Full information of Thermal Power Plant by Rupesh Kumar

POWER MECH PROJECTS Ltd. AT 2x 660 MW JAYPEE
NIGRIE SUPER THERMAL POWER PLANT
NIGRIE, DIST- SINGRAULI, M.P.
An Internship Report Submitted to
UKA TARSADIA UNIVERSITY
Final Year Student of
Bachelor of Technology
in
Electrical Engineering
By
Rupesh Kumar
(Enrolment No. 201503100610058)
Guided by
Mr. Afaque Nomani
Dy. Manager, Electrical & Instrumentation Dept.
Mr. Naitik M. Nakrani
Assistant Professor
Department of Electircal Engineering
Chhotubhai Gopalbhai Patel Institute of Technology
Bardoli, Surat, Gujarat
2018

II
CERTIFICATE
This is to certify that work embodied in this internship report
entitled “POWER MECH PROJECTS Ltd. AT 2x 660 MW JAYPEE NIGRIE
SUPER THERMAL POWER PLANT NIGRIE, DIST- SINGRAULI, M.P.”
was carried out by “Mr. Rupesh Kumar” (201503100610058), at Chhotubhai
Gopalbhai Patel Institute of Technology for the partial fulfillment of B.Tech.
degree to be awarded by UKA TARSADIA UNIVERSITY. This research work
has been carried out under my supervision and is to our satisfaction.
Date:
Place:
Mr. Darshan vora Ms. Ankur Rana
Assistant Professor, Electrical Dept. Assistant Professor, Electrical Dept.
C.G.P.I.T., UTU. C.G.P.I.T., UTU.
Mrs. Krupa Dave External Examiner
Head of Electrical/EC/ICT Department.
C.G.P.I.T., UTU
Dr. R.V. Patil
Director, C.G.P.I.T
UTU

IV
ACKNOWLEDGEMENT
A internship is never an easy task and without the support of our teachers, mentors,
familie and the very environment in which we live , this would not have been a success .
A very special thanks to the Training Department, Power Mech Projects Ltd. For providing me
with a rich pool of resources in the plant, without which, it would be impossible to achieve such
tremendous results.
A mentor is the one who guides a projects and ensure that it reaches its ultimatum, thus without
Mr. Afaque Nomani, Sr. Manager Electrical and Instrumentation Department, Power Mech
Projects Ltd. Valueable guidance and support.
I also like to thanks the employes of Electrical & Mechanical section of Power Mech Projects
Ltd. For providing me with detail desdcription, operation and process of Boiler, Turbines and
maintenance involved in the power plant.

V
Contents
CERTIFICATE..................................................................................................................................................II
INTERNSHIP CERTIFICATE.............................................................................................................................III
ACKNOWLEDGEMENT..................................................................................................................................IV
Contents........................................................................................................................................................V
List Of Figures...............................................................................................................................................XI
List Of Tables..............................................................................................................................................XIV
Chapter .1 Brife introduction of Power Mech Projects Ltd. At Jaypee Nigrie Super Thermal Power
Plant 2
1.1 Brife description of power plant profile .......................................................................................2
Chapter .2 400 KV SWITCH YARD INTRODUCTION.................................................................................4
2.1 SWITCH YARD CONTAIN TOAL 12 BAY:-.....................................................................................5
2.2 SIMPLE LAYOUT OF 400 KV SWITCH YARD:-.................................................................................6
2.3 ABOUT EACH BAY AND SLD(SINGLE LINE DIAGRAM)....................................................................7
2.3.1 ABOUT BAY 1:- ......................................................................................................................8
2.3.2 ABOUT BAY 2 & 3:-..............................................................................................................10
2.3.3 ABOUT BAY 4,5 & 6:-...........................................................................................................11
2.3.4 ABOUT BAY 7:- ....................................................................................................................14
2.3.5 ABOUT BAY 8,9,10,11 & 12:-...............................................................................................15
2.4 PROTECTION IN SWITCH YARD:-.................................................................................................17
2.5 STANDARD VALUE OF GAS PRESSURE FILLING IN CIRCUIT BREAKER .........................................19
2.5.1 HOW WE OBSERVE PRESSURE FROM PRESSURE GAGE......................................................20
2.6 READING SHEET OF SF6 PRSSURE OR ON/OFF OR CHARGE/DISCHARGE CONDITION FOR EVERY
DAY (24 HOURS)......................................................................................................................................23
2.7 INSIDE SF6 CIRCUIT BREAKER HOW IT LOOK LIKE.......................................................................24
2.8 FORM WHERE WE FILL SF6 GAS IN CIRCUIT BREAKER................................................................25
2.9 HOW CIRCUIT BREAKER IS TRIP...................................................................................................26
2.10 PLCC (POWER LINE CARRIER COMMUNICATION) BY USING THIS DEVICE WE PROVIDE DC
SUPPLY TO RELAY COIL TRIP. ..................................................................................................................27
2.11 THERE ARE TRIP RELAY FOR EACH PHASE...................................................................................28

VI
2.12 TRIP RELAY IMAGE:-...................................................................................................................29
2.13 400 KV SWITCH YARD CONTROL ROOM .....................................................................................30
2.13.1 BATTERY CHARGEING IN CONTROL ROOM:- ......................................................................30
2.13.2 CHARGEING PANNELS IN CONTROL ROOM:-......................................................................31
2.13.3 FROM HERE WE TAKE READING OF CHARGEING BATTERY ................................................33
2.14 PROTECTION OF ISOLATOR.........................................................................................................34
2.14.1 BELOW BOTH PANNELS ARE CONNECTED TO ISOLATOR ...................................................35
2.15 ABOUT EARTH SWITCH :-............................................................................................................36
2.16 ABOUT DISCONNECTOR:-............................................................................................................37
2.17 WHAT HAPPEN WHEN WE DISCONNECT ISOLATOR..................................................................38
2.18 THERMAL CAMERA:-...................................................................................................................39
2.18.1 THERMAL CAMERA:- ...........................................................................................................41
2.19 PROTECTION OF FREQUENCY:-...................................................................................................41
2.20 USE OF WAVE TRAP :- .................................................................................................................42
2.21 PROTECTION OF SWITCH YARD FROM LIGTHING.......................................................................44
2.21.1 HOW WE KNOW THAT ANY LIGTHING IS IS ARRESTED BY LIGTHING ARRESTOR OR NOT. 45
2.22 PROTECTION IN SWITCH YARD FOR REACTOR............................................................................46
2.23 FAN DETAIL:- ( 4 FANS ARE USED FOR COOLING).......................................................................47
2.24 READING OF REACTOR FOR OIL TEMPERATURE AND WINDING TEMPERATURE AND FAN
CONDFITION............................................................................................................................................47
2.25 HOW WE TAKE THIS ALL READING OF BUS REACTOR.................................................................49
2.25.1 FOR PROTECTION BUS REACTOR BY DISOLVE GASES WE USE CALISTO .............................49
2.26 CALISTO:-.....................................................................................................................................50
2.26.1 STANDARD VALUE OF DISSOLVED GAS ANALYSIS...............................................................51
2.27 PROTECTION IN TRANSMISSION LINE:-......................................................................................52
2.28 CONTROL ROOM 400 KV SWITCH YARD :-.................................................................................54
2.29 BATTERY BANK 1 & 2 FOR 220 VOLT...........................................................................................56
2.30 BATTERY BANK 1 FOR 48 VOLT ...................................................................................................57
2.31 MAINTAINCE FOR BATTERY :- .....................................................................................................59
2.32 HOW WE MEASURE SPECEFIC GRAVITY BATTERY ......................................................................60
2.32.1 WITHIN 15 DAYS WE HAVE TO MEASURE SPECIFIC GRAVITY OF BATTERY AND VOLTAGE 61
DCDB PANNEL .....................................................................................................................................67

VII
220 VOLT BATTERY CHARGER.............................................................................................................68
Chapter .3 400 KV TRANSFORMER YARD..............................................................................................72
3.1 GENERATOR TRANSFORMER (GT)...............................................................................................73
3.2 STATION TRANSFORMER (ST ) ....................................................................................................74
3.3 UNIT TRANSFORMER (UT)...........................................................................................................75
3.4 STATION AUXILIARY TRANSFORMER (SAT).................................................................................76
3.5 UNIT AUXILIARY TRANSFORMER (UAT) ......................................................................................77
3.6 PROTECTION IN TRANSFORMER YARD .......................................................................................78
3.7 ABOUT THE OIL TEMPERATURE AND WINDING TEMPERATURE INDICATOR.............................79
3.7.1 STANDARD VALUE OF OIL TEMPERATURE AND WINDING TEMPERATURE OF HV AND LV 80
3.7.2 READING OF OIL TEMPERATURE AND WINDING TEMPERATURE OF HV AND LV OF ALL
TRANSFORMER....................................................................................................................................81
3.7.3 MAXIMUM AND MINIMUM VALUE OF OIL AND WINDING TEMPERATURE.......................82
3.8 DISSOLVE GAS ANALYZER (DGA).................................................................................................83
3.8.1 CONNECTION FROM TRANSFORMER TO DGA....................................................................84
3.8.2 DGA (DISSOLVE GAS ANALIZER) SYSTEM ............................................................................85
3.8.3 PERMISIBLE LIMITS OF DISSOLVE GASSES ..........................................................................86
3.8.4 STANDARD VALUE OF DISSOLVE GAS .................................................................................87
3.8.5 HERE WE CAN SEE THAT THE READING OF DISSOLVE GAS.................................................88
3.8.6 READING OF DISSOLVE GASES ............................................................................................90
3.9 HYDRAN.......................................................................................................................................91
3.9.1 STANDARD VALUE OF HYDRAN SYSTEM.............................................................................92
3.9.2 READING OF GASES IN HYDRAN..........................................................................................92
3.10 PRESSURE RELIFE VALVE (PRV) ...................................................................................................93
3.11 BUCHHOLZ RELAY........................................................................................................................94
3.12 MAGNETIC OIL LEVEL GAUGE .....................................................................................................95
3.13 BREATHER :- ................................................................................................................................96
3.14 TAPPE CHANGER:-.......................................................................................................................97
3.15 OFF LOAD TAPPE CHANGER........................................................................................................98
3.16 METAL FLANGE PIPE FLEXIBLE EXPANSION JOINT......................................................................99
3.17 OIL PUMP :-...............................................................................................................................100
3.18 RADIATOR:- ...............................................................................................................................101

VIII
3.19 PROTECTION IN TRANSFORMER...............................................................................................102
3.20 CONSERVATOR..........................................................................................................................104
3.21 INSIDE CONSERVATOR ..............................................................................................................105
Chapter .4 DIESEL GENRATOR (DG) ....................................................................................................106
4.1 INSTRUCTION FOR OPERATING DG SETS ..................................................................................107
Chapter .5 ASH HANDLING PLANT......................................................................................................111
5.1 FLY ASH :- ..................................................................................................................................111
5.2 ESP – WORKING PRINCIPLE.......................................................................................................112
5.3 CORONA GENERATION..............................................................................................................112
5.4 PARTICLE CHARGEING...............................................................................................................113
5.5 ADVANTAGE OF ESP..................................................................................................................113
5.6 PURPOSE OF ESP.......................................................................................................................115
5.7 HVR- HIGH VOLTAGE RECTIFIRE ( IT IS SITUATED AT THE TOP OF ESP)....................................117
5.8 COMPONENTS USED IN ESP......................................................................................................117
5.9 TYPES OF HEATER.....................................................................................................................118
5.9.1 HOPPER HEATER ...............................................................................................................118
5.9.2 SUPPORT HEATER..............................................................................................................118
5.9.3 SHAFT HEATER ..................................................................................................................119
5.10 ELECTRODES..............................................................................................................................119
5.11 EMITTING ELECTRODE ..............................................................................................................119
5.12 COLLECTOR PLATE.....................................................................................................................119
5.13 BOTTOM ASH:-..........................................................................................................................120
5.14 LOW PRESSUER PUMP (LP PUMP) ............................................................................................121
Chapter .6 BOP ( BALANCE OF PLANT)................................................................................................123
6.1 INTAKE PUMP ( FROM GOPAD RIVER)......................................................................................123
6.2 RESERVIOR (RAW WATER) ........................................................................................................125
6.2.1 RESERVIOR PUMP ( RAW WATER PUMP).........................................................................126
6.3 PRIMARY TREATMENT PLANT...................................................................................................127
6.4 ALUM PLANT.............................................................................................................................131
6.5 STILING CHAMBER ....................................................................................................................132
6.6 COOLING WATER STOREAGE TANK ( CWST).............................................................................134
6.6.1 CEMENT PLANT PUMP :-...................................................................................................134

IX
6.6.2 PORTABLE WATER PUMP :-...............................................................................................135
6.6.3 DM PLANT PUMP :-...........................................................................................................136
6.6.4 COOLING TOWER MAKEUP PUMP :-.................................................................................137
6.6.5 AHP WASH PUMP :- ..........................................................................................................138
6.6.6 EMERGENCY PUMP :-........................................................................................................139
6.7 DM PLANT ( DEMINERALIZE WATER)........................................................................................140
6.7.1 DUAL MEDIA FILTER (DMF) :-............................................................................................141
6.7.2 ACTIVATED CARBON FILTER (ACF) :-.................................................................................142
6.7.3 STRONG ACID CATION ( SAC):-..........................................................................................143
6.7.4 DEGASSER :- ......................................................................................................................143
6.7.5 STORNG BASE ANION (SBA) :-...........................................................................................145
6.7.6 MIXED BED (MB) :-............................................................................................................146
6.7.7 ULTRA FILTRATION :-.........................................................................................................147
6.8 CIRCULATING WATER PUMP:- ..................................................................................................148
6.9 NATURAL DRAFT COOLING TOWER FOREBAY ..........................................................................149
6.9.1 CIRCULATING WATER PUMP.............................................................................................150
Chapter .7 BTG ( BOILER – TURBINE – GENERATOR)..........................................................................151
7.1 IGNITER:-...................................................................................................................................152
7.2 FUEL GUN:-................................................................................................................................152
7.3 ELEVATION IN FURNACE :-........................................................................................................153
7.4 FD FAN (FORCED DRAUGHT):-...................................................................................................154
7.5 INDUCED DRAUGHT FAN ( ID FAN):-.........................................................................................155
7.6 PRIMARY AIR FAN ( PA FAN ):-..................................................................................................156
7.7 COAL MILL :-..............................................................................................................................157
7.8 COAL FEEDER :- .........................................................................................................................159
7.9 COAL BURNERS TILT :-...............................................................................................................163
7.10 FURNACE TV CAMERA:- ............................................................................................................164
7.11 SCANNER :-................................................................................................................................165
7.12 RAPH ( ROTARY AIR PREHEATER ):-...........................................................................................166
7.13 FLOW OF STEAM IN BOILER:-....................................................................................................167
7.14 TURBINE :-.................................................................................................................................168
7.15 CONDENSATE EXTRACTION PUMP :- ........................................................................................171

X
7.16 MOTOR DRIVEN BOILER FEED PUMP ( MDBFP ):-.....................................................................172
7.17 TURBINE DRIVEN BOILER FEED PUMP ( TDBFP ):- ....................................................................173
7.18 GENERATOR DETAIL:-................................................................................................................174
7.19 EXCITER DETAIL:-.......................................................................................................................175
7.20 SEAL OIL PUMP :- ......................................................................................................................176
7.21 STATOR COIL WATER SUPPLY :- ................................................................................................177

XI
List Of Figures
Figure 1 400 KV SWITCH YARD.............................................................................................................4
Figure 2 Simple layout..................................................................................................................................6
Figure 3 Bay 1...............................................................................................................................................7
Figure 4 IMAGE OF CIRCUIT BREAKER ................................................................................................8
Figure 5 IMAGE OF ISOLATORT (IN OPEN CONDITION) ...............................................................9
Figure 6 Bay 2 & 3......................................................................................................................................10
Figure 7 Bay 4,5 & 6...................................................................................................................................11
Figure 8 Reactor..........................................................................................................................................13
Figure 9 Bay 7.............................................................................................................................................14
Figure 10 Bay 8...........................................................................................................................................15
Figure 11 Bay 9...........................................................................................................................................16
Figure 12 Bay 10,11 & 12...........................................................................................................................17
Figure 13 Sf6 pressure gage........................................................................................................................20
Figure 14HOW LOOK LIKE SF6 GAS BOX OR PANNEL ....................................................................21
Figure 15 Sf6 Mounted on pole ..................................................................................................................22
Figure 16 Sf6 circuit ...................................................................................................................................24
Figure 17 PLCC..........................................................................................................................................27
Figure 18 Relays .........................................................................................................................................28
Figure 19 Charging pannel..........................................................................................................................31
Figure 20 Isolator........................................................................................................................................34
Figure 21 Earth Switch ...............................................................................................................................36
Figure 22 Disconnector...............................................................................................................................37
Figure 23 Themal cammera ........................................................................................................................41
Figure 24 Wave Trap ..................................................................................................................................42
Figure 25 Ligthing Arrestor........................................................................................................................44
Figure 26 Ligthing Arrestor meter..............................................................................................................45
Figure 27 Calisto for measurement of hydrogen ........................................................................................50
Figure 28 MiCOM .....................................................................................................................................52
Figure 29 Battery bank................................................................................................................................56
Figure 30 Battery Room..............................................................................................................................58
Figure 31 HYDROMETER ........................................................................................................................60
Figure 32 PMCC PANNEL AC IS DISTRIBUTE TO DCDB.................................................................66
Figure 33 temperature indicator of winding ...............................................................................................79
Figure 34 DGA ..........................................................................................................................................83
Figure 35 Hydran........................................................................................................................................91
Figure 36 Pressure Relife valve (PRV).......................................................................................................93
Figure 37 Buchholze relay..........................................................................................................................94
Figure 38 MOLG ........................................................................................................................................95
Figure 39 BREATHER Figure 40 SMART BREATHER..............................96
Figure 41 ON LOAD TAP CHANGER ....................................................................................................97

XII
Figure 42 NO LOAD TAPPE CHANGER.................................................................................................98
Figure 43 OIL FLOW INDICATOR ........................................................................................................100
Figure 44 Radiator ....................................................................................................................................101
Figure 45 GAS COLLECTING DEVICE ................................................................................................102
Figure 46BLADER INSIDE CONSERVATOR.......................................................................................105
Figure 47ARRANGEING CONSERVATOR BLADER .........................................................................105
Figure 48 DG ............................................................................................................................................106
Figure 49 DG 1 -1010 KVA DG 2- 1010 KVA..................................................109
Figure 50 ESP HOPPER........................................................................................................................112
Figure 51 ESP........................................................................................................................................114
Figure 52 INSIDE ESP .........................................................................................................................115
Figure 53 HERE WE CAN SEE THAT PLATES AND SPRING...........................................................116
Figure 54 HERE WE CAN SEE THAT HAMMERS ............................................................................116
Figure 55 ASH PUMP HOUSE...............................................................................................................121
Figure 56 ASH SLURRY SUMP ............................................................................................................122
Figure 57 INTAKE PUMP HOUSE........................................................................................................124
Figure 58 LAYOUT OF RAW WATER PUMP HOUSE.......................................................................125
Figure 59 CHLORINE TONNER CYLINDER........................................................................................127
Figure 60 RAW WATER CHLORINE TO BOOSTER PUMP ...............................................................128
Figure 61 ROTAMETER..........................................................................................................................129
Figure 62 HERE WE CAN SEE THAT HOW CHLORINE IS DOSING WITH WATER.....................130
Figure 63 Stiling Chamber........................................................................................................................132
Figure 64 EMPTY STILING CHAMBER SCRAPER.................................133
Figure 65 DM PLANT...........................................................................................................................140
Figure 66 DUAL MEDIA FILTER ..........................................................................................................141
Figure 67 ACTIVATED CARBON FILTER ..........................................................................................142
Figure 68 STRONG ACID CATION ......................................................................................................143
Figure 69 DEGASSER ...........................................................................................................................144
Figure 70 STRONG BASE ANION ........................................................................................................145
Figure 71 MIXED BED............................................................................................................................146
Figure 72 ULTRA FILTRATION ...........................................................................................................147
Figure 73 Cooling Tower..........................................................................................................................148
Figure 74 UNDER NATURAL DRAFT COOLING TOWER ...............................................................149
Figure 75 FUEL GUN AND IGNITER....................................................................................................153
Figure 76FROCED DRAUGHT FAN (FD FAN) & ID FAN IS ALSO LOOK LIKE THIS FAN.........155
Figure 77 PRIMARY AIR FAN...............................................................................................................156
Figure 78 COAL MILL ( IN EACH UNIT IT CONSIST 6 MILL) .........................................................157
Figure 79 ROTORS IN MILL ..................................................................................................................158
Figure 80 COAL SENSOR AND CLEAN OUT CONVYER ( COC )...................................................160
Figure 81COAL BURNER TILT .............................................................................................................163
Figure 82 FURNACE TV CAMERA.......................................................................................................164
Figure 83 FLOW OF STEAM IN BOILER.............................................................................................167

XIII
Figure 84TURBINE GENERATOR ( TG )..............................................................................................168
Figure 85RECOVERY OF STEAM.........................................................................................................170
Figure 86 GENERATOR..........................................................................................................................174
Figure 87 EXCITER .................................................................................................................................175

XIV
List Of Tables
Table 1 12 Bays ............................................................................................................................................5
Table 2 Standard value of Sf6.....................................................................................................................19
Table 3 Standard value of dissolve gases....................................................................................................51
Table 4FOR 220 VOLT BATTERY BANK 1 & 2 THERE ARE TOTAL 108 BATTERY....................61
Table 5 Standard value of temperature of winding.....................................................................................80
Table 6 Reading of oil temperature.............................................................................................................81
Table 7 Limit of dissolve gases in oil .........................................................................................................86
Table 8 Reading of dissolve gases..............................................................................................................92

1
POWER MECH PROJECTS LIMITED JAYPEE NIGRIE SUPER
THERMAL POWER PLANT 2X660 MW
BY:- RUPESH KUMAR
ENROLLMENT NO:- 201503100610058
SEMESTER:- 6TH
A(EE) C.G.P.I.T

2
Chapter .1 Brife introduction of Power Mech Projects Ltd. At
Jaypee Nigrie Super Thermal Power Plant
Power Mech Projects Ltd. At Jaypee Nigrie Super Thermal Power Plant is situated in Nigrie -
Village, Tehsil - Deosar, District - Singrauli in Madhya Pradesh. PMPL, JNSTPP is 591.3 Km
from the state capital Bhopal M.P., via SH 14.
1.1 Brife description of power plant profile
Name of Project : 2x660 MW Jaypee Nigrie Super Thermal Coal Based Power Project at
Nigrie, M.P, India
Owner : Jaiprakash Power Ventures Limited (JPVL), India
Client : Larsen & Toubro Limited, India
with L&T-MHPS Boilers Pvt. Limited, India
Capacity : 2x660 MW (Supercritical)
L&T-S&L’s scope : Complete Basic and Detail engineering services of Boiler and STG Island
and its auxiliaries including critical piping, excluding civil and structural design
Configuration :
 Two (2) L&T-MHPS make Supercritical Boilers
 Two (2) L&T-MHPS make Steam Turbine Generators (STGs)
Key Technical Features :
 Supercritical Boilers with vertical water walls with internal rifle tubes simpler in
construction, lower pressure drop and lower slag deposition.
 STG of capacity 660 MW each consists of one combined HP/IP and two (2) LP cylinders,
tandem –compound quadruple exhaust, condensing reheat type designed for high
operating efficiency and maximum reliability
 TG auxiliaries like BFP, CEP, DM CW pump, Vacuum pumps, Heat-exchangers etc.

3
 Deaerator with stork design, HP/LP Heaters
 L&T make dual pressure once through type Condensers having divided water box
Fuel : Indian Coal
Year of commissioning : 2015
General requirements details :-
Water requirement :- 3200 m3/hr
Source :- Reservoir, Gopad River
Coal requirement :- 1600 Mt
Source :- Amelia ( North) and Dongri Tal
Enviromental Aspects :-
ESP to minimize the emission of particulate matter
Fire protection system

4
Chapter .2 400 KV SWITCH YARD INTRODUCTION
ABOUT :- 400 KV Switch Yard
Switch Yard :- Switch Yard is enclosed area for the switching facilities of a power station and
for protection of power sation equipment.
Switch Yard is the inter connector between. generation and transmission.
Figure 1 400 KV SWITCH YARD

5
Table 1 12 Bays
2.1 SWITCH YARD CONTAIN TOAL 12 BAY:-
BAY NO. GASS PRESSURE BKR NO. OTHER NAME
1. 4-1-52 BAR 230340 LINE 1
2. 4-2-52 MPa 161243 TIE 1
3. 4-3-52 BAR 230339 LINE 2
4. 4-4-52 MPa 161238 BUS REACTOR-B
5. ------------------------------------------------------------------------- INTERLINK BAY 4&6
6. 4-6-52 MPa 161241 BUS REACTOR-A
7. 4-7-52 MPa 161244 GT-1
8. 4-8-52 MPa 161245 TIE-2
9. 4-9-52 MPa 161246 ST-1
10. 4-10-52 MPa 161242 ST-2
11. 4-11-52 MPa 161240 TIE-3
12. 4-12-52 MPa 161237 GT-2

6
2.2 SIMPLE LAYOUT OF 400 KV SWITCH YARD:-
Figure 2 Simple layout
IT CONSIST OF 12 BAY. EACH SIDE 6 BAY WHICH IS CONNECTED TO MAIN BUS 1
AND MAIN BUS 2. WHICH CONSIST OF LINE 1&2 AND TIE 1,2&3 AND REACTORAND
CONNECTION OF GT 1&2(GENERATOR TRANSFORMER) AND ST1&2 (STATION
TRANSFORMER).

7
2.3 ABOUT EACH BAY AND SLD(SINGLE LINE DIAGRAM)
1. BAY 1(LINE 1)
Figure 3 Bay 1

8
2.3.1 ABOUT BAY 1:-
MAIN PURPOSE OF BAY LINE 1 IS TO TRANSFER SUPPLY TO STANA GRID. IT IS CONNECTED MAIN BUS 2.
HOW IT TRANSFER SUPPLY TO GRID (AT STANA (M.P)).
FIRSTLY GENERATED SUPPLY IS TRANSFERRED TO CIRCUIT BREAKER .
CIRCIUT BREAKER :- THE CIRCUIT BREAKER BREAK DOWN THE SUPPLY
VOLTAGE .THEN THIS BREAK DOWN VOLTAGE IS TRANFERED TO THE ISOLATOR.
THE PURPOSE OF ISOLATOR IS TO ISOLATE CIRCUIT BREAKER OR CONNECT AND
DISCONNECT THE CIRCUIT BREAKER .
Figure 4 IMAGE OF CIRCUIT BREAKER

9
Figure 5 IMAGE OF ISOLATORT (IN OPEN CONDITION)
THEN SUPPLY IS TRANSFERRED TO REACTOR . BECAUSE THE GENERATION FROM
GT IS NOT APROXIMATE OR IN MAINTAINED . BECAUSE THE GENERATION FROM

10
UNIT 1 & 2 IS MORE OR LESS THAN GENERATION SO, REACTOR MAINTAINED
THE SUPPLY VOLTAGE AND SUPPLY TO TRANSMISSION LINE .
2.3.2 ABOUT BAY 2 & 3:-
Figure 6 Bay 2 & 3
BAY 2&3:- BAY 2 IS ALSO CALLED TIE .THE FUCTION OF TIE IS TO TRANSFER
BOTH GENERATION SUPPLY TO ANY OF THE LINE . WHEN THERE IS ANY FAULT
OR PROBLEM OCCUR IN ANY BAY WE TAKE HELP FROM TIE TO STOP SUPPLY BY
USING TIE AND TRANSFER SUPPLY TO ANOTHER LINE .

11
BAY 3 IS ALSO LIKE BAY 1 IT IS ALSO USED TO TRANSFER SUPPLY TO GRID . BUT
IT IS CONNECTED TO MAIN BUS 1 .
2.3.3 ABOUT BAY 4,5 & 6:-
Figure 7 Bay 4,5 & 6

12
IT IS ALSO CALLED BUS REACTOR OR SHUNT TEACTOR. A SHUNT REACTOR IS
INTENTED ONLY TO CONSUME REACTIVE VArs.
IN OTHER WORDS IT CAN BE SDTATED TO PRODUCE LAGGING VArs. IN SWITCH
YARD THROUGH REACTOR SUPPLY IS MAINTAINED IN ORDER TO DISTRIBUTE
POWER SUPPLY TO GRID (SATNA(M.P)). BECAUSE IF WE DISTRIBUTE LESS
AMOUNT OF VOLTAGE TO GRID WHICH IS LESS THEN REQUIRED DEMAND ,SO IT
ARISE LOSE TO PLANT BECAUSE GOVERNMENT GIVE LESS PRICE TO THAT
POWER SUPPLY OR ANY COMMERCIAL GRID.

14
2.3.4 ABOUT BAY 7:-
Figure 9 Bay 7
BAY 7 IS ALSO CALLED GT-1, IT CHARGE THE MAIN BUS 2 AND DISTRIBUTE
SUPPLY TO LINE 1. WHEN IT CHARGE THE MAIN BUS 2 IT ALSO CHARGE THE ST-2
( STATION TRANSFORMER ).

15
2.3.5 ABOUT BAY 8,9,10,11 & 12:-
BAY 8 IS ALSO CALLED TIE (TIE-2) WHICH IS PROVIDE INTERLINK BETWEEN BAY
7 & BAY 9.
Figure 10 Bay 8
BAY 9 IS ALSO CALLED ST-1 (STATION TRANSFORMER-1) THIS BAY IS
CONNECTED TO MAIN BUS-1. THIS BUS IS CHARGE THROUGH GT-2 AND ST-2 IS
CHARGED BY THIS PROCESS .
ST-1 & ST-2 IS IMPORTANT PART OF POWER SYSTEM BECAUSE IT IS HELPFULL
FOR ALL EQUIPMENT IN OPERATION OF POWER SYSTEM. IT IS ALSO USEFULL

16
WHEN THERE IS BLACKOUT OR TRIPPING OF UNIT (GT) . IT TAKE SUPPLY FROM
GRID AND STEP DOWN WHICH IT REQUIRED .
Figure 11 Bay 9
BAY 10 IS ALSO CALLED ST-2 (STATION TRANSFORMER-2) THIS IS SIMILAR TO
ST-1. THIS IS CONNECTED TO MAIN BUS -2 WHICH IS CHARGED BY GT-1.
BAY 11 IS ALSO CALLED TIE-3 IT INTERCONNECTED BETWEEN BAY-10 & BAY 12.

17
BAY 12 IS ALSO CALLED GT-2 (GENERATOR TRANSFORMER-2) WHICH IS USED TO
CHARGE THE MAIN BUS-1.THROUGH MAIN BUS-1 LINE-2 CHARGE.
Figure 12 Bay 10,11 & 12
2.4 PROTECTION IN SWITCH YARD:-

18
PROTECTION FOR CIRCIUT BRAKER
WE USE SF6( SULPHUR HEXA FLUORIDE)

19
2.5 STANDARD VALUE OF GAS PRESSURE FILLING IN CIRCUIT
BREAKER
Table 2 Standard value of Sf6
THERE IS SF6 GAS WHICH IS FILL INTO THE CIRCUIT BREAKER .THIS GAS IS
FILLING FOR LINE 1&2 AT PRESSURE 6.5 BAR AND IN OTHER BREAKER GAS IS
FILLING AT PRESSURE .75 MPa .
THE PRESSURE OF THIS GAS MUST BE EQUAL TO THAT STANDARD PRESSURE
OTHEREWISE IT INDICATE ALARM WHEN PRESSURE IS GOES TO FOR LINE 1&2 IS
5.4 BAR AND FOR OTHER BREAKER IS .64 MPa.
THE CIRCUIT BREAKER IS TRIP OR LOCKOUT WHEN THE PRESSURE OF SF6 IS
GOES TO FOR LINE 1&2 IS 5.1 BAR AND FOR OTHER BREAKER IS .61 MPa THEN THE
CIRCUIT BREAKER IS TRIP.

20
2.5.1 HOW WE OBSERVE PRESSURE FROM PRESSURE GAGE
Figure 13 Sf6 pressure gage
FROM THIS IMAGE WE CAN SEE THAT THE SF6 GAS PRESSURE IS BETWEEN 6 TO 8
SO IT IS IN NORMAL CONDITION . THE POINTER IS IN GREEN SIDE SO THAT SF6
GAS PRESSURE IS AT NORMAL CONDITION .
THIS PRESSURE GAGE IS ONLY FOR OTHER BREAKER WHICH SO PRESSURE IN
MPa. THIS PRESSURE GAGE IS CONNECTED WITH SF6 CONTAINER .
THIS PRESSURE GAGE IS USE FOR LINE 1 & 2 IT SHOW PRESSURE IN BAR.

21
Figure 14HOW LOOK LIKE SF6 GAS BOX OR PANNEL

22
Figure 15 Sf6 Mounted on pole
FROM HERE WE CAN KNOW THAT OUR CIRCIUT BREAKER IS CHARGE OR NOT.IF
POINTER IS IN POSITION ON SIDE IT MEANS OUR CIRCUIT BREAKER IS CHARGE
.HENCE WE CAN WRITE THAT OUR CIRCUIT BREAKER IS ON/CHARGE .

23
2.6 READING SHEET OF SF6 PRSSURE OR ON/OFF OR
CHARGE/DISCHARGE CONDITION FOR EVERY DAY (24 HOURS)
FROM HERE WE CAN OBSERVE THAT WE TAKING READING OF ALL 12 BAY OF
SF6 GAS PRESSURE. IN THIS THERE IS NO READING OF BAY 5 BECAUSE IT
PROVIDE INTERLINK BETWEEN BAY 4 AND BAY 6 THAT’S WHY THERE IS NO SF6
PANNEL IS CONNECTED .
HERE WE CAN ALSO SEE THAT COUNTER READING AND SPRING POSITION.
THE COUNTER READING SHOW THAT HOW MANY TIME CIRCUIT BREAKER IS
CHARGE.
SPING POSITION SHOW OUR CIRCUIT BREAKER IF CHARGE OR NOT IF IT IS
CHARGE IT SHOW ON POSITION (ON/CHARGE).

24
2.7 INSIDE SF6 CIRCUIT BREAKER HOW IT LOOK LIKE
Figure 16 Sf6 circuit
HERE WE CAN SEE THAT TWO INDICATOR .
FIRST FOR ON/OFF CONDITION AND SECOND FOR COUNTER READING.
COUNTER IS INCREASED WHEN THE CIRCUIT BREAKER IS CHARGE , THE
PURPOSE COUNTER IS THAT HOW MANY TIME CIRCUIT BREAKER IS CHARGE.

25
2.8 FORM WHERE WE FILL SF6 GAS IN CIRCUIT BREAKER
IN IMAGE WE CAN SEE RIGHT HAND SIDE ONE BOLT IS THERE FROM HERE WE
FILL SF6 GAS WITH HELP OF REGULATOR .
THIS ALL ABOUT SF6 WORK AND IT PROTECT FROM TRIPING OF CIRCUIT
BREAKER AND WHY IT TRIP.

26
2.9 HOW CIRCUIT BREAKER IS TRIP
WHEN GENERATED SUPPLY IS MORE THAN THE RATED CAPACITY OF CIRCUIT
BREAKER AT THAT TIME SF6 GAS PRESSUTRE IS DECREASE DUE TO THIS RELAY
IS TRIP.
THIS RELAY IS TRIP BY TRIP COIL WHICH IS ENERGISED BY 220 VOLT DC FOR
LINE 1 & 2 AND FOR OTHER CIRCUIT BREAKER COIL IS ENERGISED BY 48 VOLT
DC.
THIS DC SUPPLY IS TAKEN FROM BANK-1 220 VOLT BATTERY AND BANK-2 48
VOLT BATTERY.
THERE ARE 4 KIOSK. THE PURPOSE OF THIS ROOM IS TO PROVIDE AC AND DC
SUPPLY TO CIRCIUT BREAKER . ALL BAY IS CONNECTED RELAY TRIP .

27
2.10 PLCC (POWER LINE CARRIER COMMUNICATION) BY USING
THIS DEVICE WE PROVIDE DC SUPPLY TO RELAY COIL TRIP.
Figure 17 PLCC

28
2.11 THERE ARE TRIP RELAY FOR EACH PHASE
Figure 18 Relays
HOW WE KNOW THAT OUR CIRCUIT BREAKER IS TRIP .HERE WE CAN SEE THAT
FOR RELAY IS PROVIDE WHEN ANY RELAY IS TRIP IT SHOW ONE FLAG WITH RED

29
COLOUR FLAG THAT FLAG IS DOWN . SO, IT MEANS THAT CIRCUIT BREAKER IS
TRIP OR LOCKOUT.
2.12 TRIP RELAY IMAGE:-

30
2.13 400 KV SWITCH YARD CONTROL ROOM
400 KV SWITC H YARD CONTROL ROOM PROVIDE VERY IMPORTANT ROLE IN
POWER PLANT. FROM HERE WE CAN MONITOR WHAT AMOUNT OF POWER IS
SUPPLY TO GRID BY USING METRING PANNEL OF LINE 1 & 2WITH THE HELP OF
SCADA .
2.13.1 BATTERY CHARGEING IN CONTROL ROOM:-
THERE IS TWO BATERRY BANK
BANK 1 WHICH IS 220 VOLT RATING
BANK 2 WHICH IS 48 VOLT RATING
BANK 1 CONSIST 108 CELLS. EACH CELL RATING IS 2.2 VOLT. INPUT OF BATTERY
IS 415 V AC AND OUTPUT BATTERY IS 237 VOLT DC.

31
BANK 2 CONSIST 24 CELLS . EACH CELL RATEING IS 2.2 VOLT .INPUT OF BATTERY
IS 415V AC AND OUTPUT IS 54 VOLT.
IN BATTERY DEMINREALIZED WATER IS USED TO PRODUCED CHARGE. BATTERY
SPECIFIC GRAVITY MUST BE LIE BETWEEN 1200-1220.
2.13.2 CHARGEING PANNELS IN CONTROL ROOM:-
Figure 19 Charging pannel

32
THIS IS BATTERY PANNEL IS USED TO CHARGE THE BATTERY BANKS.

33
2.13.3 FROM HERE WE TAKE READING OF CHARGEING BATTERY

34
2.14 PROTECTION OF ISOLATOR
Figure 20 Isolator
THIS ISOLATOR IS IN OPEN CONDITION . ABOVE RING TYPE CONDUCTOR IS
CALLED CRONA RING. TWO TYPE OF CRONA RING MALE AND FEMALE IS TO
CONNECT OTHER ISOLATOR.

35
2.14.1 BELOW BOTH PANNELS ARE CONNECTED TO ISOLATOR
THIS PANNELS ARE USED TO CONNECT OR DISCONNECT THE ISOLATOR UISING
THESE PANNELS.
AT RIGHT SIDE PANNEL IS CALLED EARTH SWITCH . IT IS COMMON FOR ALL
PHASE(R,Y,B) (SINGLE).
AT LEFT SIDE PANNEL IS CALLED DISCONNECTOR. IT IS FOR EACH PHASE.

36
2.15 ABOUT EARTH SWITCH :-
Figure 21 Earth Switch
THIS SWITCH IS COMMON FOR ALL PHASE . IT IS USED WHEN WE HAVE TO OPEN
ALL PHASE OF ISOLATOR THEN WE USE THIS SWITCH.

37
ABOVE YOU CAN SEE THAT ROTATING PART IT IS USED TO MOVEMENT OF
ISOLATOR OR OPENING AND CLOSEING OF ISOLATOR.
2.16 ABOUT DISCONNECTOR:-
Figure 22 Disconnector

38
DISCONNECTOR IS NOTHING BUT DISCONNECTING SWITCH . IT IS USED FOR
DISCONNECTING INDIVISUAL ISOLATOR. IT IS ALSO WORKING LIKE EARTH
SWITCH.
2.17 WHAT HAPPEN WHEN WE DISCONNECT ISOLATOR

39
WHEN WE DISCONNECT THE ISOLATOR THE EARTH SWITCH IS CONNECTED TO
CRONA RING.
2.18 THERMAL CAMERA:-

40
THIS CAMERA IS NOT SIMPLE PHOTO CAMERA IT IS CALLED THERMAL CAMERA.
IT IS VERY USE FULL FOR PROTECTION OF SWITCH YARD . IT IS USED TO DETECT
TEMPERATUR ON ISOLATOR AND ANY PART OF SWITCH YARD.
IF ANY FAULT IS ARISE IN ISOLATOR OR ANY BENDING OR TILTING IN ISOLATOR
SO WE HAVE TO TAKE TEMPERATURE AT EVERY 1 OR 2 HOUR .BECAUSE IF THE
TEMPERATURE OF ISOLATOR IS INCREASED COMPARED TO RATED CAPACITY OF
ISOLATOR SO, IT CAN DAMAGE OR TRIP THE UNIT. OR IT CAN SUPPLY MORE
VOLTAGE WHICH DAMAGE ALL EQUIPMENT OF SWITCH YARD.
THERMAL CAMERA

41
(DETECTING TEMPERATURE ON ISOLATOR CRONA RING)
AT ISOLATOR MAXIMUM TEMPERATURE IS AT JOINT OF CRONA RING.
2.18.1 THERMAL CAMERA:-
Figure 23 Themal cammera
2.19 PROTECTION OF FREQUENCY:-

42
Figure 24 Wave Trap
WE CAN MAINTAIN GENERATED FREQUENCY BY USING WAVE TRAP. WAVE
TRAP IS A CYCLINDRICAL PART OF SWITCH YARD WHICH IS VERY USEFULL FOR
FREQUENCY .
2.20 USE OF WAVE TRAP :-

43
WHEN THE GENNERATED SUPPLY IS DISTRIBUTE TO GRID IT HAVING
FREQUENCY 50 HZ , B UT IT IS DECREASED DUE TO LOSSES IN TRANSMISSION
LINE SO, THERE IS LOSSES IN FREQUENCY . IF WE SUPPLY POWER TO GRID WITH
LESS FREQUENCY SO, THAT COMPANY WHICH TAKE SUPPLY FROM US THEY
GIVE LESS COST FOR THAT DISTRIBUTED .
DUE TO THIS PROBLEM WE HAVE TO MAINTAINED FREQUENCY UPTO 50 HZ
THAT’S WHY WE USE WAVE TRAP .
THIS WAVE TRAP IS USED ONLY FOR R AND B PHASE (ONLY FOR R & B).

44
2.21 PROTECTION OF SWITCH YARD FROM LIGTHING
WE USE LIGTHING ARRESTER
Figure 25 Ligthing Arrestor
AT RIGHT SIDE WE CAN SEE LIGTHING ARRESTOR. THIS VERY IMPORTANT PART
OF SWITCH YARD IT HELP FROM LIGHTING .THE LIGTHING STROM HAVING VERY
LARGE AMOUNT VOLTAGE WHICH IS GROUND WITH HELP OF LIGHTING
ARRESTOR. IT IS IMMPOSIBLE TO SUPPLY EXTRA VOLTAGE TO TRANSMISSION
LINE BECAUSE THROUGH SWITCH YARD ALREADY 1320 MW IS SUPPLIED TO
GRID IF EXTRA VOLTAGE AND IT HAVING CAPACITY , IF IT SUPPLY VOLTAGE
THEN CAPACITY SO IT DAMAGE TRANSMISSION LINE. IN ORDER TO REDUCE
LIGTHING EFFECT ON TRANSMMISON LINE LIGHTING ARRESTOR IS USE.

45
THE LIGHTING ARRESTOR DOESN’T ATRACT SMALL POWER LIGTHING . IT ONLY
ATTRACT LARGE LIGTHING AND GROUND THAT VOLTAGE INTO THE EARTH.
2.21.1 HOW WE KNOW THAT ANY LIGTHING IS IS ARRESTED BY LIGTHING
ARRESTOR OR NOT.
SURGE MONITOR:- SURGE MONITOR IS A DEVICE WHICH IS USE TO DETECT HOW
MANY TIMES LIGTHING IS ARREST B Y LIGHTING ARRESTOR . IT IS CONNECTED
WITH LIGHTING ASRRESTOR.
Figure 26 Ligthing Arrestor meter

46
HERE WE CAN SEE THAT ONE POINTER IS ON GREEN COLOUR CURVE, WHEN THIS
POINTER REFLECT UPTO THE END OF CURVE SO, THE COUNTER READING IS
INCREASED .
ABOVE POINTER WE CAN SEE ONE SMALL BLACK BOX THAT IS COUNTER. IT
SHOW HOW MANY TIMES LIGTHING IS ARREST IN LIGTHING ARRESTOR.
2.22 PROTECTION IN SWITCH YARD FOR REACTOR
BUS REACTOR IS INTERCONNECTED THROUGH BAY 4 AND BAY 6 WITH THE HELP
OF BAY 5 .IT IS VERY IMPORTANT PART OF SWITCH YARD . THE GENERASTION
FROM GT-1 AND GT-2 IS TRANSFORMED TO REACTOR WITH HELP OS CIRCUIT
BREAKER AND ISOLATOR IN ORDER TO MAINTAIN GENERTATED POWER SUPPLY
THEN THROUGH THIS REACTOR POWER SUPPLY IS DISTRIBUTED TO LINE-1 AND
LINE-2.

47
SO,IT ALSO REQUIRED PROTECTION FROM DAMAGE.
HENCE WE PROVIDE PROTECTION LIKE COOLING OF REACTOR BY ONAF (OIL
NATURAL AND AIR FORCED)AND ONWF (OIL NATURAL AND WATER FORCED).
2.23 FAN DETAIL:- ( 4 FANS ARE USED FOR COOLING)
PHASE – 3 PHASE AC
VOLT – 400/415 V
RPM -550
AMP-1.5
2.24 READING OF REACTOR FOR OIL TEMPERATURE AND
WINDING TEMPERATURE AND FAN CONDFITION.
STANDARD VALUE OF OIL AND WINDING OF REACTOR (NO.5)

48
HERE WE CAN SEE THAT OIL AND WINDING TEMPERATURE IS NORMAL
ACCORDIG TO STANDARD VALUE O F BUS REACTOR .
IF OIL AND WINDING TEMPERATURE IS INCREASED ACCORDING TO STANDARD
VALUE THEN ALARM IS INDICATE AND IF OIL AND WINDING TEMPERATURE IS
INCREASED THEN THE ALARM INDICATION VALUE SO, BUS REACTOR IS TRIP.

49
2.25 HOW WE TAKE THIS ALL READING OF BUS REACTOR
EACH AND EVERY TRANSFORMER HAVE TEMPERATURE METER WE TAKE
READING OF OIL AND WINDING TEMPERATURE.
2.25.1 FOR PROTECTION BUS REACTOR BY DISOLVE GASES WE USE CALISTO
IT IS A DEVICE WHICH SHOW LEVEL OF HYDROGEN AND MOISTURE. IT IS VERY
IMPORTANT TO TAKE READING OF THESE TWO GAS BECAUSE IF THE LEVEL OF
GAS IS INCERASED SO INSIDE BUS REACTOR TEMPERATURE IS INCREASED THEN
IT WOULD BE CHANCE TO TRIPING OF REACTOR . IF REACTOR IS TRIPED THEN
WE TO SHUT DOWN THE GENERATION UNIT SO IT ARISE SO MANY LOSSES
THAT’SWHY WE TAKE REDING OF CALISTO TO MINIMISE LOSSES.

50
2.26 CALISTO:-
Figure 27 Calisto for measurement of hydrogen

51
2.26.1 STANDARD VALUE OF DISSOLVED GAS ANALYSIS
Table 3 Standard value of dissolve gases
HERE WE CAN OBSERVE THAT THE VALUE OF HYDROGEN AND MOISTURE (WRS)
IS VERY LESS . IF THE VALUE OF HYDROGEN AND MOISTURE(WRS) IS INCREASED
THEN THE ALARM IS TRIP.

52
2.27 PROTECTION IN TRANSMISSION LINE:-
MiCOM IS USED TO DETECT FAULT IN TRANSMISSION LINE . IT VERY IMPORTANT
DEVICE FOR DETECTING FAULT IN TRANSMISSION LINE.
Figure 28 MiCOM
(USED TO DETECT FAULT IN TRANSMISSION LINE)
THIS SYSTEM STORE DATE ,TIME AND DISTANCE IN WHICH LINE FAULT IS
OCCURE. BY THE HELP OF MiCOM WE CAN DIRECTLY FIND PLACE AND
DISTANCE WHERE THE FAULT IS OCCURE AND IT REDUCED TIME TO MINIMISE
FAULT LINE.

53
THIS PROVIDE IMPOTANT ROLE IN PROTECTION OF TRANSMISSION LINE.FROM
THIS PANNEL WE CAN EASILY IDENTITYFY THE DISTANCE WHERE THE FAULT IS
OCCURE. THIS IS FULLY AUTOMATIC SYSTEM IT FAULT ON TRIP RELAY IN

54
WHICH FLAG IS DOWN. WHEN FLAG IS DOWN IN TRIP RELAY IT MEANS ANY
FAULT IS ARISE IN TRANSMISSION LINE.
2.28 CONTROL ROOM 400 KV SWITCH YARD :-
HOW WE SUPPLY DC POWER TO SWITCH YARD FOR PROTECTION
MOST OF THE DEVICE IN SWITCH YARD NEED DC SUPPLY THAT’S WHY WE NEED
DC SUPPLY .WE GET DC SUPPLY FROM BATTERY BANK.
THIS BATTERY BANK IS STIUATED IN CONTROL ROOM . THERE IS TWO BATTERY
BANK AS REQUIREMENT . ONE BATTERY BANK GIVE 220 VOLT AND ANOTHER
BATTERY BANK GIVE 48 VOLT.
THIS ALL BATTERY IS CONNECTED IN PARALLEL . EACH BATTERY GIVES 2.2
VOLT .
IN CONTROL ROOM THIS BANKS ARE CONNECTED . WE USE BATTERY HAVING
RATING 2.2 VOLT INSTEAD OF 220 VOLT BATTERY DIRECTLY BECAUSE IF WE
USE 220 VOLT DIRECTLY IF ANY FAULT IS OCCUR IN BATTERY SO WHOLE
BATTERY IS DAMAGE.
THAT’S WHY WE USE LESS RATING OF BATTERY . BECAUSE IN PARALLEL
CONNECTION OF BATTERY HAVING VOLTAGE 2.2 VOLT IF ANY FAULT IS OCCUR
WE CAN EASILY DETECT BY MEASUREING VOLTAGE .
THERE ARE TOTAL 132 BATTERY IN BATTERY ROOM. IN WHICH IT IS DIVIDED
INTO TWO PARTS .
220 VOLT DC SUPPLY IS PRODUCE FROM BATTERY BANK 1 & 2
48 VOLT DC SUPPLY IS PRODUCE FROM BATTERY BANK 1
IN BATTERY BANK 1 & 2 FOR 220 VOLT HAVING 108 CELL WHICH IS HAVING
RATING 2.2 VOLT EACH CELL. INPUT OF BATTERY CHARGER IS 415 V AND

55
OUTPUT IS 237 V. THIS ALL BATTERY IS CHARGE IN FLOAT MODE AND BOOST
MODE.
IN BATTERY BANK 1 FOR 48 VOLT HAVING 24 CELL WHICH IS HAVING RATING 2.2
VOLT EACH CELL. INPUT OF BATTERY CHARGER IS 415 V AND OUTPUT IS 54
VOLT .THIS ALL BATTERY IS CHARGE IN FLOAT MODE AND BOOST MODE.

56
2.29 BATTERY BANK 1 & 2 FOR 220 VOLT
Figure 29 Battery bank

57
2.30 BATTERY BANK 1 FOR 48 VOLT

58
IN BANK 1 & 2 FOR 220 VOLT HAVING BATTERY CAPACITY 300 AH
FOR 10 HOUR.
IN BANK 1 FOR 48 VOLT HAVING BATTERY CAPACITY 150 AH FOR 10
HOUR.
Figure 30 Battery Room

59
2.31 MAINTAINCE FOR BATTERY :-
WE HAVE MAINTAIN SPECEPFIC GRAVITY OF BATTERY AND
CLEANING OF BATTERY.
WE HAVE TO MANAGE DM WATER LEVEL BECAUSE OF PRODUCTION
OF VOLTAGE .

60
2.32 HOW WE MEASURE SPECEFIC GRAVITY BATTERY
WE USE HYDRO METER TO MEASURE SPECEFIC GRAVITY OF BATTERY.
Figure 31 HYDROMETER

61
2.32.1 WITHIN 15 DAYS WE HAVE TO MEASURE SPECIFIC GRAVITY OF
BATTERY AND VOLTAGE
Table 4FOR 220 VOLT BATTERY BANK 1 & 2 THERE ARE TOTAL 108 BATTERY

66
CHARGEING PANNELS OF BATTERY
Figure 32 PMCC PANNEL AC IS DISTRIBUTE TO DCDB
PMCC PANNEL IS USED TO SUPPLY AC SUPPLY TO DCDB. HERE 3.3 KV IS STEP
DOWN WITH THE HELP OF TRANSFORMER TO 415 VOLT .

67
DCDB PANNEL
THIS PANNEL IS USED TO SUPPLY TO 220 VOLT CHARGER

68
THIS SUPPLY IS GOES TO 220 V CHARGER.
220 VOLT BATTERY CHARGER
220 VOLT BATTERY CHARGER( FLOAT CHARGER-1)

69
THIS FLOAT-CUM- BOOST CHARGER CAN WE USED FOR BOTH PURPOSE

70
220 VOLT BATTERY CHARGER( FLOAT CHARGER-2)
PANNELS FOR 48 VOLT CHARGER
48 V CHARGER- 1
48 V CHARGER-2
FROM HERE DC SUPPLY IS GOES TO 220 VOLT BATTERY.

71
48 VOLT BATTERY CHARGER-1 48 VOLT BATTERY CHARGER-2

72
Chapter .3 400 KV TRANSFORMER YARD
IN THIS TRANSFORMER YARD TOTAL NUMBER OF TRANSFORMER IS 21.
NUMBER OF GENERATOR TRANSFORMER = 6 (GT 1 & GT 2 R,Y,B)
NUMBER OF UNIT TRANSFORMER = 4 ( UT 1,UT 2,UT 3 & UT 4)
NUMBER OF STATION TRANSFORMER = 4 (ST1,ST2,ST3 & ST4)
NUMBER OF STATION AUXILARY TRANSFORMER= 2 ( SAT1 & SAT2)
NUMBER OF UNIT AUXILARY TRANSFORMER = 4 ( UAT1,UAT2,UAT3 & UAT4)
NUMBER OF GENERATOR TRANSFORMER IN SPARE= 1
TOTAL NUMBER OF GENERATOR = 21

73
3.1 GENERATOR TRANSFORMER (GT)
RATING OF GT
TYPE OF COOLING ONAN ONAF OFAF
RATED POWER HV 165 MVA 220 MVA 275 MVA
RATED POWER LV 165 MVA 220 MVA 275 MVA
RATED VOLTAGE HV 420/sqrt3 KV
RATED VOLTAGE LV 21 KV
RATED CURRENT HV 680.4 A 907.2 A 1134.0 A
RATED CURRENT LV 7857.1 A 10476.1 A 13095.2 A
NO. OF PHASE 01
CORE COIL MASS = 130000 KG
TANK FITTING MASS = 50000 KG
MASS OF OIL = 44800 KG
TOTAL MASS = 224800 KG
TRANSPORT MASS ( GAS FILLED) = 170000 KG
VOLUME OF OIL = 50400 LITER

74
3.2 STATION TRANSFORMER (ST )
TYPE OF COOLING ONAN ONAF
RATED POWER HV 80 MVA 100 MVA
RATED VOLTAGE AT HV 400 KV
(NO LOAD)
RATED LINE CURRENT HV 115.6 A 144.5 A
RATED LINE CURRENT LV 2010.5 A 2513.1 A
NO. OF PHASE 03
CORE & COIL MASS = 78000 KG
TANK & FITTING MASS = 37500 KG
TRANSPORT MASS (GASS FILLED ) = 105000 KG

75
3.3 UNIT TRANSFORMER (UT)
RATED POWER HV & LV 32 MVA 40 MVA
RATED VOLTAGE AT HV 880.81 1101.2
(NO LOAD)
RATED VOLTAGE AT LV 1608.44 2010.56
(NO LOAD)
NO. OF PHASE 03
TYPE = DOUBLE WOUND
FREQUENCY = 50 Hz
TRANSPORT MASS (OIL FILED) = 62500 KG
VOLUME OF OIL = 19000 KG

76
3.4 STATION AUXILIARY TRANSFORMER (SAT)
TYPR OF COOLING ONAN ONAF
RATED POWER HV & LV 08 MVA 10 MVA
RATED LINE VOLTAGE AT HV 11 KV
(NO LOAD)
RATED LINE VOLTAGE AT LV 3.45 KV
(NO LOAD)
RATED LINE CURRENT HV 420.38 A
RATED LINE CURRENT LV 1340.37 TO 1675.46
NO. OF PHASE = 03
TYPE = DOUBLE WOUND
FREQUENCY = 50 Hz
TANK & FILLING MASS = 8000 KG
TRANSPORT MASS (OIL FILLED) = 20000 KG

77
3.5 UNIT AUXILIARY TRANSFORMER (UAT)
RATED POWER HV & LV 6.3 MVA 08 MVA
RATED LINE VOLTAGE HV 11 KV
(NO LOAD)
RATED LINE VOLTAGE LV 3.45 KV
(NO LOAD)
RATED LINE CURRENT HV 331.03 A 420.39 A
RATED LINE CURRENT LV 1055.54 A 1340.37 A
NO. OF PHASE = 03
TYPE = DOUBLE WOUND
FREQUENCY = 50 Hz
TRANSPORT MASS (OIL FILLED) = 16500 KG

78
3.6 PROTECTION IN TRANSFORMER YARD
ABOUT COOLING FANS
PHASE – 3 AC
VOLT – 400/415 V
WATTS – 700
RPM – 550
AMPERE – 1.5
NUMBER OF COOLING FANS IN :-
GT – 10
ST – 8
UT – 6
HAVING THE SAME VALUE AS ABOVE
NUMBER OF COOLING FANS IN :-
SAT – 4
UAT – 4
HAVING RATING:-
WATT – 240
RPM – 700
AMPERE – 0.5

79
3.7 ABOUT THE OIL TEMPERATURE AND WINDING
TEMPERATURE INDICATOR
Figure 33 temperature indicator of winding
FROM HERE WE CAN SEE OIL TEMPERATURE ,LV WINDING TEMPERATURE AND
HV WINDING TEMPERATURE. HERE WE CAN SEE THAT INDICATION OF ALARM
AND TRIP AT STANDARD TEMPERATURE.

80
3.7.1 STANDARD VALUE OF OIL TEMPERATURE AND WINDING
TEMPERATURE OF HV AND LV
Table 5 Standard value of temperature of winding
HERE WE CAN SEE THE STANDARD VALUE OF OIL TEMPERATURE AND WINDING
TEMPERATURE OF HV AND LV OF ALL TRANSFORMER.

81
3.7.2 READING OF OIL TEMPERATURE AND WINDING TEMPERATURE OF HV
AND LV OF ALL TRANSFORMER.
Table 6 Reading of oil temperature
HERE WE TAKE READING AT EVERY 2 HOURS BECAUSE TO PROTECTION FROM
OVER HEAT OF OIL IN TRANSFORMER. IF OIL IS HEATED ACCORDING TO
STANDARD VALUE OF OIL THEN WE COOLED THE OIL BY FAN AND WATER.
AROUND THE TRANSFORMER FIRE EXTINGUSHER SYSTEM IS INSTALLED. IF
AROUND THE TRANSFORMER TEMPERATURE IS INCREASED THEN THAT FIRE

82
SYSTEM OPERATE AUTOMATICALLY . THAT FIRE SYSTEM IS CONNECTED TO
PUMP .
3.7.3 MAXIMUM AND MINIMUM VALUE OF OIL AND WINDING TEMPERATURE
IT IS VERY IMPORTANT TAKE MAXIMUM AND MINIMUM VALUE OF OIL AND
WINDING TEMPERATURE OF HV AND LV PER DAY IN ORDER TO SEE THE STATUS
OF TRANSFORMER.

83
3.8 DISSOLVE GAS ANALYZER (DGA)
Figure 34 DGA

84
WE USE DGA TO ANALIZE GAS . SOME OF GAS IS PRODUCE FROM TRANSFORMER
OIL WHEN THE OIL IS HEATED. THE DGA SYSTEM IS ONLY USED FOR GT AND ST.
3.8.1 CONNECTION FROM TRANSFORMER TO DGA
HERE WE CAN SEE THAT HOW OIL TUBES ARE CONNECTED FROM TRANSFORMER
TO DGA. FOR EACH PHASE (R,Y,B) INDIVISUAL TUBES ARE CONNECTED TO DGA.

85
3.8.2 DGA (DISSOLVE GAS ANALIZER) SYSTEM
HERE WE CAN SEE THAT ONE DISPLAY FORM WE TAKE READING OF DISSOLVE
GAS BY SCROLLING THE BUTTON.

86
3.8.3 PERMISIBLE LIMITS OF DISSOLVE GASSES
Table 7 Limit of dissolve gases in oil

87
3.8.4 STANDARD VALUE OF DISSOLVE GAS
TAKING READING OF DGA
WHEN WE START TO TAKE READING OF GAS IN DISPLAY IT SHOW LAST
MEASUREMENT.

88
3.8.5 HERE WE CAN SEE THAT THE READING OF DISSOLVE GAS

90
3.8.6 READING OF DISSOLVE GASES
HERE WE CAN SE THAT PERCENTAGE OF GASES IN TRANSFORMER.THIS DGA IS
ONLY USED FOR LARGE TRANSFORMER LIKE GT & ST. THIS IS BECAUSE LARGE
SIZE OF TRNASFORMER HAVING LARGE AMOUNT OF OIL THAT WE REQUIRED
DGA SYSTEM OR WE USE DGA BECAUSE LARGE AMOUNT OF OIL IS WHEN
HEATED SO IT GENERATE MORE GASES THAT’S WHY WE NEED DGA SYSTEM.

91
3.9 HYDRAN
IT IS ALSO LIKE DGA BUT IT IS USED FOR SMALL TRANSFORMER LIKE UT,UAT
AND SAT. BECAUSE IN SMALL TRANSFORMER LESS AMOUNT OF OIL IS IN
TRANSFORMER. WHEN LESS AMOUNT OF OIL IS HEATEDV SO VERY LESS GAS IS
PRODUCE. THAT’S WHY WE USED HYDRAN AND IT ALSO REDUCE COST OF
INSTALLATION AN D MAINTAINANCES.
Figure 35 Hydran

92
3.9.1 STANDARD VALUE OF HYDRAN SYSTEM
3.9.2 READING OF GASES IN HYDRAN
Table 8 Reading of dissolve gases

93
3.10 PRESSURE RELIFE VALVE (PRV)
Figure 36 Pressure Relife valve (PRV)
PRV TRIP WHEN TOO MUCH GAS PRESSURE IN WITHIN THE TRANSFORMER OIL.
GAS PRESSURE INCREASE IN TRANSFORMER FOR TWO REASONS:-
1. THE TRANSFORMER IS OVERLOAD
2. THERE IS SOME FAULT IN THE TRANSFORMER

94
3.11 BUCHHOLZ RELAY
BUCHHOLZ RELAY IS A PROTECTION DEVICE USED TO DETECT TRANSFORMER
FAULTS IN OIL FILLED TRANSFORMER. THE RELAY IS USUALLY FITTED ACROSS
THE PIPE BETWEEN THE TRANSFORMER MAIN TANK AND THE CONSERVATOR.
Figure 37 Buchholze relay

95
BUCHHLOZ RELAY
3.12 MAGNETIC OIL LEVEL GAUGE
Figure 38 MOLG
THIS DEVICE IS USED TO INDICATE THE POSITION OF TRANSFORMER
INSULATINGH OIL LEVEL IN CONSERVATOR OF TRANSFORMER. THIS IS A
MECHNICAL DEVICE.

96
3.13 BREATHER :-
Figure 39 BREATHER Figure 40 SMART BREATHER
BREATHER:- THE PURPOSE OF THESE SILICA GEL BREATHER IS TO ABSORB THE
MOISTURE IN THE AIR SUCKED IN BY THE TRANSFORMER DURING THE
BREATHING PROCESS.
SMART BREATHER:- THE SAME PROCESS LIKE SIMPLE BREATHER . IT CONSIST
OF HEATER ,FAN AND HUMITIY SENSOR. THE HEATER IS USED TO HEAT THE AIR
WHICH REMOVE MOISTURE . FAN IS USED REMOVE MOISTURE PARTICAL FROM
AIR.
IN ORDER TO MONITOR ANS ENSURE CORRECT OPERATION OF HUMIDITY, LED
INDICATORS ARE PROVIDE IN THE CONTROLLER.
VALVES,HEATERS AND FAN STATUS SHALL BE MONITORED, RESPECTIVE LED
INDICATORS WILL GLOW WHENEVER IT ASSOCIATED ELEMENTS ARE
ENERGIZED.

97
3.14 TAPPE CHANGER:-
THERE ARE TO TYPE OF TAPPE CHANGERS:-
1. NO LOAD TAPPE CHANGER
2. ON LOAD TAPPE CHANGER
Figure 41 ON LOAD TAP CHANGER
A TAP CHANGER IN A TRANSFORMER IS A DEVICE OR MECHANSIM,THAT
AUTOMATICALLY OR MANUALLY CHANGES THE OUTPUT BY CONNECTING TO
DIFFERENT TAPS PROVIDED IN THE SECONDARY WINDING.

98
3.15 OFF LOAD TAPPE CHANGER
Figure 42 NO LOAD TAPPE CHANGER

99
3.16 METAL FLANGE PIPE FLEXIBLE EXPANSION JOINT
THIS FLEXIBLE JOINT PROVIDE CONNECTION BETWEEN TRANSFORMER AND OIL
PIUMP. IN ORDER TO PROVIDE FLEXIBILTY . IT PROTECT PIPE FROM DAMAGE BY
OVER HEATING OF OIL.

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3.17 OIL PUMP :-
IN TRANSFORMER OIL PUMP IS USED TO CIRCUILATE OIL .
Figure 43 OIL FLOW INDICATOR
HERE WE CAN SEE THAT OIL IS IS FLOW IN FULL FLOW. IF INDICATOR GET DOWN
IT MEAN THE FLOW OF OIL IS DECREASE.

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3.18 RADIATOR:-
Figure 44 Radiator
THE PURPOSE OF RADIATOR IS TO PROVIDE COOLING TO TRANSFORMER OIL. IT
DISSIPIATE HEAT FROM ONE FORM OF ENERGY TO ANOTHER FORM.
HERE WE CAN SEE THAT 6 NUMBER OF RADIATOR BANK IN WHICH OIL IS
COOLED BY FAN.

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3.19 PROTECTION IN TRANSFORMER
Figure 45 GAS COLLECTING DEVICE
GAS COLLECTING DEVICE IS A DEVICE FITTED ON BUCHHLOZ RELAY TO
COLLECT UNWANTED GAS THAT IS CREATED . IN OIL FILLED TRANSFORMER
CREATION OF GAS IS NOT DESIREABLE AND IF ANY GAS IS GENERATED THEN IT
IS VERY IMPORTANT TO TAKE NECESSARY ACTION AGAINST IT.

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GAS COLLECTING DEVICE WITH OBSERVED GAS
HERE WE CAN SEE THAT GAS COLLECTING DEVICE IS OBSERVEDSOME GASES
WHICH IS CHANGE INTO LIQUID.

104
3.20 CONSERVATOR
WHEN TRANSFORMER IS LOADED AND WHEN AMBIENT TEMPERATURE RISES
THE VOLUME OF OIL INSIDE TRANSFORMER INCREASES. A CONSERVATOR TANK
OF TRANSFORMER PROVIDE ADEQUATE SPACE TO THIS EXPANDED
TRANSFORMER OIL.

105
3.21 INSIDE CONSERVATOR
Figure 46BLADER INSIDE CONSERVATOR
THE BLADDER IN A TRANSFORMER TANK ALSO CALLED A COPS TANK
(CONSTANT OIL PRESERVATION SYSTEM ).
Figure 47ARRANGEING CONSERVATOR BLADER

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Chapter .4 DIESEL GENRATOR (DG)
Figure 48 DG
THERE ARE 4 DG SET EACH HAVING 1010 KVA AND 1405 A RATING.THIS IS VERY
IMPORTANT PART OF POWER PLANT. THIS DG SUPPLY IS USED DURING BLACK
OUT OR TRIPING OF POWER PLANT

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4.1 INSTRUCTION FOR OPERATING DG SETS

108
STATUS PANNEL FOR DG SET
FROM HERE WE CAN SEE THAT ALL DG SET ARE IN AUTO MODE OR IN OFF
CONDITION. FROM HERE IT REPRESENT GENERASTION VALUE OF DG AND ITS
FREQUENCY.

109
Figure 49 DG 1 -1010 KVA DG 2- 1010 KVA
DG 1 & 2- 1010 KVA
IN ORDER TO ENSURE THAT ALL DG SET IS WORKING OR NOT WE TAKE TRIAL OF
ALL 4 DG EVERY DAY.

110
BECAUSE IF ANY GENERATOR IS NOT IN WORTKING CONDITION SO, IT GIVES
VERY BAD IMPACT ON POWER SYSTEM DURING BLACKOUT. THAT’S WHY IT IS
NECCESARY TO TAKE TRIAL OF ALL DG EVERY DAY.
WHEN WE TAHE TRIAL WE OFF PMCC OF SWITCVH YARD AND UNIT BECAUSE TO
PROTERCT FORM DAMAGE BY OVER VOLTAGE. THEN WE GIVE MANUALLY
SUPPLY TO GENERATOR AND OPERATE ANY OF TWO DG SET AND OTHER TWO IN
AUTO MODE.
THIS IS BECAUSE WHEN WE TAKE TRIAL OF DG SET IF ANY FAULT IS OCCUR
DURING TRAIL SO IT CREAT MORE LOSSES DUE TO FAULT. THAT’S WHY WE
OPERATE TWO DG SET MANUALLY AND OTHER TO IN AUTO MODE WHICH IS
CONNECTED TO SWITCH YARD AND UNIT 1 & 2 . IF ANY FAULT IS OCCURRED SO
IT NOT EFFECT ON POWER PLANT.

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Chapter .5 ASH HANDLING PLANT
IN ASH HANDLING PLANT THE ASH IS COLLECTED BY TWO WAYS.
1. FLY ASH
2. BOTTOM ASH
5.1 FLY ASH :-
WHEN COAL IS BURN OUT IT RELEASED SULPHUR POWDER HAVING
NEGATIVE CHARGE (-2). SO IN ESP ( ELECTRODE SEPRATOR PLATE) IT CONSIST
OF TWO TYPE OF PLATES . COLLECTIVE PLATE AND EMMITING SPRING .
THE COLLECTIVE PLATE IS CHARGED WITH POSITIVE CHARGE AND CONNECTED
WITH EARTHING .
THE EMMITING SPRING IS CHARGE WITH NEGATIVE . WHEN SULPHUR PARTICLES
IS PASSED IN ESP DUCT IT IS CHARGED MORE BY EMMITING SPRING BY
NEGATIVE CHARGE . SO SULPHUR PARTICLES IS CHARGED MORE . SO
COLLECTIVE PLATE IS ALREADY CHARGED WITH POSITIVE CHARGE WHICH
ATTRACT THE NEGATIVE PARTICLES OF SULPHUR , THEN WHOLE SULPHUR
PARTICLES ARE COLLECTED ON COLLECTIVE PLATES.
WHICH IS HAMERED BY SMALL SMALL HAMER THEN ALL ASH IS GET DOWN IN
HOPPER AND ASH CONVEYING TO IM SILO AND FROM IM SALO ASH IS GOES TO
CEMENT PLANT BY USING AIR COMPRESSOR .

112
Figure 50 ESP HOPPER
5.2 ESP – WORKING PRINCIPLE
CORONA GENERATION
PARTICLE CHARGING
PARTICLE COLLECTION
REMOVAL OF PARTICLES
5.3 CORONA GENERATION
DUE TO IONIZATION OF GAS MOLES +VE IONS , -VE IONS AND FREE ELECTRON
ARE GENERATED .

113
5.4 PARTICLE CHARGEING
THE –VE CHARGE OF IONS AND FREE ELECTRONS MOVE TOWARDS +VE
ELECTRODE AND THE +VE CHARGE OF IONS MOVE TOWARDS -VE
ELECTRODES.
WHEN –VE IONS TRAVEL TOWARDS +VE ELECTRODE THE –VE CHARGE
ATTACHED TO THE DUST PARTICLES AND THUS THE DUST PARTICLE ARE
ELECTRICALLY CHARGED.
THIS IA ABOVE ESP HOW ASH IS HANDLING.
5.5 ADVANTAGE OF ESP
IT REMOVE TINY DUST PARTICLE
IT REDUCE 99% POLLUTION. ( MAIN PURPOSE)
ONLY 1% OF SMOKE IS EXHOUST FROM CHIMNEY.
THIS 1% SMOKE IS REMOVED BY ID FAN. THE DUCT OF ESP IS CONNECTED TO ID
FAN ( INDUCED DRAFT FAN)
THERE ARE TWO ID FAN FOR EACH UNIT.
TOTAL ID FAN FOR BOTH UNIT IS 4 ID FAN ( FOR EACH UNIT 2 ID FAN)

114
Figure 51 ESP
MAKE – KAY INTERNATIONAL LIMITED
TYPE/MODEL – TWIN LOBE BLOWER, OIL FREE
CAPACITY – 840 CuM/HR
DISCHARGE PRESSURE – 6000 MMWG
WEIGHT PRESSURE – 0.8 TON

115
MOTOR
MAKE – ABB
KW/SPEED IN RPM – 22 KW/1460 RPM
WEIGTH - 0.2 TON
5.6 PURPOSE OF ESP
THE MAIN TASK OF ELECTROSTATIC PRESIPATOTOR IS TO CLEAN DUST WHICH
IS GIVEN OUTBY THE POWER PLANT.
Figure 52 INSIDE ESP

116
Figure 53 HERE WE CAN SEE THAT PLATES AND SPRING
Figure 54 HERE WE CAN SEE THAT HAMMERS

117
5.7 HVR- HIGH VOLTAGE RECTIFIRE ( IT IS SITUATED AT THE TOP
OF ESP)
HVR HAVING 415 V WHICH IS SUPPLIED TO THE DIFFERENT MOTOR ARE
CONNECTED TO ESP.
FOR BOTH UNIT HAVING DIFFERENT ESP. IN EACH UNIT HAVING 96 ESP. AT EACH
UNIT HAVING 6 COLUMN A,B,C,D,E,F.
EACH COLUMN HAVING 16 ESP . SO IN EACH UNIT 16 X 6 = 96 ESP.
5.8 COMPONENTS USED IN ESP
EMITTING ELECTRODE
COLLECTING PLATES
440 V 50 Hz 3phase AC
HIGH VOLTAGE TRANSFORMER
RECTIFIER
ESP HOPPER
GDRM – GAS DISTRIBUTED RAPPING MOTOR
EERM – EMITTING ELECTRODE RAPPING MOTOR
CERM – COLLECTIVE ELECTRODE RAPPING MOTOR
HOPPER HEATER

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5.9 TYPES OF HEATER
1. HOPPER HEATER
2. SUPPORT HEATER
3. SHAFT HEATER
5.9.1 HOPPER HEATER
TOTAL 16 ESP IN COLUMN SO AT 1 ESP HOPPER HAVING 16 HEATER
HOPPER HEATER = 16 X 16 = 256 IN 1 COLUMN
TOTAL HOPPER HEATER IN UNIT 1 = 256 X 6 = 1536 HEATERS
SAME IN UNIT 2 NO. OF HEAYTER IS = 1536
TOTAL ESP HOPPER HEATER = 1536 X 2 = 3072 HEATERS
RATEING = 500B W ( EACH HEATER)
5.9.2 SUPPORT HEATER
SUPPORT HEATER =16 X 4 = 64 IN COLUMN
TOTAL SUPPORT HEATER IN UNIT 1 =64 X 6 =384 HEATERS
SAME AS IN UNIT 2 NO. OF HEATER IS = 384 HEATERS
TOTAL ESP SUPPORT HEATER = 384 X 2 = 768 HEATERS
RATEING = 500 W ( EACH HEATER)

119
5.9.3 SHAFT HEATER
SHAFT HEATER = 16 X 1=16 HEATER IN EACH COLUMN
TOTAL SHAFT HEATER IN UNIT 1 = 16 X 6 = 96 HEATERS
SAME AS IN UNIT 2 NO. OF HEATER IS = 96 HEATERS
TOTAL ESP SHAFT HEATER = 96 X 2 = 192 HEATERS
HEATER ARE USED TO MELT THE ASH WHICH IS PASSES THROUGH HOPPER AND
CONVEYING PIPES . IF ASH PARTICLES ARE BECOME SOLID IN PIPE SO THERE IS
NO SUPPLY IN ASH POUND AND CEMENT PLANT . THAT’S WHY DIFFERENT
HEATERS ARE USED IN ESP.
5.10 ELECTRODES
BASED ON DC CURRENT FLOW TERMINAL ELECTRODE CAN BE DIVIDED AS
5.11 EMITTING ELECTRODE
ELECTRODES WIRE WHICH CARRIES NEGATIVELY CHARGED HIGH VOLTAGE UP
TO 95 KV ACT AS DISCHARGE OR EMITTING ELECTRODES.
5.12 COLLECTOR PLATE
ELECTRODE WIRE WHICH CARRIES POSITIVELY CHARGED HIGH VOLTAGE ACT
AS COLLECTIVELY ELECTRODE / COLLECTING PLATES.

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5.13 BOTTOM ASH:-
WHEN SOME OF COAL IS NOT BURNT IN FURNACE IT GET MELT AND TAKE BIG
SHAPE OF STONE SO IT IS VERY IMPORTANT TO REMOVE FROM HOPPER AND
THAT STONE IS CALLED CLEANKER. SO IN ORDER TO REMOVE CLEANKER WE
USE CLEANKER GRINDER TO GRIND COAL INTO ASH . THAT ASH IS CONVEYING
THROUGH WATER . THAT WATER IS COMEINGH FROM HIGH PRESSURE PUMP(HP
PUMP) .
AFTER CONVEYING OF ASH IT GOES TO ASH SULLARY SUMP. HERE 6 PUMP
IS CONNECTED TO SUPPLY ASH TO ASH POUND.
ASH WATER PUMP HOUSE
HIGH PRESSURE PUMP
PUMP DETAIL:-
MAKE – FLOW MORE
HEAD IN MWC – 100 M
MOTOR DETAIL:-
MOTOR MAKE – MARATHON ELECTRIC
POWER – 250 KW
SPEED – 1486 RPM
VOLTAGE – 3300 VOLTS
CURRENT – 52.5 AMPERE

121
5.14 LOW PRESSUER PUMP (LP PUMP)
PUMP DETAIL :-
MAKE –FLOW MORE
HEAD IN MWC – 34 METER
MOTOR DETAIL:-
MOTOR MAKE – ABB
POWER – 45 KW
SPEED – 1470 RPM
CURENT – 81 AMPERE
Figure 55 ASH PUMP HOUSE

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ASH SLURRY SUMP:- FROM HERE ASH SLURRY IS MIXED WITH WATER
AND SUPPLY TO ASH POUND WITH THE HELP OF ASH SLURRY PUMP . HERE
TOTAL NUMBER OF PUMP IS 6, IN WHICH 2 PUMP IS USED FORM SUPPLYING
AND OTHER 4 PUMPS ARE USED AS THEIR NEED OR DEMAND .
MOTOR DETAIL:-
MAKE – ABB
POWER – 110 KW
SPEED – 1485 RPM
CURRENT – 190 AMPERE
Figure 56 ASH SLURRY SUMP

123
Chapter .6 BOP ( BALANCE OF PLANT)
BOP IS A AREA WHICH CONTAIN WATER RELATED SITE FOR DIFFERENT
PURPOSE.
IT CONTAIN SITE RELATED:-
INTAKE
RESERVIOR (RAW WATER)
PRIMARY TREATMENT PLANT (PT)
STILING CHAMBER
COOLING WATER STORAGE TANK ( DISTRIBUATION CHAMBER)
CIRCULATING WATER
6.1 INTAKE PUMP ( FROM GOPAD RIVER)
IT CONSIST OF 4 PUMP . 2 IS IN WORKING CONDITION AND 2 IS IN
STAND BY CONDITION.
MANUFACTURE – FLOWMORE
TYPE OF PUMP – VERTICAL TURBINE PUMP
FLOW – 3000 M3/HR
POWER – 350 KW
VOLTAGE – 3300 V
SPEED – 987 RPM
MOTOR MAKE – BHEL

124
WITH THE HELP INTAKE PUMP WE SUPPLY WATER FROM GOPAD
RIVER TO RESERVIOR (RAW WATER).
Figure 57 INTAKE PUMP HOUSE
IT IS VERY IMPORTANT FOR POWER PLANT (FOR EVERY STEAM POWER PLANT) .
BECAUSE IN ANY STEAM POWER PLANT WATER IS IMPORTANT THAT’S WHY
POWER PLANT CREAT ONE OF BARRIER OR DAM WHICH STORE OR COLLECT THE

125
WATER FROM RIVER , IT ALSO PROVIDE SOME OF WATER TO OTHER SIDE OF
GATE OR DAM . IF WE WANT TO BUILT ANY STEAM POWER PLANT THAN WE
HAVE TO SELECT PLANT AREA WHICH IS NEARER TO ANY RIVER OR MANMADE
RIVER .
6.2 RESERVIOR (RAW WATER)
AN OPEN AIR STORAGE AREA WHERE EARTH IS COLLECTED AND KEPT IN
QUANTITY SO THAT IT MAY BE DRAWN OFF FOR USE.
A RESERVIOR IS AN ARTIFICIAL LAKE WHERE WATER IS STORED. MOST
RESERVOIRS ARE FORMED BY CONSTRUCTING DAMS ACROSS RIVERS. A
RESERVIOR CAN ALSO BE FORMED FORM A NATURAL LAKE WHOSE OUTLET HAS
BEEN DAMMED TO CONTROL THE WATER THE WATER LEVEL. THE DAM
CONTROLS THE AMOUNT OF WATER THAT FLOWS OUT OF THE RESERVIOR.
Figure 58 LAYOUT OF RAW WATER PUMP HOUSE

126
6.2.1 RESERVIOR PUMP ( RAW WATER PUMP)
PUMP MAKE – FLOW MORE
TYPE – VERTICAL TURBINE PUMP
FLOW – 2300 M3/H
MOTOR MAKE - BHEL
POWER – 270 KW
SPEED – 1480 RPM
VOLTAGE – 3300 V
IN RAW WATER PUMP HOUSE CONSIST OF 3 PUMP. IN WHICH 2 PUMP IS IN
WORKING CONDITION AND 1 IS IN STANDBY CONDITION.
IN RESERVIOR AREA CONSIST OF 2 RAW WATER AREA .
1ST
RESERVIOR CONSIST OF 4500000 CuM WATER
2ND
RESERVIOR CONSIST OF 4300000 CuM WATER
THIS RESERVIOR WATER IS SUPPLIED BY RAW WATER PUMP TO PRIMARY
TREATMENT PLANT.

127
6.3 PRIMARY TREATMENT PLANT
IT IS AN AREA WHERE WATER IS TREATED WITH SOME CHEMICALS FOR
CLARIFIED WATER .
CHLORINATION , ALUM ,SLAKED LIME AND ELECTROLYTES ARE ADDED TO RAW
WATER
CHLORINE LIQUID IS ADDED OR MIXED WITH WATER. IT IS NOT TO DOES WITH
WATER BECAUSE CHLORINE DENSITY IS MORE THAN WATER SO IT CAN NOT
MIXED WITH LARGE AMOUNT WATER . THAT’S WHY WE FIRST ADD SOME OF
WATER AND CHLORINE WITH PRESSURE AND WATER IS MIXED WITH RAW
WATER IN SUMP.
Figure 59 CHLORINE TONNER CYLINDER
IT HAVING 4 CHLORINE TONNER CYLINDER. EACH CYLINDER HAVING WEIGHT
900 KG AND IT CONSIST GAS UPTO 500 KG TO 600 KG .
WE USE CHLORINE TO KILL JERMS AND BACTERIA FROM WATER.

128
Figure 60 RAW WATER CHLORINE TO BOOSTER PUMP
THIS PUMP TAKE WATER FROM RAW WATER PIPE LINE AND THIS WATER IS
MIXED WITH CHLORINE . THIS PUMP IS IN PRIMARY TREATMENT PLANT.
CHLORINATION SYSTEM CONNECTED WITH ROTA METER

129
Figure 61 ROTAMETER
A ROTAMETER IS DEVICE THAT MEASURE THE VOLUMETRIC FLOW RATE IN
FLUID IN CLOSED TUBE.
AFTER MIXING OF CHLORINE AND WATER THAT WATER IS SUPPLIED TO RAW
WATER SUMP.

130
Figure 62 HERE WE CAN SEE THAT HOW CHLORINE IS DOSING WITH WATER
AFTER DOSING OF CHLORINE . WATER IS GOES TO STILING CHAMBER. OTHER
CHEMICALS ARE ADDING TO WATER IN ORDER TO MAINTAIN PH OF WATER AND
TURBIDITY.
TURBIDITY IS THE CLOUDNESS OR HAZINESS OF A FLUID CAUSED BY LARGE
NUMBER OF A FLUID CAUSED BY LARGE NUMBER OF INDIVIDUAL PARTICLES
THAT ARE GENERALLY INVISIBLE TO THE NAKED EYE.

131
6.4 ALUM PLANT
TO REMOVE TURBIDITY FROM WATER ALUM IS REQUIRED THAT
WATER IS MIXED WITH RAW WATER.
HERE WE CAN SEE THAT FROM PVC PIPE WATER IS DRWAN. THIS WAER IS
NOTHING BUT IT ALUM WATER . THIS ALUM WATER IS USED TO MAINTAIN
TURBIDITY IN WATER .
HERE WE CAN SEE OTHER TO TWO PIPE . FROM GREEN PIPE IS USED FOR SLAKED
LIME .
SLAKED LIME IS USED IN TO MAINTAIN PH (POWER OF HYDROZEN).
AFTER MIXING OF THIS CHEMICAL THIS WATER IS GOES TO STILING CHAMBER
CALLED HIGH RATED SOLID CLARIFIED CONTACT .

132
6.5 STILING CHAMBER
Figure 63 Stiling Chamber
THIS IS CALLED STILING CHAMBER HERE WATER IS TREATED AND MIXING OF
WATER . IN CENTER IT HAVING ONE TYPE OF GRINDER WHICH MIXED THE
WATER . THE DIRTYNESS IS REMOVED AND SMALL PARTICAL ARE COMBINED
TOGETHER TO FORM SOLID DIRT WHICH IS GET DOWN IN BOTTOM OF STILING
CHAMBER . THAT SLUDGE IS COLLECTED BY SCRAPER.
AFTER CLAENING OF WATER THAT WATER IS GOES TO COOLING WATER
STORAGE TANK (CWST).

133
Figure 64 EMPTY STILING CHAMBER SCRAPER

134
6.6 COOLING WATER STOREAGE TANK ( CWST)
IN COOLING WATER STOREAGE TANK IT CONSIST OF 15 PUMP WHICH SUPPLY
WATER TO DIFFERENT AREA OF POWER PLANT. CAPACITY – 31000 MT .
1. CEMENT PLANT PUMP
2. PORTABLE WATER PUMP
3. DM PLANT PUMP
4. COOLING TOWER MAKEUP PUMP
5. AHP WASH PUMP
6. EMERGENCY PUMP
6.6.1 CEMENT PLANT PUMP :-
IT TAKE WATER FROM CWST AND THIS WATER IS SUPPLYED TO CEMENT
PLANT . IT HAVING 2 PUMP 1 IS AN WORKING CONDITION AND OTHER IS IN
STANDBY.
MOTOR DETAIL :-
POWER – 30 KW
CAPACITY – 40 HP
TEMPERATURE – 35 TO 60 CELLSEUS
PUMP DETAIL :-
FLOW – 50 M3/HR
PRESSURE – 11 KG/CM2

135
TDH – 109 MTR
SPEED – 2940 RPM
POWER – 19 KW
6.6.2 PORTABLE WATER PUMP :-
IT TAKE WATER FROM CWST AND THIS WATER IS SUPPLYED FOR
DRINKING PURPOSE . IT CONSIST OF 2 PUMP 1 IS AN WORKING CONDITION
AND OTHER IS IN STANDBY .
MOTOR DETAIL :-
POWER – 18.5 KW
CAPACITY – 25 HP
PUMP DETAIL :-
FLOW – 130 M2/HR
TDH – 33 MTR
SPEED – 1455 RPM
POWER – 13 KW

136
6.6.3 DM PLANT PUMP :-
DM PLANT IS AN AREA WHERE WATER IS DEMINERALIZE. IT IS
NECESSARY TO DEMINERALIZE BECAUSE DM WATER IS USED IN BOILER
WHICH MAKE STEAM IS GOES TO TURBINE THAT’S WHY WE USE DM
WATER IF WE USE ONLY CLARIFIED WATER SO IT DAMAGE BOILER AND
TURBINE.
THE SIMPLE WATER CREAT CROSSION AND DUST ON TURBINE BLADES , IF
THIS CROSSION AND DUST ARE COLLECTED AT TURBINE BLADES SO IT
DAMAGE TURBINE SO, IT IS NOT CHEAP TO MAINTAIN TURBINE ON
RUNING CONDITION AND IT IS IMPOSBILE TO CHANGE NEW TURBINE
BECAUSE TURBINES FOR LARGE POWER PLANT IS MORE COSTLY. THAT’S
WHY WE DEMINERALIZE THE WATER.
MOTOR DETAIL :-
POWER – 45 KW
CAPACITY – 60 HP
CURRENT – 78.4 AMPERE
PUMP DETAIL :-
FLOW – 150 M2/HR
TDH – 65 METER
SPEED – 1470 RPM
POWER – 33

137
IT CONSIST OF 4 PUMP. 2 PUMP FOR UNIT 1 AND OTHER 2 FOR UNIT 2.
6.6.4 COOLING TOWER MAKEUP PUMP :-
IT TAKE WATER FROM COOLING WATER STORAGE TANK AND IT SUPPLY
WATER TO FOREBAY FOR MAKEUP OF CIRCULATING WATER. FOR BOTH
UNIT IT IS NECESSSARY TO SUPPLY WATER IN FOREBAY FOR
CIRCULATING WATER.
MOTOR DEATAIL :-
POWER – 110 KW
CAPACITY – 150 HP
PUMP DETAIL :-
FLOW CAPACITY – 2000 M3/HR
TDH – 15 METER
SPPED – 998 RPM
POWER – 92 KW
IT CONSIST OF 3 PUMP . PUMP 1 IS USED FOR UNIT AND PUMP 2 IS USED UNIT 2
AND 3RD
PUMP IS USED AS STANDBY.

138
6.6.5 AHP WASH PUMP :-
THIS PUMP TAKE WATER FROM COOLING WATER STOREAGE TANK. IT IS
NECESSARY TO SUPPLY WATER TO ASH PUMP HOUSE TO USE IN
CONVEYING OF ASH TO ASH POUND.
MOTOR DETAIL :-
POWER – 360 KW
VOLTAGE – 33 KV
PUMP DETAIL :-
FLOW – 700 M2/HR
TDH – 137.7 METER
SPEED – 1481 RPM
POWER – 294 KW

139
6.6.6 EMERGENCY PUMP :-
THIS PUMP TAKE WATER FROM COOLING WATER STOREAGE TANK AND
THIS WATER IS SUPPLYED FOR ASH PLANT IN EMERGENCY AND FOR
FIREFIGTHING PURPOSE.
MOTOR DETAIL :-
POWER – 55 KW
CAPACITY – 75 HP
PUMP DETAIL :-
FLOW – 300 M3/HR
PRESSURE – 4.2 KG/CM2
TDH – 41 METER
SPEED – 1475 RPM
‘POWER – 18 KW

140
6.7 DM PLANT ( DEMINERALIZE WATER)
Figure 65 DM PLANT

141
6.7.1 DUAL MEDIA FILTER (DMF) :-
THIS IS A INTAKE OF DM PLANT OR FIRST STAGE OF DM PLANT IT TAKE
WATER FROM CWST . HERE MUD, TURBIDITY, SAND AND WATER COLOUR
IS REMOVED FROM CLARIFIED WATER.
AFTER THIS PROCESS WATER IS GOES TO ACTIVATED CARBON FILTER
TANK.
Figure 66 DUAL MEDIA FILTER

142
6.7.2 ACTIVATED CARBON FILTER (ACF) :-
HERE CHLORINE, OIL AND COLOUR OF WATER IS REMOVED BY WATER.
Figure 67 ACTIVATED CARBON FILTER

143
6.7.3 STRONG ACID CATION ( SAC):-
IT EXCHANGE POSITIVE ION (+VE) . DEMINERALIZATION OF WATER IS THE
REMOVAL OF ESSENTIALLY ALL INORGANIC SALTS BY ION EXCHANGER
OR SOFTENING OF WATER OR REMOVING SODIUM FRO WATER.
Figure 68 STRONG ACID CATION
6.7.4 DEGASSER :-

144
DEGASSER IS TO APPLY A VACCUM TO THE SOLVENT FOR REMOVING GAS
BUBBLES ANS DISSOLVED GAS FROM WATER OR TO REMOVE CO2 FORM WATER.
Figure 69 DEGASSER

145
6.7.5 STORNG BASE ANION (SBA) :-
FROM DEGASSER TANK WATER IS SUPPLYED TO SBA WITH THE HELP OF
DEGASSER PUMP. IT EXCHANGE NEGATIVE ION (-VE) OR REMOVEING OF
SILLICA FROM WATER.
Figure 70 STRONG BASE ANION

146
6.7.6 MIXED BED (MB) :-
HERE BOTH CATION AND ANION IS TOTALLY REMOVED OR REMOVEING
OF SILLICA FROM WATER.
Figure 71 MIXED BED

147
6.7.7 ULTRA FILTRATION :-
ULTRAFILTRATION IS USED FOR REVERSE OSMOSIS. ULTRAFILTRATION IS
A LOW PRESSURE MEMBRANCE PROCESS USED TO SEPARATE BACTERIA
AND HIGH MOLECULAR WEIGHT COMPOUND COLLOIDAL.
AFTER ALL THIS PROCESS DEMINERALIZE WATER IS STORED IN DM TANK.
HERE 2 DM TANK IS SITUATED AND HAVING CAPACITY 2 X 1250 M3.
Figure 72 ULTRA FILTRATION

148
6.8 CIRCULATING WATER PUMP:-
THE PURPOSE OF CIRCULATING WATER PUMP IS TO CIRCULATE WATER OF
WHOLE PLANT. LIKE FROM FOREBAY WATER IS DISCHARGE TO CONDENSOR
WHERE COOLING WATER IS USED TO CONDENSE STEAM OF TURBINE. FROM
TURBINE EXHAUST STEAM IS PASSED TO CONDENSOR IN WHICH COOLING
WATER IS PASSING FROM WATER TUBES WHICH TAKE HEAT FROM STEAM AND
CONDENSE THE WATER AND CONDENSE WATER IS GOES TO THE BOILER FOR
REUSE. AFTER CHANGEING THE THE PHASE OF STEAM AND HOT WATER IS
RETURN TO NATURAL DRAFT COOLING TOWER AND WATER IS COOLED BY
NATURALLY.AGAIN THIS COOLED WATER IS DISCHARGE INTO FOREBAY FOR
RREUSE.
Figure 73 Cooling Tower

149
6.9 NATURAL DRAFT COOLING TOWER FOREBAY
IN COOLING TOWER THE HOT WATER FROM HEAT EXCHANGER IS DRWANOUT
AT 20 METER AND IT CONSIST OF THOUSANDS OF PLATES HAVEING SMALL
SMALL HOLES IN THAT PLATES FROM WHERE WATER IS GET DOWN IT LOKE
LIKE SPRAY WATER WHICH IS COOLED DOWN NATURALLY AND HIGH
TEMPERATURE STEAM IS EVAPORATE .
Figure 74 UNDER NATURAL DRAFT COOLING TOWER

150
6.9.1 CIRCULATING WATER PUMP
IN CIRCULATING WATER PUMP AREA CONSIST OF 5 CIRCULATING PUMP AND 3
AUXILARY CIRCULATING PUMP.
AUXILARY CIRCULATING WATER PUMP
MOTOR DETAIL :-
MOTOR MAKE – BHEL
POWER – 800 KW
VOLTAGE – 11000 VOLT
SPEED – 743 RPM
PUMP DETAIL :-
PUMP MAKE – FLOW MORE
RATED CAPACITY – 4500 M3/HR
CIRCULATING WATER PUMP
MOTOR DETAIL:-
MOTOR MAKE – HYUNDAI
POWER – 4500 KW
VOLTAGE – 11000 VOLT
CURRENT – 296.4
SPEED - 330 RPM

151
Chapter .7 BTG ( BOILER – TURBINE – GENERATOR)
BOILER SPECIFICATION :-
BOILER DESIGNER – MITSUBISHI HEAVY , INDUSTRIES LTD JAPAN
BOILER MAKER – LARSEN & TOURBO LTD INDIA
BOILER REGISTRATION MP – 5024
BOILER TYPE – SUPERCRITICAL , SLIDING PRESSURE OPERATION, ONCE
THROUGH BOILER AND SINGLE REHEAT CYCLE, HANGING TYPE TOP SUPPORTED.
MAIN STEAM FLOW – 2322 TPH
MAIN STEAM PRESSURE – 22.12 MPa ( SUPER HEATER OUTLET)
REHEAT STEAM FLOW – 1886 TPH
SUPERHEATED OUTLET TEMPERATURE – 568 CELSIUS
DESIGN PRESSURE OF COLD REHEAT INLET – 73 KG/CM2
COLD REHEAT INLET PRESSURE – 63 KG/CM2
COLD REHEAT INLET TEMPERATURE – 350 CELSIUS
FEED WATER TEMPERATURE AT ECONOMIZER INLET – 312 CELSIUS
FUEL – COAL (LDO AND HFO)
HEATING SURFACE AREA – 83357 M2
A BOILER IS A CLOSED VESSEL IN WHICH FLUID IS HEATED AND FLUID IS
CONVERTED INTO STEAM. THE BOILER IS A RECTANGULAR FURANACE.
PULVERIZED COAL IS AIR BLOWN INTO THE FURANACE THROUGH BURNERS
LOCATED AT THE 8- CORNERS TWO OPPOSITE WALLS.

152
7.1 IGNITER:-
WEIGHT – 15.5 KG
INPUT VOLTAGE – 240 V
OUTPUT VOLTAGE – 1400 V
IN BOILER IT CONSIST 4 ELEVATION . AT EACH ELEVATION HAVING 8 CORNERS
WITH 8 IGNITER.
HERE WE CAN SEE THAT AT EACH CORNER IGNITER ARE CONNECTED
DIAGONALY. IGNITER IS USED FOR LIGTHUP AT STARTING WE REQUIRED
COMBUSTION THIS IS DONE WITH THE HELP OF IGNITER. IGNITER JUST PRODUCE
SPARK WHICH IS HELP IN COMBUSTION .
7.2 FUEL GUN:-
PRESSURE – 0.59 MPa
BORE – 100 MM
STROKE – 350 MM
FUEL GUN IS A DEVICE IS USED TO PROVIED OIL AT LIGTHUP TIME . IT PROVIDE
OIL LIKE LIGTH DIESEL OIL ( LDO) & HEAVY FUEL OIL. IT ALSO AT EACH
ELEVATION HAVING 8 CORNER WITH 8 FUEL GUN .

153
IT IS VERY IMPORTANT FOR FURNACE AT STARTING LIGTHUP AFTER LIGTHUP IT
IS CLOSED. IT IS USED ONLY AT STARTING LIGTHUP BECAUSE IT NECCESARY
FOR COMBUSTION OF FUEL (COAL) .
7.3 ELEVATION IN FURNACE :-
AB ELEVATION – LDO + AIR
CD ELEVATION – HFO + STEAM
EF ELEVATION – HFO + STEAM
AA ELEVATION – ADDITIONAL AIR
Figure 75 FUEL GUN AND IGNITER

154
AT ELEVATION AB:- LIGTH DIESEL OIL ( LDO) IS USED WITH AIR . IT IS
NECCESARY TO USE AIR WITH OIL BECAUSE ONLY WE SUPPLY OIL IN FURNACE
SO IT GET DOWN AT ONE PLACE. AIR IS USED FOR PRESSURE THAT’S WHY AIR IS
USED WITH OIL SO IT SUPPLY LIKE SPRAY OR INTO SMALL PARTICAL WHICH
COVER MORE SPAC E OF FURNACE OR SPREAD ALL OVER THE FURNACE. WHICH
IS HELP IN EASLY COMBUSTION AND UTILIZED ALL OIL ( MEANS NO WASTAGE
OF OIL OR SAVE FUEL).
AT ELEVATION CD & EF :- WE PROVIDE HEAVY FUEL OIL + STEAM IN FURNACE
. HERE WE USE HFO + STEAM BECAUSE HFO IS VERY HEAVY SO WE USE STEAM
INSTEAD OF AIR. IT SUPPLY THE OIL WITH HIGH PRESSURE .
AT ELEVATION AA :- FROM HERE WE ADD OR SUPPLY AIR TO FURNACE FOR
COMBUSTION PROCESS BECAUSE WITHOUT OXYGEN NO COMBUSTION PROCESS
IS THERE .
WE TAKE AIR (OXYGEN) WITH HELP OF FD (FORCED DRAUGHT) FAN .
7.4 FD FAN (FORCED DRAUGHT):-
FD FAN IS USED TO FULL FILL THE REQUIREMENT OF OXYGEN IN BOILER..
MAKE – VARIAX, HOWDEN, DENMARK
FANTYPE – AXIAL FLOW , HORIZONTAL
FLOW – 18600 M3/MIN
MOTOR DETAIL:-
RATED POWER – 2800 KW
RATED VOLTAGE – 11000 V
RATED SPEED – 993 RPM
FULL LOAD CURRENT – 174 A

155
7.5 INDUCED DRAUGHT FAN ( ID FAN):-
ID FAN IS USED TO EXHAUST THE FLUE GASES FROM BOILER TO CHIMNEY. IN
EACH UNIT IT CONSIST OF 2 ID FAN.
MAKE – VARIAX, HOWDEN, DENMARK
FANTYPE – AXIAL FLOW HORIZONTAL
FLOWRATE – 38,900 M3/MIN
MOTOR DETAIL :-
MAKE – WEG EQUIPMENT ELECTRIC
Figure 76FROCED DRAUGHT FAN (FD FAN) & ID FAN IS ALSO LOOK LIKE THIS FAN

156
7.6 PRIMARY AIR FAN ( PA FAN ):-
PA FAN IS USED TO SUPPLY AIR TO COAL MILL. IT PRESSUREZIE THE AIR INTO
MILL TRANSPORT THE FINE PARTICALS OF COAL TO BOILER AND IT PREHEAT
THE COAL IN ORDER TO REMOVE MOSITURE FROM COAL IT HELP IN EASY TO
BURN. IN EACH UNIT IT CONSIST OF 2 PA FAN.
MAKE – VARIAX HOWDEN DENMARK
FAN TYPE – AXIAL FLOW HORIZONTAL
FLOWRATE – 8300 M3/ MIN
MOTOR DETAIL :-
FULL LOAD CURRENT – 181.3 Amp
Figure 77 PRIMARY AIR FAN

157
7.7 COAL MILL :-
MAKE – L&T , MHI VERTICAL , MILL
CAPACITY OF MILL ( DESIGN ) – 101 TPH
WORKING CAPACITY OF MILL – 85 TPH
MOTOR MAKE – WEG
POWER – 840 KW
CURRENT – 192.4 A
INPUT SPEED – 990 RPM
OUTPUT SPEED – 32.97 RPM
Figure 78 COAL MILL ( IN EACH UNIT IT CONSIST 6 MILL)

158
HERE COAL IS CONVERTED INTO COAL POWDER INTO 74 MICRON SIZE WITH
HELP OF ROTORS . IN EACH MILL CONSIST OF 3 ROTORS.
Figure 79 ROTORS IN MILL

159
FROM HERE COAL IS COMING FROM CONVYER BELT TO BUNKER VIA COAL
FEEDER. HERE COAL IS CONVERTED INTO FINE PARTICALS OF COAL POWDER
AND GOES TO COAL BURNERS WITH HELP OF PRIMARY AIR FAN TO BOILER.
7.8 COAL FEEDER :-
MOTOR DETAIL :-
POWER – 7.5 KW
CAPACITY – 106 MT/H
COC – CLEAN OUT CONVYER
MOTOR- 0.37 KW

160
FROM HERE COAL SUPPLY IS CONTROLED FOR COAL MILL WITH HELP OF ROD
GATE AND KNIFE GATE.
COAL SENSOR – IT IS USED IN COAL FEEDER TO KNOW WHETER COAL IS
FEEDEING OR NOT INTO COAL MILL. IT IS LIKE SQUARE PLATE HANGHING ON
TOP INSIDE OF FEEDER AND ABOVE CONVYER BELT.
Figure 80 COAL SENSOR AND CLEAN OUT CONVYER ( COC )
HERE WE CASN SEE THAT HOW COAL SENSOR IS CONNECTED.

161
ROD GATE (USED ABOVE THE COAL FEEDER )
BY USING THIS TROD GATE WE CASN STOP THE SUPPLY OF COAL TO COAL
FEEDER . IT IS USED DURING THE WORKING DURATION .

162
AFTER ALL THIS COAL IS GOES TO FURNACE WITH THE HELP OF COAL BURNERS .
COAL BURNERS TUBE IS INSTALED AT EACH CORNERS OF ANY ELEVATION.

163
7.9 COAL BURNERS TILT :-
IT IS USED TO GIVE THE DIRECTION OF COAL POWDER IN FURNACE ( UP AND
DOWN).
Figure 81COAL BURNER TILT

164
7.10 FURNACE TV CAMERA:-
THIS CAMERA IS USED TO DETECT THE COMBUSTION PROCESS AND
TEMPERATURE IN FURNACE.
Figure 82 FURNACE TV CAMERA

165
7.11 SCANNER :-
THE SCANNER IS USED TO DETECT THE TEMPERATURE IN FURNACE.
FOR THE COOLING OF THIS SCANNER IN FURNACE WE USE DC SCANNER FAN
AND AC SCANNER FAN. THIS FAN IS USED TO PROTECTION FROM HIGH
TEMPERATURE . IF WE NOT PROVIDE COOLING SYSTEM FOR SCANNER THAN
SCASNNER GET MELT IN FURNACE.
DC SCANNER FAN:-
SPEED – 2930
POWER – 30 KW
CURRENT – 159 Amp
AC SCANNER FAN :-

166
CAPACITY – 185.7 M3 / MIN
POWER – 30 KW
CURRENT – 50 Amp
WORKING OF THESE FAN TO COOL DOWN THE SCANNER.
7.12 RAPH ( ROTARY AIR PREHEATER ):-
THE PURPOSE OF THE AIR PREHEATER IS TO RECOVER THE HEAT FROM THE
BOILER FLUE GAS WHICH INCREASE THE THERMAL EFFICIENCY OF THE BOILER
BY REDUCING THE USEFUL HEAT LOST IN THE FLUE GAS.
TYPE – REGENERATIVE , TRI – SECTION
MAKE – HOWDEN
EFFECTIVE HEATING SURFACE IN M2 – 54605 M2

167
MOTOR DATA :- AIR MOTOR:-
MAKE – ABB POWER – 7 KW
POWER – 18.5 KW SPEED – 975 RPM
SPEED – 1470 RPM
VOLTAGE – 415 V
CURRENT – 34 Amp
7.13 FLOW OF STEAM IN BOILER:-
Figure 83 FLOW OF STEAM IN BOILER
HERE WE CAN HOT WATER IS COMING FROM HPH TO ECONOMISER INLET AFTER
HEATING OF WATER FROM ECONOMISER . WATER IS GOES TO WATER WALLS
FROM HERE IT GOES TO PRIMARY SUPER HEATER , SECONDARY SUPERHEATER
AND FINALLY TO TERATIORY SUPER HEATER THIS STEAM IS ALSO CALLED

168
FINAL SUPER HEATER THEN THIS MAIN STEAM IS TRANSFER TO HIGH PRESSUE
TURBINE (HPT) AFTER THE USES OF STEAM FROM HPT IT GOES TO PRIMARY
REHEATERAND SECONDARY REHEATER AND THAT STEAM GOES TO IPT (
INTERMIDIATE PRESSURE TURBINE) . AFTER THE USE FULL WORK OF STEAM
THAT STEAM IS GOES TO LOW PRESSURE TURBINE ( LPT ).
7.14 TURBINE :-
A STEAM TURBINE IS A DEVICE THAT EXTRACT THERMAL ENERGY FROM
PRESSURIZED STEAM AND USES IT TO DO MECHANICAL WORK ON ROTATING
OUTPUT SHAFT.
Figure 84TURBINE GENERATOR ( TG )

169
LOW PRESSURE TURBINE ( LPT )

170
AFTER THE COMPLETE PROCESS OF STEAM FROM TURBINE ONCE AGAIN THIS
STEAM IS USED BY CONDENSE IT WITH THE HELP OF CONDENSOR.
Figure 85RECOVERY OF STEAM
CONDENSOR:- CONDENSOR ISUSED TO CONDENSE THE EXHAUST STEAM
FROM TURBINE.
LP CONDENSOR HP CONDENSOR
MAKE L&T HED
TYPE RECTANGULAR DUAL PRESSURE TWO SHEL,
SURFACE CONDENSOR
DESIGN HEAT LOAD 342741538 K CAL /HR 340784620 K CAL /HR
WATER FLOW 72176 TON/HR 72176 TON/HR
CONDENSATE TEMPERATURE 43 DEGREE CELCEUS

171
CW INLET/OUTLET TEMP. 33/37.7 37.76/425
TUBES IN CONDENSING- 25560 25572
-ZONE NOS
7.15 CONDENSATE EXTRACTION PUMP :-
THIS PUMP IS USED TO TAKE THE CONDENSATE WATER FROM HOTWELL AND
TRANSFER TO LP HEATER AND AFTER LP HEATER IT IS TRANSFER TO
MDBFP/TDBFP ( MOTOR/TURBINE DRIVEN BOLIER FEED PUMP).
MAKE – KSB PUMPS LTD
TYPE OF PUMP – VERTICAL CAN TYPE RING SECTION PUMP
SUCTION TEMPERATURE – 43.6 DEGREE CELCEUS
CAPACITY – 975 M3/HR
SUCTION PRISSURE – 0.44 KG/CM2
DISCHARGE PRESSURE – 28.88 KG/CM2
MOTOR MAKE – ABB
MOTOR RATING – 1170 KW
VOLTAGE – 11000 V
RATED CURRENT – 73.45 Amp
AFTER CLEANING OF WATER FROM CONDENSATE PLOZING UNIT ( CPU ) THAT
WATER GOES TO MDBFP/TDBFP.

172
7.16 MOTOR DRIVEN BOILER FEED PUMP ( MDBFP ):-
THIS IS A PUMP IS USED TO TRANSFER WATER TO THE ECONOMISER. IT IS
MOTOR DRIVEN PUMP IT IS USED DURING STARTI G OF POWER PLANT.
MAKE – FLOWSERVE
TYPE – HORIZONTAL, MULTISTAGE, BARREL CASING AND CENTRIFUGAL TYPE
MOTOR MAKE – WEG
POWER – 9710 KW
VOLTAGE – 11000V
RATED CURRENT – 583.8 Amp
MAIN PUMP BOOSTER PUMP
SUCTION TEMP. 186.4 C 186.1 C
CAPACITY 749 M3/HR 765 M3/HR
TOTAL DEVELOPED HEAD 3381.9 M 170.8 M
PUMP EFFICIENCY 84.5 % 75.3 %
THIS MDBFP MOTOR IS THE BIGEST MOTOR IN ALL OVER THE THERMAL POWER
PLANT.

173
7.17 TURBINE DRIVEN BOILER FEED PUMP ( TDBFP ):-
MAKE – FLOWSERVE
TYPE OF DRIVE – TURBINE
MAIN PUMP BOOSTER PUMP
SUCTION TEMP. 186.3 C 186.1 C
CAPACITY 1498 M3/HR 1520 M3/HR
INLET FLOW 1498 M3/HR 1520 M3/HR
MINIMUM FLOW 374.5 M3/HR 419.5 M3/HR
RUNOUT FLOW 1943 M3/HR 1965 M3/HR
SUCTION PRESSURE 26.3 KG/CM2 14 KG/CM2
TOTAL DEVELOPED HEAD 3400.8 M 152.9 M
PUMP EFFICIENCY 86.9 % 84 %
OPERATING SPEED 5530 RPM 1507 RPM
THIS PUMP IS OPERATE WHEN TURBINE GET SPEED UPTO 2950 RPM THEN THIS
PUMP IS OPERATED AND MDBFP IS OFF. THIS DONE BECAUSE MDBFP CONSUME
MORE POWER THAT’S WHY ANOTHER PUMP IS USED AFTER STARTING OF
TURBINE.

174
7.18 GENERATOR DETAIL:-
THE ELECTRICITY IS GENERATE ON THE PRINCIPLE, WHEN THE CURRENT
CARRYING CONDUCTOR CUT THE MAGNETIC FIELD OR MAGNETIC FIELD CUT
THE CONDUCTOR SO, IT INDUCED EMF, SO THAT INDUCED EMF GENERATE
ELECTRICITY.
824000 KVA
21000 VOLT
22654 Amp
0.85 P.F
3 PHASE
50 HZ
3000 RPM
36 C COOLING WATER PUMP
H2 PRESSURE – 4 KG/CM
Figure 86 GENERATOR

175
7.19 EXCITER DETAIL:-
EXCITER VOLTAGE – 550 V
FIELD CURRENT – 5855 Amp
AT GENERATOR SIDE THE ROTOR IS HAVING CONDUCTOR WINDING AT WHICH
DC SUPPLY IS DRAWN. THAT DC SUPPLY PRODUCED MAGNETIC FIELD, WHICH IS
INDUCED EMF, HERE MAGNETIC FIELD IS ROTATE AND CUT THE CURRENT
CARRING CONDUCTOR AND PRODUCE ELECTRICITY.
Figure 87 EXCITER

176
IN GENERATOR HYDROGEN GAS IS USED FOR COOLING OF STATOR WINDING.
THE TEMPERATURE OF HYDROGEN GAS IN GENERATOR IS BETWEEN -5 C TO -15
C. FOR THE PROTECTION FROM LEAKAGE OF HYDROGEN GAS WE USE SEAL OIL
IN GENERATOR.
7.20 SEAL OIL PUMP :-
NO. OF PUMPS:- AC AIR PUMP -2 ( ONE FOR STRANDBY )
AC H2- SIDE PUMP : 1
AC FLOAT PUMP : 1
DC EMERGENCY SEAL OIL PUMP
MAKE – SHIMADZU MECTEMING
AIR SIDE SEAL PUMP – PUMP CAPACITY 1460 L/MIN
AND MOTOR CAPACITY – MOTOR : AC 15 KW
FLOAT OIL PUMP – PUMP CAPACITY : 35 L/MIN
AND MOTOR CAPACITY – MOTOR : AC 15 KW
H2 SIDE SEAL OIL PUMP – PUMP CAPACITY : 145 L/MIN
AND MOTOR CAPACITY – MOTOR : AC 3.7 KW
EMERGENCY SEAL OIL PUMP – PUMP CAPACITY : 460 L/MIN
AND MOTOR CAPACITY – MOTOR : DC 15 KW

177
DISCHARGE PRESSURE – 7.9 KG/CM2
VOLTAGE – AC 415 V, DC 220 V
7.21 STATOR COIL WATER SUPPLY :-
MAKE – MITSUBISHI ELECTRIC CORPORATION
CIRCULATING WATER PUMP TYPE – CANNED MOTOR PUMP
PUMP TYPE – CENTRIFUGE
PUMP CAPACITY – 1830 LIT/MIN
SUCTION HEAD – 0.5 KG/CM2
SPEED – 3000 RPM
PUMP MAKE – TEIKAKU ELECTRIC MFG.
MOTOR POWER – 45 KW
VOLTAGE – 415 V
RATED CURRENT – 94 Amp
WATER TANK CAPACITY – 22OOO LIT
DESIGN PRESSURE – 10 KG/CM2
CAPACITY – 260 LIT
MAX WATER TEMP – 95 C
COOLER TYPE – PLATE TYPE HEAT EXCHANGER
THIS WATER SUPPLY IS USED FOR COOLING PURPOSE IN GENERATOR STATOR
COIL. IT IS VERY IMPORTANT TO MANAGE TEMPERATURE INSIDE GENERATOR

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