1. A Project Report on
STUDY OF THERMAL POWER PLANT
UDUPI POWER CORPORATIONLIMITED
2*600MW
Submitted By
Aquib Nadaf
Department of Electrical and Electronics Engineering
National Institute of Technology Karnataka, Surathkal

2. ACKNOWLEDGEMENT
It is an immense pleasure for me to complete the report on Industrial Training in UPCL for a
duration of 15 days from 15/5/15 to 28/5/15. I express my deep respect & gratitude towards the
invaluable guidance, enormous assistance & excellent cooperation extended to form every
corner of the knowledge.

3. UdupiPowerCorporationLimited
The 2 x 600 MW Udupi Power Project is located in Udupi District of Karnataka, about 35 km
north of Mangalore city. The area was declared as industrial by the state in 1995 and 1998. The
nearest seaport is at Mangalore (New Mangalore Port Trust) and the project is well connected by
rail and road.
Each unit of 600 MW capacity has one sub-critical coal-fired steam generator connected to a
reheat type condensing steam turbine and generator with sea water cooled condenser and all
other required auxiliaries. Each steam generator is rated to generate about 2,028 tonnes/hour of
superheated steam at a pressure of about 175 kg/cm2 and superheat temperature of 540 C. The
steam generators are equipped with facilities for Heavy Fuel Oil/Light Diesel Oil (HFO/LDO)
firing for startup and flame stabilisation at low loads.
Each steam turbine operates at 3,000 revolutions per minute (rpm), tandem compound, single re-
heat, condensing type machine with extractions for regenerative feed water heating. The turbine
will be designed for main steam pressure of 170 kg/cm2 and inlet temperature of 5370C. The
fuel for power generation coal is imported from Indonesia and Africa and the platstotal annual
requirement is projected at 3.64 tonnes. HFO and LDO for startup are sourced from the Indian
Oil Company depot in the region.
Sea water for the condenser cooling water system is obtained from the sea coast 6 km away. A
re-circulating type natural draft cooling tower has been installed, and the sea water is returned
after cooling in the cooling towers. A desalination unit meets the fresh water and demineralised
water requirements of the plant.
Bottom ash is planned to be collected in silos in moist form and fly ash in dry form from the
electrostatic precipitator and stored in silos. Fly ash usage is envisaged for cement manufacture,
and unutilised fly ash and bottom ash are planned to be disposed at the identified ash disposal
area.
The power generated will be evacuated at two levels: 220 kV and 400 kV. A 400 kV
transmission line connects the UPCL substation to the Power Grid Corporation of India Limited
(PGCIL) substation at Hassan, 180 km away. A 220 kV transmission line connects the UPCL
power plant to the substation at Kemar, 25 km away, to cover local loads.
Environment Protection
The plant has a 275 m chimney with a biflue stack inside, a flue gas desulphurisation plant to
control sulphur, and low NOx burners to mitigate NOx emissions. The plant has high efficiency
electrostatic precipitators to limit the suspended particulate matter (SPM) within the prescribed
permissible limits. The coal and ash storage area in the ground is provided with impervious
layers to avoid contamination, if any. Quality Assurance

4. Coal Handling Plant
 Coal handling is most important part of fuel management of a Thermal Power Plant where a
lot of money is invested in purchasing a high quality coal and care is to be taken reduce
production cost by using minimum fuel including transportation losses for producing one
unit of Power.
 In UPCL, 2*600 MW, coal is imported from countries like Indonesia and South Africa
through water ways.
 For a Cargo ship, it can carry coal up to of 70,000 to 90,000 Tons. In a month,
approximately 5 to 6 ships are unloaded for UPCL Plant. A total of approximately 3.2 to 3.5
lakh tons of coal is consumed by the plant in a month.
 From New Mangalore Port Trust (NMPT) with the help of Southern Railways and Konkan
Railways, the coal is transported to the plant by Bogie Bottom Open Rapid Discharge
Railway wagons.
MAIN COMPONENTS OF CHP
 Track Hopper:
Place where coal is unloaded from railway wagons. Here bottom discharge box is used.
It has Pneumatic cylinder which requires an air pressure of 6.3 bar for opening and
closing of bottom doors of the wagon. This air pressure is supplied by air compressors
present beside the track hopper.
 Paddle Feeder:
There are 2 no’s of paddle feeder to feed coal to two conveyor belts 1A and 1B from the
track hopper. The paddle feeder has got a load to measure the flow of coal. This can be
adjusted by the operator to control the flow of coal on the conveyor belt.

5. CHP LAYOUT
 Mainly there are 3 modes of operation in coal handling.
They are:
Mode 1 - Track Hopper to Bunker.
Mode 2 - Track Hopper to Stacker 1 or Stockyard to Reclaimer 1.
Mode 3 - Track Hopper to Stacker 2 or Stockyard to Reclaimer 2.
 The BRDBO (Bogie bottom open rapid discharge wagon) is unloaded in the track hopper.
The unloaded coal is further fed to conveyors 1A and 1B through paddle feeders
 As this coal is of above 50mm size, coal is sent to bunkers through conveyors 2A, 2B, JT 2,
3A, 3B.

6.  After crushing up to 25mm size, the coal is sent to bunkers through conveyors 5A, 5B, JT8,
JT9, 9A, 9B in mode A.
 For stacking and reclaiming operations coal is sent to coal yard or reclaimed from there
respectively.
 During stacking operations coal is sent through 4A, 4B, 6A, 6B, JT3, RYCI and coal yard or
6A, 6B, JT4, RYC2. RYC1 and RYC2 are reversible and for reclaiming operations the coal
is reclaimed from the coal yard through RYC1 and RYC2 to JT3 or JT4 to JT6 to JT7, 7A,
7B to bunkers.
 There are 6 bunkers for each unit in which under full load 5 bunkers will be under operation
and the 6th
bunker will be in standby.
 The coal is fed to the bunkers through the travelling tipplers.
Layout of CHP in UPCL
CRUSHER HOUSE

7.  3A, 3B conveyors belt take the coal to the top of the crusher house >50mm. For this purpose
a HT motor is used of 11 KV. It is further connected to driving pulley through scoop
mechanism.
 The coal enters through the ILMS where the iron pieces are removed and thrown out of the
conveyer belt from the coal.
 Another set of ILMS is present at JT7. Pent house contains metal detector which detects
metal parts. 4A and 4B are reversible belt and can be used for both bunkering and stacking
operations.
STACKER/RECLAIMER
 UPCL Plant has got 2 stacker/reclaimer one between CY1, CY2 and the other between CY2
and CY3.
 The RYC1 and RYC2 has got 2 LT motors at their ends running at exact equal speed.
 In case of stacking operation, the RYC1 lifts up the coal into the machine then to
intermediate conveyor and then to boom conveyor and then to coal yard. In this case, the
bunkers remain idle.
 In case of reclaiming operations, the coal from coal yard if lifted by rotating buckets in the
coal heap and coal is cut in benches. The coal heap can be trapezoidal or conical. The coal
lifted by the buckets fall down on the boom conveyors and then transferred to RYC1 and
RYC2.
 RYC1 and RYC2 is also called Long Travel conveyor.
 To move the sleeve right or left, sleeve drive is provided and it is rotated by 2 no’s sleeve
wheels
using 2no’s of meters.
ELECTRICAL MOTORS USED IN STACKER/RECLAIMER
Bucker wheel 75 KW ABB
Intermediate conveyor motor 55 KW ABB
Boom Conveyor motor 55 KW, ABB
Vibro feeder motor 22 KW, ABB
Long travelling motor 5.5 KW, ABB
And dry type Transformer of 11KVA/50KVA is used.

8. COAL FEEDER AND BUNKERS
 The coal comes to the bunkers through long conveyors 8A, 8B and these conveyors are
again driven by HT motors of 11KV.
 The coal is then enters the bunkers through conveyors 9A, 9B. The travelling tippler fills the
bunkers as per requirement.
 In this plant, each unit has got 6 bunkers. Capacity of bunker is 660 tones.
 From the bunker, coal is fed to coal mill through gravity metric coal feeder.
 For removing coal dust, the top of the bunkers are provided with Dust Extraction System
and exhaust fans.
COAL MILLS:
 There are 6 no. of coal mills provided for each unit out namely A, B, C, D, E & F of which
5 of them will be running at full load and 1 will be in standby.
SAFETY SYSTEMS AND EMERGENCY
 Pull Chord:
In case of emergency or hazard, pull chord can be operated by the operator to
immediately stop the conveyor. Pull chord wire runs throughout the conveyor.
 Belt sway switch:
If the belt is running out of axis, it is sensed by the Belt Sway switch and the belt is
stopped.
 Zero speed switch:
Zero speed switches sends a pulse signal depending upon the speed of the conveyor. If
the speed of conveyor is zero due to any reason, the zero speed gets activated and trips
the machine.

9.  Since coal is a combustible element, it can easily catch fire. Auto fire detection systems are
provided through out the conveyor belt which is provided with a cable wire. If the cable
wire burns, then the water immediately flushes through the pipe and extinguish the fire.
COAL ANALYSIS
 GCV of Indonesian coal is 5400 to 6400 kcal/kg.
 UPCL requires 6000 tons per day to produce 600MW of Power for each unit.
 Indonesian coal has a moisture content of 15%. Ash content of 2 to 12%. Volatile Matter
40%.
 There are 2 types of analysis of coal a) Proximate analysis
b) Ultimate analysis
 Ultimate analysis is not done in the plant. It is to be done before setting up of the plant as
the capacity and structure of the plant.
a) Proximate analysis: Proximate analysis of coal is done to find
1) Total Moisture
2) Ash
3) Carbon fixed
4) Volatile matter
5) GCV of coal
b) Ultimate analysis: In this analysis we fine the percentage of Calcium, Sulphur, Nitrogen,
Hydrogen and Oxygen.
FLUE GAS DESULPHURIZATION
 One of the major constituents of flue gas is Sulphur oxides and Nitrous oxides. Sulphur
oxides when mixes with moisture in air below dew point (around 100degc) it forms H2SO4.
 The Sox, NOx when reacts with atmosphere, it may pollute the atmosphere.
 In order to prevent this happening both the units of UPCL are installed with
Desulphurization plant which remove sulphur from the flue gas not completely but to
acceptable limits.The desulphurization plant mainly consists of scrubber units technically
called as absorber.Absorbers are connected through a duct to the main flue gas path after the
ID fans and before the chimney.

10.  Booster fans are connected in parallel to the flue gas path to absorb part of the flue gas
from which sulphur is removed. Booster fans have got blade pitch control to control the flow
of flue gas to absorber.The absorber units are provided with limestone storage tanks.
Limestone is basic in nature; it reacts with sulphur which is acidic in nature and neutralizes
forming Gypsum.
CaCO3 + SO2------------CaSO3+CO2
½ 02+CaSO3+2H20-----------CaSO4+2H2O
In the absorber, limestone powder has to be fed from the top of it, but limestone is received in
the form of solid lumps which has to be crushed.
 VFD weigh Belt feeder is provided below the limestone silo in order to weigh the lime
consumption. After the belt weight feeder the lime stone falls on a reversible belt where it can
be fed to ball mill 1 or 2.
 Hydro cyclone works on the principle of cyclone precipitators where heavy particles
settle down and lighter particles raises upwards.
 After hydro cyclone, the lime slurry with water in the slurry recirculation tank and this
slurry water is fed to the absorber which falls down the top and flue gas enters from the
bottom.
 gas with Agitations are provided at the bottom of the absorber to provide thorough
mixing of flue lime slurry.
 Oxidation blowers are provided to give extra O2 to form gypsum and to remove air from
gypsum. The gypsum formed at the bottom of absorber is in liquid state and to make it to solid
state vacuum belt fitter are provided.
 Temperatures inside the absorber are continuously monitored. Temperature should not
exceed above 100degc as the internals of the absorber are made up of rubber. If temperature
exceeds above normal level, water is flushed through quenching spray to reduce temperatures.

11. ASH HANDLING PLANT
BOTTOM ASH HANDLING
 There are 4 bottom ash hoppers for each unit. Whenever there is steam blowing inside the
boiler the bottom ash falls on the refractory walls and then to bottom ash hoppers.
 The bottom ash hoppers are immersed in seal trough to avoid ingress of air into the boiler
in order to prevent disturbance to boiler draft. The bottom ash lumps fall on to the scrapper
conveyor which is run by chains and pulley.
 Each unit has got two scrapper conveyors out of which one will be running and the other
will be in standby.
 The bottom ash from scrapper conveyor is carried forward to the clinker grinder where
the bottom ash lumps are grinded and carried forward on a belt conveyor to bottom ash storage
bin when the ash is disposed to the ash dyke with the help of trucks. The ash slurry from
scrapper conveyor overflow comes and falls in drain sump.
 The water from drain sump is recovered and re used again. For that purpose, we have
settling tank and surge tank.
 Settling tank separates ash, water and surge tank collects the separated water.

12. ECONOMIZER ASH HANDLING:
 After Economizer, there is a bend in duct of the boiler furnace and then flue gas goes to
air pre heater.
 As ash travelling in this path and due to a sudden change in its path, the ash tries to settle
down due to gravity.
 At this path, 7 hoppers are provided for each unit to collect economizer ash.
 Each economizer hopper is provided with a manual gate and solenoid gate to open and
close. The hopper’s end is enclosed in a seal trough to avoid ingress of air into boiler furnace
to avoid disturbance to boiler furnace.
 The economizer ash reaches the scrapper conveyor where the next process is all same as
in the case of bottom ash handling. After seal trough the economizer ash is sprinkled with
water in the flushing apparatus.
FLY ASH HANDLING

13.  Fly ash is totally collected in “Electro static precipitator”. The ESP contains a cathode
and anode in every field which are supplied with a DC voltage of 60KV.
 When the ash particles enter the ESP fields, they get negatively charged and gets pushed
away from the cathode as like charges repel. The ash particles get attracted by the anode walls
which are positively charged. The ash particles are uniformly distributed to each ESP Field by
a Gas Discharger Plate. Thus clean flue gas moves out from the ESP outlet. The efficiency of
ESP is 99.7%.
 To avoid fouling of the anode, cathode and gas discharger of ESP by the ash particles,
emitting electrode rappers, collecting electrode rappers and gas discharger plate rappers are
provided.
 After rapping of the electrodes the ash is finally collected in the ESP hoppers which are
transported to the Buffer Hopper by 3 vacuum pumps out of which 2 vacuum pumps are
generally in running.
 The buffer hopper consists of a bag filter to which the ash gets deposited. The ash
particles fall down in the buffer hopper by giving a puffing of Instrument Air of 6 bar which
are then moved to ALU.
 The fly ash is collected in the Air Lock Vessel (ALV) is transmitted to Ash Silo as air +
ash mixture with the help of 3 no’s of TAC (Transport Air Compressor) having a pressure of
2.5 to 3 kg/cm2
.
ASH SILO
 For fly ash disposal system, there are 4 Silos constructed far away from the main plant.
The fly ash which is collected in the ESP is transferred to the Silo with the use of 3Transport
Air compressor (TAC).Each Silo has got a height of 16mts. Each meter can store up to 90 tons.
Thereby the capacity of each silo is 16*90=1440 tons. Total capacity of 4 silos is 5760 tons.
 Bag filter is installed at the top of the silo. Three Pneumatic valves for 3 pipe lines (2 for
two units each and 1 is common) is installed at the top of the silo. Purging of Bag filters is
done at regular intervals.
 Vent fans are provided to remove compressed air and to maintain vacuum.
 Aeration blowers are provided at the bottom of the silo which blows air through fluidized
bed in order to level the fly ash and prevent choking of silo.
 The bottom of the silo is provided with pneumatic gate and paddle feeder and volumetric
feeders to load the fly ash through chute provided at the bottom of the silo. Scavenging air fan
is provided to maintain the vacuum in the chute. The ash collected in the Ash Silo is moved out
of the plant by ash carrying trucks to the Ash Dyke or to the cement manufacturing companies.

14. 5. SEA WATER INTAKE PUMP HOUSE
 Raw water is taken from the Arabian Sea with the help of gravity by GRP pipelines into the
fore bay which is of 7.5mts of depth. Sump is further divided into 4 canals.
 The intensity of a water intake totally depends upon the wave intensity. For a high tide
water intake will be more and low tide water intake will be less.
 4 stop gates for two intake pipelines are provided to stop the water intake if necessary.
Cleaning/maintenance can be done at this time.
 There are 2 pipe lines provided to mix chlorine water in the sump water for chlorination in
order to reduce turbidity. 2 gates are provided to stop chlorination.
 There are 3 no’s of 11KV intake pumps which pumps water to the balancing sump and
NDCT in the plant and the water is further sent to clarifier. Under normal condition 1 pump
will be running and 2 pumps will be in standby. The flow through the pipe will be
5500m3
/hr. The pump runs with a pressure of 4 kg/cm2
.
 Before the pump intakes water there are travelling screens present in the way which will
stop the entry large size particles like dust/fungus, plastic, fish, prawns, grass etc. A back
flush jet is provided to clean the travelling screens. The dust is all collected in a separate
drain tank. Cleaning of screens is done for 20 minutes in a shift.
 There are certain permissive for a pump to start like thrust bearing temperature, winding
temperature, current sump level, NRV open and flow in the pipe etc.
 There are total 3 no’s of intake pipes (2GRP, 1MS)and 2 no’s of return drain pipe from and
to the sea from the main plant.

15. 6. CW AND ACW PUMP HOUSE
6.1 CW PUMP HOUSE
 CW pump specifications:
Pump output flow: 35300m3
/hr
Input voltage: 6.6kv
Power: 3000kw
Speed: 372 rpm
Discharge pressure: 2 to 2.3 kg/cm2
Header pressure: 2.7 kg/cm2
 In order to refresh, the cooling water is blow down is provided and at the bottom of the sump
and fresh water is added as make up.
 In order to treat sea water and reduce algae, chlorination is done for sea water.
6.2Chlorination Plant:
 For chlorine dozing, the sea water is taken from CW pump outlet normally. Two sea water
pumps are also provided for this purpose.
 The sea water then moves on to 4 no’s of Electrolyzes out of which 2 no’s of Electrolyzes
will be in running.
 The Electrolyze will be consisting of one cathode and one anode and it is supplied with a dc
voltage of 135V and current of 750 A. 4 no’s rectifier cubicles are present for this purpose.
 The sea water then moves on towards 4 no. of Electrolyzes out of which 2 no. of Electrolyzes
will be in running and 2 no. will be in standby.
 The Electrolyzes will be consisting of one cathode and one anode and it is supplied with a dc
voltage of 135V and with a current of 750A with the help of 4 no. of Rectifier cubicles one
of each Electrolizer.
Nacl+H2O NaOH+HCl
NaOH+HCl NaOCl+2H+
 Sodium Chloride (NaCl) is present in sea water. In Electrolizer NaCl reacts with H2O &
forms NaOCl solution which is called HYPO. This HYPO solution is stored in a 50 KL
capacity tank.
 This solution can be dozed to sea water with the help of 2 no. of NaOCl pumps out of which
one is kept in running and one is kept in standby normally as per requirement.
 Some of salts which are deposited on the electrode plates of Electrolizer are cleaned by
flushing HCl acid which is pumped using 2 no. of acid pumps and blowers are provided to
form Hydrogen ions by blowing adequate air.

16. 6.3ACW PUMP HOUSE
 The Auxiliary Cooling Water used for cooling of Turbine/ Boiler Auxiliaries is also sea
water taken from the CW fore bay. There are 3 no. of ACW Pumps out of which normally 2
are in running and one is in standby. The ACW inlet contains a strainer.
ACW Pump Specifications:
Power - 449.4KW
Voltage - 6.6KV
Speed - 1490 rpm
TDH - 52.4mm
No. of stages - 1
Balancing sump depth - 3.7 mtrs
GUARD POND:
The waste water or return water from DM plant, BOP, Boiler, CW sump are collected here
and this water should be sent to disposal, into sea. For this, there are 5no’s of pumps out of
which 2 are running normally and 3 no’s of pumps are standby.

17. Guard pond Pump specifications: Motor details:
Make: Flow more limited Make: Marathon Electric
Pump input: 138.6KW Voltage: 415V, 50HZ
TDH: 21Mtr Capacity: 180 KW
Speed: 1485RPM Amps: 305A, RPM: 1485,
PF: 0.86 Capacity: 2000m3
/hr Efficiency: 95%
7. EFFLUENT TREATMENT PLANT
 The main function of the ETP is to maintain the normal PH value of the waste water which
can be left into the sea or for watering the garden which would otherwise it will be a problem
to the environment.
 For this purpose, the waste water is treated with ALUM and Limestone and turbidity is also
reduced.
 The waste water from Boiler side, CHP, AHP, DM plant, Ash Silo etc comes to ETP sump
where it is carried forward with the help of 3 pumps out of which normally 2 will be running
and one is standby.
 After the water is taken out from the sump, the Alum and Limestone are added in the water
and this water reaches the flash mixer where Poly is added to reduce the turbidity.
 The PH of the waste water should be around 6.5 to 8. The flash mixer contains a motor for
rotating the mixing rod.
 In the ETP sump, to remove the oil content from the water which settles at the top portion of
water, always a pulley driven belt system is provided.
 After mixing of water in flash mixer, the water is further sent to flocculator where the water
is mixed gently with the stilling rod and the water further moves on to clarifier.
 In the clarifier, water enters from the center of the clarifier tank and overflows to the outer
tank through V notches and reaches the CMB sump finally. The sludge of the waste water is
collected at the sludge tank.
 There are two no’s of sumps provided at the CMB sumps ( 1W + 1S ) which are used for
sending treated water to guard pond.

18. WATER TREATMENT PLANT & D.M. PLANT

19. Cascade Aerator:
 Water from the sea water balancing sump is pumped to Cascade Aerator with the help of 3
no. of Clarifier feed pumps out of which one is working and the other is in standby. In
cascade aerator sea water is exposed to oxygen and ultraviolet radiation of sun in order to
improve taste and odor.
 NaOCl is added to the sea water in cascade aerator for chlorination purpose to reduce algae
formation. The chlorinated water moves forward to the stilling chamber.
 Flow rate, maximum of cascade aerator is 2400 m3/hour and Number of steps in cascade
aerator are 8.
Stilling Chamber:
 The velocity of the water is reduced in the stilling chamber so that we can maintain stable
water flow.
FeCl3 & PolyElectrolyte to be added in the path of stilling chamber and flash mixer.
 FeCl3 is used to gather all small particles in water. Poly Electrolyte is used to gather all
suspended particles present in the water. The capacity of stilling chamber is 20m3
.
Flash Mixer:
 Alum and Lime solution is dozed for coagulation through dosing pump. 1 no. of agitator is
provided for proper mixing. The capacity of Flash mixer is 40 m3
.

20. Clariflocculator:
 2 no. of Clarriflocculator of circular type are provided with rotating bridge and suspended
scrapper.
Clariflocculator is a combination of flocculation and clarification in a single tank.
 It has 2 concentric tanks where the inner tank act as a flocculator and outer tank act as a
clarifier.
 In the clariflucculator, the water enters the flocculator where the rotating bridge improves the
flocculation of the solids.
 As heavy particles settle at the bottom, the liquid flows upwards in the clarifier zone. The
clarifier discharges water over a peripheral weir into the peripheral launder.
 The deposited sludge is settled at the bottom from where it is routed to the sludge sump and
discharged to the sludge tank. Thus general service water is produced for drinking and other
domestic purposes.
 The normal feed flow through the Clariflocculator is 1050 m3
/hr and maximum feed flow is
1200m3
/hr.
Rapid Gravity Filter:
 The water coming out of clariflocculator mixes with anthracite coal, gravel and sand for
attracting the suspended particles for 24 hours in the Rapid Gravity Filter zone.
 Air Blowers and flushing line are connected to the rapid gravity filters for cleaning filters.
 The normal/ maximum feed flow of RGF is 400 & 500 m3
/hr respectively.
Filter Water Reservoir:

21.  After RGF filter water is stored in the reservoir. Then water moves forward to the pressure
sand filter. The capacity of filter water reservoir is 5800 m3
. The working pressure is ATM.
Pressure Sand Filter:
 The 4 no of RO Make Up pump is used to pump water to the PSF out of which 3 are
normally under running and 1 is in standby. The capacity of RO Make Up Pump is 710
m3
/hr.
 PSF consists of gravel and sand tightly packed up to 400mm and 900mm respectively. PSF
allows only 20 microns particles to flow through it. Its output pressure is 4 Kg/cm2
.
 There are total 7 no. of PSF out of which 6 will be service generally and 1 is in standby. The
flow of water through PSF is 325 m3
/hr.
 To clean the PSF a 3 No. of Backwash Water Pump are provided whose flow is 580m3
/hr.
Micron Cartridge Filter:
 Before MCF we are adding anti oxidant, HCL and sodium meta bisulphate. Sodium Meta
Bisulphate (SMBS) is used to remove chlorine. There are 3 no. of MCF provided. Flow of
MCF is 643m3
/hr. No. of Cartridges are 161. Size of each cartridge is 100mm * 65 mm.
Sea Water Reverse Osmosis:

22.  4 no. of High Pressure Pump is used pump water to SWRO whose flow is 643 m3
/hr. There
is only 35% water permissive in the Sea Water Reverse Osmosis Filter. The remaining 65%
water is rejected through the ERT (Energy Recovery Turbine) reject line and goes to the
sludge sump.
 3 no. of Energy Recovery Turbine with a pressure of 418 m3
/hr is used increase the pressure
at the SWRO feed inlet by using SWRO reject water discharge pressure.
Degasser:
 It works on the same principle as that of Deaerator. It is used to remove CO2 from the water.
In the degasser tank gas flows through the bottom and water is sent through the spray type
tray from the top side.
 The sprinkled water comes in contact with gas so that CO2 is removed from water. Then the
water moves to BWRO.
Back Water Reverse Osmosis:
 There is only 20% water permissive in Back Water Reverse Osmosis Filter. The remaining
80% of water is sent back to the reject line to sludge sump.  The permitted water moves to
mixed bed Filter.
Mixed Bed Filter:
 Mixed bed filter contains cation and anion resins for removing cations and anions from the
water.
 For the continuous activation of resins we are adding HCL for cations and NaOH for anions.
DM Water Storage Tank:
 After all the above process DM water is finally stored in 2 no. of DM Storage Tanks.
Sr. No.
1. pH of DM Water 6.8 to 7.1
2. Conductivity of DM Water < 0.2 us/cm
3. SiO2 < 10ppb
4. Total Dissolved Solids < 0.1 ppm
5. Capacity of each DM tank 1200 m3
6. Capacity of each DM Transfer Pump 3 no.s (2+1) 80m3
/hr

23. DM Transfer Pump & Motor Specifications:
Sr. No Specification Details
1. Power 27.6 KW
2. Stator Voltage 415 V
3. No. of Pumps 2 W+1S
4. Frequency 50 Hz
5. Discharge Flow 80 m3
/hr
6. Stator Current 65 A
7. Speed 1450 rpm

24. COOLONG TOWER
 Cooling Towers for Refrigeration
An important device used in any refrigeration or air conditioning system is a condenser. A
condenser is used in the high pressure side of a refrigeration or air conditioning system to
convert the high-pressure vapour refrigerant from the compressor into liquid refrigerant. The
medium used in a condenser may be water or air, depending upon the application. In the case of
water cooled condensers, the warm water being pumped by the condenser should be cooled with
the help of cooling towers so that the same water may be re-circulated to the condenser.

25.  Principle of Operation for Cooling Towers
The principle of operation of cooling towers is very similar to that of the evaporative type of
condensers, in which the warm water gets cooled by means of evaporation. Water evaporates as
a result of the hot water droplet coming in contact with the air (which is being pumped out by
means of a fan). This evaporating water also absorbs the latent heat from the water surrounding
it. By losing latent heat, the water is cooled.
SWITCHYARD
Electrical System in Power Plant
STEAM TURBINE GENERATOR SPECFICATIONS:
Sr. No. Specification Rating
1. Make DONGFANG Electrical Machinery Co. Ltd.
2. Rated Capacity 706 MVA
3. Rated Output 600 MW
4. Rated Stator Voltage 22 KV
5. Rated Stator Current 18,525 A
6. Rated Power Factor 0.85
7. Frequency 50 Hz
8. Rated Speed 3000 rpm
9. Rated H2Pressure 0.45 MPa
10. Maximum H2 Pressure 0.5 MPa
11. Winding Connection 2-Y
12. Cooling Water Flow of Stator Winding 96 m3
/hr
13. Cooling Water Pressure of Stator Winding 0.20 MPa
14. Rated Field Current 4,727 A
15. Running Temperature 450
C
STATIC EXCITATION SYSTEM
 The excitation supply is given to the field winding of the Turbo Alternator.
 During start up, when there is no output from the generator, a large battery bank provides the
necessary power for excitation.
 Once the generator output reaches 10% of the rated voltage, the excitation supply is tapped
from the output of the Turbo Generator terminals via excitation Transformer. This rectified
supply is fed to the rotor of the Turbo Alternator. AVR has a Voltage and Current feedback

26. from the generator terminal such that it can automatically maintain the machine to operate in
the permissible region of the Capability graph of the machine.
Excitation Transformer Specifications:
Sr. No. Specification Rating
1. HV side voltage 2400 KVA
2. Operating Frequency 50 Hz,1phase
3. LV side Voltage 900 V
4. Tapping -2 to +2 V *2.5%
5. HV Current 1890 V
6. LV Current 2666.7 A
7. Temperature 810
C
8. Present Temperature 52.80
C
9. Insulation Class F
10. Impedance Voltage 8.46%
Generator Excitation Specifications:
Sr .No Specification Details
1. Rated excitation voltage 431 V
2. Ceiling voltage of excitation system 1000V
3. Rated continuous excitation current 4727 A
4. Ceiling voltage for 20 seconds 8986 A
5. Response time 80 ms
6. Excitation Mode DC 220 V
7. Total power consumption of excitation cabinet 58 KW
400KV GT-1 Transformer Details:
Transformer capacity in MVA 250 * 3
Transformer total capacity in MVA 750
HV voltage rating in kV (primary) 420
HV current rating in A (primary) 1030.98
LV voltage rating in kV (secondary) 22
LV current rating in A (secondary) 19682.4
Rated Voltage in kV 420
Voltage at Maximum tap in kV 441
Voltage at Minimum tap in kV 399
Transformer % Impedance 14.8
OLTC Range +5% to -5%

27. Step 2.5%
Vector Group YNd11
400KV/220KV ICT#1 (R3A&R3B ) Transformer Details:
Power in MVA 315
HV side Voltage in kV 400
LV side Voltage in kV 220
HV side CTR Primary in A 2000
HV side CTR secondary in A 1
% Impedance 10.3
LV side CTR Primary in A 1600
LV side CTR secondary in A 1
Vector Group YNyn0
OLTC Range 10%
STATION TRANSFORMER-1: 220/11.5/6.9 kV, 63 MVA TRANSFORMER Details:
Power 63 MVA
HV side Voltage 220 kV
HV side CT Ratio 1600/1 Amps
LV1 side Voltage 11.5 kV
LV1 side CT Ratio 2500/1 Amp
LV2 side Voltage 6.9 kV
LV2 side CT Ratio 2500/1 Amp
% Impedance 25%
Vector Group YNyn0yn0
UNIT AUXILLARY TRANSFORMER (UAT): 22/6.9 kV, 25MVA Transformer Details:
Capacity 25MVA
HV side rating 22kV
LV side rating 6.9kV
Tap Range -10% to +10%
Tap Increment 1.25%

28. Vector Group Dyn1
High Voltage Switch Yard [400KV & 220KV]
400KV Switch Yard [One and Half Bus Bar Scheme]
 In UPCL the power generated is supplied to two different Power grids. One of them is
400KV Southern India Power Grid and the other is 220KV Karnataka State Power Grid
Corporation.
 The 400KV Switch Yard is a One and Half Bus bar Scheme and the main advantage of this
scheme is feeders will be intact in case of bus faults.

29.  The transmission lines coming from PGCIL Hassan District in Karnataka are connected to
this Switchyard.
 Each line and Bus Bar are provided with CTs and CVTs for the measurement of current and
voltages for metering and relaying.
220KV Switch Yard [Double Bus bar Scheme]
 The 220KV switch yard is a Double Bus Bar Scheme in which two lines from KPTCL from
Kemmar Area in Karnataka are connected.
 . There are 2 tapping provided for the station transformer which gives supply for all the
station auxiliaries.
 Each station transformer has 2 LV windings, i.e. 6.6kV and 11kV. 6.6kV can feed Unit
auxillaries while lighting up the generator units. 11kV feeds station auxillary switch boards.