ACKNOWLEDGEMENT

I would like to express my sincere thanks to Mr. Vinesh agrawval , (H.O.D of electrical engg. ) for giving me the opportunity to work in Hindustan Zinc Limited. I am also deeply indebted to him for his immense help and cooperation and valuable suggestions. I would also like to thank my project mentor Mr. P.Duraipandi (Head, Electrical Department CPP) for giving me this opportunity to work under him. It was because of his constant guidance and the study material that he provided me that I was able to study and work in CPP-CLZSI would also like to thank all the employees of Captive Power Plant (CPP) for giving support and encouragement.

Sudarshan Singh Chundawat

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PREFACE
Engineering students gain theoretical knowledge only through their books. Knowledge given our books is not of much use without knowing its practical. Implementation it has been experienced that theoretical knowledge his volatile in nature however Practical knowledge makes solid foundation our mind. To accomplish this aspect, the Rajasthan technical university, Kota has included practical training for the student of B.Tech. in the summer vocation. I took training in CAPTIVE POWER PLANT (THERMAL) Hindustan Zinc limited Chittorgarh from 10th may 2010 to 10th August 2010 ,succeeding chapter give detail about what I have learnt in this prestigious. Only

theoretical knowledge is not sufficient for absolute mastery in any field theoretical

Sudarshan Singh Chundawat

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S. NO.

TITLE
1.1 INTRODUCTION OF HZL 1.1.1. 1.1.2. 1.1.3. VISION MISSION HIGH LIGHT

PAGE NO.

1.2 TYPES OF POWER PLANT 1.3 ITRODUCTION OF CPP 1.4 NEED OF CPP 1.5THERMAL POWER PLANT

REQUIREMENT OF CPP
2.1 COAL HANDLING PLANT 2.1.1 WEIGHT BRIDGE 2.1.2 WEGON TIPPLER 2.1.3 SIDE ARM CHARGER 2.1.4 COAL YARD 2.1.5 RECLAIM HOPPER 2.1.6 CRUSHER HOUSE AND JUNCTION TOWER

2.2 BOILER AND ITS AUXILIRIES 2.2.1 WATER DRUM

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2.2.2 FURNANCE AND WATER WALL TUBE 2.2.3 REHEATER AND DESUPERHEATER 2.2.4 ECONOMISER 2.2.5 AIR PRE HEATER(APH) 2.2.6 FANS 2.2.6.1 PRIMARY AIR FAN 2.2.6.2 FORCED DRAUGHD FAN 2.2.6.3 INDUCED DRAUGHED FAN 2.3 TURBINE AND ITS AUXILIRIES 2.3.1 PRINCIPLE OF TURBINE 2.3.2 TURBINE COMPONENT 2.3.3 TURBINE AUXILIRIE 2.3.3.1 CONDENSER 2.3.3.2 MAIN AIR EJECTOR 2.3.3.3 COOLING WATER PUMP 2.3.3.4 CONDESATE EXTRACTION PUMP 2.3.3.5 DEAREATER 2.3.3.6 LOW PRESSURE HEATER(LPH) 2.3.3.7 BOILER FEED PUMP(BFP) 2.3.3.8 OIL PUMPS 2.4 ESP AND ASH HANDLING PLANT
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2.4.1 APPLICATION OF ESP 2.4.2 WORKING OF ESP 2.4.3 ASH HANDLING SYSTEM 2.4.3.1 BOTTOM ASH SYSTEM 2.4.3.2 FLY ASH SYSTEM 2.5 COOLING TOWER AND D.M. PLANT 2.5.1 COOLING TOWER 2.5.2 TYPE OF COOLING TOWER 2.5.3 D.M. PLANT

HT MOTORS INSTALLED AND MAITENANCE

3.1 PA(PRIMARY AIR) FAN 3.2 FD(FORCED DRAUGHED )FAN 3.3 ID(INDUCED DRAUGHED) FAN 3.4 COAL MILL MOTOR 3.5 CEP(CONDESATE EXTRACTION )PUMP 3.6 BFP(BOILER FEED PUMP) 3.7 CW(COOLING WATER) PUMP 3.8 SEALING FAN 3.9 MEASURING CHECK LIST FOR MOTORS

4
4.1 SYNOPSIS OF TG

TURBO GENERATOR

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4.2 TYPES OF TG 4.3 COMPONENT OF TG 4.3.1 STATOR 4.3.2 ROTOR 4.3.3 BEARINGS 4.3.4 COOLING SYSTEM 4.3.5 EXCITATION SYSTEM

5.1 TRANSFORMER 5.2 CONSTRUCTION OF TRANSFORMER 5.3 INSPECTION AND MAINTENANCE 5.4 FAULT AND PROTECTION 5,5 TRANSFORMER USED AT CPP AND RATING

132 KV SWITCH YARD 6.1 CIRCUIT BREAKER 6.2 AIR BLAST CIRCUIT BREAKER 6.3 ISOLATOR 6.4 LIGHTINING ARRESTER 6.5 CAPACITIVE VOLTAGE xmer 6.6 WAVE TRAPPER 6.7 CURRENT xmer

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6.8 VOLTAGE xmer 6.9 SWITCH YARD AIR COMPRESSERE

. DISTRIBUTED CONTROL SYSTEM

VARIABLE FREQUENCY DRIVE

List of figures

SR

TITLE

PAGE
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NO. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.1 3.2 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 Boiler Work flow diagram of t.p.s. Coal mill Primary fan Force draught fan Induced draught fan Turbine Electrical field generation Generator Schematic of turbo generator Stator Rotor Generation main & pilot exciter Basic principal of xmer Core type xmer Shell type xmer Bucholze relay Switch yard 132 kv switch yard of cpp Air blast circuit breaker

NO. 1

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1.1

INTRODUCTION OF HINDUSTHAN ZINC LIMITED

Hindustan Zinc Limited (HZL) is Indias leading Zinc producer. A vertically integrated Mining & Smelting company, with a purpose to make India self-reliant in Zinc, HZL, is currently gearing up to become a global lowest-cost producer. As apart of Vedanta Resource, HZL take advantage of its mineral resource and related core competencies and believes it has growth opportunities for increasing product and improving returns. Continuous operational improvements and much more HZL has come a long way and grown into multi location company producing zinc, lead and silver.HZL is the

3rd largest integrated producer of Zinc in the World.

1.1.1 VISION
Be a world-class zinc company, creating value, leveraging mineral resources and related core competencies

1.1.2 MISSION
Be a lowest cost Zinc producer on a global scale, maintaining market leadership Produce One Million Ton/Year of Zinc and lead by 2010
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 Be innovative, customer oriented and eco-friendly, maximizing stake-holder value

1.1.3 HIGHLIGHT
Only fully integrated Zinc-lead producer in the country. Having three lead-zinc mines, Three smelter in Rajasthan and one in Vizad.

Turnover Rs.3877 Cr with EBITDA of Rs.2418 Cr for the FY 2006 Marketing leader with 68% market share of countrys demand (0506). Providing employment to over 12,000 people. Strive for continuous improvement in Environment, Health & Safety performance of its operations. Galvanizing Indias growth Refined Zinc production capacity 411,000 tpa Refined Lead production capacity 85000 tpa Ore treatment capacity 5.86 Mtpa

CHANDERIYA LEAD ZINC SMELTER

Commissioned Location Capacity

1991 120 km east of Udaipur, Rajasthan, India 100,00 tpa of refined zinc 35,000 tpa of Refined

Lead

Certifications

ISO 9001:2000,ISO 14001:1996,OHSAS 18001:1999

CHANDERIYA ZINC SMELTER HAVE FOLLOWING PLANTS

1. UNIT-1 PYRO PLANT

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2. UNIT-2 HYDRO PLANT 3. UNIT-3 CCP

1.2 TYPES OF POWER PLANT

Hydel power plant Nuclear power plant Thermal power plant Wind power plant Solar power plant

1.3 INTRODUCTION OF CPP

Power generation is one of the most important aspects of an industry. An industry cannot depend on grid power because of its disturbances. Captive power generation is reliable both in quality and quantity. The main focus of this study is on the procedure of power generation and functions of various units in a captive power plant. Variable frequency drives are efficient machines which can be installed to a motor so that the power consumption by the motor is regulated and thus saving energy efficiently. A power plant is an industrial facility for the generation of electric power. The power produced in Hindustan Zinc Limited is for its own production purposes, and is known as a captive power plant (CPP). While supplying uninterrupted and reliable power to Chanderiya Lead Zinc Smelter, the CPP has been additionally wheeling power to its Agucha, Debari and Dariba units of Hindustan Zinc Limited. Recently sale of power has also been initiated with both RSEB and power exchange. Captive power plant in Chanderiya consists of 3 units (2x77 mw + 1x80 mw). All three units are supplied by BHEL, Hyderabad.

1.4 NEED OF CPP:

Disturbances in taking power from grid.
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 Grid power distribution is unreliable both in quality and quantity.

Taking power from grid is much more expensive as compared In generating its

own power i.e. Self generation CPP.

1.5THERMAL POWER PANT

Thermal Power Stations produce electricity by burning fuel in a boiler to heat water to produce steam. This steam at high pressure rotates the blades of a turbine which spins a generator to produce electricity. The steam is further cooled in a condenser to form water and sent again to boiler.In this thermal power plant, we are using coal because of following advantages: Advantages of coal fuel: Abundantly available in India. Low cost Technology for power generation well developed. Easy to handle, transport, store and use.

Shortcomings of coal: Low calorific value Large quantity to be handled Produces pollutants, ash Disposal of ash is problematic Reserves depleting fast.

2. C.P.P MAJOR REQUIREMENT

2.1 Coal Handling Plant

2.2

Boiler and Auxiliaries

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2.3 2.4 2.5 2.6

Turbine, Generator & Auxiliaries ESP & Ash Handling Plant Cooling tower De Mineralizing plant

2.1 COAL HANDLING PLANT

C.H. P is divided into five sections:

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 Weigh bridge Wagon tippler Coal yard Reclaim hopper Crusher house & junction tower 2.1.1 WEIGHT BRIDGE This is used to measure the weight of coal coming in the wagon (BOXN). This is in motion weighing system. We are using two systems: Senlogic Systems Avery India Systems Through this, we can weigh the quantity of coal by taking the Gross Weight (when boxn is coming with coal) and tare weight (the weight when the empty boxn passes away) from which we can difference it by gross weight so that weight of coal is measured. Gross Weight Tare Weight = Weight of Coal
2.1.2 WAGON TIPPLER

Through this, we can tipple the wagon & coal will fall on appron feeder through which coal goes to coal yard through belt conveyor. It can rotate near about 126 degree.
2.1.3 SIDE ARM CHARGER(SAC):

This is used to drag the boxns and placed it suitably on wagon tippler. Each boxn is decoupled manually and then sac takes it to the wagon tippler platform using magnetic sensors and limit switch. Four magnetic sensors are fixed at different locations to control the position of side arm charger namely as A, B, C and D. From position A,
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the side arm charger firstly comes to boxn, lower the arm and couple the boxn and go to the B position. At B position, each boxn is decoupled manually and the sac goes to the c position. At C position, the boxn stops at platform of wagon tippler and auto decouple occurs. Then sac moves to position D. At D position, arm is automatically lifted and the hooter sounds. Then the wagon tippler rotates near about 126 degree for 1 minute. In this time, the side arm charger again goes to the position a and the process go on.
2.1.4 COAL YARD: Through conveyor belt, coal is transferred to the coal yard where it is further goes to the reclaim hopper through trucks. There are different types of coal comes in coal yard especially from

Indonesia, South Africa. These coal mixes in proportion with Indian coal to maintain a required gross calorific value.
2.1.5 RECLAIM HOPPER:

Coal is dumped into this hopper by using dumpers. Below this hopper there is unbalanced mode system in which coal from hopper falls on vibrating screen and conveyed through belt conveyor to crusher house.

2.1.6 CRUSHER HOUSE AND JUNCTION TOWER :

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The raw coal is fed to primary crusher house via belt conveyor where the size of coal is reduced from 600mm to 100mm. Magnetic separator, separates the iron particles & then to secondary crusher house for further reduction of coal (20mm sized). Vibrating screen allows only 20mm sized coal to drier & through tippler or trolley, it passes over to coal bunker through junction tower by conveyor belt.

2.2 BOILER AND ITS AUXILIARIES

In boiler, water is heated to produce steam which is used to rotate a turbine.

BOILER OVERVIEW

Boiler Overview:

Furnace Water wall tubes Pressure parts

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Drum Super heaters Reheaters Economizers

Air Pre Heaters

Soot blowers Coal bunkers and feeders Pulverizes Coal piping Burners Igniters & warm-up burners Duct work Insulation and legging
2.2.1 Water Drum:

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It is a reservoir of water/steam at the top end of the water tubes in the water-tube boiler. They store the steam generated in the water tubes and act as a phase separator for the steam /water mixture.

Steam and water mixture enter the steam drum through riser tubes. The saturated water at the bottom of steam drum flows down through down comers.

Feed water is also fed to the steam drum trough a feed pipe extending inside the drum.

2.2.2 Furnace & Water Wall Tubes Furnace is the primary part of boiler where the chemical energy of fuel is converted to thermal energy. Furnace is incorporated with water wall tubes where water is evaporated to steam. In the water wall tubes heat is added to evaporate the feed water to steam. As tubes are heated, a part of water is converted to steam & mixture flows back to drum. In drum steam is separated. 2.2.3 Reheaters & Desuperheaters: Reheater is used to raise the temperature of steam from which part of the energy has been extracted in high pressure turbine.

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By reheating efficiency can be increased which increases with number of stages. Single reheating is usually applied for capacity above 100mw & 2 reheat above 500mw. Desuperheater is located between two super heater header and the steam flows through it.

Water of high quality is introduced into the superheated steam through a spray nozzle at the throat of a venturi section which mixes and cools the superheated steam. By regulating the water spray steam temperature can be easily controlled. The spray water will normally obtain from feed water line after the hp heaters and before feed regulation station. 2.2.4 ECONOMISER An economizer absorbs heat from the flue gases and adds this as sensible heat to the feed water before water enters the evaporative circuit of boiler. Feed water is supplied to economizer inlet header via feed stop and check valves. Flow of feed water is upward through the economizer that is counter flow to flue gases & from outlet header feed water is led to steam drum. By recovering heat from flue gases and supplying it to feed water it increases efficiency in steam generation or in other words saves fuel. 2.2.5 AIR PRE HEATER(APH): APH is a heat exchanger in which air temperature is raised by transferring heat from other fluid such as flue gases. Stability of combustion is improved by use of hot air. Less unburnt flue particles in flue gas. In case of pulverized coal combustion, hot air can be used for drying the coal as well as for transporting the pulverized coal to burners. 2.2.6 FANS:

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 PA (Primary Air Fan) : These are the high pressure fans which supply the air needed to dry & transport coal either directly from the coal mills to the furnace or to the intermediate bunker. These fans are usually of the radial aerofoil type. FD (Forced Draft Fan) : These fans supply the air necessary for fuel combustion and must be seized to handle the stoichiometric air plus the excess air excess air needed for proper burning of the fuel. These fans are usually of the radial aerofoil or variable pitch axial type. ID (Induced Draft Fan) : These fans evacuate combustion products from the boiler furnace in atmosphere through stack by creating sufficient negative pressure.

2.3 TURBINE, GENERATOR AND ITS AUXILIARIES

Turbine is a prime mover which converts thermal energy of fuel into mechanical energy.

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2.3.1 PRINCIPLE OF TURBINE Steam is allowed to expand through narrow orifice, it assumes kinetic energy at the expenses of enthalpy, and this kinetic energy is converted into mechanical energy through the impulse or reaction of steam against the blade. Steam moves continuously through blades as a result centrifugal pressure exerted on the blade. Total motive force = Centrifugal force + Change of momentum (rotational energy) 2.3.2 TURBINE COMPONENT Main component: 1. Inner & Outer Casing 2. Fixed Blade or Diaphragm 3. Rotor with moving blades, shaft , couplings 4. Gland Seal & Inter Stage Seal CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 21

5. Balance Piston Other Component: 1. Bearings (radial & thrust) 2. Bearing housing 3. Pedestal 4. Mop 5. Steam admission valves (ESV, IV, CV) 6. Steam admission & exhaust piping 2.3.3 TURBINE AUXILIRIES

2.3.3.1 Condenser: It condenses the steam & maintains the vacuum at the exhaust of LP turbine. 2.3.3.2 Main air ejector: Main the vacuum by extracting the non condensable gases from the condensate. 2.3.3.3 Cooling Water (CW ) Pumps:

To circulate cooling water through condenser tubes for cooling the system. 2.3.3.4 Condensate Extraction Pump (CEP ): Extract condensate from condenser hot well & passes it to deaerator. 2.3.3.5 Low pressure heater (LPH): To raise the temperature of condensate by transferring heat taken from turbine extraction. 2.3.3.6 Deaerator: To remove dissolved gases from feed water by increasing their temperature with pegging steam taken from APRDS. 2.3.3.7 Boiler feed pump (bfp): To pump the feed water from deaerator to boiler (economizer) at a very high pressure. 2.3.3.8 Oil pumps: CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 22

Different types of oil pump used: Main oil pump(MOP) To supply lube oil & control oil during normal operation of turbine. Auxiliary oil pump (AOP) To supply lube & control oil during start up & shut down of turbine. Emergency oil pump (EOP) To supply lube oil to bearings during ac failure. Jacking oil pump (JOP) For lifting turbine shaft during startup & shut down

2.4

ESP AND ASH HANDLING PANT

ESP stands for electrostatic precipitator. It is used to separate dust and ash present in flue gases as it will produced a large amount of pollution.

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2.4.1 Application of ESP: Removal of dirt from flue gases in steam plants. Cleaning of air to remove fungi and bacteria in establishments producing antibiotics and other drugs. Cleaning of air in ventilation and air conditioning systems. Removal of oil mists in machine shops and acid mists in chemical process plants. Cleaning of blast furnace gases. Recovery of valuable materials such as oxides of copper, lead, and tin. 2.4.2 ELECTROSTATIC PRECIPITATOR WORKING PRINCIPLE

The precipitation process involves 4 main functions Corona generation Particle charging Particle collection Removal of particles
1. Corona Discharge:

Due to the ionization of gas molecules, + ve ions, -ve ions and free electrons are generated. CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 24

2. Particle Charging: o In this, we apply a voltage of 40 KV between the collecting electrode and the emitting electrode. o The -ve charges of ions and free electrons travel towards +ve electrode and the +ve charges of ions travel towards -ve electrodes. o When -ve ions travel towards +ve electrodes, the -ve charges get attached to the dust particles and thus the dust particles are electrically charged. 3. Particle collection:

4. Removal of particles: Through rapping mechanism, we remove the particles collected on the plate. In this, there is a shaft on which several hammers are attached. This shaft is rotated and hammer strikes the plate and ash is collected in the hopper.

2.4.3 ASH HANDLING SYSTEM

2.4.3.1 Bottom ash handling plant:

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At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from the bottom of the furnace. This hopper is always filled with water to quench the ash and clinkers falling down from the furnace. Some arrangement is included to crush the clinkers and for conveying the crushed clinkers and bottom ash to a storage site. 2.4.3.2 Fly ash system:

Fly ash is captured and removed from the flue gas by electrostatic precipitators located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators. Generally, the fly ash is pneumatically transported to storage silos for subsequent transport by trucks.

2.5 COOLING TOWER AND DE- MINERALISING PLANT

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2.5.1 Cooling tower: Cooling tower is an application where the plant heat exchangers are cooled with water. The pump keeps the water re-circulation through the heat exchangers where it picks up heat and distributes on to the cooling tower. The heat is released from the water through evaporation. The cold water enters the heat exchangers for cooling. The resulting hot water from heat exchangers is sent to cooling tower. The cold water exits the cooling tower and is sent back to the exchangers for cooling. Make up water source is used to replenish around 2 % of water lost due to evaporation and drift. Classification of cooling:

2.5.2 Types of cooling tower: 1. Natural draft cooling towers : Distinct shape much like a tall cylinder, it operates on a chimney principle that allows air movement on density differential. Such towers have the advantage of not requiring any fans, motors, gear boxes etc. Due to the tremendous size, these type of towers are used only for very high flow rates. CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 27

2. Mechanical draft cooling towers: These are more widely used. These towers utilize large fans to force air through circulating water. The water falls downward over fill surfaces which help increase the contact time between the water and the air. This helps maximize heat transfer between the two. 2.5.3 DE - MINERALISING PLANT: De-mineralization (DM) is the process of removing mineral salts from water by using the ion exchange process which produces water with high quality & purity that used in boiler as feed water. De- Mineralization System Consisting of Clarifier PSF (pressurized sand filter) ACF (activated carbon filter) SAC (strong acid cation exchanger) Degasser WBA (weak base anion exchanger) SBA (strong base anion exchanger). MB (mix bed). UF filter All these have the following functions:

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4. TURBO-GENERATOR

RATING CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 29

DRIVE KW FREQUENCY PHASE STATOR VOLTS ROTOR VOLTS COOLING INSULATION

S.T 77001 50HZ 3 11000 230 AIR CLASS F

KVA PF RPM CONECTION STATOR AMP. ROTOR AMP. DUTY TYPE

90590 .85 3000 STAR 4755 630 CONT. TARI

4.1 SYNOPSIS OF THE FUNCTION OF T.G.:

1.The generator is driven by a prime mover which is steam turbine in this case. 2. The other side of generator is provided by a rotating armature of an exciter which produces A.C. voltage. This is rectified to D.C. by using a rotating diode wheel. 3. The rear end of above exciter armature is mounted by a permanent magnet generator rotor. 4.As the above system is put into operation, the PMG produces A.C. voltage. 5. The voltage is rectified by thyristor circuit to D.C. 6. This supply is given to exciter field. This field is also controlled by taking feedback from main generator terminal voltage, to control exciter field variation by automatic voltage regulator. The rectified DC supply out of exciter is supplied to turbo generator rotor winding either through brushes or central which will be directly connected to turbo generator. This depends on the type of exciter viz. DC commutator machines or brushes exciter. 7. The main A.C. voltage is finally available at the stator of Turbo Generator.
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4.2 MAIN TYPES OF T.G.:1. THRI 2. TARI 3. THDI 4. THDD 5. THDF 6. THFF 1 s t LETTER = (here-T) = 3-phase turbo generator 2 nd LETTER = (here H or A) =Medium present for generator cooling (H= hydrogen, A or L=air) 3 rd LETTER =type of rotor cooling employed R= radial, F= direct water cooling D= direct axial gas cooling) 4 th LETTER = type of as used for stator winding cooling I= indirect gas cooling D= direct gas cooling F= direct water cooling

4.3 COMPONENTS OF T.G. :4.3.1 STATOR

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The generator stator is a tight construction supporting and enclosing stator winding, core and hydrogen cooling medium. Hydrogen is contained within the frame and circulated by fans mounted at either end of rotor. The generator is driven by a direct coupled steam turbine at the speed of 3000 rpm. The generator is designed for continuous rated output. Temperature detector or other devices installed or connected within the machine, permits the winding core and hydrogen temperature, pressure and purity in machine.

4.3.1.1 STATOR FRAME

The stator frame is used for housing armature conductors. It is made of cylindrical section with two end shields which are gas tight and pressure resistant. The stator frame accommodates the electrically active parts of stator i.e. the stator core and the stator winding. The fabricated inner cage is inserted in the outer frame after the stator has been constructed and the winding completed.

4.3.1.2 STATOR CORE:The stator core is stacked from the insulated electrical sheet steel lamination and mounted in supporting rings over the insulated dovetail guide bars. In order to minimize eddy current losses core is made of thin laminations. Each lamination layer is made of individual sections. The ventilation ducts are imposed so as to distribute the gas accurately over the core and in particularly to give adequate support to the teeth. The main features of core are 1. To provide mechanical support. CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 32

2. To carry efficiently electric, magnetic flux. 3. To ensure the perfect link between the core and rotor.

4.3.1.3 STATOR WINDING:Each conductor must be capable of carrying rated current without over heating. The stator winding consists of two layers made up of individual bars. Windings for the stators are made of copper strips wound with insulated tape which is impregnated with varnish, dried under vacuum and hot pressed to form a solid insulation bar. These bars are then placed in the stator slots and held in with wedges to form the end turns. These end turns are rigidly placed and packed with blocks of insulation material to withstand heavy pressure.The stator bar consists of hollow (in case of 500 MW generators) solid strands distributed over the entire bar cross-section, so that good heat dissipation is ensured. In the straight slot portion the strands are transposed by 540 degrees. The transposition provides for mutual neutralization of the voltage induced in the individual strands due to slot cross field and end winding flux leakage and ensure that minimum circulating current exists. The current flowing through the conductors is thus uniformly distributed over the entire cross section so that the current dependent losses will be reduced.The alternate arrangement of one hollow strand and two solid strands ensures optimum heat removal capacity and minimum losses. The electrical connection between top and bottom bars is made by connecting sleeve.Class F insulation is used.

4.3.2 ROTOR
Rotor shaft consists of single piece alloy steel forging of high mechanical and magnetic properties performance test includes :1. 2. Tensile test on specimen piece. Surface examination.
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3. 4. 5. 6.

Sulfur prist tests. Magnetic crack detection . Visual examination of bore. Ultrasonic examination.

Slots are milled on the rotor gorging to receive the rotor winding. Transverse slots machined in the pole faces of the rotor to equalize the moment of inertia in direct and quadrilateral axis of rotor with a view minimizing the double frequency.
4.3.2.1

ROTOR WINDINGS :

rotor winding is of direct coil type and consists of parallel strips of very high conductivity Silver Bearing Copper, bent on edge to form coil. The coils are placed in impregnated glass, laminated short shells; using glass strips inter turn insulation and will be brazed at the end to form continuous winding. The complete winging will be packed at high temperature and pressed to size by heavy steel damping rings. When the windings have cooled, heavy dove tail wedges of non-magnetic materials will seal the insulation at the top of slot portion. 4.3.2.2 SLIP RINGS The slip rings are made of forged steel. They are located at either side of Generator Shaft. The slip ring towards the exciter side is given +ve polarity initially. They have helical grooves and skewed holes in the body for cooling purpose by air 4.3.2.3 BEARINGS : Generator bearings have electrical seats of consists of steel bodies with removable steel pads. The bearings are formed for forced lubrication of oil at a pressure From the same pump that supplies oils to the turbine , bearings & governing gears. There is a provision to ensure & measure the rotor bearing temperature by inserting a resistance thermometer in the oil pockets.

4.3.4 GENERATOR COOLING SYSTEM:

The 77 MW Generator is provided with an efficient cooling system to CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 34

avoid excessive heating and consequent wear and tear of its main components during operation. This Chapter deals with the rotor-hydrogen cooling system and stator water cooling system along with the shaft sealing and bearing cooling systems. 4.3.4.1 ROTOR COOLING SYSTEM : The rotor is cooled by means of gap pick-up cooling, wherein the hydrogen gas in the air gap is sucked through the scoops on the rotor wedges and is directed to flow along the ventilating canals milled on the sides of the rotor coil, to the bottom of the slot where it takes a turn and comes out on the similar canal milled on the other side of the rotor coil to the hot zone of the rotor. Due to the rotation of the rotor, a positive suction as well as discharge is created due to which a certain quantity of gas flows and cools the rotor. This method of cooling gives uniform distribution of temperature. Also, this method has an inherent advantage of eliminating the deformation of copper due to varying temperatures. 4.3.4.2 HYDROGEN COOLING SYSTEM: Hydrogen is used as a cooling medium in large capacity generator in view of its high heat carrying capacity and low density. But in view of its forming an explosive mixture with oxygen, proper arrangement for filling, purging and maintaining its purity inside the generator have to be made. Also, in order to prevent escape of hydrogen from the generator casing, shaft sealing system is used to provide oil sealing. The hydrogen cooling system mainly comprises of a gas control stand, a drier, an liquid level indicator, hydrogen control panel, gas purity measuring and indicating instruments, valves and necessary instruments necessary for controlling and the inter connecting piping The system is capable of performing the following functions : 1.Filling in and purging of hydrogen safely without bringing in contact with air. 2.Maintaining the gas pressure inside the machine at the desired value at all the Times 3. Provide indication to the operator about the condition of the gas inside the machine i.e its pressure, temperature and purity. CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 35

4. Continuous circulation of gas inside the machine through a drier in order to remove any water vapour that may be present in it. 5. Indication of liquid level in the generator and alarm in case of high level. 4.3.4.3 STATOR COOLING SYSTEM:The stator winding is cooled by distillate. which is fed from one end of the machine by Teflon tube and flows through the upper bar and returns back through the lower bar of another slot. Turbo generators require water cooling arrangement over and above the usual hydrogen cooling arrangement. The stator winding is cooled in this system by circulating demineralised water (DM water) through hollow conductors. The cooling water used for cooling stator winding calls for the use of very high quality of cooling water. For this purpose DM water of proper specific resistance is selected. Generator is to be loaded within a very short period if the specific resistance of the cooling DM water goes beyond certain preset values. The system is designed to maintain a constant rate of cooling water flow to the stator winding at a nominal inlet water temperature of 40 deg.C.As it is closed loop working, the cooling water is again cooled by water which is also demineralised to avoid contamination with any impure water in case of cooler tube leakage. The secondary DM cooling water is in turn cooled by clarified water taken from clarified water header.

4.3.5 EXCITATION SYSTEM OF ALTERNATOR:The electric power generators require direct current excitation magnets for its field system. The excitation! field system must be reliable, stable in operation and must respond quickly to excitation current requirements The excitation system of a generator comprises of : 1. The main exciter 2. The pilot and auxiliary exciters 3. The voltage control system 4.3.5.1 DEVELOPMENT OF EXCITATION SYSTEM Initially the DC Excitation system was being used. The development of improved

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Techniques resulted in the increased capacity of generators, which in turn raised the Demand of excitation power. But it was found that DC excitation could not meet the Demands of large capacity turbo- generators High excitation currents at comparative low voltage were required and these would entail a large number of brushes operating on the exciter commentator. This will create difficulties in operation and will require extensive maintenance of commentator and Brush Gear. The other disadvantage of DC exciter is that commentator may be satisfactory during steady state but during load fluctuations, there is a risk of flash over at the commentator. The maximum peripheral speed of commentator for proper operation should not be more than 45 meters per second. Reliability is one of the main requisites of excitation system of the generator. This accelerated development of AC excitation system, where AC generator along with rectifier system is used for field excitation. In India practice is to use DC excitation system for 77 MW system and AC excitation for higher capacity turbo generators. 4.3.5.2 DC EXCITATION SYSTEM Direct current exciters are shut wound machines and compounding can be included to improve response. The open-circuit characteristics and basic diagram of a Self excited compounded shut wound exciter are shown in fig.49 (a and b ). It is important to notethe unstable voltage region HB on the open circuit characteristic of the exciter. Since OE is the excitation current when voltage BE is across the shunt field. BE/OE is the value of the critical resistance of the circuit. The line of this cri tical resistance coincides with slope of the voltage characteristic therefore, the voltage is indefinite and can vary freely between the valve M due to the exciter permanent magnetism, and value B the voltage due to field current OE. Even small temperature increases in the field winding will contribute to voltage in stability. A method of overcoming this effect is to insert a saturation liner behind each pole piece. Because of reduced magnetic section the liner is saturated much sooner than the pole body; thereby introducing the required non-linearity in the open circuit characteristic. One adverse effect of the saturation liner however, is to depress the ceiling.

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Fig 3.5 generator main exciter & pilot exciter

Exciter field windings can comprise two or three separate windings. The main field winding is often duplicated to provide parallel current paths to reduce contact wear and field rheostat wear. The provision of a negative field gives a negative bias in the exciter by which response is improved when load is thrown off. It also improves the lowering response of the exciter system following as external fault clearance and reduces the range of main exciter field current needed for a given change in exciter voltage. But this negative field constitutes a constant load on the pilot exciter and necessitates a more powerful positive main field than would be the case without negative bias. These disadvantages are justified. However, on the ground of improve exciter performance, it should be noted that negative excitation like this cannot be achieved in present AC exciter/rectifier systems. Based on the principle detailed above, the basic schematic diagram of DC Excitation system has been given 4.3.5.3 AC EXCITATION SYSTEM The AC exciter for large units gained favors because it was possible to use 2 or 4 pole revolving field type machines possessing all the robustness associated with the generator. Commentator and DC brush gear were eliminated giving place to the simple slip-rings and associated brush gear. A pilot exciter is a necessary piart of the ac exciter system. It is common practice to have pilot CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 38

exciter, itself an a.c. machine. The pilot exciter can also be a permanent magnet generator. The main a.c. exciter is generally a turbo-type generator. It must operate over a wide voltage and current range with ceiling valves considerably greater than the rated full load valve. Furthermore the exciter output must respond quickly to excitation changes at its own rotor terminals. The excitation is controlled by the AVR.The excitation for the pilo exciter is obtained from a permanent magnet of exciter where output is rectified. The pilot Output, which excites the field of AC main exciter, is controlled by Automatic voltage Regulator. The rectified output of the main exciter than energies the rotor of the synchronous generator. In lieu of main exciter the A.C. supply can be taken from the grid, or generator itself rectified and given to the generator field. This is called static excitation. In India for 200/210 MW the following two excitations system have been adopted: High frequency Excitation system with an AC exciter, permanent magnet pilot exciter and an uncontrolled rectifier.Generator potential fed static Excitation system with controlled rectifiers (SCR) and a rectifier transformer.

5 TARNSFORMER
5.1 CONSTRUCTION
Transformer assembles of following parts. 5.1.1

CORE

The material used for is silicon steel, which gives a high resistively and also a low hysteresis loss. The silicon contents are about 4%to5%. A thickness of .33mm is normally used for transformer but for big core type. The cross section of core should be circle. This type of practice involves the change in dimension of each lamination, which uneconomical. Lamination can be of any type such as: 1. I-type Lamination 2. E-type Lamination 3. L-type Lamination

5.1.2 YOKE SECTION

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The yoke section is for transformer using let rolled lamination is made 15% greater than that of core so as to reduce the iron the losses in yoke and also decrease the magnetizing current. The various type of yoke are shown (a) is used for small capacity transformer while section (b) &(c) are used for large capacity transformers.

5.1.3 WINDING
The transformer winding are classified into the following categories. (a) (b) Concentric windings Sandwich windings

The concentric winding is used for core type transformer. The L.V. winding are placed next to the core and H.V. winding on the out side. Concentric winding can be divided into the following. 1. Cross-over 2. Helical 3. Disc

5.1.4 TERMINAL LEADS

The connection to the winding are of insulated copper road or parts. The voltage in a supply network can control by changing the ratio of transformation. This can be condoning by tapping the winding in order to alter the no of turns. The tapping is provided on the high voltage side because a find voltage variation is obtained owing to large on of turns.

5.1.5 COOLING SYSTEM

Cooling for larger transformers necessary for perceiving the insulating solid and liquid from deterioration. The various methods for cooling are:-

AN: natural cooling by atmosphere circulation without any special devices. The transformer ore and coils are open all around to the air. This method is confined to very small units to few KVA and low voltages
AB: CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 40

In this case the cooling is improved by an air blast directed by suitable trucking and produced by a fan ON: The great majority of transformers are oil immersed with natural cooling i.e., the heat developed in the cores and the coils is passed to the oil and hence to the walk of the tank from which it is dissipated. The advantage over air cooling ducts or of moisture affecting the insulation and the design higher voltage is greatly improved OB: In this method the cooling of an ON type transformers is improved by air blast over the outside of tank OFN: The oil is circulated by pump to natural air cooler OFB: for larger transformer artificial cooling may be used. The OFB method comparisons a forced circulation of the oil to a refrigerator, where it is cooled by air blast OW: An oil immersed transformer of this type is cooled by the circulation of water in cooling tube situated at the top o the tank but below oil level OFW: Similar to OFB, except that the refrigerator employs water instead of air blast or cooling the coil, which is circulated by pump through the transformers to the top. Mixed cooling:

ON/OB : as on , but with alternative additional air blast cooling ON/OFN : on/ofb; on/ob/ofb; on/ow/ofw: A transformer may have two

or three ratings when more than one method of cooling provided.

5.1.6 OIL TANK

The tank bodies of most of the transformer are made from solid steel state which is fabricated to from the container aluminum is employed to make oil tank which result reduce the stray losses. However it costs more.

5.1.7 TRANSFORMER OIL

It is mineral oil obtained by refining crude petroleum. It serves the double purpose of cooling and insulation. This prevents the sludge formation. The air should not come in contract with the

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surface of oil. Dielectric strength of oil is greatly affected by moisture so oil should be kept free from moisture.

5.1.8 BREATHER
When the oil expends or contracts due to change in temp. There is displacement in air when the transformer coils the oil level goes down and air is drawn in. this is known as breathing. The air coming in is passed through the apparels called breather for the purpose of extracting moisture. The breather consists of a small varsal, which contain a drying agent like silica gets crystal impregnated with cobalt chloride.

5.1.9 CONSERVATOR
These are provided to keep oil out of contact with air. The function on conservator is taken up expansion and construction of oil without allowing it to come in contact with outside air. It consists of an airtight metal drum fixed above the level of the top of the tank and connected with it by a pipe. The main tank is completely filed when oil is cool. But conservator is partially filled. So the surface oil in contact with outside air is reduced to a great extent. The sludge thus formed remain in the conservator it self and does not go to she main tank.

5.1.10 POWER FANS The natural cooling of the transformer can be increased by the addition of power fans placed at the base or along the side of radiators, whether they are fitted directly to the tank or groups in outside gangs.
.5.1.11

BUCHILZ TUPE GAS ACCUMULATION RELAY:

This relay is provided for transformer protection when electrical breakdown occurs between the live parts, or in the event of fault to ground, short circuits between turns, phase interruptions, burning of core, oil leakage in the tank or in the oil cooling system. This relay will operate on the occurrence of gas formation or on sudden variations of oil level resulting from abnormal transformer conditions by actuating an alarm signal and if the fault is serious or persistent, by putting the transformer out of service.

5.1.12 WINDING TEMPERATURE CONTROLLER

A thermal image device is used to detect the Hot Spot temperature in the winding of a power transformer. A coil is immersed in the hottest oil layer of the transformer,
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transmits through the capillary tube, the temperature variation to the temperature indicator. A heater coil is placed around the thermometer bulb and is supplied by the secondary of main current transformer. The current in the heater is proportional to that is flowing in the winding. The heater is designed to obtain a temperature rise and a thermal inertia equal to those of transformer winding.

.5.1.13 TEMPRATURE INDICATOR

The indicator is sealed in the tank; it is a potentiometer for remote indication and is mounted at mans height at the tank of the transformer. The thermometer bulb located in the probe, is connected through the capillary tube to the actuating bellows of the instruments. A second capillary tube runs parallel to the preceding one and is connected to the compensating bellows to cancel the influence of the ambient temperature. The system is filled with a special stable and non corrosive liquid.

5.1.14 INSPECTION AND MAINTENANCE SCHEDULE Power Transformers

In addition to the log sheet, which is maintained by the shift staff, each transformer should have its own maintenance register, with history card affixed to it. Routine inspection schedule (Power Transformers) Sr.No 1. 2. 3. 4. 5. Items to be inspected Current (Load) Voltage Ambient temperature Oil temperature Winding temperature Recommended schedule (observation to be recorded) Hourly Hourly Hourly Hourly Hourly (Depends upon the capacity of the Transformer and provision of the winding temperature gauge) 6. 7. Oil level in transformer Oil level in Bushing Each shift Each shift
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8. 9.

De-hydrator or Silica Gel. Water cooling system (a) (b) (c) Water temperature incoming and out going Water pumps Oil circulating pumps Fans and motors Bearing (Lubrication) Heat exchanger

Each shift Each shift Each shift Each shift Each shift (as per recommendations of) Chapter V Annually

10.

Blast air cooling system (a) (b) (c)

5.1.15 FAULT AND PROTECTION

A power transformer is subjected to the following fault: 1. 2. 3. 4. Overload and external short circuits Terminal Faults Windings faults Incipient fault

All four conditions produce mechanical and thermal stress with the transformer windings overload can be sustained for long periods being limited only by the permissible temperature rise in the transformer windings and oil excessive overloading results in deterioration of insulating and subsequent failure. It is used to provide winding and oil temperature indicators with alarm and trip contacts. As soon as the temperature of winding and/or oil exceeds the predetermined values of the contacts and bridges completing the circuit of an alarm bell and if the temperature reached the hot spot values the transformer is tripped. The external faults subject the transformer to electromagnetic stress and over heating.
It is therefore, desirable to limit the duration of such fault currents. Terminal faults on the feeding side of the transformer have no adverse effect on the transformer but those on the load side do have such fault can not operate the gas and oil pressure relay more commonly known as "Buchholz relay".These no fall in the protective zone of the restricted earth fault or differential CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 44

relays. The majority of internal fault is either earth fault or inters turn faults. The severity of faults depends on the location of fault transformer design and methods of system earthing, phase faults within a transformer are rare.

Incipient faults are internal faults, which constitutes no immediate hazard. However, if they are left undetected. They may develop into a major fault. The main fault in this group are core faults due to isolation failure between the core lamination and oil failure due to either loss of oil or obstruction in the circulation due of the oil. In that Case overheating will occur the protective systems applied to a power transformer are as follows:
1. 2. 3. 4. Gas and oil pressure relay (Buchholz relay) over current and earth fault differential frame leakage

Simple over current earth fault protection is applied against external short circuits and excessive over loads. These over current relays and earth faults relays were inverse and definite minimum time types.
The over current relay fails to distinguish between conditions of external short circuits over load or internal faults of the transformer. The operation is governed primarily by currents and time ratings and the characteristics curve of the relay. To permit the use of overload capacity of the transformer and co-ordination with either similar relay at about 125 to 150 percent of the full load currents of the transformer but below the minimum secondary current.

The simple over current relays therefore seldom serves the function of primary and relays protection of the power transformers. They serve only as the back up protection both for the transformer, internal and external faults. It is a common practice to provide the over current and earth fault protection on the in feed side of the transformer and is made to trip both H.V. and L.V. breakers over current and earth faults relays are provided on the other windings which are not connected to any power sources but to serve primarily as back up protector to the circuit of load of the respective voltage. In the latter case no interruption of primary side breakers is provided with the over current relays on the secondary side.
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The over current relays have three elements one for each phase and earth fault has a single element. The normal large of current setting available on IDMT over current relays is 50-200% and on earth fault element 20 to 80 per cent on the latter another range 15 to 40 per cent is also available and may be selected where the earth fault current is restricted. Due to insertion of impedance in the neutral grounding. In the case of transformer winding with neutral earthen unrestricted earth fault protection is obtained by connecting an ordinary earth fault relay areas a neutral current transformer. The unrestricted over current and earth fault relays should have proper time lag to coordinate with the protective relays of other circuit to avoid indiscriminate tripping. It is a common practice to provide differential relays on all transformers above 5 to 10 MVA. The advantages over other scheme of protection are (i) the feeds between the current transformer and power transformer provided the current transformer are separately mounted and not in the transformer bushings. In case of very serve internal faults differential relays operate faster than the buchholz relay they control the external damages. (ii) The differential protection responds to phase to phase faults and the protective zone. This generally comprises all equipment and connection between the current transformers on all sides of the transformer. (iii) A transformer differential relay operates on circulation current principle, the currents in various branches windings of transformer are through the media of current transformers. The ratio and connections of various winding of all the secondary to earth through the tank and signal earth connection thus energizing the current transformer and operating the relay. The buchholz can defect faults caused under oil only. The flash over the bushings are not adequately covered by other protective scheme defects such faults and also on

This protective scheme is externally sensitive in detecting earth fault in the transformer zone, the application is independent of normal load through fault conditions and to ratio variations due to two transformers tapping it is possible to set the relay at very low value of fault current an order to obtain successful results. It is essential that the flow of fault current is correspondingly (that the flow of fault current) to the path of transformer earth
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connection. Precaution should be taken to ensure that there is no possibility of a portion of the fault current finding its way to the transformer frame circuit of the other adjustment transformer filled with the same type of protection else false tripping of healthy transformer might occur.
The local distribution systems are of shorter length and operate on comparatively lower voltage. The transmission lines operate on considerably longer distance and at much higher voltages more over the over head transmission lines or network or susceptible to more frequent and numerous fault conditions. The requirements of the protective gear equipment are different in the two cases particularly in the high speed and unit type protection. The relay used for feeder protection is commonly time graded over current and earth fault instantaneous directional over current and earth fault in input ends only or instantaneous nondirectional. Instantaneous pilot wire protection with time graded over current and earth fault acts as back up at input . The time graded over current relay is simple and versatile in application. However, to

achieve proper selectivity the operating times have to be increased to each step. To minimise the damage due to fault and improve systems, stability faster schemes are necessary ,the pilot can be set independently to operate at high speeds such schemes often need to be start by protection which is provided by time graded over current and earth fault relays.

5.1.16MAJOR TRANSFORMER AT CPP 5.1.16.1 GENERATING TRANSFORMER

We are generating the 11kv from the generators 11kv is stepped up to 132 kv from the generating transformer Of 100 MVA
RATING

PHASE
RATED POWER NO LOAD VOLTAGE(HV) LINE CURRENT(HV) AMBIENT TEMP TEMP RISE WINDING IMPEDANCE

3 100 MVA 138 KV 418.37 50 50.7 12.50

FREQUENCY TYPE OF COOLING NO LOAD VOLTAGE(LV) LINE CURRENT (LV) TEMP RISE OIL CONNECTION SYMBOL

50 ONAF 11 KV 5248.64 45.7 YND1

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VOLTAGE

5.1.16.2 STATION TRANSFORMER Station transformer is connected to switchyard .It is step down transformer .it converts 132kv to 6.6kv. PHASE
RATED POWER NO LOAD VOLTAGE(HV) LINE CURRENT(HV) AMBIENT TEMP TEMP RISE WINDING IMPEDANCE VOLTAGE 3 16 MVA 132 KV 69.98 AMP 50 50.7 12.50 FREQUENCY TYPE OF COOLING NO LOAD VOLTAGE(LV) LINE CURRENT (LV) TEMP RISE OIL CONNECTION SYMBOL 50 ONAF 6.9 KV 1338.8 AMP 45.7 YnYn0

UST--- Unit service transformer SST---- Station service transformer PHASE

RATED POWER NO LOAD VOLTAGE(HV) LINE CURRENT(HV) AMBIENT TEMP TEMP RISE WINDING IMPEDANCE VOLTAGE 3 2000 KVA 6600 V 175 AMP 50 50.7 12.50 FREQUENCY TYPE OF COOLING NO LOAD VOLTAGE(LV) LINE CURRENT (LV) TEMP RISE OIL CONNECTION SYMBOL 50 ONAF 433 2666.7 AMP 45.7 YND1

132 KV SWITCH YARD OF HZL TPS:

The main components of 220 KV switch yard is:6.1 Circuit Breaker The Circuit breakers generated generally under over voltage or over current due to any fault on the line. For operation of circuit beaker the signal is given by relay. The relay sends the signal to circuit breaker and circuit breaker isolates the faulty section from the line. Generally the circuit breakers are provided before the equipment for safety. It also put up where bur bars are CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 48

sectionalized. Types of Circuit breaker: Oil Circuit Breaker Air Blast Circuit Breaker SF6 Circuit Breaker Vacuum Circuit Breaker

Principal of operation:-

A Circuit Breaker essentially consists of fixed and moving contacts, called Electrodes. Under normal operation, there contacts regain, closed and will not open automatically unless system becomes faulty. The contacts are moved apart by some mechanism under fault. When the contacts of circuit breaker are separated under fault conditions, an arc is struck between them. The current is thus able to continue until the discharge cease. 6.2 Air Blast Circuit Breaker:-

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Fig 3.12 Air

Blast Circuit Breaker:-

In HZL T.P.S. Switchyard all 132 KV breakers are ABB make AIR BLAST CIRCUIT BREAKER. A.B.C.B. uses compressed air for both as direct medium a well as are extinction purpose. When breaker is in closed position, contacts remains closed due to spring action and there is no air inside the chamber. When breaker sets trip signal, air will pass through solenoid. Common shaft will move and fresh air with pressure will enter from receiver tank to hollow arcing chamber to keep contact separated under air pressure against the spring force. Six arcing chambers are provided for quenching the arc is each phase. When breaker opens the arc is divided in six parts and ionized gases are taken away by air blast and quenching the arc rapidly. To open the breaker minimum 30 Kg/cm air pressure is required, air pressure normal and low indication/Annunciation is provided in control room. The A.B.C.B. can be operated locally as well as from remote control (Control Room) depending on position of selector . 6.3 Isolators

Fig 3.13 Isolators

In substation it is often desired to disconnect a part of the system for general maintenance and repairing. This is accomplished by an isolating switch or isolator. An isolator is essentially a CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 50

knife switch and is designed to open a circuit under no load, under no current on line. The isolators are generally located at entrance of transmission line, after and before the circuit breaker. The isolators are opened with pneumatic driven. A notching device is also provided in pneumatic drive additionally to hold the operating rod extreme open or closed position. The ball catching locking device is provided at the top of the operating nod which holds the isolators in extreme on or off position. The above locking device avoids the chance of accidental opening of the isolator when the breaker is on isolator can be put on local or remote operation. 6.4 Lightening Arrestors

Fig 3.14 Lightening Arrestors

Arrester is a lightning arrester used for protecting transmitters and receivers from abnormal voltages induced in the transmission lines due to lightning surges, field-mount type (Type FXC), and panel-mount type (Type PXC) are also available. Since this arrester uses Fuji Z-trap (sintered zinc oxide) as the lightning arrester elements, it features the following advantages over the conventional gap discharge type arresters using discharge tubes: (1)Potential rise in the transmission line is controlled to a minimum relative to ground since discharge starts at low voltage level, and starts extremely rapidly to the input of steep waves (less than 50V excluding potential rise due to grounding resistor).

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(2) Arrester is designed very compactly since it is free from time delay in discharging and does not require any inductance elements. (3) Abnormal voltage can not be induced between the transmission lines since Arrester is free from response deviation to impulse waves. Though Arrester is connected in series to a transmission line, it never affects normal operations of related instruments. The Lighting Arrestor is protective equipment against the over voltage on the transmission line. The causes of over voltages are as follows: Switching surges Insulation failure Arcing ground Resonance Lightning

6.5 Capacitive Voltage Transformer (C.V.T.) C.V.T. is installed at the entry of 220 KV line. The object of this equipment is to tap the high freq. wave and to give these waves in matching unit for communication purpose. Capacitive Voltage Transformers (CVTs) are common in high-voltage transmission line applications. These same applications require fast, yet secure protection. However, as the requirement for faster protective relays grows, so does the concern over the poor transient response of some CVTs for certain system conditions. Solid-state and microprocessor relays can respond to a CVT transient due to their high operating speed and if Creased sensitivity .This paper discusses CVT models whose purpose is to identify which major CVT components contribute to the CVT transient. Some surprises include a recommendation for CVT burden and the type of ferroresonantsuppression circuit that gives the least CVT transient. This paper also reviews how the System Impedance Ratio (SIR) affects the CVT transient response. The higher the SIR, the worse the CVT transient for a given CVT Finally, this paper discusses improvements in relaying logic. The new method of detecting CVT transients is more precise than past detection methods and does not penalize distance protection speed for close-in faults. 6.6 Wave Trapper

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Fig 3.15 Wave Trapper

This Equipment is connected is series with line and before coupling capacitor towards 29D isolator the wave trap will not allow communication frequency to pass through while it will allow only power frequency and hence is switch yard only power freq. will enter so system will not be affected.This equipment is a parallel tuned circuit comprising lades. It has a low impedance to 50 Hz and high impedance to carrier frequencies. 6.7 Current Transformer

Fig 3.16 Current Transformer

Current Transformers are connected in series with line phases to read amp and & also use for protection in relay circuit. Current Transformers (CTs) are instrument transformers that are used to supply a reduced value of current to meters, protective relays, and other instruments. CTs provide isolation from the high voltage primary, permit grounding of the secondary for safety, and step-down the magnitude of the measured current to a value that can be safely handled by the instruments. CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 53

6.8 Voltage Transformer (P.T. OF V.T.)

Fig 3.17 Voltage Transformer

Voltage Transformer or P.T. are connected in each transformer or P.T. are connected in each phase of Bus-1 & Bus-2 voltage transformers are used to read voltage and give protection in relay circuit. Voltage Transformer and current form former one combined used to read MWH . 6.9 Switch Yard Air Compressors:For operation of A.B.C.B. and isolators compressed air is required at definite pressure. To fulfill air requirement & Nos. of air compressors are installed is switch yard. The outlet of both compressors is connected is common heads and supplies air in two path A & B. In each path there are foul air receiver tanks connected in series. Both paths are made common and again divided in two lines and two pressure reducers and provided to regulate the line pressure to 16.00 Kg/cm, in all receiver tanks 26 Kg/Cm to 30 Kg/Cm pressure is maintained with help of the compressors.Both compressors can be started manually or automatically through the pressure gauges in any sequence pending on selector switch position. The starting and stopping pressure retting are 25 Kg/Cm and 30 Kg/Cm respectively. Switch Yard air receiver pressure now and high alarms are provided in control rooms at the retting of 24 Kg/Cm and 39 Kg/Cm respectively.

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7 DISTRIBUTED CONTROL SYSTEM

Distributed control system(DCS) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented such as oil refining, petrochemicals , central station power generation, pharmaceuticals, food and beverage manufacturing, cement production, steelmaking and papermaking. DCSS are connected to sensors and actuators use set point control to control the flow of material through the plant. The most common example is a set point control loop consisting of a pressure sensor, controller and control valve. Pressure and or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning input/output(i/o) device. When the measured variable reaches a certain point , the controller instructs a valve or actuation device to open and close until the fluidic flow process the set point. Large oil refineries have many thousands of i/o points and employ very large DCSS. A typical DCS consists of functionally and/or geographical distributed digital controllers capable of executing from 1 to 256 or more regulatory control loops in one control box. The i/o can be integral with the controller or located remotely via a field network todays controllers have extensive computational capabilities and in addition to proportion, integrative and derivative (PID) control can generally perform logic and sequential control. In CPP, DCS is being used as control system. Two DCS systems are being used. 1. Honeywell system 2. Max yokogava Four types of signals are used in DCS for controlling 1. Analog input 2. Analog output 3. Digital input 4. Digital output

8 VARIABLE FREQUENCY DRIVES

A variable-frequency drive (VFD) is a system for controlling the rotational speed of an alternating current (AC) electric motor by controlling the frequency of the electrical power supplied to the motor. A variable frequency drive is a specific type of adjustable-speed drive. CAPTIVE POWER PLANT (HZL, CHANDERIYA) SUDARSHAN SINGH CHUNDAWAT(07EIMEE042) Page 56

Variable-frequency drives are also known as adjustable-frequency drives (AFD), variable-speed drives (VSD), AC drives, micro drives or inverter drives. Since the voltage is varied along with frequency, these are sometimes also called VVVF (variable voltage variable frequency) drives. Variable-frequency drives are widely used. In ventilation systems for large buildings, variablefrequency motors on fans save energy by allowing the volume of air moved to match the system demand. They are also used on pumps, conveyor and machine tool drives. VFD system description: A variable frequency drive system generally consists of an AC motor, a controller and an operator interface.

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