or development of sudden pressure inside the oil tilled transformer. It isconnected to
protection circuits to give an early audible alarm incuse of gas collectionand to disconnect the
transformer from supply incase of severe fault inside thetransformer.
The basic function of the relay is to initiate an electrical signal in the protection circuit when:
Air or gas is accumulated in the relay.
Surge of oil is developed on account of sudden increase in pressure inside
thetransformer due to severe fault.
Oil level is reduced below the minimum oil level in the conservator.
The initiation takes place by operation of the contacts in the relay in the followingmanner:-
1.UPPER FLOAT BUCKET

When oil level inside the relay drops, the oat bucket also moves down. This tilts themercury
switch which actuates the alarm contacts. The contacts are normally open typewhich close
when the oat bucket drops. Probable reasons for dropping of the Oil levelin the relay could
be:
Leakages of oil from main tank, conservator or from relay itself.
Collection of air in the relay which is trapped earlier in the tank and windings or
otherplaces inside the tank.
Collection of the gas in the relay, generated inside the transformer on account offailure
of electrical insulation.
2.LOWER FLOAT BUCKET

The lower oat bucket operates similarly to upper oat bucket when level in the relaydrops
further. However, important function of this oat bucket is to disconnecttransformer from
circuit under sudden development of pressure inside the transformer. Insuch cases, oil from
transformer is suddenly pushed towards conservator. The impact ofthis oil tilts the lower oat
bucket with mercury switch which then actuates the other pairof contacts from no to no
position momentarily.
Upper oat bucket contacts are usually connected to audible alarm circuit and loweroat
bucket contacts are connected to trip circuit.
RADIATORS

Transformers are provided with pressed sheet radiators depending upon the coolingcapacity.
Large transformers are provided with detachable radiators with radiator valves.After lling
the oil in radiators and venting air from them, radiator valves at top andbottom must be kept
in open position.
The radiator sections are made of 1mm thick cold rolled carbon steel sheets. The
distancebetween each section is 50mm. The number of sections per radiator and the number
ofradiators per transformer will depend upon the cooling requirements of that
transformer.When transformer is in operation, warm oil rises and enters the radiators from the
topvalve cools and then descends to enter the bottom of the tank through the bottom
radiatorValve. This cycle is continuously repeated. Cooling is sometimes assisted by blast of
airprovided by fans.
OIL PUMPS
There are four oil pumps two of out of them are in running position two are on standby.Oil
pumps are used for circulating the oil from the transformer to radiator ns. Sinceduring the
operation the oil in use is very much heated up so it is very important tocirculate this oil and
cool it down. For generating transformer forced oil and forced aircooling is used.
COOLING FANS
The fans are intended for blowing air vertically upwards on the bank of radiators toincrease
the rate of cooling in radiators. The fan consists of a cylindrical sheet steelcasing to which
inter rotor motor is attached. There are total 22 cooling fans. These aredivided in two groups
of a, b and c, d each having 11 cooling fans. Generator transformercan work on 125 KV load
radiators without fans and oil. It can work on 175 KV load withcooling fans. It can work on
220 KV load with cooling fans and radiators.
TAP CHANGERS
The transformer output voltage and hence providing taps either on primary side or
onsecondary side can control the consumer terminal voltage. In transformer at
generatingstation, primary voltage can be kept constant, consequently the taps should be
providedon secondary side. If the transformer is energized at from a variable volt -age source,
asat the receiving end of transmission line, the taps should be provided on primary side.

Tap changers are of two types:
I. On load tap changers (ONLTC)
2. Off load tap changers (OFLTC)
If the tap changer is designed to operate with the transformer out of circuit it is called offload
tap changer. A tap changer designed to operate with the transformer in the circuit iscalled on
load tap changers.On load tap changers is used for short period voltage variations. On load tap
changers arealways installed on high voltage side. Because on high voltage size of wires is
small andcurrent is lesser. Thus danger of sparking is lesser. Hence smooth control is possible.
Ongenerator transformer only off load tap changer (OFLTC) is installed. In UAT
(unitauxiliary transformer), ST (station transformer) there is on load tap changers.
DEHYDRATING BREATHERS
It gives back up protection to buchholz relay. The dehydrating breather removespractically all
moisture from the air, which ows through it into the conservator, whentransformer is
cooling. This has the effect of largely preventing any reduction ofdielectric strength of the
insulation due to moist ambient air and any formation ofcondensation in the conservator. Thus
the dehydrating breather increases the operationalintegrity of the transformer.
There are two types of dehydrations: -
l. Nitrogen gas is lled with cylinders in conservator tank to avoid moisture.
2. In this case silica gel breather passes air, which goes to conservator, passedthrough the
breather containing silica gel.
As silica gel goes on consuming its color goes on changing from blue to red.Dehydrating
breather operates on the pressure of 0.42kg and is of diaphragmconstruction.
Apart from these above-mentioned protections, there are other protections also likedifferential
protection, over current protection, over temperature protection and lightningarresters etc.
CONTACT RATING FOR MERCURY CONTACTS

The two pairs of contacts provided by the mercury switches will make break and
carrycontinuously for 0.5 second 10 amps at 250 volts A.C. or D.C.
EMULSIFIER SYSTEM FOR FIRE

Dry air emulsier system is installed here. Air pressure of 7.5 kg/cm2 is maintained in
thepipes having one end connected to mercury valves. Deluge valve supplies second
side.When temperature of mercury valves reaches a preset value then, pressure of air
reducesand deluge valve Operates and giving air water emulsication spray on the
transformer toprevent the temperature rise and further any further destruction.
COOLING SYSTEM OF A TRANSFORMER

During operation of transformer, the temperature of oil and the winding in the transformer
increases w.r.t. load current. For proper operation, temperature oftransformer oil and winding
must be kept within limit i.e. below 80C and 90Crespectively. In transformer there are three
types of cooling systems:
Oil Natural Air Natural (ONAN) In this type of cooling systems, oil aswell as air ows
naturally.
Oil Natural Air Forced (ON AF) When loud on the transformer is between125 MVA to 180
MVA this type of cooling is provided. As natural air is not soefcient to cool down the oil and
bring it to safe limits. So air is forced on theradiating ns with the help of fans installed below
the radiator ns.
Oil Forced Air Forced (OFAF) With further increase in load, more heat is generated,which
necessitates forced cooling of oil. This is achieved by energizing the pumps placedat the
bottom near the main tank. These pumps force the oil to ow frequently throughthe radiating
ns for cooling of the transformer.

220KV GRID
When electricity is produced in Thermal plant it cannot be stored; it is consumed bypassing to

various substations. In grid structure, only transmission of electricity is carried and not the
distribution.
BUS SYSTEM
Conductors to which a number of circuits are connected are called bus bar. Buses are provided
for the transmission of electricity from supply to various sub-stations.
There are two type of bus bar arrangement:

1. Main bus with three sections and bus coupler.
2. Reserve bus.
Reserve bus is kept for emergency, like if main bus stops working due to some fault. This part
is made free and making operational the reserve bus carries out transmission of electricity.
BUS COUPLER -I can be used as G.T. breaker for units 1, II, III.
BUS COUPLER -II can be used as G.T. breaker for units IV, V,VI.
Figure 10: Bus Bar System in Substation at GGSSTP

Materials of Busbar
Tarantula aluminum conductor is used because of its low cost, low resistivity and good
mechanical properties. Its capacity is 1800 amperes.
Bus coupler 1 can be used as (ET-breaker for unit i, ii and iii.
Bus coupler H 2 can be used GT breaker for unit iv, v and vi.
But only one bus coupler can be used as GT. breaker at a time.
Circuit Breakers
Circuit Breakers are the switches used to break the electrical circuits Onload by manual
for automatic operation. They differ from conventional switches in the manner that circuit
breakers are very sophisticated switches, which can limit the fault current and are generally
used for high voltage and high current operations.
We have 2 type of Circuit Breakers at Switchyard:
1. ABCB (air blast circuit breaker, for unit 1 &2)
2. SF6(sulphur hexaouride breaker, for unit 3, 4, 5, 6)
ABCB
It is an air blast circuit breaker, here closing, tripping and quenching is done withthe help of
air. When contacts are separated arc is struck, simultaneously the blast valve is opened The
blast cools the arc and sweeps away the ionized medium between the contacts. Thus the arc is
extinguished and current is interrupted.
At l5kgf/cm2 -breakers automatically gets closed which is quite dangerous.
Made Hindustan brown Boveri

Volts 245 kv
Current 2000 amp
Mass 1630 kg
Short time current 3l.5 kA, 3 see.
Trip coil volts 220 v dc
Operating pressure 27-31 kg/cm2

Figure 11: Air Blast Circuit Breaker
SF6 BREAKER
In this case closing is done with the help of a spring. Tripping is done with the help of air,
quenching is done by SF6 gas. Under normal conditions the moving contact is connected with
the xed contact. The movable cylinder is coupled with the moving contact. When the moving
contact is separated from the xed contact the arc comes into play but due tocompressed
sulphur hexauoride, this arc gets extinguished. To avoid the condition of closing of two
breakers, two isolators are automatically opened
13 kgf/cm2 - cut of pressure

Gas pressure 6kgf/cm2
SF6 Circuit Breakers:-

Made Crompton greaves ltd.
Rated volts 245 IN
Rated frequency 50 Hz
Rated lightning impulse
with stand voltage 1050 kV
Rated short circuit breaking
Current 40 kA
Rated operated pressure 15 kg/ cm2
Total weight 3800 kg

Figure 12: SF6 Circuit Breaker
ISOLATORS
Isolators are used for making and breaking the contact but this can be done without load. It is
just like a switch, when main contact is made b/w springs an arc is produced. In isolators,
parallel operation is possible. Never on or closes the isolators while on load. There are four
jaws, two for input supply and two for output supply, i.e. supplying cables containers under
pole parts contain transfer oil. The current capacity of isolator is 1200 amp and they are of
double break type. A d.c. motor working on 110v carries out their operation. They can be
operated from local as well as from remote control.
Isolators are of two types:
a. Off load isolators.
b. On load isolators.
Earthing switches are mounted on isolating switches base on line side. Earth usually
compromises a vertical break switch arm with contact at extremity which engages with
isolator contact on line side.
Make Switchgear Manufacturing Co. Ltd.

Type DBR Voltage 220 KV
Current 1600-2000 Amps.
Control Voltage 220V D.C.

Figure 13: Isolators
C.T. AND P.T.

CT& PT are is used for the purpose of measurement and protection. Current transformer has
all the protective relays in a.c. power systems in their secondary circuit.
CURRENT TRANSFORMER (CT)
Highest system voltage 245kV

Frequency 50hz
Rated primary current 1000amp
Adopted ratio 800/1amp
CT has ve secondary cores which are used for different purposes such as, formeasurement of
current, for protection etc. CT is connected in series before load in any of the three phases

Figure 14: Current Transformer
POTENTIAL TRANSFORMER
Made Nagpur transformers ltd.
Insulation level 460/1050 kv
No. of Phases 1
Frequency 50 hz
Highest system voltage 245 kv
Voltage factor 1.5 for 203cc
Neutral earthed
Adopted ratio 220 kv/l10 v
PT is always connected in parallel between any two phases but here in the switch yard
only one phase is connected to PT and other terminal of PT is connected to earth.
Figure 15: Potential Transformer

LIGHTENING ARRESTERS
For the safety of electrical equipment, from the lightening and over voltage surges
lightening arresters are used. For each phase of line separate lightning arresters are
installed.
Type Thyrite alugard station class

Rated arrestor voltage 198kv
Rated frequency 50hz
Nominal discharge current 10ka
High current duration 100kA
Figure 16: Lightning Arrestor
CAPACITOR VOLTAGE TRANSFORMER

This equipment is installed near the line trap in the switchyard. The capacitor voltage
transformer is installed for telemetry and voltage measurement and protection. As far as outer
shape is concerned it looks similar to the lightening arrester.
LINE TRAP UNIT

Line trap units are hanging in air from the lines and towers and they look like cylinders. These
are installed between bus bar and connections of CVT to line. It is made up combination of
capacitor and inductor. It offers low impedance (0.1 ohm) to power frequency (50hz) and high
impedance to carrier frequencies (35khz to 500khz). This unit prevents the high frequency
communication signals from entering the consumer side. The communication signals are used

to communicate between different sub stations situated at different places.
Figure 17: Line Traps
POWER LINE CARRIER COMMUNICATION SYSTEM

The power system of an organization like PSEB comprising power houses, ht lines and
substations is so complex and extensive that to control the same, an equally large and
complex telecommunication system of high reliability is required. For PSEB its own power
line carrier channels provide the telecommunication system about 300 power houses and 200
kv, 132 kv, 66 kv substations are served by the PLC system.
A PLC channel consists of two PLC terminals at two stations A & B. PLC terminals use
amplitude modulation with single side band (ssb) transmit ion if f 1, 12 are high frequency
carrier frequencies used by one plc terminal for transmitting/receiving carrier signals then
f2/f1 are used by the opposite end plc terminals for transmitting/receiving the same. The f1/f2
lies between 30 khz to 500 khz.
The system uses wave traps, one coupling device, power supply unit and switching equipment
at both the transmitting and receiving ends. Wave trap blocks the carrier frequency signals and
sends them to power supply unit through coupling device the capacitor allows the high
frequency carrier signals to pass through it.
From power supply unit the signal is transferred to PLC terminal. PLC terminal is just a
cabinet which comprises of a number of electronic circuits. This is the place where the speech
signal is modulated with carrier frequency or vice versa. After that the signal is fed to the
switching equipment where it is used for any one operation such as tele-metering, tele-
printing, tele-control or tele-voice etc.
BATTERY ROOM

For control of isolators and other equipments 220 volts d.c. supply is needed. During the grid
failure or during the emergency shut down, there is a battery room that can supply 40 amp. At
220volts continuously for 10 hours.
There are two groups of batteries: -
Source-1 and Source-2
Each source has 108 numbers of battery cells.
COMPRESSOR ROOM
Compressors are installed in the compressor room in the substation. The function ofthese
compressors is to supply pressurized air for the circuit breakers. There are fourcompressors
out of which three works at a time and one is on standby. The compressorsare capable of
generating the air pressure of 60 kg. This compressed air is then passedthrough silicon valve
and lters to remove any moisture contents. After that air pressureis reduced to 31 kg., which
is suitable for the operations of circuit breakers.
CONTROL ROOM
All the apparatus installed at the substation can be controlled in two ways; one ismanually at
local and second is by automatic at remote control. Control room consists ofvarious control
panels including metering equipments, relays and protection equipments.
All the activities of substation can be monitored by the control room and can becontrolled by
using it.
All the controls installed in substation are 220 volts D.C. operated. The control panel
alsoshows Visually the operation of various circuit breakers. All the relays and
protectionsystems are installed on the secondary side of the current transformer and
potentialtransformer. All the cables laid to the control room are underground and are
passedthrough concrete ducts. The network of grounding wires to protect the bus bars, lines
andother installed equipments from lightening hazards, surrounds the entire substation.
SWITCH YARD PROTECTION

EARTH SHIELDING: It is a mesh of wire on the tower. Its main purpose is to protectthe
substation equipment from direct lightening strokes. Metallic body of all theequipments is
properly earthed, the earthing resistance is 0.2 ohm. To decrease theearthing resistance,
earthing electrodes are provided at various points.
FEEDER PROTECTION:
Overcurrent protection
Earth fault protection
Distance protection
Differential protection
Carrier current protection
PROTECTION& PROTECTION SYSTEM

PURPOSE OF PROTECTIVE RELAYS
The capital investment involved in a power system for the generators, transformers
anddistribution of electrical power is so great that the proper precautions must be taken
toensure that equipment not only operates as nearly as possible to peak efciency but alsothat
is protected from accidents, due to insulation failure, short circuit, equipment failureetc.
The purpose of protective relays and relaying system is to operate the correct
circuitbreakers,so as to disconnect minimizing the trouble and damage caused by faults
whenthey do occur it would be ideal if protection could anticipate and prevents faults, butthis
is obviously impossible except where original cause of faults creates some effect,which can
operate a protective relay. Otherwise it is only possible to mitigate the effect ofshort circuit by
disconnecting the equipment as quickly as possible, so that the destructiveeffect of the energy
into the fault may be minimized. Keeping above facts in viewfollowing electrical protection
have been provided for different types of faults atG.G.S.S.T.P.Ropar.
CLASSIFICATION OF ELECTRICAL PROTECTION

The electrical protection is classied into three categories
1. CLASS A PROTECTION - The relays included in class A protection willextend tripping

to master trip relay 8601 and 86 02, which will further performthe following function.
a. Generator breaker trip.
b. Field breaker trip.
c. Turbine trip.
d. UAT change over.
e. Start the LLB protection.
2. CLASS B PROTECTION-The relays included in class B protection will extendtripping to

master trip relay 86T4, which will further perform the followingfunction:
(a) Turbine trip (b) UAT change over
After tripping of turbine the forward power ow will become zero, since the generator isstill
connected with system, it will draw power from the system; when reverse powerows (the
power ow towards generator) becomes more than 1 MW, then after twoseconds the reverse

power relay will extend tripping to master trip relay, 86 GB, whichwill perform the following
function: -
It will open the generator breaker. The unit will run on house load.
MOTOR PROTECTION
All motors whether L.T to be protected against various abnormal conditions mentionedbelow:
a) Over load or over current
b) Short circuit or insulation failure
c) Earth fault
d) Over voltage
e) Low voltage
f) Single phasing.
Several protective relays are provided. The relays sense the abnormal conditions & closethe
trip circuit of motor circuit breaker. Thus, the breaker trips to isolate the motor from A.C.
supply.
PROTECTION OF L.T MOTORS < 100 KW RATING

In this plant, generally these motors are provided with following protections/relays
Thermal overload relay- for protecting over loading of motors.
Single phasing protector for isolating the motor when single phasesupply is fed to
motor.
HRC fuses for protection of motor against short circuit etc.
PROTECTION OF LT MOTOR-l00KW RATING

In addition to above protections, following relays are provided:
a) Instantaneous over current
b) Locked rotor.
These relays cause only opening & closing of breaker during development of above
conditions. Brief description as follows:
THERMAL OVERLOAD RELAYS PRINCIPLE

The essential element in thermal relay is a bi-metal strip which is heated directly orindirectly
by the lead current. The bi-metal strip bends when current through it exceedsthe set value,

resulting in Operation of relay. Time delay is adjustable by a tension spring.The relay recloses
when the element cools down.
SHORT CIRCUIT PROTECTION (L. T MOTORS)

When the short circuit takes place, the fuses get blown. In all the above cases, theoperator
before giving next starting command must get clearance from protection &motors MTC cells.
In variably, it has been seen that the operators go to on giving starting commands to LTmotors
without knowing the cause of tripping and resetting of the relays, regarding thestarting
commands to motors, the instructions given in following paragraphs should befollowed:
MOTORS IN COLD CONDITION

Two starts in succession with coasting to rest between starts & minimum intervals of
5minutes between two starts 8, motor initially at ambient temperature.
MOTORS IN HOT CONDITION

1. One start with motor initially at a temperature not exceeding the rated load
Operatingtemperature i.e. in hot condition.
2. Three equally spread starts in an hour. The motor initially at a temperature notexceeding the
rated load operating temp.
Repeated starting commands overheat the motor due to high magnitude of startingcurrent.
Motor can get damaged & loss occurred to, thus in lacs of rupees.
DIFFERENTIAL PROTECTION
This is an additional protection provided in case of H.T motors above 1000 kw rating. Atthe
plant, ID, PA and BFP motors have been provided with this protection.The differential relay
operation responds to the vector difference between currententering the stator winding and
current leaving the stator winding of motor.
The C.Ts are connected in star in both sides of the stator winding of motor. Duringnormal
condition and external fault the protection system is balanced and C.Ts ratios ofboth sides
match each other so that secondary currents are equal, and relay does notoperate.

When fault occurs in the protected zone, C.T secondary currents do not remain matched.The
differential current ows through the relay operating coil and the relay operates, and tripsthe
breaker.
On receiving such fault message, the meggaring is required to be done by opening thestar
connections on motor end, with 2.5 KV motorized meggar.
1. Phase to phase ir valves is taken.
2. Phase to earth ir valves is taken.
3. Winding resistance with due to micro, motor is taken, of allthe three phases.
4. Also cable is meggared from switchgear end after isolating the motor, to detectany shorting
of phases, or leakage of current or unbalance current.
UNDER VOLTAGE PROTECTION

All H.T & L.T buses are provided with under voltage protection. Under voltage relay is set at
about 70 -75 % with a time lag of 2-3 seconds so that any momentary voltage dipmay not trip
the buses. In other way, all motors connected on bus get disconnected and under voltage
supply is not fed to the motor.
MOTOR BEARING TEMPERATURE & WINDING TEMPERATURE PROTECTION

Apart from the above protections of the motor, driving end and non-driving end
bearingtemperature gauges are provided on the motor to know the temperature use of
bearings.On these temperature gauges, alarm & trip setting of the temperature are made to
protectthe motor against abnormal temperature rise & to take remedial measures on
indicationsof alarm annunciation. Similarly, winding temperatures are monitored through
RTDswhich senses the temperature in switchgear panel.

Electrostatic Precipitator
Figure 18: Electrostatic Precipitator at GGSSTP
Electrostatic precipitator (ESP) is that unit of ash handling plant that collects the ash with
the help of electric eld, using electrodes.
SPECIFICATIONS
Incoming Supply 415 +-10%,1 phase, 50Hz +-5%

Current Drawn from Supply 167 amps A.C. for 800mA D.C.
I/p Voltage to primary of HVR after A.C. 0 to 373.5 volts A.C.
reactor
Output voltage to Thyristor 0-415V R.M.S
Continuously Adjustable
Dc Output to HVR 0-70KV(Peak)
Form Factor 1.4(max)
Max Arcing Current 3 amp(Peak)
Operating Temperature -5 to 50 degree Celsius
Table 1: Specifications of ESP

ESP Analysis
BASIC THEORY
An ESP controls particulate emissions by: (1) charging the particles, (2) applying an electric
field to move the particles out of the gas stream, then (3) removing the collected dust.
Particles are charged by gas ions that are formed by corona discharge from the electrodes. The
ions become attached to the particles, thus providing the charge.
Figure 19:Tubular collection electrode

In a typical ESP, vertical wires are used as the negative discharge electrode between vertical,
flat, grounded plates. The dirty gas stream passes horizontally between the plates and a dust
layer of particulate collects on the plates. The typical spacing between the discharge electrode
and the collector plate is 4 to 6 in. The dust layer is removed from the plates by rapping, or
in the case of a wet ESP, by washing with water. An alternative to the plate and wire design is
the tube and wire design, in which the discharge electrode wire is fixed in the center of a
vertical tubular collection electrode. In this configuration, the gas flow is parallel to the
discharge electrode.

CORONA FORMATION
An electrical potential of about 30,000 volts/cm is applied between the wires (discharge
electrodes) and collecting plates of the ESP. In most cases, the wires are charged at 20 to 100
kV below ground potential, with 40 to 50 kV being typical. For cleaning indoor air, the wires
can be charged positively to avoid excessive ozone formation. However, the negative corona
is more stable than the positive corona, which tends to be sporadic and cause sparkover at
lower voltages, so negative corona is used in the large majority of industrial ESP. In the
intense electric field near the wire, the gas breaks down electrically, producing a glow
discharge or corona without sparkover, as depicted in Figure 20.
In a negative corona, ionized molecules are formed from the corona glow caused by the high
electrical gradient around the discharge wire. The space outside the corona is filled with a
dense cloud of negative ions. The dust particles will collide with some of the ions giving them
a negative charge. These charged particles will be driven by the electric field toward the plates
where they are collected
Figure20: Corona formation plan view plate and wire configuration.

Figure 21:Particle charging.
PARTICLE CHARGING
As particles move through the electric field they acquire an electrostatic charge by two
mechanisms, bombardment charging and diffusion charging, as illustrated in Figure 21. Both
types of particle charging act simultaneously, but bombardment charging is of greater
importance for larger particles and diffusion charging is more important for submicron
particles. The magnitude of the charging for both mechanisms is lowest for particles in the
size range of 0.1 to 1 microns, therefore, the minimum collection efficiency will occur for this
size range. However, a well designed ESP will be capable of collecting greater than 90% of
even these difficult to collect particles.
Bombardment charging is of primary importance for particles greater than 1 micron. Ions and
electrons move along the lines of force between the electrodes normal to the direction of flow
of particles in the gas stream. Some of the ions and electrons are intercepted by uncharged
particles, and the particles become charged. Because the particles are now charged, ions of
like charge are now repulsed by the particle, thus reducing the rate of charging. After a time,
the charge on the particles will reach a maximum that is proportional to the square of the
particle diameter. Because extremely small particles (less than 0.1 micron) have an erratic
path in the gas stream due to Brownian motion, they can acquire a significant charge
bydiffusion charging. Thus, an ESP can be an efficient collection device for submicron
particles. However, these

particles represent only a small fraction of the mass of dust entering an ESP, so they are often
neglected in studies of ESP performance, even though they can be of great importance to
particulate emissions.
PARTICLE MIGRATION
Most charged particles migrate under the influence of the electric field towards the plate,
although a few particles in the vicinity of corona discharge will migrate towards the wire. The
presence of charged particles in the gas space affects the overall electric field. Near the plate,
the concentration of charged particles will be high, and interparticle interferences can occur.
Finally, particles will collect as a dust layer on the plates, and a portion of their charge may be
transferred to the collecting electrode. Ideally, charged particles will migrate to the plate
before exiting the ESP, as illustrated in Figure 22, and will stick to the dust layer on the
collecting electrode until it is cleaned. When the plate is rapped, the dust layer should fall as a
sheet into dust collection hoppers without re-entraining into the gas stream.
FIGURE 22:Migration velocity vs. treatment time.
The velocity at which charged particles migrate towards the plate can be calculated by
balancing the electrical forces with the drag force on the particle moving through the flue gas.
The electric field produces a force on the charged particle proportional to the magnitude of the
field and the charge:

Fe=qE
where
Fe= force due to electric field
q = charge on particle
E = strength of the electric field (volts/cm)
However, several simplifying assumptions are needed for calculation of balancing
electrical force with drag force:
Repulsion effects between particles of like charge are neglected
The effect of the movement of gas ions (electric wind) is neglected
Gas flow within the ESP is turbulent
Stokes Law can be applied for drag resistance in the viscous flow regime
Particles have been fully charged by bombardment charging
There are no hindered settling effects in the concentrated dust near the plate.
After applying these simplifying assumptions, the migration velocity for particles larger than
1 micron charged by bombardment charging is calculated using
Equation 2:
where
D = dielectric constant for the particle
e= permittivity, 8.8541012 coulombs/volt-meter
Ec = strength of the charging electric field
Ep= strength of precipitating (collecting) electric field
Dp= particle diameter
g= gas viscosity
C= Cunningham slip correction factor

Note that the migration velocity is proportional to the square of the electrical field strength,
directly proportional to the particle diameter, and inversely proportional to the gas viscosity.
DEUTSCH EQUATION
Using the migration velocity to complete a material balance for particles moving toward the
ESP plates and particles being carried through the ESP with the gas flow, a common
description of particle collection efficiency for mono disperse (same size) particles can be
derived:
where
= fractional collection efficiency
= migration velocity
A = plate area
Q = volumetric gas flow
Any consistent set of units can be used for , A, and Q. The expression A/Q is the specific
collection area (SCA) of the ESP, commonly expressed as square feet per thousand actual
cubic feet per minute (ft2/kacfm). When calculating plate area, remember that the surface area
of interior plates includes area exposed to gas flow on both sides of the plate, while the two
exterior plates are exposed on only one side. An inherent assumption in the Deutsch Equation
is that when particles reach the plates, they are permanently removed from the gas stream.
This assumption works reasonably well for low-efficiency ESPs. However, when the
collection efficiency is high (greater than 99%), mechanisms other than balancing migration
velocity with treatment time dominate the particle emissions. Sneakage, rapping
reentrainment, scouring re-entrainment, low-resistivity re-entrainment, and poor gas
distribution can become controlling non-ideal effects that limit collection efficiency. For very
high efficiency ESPs, empirical modifications of the Deutsch Equation have been used to fit
observed data. These include the

Hazen Equation:
Rapping Re-Entrainment
Another non-ideal effect in a dry ESP is rapping re-entrainment. The dust layer of collected
particles on the collection plates is knocked loose periodically by rapping or knocking the
plates, often with a trip hammer. Most of the dust falls as a sheet into collection hoppers, but
some particulate is re-entrained into the gas stream. Factors affecting rapping re-entrainment
include the aspect ratio of the ESP (length of the ESP divided by plate height), rapping
intensity, dust cohesivity, and dust cake thickness (rapping frequency). With a low aspect
ratio, dust has further to fall to reach the hopper before it would exit the ESP.
Particles in a cohesive dust cake will tend to stick together as a falling sheet when the plates
are rapped. This minimizes re-entrainment. The rapping intensity needs to be strong enough to
shear the dust cake from the plate, but not strong enough to produce a cloud. Increasing dust
cohesivity with conditioning additives is one of the primary mechanisms for improving fine
particle collection.
The frequency of rapping should be adjusted to allow a sufficient dust layer to accumulate so
that the layer will fall as a cohesive sheet. Experimental studies with fly ash have shown that a
re-entrainment cloud forms when the plate loading is below 0.1 g/cm2, while the dust layer
develops a more cohesive sheet when rapped at a higher loading. However, if the dust layer
becomes too thick, it can act as an insulator and cause a potential gradient to build up within
the layer. This reduces the electric field strength in the gas space, and could lead to sparking
within the dust layer with subsequent re-entrainment.
Particulate Resistivity
Once particles reach the dust layer on the collecting electrode, they must stick to the surface
until it is cleaned. This is not a problem in a wet ESP because the particle sticks to the wet
collection surface until they are washed off by flushing. But in a dry ESP, re-entrainment

resulting from dust resistivity that is either too high or too low can reduce the collection
efficiency of the ESP. To achieve high collection
Figure 23: Comparison of Potential Gradient In Clean Vs. Dust Laden Plate
efficiency when re-entrainment is a factor, the ESP must be oversized to allow particles to be
captured again. The forces that hold particles onto the plate include molecular adhesive forces
of the London-van der Waals type and electrostatic forces. The optimum resistivity for good
removal in a dry ESP is approximately 1109 to 11010 ohm-cm.
When charged particles arrive at the plate, they are partially discharged. Theextent of
electrostatic adhesion depends on the rate at which charge leaks away fromthe particles,
which depends on the resistivity of the dust layer. The resistivity of some dusts, including lead
smelter fume and coal-fired-boiler fly ash from low-sulfur or alkaline coals, is relatively high.
When the resistivity is high, the rate of discharge from the collected particle layer is low. A
potential gradient builds up within the layer of collected particles.
Figure 23 illustrates the potential gradient as voltage vs. distance between the discharge and
collection electrodes. Two points on the curve are fixed. The discharge electrode is charged to
the maximum voltage for the limits of the power supply. The collection electrodes are
grounded. Without a resistive dust layer, the potential gradient will appear as in Figure 23,
with the greatest gradient at the discharge electrode where corona is formed. Figure 23
illustrates the effect of a highly resistive dust layer. A substantial portion of the voltage drop
occurs across the dust layer, leaving a reduced potential gradient across the gas space. With
the lower gradient, the driving force for particle migration is reduced. If the dust resistivity is

sufficiently high, the steep potential gradient within the dust layer itself can begin to
breakdown of the gases
between the dust particles. This is back corona. Ions of both charges, including the opposite
charge from the discharge electrode, are formed and charge particles. These opposite-charge
particles are re-entrained as they migrate back toward the discharge electrodes. Sometimes the
potential gradient within the dust layer can be severe enough to cause a spark within the dust
layer, which violently re-entrains some dust and can limit the maximum voltage that can be
maintained by the power supply.
Low-resistivity dust also can result in a re-entrainment problem. The particle charge is lost
quickly when the dust has low resistivty. A dust layer of uncharged particles is not held
against the collecting plate by the potential gradient from the discharge electrode.Carbon dust
and moist, low-temperature particles are examples of dusts that have a low resistivity.
Two gas properties that have a significant effect on particle resistivity are temperature and
humidity. At high temperatures, above about 400F, volume conduction of electric charge
through the particles tends to control resistivity. Such passage obviously depends upon the
temperature and composition of the particles. For most materials the relationship between
resistivity and temperature is given by an Arrhenius- type equation:
where
e= resistivity
A = constant
E = electron activation energy (a negative value)
k = Boltzmanns constant
T = absolute temperature
Thus, resistivity decreases as temperature increases.
At lower temperatures, less than 200F, surface conduction is the predominant mechanism of
charge transfer. Electric charges are carried in a surface film adsorbed on the particulate. The
presence of moisture increases surface conduction. Humidification of the flue gas upstream of

an ESP both decreases temperature and increases moisture content, which reduces particle
resistivity
Gas-Flow Distribution
An idealized assumption that is used when applying the Deutsch Equation is that the gas flow
and the particulate concentration in the gas are distributed uniformly. Customized flow vanes,
baffles, and/or perforated-plate gas distributors often are used at the inlet to produce uniform
flow. Sometimes these devices are used at the outlet also. A typical specification for uniform
flow distribution requires that 85% of the velocity distribution is within 1.15 times the
average velocity, and 99% of the velocity distribution is within 1.40 times the average
velocity.
Two approaches are used to ensure uniform velocity distribution: scale-model studies and
Computational Fluid Dynamics (CFD) modeling. CFD modeling is relatively new, but is
becoming common as software, computing power, experience, and availability have enabled
this tool to be used in a variety of fluid-flow applications. Although uniform gas distribution
is generally accepted as the ideal gas flow distribution, computer modeling and a full-scale
demonstration at a coal-fired power station in South Africa show that a skewed distribution
reduced particulate emissions by more than 50%.
In this patented configuration, the inlet flow distribution is skewed with low flow at the top of
the precipitator and higher flow at the bottom
Figure 24:Skewed gas flow distribution
At the outlet, the gas flow is skewed with high flow at the top of the precipitator and low flow
at the bottom, as shown in Figure 24. This distribution utilizes the fact that collected dust
exits the precipitator by falling to the bottom. Dust cake dislodged by rapping is less likely to

be re-entrained when the distance that it must fall is short. Thus, particles near the bottom are
more likely to be removed than particles near the top of the precipitator. At the inlet, a low
velocity gives those particles near the top more treatment time for better collection. At the
outlet, particles still near the top have not yet worked their way down the precipitator, so are
likely to be emitted anyway, so it is better to maximize the collection efficiency of those
particles that have been worked toward the bottom and still can be collected. During
operation, flow distribution can be affected by deposits that accumulate on the gas distribution
devices. Sometimes, rappers or vibrators are used to remove these deposits.

PRACTICAL APPLICATION OF THEORY
EFFECTIVE MIGRATION VELOCITY

In most cases, it is far more practical and reliable to determine an effective migration
velocity from operating experience than it is to calculate the migration velocity from
Equation 24.2. Then the effect of many unknown properties, including particle size
distribution, and simplifying assumptions are buried in the measured performance. The
fractional particulate removal efficiency is determined by measuring the inlet and outlet
loading in either a pilot-scale, or better a full-scale, ESP. The effective migration velocity,, is
calculated after rearranging Equation 3:
Having the effective migration velocity enables sizing the required collection area for the
desired efficiency under similar conditions, bearing in mind the simplifying assumptions and
limitations of the Deutsch Equation discussed previously.
AUTOMATIC VOLTAGE CONTROLLER

The potential gradient is the source of corona formation and the driving force for charged
particle migration. Equations 2 and 3 can be used to estimate the effect of increasing voltage
for a given application.
The automatic voltage controller (AVC) increases the secondary (i.e., DC) voltage that is
applied to an ESP field until either:
The spark rate limit is reached; or
The current limit of the power supply is reached
A spark is an electrical breakdown of the gas space. Modern electronics are able to detect an
incipient spark and immediately reduce the voltage to quench the spark,
after which the voltage is slowly increased again.
FLUE GAS CONDITIONING

Flue gas conditioning has been successfully used to lower fly ash resistivity in cold side

ESP for a number of years and, more recently, has been demonstrated effective in hot-side
precipitator applications as well. There are several mechanisms by which conditioning may
affect ESP performance including:
Reducing back corona and increasing potential gradient in the gas space by lowering fly ash
resistivity.
Reducing re-entrainment by increasing the cohesive properties of fly ash.
Increasing agglomeration or growth of small particles to form larger particles.
Increasing space charge to produce a more uniform potential gradient in the interelectrode
space, thereby allowing operation at higher voltages.
In cold-side ESP applications, conditioning agents that have been effective include:
Water vapor
Sulfuric acid or SO3
Ammonia
Ammonium sulfate
Triethylamine
Proprietary additives (e.g., ADA-23)
HUMIDIFICATION
Cooling a hot flue gas stream by evaporating a spray of fine water droplets produces a net
decrease in the gas volumetric flow rate, increases the gas density, increases the moisture
content of the gas stream, and reduces the particulate resistivity. Increasing both the gas
density and the moisture content, increases the spark-over voltage at which the gas breaks
down. Therefore, higher field strength can be achieved before spark rate limits further voltage
increases.
A key concern with spraying water droplets is that the water droplets are completely
evaporated before they impact the interior surfaces in ductwork. If water wets the walls of the
ductwork, particulate may stick and accumulate and corrosion may be accelerated rapidly.
Generally, at least 1 s residence time for drying in a straight section of duct is desired for a
fine spray with a Sauter mean diameter of 50 microns. Dual-fluid atomizing nozzles are
typically used to achieve the fine spray, because high-pressure hydraulic nozzles would
require 500 to 5000 psi with very small orifices that are prone to plugging and wear.

SO3
Addition of sulfuric acid or SO3is a common method of lowering particulate resistivity.
Sulphuric acid has been used as a source of SO 3 as it decomposes at flue gas temperatures
upstream of the air heater. The conditioning effect is attributed to the formation of sulphuric
acid as SO3 combines with water and condenses on the particulate surfaces, and/or to the
direct adsorption of SO3 on the surface of the particles with the subsequent formation of
sulfates which act as electrolytes and enhance surface conduction. Because the mechanism of
SO3 conditioning relies on condensation of H2SO4, the method is not effective at
temperatures above 375F. Therefore, it is not used for hot-side ESPs, which are located
upstream of the air heater in a power boiler. Also, neutralization of acid by basic components
such as calcium oxide in the fly ash may produce insoluble sulfate salts having a high
resistivity. Thus, fly ash alkalinity is another factor in determining the effectiveness of SO3
conditioning.
AMMONIA
Addition of ammonia or ammonia compounds is another method of conditioning that has been
used to improve ESP performance, particularly in the petroleum refining industry on fluid
catalytic cracking (FCC) units. Catalyst dust from FCC units typically has a high resistivity.
Several hypotheses for the mechanism for improved ESP performance by NH 3 conditioning
have been proposed. Explanations include neutralization of sulphuric acid in the case of low-
resistivity fly ash; reduction of back corona as characteristics of the gas are changed; and
higher voltage operation due to an enhanced potential gradient resulting from space charge
effects.
The presence of very fine ammonium sulfate particles produced by the reaction of ammonia
and SO3 increases space charge, which would decrease the electric field strength near the
corona discharge and allow a steeper gradient near the collecting plate. Although excessive
space charge can lead to corona quenching, moderate space charge produces a higher driving
force for particle migration outside of the corona discharge region. The space charge effect
can be beneficial when the enhancement in the collecting electric field more than compensates
for the decreased corona discharge. Another explanation is that ammonia reacts with sulfuric
acid mist in the flue gas, forming ammonium bisulfate, NH4HSO4, and ammonium sulfate,
(NH4)2SO4. Ammonium bisulfate is deliquescent (absorbs water readily, then dissolves in the

absorbed water) and has a melting point of 296.4F.Therefore, it would form a cohesive,
sticky materialin the ESP.
Recent work with FCC units indicates that ammonia increases the breakdownstrength of the
gas space between particles in the dust layer. Sparking within thedust layer occurs when the
electric field in the dust layer exceeds the breakdown strength of the gas in the interparticle
spaces. Since the dust layer in FCC unit applications has a high resistivity, the potential
gradient within the dust layer is high. It has been demonstrated that ammonia conditions the
gas rather than the dust as evidenced by the lack of residual ammonia in collected dust and a
rapid response to changes in concentration. Unfortunately, ammonia conditioning generates
emissions of unreacted ammonia.
This disadvantage has become more apparent in recent years with public attention focused by
the Toxic Release Inventory reporting requirements and the emphasis to reduce hazardous air
pollutants.
SO3 AND AMMONIA

The addition of both SO3 and ammonia would provide ESP performance enhancements by
most of the mechanisms discussed above for ammonia alone, but allows control over the
amount of each additive and their ratio. The normal flue gas SO3 concentration produced by
coals with the same sulfur content may vary considerably due to basic components in the coal
such as calcium oxide, and to trace metal catalysts such as vanadium which would convert
SO2 to SO3
ADVANCED MICROPROCESSOR TECHNOLOGY

FOR ELECTROSTATIC PRECIPITATOR HIGH VOLTAGE CONTROL SYSTEMS
INTRODUCTION
Effective control of the power applied to an electrostatic precipitator is essential in optimizing
its performance. Since the power level at which the electrostatic precipitator s performance
will be optimized is constantly changing, it is important that the high voltage control system
quickly and accurately adjust power levels so that optimum power is maintained.
The development of a sophisticated microprocessorbased control system provides a tool

with the necessary capacity to analyze the operating conditions of an electrostatic precipitator.
Once the operating conditions have been analyzed, an intelligent decision can be made
regarding the power level in the electrostatic precipitator at which performance will be
optimized. The control is then able to energize the electrostatic precipitator to the selected
power level.
Special functions and integration to centralized monitoring data recording and reporting
systems are readily achievable. Intermittent energization or power modulated precipitation
can be utilized. Data is reported to a central monitoring unit (CMU) which make possible the
reproduction of secondary voltage and current waveforms on the cathode ray tube (CRT)
display of the CMU.
The functions that a microprocessor must perform to ensure that the high voltage
control operates in an optimum manner will now be reviewed.
CONTROL FUNCTIONS
The primary control function is to optimize the collection efficiency of the electrostatic
precipitator. This is achieved by operating at the maximum sustainable power level. This
power level comprises the voltage and current levels that are slightly below the level which
will cause a breakdown of the electric field in the form of a spark. If the conditions at which
sparking occurs were constant the control of power levels to the precipitator would be quite
simple. However, the maximum power level achievable depends upon a set of constantly
changing variables.

These variables include the size distribution and chemical composition of the dust, the amount
of dust in the gas stream, flue gas temperature, gaseous constituents in the flue gas, the
amount of dust on the discharge electrodes, and the amount of dust deposited on the collecting
plates. Because of the large number of variables and their propensity towards rapid change,
the variations in the maximum power level achievable can be large and can occur very
quickly.
Power Optimization
Microprocessor based control systems must be capable of analyzing and responding to these
changing conditions in real time so as to ensure that maximum electrostatic precipitator
collection efficiency is maintained. In order to achieve this, the control must effectively
perform several functions. First, the control must constantly check to determine the maximum
power level that is achievable. This is accomplished by comparing operating information to
historical data and other preprogrammed control performance data. If a spark does occur, the
process of extinguishing the spark and returning to the optimum power level must be as rapid
as possible. Also, the spark must be identified as self extinguishing or nonself
extinguishing. If the spark is self extinguishing, the power level can be returned close to the
pre-spark power level in the next half cycle of operation. Should the spark not self extinguish,
the control must turn off power for one half cycle in order to extinguish the spark. In the next
half cycle of operation, the alternating current (AC) side of the transformerrectifier will
have the same polarity as the half cycle in which the spark occurred and energization to a high
power level would saturate the transformer and induce another spark. This condition is
effectively avoided by control design so that re-energization occurs in the following half cycle
of operation. The power level that the system is energized to will then be as close to the pre-
spark power level as possible. A simplified control logic for power optimization is shown in
Figure 25.

Figure 25: Precipitator Power Optimization
Back Corona Detection

Another essential control function is back corona detection and prevention. Back corona
occurs when collecting high resistivity dusts. As the high resistivity dust accumulates on the
collecting plate, the normal flow of negative ions through the dust layer to the collecting plate
is slowed. If the condition becomes severe, the gas in the dust layer will ionize and break
down, sending positive ions out towards the discharge electrode. This condition is extremely
detrimental to electrostatic precipitator performance.

Figure 26: Back Corona Current and Voltage Waveform
The secondary voltage waveform will indicate when a back corona condition occurs. The
voltage at the onset of conduction, that is the point where the positive slope of the voltage
waveform begins, will decrease in each ensuing half cycle of operation. This is due to the fact
that as back corona continues to increase in intensity the equivalent resistance in the RC
constant changes, the voltage decays more rapidly with time, and conduction begins sooner in
each ensuing half cycle of operation. By monitoring the secondary voltage and current
waveforms, it is possible to detect the presence of back corona. Power levels can then be
adjusted so that the operation of the system is at its optimum point, just below the onset of
back corona. waveforms that are typical of back corona are shown in Figure 26.

Intermittent Energization
A final control function to be examined is intermittent energization (IE), or power modulated

precipitation (PMP). IE can increase precipitator efficiency while decreasing power
consumption in cases of high resistivity dust, and can substantially reduce power consumption
with little impact on precipitator efficiency in cases of moderate dust resistivity.
To appreciate why precipitator power consumption and performance are affected by IE, it is
necessary to understand the basic principles of IE. Simply, IE modifies the energization of the
precipitator by normally energizing the precipitator for one or more half cycles and then not
energizing the precipitator for a series of half cycles. Figure 27 shows typical oscilloscope
tracings of secondary voltage and current for normal energization and for a one in five (one
half cycle on, four half cycles off) mode of IE. Two items to note are the peaks of the voltage
and current and the manner in which secondary voltage dissipates until the precipitator is re-
energized. In typical cases of high resistivity dust, the peak voltages that can be obtained with
IE are much higher than in cases of conventional energization. This is due to the fact that the
maximum voltage is normally limited to the value .At which back corona is induced. By not
energizing the precipitator for several half cycles in an IE mode of operation the ions
produced during the energization have more time to dissipate through the dust layer. Thus
when the precipitator is again energized it can be at a much higher voltage level without
causing back corona. The average voltage is increased and thus the precipitator efficiency is
increased
In cases of moderate resistivity, the voltage peaks are also increased slightly. However, the
voltage dissipates to a noticeably lower level than during conventional energization. The
result is very little change in the average voltage levels, and thus the collection efficiency of
the precipitator remains unchanged.

Figure 27: Normal and Intermittent Energization

MICROPROCESSOR OPERATION
With the advent of economical 16 bit microprocessor circuits, it has become feasible to re-
focus the high voltage control design approach by transposing more of the control and
integration functions from circuitry to program instructions. This approach, in addition to
reducing the number of components and improving reliability can support a wide range of
control philosophies. The primary benefit of this type of control is the ability to modify any
control operation through the software. The hardware becomes a true servant of the operation
and is not solely designed for any specific function. A second benefit of this type of design is
the ability to reconstruct operating waveforms from the memory of individual controls which
then can be transmitted to a remote display. allowing for oscilloscope waveforms to be
available and recorded during any operating period without additional test equipment.
These waveforms also provide detailed information which allows the microprocessor to fully
analyze the operation of the system. The advent of integrated circuitry with the necessary
speed and power has permitted this method of operation to be truly realized.
Design considerations to support this mode of operation and monitoring are primarily
concerned with data acquisition without integration or modification, sufficient speed of
operation to allow all data to be timely refreshed, program benchmarks at fundamental power
frequencies and scaled functions thereof, and algorithms developed solely to make full use of
dynamic waveform availability.
Circuitry Considerations
The signals which must be monitored and used for control include the following:
1. Primary voltage, linked through a potential transformer and presented to an analog to

digital converter as a rectified but unfiltered signal.
2. Primary current, linked through a current transformer and presented to an analog to digital
converter as a rectified but unfiltered signal.
3. Secondary voltage, derived from a voltage divider and presented to an analog to digital

converter as an unfiltered signal.
4. Secondary current, derived from applying the voltage across a resistor to an analog to
digital converter as an unfiltered signal.
5. Reactor voltage, linked through a potential transformer and presented to an analog to digital
converter as a rectified but unfiltered signal.
These signals are level translated through circuitry with a band width of at least one
megahertz. The rectification of the AC signals is primarily to expand the range of the analog
to digital converter as the zero crossing of these signals should remain constant.
Circuitry is incorporated to notify the program when different timing benchmarks have
transpired; the most common of these benchmarks being the zero crossing of the input power
line. This is coordinated with a higher frequency benchmark to represent the maximum
sampling rate with which to decipher the input waveforms. This frequency is high enough to
allow a maximum of 1 degree of silicon controlled rectifier (SCR) angle per increment of
timing. This benchmark is used for SCR output and also to digitize the input signals into
frequency points during each half cycle of line operation.
Metering
The signals in memory are used for local and/or remote metering. Each half cycle's number of
readings for each point must be averaged and combined with the average of other half cycles
to arrive at a smooth value to be used for operator interface. Normally the total number of half
cycles to be averaged is operator set allowing for personal preference. The primary voltage
and primary current are coordinated with the operating phase angle of the SCR's to arrive at
an RMS value for each level.
Such a system of metering and data retrieval separates average voltage or current readings for
each half cycle. This allows the control to separate the displayed currents in each rectifier leg
even though the transformerrectifier has no provisions for independent metering of each
leg. Only one secondary current metering wire is required.. These readings are sensitive to
SCR unbalance or an unsymmetrical power source, allowing for better annunciation of
possible problems. The metering will display peak voltages and currents for any half cycle

when in the intermittent mode of operation, giving a wealth of information about actual
activity during the application of power and about the voltage decay when power is removed
or the time between energizing pulses.
System Control
The digitizing of the phase angle and zero crossing allows for the SCR's output and the
metering input to be placed in phase with the operation by delaying the zero crossing in the
program based on the size of the reactor and the delay it presents. The inductance of the linear
reactor causes a phase lag in the voltage applied to the transformer rectifier which also limits
the available control range of the SCR's. Proper framing of the firing angle to the SCR's
prevents this from occurring. Digitizing the phase angle provides for all secondary
information to be properly stored in memory and recalled for the appropriate half cycle.
Having peak and valley information available for the secondary high voltage allows the
control to operate around an acceptable ratio of change between the peak and
valley to further detect the presence of back corona. This is evaluated against
different time frames for more accurate detection of back corona activity.
Spark rate limits have proven to reduce control capabilities and cause severe degradation of
applied power simply to satisfy a preset spark limit. A more reliable system is to weigh the
spark rate, but also keep close records of different operating currents prior to spark initiation
and use these for short range goals in the neverending search for greater secondary voltage.
This spark current limit, sometimes called a floating current limit, makes the control's
operation truly independent of gas conditions.

Figure 28: Performance Comparison visualization of Analog controls v/s Microprocessor
through Stack Opacity

CONCLUSON AND FUTURE SCOPE OF WORK
In the light of the presented theory of working and its application to control efficiencies of
ESP, it can be chalked out that the two most viable processes for increasing efficiencies are:
Gas Conditioning
Microprocessor Control System
The scheme of gas conditioning (by Ammonia or SO3) to boost efficiencies has proved to be
economically unviable according to past field experiences, on the account that such schemes
would require continuous running , amounting to huge expenditure in terms of chemical cost
and running cost and in addition imposing a menace of chemical decomposition, hence
rendering it economically unviable.
On the other hand the microprocessor control scheme is inherently dynamic and requires little
modification to existing system for its implementation hence making it economically more
feasible than other control schemes for improving efficiencies. The unique features of
advanced microprocessor control scheme can be summarized as-
Accurate Back Corona Detection
Power Optimization By Power Modulated Precipitation
Remote Monitoring of actual field operation
All these features effectively summarizes the advantage of using the presented control scheme
to meet efficiencies requirement.
The current efficiencies of stages 1,2 and 3 of GGSSTP Ropar ESPs are close to 99.5%,
hence the scope of improvement of ESPs efficiencies is very bleak. However, in future if
more stringent norms for pollution control are imposed by Ministry of Environment and
Forest India, the implementation of presented scheme of advanced microprocessor control
will successfully boost efficiencies up to 99.6-99.7%
It is important to mention that presented control scheme may be employed for modification of
stage 3 ESPs unit(s), as already been implemented in Stage 1 and 2 in the past. Features like
Accurate Back Corona detection and its removal will improve the efficiency of ESPs
consequently optimizing power and making Stage 3 ESP unit(s) to come at par with other two
stages in terms of operating efficiencies.
REFERENCE:

1. GGSSTP Generator Manual.
2. GGSSTP Static Excitation Manual.
3. GGSSTP Protection Manual.
4. GGSSTP Switchgear Manual.
5. GGSSTP 220 KV Switchyard Manual.
6. www.pspcl.in

Performance Improvement of Electrostatic Precipitator: Analysis and Improvement

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PROJECT REPORT

(Project Semester January-June 2016)

Performance Improvement of Electrostatic Precipitator:

Under the Guidance of

Dr. Jagdish Kumar Er. Naveen Malhotra

Department of Electrical Engineering

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(Name & Designation) (Name & Designation)

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S.No. TOPIC PAGE

4. Introduction to GGSSTP 6-8

5. Working of Thermal Plant 9-10

6. Coal Handling Plant 11-14

7. Boiler & its Auxiliaries 15-21

9. Generator and its Auxiliaries 26-33

10. Draft Fans 34-36

11. LT Switchgear 37-39

12. HT Switchgear 40-42

13. Transformer Yard 43-54

14. 220 KV Grid 55-64

15. Protection & Protection System 65-68

16. Electrostatic Precipitator Analysis 69-80

17. Practical Application of Theory 81-84

18. Advanced Microprocessor control 85-94

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Figure No. Description Page no.

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My training was divided into five modules:

5.Analysis of Electrostatic Precipitator

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Punjab State Power Corporation Ltd. (POWERCOM)

1. Er.K.D.Chowdhry Chairman cum Managing Director

3. Er.Arun Kumar Director/Distribution

1. Sh.Anurag Agarwal Chairman cum Managing Director

3. Sh.Uma kanta Panda Director/Finance

Prior to this unbundling the organization was PSEB.

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Introduction to GGSSTP, ROPAR

Salient Features of GGSSTP, Ropar: -

1. Location ROPAR, about 50 km from Chandigarh on

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Figure1: Plant Water and Air Cycle

LPH-Low Pressure Heater Mills HPT-High Pressure Turbine

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HOW COAL HANDLING PLANT FUNCTIONS

COAL WAGONS ARE UNLOADED IN 2 WAYS

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COAL PULVERISING SYSTEM

Figure 2: Stacker and Reclaimer in GGSSTP

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COAL MILLS AND MILLING SYSTEM

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Salient Features of Boiler have been given below:

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Flue Gas Path

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