Thermal Power Plant Training Report (Formal)

PORJECT REPORT
(Internship Semester January-June 2019)
STUDY OF 6×210 MW THERMAL POWER PLANT
Submitted by
Gurpreet Singh
16104068
Under the Guidance of
Anupam Sir Suminderjeet Singh

Assistant Professor Additional Associate Engineer
Department of Electrical Engineering Thermal Training Cell
PEC, Chandigarh GGSSTP, Ropar
Department of Electrical Engineering

PUNJAB ENGINEERING COLLEGE (DEEMED TO BE UNIVERSITY)
CHANDIGARH
January to June, 2019

Guru Gobind Singh Super Thermal Plant, Ropar
DECLARATION
I hereby declare that the project work entitled “Study of 6×210 MW Thermal Power Plant” is an
authentic record of my own work carried out at Punjab State Power Corporation Limited as
requirement of six months project semester for the award of degree of B.Tech., Electrical
Engineering at Punjab Engineering College (Deemed to be University), Chandigarh, under the
guidance of industrial coordinator AAE. Suminderjeet Singh and faculty coordinator Anupam
Sir, at Punjab Engineering College (Deemed to be University), Chandigarh, during January to June,
2019.
Gurpreet Singh
Date: 2 July 2019 16104068
Certified that the above statement made by the student is correct to the best of our knowledge and
belief.
Anupam Sir Suminderjeet Singh

Assistant Professor Additional Associate Engineer
Faculty Coordinator Industrial Coordinator
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ACKNOWLEDGEMENT
Industrial training has an important role in exposing the real-life situation in an industry. It was a
great experience for me to work on training at Punjab State Power Corporation Limited through
which I could learn how to work in a professional environment.
I am thankful to Head of Department, Dr. Tilak Thakur and training coordinator Prof. Tejinder
Singh Saggu for providing me with an opportunity to undergo training at Punjab State Power
Corporation Limited and for their invaluable guidance and enormous help & encouragement, which
helped me to complete my training successfully.
Now, I would like to thank the people who guided me and have been a constant source of inspiration
throughout the tenure of my training period.
I am greatly thankful to “Training Cell, Guru Gobind Singh Super Thermal Plant, Ropar” for
conducting training (03-01-2019 to 28-06-2019).
I am sincerely grateful to Anupam Sir and Suminderjeet Singh, who rendered me their valuable
assistance, constant encouragement and able guidance which made this training actually possible.
Finally, no word will be enough to express my deepest reverence to family and friends without
whom enthusiasm and support, I wouldn’t have been able to pursue my goals.
Gurpreet Singh
16104068
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SUMMARY
After this training at the Guru Gobind Singh Super Thermal Plant, Ropar we can visualized the
complex study of power generation using coal as a fuel, which will help us a lot in future in many
field & we can understand the function of each component in thermal power station, their
importance, their arrangement & precautions that to be used for the safety in the plant.
I am only say that we really enjoyed us training over here and we again want to thank all my
facilities, staff of Guru Gobind Singh Super Thermal Plant to give us this great pleasure of training.
At last we conclude that we got good knowledge and great experience at the GGSSTP, Ropar.
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TABLE OF CONTENTS
DECLARATION .......................................................................................................................... iii
ACKNOWLEDGEMENT............................................................................................................ iv
SUMMARY ................................................................................................................................... vi
LIST OF FIGURES ................................................................................................................... XII
LIST OF TABLES .................................................................................................................... XIV
CHAPTER 1 ABOUT GURU GOBIND SINGH SUPER THERMAL PLANT .................... 1
1.1 INTRODUCTION ..................................................................................................................... 1

1.2 UNIT COMMISSIONING .......................................................................................................... 2
1.3 BOILER ................................................................................................................................. 2
1.4 FAN ....................................................................................................................................... 4
1.4.1 Primary Air Fan........................................................................................................... 4
1.4.2 Forced Fraft Fan ......................................................................................................... 4
1.4.3 Induced Draft Fan ....................................................................................................... 4
1.5 TURBINE ............................................................................................................................... 4
1.6 CONDENSER .......................................................................................................................... 5
1.7 WORKING OF THERMAL POWER PLANT ................................................................................ 6
1.8 COAL HANDLING PLANT ...................................................................................................... 7
1.8.1 Basic functions ................................................................................................................ 8
1.8 2 Equipments installed ....................................................................................................... 9
1.8.3 Wagon tippler ................................................................................................................. 9
CHAPTER 2 HIGH TENSION (H.T.) & LOW TENSION (L.T.) SWITCHGEAR ........... 11
2.1 HIGH TENSION SWITCHGEAR .............................................................................................. 11

2.1.1 Station And Unit Buses ................................................................................................. 11
2.1.2 Circuit Breakers ............................................................................................................ 14
2.2 LOW TENTION SWITCHGEAR ................................................................................................. 16
2.2.1 415 V Station Service Switchgear ................................................................................. 16
2.2.2 415 V Unit Service Switchgear ..................................................................................... 17
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2.2.3 415 V Emergency Bus Stage III ..................................................................................... 17

2.2.3 About Modules & L.T. Circuit Breaker ......................................................................... 18
CHAPTER 3 ELECTRIC MOTOR REPAIR WORKSHOP ................................................. 19
3.1 SMALL SIZED INDUCTION MOTORS ...................................................................................... 19

3.1.1 Repairing of Ceilling Fan.............................................................................................. 19
3.2 MEDIUM SIZED INDUCTION MOTOR .................................................................................... 21
3.2.1 Repairing of 200 HP Induction Motor ....................................................................... 22
CHAPTER 4 220 KV, 132 KV SUB-STATION AND ITS INSTALLED VARIOUS

EQUIPMENTS ............................................................................................................................. 28
4.1 ABOUT SUBSTATION............................................................................................................ 28

4.1.1 Various Outgoing Feeders ......................................................................................... 30
4.2 EQUIPMENTS INSTALLED AT SUB-STATION ......................................................................... 30
4.2.1 Isolator ....................................................................................................................... 30
4.2.2 Main & Reserve Bus ................................................................................................... 31
4.2.3 Insulator ..................................................................................................................... 32
4.2.4 Circuit Breaker ........................................................................................................... 32
4.2.5 Lightning Arrestor ......................................................................................................... 36
4.2.6 Instrument Transformer ................................................................................................ 37
4.2.7 Wave Trap ..................................................................................................................... 39
4.2.8 Coupling Capacitor ....................................................................................................... 40
4.2.8 Power Line Carrier Cummunication system ................................................................. 40
CHAPTER 5 VARIOUS TRANSFORMER INSTALLED AT PLANT ............................... 42
5.1 TRANSFORMER’S BASIC STRUCTURE ..................................................................................... 42

5.1.1 Core ............................................................................................................................... 42
5.1.2 Winding ......................................................................................................................... 44
5.1.3 Transformer Oil ............................................................................................................. 45
5.1.4 Oil Gauge ...................................................................................................................... 45
5.1.5 Conservator or Expansion Tank.................................................................................... 45
5.1.6 Breather ......................................................................................................................... 46
5.1.7 Radiators ....................................................................................................................... 46
5.1.8 Bushing .......................................................................................................................... 46
5.1.9 Oil Purifying Tank ......................................................................................................... 47
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5.1.10 Pressure Relief Valve .................................................................................................. 48

5.1.11 Explosion Vent ............................................................................................................ 48
5.2 COOLING SYSTEM USED IN TRANSFORMER ........................................................................... 49
5.2.1 Oil Natural (ON) Cooling ............................................................................................. 49
5.2.2 Oil Natural Air Forced (ONAF) Cooling ..................................................................... 49
5.2.3 Oil Natural Water Forced (ONWF) Cooling ................................................................ 49
5.2.4 Forced Circulation of Oil (OF) .................................................................................... 49
5.3 GENERATOR TRANSFORMER (GT) ........................................................................................ 51
5.4 STATION TRANSFORMER (ST) ............................................................................................... 52
5.5 UNIT AUXILIARY TRANSFORMER (UAT) ............................................................................... 53
5.6 UNIT SERVICE & STATION SERVICE TRANSFORMER ............................................................. 53
5.7 NEUTRAL GROUNDING TRANSFORMER (NGT) ..................................................................... 54
5.7 AUTOTRANSFORMER (AT) .................................................................................................... 54
CHAPTER 6 GENERATOR AND ITS AUXILIARIES ........................................................ 55
6.1 SALIENT FEATURES OF GENERATOR ..................................................................................... 55

6.2 STATOR ................................................................................................................................. 56
6.3 STATOR WATER COOLING ..................................................................................................... 57
6.3 ROTOR .................................................................................................................................. 58
6.4 SLIP RING & CARBON BRUSH GEAR ..................................................................................... 59
6.5 OPERATING PROCEDURE OF TURBO-GENERATOR ................................................................. 60
6.5.1 Starting of Generator .................................................................................................... 60
6.5.2 Synchronization ............................................................................................................ 61
6.5.3 Unloading and Shut Down ............................................................................................ 61
6.6 OBSERVED DATA AT PLANT .................................................................................................. 62
CHAPTER 7 ELECTROSTATIC PRECIPITATOR ............................................................. 63
7.1 WORKING PRINCIPLE ............................................................................................................ 64

7.1.1 Corona Generation .................................................................................................... 64
7.1.2 Particle Charging ...................................................................................................... 65
7.1.3 Particle Collection ..................................................................................................... 65
7.1.4 Removal of Dust ......................................................................................................... 66
CHAPTER 8 PROTECTION SYSTEM................................................................................... 67
8.1 VARIOUS EQUIPMENT FOR PROTECTION SYSTEM ............................................................... 67
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8.2 GENERATOR PROTECTION ................................................................................................... 67

8.3 GENERATOR TRANSFORMER (GT) PROTECTIONS ................................................................ 68
8.4 UAT PROTECTIONS ............................................................................................................. 68
8.5 MOTOR PROTECTION ........................................................................................................... 68
8.5.1 Protection of L.T. Motors (<100 kv Rating) .............................................................. 69
8.5.2 Protection of H.T. Motors (>100 kv Rating) .............................................................. 69
8.6 EQUIPMENT TESTING ........................................................................................................... 69
8.6.1 Tan-Delta or Dissipation factor testing ..................................................................... 69
8.7 OVER CURRENT RELAY MESURMENTS................................................................................ 72
REFERENCES ............................................................................................................................. 75
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LIST OF FIGURES
FIGURE 1.1: EXTERNAL VIEW OF PLANT ........................................................................................... 1

FIGURE 1.2: BOILER .......................................................................................................................... 3
FIGURE 1.3: FORCED DRAFT FAN...................................................................................................... 4
FIGURE 1.4: INDUCED DRAFT FAN .................................................................................................... 4
FIGURE 1.5: TURBINE ........................................................................................................................ 5
FIGURE 1.6: CONDENSER .................................................................................................................. 5
FIGURE 1.7: LAYOUT OF GGSSTP .................................................................................................... 6
FIGURE 1.8: COAL HANDLING PLANT ............................................................................................... 7
FIGURE 1.9: COAL PIT ....................................................................................................................... 8
FIGURE 1.10: WAGON TIPPLER ......................................................................................................... 9
FIGURE 2.1: MAINTENANCE WORK HELD AT PLANT ........................................................................ 15
FIGURE 2.2: MOCB WIRING DIAGRAM .......................................................................................... 15
FIGURE 2.3: INSIDE VIEW OF MODULE ............................................................................................ 18
FIGURE 3.1: CIRCUIT DIAGRAM OF CELLING FAN ........................................................................... 19
FIGURE 3.2: WINDING MACHINE..................................................................................................... 20
FIGURE 3.3: CELLING FAN COILS ARRANGEMENT .......................................................................... 20
FIGURE 3.4: WINDING ARRANGEMENT ........................................................................................... 21
FIGURE 3.5: COIL MADE OF MULTI-TURNS ...................................................................................... 23
FIGURE 3.6: STATOR UNDER REPAIR AT PLANT .............................................................................. 25
FIGURE 3.7: EMF INDUCED IN VARIOUS COILS ................................................................................. 26
FIGURE 3.8: 3 PHASE, 24 SLOT, 4 POLE, DOUBLE LAYER LAP WINDING WITH FULL PITCH COILS. 27
FIGURE 4.1: SINGLE LINE DIAGRAM OF 220 KV & 132 KV SUBSTATION ........................................ 29
FIGURE 4.2: DBR ISOLATOR ........................................................................................................... 30
FIGURE 4.3: MAIN & RESERVE BUS ................................................................................................ 31
FIGURE 4.4: SUSPENSION TYPE INSULATOR CONNECTED IN 220KV LINE ....................................... 32
FIGURE 4.5: AIR BLAST CIRCUIT BREAKER .................................................................................... 33
FIGURE 4.6: SF6 CIRCUIT BREAKER ................................................................................................ 34
FIGURE 4.7: LIGHTNING ARRESTOR ................................................................................................ 36
FIGURE 4.8: POTENTIAL TRANSFORMER ......................................................................................... 37
FIGURE 4.9: CURRENT TRANSFORMER ............................................................................................ 38
FIGURE 4.10: WAVE TRAP .............................................................................................................. 39
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FIGURE 4.11: COUPLING CAPACITOR............................................................................................... 40

FIGURE 5.1: GENERAL LAYOUT OF VARIOUS TRANSFORMS COMBINATION .................................... 43
FIGURE 5.2: TRANSFORMER WINDING ............................................................................................. 44
FIGURE 5.3: CONSERVATION TANK ................................................................................................. 45
FIGURE 5.4: BEATHER ..................................................................................................................... 46
FIGURE 5.5: RADIATOR ................................................................................................................... 46
FIGURE 5.6: BUSHING OF TRANSFORMER ........................................................................................ 47
FIGURE 5.7: OIL PURIFYING TANK .................................................................................................. 47
FIGURE 5.8: PRESSURE RELIEF VALVE ............................................................................................ 48
FIGURE 5.9: EXPLOSION VENT ........................................................................................................ 48
FIGURE 5.10: OIL FORCED AIR FORCED COOLING (OFAF) ............................................................. 50
FIGURE 5.11: GENERATOR TRANSFORMER (GT) ............................................................................. 51
FIGURE 5.12: STATION TRANSFORMER (ST).................................................................................... 53
FIGURE 5.13: AUTOTRANSFORMER (AT) ......................................................................................... 54
FIGURE 6.1: 210 MW TURBO-GENERATOR ..................................................................................... 55
FIGURE 6.2: STATOR WATER PIPES ................................................................................................. 57
FIGURE 6.3: ROTOR ......................................................................................................................... 58
FIGURE 6.4: MAINTAINING CARBAN BRUSH AT PLANT ................................................................... 59
FIGURE 7.1: ELECTROSTATIC PRECIPITATOR ................................................................................... 63
FIGURE 8.1:HV & LV 'S CAPACITANCES ......................................................................................... 70
FIGURE 8.2: OVERCURRENT RELAY (INVERSED) TYPE .................................................................... 72
FIGURE 8.3: RELAY IS SET ON 1.25 PLUG SETTING .......................................................................... 72
FIGURE 8.4: PMS VS TIME DATA .................................................................................................... 73
FIGURE 8.5: TSM OF RELAY ........................................................................................................... 73
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LIST OF TABLES
TABLE 1.1: UNIT COMMISSIONING .................................................................................................... 2

TABLE 1.2: BOILER'S TECHNICAL DATA ........................................................................................... 3
TABLE 1.3: TURBINE'S TECHNICAL DATA ......................................................................................... 5
TABLE 3.1: REPAIRED FAN'S TECHNICAL SPECIFICATION ............................................................... 21
TABLE 3.2: MOTOR'S SPECIFICATION .............................................................................................. 24
TABLE 4.1: ISOLATOR'S SPECIFICATION .......................................................................................... 31
TABLE 4.2: NO. OF DISK FOR KV RATING AT PLANT ...................................................................... 32
TABLE 4.3: ABCB'S SPECIFICATIONS ............................................................................................. 34
TABLE 4.4: SPECIFICATIONS OF SF6 CIRCUIT BREAKER .................................................................. 35
TABLE 4.5:LIGHTNING ARRESTOR'S SPECIFICATION ....................................................................... 36
TABLE 4.6: PT'S SPECIFICATIONS ................................................................................................... 38
TABLE 4.7: CT'S SPECIFICATIONS ................................................................................................... 39
TABLE 5.1: TECHNICAL DATA OF GT............................................................................................. 52
TABLE 5.2: TECHNICAL DATA OF ST .............................................................................................. 52
TABLE 5.3: AUTOTRANSFORMER’S (AT) SPECIFICATIONS .............................................................. 54
TABLE 6.1: GENERATOR'S TECHNICAL DATA ................................................................................. 56
TABLE 8.1: MEASUREMENT OF CHL ................................................................................................ 70
TABLE 8.2: MEASUREMENT OF CHG ................................................................................................ 70
TABLE 8.3: MEASUREMENT OF CLG (LINE TO GROUND) ........................................................................... 71
TABLE 8.4: MEASUREMENT OF CHG+CLG ....................................................................................... 71
TABLE 8.5: CT'S TAN-DELTA OBSERVATIONS ................................................................................ 71
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CHAPTER 1
ABOUT GURU GOBIND SINGH SUPER THERMAL PLANT
1.1 INTRODUCTION
Guru Gobind Singh Super Thermal Power Plant (GGSSTP, 6 × 210 MW) is situated near Ropar
(also known as Rupnagar) in the eastern region of Punjab Bordering Himachal Pradesh. It is built
by side of Nagal Hydrel Channel and bounded by Sirsa, Mansali and Sutlej rivers. It is about 12
km from Ropar and about 55 km from Union Territory of Chandigarh. The Power Station site is
accessible from the National Highway NH-21. The nearest village to the site is Ghanauli. To bridge
the gap between Power demand and supply in Punjab, this project was planned in 3 stages, each
having 2 units of 210 MW capacity. The historic town of Ropar was selected for this project due
to availability of railway track capacity for transportation of coal, cooling water from Nangal Hydel
Channel and Land.
Figure 1.1: External View of Plant
The power plant is one of the coal-based power plants of PSPCL. The plant has an installed capacity
of 1260 MW. The first unit was commissioned in September, 1984. During March 1985, the second
unit was commissioned and in later years four more units were added. The station received the
Incentive award for reducing fuel oil consumption in 1999.
1
The station also received the Shield and excellent performance by Prime minister of India during
1986-87 for achieving 70.08% PLF against 53.2%. Currently the Major source of coal is the coal
mines in Chhattisgarh.
1.2 UNIT COMMISSIONING
Table 1.1: Unit Commissioning
Stage Unit Installed Capacity Date of Status

Number (MW) Synchronization
First 1 210 September, 1984 Not-Running
First 2 210 March, 1985 Not-Running
Second 3 210 March, 1988 Running
Second 4 210 January, 1989 Running
Third 5 210 March, 1992 Running
Third 6 210 March, 1993 Running
1.3 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 fluid, 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) firing 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
2
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 fin welded walls.
Figure 1.2: Boiler
The maximum flue 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.
Table 1.2: Boiler's Technical Data
TYPE WATER TUBE SINGLE DRUM

WITH
REHEATER
CAPACITY 680 TONS/HR
MAKE BHEL
STEAM TEMPERATURE 540 C
EFFICIENCY 87.16%
STEAM PRESSURE 155 KGMS/CM2
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 flows
and is connected to the drum by Down Comers. This arrangement of boiler avail 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.
3
1.4 FAN
1.4.1 PRIMARY AIR FAN

The functions of the P.A fan are to supply air in the furnace or combustion. Air supplied by P.A
fan and FD fan combine together to make total air flow in furnace and air supplied by PA fan is
used to dry and transport the pulverized coal from coal mills to furnace and referred to as primary
air. There are 2 PA fans per boiler and fan capacity is 70 m3/sec.
1.4.2 FORCED FRAFT FAN

The functions of the forced draft fan are to supply air at required pressure to furnace for proper
combustion and to control the quality of air in furnace. There are 2 F.D fans per boiler and fan
capacity is 110 m3/sec.
Figure 1.4: Forced Draft Fan Figure 1.3: Induced Draft Fan
1.4.3 INDUCED DRAFT FAN

The functions of the induced draft fan are to remove flue gases from the furnace and to maintain
negative pressure in the furnace. There are 3 I.D. fans per boiler. The fan capacity is 230 m3/sec.
1.5 TURBINE
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 blades & a ring of moving blades. The
steam glides over blade surface without striking it. As the steam flows over the covered surface of
blade, it exerts pressure on the blade along its whole length owing to its centrifugal force. The
4
Figure 1.5: Turbine
motive force on the blade will be the resultant of the centrifugal pressures on the blade length plus
the effect of change of the steam as it flows over the blade.
Table 1.3: Turbine's Technical Data
TYPE 3 Cylinder mixed flow tandem

coupled
MAKE BHEL
CAPACITY 210 MW
SPEED 3000 rpm
STAGES 3 (HP, IP, LP)
INLET STEAM PRESSURE 150 kg/cm2
INLET STEAM 535°C

TEMPERATURE
1.6 CONDENSER
The steam after working in the turbine is condensed in
the condenser in each unit installed below the LP
exhaust. The condenser is of surface type made of
fabricated construction in single shell. The tube nest is
of divided type double pass arrangement, having two
independent cooling water inlet, outlet and reserve and
Figure 1.6: Condenser
water boxes. This arrangement facilitates the operation
5
of one half of condenser hen the other half is under maintenance. It is provided with integral air-
cooling zone at the center from where air and non-condensable gases are continuously drawn out
with the help of mechanical vacuum pump. The condensate is collected at the bottom portion of
the condenser called the hot well from where it is pumped up to the deaerator by the condensate
pumps through the different heating stages. The function of the condenser is to condense the out
coming steam from LP turbine. In the condenser cooling water flows through the tubes and exhaust
steam from the turbine outside the pipes.
1.7 WORKING OF THERMAL POWER PLANT

Water from Bhakra Main Line Canal is taken for condensing exhaust steam & cooling of bearings
of the auxiliary equipment and purified in Demineralization Plant for converting into superheated
steam in the boiler. The hot cooling water from the condensers is discharged into Sutlej River via
its tributary, the Sirsa River.
Figure 1.7: Layout of GGSSTP
680 Tons of steam per hour at a temperature of 540 ⁰C and pressure 155 kg/cm2 produced in boiler,
is fed to turbine for rotating the rotor of generator at 3000 rpm to generate electricity at 15.75 KV.
It is stepped up to 220 KV by 250 MVA step up power transformer and is fed into Grid. Each unit
consumes about 3000 Tons of coal daily. Coal is transported from distant collieries in Bihar and
Chhattisgarh by Railways in rakes. Each rake consists of about 58 wagons and each wagon contains
about 58 Tons of coal. Coal is unloaded in Coal Plant by Wagon Tipplers. About 12 wagons are
6
emptied by Wagon Tippler in one hour. After tippling of wagons, coal passes through Primary and
Secondary Crushers from where 25 mm sized coal is further pulverized in Bowl Mills to feed in
the Boiler for burning to produce superheated steam. To start the units, start-up power is taken from
220 KV Grid Sub Station through 50 MVA, 220/6.6 KV start-up/Station Transformers, one
transformer for each stage.
1.8 COAL HANDLING PLANT
Figure 1.8: Coal Handling Plant
The coal handling plant is that unit of the 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. In addition, it
should burn in such a way that it gives out maximum heat with minimum wastage. The coal is
transported to the coal yard from the coalmines through railways. A rake is defined as a train
containing about 58-60 wagons. Each wagon contains about 58 Tons of coal and weight of the
wagon itself is 2 Tons. There are shunt engines, which are used for placement of wagons. The plant
has six shunt engines, two of which are of 350 H.P. capacities and four are of 650 H.P. each. There
are two ways of placing a wagon for emptying, either through shunt engines or through a beetle
charger. The wagon tippler used to empty the wagon uses an induction motor. The induction motor
7
has a capacity of about 96 H.P. There is a gear system connected with the motor that helps in
increasing the torque of the motor, thereby reducing the speed.
Figure 1.9: Coal Pit
The coal used at Ropar Thermal Plant is bituminous type. Coal, which is used in the boiler, is of
two types. One is the Indian coal, which has high ash content, and the other one is the coal imported
from Australia and New Zealand, which has very low ash content. The boilers used here are of E
grade. If only Australian coal is used, it may burst the boiler due to the generation of excessive
steam. So, 75:25 ratio of Indian and Australian coal is used. It is transported from coalmines to the
plant site by railways. The coal consumption at Maximum Continuous Rating (MCR) is about 160
tons/hour. The plant has Dead Storage in a corner of plant having capacity to store coal for ½ or 1
year whereas Live Storage can store coal for 24 to 30 Hours and is situated near boiler furnace.
Since the daily requirement of coal for both stages is 12,000 MT, 3.5 Lakh Tons of coal can be
stored. To transfer coal in the coal yard Portable conveyors or Tractor scrappers are employed.
Stationary conveyers are used to transport coal to bunkers or to stack it in the coal stockyard area.
1.8.1 BASIC FUNCTIONS
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.
8
1.8 2 EQUIPMENTS INSTALLED
Wagon Tipplers 5 Nos.
Primary Crushers 4 Nos.
Secondary Crushers 4 Nos.
Stacker cum Reclaimer 3 Nos.
Beetle Charger 3 Nos.
Tippler Trolley 6 Nos.
Coal Pulverizing System 6 Nos./ Unit
1.8.3 WAGON TIPPLER

Wagons tippler- these are 5 in no are used for unloading the coal wagon tippler consists of rail
table, tracks, pits holding beam. It has a pit. 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 rail table is
turned at an angle of 135°. With the help of A.C. motor whose H.P. is 95.
Figure 1.10: Wagon Tippler
9
The whole process is mechanical. Shunters are used for placing the wagons on rail table. The whole
wagon get unload in 4 minutes (app.). The weight of wagon is measured with the help of electronics
motion wave Bridge. Approximately weight of wagon is 82 ton including weight of wagon. Each
wagon contains 58 tons of coal. The types of wagon are n-type and c-type. Shunter or loco have
the H.P. of 450 H.P. and 650 H.P. During measuring of wagon, the speed of train should be 5Km/hr-
10Km/hr and weight is measured with electronics motion wave bridge. Coal is stored in crushed
and uncrushed form uncrushed form, raw coal pile area where uncrushed coal is stocked. Crushed
coal at stacker cum reclaimer. Stone pickers are stationed at primary and secondary crushers to
remove the stones the iron particles are removed by magnets. Magnets used are of permanent
magnet or cross belt suspended magnets. Permanent magnets are on the conveyer belts used to lift
the particles and particles are removed. Cross belt suspended magnets are surrounded the belt in
circular motion it has iron bars comes near the belt and become magnet and picks up the iron
particles. When it moves away, it demagnetizes and removes the particles.
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CHAPTER 2
HIGH TENSION (H.T.) & LOW TENSION (L.T.)
SWITCHGEAR
2.1 HIGH TENSION SWITCHGEAR

All the major auxiliaries are drawn by H.T. Supply. Various H.T. switchgears are used for various
system requirements
1.) 6.6 kV H.T. Switchgear  Stage I (Unit I & II)

2.) 6.6 kV H.T. Switchgear  Stage II (Unit III & IV)
3.) 6.6 kV H.T. Switchgear  Stage III (Unit V & VI)
4.) Ash Handling Plant Switchgear  Stage III Only
2.1.1 STATION AND UNIT BUSES

The 6.6 kV switchgear for stage I of GGSSTPP, Ropar comprises of station board C-1A, C-1B and
unit boards 1A, 1B and 2A, 2B, apart from these there are also coal handling and coal ash handling
switch boards. In addition, there are station boards C-2A and C-2B. Station boards C-1A & C-1B
are being fed from 50MVA, 220/6.6 kV Station Transformer No.1 and Station boards C-2A and
C-2B are being fed from 50 MVA, 220/6.6 kV Station Transformer No.2. There is provision for
feeding C-1A and C-1B buses from C-2A and C-2B buses respectively through tie-breakers.
For stage II, Station buses C-2A and C-2B are fed from Station Transformer No.3, Unit Buses 3A
and 3B are from unit 3, 4A and 4B are from unit 4. When unit is not running, unit buses 3A and
3B are fed from C-3A and C-3B, and 4A and 4B are fed from C-3B. When the unit is running, unit
buses 3A and 3B can be switched over to Unit Auxiliary Transformer (UAT) 3A and 3B and
Similarly unit buses 4A and 4B can be switched over to Unit Auxiliary Transformer (UAT) 4A and
4B respectively.
Stage III, buses C-4A and C-4B are fed from station transformer no. 4. The buses C-4A & C-4B
can be fed from Station Transformer no. 2 also making an extension bus at C-3A & C-3B bus has
made this arrangement.
The 6.6 kV system has the following buses and Feeding transformer:
1.) Station bus: (2 no. For each stage)

2.) Unit bus: (2 no. For each unit)
11
12
13
At stage I, the station bus is fed from station transformer (50 MVA, 220/6.6 kV). For tie to unit
buses there is isolator in between the station and unit buses on the unit buses (which all the time)
and there is breaker on the station bus which has the selective change over and fast change over
and flow change over facility. There is a set of two breakers for the purposes of Tie link between
the station bus 1 and station bus 2. For this purpose, there are two no. Of isolators on station bus 2
are provided. In stage 1 the station transformer no. 2 is installed. This is a stand by transformer.
Unit buses are fed from 15 MVA, 15.75/6.6 kV-Unit Auxiliary Transformer. The unit buses are
supplying the following load.
1) Primary air fan 2) Induced draft fan
3) Forced draft fan 4) Coal mills
5) Boiler feed pumps 6) Condensate extraction pump
7) Electrostatic precipitator transformer 8) Unit service transformer
2.1.2 CIRCUIT BREAKERS

At GGSSTP following types of circuit breakers are installed:
1) Minimum Oil Circuit Breaker (by Jyoti Ltd.)

2) Vacuum Circuit Breaker (by Siemens)
3) Vacuum Circuit Breaker (by ABB)
MOCB type of circuit breaker minimum oil is used as an arc quenching medium and it is mounted
on a porcelain insulator to insulate it from the earth. The arc chamber of such type of circuit breaker
is enclosed in a bakelised paper. The lower portion of this breaker is supported by the porcelain
and the upper porcelain enclosed the contacts.
This circuit breaker is of the single breaker type in which a moving contact tube moves in a vertical
line to make or break contact with the upper fixed contacts mounted within the arc control devices.
A lower ring of fixed contacts is in permanent contact with the moving arm to provide the other
terminal of the phase unit. Within the moving contact, the tube is a fixed piston. When the moving
contact moves downwards, it forces the insulating oil to enter into the arc control devices. Thus,
the arc gets extinguished. Mainly in plant the installed breakers are of 1250A and 2000A rating.
14
Figure 2.1: Maintenance work held at Plant
Figure 2.2: MOCB Wiring Diagram
As in wiring diagram of MOCB ‘C’ represents Closing coil, ‘S’ represents Shunt tripping coil, ‘H’
is contactor for spring charging motor mechanism, and ‘M’ is Spring Charging Motor.
In Vaccum type circuit breaker mainly used for medium voltage ranging from 11 KV to 33 KV.
Vacuum circuit breaker has a high insulating medium for arc extinction as compared to the other
circuit breaker. The pressure inside the vacuum interrupter is approximately 10-4 torrent and at this
15
pressure, very few molecules are present in the interrupter. The vacuum circuit breaker has mainly
two phenomenal properties.
When the fault occurs in the system, the contacts of the breaker are moved apart and hence the arc
is developed between them. When the current carrying contacts are pulled apart, the temperature
of their connecting parts is very high due to which ionization occurs. Due to the ionization, the
contact space is filled with vapour of positive ions which is discharged from the contact material.
The density of vapour depends on the current in the arcing. Due to the decreasing mode of current
wave their rate of release of vapour fall and after the current zero, the medium regains its dielectric
strength provided vapour density around the contacts reduced. Hence, the arc does not restrike
again because the metal vapour is quickly removed from the contact zone.
2.2 LOW TENTION SWITCHGEAR

415V L.T. switchgear is installed to control the internal drives of the plant which are three phases
AC motors. All drives which operate at 415V AC supply are controlled from this section. Small
size motors IE (International Efficiency) motors of capacity 90 kW & current carrying capacity
below 300 A are controlled from modules. On the other hand, motors of capacity more than 90 kW
are controlled through circuit breakers.
For modules control supply is 110V AC and for circuit breakers control supply is 220V DC. To get
110V AC step down transformers (415/110 V) are installed inside the modules. For 220V DC
supply 12 V batteries are connected in series.
2.2.1 415 V STATION SERVICE SWITCHGEAR

There are two 415V station service switchgear buses, which are energized through two Station
Service Transformers (2000 KVA, 6600/433 V). There is a bus coupler between the two buses.
11F is the isolator (which is always kept closed). In case any of the SSS/G incomer breaker trips
bus coupler 10F (also called tie to another unit) will close automatically. These buses feed the
common 415V auxiliaries of unit 5 and 6.
Under normal Conditions both the 415V SSS/G buses A & B should be independently charged
from SST A & B respectively. Bus coupler 10F should be off and tie isolator 11F should be in
closed position.
Dead Bus Closing
1) Close 6.6 kV Breakers of SST.
16
2) Give a trip command to 9F.

3) Close breaker 9F, 10F will also get closed and both the buses will be charged.
To isolate one of the SST
1) 415 V SSS/G trip selection switch to be put on breaker.

2) Synchronization Switch of bus coupler 10F in synchronization position.
3) Check that synchronization relay lamp should be glow.
4) Closed breaker 10F, 9F will trip accordingly.
2.2.2 415 V UNIT SERVICE SWITCHGEAR

There are two-unit service switchgear buses for each of units 5 & 6. These buses are energized
through two Unit Service Transformers (1600 KVA, 6600/433 V). There is a bus coupler between
two buses. These buses feed 415 V unit auxiliaries.
Under Normal Conditions both the 415V USS/G buses A & B should be independently charged
from UST A & B respectively. Bus coupler should be open. In case any of UST incomer breakers
trips bus coupler 11F will automatically close.
Dead Bus Closing
1) Close 6.6 kV Breakers of UST.

2) Give a trip command to 10F.
3) Close breaker 13F.
4) 11F will also get closed and both the buses will be charged.
2.2.3 415 V EMERGENCY BUS STAGE III

Buses of unit 5 & 6 are normally energized from emergency service transformer 3 & 4 respectively.
These buses can be alternatively energized from USS/G 5B/6B also. In case of grid failure, the
emergency supply buses are charged from Diesel Generator sets. There are three DG sets IE DG
set 7, 8 & 9. Set 7 is for unit 5, 8 for unit 5 & 6 and 9 for unit 6.
Under normal conditions
1) EM bus is charged from EST.

2) Breaker 8F,10F, 6F & 4F is off.
3) Breaker 7F and 9F are off.
In case of Grid Failure
17
1) DG set 7 & 8 will start due to under voltage on EM bus 5.

2) Check that Breaker 8F, 9F, 10F on EM bus are off.
3) Trip breaker 4F.
4) Close breaker 10F, 6F, 5F.
5) In Case 5F DG does not closed or DG set 7 does not start.
2.2.3 ABOUT MODULES & L.T. CIRCUIT BREAKER

Modules are used for drives of capacity below 90kW. Modules are designed using power contactor
and some auxiliary contactors. Module consists of: -
1) One power contactor.

2) One over load relay or coil.
3) Auxiliary contactor 1 for 24V AC supply to motor
winding under stand still conditions.
4) Contractor 3 for indication purpose on panel.
5) 500VA, 415/110 V transformer.
Power contactor is a main contactor through which 45 V supply is

given to the motor and motor is switched on or off from is
contactor. Overload relay will be energized when motor is over
Figure 2.3: Inside view of Module
loaded and this will cut the supply to the motor by tripping the
power contactor.
There is provision for 24V AC supply provided to the motor which keeps the motor in warm
condition so that moisture could not affect the winding, when the motor is in stand still position.
Another auxiliary contactor is used which will trip with an over load on motor. This will not close
if the main contactor is not closed. Once this contactor is tripped this will not close automatically
even if the main contactor is closed. To close this contactor an additional command is required
which will close this contactor to bring the motor in working condition.
18
CHAPTER 3
ELECTRIC MOTOR REPAIR WORKSHOP
Guru Gobind Singh Super Thermal Plant has separately installed site which is specially made for
repairing electric motors. As we know that there are dozens of auxiliary systems in GGSSTP, that
support the main generator and prime mover. Electric motors are essential to numerous plants
operations. There are electric motors used for lube oil circulation, cooling including air and water.
air compressor, water processing, and many other power plant specific applications.
Electric motors are essential for making sure that plants are running smoothly and effectively. If
one fails, it can mean costly downtime for the plant and create a variety of safety hazards. There
are a number of different failure modes out there. Why they come out, well there are many reasons
for failed or burned motor. It might be due to moisture inside it, bearing failure, insulation failure,
overloading there are a number of potential issues. Contamination and moisture can lead to winding
failures. Often times, this is because they are not stored in ambient areas. Overheating is another
issue that can cause a motor failure. In one word we say that during abnormal conditions, when
rate of heat generation inside motor is more than heat dissipation then motor winding insulation
damaged and motor will burn out.
3.1 SMALL SIZED INDUCTION MOTORS
3.1.1 REPAIRING OF CEILLING FAN

Ceiling fans run on single phase 220V AC and power consumption is usually between 60 to 120
watts. The speed of a ceiling fan is commonly
between 200 RPM to 400 RPM where RPM
stands for revolutions per minute. The electric
motor in a ceiling fan is generally a single-phase
AC induction motor. Spilt phase capacitor type
Single phase AC motor is generally used in
Ceiling fans. Ceiling fan’s outer part is the rotor
Figure 3.1: Circuit Diagram of Celling Fan
and inner part is the stator. The rotor is a closed
ring like magnetic core and is made of laminated steel. It has slots. Copper or aluminum bars are
placed on the slots and are short circuited on both ends.
19
The stator consists of a hollow shaft to which is attached a core of laminated steel. The core has
slots for placing winding. There are two windings in a
ceiling fan. The windings are distributed windings and
are placed in the slots of the core attached to the hollow
shaft. One winding is called starting winding and the
other winding is called running winding. A capacitor is
connected with the starting winding. The value of the
capacitor is between 2 to 5 microfarads. Three leads
come out of the stator winding. One lead is common to
Figure 3.2: Winding Machine
both starting winding and running winding. The resistance of the running winding is generally less
than that of the starting winding. Running winding and the series connection of the capacitor and
starting winding are connected in parallel with the 220 volts AC supply.
Figure 3.3: Celling Fan Coils Arrangement
The capacity and efficiency depend on RPM, blade length, blade area and angle of tilt of fan blades.
Blades are usually made of metals like aluminum. When the fan rotates, the diameter of the circle
described by the outer ends of the blades is called the sweep diameter. Usual sweep diameters are
36", 42" and 52" but sweep diameters between 24" and 72" is possible. The angle of tilt of blades
is commonly between 9 to 13 degrees.
20
Table 3.1: Repaired Fan's Technical Specification
Stack Size 16 mm No. of Slots 28

Running Coils Starting Coils
No. of Coils 14 No. of Coils 14
No. of Turns 360 No. of Turns 410
S.W.G. 36 S.W.G. 36
Slot Pitch 2 Insulation Class F
Common problems are break in the winding, leakage from the winding, defective capacitor, fault
in speed regulator etc. Incorrect fixing of fan blades may cause wobbling of the whole fan. Noise
while the fan is running indicates problem in the bearing and the bearings should be cleaned and
re-lubricated.
3.2 MEDIUM SIZED INDUCTION MOTOR

Large size induction motors are widely used in thermal plant. Induction motors are the most
commonly used prime mover for various equipment in industrial applications. In induction motors,
the induced magnetic field of the stator winding induces a current in the rotor. This induced rotor
current produces a second magnetic field, which tries to oppose the stator magnetic field, and this
causes the rotor to rotate. The 3-phase squirrel cage motor is the workhorse of industry; it is rugged
and reliable, and is by far the most common motor type used in industry specially in power plant.
The 3-phase induction motor has three windings each connected to a separate phase of the power
supply.
The current through each coil varies sinusoidal with

time, 120o out of phase with the other coils. This
means that the current in coil B is delayed by 1/3 of a
period from that in A, and the current in coil C is
delayed 1/3 of a period from that in B (Figure 3.5).
The rotor sees the net rotating magnetic field created

by the three coils and rotates, creating the torque on
Figure 3.4: Winding Arrangement
the motor drive shaft. This field rotates either
clockwise or counter clockwise, depending on the order of the phases connected to the motor.
21
Reversing a 3-phase motor's direction is simply achieved by changing the connection order of two
of the three conductors. The rotating field speed depends on the number of magnetic poles in the
stator and is referred to as the synchronous speed.
120 × 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 (𝑓)

𝑆𝑦𝑛𝑐ℎ𝑟𝑜𝑛𝑜𝑢𝑠 𝑆𝑝𝑒𝑒𝑑 (𝑁) =
𝑁𝑜. 𝑜𝑓 𝑃𝑜𝑙𝑒𝑠
Where 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 refers to the power supply frequency (e.g. 50 Hz).
The number of magnetic poles (or simply poles) is the principal design factor affecting speed in
AC motors.
3.2.1 REPAIRING OF 200 HP INDUCTION MOTOR

At GGSSTP, we have repaire burned 200 HP induction motor. It has Double layer fractional type
Lap winding.Double layer windings are universally used for armatures of synchronous generators
and motors and most induction motors of large and medium sizes. Double layer windings may be
classified into two categories depending upon the method used to bring about the transition from
the top layer to bottem layer. There are
1) Lap type 2) Wave Type
Lap windings have their widest field of application in the stators of high speed machines. Wave
windings are used for wound roter of medium and large size induction motors.
The number of coil sides per slot in double layer windings of a.c. machines is invariably 2.
Therefore number of coils is equal to number of slots.
i.e. C = S
the winding used for a.c. machines are usually chorded. The advantage of a chorded (short phich
or fractional pitch) winding are :
i) The amount of copper used in the overhang is reduced.

ii) The magnitude of certain harmonics in the mmf and also emf is reduced.
Double layer windings can be either
1) Integral Slot or
2) Fractional Slot
When number of slots per pole per phase is an integer, it is known as integral slot winding.
22
Figure 3.5: Coil made of multi-turns
For example: Consider a stator having 48 slots and wound for 4 poles and 3 phases. The
number of slotes per pole per phase is
𝑆
𝑞=
𝑚 × 𝑝
Where S = no. of slots, 𝑚 = phase System , p = no. of poles
48
Hence q = = 4, which is an integer. The winding is thus an integral slot winding.
3× 4
When number of slots per pole and also number of per pole per phase is not integer, the winding is
known as Fractional slot winding.
For example: Consider a stator having 78 slots and wound for 8 poles and 3 phases. The
78 1
number of slotes per pole per phase, q = = 3 4 , Thus q is not an integer. The winding
3× 8
is thus an Fractional slot winding.
23
Table 3.2: Motor's Specification
Power Rating 200 H.P.

R.P.M. 1500
No. of Poles 4
No. of Slots 24
Type of Winding Layers Double Layer
Winding Kind Lap winding with full pitch coils
S.W.G. of Copper wire 18.5
No. of Coil Sides 48
Coil Side per slot 2
Calculation:
24
Slot per pole per phase, q = =2
3× 4
180° 180°
Phase spread, 𝜎 = = = 60⁰
𝑚 3
Number of pole phase groups/pole = 3.
Thus, there are 3 phase groups per pole each comprising of q = 2 slots. The distribution of slots, of
phase sequence RYB, is :
R 1, 2 7, 8 13, 14 19, 20
B 3, 4 9, 10 15, 16 21, 22
Y 5, 6 11, 12 17, 18 23, 24
For full pitch coils, coil span Cs = 24/4 = 6 slots.
Back Pitch, Yb = Coil span + 1
Front Pitch, Yf = Coil span – 1
This means that the top coil side in slot 1 is to be connected to bottom coil side in slot (6 + 1) = 7
or in terms of coil sides we have Yb = 13 and Yf = 11
24
Coil side 1 (top) is connected to coil side (1+13) =14 (bottom). Coil sides 1 and 14 form a coil.
Figure 3.6: Stator Under Repair at Plant
Similarly, Coil side 3 is connected to coil side (3+13) = 16 (bottom).

The starts of the phases must be displaced by 120° and so must the finishes.
The angle between adjacent slots is as
180 × p 180 × 4
𝛼𝑠 = = = 30⁰
𝑆 24
So, if the start of phase R lies in slot 1, the start of phase Y must be in slot (1 + 120°⁄30°) = 5 and
that of phase B in slot No. (5 + 120°⁄30°) = 9. This makes the phase sequence RYB.
25
Figure 3.7: Emf induced in various coils
The starts of phases R, Y and B are represented by SR, Sy, SB respectively.
Figure 3.6, represents the emfs induced in various coil sides. e1, e2, e3 …. etc. denote the
emfs induced in coil sides 1, 2, 3 ...... etc. It is clear that in the case of full pitch coils the
emfs of two coil sides forming a coil add algebraically.
Complete winding diagram is shown in Figure 3.8.
26
27
Figure 3.8: 3 Phase, 24 Slot, 4 Pole, Double Layer Lap Winding with Full Pitch
Coils.
CHAPTER 4
220 KV, 132 KV SUB-STATION AND ITS INSTALLED
VARIOUS EQUIPMENTS
4.1 ABOUT SUBSTATION

Guru Gobind Singh Super Thermal plant’s substations plays an important role for transmitting
generated power to various another substation. It is a main source of power supply of this substation
is the Generator Transformers GT-1, GT-2, GT-3, GT-4, GT-5 and GT-6 that are installed on
Transformer Yard on plant side. In order to initially run the plant, there is need of external power
supply which is also given by it to plant through Station Transformers ST-1, ST-2, ST-3 and
ST-4. As we know that, the main function of the switchyard or the substation is to receive the
electrical power generated by the generator at desired level and then step-up or step-down to certain
level and distribute it with the help of various equipment 's installed in substation such as
Transformer, Circuit Breaker, Bus-Bar, Lightening Arrestor, Isolator, CT's, and PT's etc.
The whole substation is divided into four parts:

1) 220 kV Switch-yard
2) 132 kV Switch-yard
In 220 kV, 132 kV switch-yard following equipment are used:

1) Two 132/220 kV transformers of 100MVA
2) 220 kV, 132 kV of Main Bus & Reserve Bus
3) Circuit breakers
4) Isolators
5) Current transformer
6) Potential transformers
7) Wave trap
8) Coupling capacitor
9) Lightning arrestor
10) Disk type insulators
28
29
Figure 4.1: Single line Diagram of 220 kV & 132 kV Substation

4.1.1 VARIOUS OUTGOING FEEDERS
220 kV Feeders going to 132 Feeders kV going to
Gonsgarh Gujrat Ambuja Cement Factory

Ghulal Ropar
Jadla-1 Asron
Jadla-2
Gobindgarh-1
Gobindgarh-2
Gobindgarh-3
Bassi Pathana
Kharar
Mohali
4.2 EQUIPMENTS INSTALLED AT SUB-STATION
4.2.1 ISOLATOR
In Sub-Station, it is often desired to disconnect a part of the system for general maintenance and
repairs. This is accomplished by an isolating switch or isolator.
Figure 4.2: DBR Isolator
An isolator is essentially a knife Switch and is design to often open a circuit under no load, in other
words, isolator switches are operateable only when the line on which they are connected carry no
load. It prevents the voltage from being applied to some given sections of the bus in a switchgear
installation or to one or another piece of apparatus in installation.
30
Table 4.1: Isolator's Specification
Make SMCL
Type Double Break Rotating
Rated Voltage 220 kV
Current 1600-2000 A
Control Voltage 220V DC
For example, consider that the isolator is connected on both side of a circuit breaker, if the isolators
are to be opened, the C.B. must be opened first.
4.2.2 MAIN & RESERVE BUS

When numbers of generators or feeders operating at the same voltage have to be directly connected
electrically, buses are used as the common electrical component. The size of the bus bar determines
the maximum amount of current that can be safely carried. Material used for Bus bar conductors is
Tarantula Aluminum with capacity of 1800 Amps.
Figure 4.3: Main & Reserve Bus
It is important that break downs and maintenance should interfere as little as possible with
continuity of supply to achieve this, duplicate bus bar system is used. Such a system consists of
two buses, a main bus and a reserve bus with the help of bus coupler, which consist of the circuit
breaker and isolator.
31
4.2.3 INSULATOR
The insulator serves two purposes. They support the
conductor (or bus bar) and confine the current to the
conductor. The most commonly used material for the
manufacture of insulators is porcelain. There are
several types of insulator (i.e. pin type, suspension type
etc.) and there used in Sub-Station will depend upon the
service requirement.
At GGSSTP,
Figure 4.4: Suspension Type Insulator
Table 4.2: No. of Disk for KV Rating at Plant Connected in 220kV line
Voltage Rating No. of Disk in Suspension

type Insulators
220 kV 15
132 kV 8
4.2.4 CIRCUIT BREAKER

Circuit Breakers are used to Make and Break the contacts under normal or abnormal conditions.
They can be operated manually or automatically from remote as well as local. These breakers are
interlocked with isolators. Circuit breakers are provided with bypass line Isolators, which operates
in case of any fault in the circuit breaker. The circuit breaker installed in the switch-yard are triple-
pole, comprises of one or more Interrupters (one in SF6 CB & two in ABCB) per pole. There is a
set of fixed and moving contacts per interrupter and moving contacts can be drawn apart by means
of operating medium (spring or air). Suitable medium i.e. SF6 gas or Air extinguishes the arc
produced by the separation of current carrying contacts under normal or abnormal conditions.
Functions of circuit breaker are as under:
 It carries full load current continuously without overheating or damage.

 It opens and closes the circuit on load.
 It makes and breaks the normal operating currents.
 It makes and breaks the short circuit currents of magnitude up to which it is
designed for.
The Circuit Breakers used in the switchyard at GGSSTP are of two types:
32
4.2.4.1 Air blast Circuit Breaker

In this type of circuit breaker, air is used a s a quenching medium for arc. Air is used for closing
and tripping the circuit breaker. ABCB installed in switchyard is Axial Flow, Double Break,
Vertical Air Receiver and Two Interrupters per Pole. For Opening Operation the air pushes away
the moving contacts against spring pressure whereas for Closing Operation, air is let out of the
chamber there by closing the contacts by spring pressure.
Figure 4.5: Air Blast Circuit Breaker
In closing or opening operations if one of the poles fails to operate, the reverse pressure from same
pole automatically closes the other poles hence activate Backup Relay. Air compressors installed
at a central compressor room maintain the air pressure between the two contacts of the ABCB.
There are three compressors, which supply air to storage tanks at 65 kg/cm2. From storage tanks,
the pressure further reduces through reducer to 29 kg/cm2 at breaker's end. At 10 kg/cm2 the breaker
closes automatically. ABCB is preferred because of its Faster Operation, Low Maintenance,
Repeated Operation and Simple Assembly.
33
Table 4.3: ABCB's Specifications
Make ABB
Operation
By Air
(Closing, Tripping Quenching)
Working Pressure 28.5 kg/cm2
Impulse Voltage 1050 kVp
Rated Voltage 245 kV
Rated Current 4000 A
Rated Coil Opening Voltage 220V DC
Rated Coil Closing Voltage 220V DC
Breaking Current 31.5 kA
4.2.4.1 SF6 Circuit Breaker

In such circuit breaker, Sulphur hexafluoride (SF6) gas is used
as the arc quenching medium. The SF6 is an electronegative
gas and has a strong tendency to absorb free electrons. The
SF6 circuit breaker have been found to a very effective for
high power and high voltage service. SF6 circuit breakers have
been developed for voltage 115 KV to 230 KV.
It consists of fixed and moving contacts. It has chamber,

contains SF6 gas. When the contacts are opened, the
mechanism permits a high pressure SF6 gas from reservoir to
flow towards the arc interruption chamber. The moving
contact permits the SF6 gas to let through these holes. Also, if
the gas gets decreases there is a motor connected to the circuit
breaker. The motor starts operating if the gas went lower than
20.8 bar. There is a meter connected to the breaker so that it
Figure 4.6: SF6 Circuit Breaker
can be manually seen if the gas goes low. The circuit breaker
uses the SF6 gas to reduce the torque produce in it due to any fault in the line. The circuit breaker
has a direct link with the instruments in the station, when any fault occurs alarm bell rings.
34
Sulphur hexafluoride remains in a gaseous state up to 9 degree centigrade. Its density is about 5
time that of air and the free heat convection is 1.6 times as much as that of air a part from being
inert as a gas it is non-flammable, non-poisonous and odourless.
Table 4.4: Specifications of SF6 Circuit Breaker
Make Crompton Greaves Ltd.
Rated voltage 245 kV
Rated insulating level 1050 kVp
Rated frequency 50 Hz
Rated normal current 4000 A
Rated short circuit breaking 50 kA

current
Rated short circuit making 125 kAp
current
Control Voltage 110/220 V DC
Some of the advantages of using Sulphur hexafluoride are:
1) Due to outstanding arc quenching properties of sulphur hexafluoride, the arcing

time is very small. This reduces contact erosion.
2) Using sulphur hexafluoride gas at low pressure and low velocity, the current
chopping can be minimized.
3) During arcing of sulphur hexafluoride breaker, no carbon dioxide is formed and
hence no reduction of dielectric strength.
4) Sulphur hexafluoride is silent in operation and moisture ingression into the gas
cycle is almost null.
5) Sulphur hexafluoride is not affected due to variation conditions.
Despite its too many advantages there are few disadvantages too which is affecting its operation:
1) The disadvantage is the sulphur hexafluoride is suffocating to some extent. In case

of leakage in the breaker tank this gas being heavier than air settles in the
surrounding and may lead to suffocation of the operating person. However, is non-
poisonous.
35
2) SF6 is heavier than air so care must be taken when entering low confined spaces
due to the risk of oxygen displacement. Also, these circuit breakers are expensive
due to high cost of gas used and since gas has to be reconditioned after every
operation of the breaker, additional equipment is required for this purpose.
4.2.5 LIGHTNING ARRESTOR

Lightening Arrestor after the current transformer are used
so as to protect it from lightening i.e. from high voltage
entering into it. This lightening arrestor has an earth
switch, which can directly earth the lightening. The
typical lightning arrester also known as surge arrester has
a high voltage terminal and a ground terminal. It made up
of ZnO (Zinc oxide) material which acts as insulator
under normal condition but when a lightning surge or
switching surge travels down the power system to the
arrester, then it behaves like conductor and the current
from the surge is diverted around the protected insulation
in most cases to earth. In this way it protects the system
from surges.
Figure 4.7: Lightning Arrestor
Properties of good lightening arrestors: -
1) It should not take any current at working voltage.

2) It must provide a conducting path as abnormal voltage occurs on the system
3) It must be capable of carrying discharge current without damaging itself under abnormal
voltages.
Table 4.5:Lightning Arrestor's Specification
Make M/S insulator India Ltd.
Rated Arrestor Voltage 198 kV
Frequency 50 Hz
Normal Discharge
10 A
Current
36
4.2.6 INSTRUMENT TRANSFORMER

The line in Sub-Station operates at high voltage and carries current of thousands of amperes. The
measuring instrument and protective devices are designed for low voltage (generally 110V) and
current (about 5A). Therefore, they will not work satisfactory if mounted directly on the power
lines. This difficulty is overcome by installing Instrument transformer, on the power lines.
There are two types of instrument transformer:
1) Current transformer
2) Potential transformer
4.2.6.1 Potential Transformer

It is essentially a step down transformer and step down the voltage in known ratio. The primary of
these transformer consist of a large number of turn of fine wire connected across the line. The
secondary wire consists of a few turns and provides for measuring instruments and relay a voltage
which is known fraction of the line voltage.
Figure 4.8: Potential Transformer
The potential transformer works along the same principle of other transformers. It converts voltages
from high to low. It will take the thousands of volts behind power transmission systems and step
the voltage down to something that meters can handle. These transformers work for single and
three phase systems, and are attached at a point where it is convenient to measure the voltage.
Potential Transformer is designed for monitoring single-phase and three-phase power line voltages
in power metering applications.
37
Table 4.6: PT's Specifications
Make BHEL
High Voltage 245 kV
Insulation Level 1050 kVp
Frequency 50 Hz
Neutral Earthed
Nominal Primary Voltage 220 kV/ 110 V
4.2.6.2 Current Transformer

A current transformer is essentially a step-down transformer which steps-down the current in a
known ratio, the primary of this transformer consists of one or more turn of thick wire connected
in series with the line, the secondary consists of thick wire having large number of turns of fine
wire and provides for measuring instrument in order to measure the fraction of line current.
Current transformers are basically used to take the readings of the currents entering the substation.
This transformer steps down the current from 800 amps to 1 amp.
This is done because we have no instrument for measuring of such a large current. The main use
of his transformer is
1) Distance protection
2) Backup protection
3) Measurement
Like any other transformer, a current transformer has

a primary winding, a magnetic core, and a secondary
winding. The alternating current flowing in the
primary produces a magnetic field in the core, which
then induces a current in the secondary winding
circuit. A primary objective of current transformer
design is to ensure that the primary and secondary
circuits are efficiently coupled, so that the secondary
current bears an accurate relationship to the primary
current. The most common design of CT consists of
a length of wire wrapped many times around a silicon Figure 4.9: Current Transformer
38
steel ring passed over the circuit being measured. The CTs primary circuit therefore consists of a
single 'turn' of conductor, with a secondary of many hundreds of turns. The primary winding may
be a permanent part of the current transformer, with a heavy copper bar to carry current through
the magnetic core.
Table 4.7: CT's Specifications
Make Hindustan Brown Boveri Ltd.
C T Ratio 800/1, 1200/1, 1600/1 Amps.
Insulation Level 1150 kVp
Frequency 50 Hz
Short Time Current 31.5 kA
Care must be taken that the secondary of a current transformer is not disconnected from its load
while current is flowing in the primary, as the transformer secondary will attempt to continue
driving current across the effectively infinite impedance. This will produce a high voltage across
the open secondary which may cause arcing. The high voltage produced will compromise operator
and equipment safety and permanently affect the accuracy of the transformer.
4.2.7 WAVE TRAP

Line trap also is known as Wave trap. Its shape is like a
drum. It is connected to the main incoming feeder so that it
can trap the waves which may be dangerous to the
instruments here in the substation. What it does is trapping
the high frequency communication signals sent on the line
from the remote substation and diverting them to the
telecom/teleportation panel in the substation control room
(through coupling capacitor) and acts like Low pass filter
when power frequency currents are passed to switch yard
and high frequency signals are blocked. The Line trap
offers high impedance to the high frequency Figure 4.10: Wave Trap
communication signals thus obstructs the flow of these signals in to the substation bus bars. If there
were not to be there, then signal loss is more and communication will be ineffective/probably
39
impossible. Wave Trap unit is inserted between bus bar and connection of coupling capacitor to
the line. It is parallel tuned circuit comprising of inductor coil and capacitor. Main coil has
inductance of 0.2 mH to 2 mH. It offers high impedance to carrier frequency (35 kHz, 500 kHz)
and offer low impedance (less than 0.1 ohm) to the power frequency (50 Hz).
4.2.8 COUPLING CAPACITOR

The modulated carrier is let into power line through
coupling capacitor specially designed to with stand line
voltage under all-weather condition. The upper end of the
coupling capacitor is connected directly to the line and the
lower end is connected to the ground through a carrier
frequency chock coil or drain coil. Thus, coupling
capacitor forms the link between the PLCC equipment and
power line. They are used in range from 2200 pF to 10000
pF. It offers low impedance to high frequency and allows
them to enter line matching unit also it offers high
impedance to low frequency signals and block it.
Figure 4.11: Coupling Capacitor
The coupling capacitor are designed for outdoor use and hence to withstand normal atmospheric
phenomenon such as temperature & humidity changes, rain, snow, anticipated wind load, nominal
wire tension etc. at full rated voltage. In some case capacitive voltage transformers (CVT) used as
a source of line voltage for metering and protection as also used coupling capacitor for PLCC.
4.2.8 POWER LINE CARRIER CUMMUNICATION SYSTEM

The main purpose of PLCC is to transmit speech or to convey message from one sub-station to the
other sub-station through transmission line at high frequencies. Other purposes solve by PLCC are
Tele-control, Tele-metering, Tele-printing, Tele-indication and Tele-protection. All these signals
are being communicated in the carrier frequency range from 35 kHz to 500 kHz. Thus, by PLCC
system the various electrical quantities (voltage current & power) can be measured.
Principle of Operation of PLCC

In PLCC a speech signal is modulated with the carrier frequency ranging from 35 kHz to 500 kHz.
The voice signal is superimposed on carrier frequency waves, modulated signal is filtered &
amplified, and then it is transmitted over the power lines through Line-Matching Unit, protective
device and coupling capacitor. At receiving end, high frequency carrier signal is separated from
40
the HY power frequency with the help of line trap and coupling capacitor. Through LMU carrier
frequency signal sent to the PLC terminal where the speech signal is separated from the carrier
frequency and is sent to sub-scriber. Main equipment used in PLCC are wave trap, coupling
capacitor, LMU, PLC terminal and switching equipment.
41
CHAPTER 5
VARIOUS TRANSFORMER INSTALLED AT PLANT
Transformer is a static machine, which transforms the potential of alternating current at same
frequency. It means the transformer transforms the low voltage into high voltage & high voltage to
low voltage at same frequency. It works on the principle of static induction principle. When the
energy is transformed into a higher voltage, the transformer is called step up transformer but in
case of other is known as step down transformer.
The various transformers installed in the transformer-yard are as follows:
i) Generator Transformer (GT)

ii) Station Transformer (ST)
iii) Unit Auxiliary Transformer (UAT)
iv) Unit Service Transformer (UST)
v) Station Service Transformer (SST)
vi) Neutral Grounding Transformer (NGT)
vii) Auto-Transformer (AT)
GTs are used to step up the output voltage of the generator from 15.75 kV to 220 kV for
transmission purposes. It is an important unit because the failure of any one causes the unit to trip.
The Unit Auxiliary Transformer (UAT) that gives the supply to the various HT motors running in
the plant. They are 12 in number, 2 for each unit i.e. a total of 12 UATs. This transformer converts
15.75 KV to 6.6 KV, for the motors of the PA fan, ID fan and the other HT motors of the plant. All
the power consumed by the unit is tapped through the UAT to the auxiliaries. The UAT further
give power to the UST that distribute the power to lighting and LT loads. The ST is used to start
up the plant in the beginning. In case of a complete shutdown ST takes power from Grid for startup.
The ST gives power to SST that also distributes the power to lighting and LT loads.
Autotransformer is used to feed 132 kV line by stepping down 220 kV from main bus to 132kV.
The NGT is used to protect system from earth fault, switching surges and over-voltage.
5.1 TRANSFORMER’S BASIC STRUCTURE
5.1.1 CORE
Cores can be constructed as either a toroidal or laminated. Toroidal units typically have copper
wire wrapped around a cylindrical core so the magnetic fluxes, which can occur within the coil,
42
43
Figure 5.1: General Layout of Various Transforms Combination

doesn't leak out, the coil efficiency is good, and the magnetic flux has little influenced another
component. Laminated refers to the laminated-steel cores. These steel laminations are insulated
with a no conducting material, such as varnish, and then formed into a core that reduces electrical
losses.
5.1.2 WINDING
In most practical transformers, the primary and secondary conductors are coils of conducting wire
because each turn of the coil contributes to the magnetic field, creating a higher magnetic flux
density than the single conductor.
Windings are usually arranged concentrically to

minimize flux leakage the winding material
depends on the application. Small power and
signal transformers are wound with insulated solid
copper wire, often enameled. Larger power
transformers maybe wound with wire, copper or
aluminum rectangular conductors, or strip
conductors for very heavy currents. High
frequency transformers operating in the tens to
hundreds of kilohertz will have windings made of
Lit wire, to minimize the skin effect losses in the
conductors. Large power transformers use multi-
stranded conductors as well, since event low
power frequencies non-uniform distribution of
current would otherwise exist in large windings.
Each strand is insulated from the others, and the
Figure 5.2: Transformer winding
strands are arranged so that either at certain points
in the winding or throughout the winding, each portion occupies different relative positions in the
complete conductor. This "transposition" equalizes the current flowing in each strand of the
conductor, and reduces eddy current losses in the winding itself. The stranded conductor is also
more flexible than a solid conductor of similar size. Windings on both primary and secondary of a
power transformer may have external connections (called taps) to intermediate points on the
winding to allow adjustment of the voltage ratio; taps may be connected to automatic on-load tap
changer switchgear for Voltage regulation of distribution circuits.
44
5.1.3 TRANSFORMER OIL

The insulating oil has three purposes. It provides additional insulation, protects the insulation from
dirt and moisture and it carries away the heat generated in the cores Coils. The heat is produced in
the metal of the transformer, passes through the insulation and raises the temperature of oil and is
then cooled either through the walls of the tank to the surrounding air or to the water through water
cooling tubes. Generally paraffinic and naphthenic oil is used in transformers.
Transformer oil must fulfill the following specifications: -
1. High dielectric strength
2. Low viscosity
3. Purity
4. High flash point
5. Good resistance to emulsion
5.1.4 OIL GAUGE

It is used to indicate the oil level so that it can be read by a person standing on the floor. The oil
gauge may be provided with the alarm contacts which give an alarm to the switch board when the
oil level has dropped beyond permissible level due to oil leak, damage of coolant and due to any
other reasons.
5.1.5 CONSERVATOR OR EXPANSION TANK

The main operation of conservator tank is to keep
the oil clean and dry utmost temperatures. The oil
level of a transformer changes with the change in
temperature. The oil expands with the increase in
temperature and vice versa. Large power
transformers are also liable to over -loads which
may overheat the oil and consequently there is a
sludge formation if air is present. Occasionally
large power transformer also suffer short-circuits
and temperature rise become excessively high.
This causes vaporizations of the oil. The oil vapors
form explosive mixture with air that ignites and Figure 5.3: Conservation Tank
45
may cause a considerable damage. For these reasons it is necessary to prevent the oil from having
contact with air as well as moisture. For this purpose, conservators are employed.
5.1.6 BREATHER
The breather is of silica gel type provided with seal to ensure the gel is not in direct contact with
the external atmosphere but only with the quantity of air entering the conservator when transformer
is breathing. As silica gel absorbs the moisture and prevent transformer to degrade its property.
When silica gel becomes whitish pink in color then it should be replaced with new gel which is
blue in color.
Figure 5.4: Breather
5.1.7 RADIATORS
It is present outside the transformer. The radiators
pipes get cool in contact with air. This process
occurs as when gets hot it comes upwards and
enters to the radiators, the fans are provided in
order to cool the oil then it comes downward and
process goes on in order to cool the oil.
5.1.8 BUSHING
Porcelain bushings are provided on both side of the
tank from which end terminals of HV and L V
Figure 5.5: Radiator
windings are connected to external circuit. These
46
bushings insulate the winding terminals from the body. Bushings are also filled with the
transformer oil, which serves two functions i.e. cooling and insulating.
Figure 5.6: Bushing of Transformer
5.1.9 OIL PURIFYING TANK

It purifies the oil on regular basis. As motor is provided in it which pulls the oil upwards and oil is
filtered through thermosyphon as it consists of aluminium foil which filter out the impurities.
Figure 5.7: Oil Purifying Tank
47
5.1.10 PRESSURE RELIEF VALVE

It is mounted over the transformer. It expelled out the gases that are formed inside the transformer.
An electrical switch operates this valve when gas pressure increases.
Figure 5.8: Pressure Relief Valve
5.1.11 EXPLOSION VENT

It is like a tube which is provide outside. During severe conditions when there are more gas
formation and also the PRV not work only then the explosion vent expelled out the as well gases
to protect the transformer. Sometimes there is leakage of gases from the diametric surface of the
explosion vent. It is also connected with silica breather through conservator tank.
Figure 5.9: Explosion Vent
48
5.2 COOLING SYSTEM USED IN TRANSFORMER

When the transformer is in operation heat is generated due to iron losses, the removal of heat is
called cooling.
There are several types of cooling methods, they are as follows:
5.2.1 OIL NATURAL (ON) COOLING

Medium and large ratings have their winding and core immersed in oil, which act both as a cooling
medium and an insulating medium. The heat produce in the cores and winding is passed to the oil
becomes lighter and rises to the top and place is taken by cool oil from the bottom of the cooling
tank.
5.2.2 OIL NATURAL AIR FORCED (ONAF) COOLING

In this method the oil circulating under natural head transfers heat to the tank walls. The transformer
tank is made hollow and air is blown through the hollow space to cool the transformer. The heat
removed from the inner tank walls can be increased to five or six times that dissipated by natural
means and therefore very large transformers can be cooled by this method. However, the normal
way Ccooling the transformers by air blast is to use radiator banks of corrugated or elliptical tubes
separated from the transformer,. tank and cooled by air blast produced by fans.
5.2.3 OIL NATURAL WATER FORCED (ONWF) COOLING

In this method, copper cooling coils are mounted above the transformer core but below the surface
of oil. Water is circulated through the cooling coils to cool the transformer.
This method proves to be cheap where a natural water ·head is already available.
The method has, however, the serious disadvantage that it employs a cooling system which carries
water inside the oil tank. Since the water is at higher head than oil, therefore, in case of leakage
water in the cooling tubes will enter the transformer tank contaminating oil and reducing its
dielectric strength.
5.2.4 FORCED CIRCULATION OF OIL (OF)

In large transformers the natural circulation of oil is insufficient for cooling the transformer and
forced circulation is employed. oil is circulated by a motor driven pump from the top of a
transformer tank to an external cooling plant, where the oil is cooled. The cold oil enters the
transformer at the bottom of the tank.
The methods of cooling transformers by forced circulation of oil are classified accordingly as:
49
5.2.4.1 Oil Forced Air Natural (OFAN)

In this method oil is circulated through the transformer with the help of a pump and cooled in a
heat exchanger by natural circulation of air. This method is not commonly used. However, this
method proves very useful where the coolers have to be well removed from the transformer.
5.2.4.2 Oil Forced Air Forced (OFAF)

The method is depicted in Figure 5.10. The oil is cooled in external heat exchangers using air blast
produced by fans. It is interesting to note that the oil pump and fans may not be used all the time.
At low loads, the losses are small and therefore natural circulation of oil with an ONAN condition
may be sufficient to cool the transformer. At higher loads, the pump and the fans may be switched
on by temperature sensing element.
Figure 5.10: Oil Forced Air Forced Cooling (OFAF)
5.2.4.3 Oil Forced Water Forced (OFWF)

In this method the heated oil is cooled in a water heat exchanger. The pressure of oil is kept higher
than that of water and therefore any leakage that occurs is from oil to water. Also, there are no
condensation problems. At sites, where the cooling water has a considerable head, it is usual to
employ cascaded heat exchangers i.e. oil/water and water/water with the intermediate water circuit
being at a low pres5ure. This cooling method is suitable for banks of transformers, but from the
system reliability considerations not more than, say, three tanks should be connected in one cooling
pump circuit. The advantages of OFWF method over ONWF are that the transformer is smaller
and the transformer tank does not have to contain cooling coils carrying water.
50
The use of water as a coolant is common at generating stations, particularly hydro-electric stations,
where large supply of water is available. Transformers with a capacity of up to 10 MVA have a
cooling radiator system with natural cooling.
The forced oil and air circulation (OFAF) method is the usual one for transformers of capacities 30
MVA upwards.
As stated earlier, the forced oil and water (OFWF) is used for transformers designed for hydro-
electric plants.
At Plant, GT, ST and Autotransformer are provided with ONAF cooling method while SST, UAT,
UST and NGT are provided with ONAN cooling method.
5.3 GENERATOR TRANSFORMER (GT)

Generator Transformer is a 3 Phase, 50 Hz, Step-up, Three winding, oil immersed, ONAF type
transformer. GT is used step up the output voltage of the generator from 15.75 kV for transmission
of power to long distances. It is an important unit because the failure of any one causes the unit to
trip. Only one Generator Transformer is installed per unit and is connected between Generator Bus
and High Voltage Bus of 220 kV at Transformer Switchyard.
Figure 5.11: Generator Transformer (GT)
51
Primary of the GT is fed from 210 MW generator through conductor, which are placed in Insulating
Ducts made up of Aluminium of diameter 1000mm. Conductors are placed in these ducts with the
help of 48 space insulators. These ducts are filled with low-pressure instrument air at 50mm to
250mm WC to avoid moisture.
Table 5.1: Technical Data of GT
Make BHEL
Power Rating 250 MVA
C.T. Ratio 800/1 A
Voltage at No Load L.V. 15.75kV H.V. 220kV
Cooling Method ONAF
5.4 STATION TRANSFORMER (ST)

Station Transformer is 3-phase, 50 Hz, Step-down, four winding oil immersed and Manufactured
by TELK. Each ST is core type, two-tier transformer. This means that it has one primary winding
and two secondary windings of 6.6 kV each. It takes power from the grid at 220KV and steps it
down to 6.6 kV. There are Four ST installed at yard (One for Two units & One Standby) and is
connected between Main Bus in switchyard and all High Voltage Auxiliaries.
At the time of starting all the auxiliaries are supplied from the station transformer. When the
generator is synchronized and starts producing power about 80 % of the load are shifted on to the
UAT. The load that requires uninterrupted supply be left connected on the ST. Normally for load
beyond 45 MW ST feeds the auxiliaries and above this load the load is shifted over to the UAT.
The cooling system for the station transformer is ONAF at 50 KVA and ONAN at 40 KVA and
below.
Table 5.2: Technical Data of ST
Make TELK
Power Rating 50 MVA
C.T. Ratio 800/1 A
Voltage at No Load L.V. 6.6 kV H.V. 220kV
Cooling Method ONAN
52
Figure 5.12: Station Transformer (ST)
5.5 UNIT AUXILIARY TRANSFORMER (UAT)

Unit Auxiliary Transformer is a 15 MVA, 3-phase, 50 Hz, Step-down, Three winding, oil immersed
and ONAN type transformer. The input to UAT is tapped from input bus bars of the generator
transformer. There are two UAT for each unit. Before starting of the unit, UAT bus is connected
to the station bus. When the load increases above 45 MW, UAT take the load from the station
transformer. This transformer steps down 15.75 kV to 6.6 kV, which is fed to drive Conveyors,
BFP, FD Fans, PA Fans, ID Fans, Bowl Mills, CWP, CEP, ESP and Crushers. Cooling method for
the U.A.T is oil natural air natural.
5.6 UNIT SERVICE & STATION SERVICE TRANSFORMER

Unit Service Transformer (UST): Unit Service Transformer is a 15 MVA, 3-phase, 50 Hz, Step-
down, Two Winding, Oil Immersed and ONAN transformer. The input power to UST is fed from
UAT. UST is used to step-down 6.6 kV to 415V to feed various LT (Conveyor Belt Charger,
Wagon Tippler, Tipple Trolley, Stacker cum Reclaimer, Lubricating and Jacking Oil Pumps) and
Lighting Loads. There are Two UST per unit i.e. 12 for three stages.
Station Service Transformer (SST): SST is similar to UST in all aspects except that it is fed from
ST and there are Two SST per unit and feeds same LT and Lighting Loads at the time of starting
of unit.
53
5.7 NEUTRAL GROUNDING TRANSFORMER (NGT)

NGT is 1-phase, 50 Hz, Step-up, Two Winding, Oil Immersed transformer. L.V. of NGT is
connected to neutral point of ST and Earth whereas HV is connected to protection devices to detect
earth fault. During earth fault on the primary side, the zero-sequence current flow to the earth. NGT
offer very low impedance to fault current. There are two NGT separate for each output of ST.
5.7 AUTOTRANSFORMER (AT)

Auto-Transformer is a 100 MVA, 3-phase 50 Hz, Step-down, Two Winding, Oil Immersed and
ONAF Transformer. Its main function is to step down 220 kV from the main bus to 132 kV. Auto-
Transformer feeds three 132 kV feeders to Asron, Ropar and Ambuja Cement Factory.
Figure 5.13: Autotransformer (AT)
Table 5.3: Autotransformer’s (AT) Specifications
Make BHEL
Power Rating 100 MVA
Rated Voltage at no load HV 220kV LV 132 kV
Cooling Method ONAF
54
CHAPTER 6
GENERATOR AND ITS AUXILIARIES
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. The generator is coupled with the turbine that acts as prime
mover to rotate it.
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’s 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.
Figure 6.1: 210 MW Turbo-Generator
6.1 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
modern excitation and control systems are a great asset to the plant.
55
Table 6.1: Generator's Technical Data
Make BHEL
Maximum Continuous MVA Rating 247 MVA
Maximum Continuous MW rating 210 MW
Rated Terminal Voltage 15.75 kV
Rated Stator Current 9050 A
Rated Power Factor 0.85 Lag
Excitation Current at MCR Condition 2600 A
Excitation Voltage at MCR Condition 310 V
Rated Speed 3000 rpm
Rated Frequency 50 Hz
Direction of Rotation (from Slip Ring Side) Clockwise
Phase Connection Double Star
No. of Terminals Brought Out 9 (3Ph & 6N)
Capacitance of 3-Phase w.r.t. Earth 0.72 mF
Hydrogen Pressure 3.5 Kg/cm2
Torque Under Normal Condition 76.32 Tons meter
Efficiency at Full Load Condition 98.55 %
6.2 STATOR
The stator body with core and stator winding form the heaviest component of the entire Turbo-
generator. The active parts to be accommodated and the forces and torques arising during operation
call for a rigid and strong stator shell. Moreover, It Is designed to withstand high Internal pressure
Which may arise due to unlikely event of explosion of hydrogen air mixture without any residual
deformations.
Stator body is a totally enclosed 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 high rigidity
and strength. The arrangement, location and shape of Inner walls is determined by the cooling
circuit for the flow of gas and the required mechanical strength and stiffness. Size of Inner cells is
also selected on the basis of vibrational considerations resulting partly in greater wall thickness
than required from the point of view of mechanical strength. The natural frequency of stator body
56
Is Well away from any of exciting frequencies. Inner and side walls are suitably blanked to house
four longitudinal hydrogen gas coolers In-side the stator body.
6.3 STATOR WATER COOLING
Figure 6.2: Stator Water Pipes
One of the efficient ways of taking away the losses due to heat from the winding of any machine
is by direct cooling using water. High quality demineralized water is circulated through the hollow
conductor of the stator winding. The cooling water must have conductivity less than 2.5 micro
mho/cm.
Cooling circuit make use of either of the following water supplies
1. Distilled water.
2. Fully demineralized water from boiler feed water plant.
3. Condensate.
Water from the feed water plant or condensate may only be used if no chemicals such as ammonia,
hydrazine or phosphates are present in water. A part of water is bypassed and is treated in mixed
bed ion exchanger, connected in parallel with the stator winding, magnetic filter and expansion
tank and returned to the section side of water pump.
57
The heat absorbed by the Demineralized water is dissipated to the secondary coolant in the primary
water cooler.
Water treatment plant provided across stator winding, essentially comprises of an exchange tank
filled with anions and cations resins. The base substance of the exchanger resins is generally a
polymer containing group of diverse character featuring exchange activity. Cation exchanger
contains highly acidic group whereas anion exchanger contains highly basic group.
Any accidental leakage of hydrogen into the main distilled water stream is detected by a gas trap
device. Water from the outlet is collected in an overhead expansion tank which provides constant
level of water during normal running conditions. A water jet ejector is connected to the expansion
tank for creating vacuum for the purpose of removing any traces of gas in the water.
6.3 ROTOR
It is a long forging measuring about 9 meters in length and 1 meter in diameter. High quality heat-
treated steel is used whose main constituents are chromium, molybdenum, nickel and vanadium.
Slot pitch is selected in such a way that the displacement between two solid poles is 180 degrees.
Additional slots of short length are provided on poles.
Figure 6.3: Rotor
One acts as an outlet for the hydrogen, which cools the overhang, and the other is used to
accommodate damper segments acting as damper windings. Longitudinal slots are milled on
58
sophisticated milling machines. These slots house the field winding. One north and one South Pole
are obtained on the shaft.
The conductors are made up of hard drawn silver bearing copper. It has low electrical resistance
and high creep resistance so that the coil deformation due to thermal cycling at the start operation
is minimized. Layer of glass laminates insulates the individual turns from each other. Coils are
insulated from the rotor body by u-shaped glass laminate molded 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 gap is sucked through elliptical holes on the rotor wedges and is directed to flow along lateral
vent ducts on rotor. Winding is secured in slots by slot wedges made from duralumin alloy of
copper, magnesium and aluminium. Slot wedges behave as damper winding bars during
unbalanced operation.
6.4 SLIP RING & CARBON BRUSH GEAR

Slip rings consist of helically grooved alloy steel rings shrunk on the rotor body shaft. Both rings
are mounted on single bush. Slip rings are connected to the field winding through a semi flexible
copper leads and current carrying bolts. Two semicircular copper bars insulated from each other
and shaft are placed in a central bore of rotor joining two sets of current carrying bolts.
Figure 6.4: Maintaining Carbon Brush at Plant
The rotor shaft is supported on pedestal type of bearing. Rotor winding is solidly connected to the
slip rings. Field current to the rotor winding is provided by a brush gear. Brush gear is rigidly fixed
59
on the exciter side. Two brush gear stands each made of two symmetrical silicon brass casting half
rings. The brushes are spring-loaded type to maintain required contact pressure of 0.2 kg/cm2.
Brushes have low coefficient of friction and are self-lubricating provided with double flexible
copper leads. Before filling brushes are rubbed with medium and fine sandpaper in the direction of
rotation to obtain equal current distribution. Excessive pressure causes chattering and bouncing of
brushes. Insufficient pressure tends to cause sparking. Hot hydrogen gas is cooled by four gas
coolers mounted longitudinally inside the stator body. It consists of cooling tubes of brass with
coiled copper wires wound on them to increase the cooling surface.
6.5 OPERATING PROCEDURE OF TURBO-GENERATOR
6.5.1 STARTING OF GENERATOR

 Before starting following work should be completed:
1. All constructional work.
2. Erection of auxiliary and main equipment.
3. Checking of oil, water and gas systems.
4. Checking and setting of all protection and signaling schemes.
5. Safety precautions including firefighting.
 Before starting following is to be ensured:
1. Proper supply of oil in the bearings.
2. Fill the generator with hydrogen up to the desired purity and rate pressure.
3. Charge the stator with distillate.
4. Generator circuit breaker should be open.
5. Field breaker should be open.
 When the generator comes to the rated speed check the:
1. Temperature of bearing Babbitt seal and bearing drain oil.
2. Performance of brush gear.
3. Phase sequence of generator.
60
4. Bearing vibration in all directions.
After ensuring that the mechanical running of the set is normal, field breaker is switched on.
6.5.2 SYNCHRONIZATION
 Conditions:
1. Phase sequence should be same.
2. Generator and system voltage should be in phase. Angle difference not to be

more than 10 degrees.
3. Effective value of voltage should be same.
4. Frequency should be same.
Generator can be synchronized in auto as well as manual mode.
6.5.3 UNLOADING AND SHUT DOWN

1. Reduce the load on unit by operating the turbine side controls.
2. Simultaneously, reduce the reactive load by de exciting the machine.
3. Open the generator line circuit breaker.
4. Cut out the auxiliary to manual mode.
5. Seal oil supply should be kept ON as long as gas is under pressure.
6. Bearing oil supply should also be kept in operation.
7. Cooling water to gas cooler may be stopped. For prolonged shut down dry
compressed air is blow into the winding at 850 m3/hr to drain out the distillate.
8. To achieve uniform cooling during shut down, the machine is put on barring speed for
some time. Even after shut down the rotor is to be turned through 180 degrees
periodically to avoid thermal deflection of rotor.
61
9. 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
decrease in speed.
6.6 OBSERVED DATA AT PLANT

Generator several parameters are checked on regular basis to avoid any abnormal consequences at
plant. The following data is observed on 26-june-2019 which is as below: -
Observations: -
Generator Current : 8000 A
Generator Voltage : 15.58 kV
Field Current : 2100 A
Field Voltage : 200 V
MW : 210
MVAR : 65
Rotor Temperature(<110⁰C) : 86 ⁰C
Stator water Temp. (27-30⁰C) : 28.4 ⁰C
Conductivity : 0.42 S
H2 Purity (>97%) : 98.1 %
H2 Pressure : 3.81 kg/m2
Turbine end temp. : 36 ⁰C
Gen. middle temp. : 46 ⁰C
Exciter side temp. : 40 ⁰C
62
CHAPTER 7
ELECTROSTATIC PRECIPITATOR
In India coal is widely used to generate power. The exhaust gases from the furnace contains large
amount of smoke and dust. If these gases are emitted directly into the atmosphere, it will cause
great environmental problems. So, it is necessary to extract this dust and smoke before emitting the
exhaust gases into the atmosphere.
There are various methods of extracting dust but electrostatic precipitator is the most widely used.
It is due to its high efficiency of about 99% and less maintenance.
Figure 7.1: Electrostatic Precipitator
Its various other advantages are as follows:
1. Ability to treat large volume of gases at high temperature.
2. Ability to cope with the corrosive atmosphere.
3. It offers low resistance to the flow of gases.
63
7.1 WORKING PRINCIPLE

The electrostatic precipitator utilizes electrostatic forces to separate dust particles from the gases
to be cleaned. The gas is passed through a chamber, which contains steel plates (vertical) curtains.
These steel curtains divide the chamber into number of parallel paths. The framework is held in
place by four insulators, which insulate it electrically from all parts, which are grounded.
A high voltage direct current is connected between the framework and the ground, thereby creating
strong electric field between the wires in the framework and the curtains. Strong electric field
creates corona discharge along the wire. The ionized gas produces positive and negative ions.
In the chamber plates are positively charged whereas the wire is negatively charged. Positive ions
are attracted towards the wire whereas the negative ions are attracted towards the plates. On their
way towards the curtains negative ions strike the dust particles and make them negatively charged.
Thus, ash is collected on the steel curtain.
The whole process is divided into the following parts:
7.1.1 CORONA GENERATION

It is basically a gas discharge phenomenon associated with the ionization of gas molecules by
electron collision in a region of high electric field strength. It requires non- uniform electric field,
which is obtained by wire as one electrode and cylinder or plate as other.
The corona process is initiated by the presence of electrons in the electric field near the wire. These
electrons are accelerated to high velocities and possess sufficient energy so that on impact with the
gas molecules in the region they emit orbital electrons from the gas molecules. These electrons also
accelerate and enter into ionization. In this region of corona discharge, there are free electrons and
positive ions. The behavior of charged particles depends upon the polarity of the electrodes. Both
positive and negative coronas are used in industrial gas cleaning.
In case of negative corona, positive ions generated are attracted towards the negative electrode
wire and the electrons towards the collecting plates. Beyond the corona glow region, the electric
field diminishes rapidly and if electronegative gases are present, electrons will be captured by the
gas molecules. On impact the negative ions thus generated moves towards the collecting electrodes
and serves as the principle means of charging dust.
Temperature and pressure influence the generation of corona by changing the gas density. In the
avalanche process, the time available for accelerating the electrons during the collision is a function
64
of gas density. With the increased molecular spacing, higher velocities can be achieved between
the collisions. Thus, energy can be achieved with low field and for low gas densities. Increased
molecular spacing results in penetration of free electrons further into the inter electrode region
before captured to form negative ions. This increases the mobility in the inter electrode space and
hence higher current.
Corona is affected by dust on emitter and collector electrodes. It alters the electric field and the
sparking condition.
7.1.2 PARTICLE CHARGING

There are two physical mechanisms by which gas ions charge the dust particles. The electric field
causes localization of field so that the electric field intersects the particles. The ion which move
along the path of maximum voltage gradient, intercepts the particle thus net charge flow through
the particle. The ion is held with the dust particle by induced image charge force between the ion
and the dust particle. As additional ions are held with the dust particle, it becomes charged to a
value sufficient to divert the electric field from the particle. For small particles field dependent
charge mechanism is less important and collision between the gas ion and the particle is governed
primarily by the thermal motion of the ions.
Rate of charging depends upon:
• Field Strength (higher the field strength more is the charging).
• Concentration of the uncharged dust.
7.1.3 PARTICLE COLLECTION

Forces acting on the charged particles are gravitational, inertial, electrical and aerodynamical.
Electrical and aerodynamical are more important.
If the particle is suspended in a laminar gas flow stream, charge will act on the particle in the
direction of the collecting electrode. This force is opposite to the viscous drag force of the gases.
In a short time, particle would reach the terminal velocity at which electrical and viscous drag
forces are equal. This is called the migration velocity. The other force is the aerodynamic force by
the gas stream. The motion is along the line defined by the vector sum of these two forces. Under
laminar flow all particles are collected at given precipitator length. But this is never achieved. The
turbulent gas flow causes particles to flow in random path through the precipitator.
65
7.1.4 REMOVAL OF DUST

Dust collected must be removed. This is done by causing the liquid to flow down the collector
electrode or by rapping mechanism. Rapping is done periodically. The success of the rapping
system depends upon accumulation of sufficient thickness of material on the plate. The acceleration
required to remove the collected dust vary with the property of the dust and gas stream. Re-
entrainment of dust during rapping is evidenced by the increased dust loading at the exit. To
minimize this effect, only small section of the precipitator is rapped at a time.
66
CHAPTER 8
PROTECTION SYSTEM
The objective of a protection system is to keep the power system stable by isolating only the
components that are under fault, whilst leaving as much of the network as possible still in operation.
Thus, protection schemes must apply a very pragmatic and pessimistic approach to clearing system
faults. The devices that are used to protect the power systems from faults are called protection
devices.
8.1 VARIOUS EQUIPMENT FOR PROTECTION SYSTEM

1) CTs & PTs
2) Relays
3) Circuit Breaker
4) Batteries
5) Fuses
6) Lightning Arresters
The capital investment involved in a power system for the generators, transformers and distribution
of electrical power is so great that the proper precautions must be taken to ensure that equipment
not only operates as nearly as possible to peak efficiency but also that is protected from accidents,
due to insulation failure, short circuit, equipment failure etc.
The purpose of protective relays and relaying system is to operate the correct circuit breakers, so
as to disconnect minimizing the trouble and damage caused by faults when they do occur. It would
be ideal if protection could anticipate and prevents faults, but this 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 of short circuit by disconnecting the equipment as quickly
as possible, so that the destructive effect of the energy into the fault may be minimized.
8.2 GENERATOR PROTECTION

1) Overvoltage Protection
2) Over flux Protection
3) Under/Over Frequency Protection
4) Negative Phase Sequence
67
5) Dead Machine relay

6) Reverse Power Protection
7) Stator Earth fault Protection
8) Stator Earth fault Protection (3rd Harmonic)
9) Loss of Excitation
10) Back-up Impedance
11) Out of step Protection
12) Generator Differential Protection
13) Stator Stand-by E/F Protection
14) Generator Interturn Differential Protection
8.3 GENERATOR TRANSFORMER (GT) PROTECTIONS

1) GT Back up Overcurrent Protection
2) GT Directional Earth Fault Protection
3) GT Stand by Earth Fault Protection
4) GT Restricted Earth Fault Protection
5) GT Overall Differential Protection
8.4 UAT PROTECTIONS

1) UAT Over Current Protection
2) UAT Differential Protection
8.5 MOTOR PROTECTION

All the motors whether LT or HT is protected against various abnormal conditions mentioned
below: -
A) Over Load or Over Current

B) Short circuit or Insulation Failure
C) Earth Fault
D) Low Voltage
E) Single Phasing
68
Several protective relays are provided. The relays sense the abnormal conditions & Close the trip
circuit of motor circuit breaker. Thus, the breaker trips to isolate the motor from a.c. supply.
8.5.1 PROTECTION OF L.T. MOTORS (<100 KV RATING)

In this plant, generally these motors are provided with following Protections/Relays: -
 Thermal Overload Relay – For Protecting overloading of motors

 Single Phasing Protector – For isolating the motor when single phase supply is fed to
motor.
 HRC fuses - For protection of motor against short circuit.
8.5.2 PROTECTION OF H.T. MOTORS (>100 KV RATING)

In addition to above protections, following relays are provided: -
 Thermal Over load Protection

 Locked Rotor Protection
 Over Current Protection
 Earth Fault Protection
 Negative Phase sequence Protection
 Under Current Protection
These Relays cause opening & closing of breaker.
8.6 EQUIPMENT TESTING
8.6.1 TAN-DELTA OR DISSIPATION FACTOR TESTING

A pure insulator when is connected across line and earth, it behaves as a capacitor. In an ideal
insulator, as the insulating material which acts as dielectric too, is 100 % pure, the electric current
passing through the insulator, only have capacitive component. There is no resistive component of
the current, flowing from line to earth through insulator as in ideal insulating material, there is zero
percent impurity.
In pure capacitor, the capacitive electric current leads the applied voltage by 90⁰.
69
In practice, the insulator cannot be made 100% pure. Also due to the aging of insulators, the
impurities like dirt and moisture enter into it. These impurities provide the conductive path to the
current. Consequently, an electric leakage current flowing from line to earth through the insulator
has a resistive component.
So, the healthiness of an electrical insulator can be determined by the ratio of the resistive
component to the capacitive component. For good insulator, this ratio would be quite low. This
ratio is commonly known as tanδ or tan delta. Sometimes it is also referred to as dissipation factor.
8.6.1 Generator’s Bushing Testing
Figure 8.1:HV & LV 's Capacitances
Observations:
Following data observed on 15-jan-2019.
Table 8.1: Measurement of CHL
Feed Capacitance D.F. (tanδ) Current

10 kV CHL=7.883 nF 0.38 % 24.92 mA
Table 8.2: Measurement of CHG
10 kV CHG = 5.980 nF 0.58 % 18.91 mA
70
Table 8.3: Measurement of CLG (Line to Ground)

2 kV CLG=23.75 nF 0.81 % 15.02 mA
Table 8.4: Measurement of CHG+CLG

2 kV 29.76 nF 0.75 % 18.83 mA
Where, CHL = HV Bushing to LV Bushing Capacitance
CHG = HV Bushing to Ground Capacitance
CLG = LV Bushing to Ground Capacitance
CHG+CLG = Combined Capacitance of HV to Ground & LV to Ground
8.6.2 CT Insulation’s tanδ testing
Observations:
Following data observed on 22-jan-2019.
Table 8.5: CT's Tan-delta Observations
Phase Feed Capacitance D.F. (tanδ) Current

R 10 kV 798.0 pF 0.37 % 2.527 mA
Y 10 kV 617.2 pF 0.29 % 1.951 mA

B 10 kV 614.5 pF 0.38 % 1.941 mA
71
8.7 OVER CURRENT RELAY MESURMENTS
Figure 8.2: Overcurrent Relay (Inversed) Type
Calculations for finding operating time:
Installed CT’s Ratio at plant is 500/5.
As CT’s Secondary side current is 5A. Therefore, from following figure pin is at 6.25 A.
It means Relay’s Pickup Value = 6.25 A
Figure 8.3: Relay is set on 1.25 Plug Setting
Which tells that relay is on (6.25-5) = 1.25 Plug setting.
Hence, Relay Plug Setting (PS) = 125%
72
Ifault = 2500A
𝐼𝑓 2500
IR = 𝐶 𝑇 𝑅𝑎𝑡𝑖𝑜 = 500/5 = 25A
Pickup Relay value = Plug Setting × Rated secondary current of CT
= 1.25 × 5
= 6.25 A
𝐹𝑎𝑢𝑙𝑡 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑖𝑛 𝑟𝑒𝑙𝑎𝑦 𝑐𝑜𝑖𝑙 25

Plug Setting multiplier of relay, PSM = = 6.25 = 4
𝑝𝑖𝑐𝑘𝑢𝑝 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑟𝑒𝑙𝑎𝑦
Time corresponding to the PSM is shown below in the figure.
Figure 8.4: PMS vs Time Data
Hence, Time corresponding to the 4 PSM is = 2.1 seconds.
Figure 8.5: TSM of Relay
From Above figure it is clear that TSM = 0.7
So Actual Operating time = 2.1 × Time Setting Multiplier (TSM)
= 2.1 × 0.7
= 1.47 sec.
73
74
REFERENCES
1) Electric Machine Design by A. K. Sawhney.
2) Switchgear & Protection by J.B. Gupta
3) Power Plant Engineering by A.K. Raja
4) http://indianpowersector.com/home/power-station/thermal-power-plant/
5) http://www.theelectricalportal.com/2019/01/working-of-thermal-power-plant.html
6) https://en.wikipedia.org/wiki/Electric_machine
7) https://www.electrical4u.com/thermal-power-generation-plant-or-thermal-power-station/
8) https://engineeringinsider.org/thermal-power-plant/
75

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PORJECT REPORT

(Internship Semester January-June 2019)

STUDY OF 6×210 MW THERMAL POWER PLANT

Under the Guidance of

Anupam Sir Suminderjeet Singh

Department of Electrical Engineering

January to June, 2019

Date: 2 July 2019 16104068

Anupam Sir Suminderjeet Singh

DECLARATION .......................................................................................................................... iii

LIST OF FIGURES ................................................................................................................... XII

LIST OF TABLES .................................................................................................................... XIV

CHAPTER 1 ABOUT GURU GOBIND SINGH SUPER THERMAL PLANT .................... 1

1.1 INTRODUCTION ..................................................................................................................... 1

2.1 HIGH TENSION SWITCHGEAR .............................................................................................. 11

2.2.3 415 V Emergency Bus Stage III ..................................................................................... 17

CHAPTER 3 ELECTRIC MOTOR REPAIR WORKSHOP ................................................. 19

3.1 SMALL SIZED INDUCTION MOTORS ...................................................................................... 19

CHAPTER 4 220 KV, 132 KV SUB-STATION AND ITS INSTALLED VARIOUS

4.1 ABOUT SUBSTATION............................................................................................................ 28

CHAPTER 5 VARIOUS TRANSFORMER INSTALLED AT PLANT ............................... 42

5.1 TRANSFORMER’S BASIC STRUCTURE ..................................................................................... 42

5.1.10 Pressure Relief Valve .................................................................................................. 48

CHAPTER 6 GENERATOR AND ITS AUXILIARIES ........................................................ 55

6.1 SALIENT FEATURES OF GENERATOR ..................................................................................... 55

CHAPTER 7 ELECTROSTATIC PRECIPITATOR ............................................................. 63

7.1 WORKING PRINCIPLE ............................................................................................................ 64

CHAPTER 8 PROTECTION SYSTEM................................................................................... 67

8.1 VARIOUS EQUIPMENT FOR PROTECTION SYSTEM ............................................................... 67

8.2 GENERATOR PROTECTION ................................................................................................... 67

FIGURE 1.1: EXTERNAL VIEW OF PLANT ........................................................................................... 1

FIGURE 4.11: COUPLING CAPACITOR............................................................................................... 40

TABLE 1.1: UNIT COMMISSIONING .................................................................................................... 2

Figure 1.1: External View of Plant

1.2 UNIT COMMISSIONING

Table 1.1: Unit Commissioning

Stage Unit Installed Capacity Date of Status

First 1 210 September, 1984 Not-Running

First 2 210 March, 1985 Not-Running

Second 3 210 March, 1988 Running

Second 4 210 January, 1989 Running

Third 5 210 March, 1992 Running

Third 6 210 March, 1993 Running

Figure 1.2: Boiler

Table 1.2: Boiler's Technical Data

TYPE WATER TUBE SINGLE DRUM

STEAM TEMPERATURE 540 C

STEAM PRESSURE 155 KGMS/CM2

1.4.1 PRIMARY AIR FAN

1.4.2 FORCED FRAFT FAN

1.4.3 INDUCED DRAFT FAN

Figure 1.5: Turbine

Table 1.3: Turbine's Technical Data

TYPE 3 Cylinder mixed flow tandem

SPEED 3000 rpm

STAGES 3 (HP, IP, LP)

INLET STEAM PRESSURE 150 kg/cm2

INLET STEAM 535°C

1.7 WORKING OF THERMAL POWER PLANT

Figure 1.7: Layout of GGSSTP

1.8 COAL HANDLING PLANT

Figure 1.8: Coal Handling Plant

Figure 1.9: Coal Pit

1.8.1 BASIC FUNCTIONS