This is a report regarding an industrial training done by me at Rosa Power Supply Ltd. which is a 1200 MW(4X300 MW) thermal power plant owned by Reliance Power.

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AN INDUSTRIAL TRAINING REPORT – I
Done by
SASHIKANT TIWARI
SAP ID.:500041217
Roll No.:R630214066
At
Rosa Power Supply Company Ltd.
Administrative Block, PO-Rosar Kothi, Sadar Tehsil
Shahjahanpur, Uttar Pradesh: 242406
Submitted to
Department of Electrical and Power Engineering
University of Petroleum and Energy Studies
Energy Acres Dehradun,Uttrakhand

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BONAFIDE CERTIFICATE
Certified that this Industrial Training Report – I is a work of
SASHIKANT TIWARI (RollNo.R630214066) who carried out the work at Rosa
Power Supply Company Ltd., Administrative Block, PO-Rosar Kothi, Sadar
Tehsil, Shahjahnpur, Uttar Pradesh
Mr. Chandra Shekhar Mr. B.S. Prasad
Head- Simulator & Training Station Director

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Acknowledgement
It is always a pleasure to remind the fine people in the Engineering
program for their sincere guidance I received to uphold my practical as
well as theoretical skills in engineering.
Firstly I would like to thank Mr Narendra Balkishan Soni (Head of
Department, Dept. of Electrical and Power Engineering, UPES) for
meticulously planning academic curriculum in such a way that students
are not only academically sound but also industry ready by including
such industrial training patterns.
I would also like to thanks Mr Ram Mohan Sharma (Group In-charge)
for the positive attitude he showed for my work, always allowing me to
question him and giving prompt replies for my uncertainties.
Finally, I would also like to thanks Mr. Chandra Shekhar (Head-
Simulator & Training), Mr. B.S. Prasad (Station Head) for giving me
this opportunity and guiding during the course of the training.

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CONTENTS
Chapter No Topic Page No.
1. Introduction 7
2. Details of the Industrial Training
2.1 Simulator Training 8
2.2 Maintenance Training 8
3. Details of study
3.1 Simulator Training 9-14
3.2 Maintenance Training 15-27
4. Conclusions 27

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CHAPTER 1
INTRODUCTION
Rosa Power Plant is a 1200 MW of coal based generation capacity at
Rosa village in Shahjahanpur, Uttar Pradesh. The power plant is being
developed in two stages with the first stage already having become
commercially operational on 12 March 2010. It is also the first project of
the company operational.
Rosa Power Supply Company Limited (RPSCL), the holding company
of Rosa Power Plant was incorporated on September 1, 1994 as a
subsidiary of Aditya Birla Power Company. It was later transferred to
Reliance Power on November 1, 2006 and is now fully owned
subsidiary of Reliance Power. It is a project that has received a
considerable support from the Uttar Pradesh government with it being
designated a ‘Priority project’. The Entire power generated will be sold
to Uttar Pradesh Power Corporation Limited (UPPCL).
There are total 4 units in operation with individual capacity of 300 MW.

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CHAPTER 2
DETAILS OF INDUSTRIAL TRAINING
2.1SIMULATOR TRAINING:

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The simulator training held for seven days at RPSCL, Sahajhanpur Uttar
Pradesh. Simulator is an imitation of the actual software that is being
used to control a single unit i.e., 300 MW in case of RPSCL. During the
simulator training we have been given the task of reaching to 300 MW at
the end of seven days. From the first day itself we have taught about the
basic operation of Rosa Power Plant along with its operation
specification. Then we learned about all those equipment’s which are
used in thermal power plant there operation and they controlled and
maintained with the help of simulator. Then we come to know the
conditions that need to be satisfied in order to a device working. With
these small steps we finally reach 300 MW at the very last day.
2.2MAINTENANCE AND PROTECTION TRAINING:
The training held for 3 days after the simulator training at RPSCL,
Sahajhanpur Uttar Pradesh. During this training we make the site visit to
switchyard, Boiler, Turbine, Steam Drum and Feeders. Theory classes
held for the same. In theory classes we came to know about types of
maintenance and testing for different equipment’s.
Simulator Training
 Electrical Charging;

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This is a process of charging all the auxiliaries from the grid. In
any Power Plant all your auxiliaries need to start first for that
electric charging is done. All 6.6 KV, 415V, 220V DC, UPS &
emergency power supply (DG) are available & buses are charged.
220 KV-6.6KV-415V
 Auxiliary Cooling Water;
ACW pumps are started first followed by air compressor. Ensure
that coal-handling system is ready. Ensure ash-handling system is
ready for ash evacuation. Ensure that all soot blowers are in non -
operating position. Start CW (Cooling Water) & CCW
(Condensate Cooling Water) system and charge all the associated
systems. Open drum, MS drain after stop valve & start up vents.
Start ID/FD fans and maintain furnace draft at -1 mmwc.
 Purging;
Fulfil all the purge permissive and purge the boiler. Boiler purging
will take exactly 300 seconds or 5 minutes. Carry out HFO and
LDO leak test if required, otherwise bypass the test.
Primary Purge conditions;
i. MFT active
ii. All burner oil valves and its purge valves, atomizing steam/
air valves closed
iii. All pulveriser stopped
iv. All coal feeders stopped
v. All pulveriser outlet dampers closed
vi. All Primary Air fan stopped
vii. Any Air Pre- heater running
viii. Any induced draft fan running

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Secondary Purge Conditions;
ix. Total air flow rate between 30% and 40%
x. Boiler drum level normal (between -150mm to 150mm)
xi. Furnace pressure normal (between -300Pa and 300Pa)
xii. Fuel oil leak test (HFO & LDO) success or test bypassed
 Boiler Lighting;
Light up the boiler with BC elevation and allow it to run for next
15 min. Take all the guns at BC elevation in service after 30
minutes & raise the drum pressure & temperature.
 Starting of Turbine;
Start main Turbine oil, Jacking oil & Seal oil system. Charge
hydrogen system and ensure that hydrogen pressure 3 bar. Charge
Generator cooling water system with one pump in service. Start
turbine barring gear RPM- 2.56. Ensure that all the HP-IP drains,
valve chamber drains are open. Put AB elevation guns in service.
Switch over the soot blowing medium from air to steam APH.
 Seal Oil;
Take second streams of ID & FD fans in service. Close HP/LP
bypass. Regulate the pressure. Ensure all turbine drains are in open
condition. Start seal Oil back up pump and check that the discharge
pressure.
Rated hydrogen pressure 0.31 MPa

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Seal oil to hydrogen diff pressure 0.084 MPa
Air side seal oil AC motor rating 15 KW
Air side seal oil DC motor rating 10 KW
Gas side seal oil AC motor rating 4 KW
Hydrogen side seal oil STD by
AC motor rating
30 KW
 Turbine Rolling;
Rolling parameters achieved. Close all HP-LP bypasses. Bypass
mode off then roll. Latch all Guide vanes (GV’s) & Transfer Vanes
(TV’s). Set the target and ramp rate of i. 600 rpm, 100 ii. 2040
rpm, 100 iii. 2950 rpm, 100 and TV-GV transfer after that, iv.
3000 rpm, 50
 Synchronization;
Open earth switch, close isolators. Check the readiness of
generator. Exciter (ON), 20 KV.DEH-CNTL mode, auto sync, in
service. Start synchronizing.
 Load Raising;
Set the target load at 30 MW. Select the load rising rate of 1
MW/min. Start Primary Air fan. Start seal air fan. Light up the mill
system. Take new mill in service & raise the firing rate. Now set
target and change over at 40 MW.

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Set the target load at 105 MW. Select the load rising rate of 1.5
MW/min.
Load will reach to 105 MW in the next 30 minutes if firing rate is
regulated properly. At 15% of rated load (45 MW), Close all the
drains of HP cylinder. At 20% of rated load (60 MW), Close all the
drains of IP cylinder. At 30% of rated load (90 MW), Close all the
drains of LP cylinder. Take Mill C in service at 40%load & raise
the firing rate. At 180 MW, Ensure that main steam pressure &
temperature is 130 bar & 537 Deg. C.
Take Mill D in service at 60% load & raise the firing rate.
Set the target load at 225 MW. Select the load rising of 2 MW/min.
At 225 MW, Ensure that main steam pressure & temperature is 158
bar & 537 Deg. C. At 240 MW, Ensure that main steam pressure &
temperature is 167 bar & 537 Deg. C. Full load 300 MW achieved.
RECOMMENDED TIME TO BRING BOILER ON FULL
LOAD
After cold start (72
hour shut down)
Hour <7.5
After 36 hrs. Shut
down
Hour <4
After 8 hrs. shut
down
Hour <1.5
Hot restart (Less than
1 hour after shut
down)
Hour <1.0
Control Point of
Boiler
Hour 60-100% BMCR for
re -heaters and 50-
100% BMCR for
super heaters

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 Mill System; All feeder in auto ( Biasing if required), Fuel master
in Auto & Remote
 Unit CCS; See base load in boiler follow mode, # Pre- set point in
fix mode # Take fuel master in remote #Send DEH Request
 DEH; Take MW loop out # Control mode- Remote in
 Unit CCS; See DEH in remote, # Put DEH master in auto, # Than
give MW set point.
 Levels;
System
Description
Low
Low
(mm)
Low
(mm)
Normal
(mm)
High
(mm)
High
High
(mm)
Very
Very
High
(mm)
Deareator -500 NA >-500
& <500
500 1200 1400
CCW
expansion
tank
<300 <750 >800 >1050 >1200 NA
Hot well 150 250 676 710 1120 1600
HP-LP
Bypass oil
tank
130 220 >220 NA 560 NA
EH oil tank 290/190 438 >438 NA 560 NA
MOT <-543 <-152 >-152 >152 NA NA
Stator water
tank
NA <550 >600 >700 >750 NA

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Hydrogen
seal oil tank
NA <-100 >-100 NA NA NA
HP heater-8 NA -630 -592 -554 -504 -454
HP heater-7 NA -630 -592 -554 -504 -454
HP heater-6 NA -554 -516 -478 -428 -378
LP heater-4 NA -462 -424 -386 -336 -286
LP heater-3 NA -462 -424 -386 -336 -286
LP heater-2 NA -609 -571 -553 -485 NA
LP heater-1 NA -609 -571 -553 -485 NA
Mill Lube
oil tank
NA <200 >200 NA NA NA
FD fan lube
oil tank
NA <200 >200 NA NA NA

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Maintenance & Protection Training
 Boiler Design;
Max Boiler Column
Height
73m
Total No of Columns 33No.s
Total No of ceiling Girder 10No.s
Total Weight of Boiler
Structure
3000 tons
Weight of Drum 218335 Kg
Total weight of pressure
parts
3237 MT
Other Non- Pressure Parts 4129 MT
Furnace Dimensions
(W*D*H)
16100x14120x40820
Max weight of Ceiling
Girder (L-Row)
60 MT
Name of Boiler- Sub critical, Single Drum, Natural Circulation,
Single reheat, Dry Bottom, Two Pass, Balanced Draft, Semi
Outdoor

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 Boiler Protections;
Protections Trip value
Both of the emergency push
button presses by operator
NA
Furnace pressure high high 20mbar
Furnace pressure low low -20mbar
Drum level high high 250mm
Drum level low low -350mm
Both FD fan stopped NA
Both ID fan stopped NA
Both APH stopped NA
Scanner fan pressure low low 32.3mbar
Total air flow 300 TPH
Loss of all fuel NA
Loss of all flame NA

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 Turbine Protection;
PROTECTION ALARM VALUE TRIPPING
VALUE
EH oil pressure low 110 Bar 93.1 Bar
Lube oil pressure 1.0 Bar/ 0.85 Bar 0.35 Bar
Vacuum low -0.87 Bar -0.80 Bar
HP exhaust pressure
high
40 Bar 48 Bar
Over speed NA 3250/3330
Rotor position -0.9/0.9 mm -1/1 mm
Rotor vibration 127 microns 254 microns
Differential
expansion
-0.6/12.7 mm -1.4/13.4 mm
HP exhaust ratio NA <=1.728
HP exhaust
temperature
400 Deg. C 427 Deg. C
Bearing temperature
high
From 1 to 4-98 Deg.
C
From 1 to 4-107
Deg. C
MFT NA Load>180 MW
Manual trip NA NA

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DEH power lost NA NA
 Isolators; Isolator switch is used to ensure that an electrical circuit
is completely de-energized for service or maintenance.
 Circuit Breaker; It is an automatically operated electrical switch
designed to protect an electrical circuit from damage caused by
overcurrent or short circuit.
 Types of Circuit Breakers;
I. Vacuum Circuit Breaker- In vacuum circuit breakers,
vacuum is used as the arc quenching medium. Since
vacuum offers the highest insulating strength, it has far
superior arc quenching properties than any other medium.
When the contacts of circuit breaker are opened in vacuum
an arc is produced b/w the contacts by the ionisation of
metal vapours of the contacts. However the arc is quickly
extinguished because the metallic vapours, electrons and
ions produced during arc rapidly condensed on the surface
of CB contacts, resulting in quick recovery of dielectric
strength.
II. SF6 Circuit Breaker- In such circuit breakers SF6 gas is
used as the arc quenching medium. The SF6 is an electro-
negative gas and has a strong tendency to absorb free
electrons. The contacts of the breaker are opened in a high
pressure flow of SF6 gas an arc is struck b/w them. The
conducting free electrons in the arc are rapidly captured by
the gas to form relatively immobile negative ions. This
loss of conducting electrons in the arc quickly builds up
enough insulation strength to extinguish the arc.

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 Maintenance;
Maintenance, repair, and operations involve fixing any sort of
mechanical, plumbing or electrical device should it become out of
order or broken (known as repair, unscheduled, or casualty
maintenance). It also includes performing routine actions which
keep the device in working order or prevent trouble from arising.
 Any activity- such as tests, measurements,
replacements, adjustments and repairs-
intended to retain or restore a functional unit in
or to a specified state in which the unit can
perform its required functions.
 For material- all action taken to retain material
in a servicing, classification as to
serviceability, repair, rebuilding, and
reclamation.
 For material- all supply and repair action taken
to keep a force in condition to carry out its
mission.
 For material- the routine recurring work
required to keep a facility in such condition
that it may be continuously used, at its original
or designed capacity or efficiency for its
intended purpose.
 Vibrations;
Vibration can result from a number of conditions, acting alone or
in combination. Keep in mind that vibration problems might be
caused by auxiliary equipment, not just the primary equipment.

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i. Imbalance- A heavy spot in rotating component will
cause vibration when the unbalanced weight rotates
around the machine’s axis, creating a centrifugal
force. Imbalance could be caused by manufacturing
defects or maintenance issues. As machine speed
increases the effects of imbalance become greater.
Imbalance can severely reduce bearing life as well as
cause undue machine vibration.
ii. Misalignment run out- Vibration can result when
machine shaft are out of line. Angular misalignment
occurs when the axes of a motor and pump are not
parallel. When the axes are parallel but not exactly
aligned, the condition is known as parallel
misalignment. Misalignment can be caused during
assembly or develop over time, due to thermal
expansion; components shifting or improper
reassembly after maintenance.
iii. Wear- As components such as ball or roller bearings
drive belts or gears become worn, they might cause
vibration. When a roller bearing race becomes pitted,
for instance, the bearing rollers will cause a vibration
each time they travel over the damaged area. A gear
tooth that is heavily chipped or worn, or a drive belt
that is breaking down, can also produce vibration.
iv. Looseness- Vibration that might otherwise go
unnoticed can become obvious and destructive if the
component that is vibrating has loose bearings or is
loosely attached to its mounts. Such looseness might
or might not be caused by the underlying vibration.

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 Shaft alignment;
Shaft alignment is the process of alignment two or more shafts
with each other to within a tolerated margin. It is an absolute
requirement for machinery before the machinery is put in service.
When a driver like an electric motor or a turbine is coupled to a
pump, generator, or any other piece of equipment, it is essential
that the shafts of the two pieces are aligned. Any misalignment
between the two increases the stress on the shafts and will almost
certainly result in excessive wear and premature breakdown of the
equipment. This can be very costly. When the equipment is down,
production might be down. Also bearings or mechanical seals may
be damaged and need to be replaced. Flexible couplings are
designed to allow a driver to be connected to the driven equipment.
Flexible coupling use an elastomeric insert to allow a slight degree
of misalignment.
Types of misalignment-
 Picture 1: Offset, or parallel- the shafts are parallel to each
other, but are not co-planar, or in the same plane. This can be
both vertical and horizontal. Offset or Parallel misalignment
is measured in thousandths of an inch, also called mils

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 Picture 2: Angular- the shafts are not in the same plane,
which causes a difference in measurement between
measurements made 180 degrees opposite on the coupling
faces. Angular Misalignment is measured in thousandths of
an inch, or mils, per inch of coupling diameter.
 Power Transformer (370 MVA, 230/20 KV);
Generation of electrical power in low voltage level is very much
cost effective. Theoretically, this low voltage level power can be
transmitted to the receiving end. This low voltage level power if
transmitted results in greater line current which indeed causes
more line losses but if the voltage level of a power is increased, the
current of the power is reduced which causes reduction in ohmic or
I^2*R losses in the system, reduction in cross sectional area of the

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conductor i.e. reduction in capital cost of the system and it also
improves the voltage regulation of the system. Because of these,
low level power must be stepped up for efficient electrical power
transmission. This is done by step up transformer at the sending
side of the power system network. As this high voltage power may
not be distributed to the consumers directly, this must be stepped
down to the desired level at the receiving end with the help of step
down transformer. Electrical power transformer thus plays a vital
role in power transmission.

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 Some of the important parts of Transformer;
 Conservator- The conservator conserves the transformer oil.
It is an airtight, metallic, cylindrical drum that is fitted above
the transformer. The conservator tank is vented to the
atmosphere at the top, and the normal oil level is
approximately in the middle of the conservator to allow the
oil to expand and contract as the temperature varies. The
conservator is connected to main tank inside the transformer,
which is completely filled with transformer oil through a
pipeline.
 Breather- The breather controls the moisture level in the
transformer. Moisture can arise when temperature variations
cause expansion and contraction of the insulating oil, which
then causes the pressure to change inside the conservator.
Pressure changes are balanced by a flow of atmospheric air in
and out of the conservator, which is how moisture can enter
the system. If the insulating oil encounters moisture, it can
affect the paper insulation or may even lead to internal faults.
Therefore, it is necessary that the air entering the tank is
moisture-free. The transformer’s breather is a cylinder that is
filled with silica gel. When the atmospheric air passes
through the silica gel of the breather, the air’s moisture is
absorbed by the silica crystals. The breather acts like an air
filter for the transformer and controls the moisture level
inside a transformer.

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 Tap Changer- The output may vary according to the input
voltage and the load. During loaded conditions the output
terminal decreases, whereas during off- loaded conditions,
the output voltage increases. In order to balance the voltage
variations, tap changers are used. Tap changers can be either
on-load tap changers or off-load tap changers. In an on-load
tap changer, the tapping can be changed without isolating the
transformer from the supply. In an off- load tap changer, it is
done after disconnecting the transformer.
 Cooling Tubes- Cooling tubes are used to cool the
transformer oil. The transformer oil is circulated through the
cooling tubes. The circulation of the oil may either be natural
or forced. In natural circulation, when the temperature of the
oil rises the hot oil naturally rises to the top and the cold oil
sinks downward. Thus the oil naturally circulates through the
tubes. In forced circulation, an external pump is used to
circulate the oil.

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 Buchholz Relay- The buchholz relay is a protective
device container housed over the connecting pipe from
the main tank to the conservator tank. It is used to
sense the faults occurring inside the transformer. It is
used to sense the faults occurring inside the transformer
oil during internal faults. It helps in sensing and
protecting the transformer from internal faults.

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 Explosion Vent- The explosion vent is used to expel
boiling oil in the transformer during heavy internal
faults in order to avoid the explosion of the
transformer. During heavy faults, the oil rushes out of
the vent. The level of the explosion vent is normally
maintained above the level of the conservatory tank.
Chapter 3
Conclusions
The 10 days spent in Rosa Power Plant Ltd. has been a unique
experience to me. It was an eye opener to how a coal based thermal
power plant actually works in real. This training gives the exposer
to both Simulator work and on-field work.
Through practical training, I have gain a great learning to
systematic work coordination in an environment that is conducive
coupled with friendly staff that is always there to help.