INTRODUCTION project apurv (1)

LALITPUR POWER GENERATION CORPORATION LIMITED
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Training report on
STATE’S LARGEST THERMAL POWER STATION
BAJAJ LALITPUR POWER GENERATION CORPORATION LIMITED (1980MW)
Apurv Rathore
B.Tech 3rd yr.
Electronics Engineering
NIELIT Aurangabad

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DECLARATION
I, Mr. Apurv Rathore, hereby declare that this industrial training report
Is the record of authentic work carried out by me during the period
from 18th
January 2016 to 18th
Febraury 2016 in LPGCL under
supervision of my training in-charge Mr. G.V Ramana (AVP ,C&I
,LPGCL).
Signature
Name of the student: Apurv Rathore

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CERTIFICATE
This is to certify that Mr. Apurv Rathore of “National Institute
Of Electronics And Information Technology” has successfully
completed the training work in partial fulfillment of requirement for
the completion of B.Tech course as prescribed by the Institute. This
training report is the record of authentic work carried out by him
during the period from 18th
February 2016.
He has worked under my guidance.
Signature
Training incharge (internal)

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Acknowledgement
With deep reverence and profound gratitude I express
my sincere thanks to Mr. G.V Ramana, AVP (C&I) for
giving me an opportunity to undergo training at LPGCL.
I also would like to thank Mr. Brij Bhan Singh,
Jr.Manager(C&I) who has helped me at the working sites,
explaining and giving me all the information needed to
complete this report. I am also very much thankful to
Mr. Manoj Verma DGM(C&I), Mr. Naveen Kumar
Dingliwala Asst.Manager (C&I) and all the members of
the staff of LPGCL for helping me throughout the
training.
Training Period: 18th
February 2016

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Contents
S.No Topic Page No.
1. Introduction on Bajaj group 6
2. About LPGCL 8
3. Coal to electricity basic 11
4. Complete description of Power plant 12
5. Coal Handling Plant 15
6. Boiler 18
7. Turbine 21
8. Water system 24
9. Electrical system 29
10. Switchyard 33
11. Transformer 38
12. Switchgear 42
13. DCS 44
14. ESP 52
15. Motors 53
16. Environmental Aspects 54
17. Conclusion 58
18. Reference 59

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INTRODUCTION
1) Bajaj Hindustan Ltd. (BHL), a part of the 'Bajaj Group', is India's Number
One sugar and ethanol manufacturing company, head quartered at
Mumbai (Maharashtra),India.
2) The Company has fourteen sugar plants, which are all Located In the
northern Indian state of Uttar Pradesh (UP): Golagokarannath, Palia
Kalan and Khambarkhera (district Lakhimpur Kheri), Barkhera (district
Pilibhit), Kinauni (district Meerut), Gangnauli (district Saharanpur),
Thanabhavan, Budhana (district Muzaffarnagar), Bilai (district Bijnore)
and Maqsoodapur (district Shahjahanpur), Kundharki (District
Gonda), Utraula (District Balrampur), Radauli (District Basti) and
Pratappur (District Deoria).
3) These fourteen plants have an aggregate sugarcane crushing capacity
of 1,36,000 tcd (tones crushed per day). BHL generates 430 MW of
power from the bagasse produced in its sugar mills. After meeting its
own energy needs, BHL has a surplus of 105 MW.
4) The Company has already begun to supply a significant part of this
surplus power to the UP state grid.

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5) BHL through their group company Bajaj Energy Private Limited (BEPL),
has now embarked upon the enhancing of the power generation
capacity by 450 MW through the setting up of new coal based
independent power plants (IPP) of 90 MW each in the vicinity of 5 of its
existing sugar units. These new projects are expected to be completed
by the second half of 2011, at an aggregate project cost of around Rs.
23 billion.
6) Now the Group in a major move in the Power Sector has embarked on
developing a mega thermal power project in UP which will produce
1,980 megawatts of power with super critical technology, ready for
commissioning in around 4 years. Towards this end, BHL has entered
into a Memorandum of Understanding (MoU) with the Government of
Uttar Pradesh (GoUP) on 22nd
April, 2010.
7) This mega thermal power project is being developed through a Special
Purpose Vehicle (SPV), namely Lalitpur Power Generation Company
Limited (LPGCL) originally promoted by Uttar Pradesh Power
Corporation Limited (UPPCL). LPGCL has since been acquired by BHL
and their group companies vide Share Purchase Agreement (SPA)
dated 10-12-2010.

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LPGCL-LALITPUR
STATION PROFILE
LOCATION:
LPGCL is a 3 x 660 MW coal fired supercritical thermal power plant in and
around villages of Mirchwara and Burogaon in tehsil Mahroni, district
Lalitpur, in the State of Uttar Pradesh.
CAPACITY:
Stage-1(Three units of 660 MW each) - 1980MW Aimed to commission in
all aspects by the FY end of 2015 – 16 i.e. by March 2016.

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LAND:
Total land acquired is 1320 acres.
WATER:
The source of raw water for the site is from Rajghat Dam (Betwa Canal
system) located about 50 km from the project site. The raw water make up
requirement for a power plant of 3 x 660 MW capacities is about 5556
m3/hr (133344 m3/day).
COAL:
Coal for this project is sourced from M/s Coal India Limited (CIL), preferably
from their Northern Coal Fields or Central Coal Fields (CCL). The rail way
line to Singrauli is located at a distance of 1.0 km from the southern
boundary of the project site. The nearest railway station is located at
Udaipura .Yearly coal requirement is about 8.13 MTPA at 85% PLF
considering a gross plant heat rate at 2255 kcal/kWh and considering
transit losses of 0.8 % as per Central Electricity Regulatory Authority
(CERC).
MAIN PLANT EQUIPMENT:
The steam generators of the 660 MW units are 100% coal
fired and are rated to generate about 2170 t/hr each, of superheated
steam at about 250 kg/cm2 (a) pressure and 565°C temperature.
Reheat steam temperature is 593°C. Steam generators are equipped with
facilities for fuel oil firing for start-up and for flame stabilization at low loads.
Steam turbine are three cylinder tandem-compound machine, driving a
turbo-generator at 3000 rpm to produce 660 MW rated output at 0.85
power factor at the generator terminals.

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The steam generators are designed as semi- outdoor equipment while the
turbine generator set with all auxiliaries and feed cycle equipment located
indoor.
POWER EVACUATION:
Power from the station is evacuated at 765 kV level to the UPPCL grid
substation at Agra which is at a distance of 250 km from the project site.

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Coal to Electricity …..
Basics

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COMPLETE DESCRIPTION
OF POWER PLANT
PA fan – Primary Air fan
FD fan- Forced Draft fan
ID fan- Induced Draft fan
ESP- Electrostatic Precipitator
CEP- Condensate Extraction Pump
BFP- Boiler Feed Pump
GSC- Gland Steam Cooler
LPH – Low Pressure Heater
DA- Deaerator
HPH- High Pressure Heater
OAC- Open Approach Channel
RAH- Regenerative Air Heater
DM water- De-Mineralized water

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The coal from mines is
received at track hopper in CHP
through BOBR Wagons. The
unloaded coal (max. size 250 mm2)
is scooped into conveyor by Rotary
Plough Feeders & is passed
through suspended magnet, magnetic separators, and metal detectors, to
ensure that sized coal, free of foreign material is supplied. Then it is sent to
Crusher House for further crushing to 25- mm2 size. After crushing, the
coal again screened for elimination of extraneous materials, weighed and
sent to boiler bunkers. Excess coal, if any, is sent to coal yard for stacking.
It then falls through a weigher into the Bowl Mill where it is pulverized. The
mill usually consists of a round metal table on which large steel rollers or
balls are positioned. The table revolves, forcing the coal under the rollers or
balls which crush it. Air is drawn from the top of the boiler house by the FD
Fan and passed through the RAH, and then send to boiler for burning of
coal. PA Fan takes air from atmosphere and distributes them into 2 parts
one send to RAH for heating and other fed directly to Mill blowing coal
along pipes to boiler furnace.
The boiler consists of a large number
of tubes extending the full height of
the structure and the heat produced
raises the temperature of the water
circulating in them to form
superheated steam which passes.
The steam is fed through the outlet
valve to the HP Turbine(High
Pressure turbine) at around
540°C.After this, it is returned to the
boiler and reheated before being
passed through the IP & LP
Turbine(Intermediate and Low Pressure
TUBES INSIDE BOILER
WAGON TRIPLER

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Turbine).The water fed into boiler is DM water.
From the turbine the steam passes into Condenser to be turned back into
water. This is pumped through CEP which sends water through GSC, LPH,
and HPH for further heating and BFP then sends it to the Economizer
where the temperature is raised sufficiently for the condensate to be
returned to the lower half of the steam boiler.
The flue gases produced in boiler are used to reheat the condensate in the
Economizer and then passes through the RAH to the ESP where ash is
collected. Finally, they are drawn by the ID Fan into the main flue and to
the chimney.
From the boiler, a steam pipe conveys steam to the turbine through a stop
valve (which can be used to shut off steam in an emergency) and through
control valves that automatically regulate the supply of the steam to the
turbine. The turbine shaft usually rotates at 3000 RPM. This speed is
determined by the frequency of the electricity system and the number of
poles of machine (2- pole machine here).
Cold water from OAC is circulated
through the condenser tubes and
as the steam from the turbine
passes round them it is rapidly
condensed into water. Water
which gets heated up in condenser
by cooling steam is sent to
Cooling tower and then left into
OAC from where it can be further
used.
The electricity is produced in turbo
generators and is fed through terminal
connections to Generator
Transformer, those steps up the
voltage to 400kv.
From here conductors carry it to
Switchyard from where it is sent for
use.
COOLING TOWER
GENERATOR TRANSFORMER

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Coal Handling Plant
Coal is the prime input for a thermal power plant, accounting for about 67%
of the total energy consumption in the country.
• Coal is a combustible black or brownish-black sedimentary rock.
• Each Thermal Power Project has been linked to a particular coal mine to
meet its coal requirements.
• LPGCL meet its coal requirement from M/s Coal
Indian Limited (CIL), preferably from their Northern Coal Fields or
Central Coal Fields (CCL).and also imports coal from Indonesia.

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Objectives of Coal
Handling Plant are
 Transportation
and Handling of Coal.
 Arrangement for
transferring of coal from
Coal- wagons to coal-
bunker or coal stock
yard.
 Supply of
Crushed coal to bunker.COAL STOCKYARD

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DESIGN CRITERIA
The design criteria for coal transportation from railway wagons, stacking,
reclaiming, and conveying is based on the following functional
requirements:
a) Coal handling system shall be designed for 3 x 660 MW units.
b) The plant load factor shall be considered as 85%.
c) The maximum lump size of the coal expected to be received at power
plant shall be about (-) 300mm.Hence, single stage crushing of coal to (-
) 25mm is considered.
d) Coal shall be received at plant site by Box N or at times by BOBR
railway wagons.
e) Each rake consists of 59 wagons of 67 tonnes capacity each, i.e. the
capacity of one rake is about 3953.
f) CSH shall be designed based on 16 hrs. Of operations per day.
Paddle Feeder is used to feed coal
to conveyor belt from track hopper.
CONVEYOR BELT

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After separation of magnetic particles from coal, it is carried to the
Crusher House through conveyor belts and after that it is either
stored at Stack Yard to be carried to coal bunker for burning.
BOILER

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Boiler is device for generating steam for power processing or heating
purposes. Boiler is designed to transmit heat from an external combustion
source contained within the boiler itself.
Boilers may be classified on the basis of any of the following
characteristics:
1. USE: The characteristics of the boiler vary according to the nature of
service performed. Customarily Boilers are called either stationary or
mobile.
2. Pressure: To provide safety control over construction features, all
boilers must be constructed in accordance with the Boiler Codes which
differentiates boilers as per their characteristics.
3. Materials: Selection of construction materials is controlled by boiler code
material specifications.
4. Size: Rating core for boilers standardize the size and ratings of boilers
based on heating surfaces. The same is verified by performance tests.
5. Tube Contents: In addition shell type of boiler, there are 2 general steel
boiler classifications, the fire tube and water tube boilers.
6. Firing: The boiler may be a fired or unfired pressure vessel.
7. Heat Source: The heat may be derived from
a). The combustion of fuel
b). The hot gases of other chemical reactions
c). The utilization of nuclear energy
8. Fuel: Boilers are often designated with respect to the fuel burned.
9. Fluid: The general concept of a boiler is that of a vessel that is to
generate a steam.
10. Circulation: The majority operate with natural circulation. Some utilize
positive circulation in which the operative fluid may be forced ‘once through’
or controlled with partial circulation.

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11. Furnace position: The boiler is an external combustion device in that
the combustion takes place outside the region of boiling water. The relative
location of the furnace to the boiler is indicated by the description of the
furnace as being internally or externally fired. The furnace is internally fired
if the furnace region is completely surrounded by water cooled surfaces.
The furnace is externally fired if the furnace is auxiliary to the boiler.
Boiler accessories:-
Boiler furnace: A boiler furnace is that space under or adjacent to a
boiler in which fuel is burned and from which the combustion products pass
into the boiler proper. It provides a chamber in which the combustion
reaction can be isolated and confined so that the reaction can be isolated
and confined so that the reaction remains a controlled force. It provides
support or enclosure for the firing equipment.
Economizer: The purpose of the economizer is to preheat the boiler feed
water before it is introduced into the steel drum by recovering the heat from
the fuel gases leaving the boiler. The economizer in the boiler rear gas
passes below the rear horizontal super heater.

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Steam Turbine Generator
1.The Steam turbine generator (STG) is rated for about 660 MW maximum
continuous output at generator terminals, with throttle steam condition of
250 kg/cm2 at 565°C/593°C reheat, 0.1 kg/cm2 (abs) condenser back
pressure with 0% make up.The STG output at valve wide-open (VWO)
condition is about 693 MW which is 5% above the maximum continuous
rating of 660 MW to enable increased output required during low frequency
operation and drop in efficiencies over years of n Operation.
2. The steam turbine is a multi-cylinder, reheat extraction and condensing
turbine.
3. The turbine generator is complete with all accessories such as protection
system, lube and control oil system, seal oil system, jacking oil system;
seal steam system, turbine drain system, electro-hydraulic control system,
automatic turbine run
Up system, on-line automatic turbine test system and turbine supervisory
instrumentation. A continuous bypass (20% capacity) method of lube oil
purification is adopted for purification of lubricating oil.
4. The turbine generator have all necessary indicating and control devices
to permit the unit to be placed on turning gear, rolled, accelerated and
synchronized automatically from the control room. Other accessories of the

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turbine generator include an external oil purification unit with transfer
pumps and oil storage tank of adequate capacity
PLANT CYCLE
1. The condensing plant comprise two condensers, one each for the two LP
turbines. The source of cooling water for condenser is river water. The
condenser is having Stainless steel tubes. The condenser is designed for a
temperature rise between 9 to100 C in the cooling water circuit. The
condenser hot well is designed for storage capacity between normal level
to low level at about 3 minutes of turbine VWO flow with 1 % makeup and
at design cooling water temperature. An online tube cleaning system is
provided across the condenser in order to keep the condenser tubes in
clean condition. Vacuum pumps of 2x100% capacity is provided for each
Steam Turbine Generator (STG) to
Create vacuum in the condenser during start-up and to remove the non-
condensable gases liberated during normal operation.
2. The regenerative cycle consist of four low pressure heaters, a variable
pressure deaerator, three high pressure heaters and one gland steam
condenser.
3. Under normal operating conditions, drains from the high pressure heater
are cascaded to the next lower pressure heater and finally to the deaerator.

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Drains from the low-pressure heaters are cascaded successively to the
next lower pressure heater and finally to the condenser hot well or pumped
forward to the condensate line. Heaters are provided with drain level
controllers to maintain the drain level automatically throughout the range of
operation of the heaters. The system consists of split-range control valves
to take the drain to a lower pressure heater or to the condenser through a
flash box under exigent conditions.
BYPASS SYSTEM
1. The STG unit is provided with a suitable HP-LP bypass system up to
60% SGMCR capacity.
a) To prevent a steam-generator trip in the event of a full export load
throw-off and to maintain the unit in operation
b) To prevent a steam-generator trip following a turbine trip and enable
quick restart of the turbine generator set
c) To minimize warm restart duration of the unit after a trip
d) To conserve condensate during start up
e) To facilitate quick load changes in both directions without affecting the
steam generator operation during start-ups

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WATER SYSTEMS
Water is used for condenser cooling, cooling of SG and TG auxiliaries and
various other requirements like SG makeup, service and potable water.The
water systems consist of various sub-systems listed below and discussed
in the subsequent paragraphs of this chapter.
a) Raw water system
b) Pre-treatment system
c) Condenser cooling water system
d) Cooling water (CW) make up system
e) Auxiliary cooling water (ACW) system
f) Water treatment (WT) system
g) Service and potable water system
g) Fire protection system
h) Effluent disposal system
i) Chemical laboratory equipment
1. RAW WATER SYSTEM
X The raw water requirement for 3x660
MW Unit is approx. 5556 m3/hr (133344
m3/day). Rajghat Dam is the main source
of raw water for the plant. The take-off
point is approximately 50 kms away from
the power plant. Raw water is pumped to a
raw water reservoir in the plant site by
means of 3 nos (2W+1S) of raw water
intake pumps of capacity 3100 m3/hr. Raw
water reservoir capacity is 1608000 m3
(12 days storage) sized to meet requirement of water for the 3x660 MW
units and takes care of any eventualities due to breakdown of intake pumps
or problems in the raw water supply
network to the plant.
RAW WATER RESERVOIR

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2. PRE TREATMENT SYSTEM
As raw water is expected to have high turbidity / suspended solids during
monsoon and the quality of inlet water required for the various systems in
the plant is clarified water, it is proposed to pre treat the water before being
used for plant services. The pre-treatment plant would consist of 2x50%
capacity of Lamella / Tubular type Main clarifier each of capacity 2800
m3/hr and 1x100% of HRSCC type DM plant clarifier of capacity 155 m3/hr.
Main clarifier cater to the requirements of CW make up, fire
protection system and plant service water requirements while DM plant
clarifier cater to the requirements of WT plant. The DM plant clarifier will
take care of any colloidal silica or organic presence in the raw water.
3. CLARIFIED
WATER PUMP
HOUSE
Clarified water from the
main clarifiers is stored
in a clarified water
storage tank (RCC) of
effective capacity
10000 m3 with two
compartments which
includes reserve
storage of 2800 m3 for
fire water. Clarified water from the DM clarifier is stored in a separate DM
clarified water storage tank (RCC) of effective capacity 600 m3.
Service water pumps
and Fire water pumps
is located in the main clarified water pump house and take suction from the
common sump of main clarified water storage tank. Water treatment (WT)
WTP

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plant supply pumps are located in the DM clarified water pump house and
take suction from the DM clarified water storage tank
4. CONDENSER COOLING WATER (CW) SYSTEM
A closed circuit recirculation type of cooling system with cooling tower is
for CW system. The system will consist of one natural draft cooling tower
(NDCT) for each unit, CW pumps, CW conduits (with valves, expansion
joints and instruments as required) and CW treatment system.
5. Cooling Towers
COOLING TOWER
It has installed three (3) natural draught cooling towers, one for each unit,
of each capacity 79000 m3/hr. The cooling water is being collected in a
RCC basin. The cooling towers are designed for a cooling range of 100C
and an approach of 4.50C. The design wet bulb temperature is about
27.0C. The design hot and cold water temperatures of the cooling tower
are 41.50C and 31.50C respectively. The towers are of RCC construction
with PVC film type fill.

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6. AUXILIARY
COOLING WATER
(ACW) SYSTEM
The ACW system is
meeting up the cooling
water requirements of all
the auxiliary equipment of the TG and SG units such as turbine lube oil
coolers, seal oil coolers, generator air coolers, ID/FD/PA fan bearing oil
coolers, BFP auxiliaries
such as lube oil coolers,
working oil coolers, drive motors, etc., condensate pump
Bearings, sample coolers and Instrument / service air / compressors.
The total estimated passivated DM water requirement for the above
auxiliaries for one unit of 660 MW plant is about 4000 m3/hr.
A closed loop system using passivated DM water is proposed for the
DMCW system. DM water is circulated using two (2) x 50% plate type ACW
heat exchangers by three (3) Nos. (2 working + 1 standby) Demineralized
cooling water (DMCW) pumps, each of 2200 m3/hr capacity for each unit.
The hot water from the auxiliaries is cooled in the plate heat 76 exchangers
by the circulating water from the CW pump sump and pumped by ACW
pumps. Four (4) ACW pumps (3 working + 1 standby) each of 5400 m3/hr
capacity, Will be provided to meet the ACW requirement of the plant and
these pumps will be vertical wet pit type and located in the CW pump
House.
7. WATER TREATMENT (WT) PLANT
The water treatment plant broadly consists of Pre-Treatment plant,
Filtration, Ultra Filtration (UF), Reverse Osmosis (RO) and Demineralized
(DM) plant.
The pre-treatment for WT plant consists of:
REVERSE OSMOSIS

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a) Chlorination system to destroy
organic matter and algae
b) Alum dosing system for the
purpose of coagulation.
The filtration plant consists of 3x50%
capacity pressure sand filters, each
of capacity 70 m3/h, to remove
turbidity and suspended solids. The
sand filters are of mild Steel
construction and filter media would
be graded sand supported on graded
gravel.
Two (2) x 100% capacity filter air
blowers are used for loosening filter
air bed before filter back washing.
Backwashing of filters is done by
means of gravity flow from a filtered
water storage tank.
8. FIRE PROTECTION SYSTEM
The system is designed to conform to the rules and regulations of the Tariff
Advisory Committee (TAC) of the insurance association of India.
A common hydrant and spray system consisting of four (4) nos pumps
(two motor-driven and two diesel engine-driven) of horizontal centrifugal
type, each of capacity 410 m3/hr are provided. Two jockey pumps (both
motor-driven) of horizontal, centrifugal type, with 50 m3 /hr capacity is
being provided to keep the system pressurized. All the above pumps are
located adjacent to the permeate storage tank which have a dead storage
of 2800 m3 of water for the fire protection systems in line with the
regulations of the TAC.
Portable extinguishers are provided in all the buildings of plant premises.
Portable trolley mounted CO2 extinguisher of capacity 22.5 kg are provided
for control room.
DUAL MEDIA FILTER

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9. EFFLUENT DISPOSAL SYSTEM
Effluent treatment system will aim at maximum reuse of the effluent generated from the
plant. The effluents are being collected and treated/recycled generally as per the
following:
a) CW blow down is used for ash handling system.
b) Side stream filtration plant back wash water and sludge water from clarifier also used
for ash handling system.
c) The waste effluents from DM plant, UF reject, CPU regeneration waste and filter
backwash are all collected in neutralizing pit and neutralized before pumping it
to the guard pond. RO reject are collected in the guard pond.
d) The oil water separator collect water from the areas where there are
possibilities of contamination by oil (transformer yard and fuel oil storage
area) and the drains from such areas are connected to an oil separator.
From the oil separator the clear waste water will be led to guard pond,
while the oily waste sludge will be collected separately and disposed off.
10. CHEMICAL LABORATORY EQUIPMENT
Suitable chemical laboratory equipment’s are being provided to enable
testing of fuel, water, flue gas, coal etc., as required for normal operation of
the power plant. This lab would be located on roof of the MCC room of WT
Plant.
ELECTRICAL SYSTEMS
Three Units of 660 MW were planned to be installed at the proposed site.
Evacuation of power from the units will be done at 765 kV level. A 765 kV
switchyard is been constructed in project site to evacuate the power from
the 3x660 MW Units through two circuits; one to 765KV UPPTCL’s grid
substation at Agra and other at Bhognipur as per preliminary power
evacuation study done by UPPCL.

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GENERATOR
1).The generator are rated to deliver 776.5 MVA (660 MW), at 21 kV, 50
Hz, 0.85-power factor, at 3000 rpm. The generators and their excitation
system are capable of stable operation under turbine inlet “valve wide open
(VWO)” condition without exceeding the temperature rise limits as per IEC-
60034. The generator winding star connected and will deliver rated MVA
output under +5% variation in voltage and -5 to +3% variations in
Frequency.
2). All generator components, rotor winding, stator core, end region flux
shield structures and lead box, except the stator winding, are hydrogen
cooled. The stator coils, parallel rings, main leads and terminal bushings
are cooled directly with water. Hydrogen coolers would be built into the
stator frame of the generators and would be sized to ensure at least 75%
of the rated output when one hydrogen cooler is taken out for maintenance.
3). The generator are provided with either brush-less or static excitation
system. Suitable fast acting non-dead band type continuous acting digital
type automatic voltage regulator are provided. The AVR will have the
required redundancy feature built in to ensure reliable operation.
GENERATOR CIRCUIT BREAKER
1). The generator circuit breaker will be provided in the run of the generator
main connection to the generator transformer to connect or disconnect the
generator during the start-up or shut down period of the plant or on
generator fault conditions.
One generator circuit breaker will be provided for each turbine generator
complete with all accessories and a local control panel.
The rated continuous current and rated voltage will be coordinated with the
Insulated Phase Bus duct (IPBD) rating.

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The main current carrying parts will be designed to withstand without
damage for a period of one second, the effects of a short circuit due to a
fault at either the generator transformer LV side or the generator side.
2).The generator circuit breaker with SF6 insulated poles (single pole
construction) will be built on a common base frame with ganged operating
mechanism and local control panel for test and maintenance operation,
assembled to form a three phase unit
GENERATOR TRANSFORMERS (GT)
GENERATOR TRANSFORMER
1).The GT will be 3 Nos. 275 MVA, 2 winding, single-phase banks, ONAN
/ONAF / OFAF cooled transformers and provided with off-loads tap
changer having taps in steps of 1.25%.
The HV side neutral will be solidly earthed.

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Lightning arrestors are provided near the generator transformer.
The HV terminals of the transformers will be connected to the associated
bays in 765 kV switchyard by overhead lines.
2).The rating and details of the generator transformer are as in Table–
below:

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EVACUATION OF POWER
1).Based on preliminary input from UPPTCL, power evacuation is proposed
to be done at 765 kV level. Hence one 765 kV switchyard will be installed in
the plant. The startup power would be supplied to the unit from 765 kV
switchyard by back charging the generator transformer.
2).The enclosed key one line diagram shows the arrangement of circuits in
the 765 kV switchyard. The 765 kV switchyard will have the following bays:
a) Three Generator Transformer Bays
b) Two line bays considering one line is required for evacuating total power
plus one redundant line. Number of lines and line details will be firmed
up after Power system study report is received from UPPTCL.
c) Line Reactor bays (for reactive power compensation) will be
Considered based on Load flow study by UPPTCL.
765KV SWITCHYARD

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1).One and half breaker-switching scheme is for 765 kV switchyard
considering its high reliability, flexibility of operation and maintenance and
keeping in view the general practice followed for 765 kV System.
2). SF6 circuit breakers are there because of its proven performance and
world wide experience and availability.
3). The Conventional (Air Insulated switchyard) scheme for 765 KV
switchyard. GIS (Gas Insulated Switchyard) has advantages such as
reduction in space, less maintenance cost and fewer inventory spares cost.
But, based on the initial review, the cost of equipment for such scheme and
very limited world wide experience, for GIS at 765KV level, so GIS is not
Considered for this project. Minimum creep age distance of 25 mm/kV is
selected.
SWITCHYARD COMMUNICATION AND
PROTECTION PHILOSOPHY:
1).To ensures reliable operation of the various feeders/bays such as
Generator Transformer bays, line bays etc. state of the art numerical
protection are provided with required redundancy.
In order to communicate between substations both at power plant and
remote grid substation either conventional PLCC or optical fiber ground
wire (OPGW) provided in line with the practice being followed at the remote
grid substation based on input from UPPTCL.
2).For each of the outgoing lines in 765 kV switchyards, precision energy
metering is been provided. The metering panel is located near the CVTs
(as per recommendation from UPPTCL) such that the length of the
metering cable is kept to a minimum to reduce errors in energy recording.
Space is provided adjacent to this metering panel to install check metering
for their verification. The metering panel would have active and reactive

35
energy and active, reactive/apparent power meters with 0.2S accuracy
class.
The technical parameters of 765 kV switchyards are indicated in Table –
below
765KV switch yard

36

37

38
TRANSFORMERS
The auxiliary loads are segregated as unit loads and common station
loads. 2 x 50% rating Unit Transformers (UTs) per Unit cater to unit load
and 2 x100% rating station transformer (ST) cater to station loads of entire
plant under normal operating conditions. The start-up power for the
auxiliaries is been supplied through generator transformer, station
transformer and unit transformers.
STATION TRANSFORMERS (ST)
Two (2) Station transformers with three winding of rating 63/31.5/31.5
MVA, 21/11.5/11.5 kV each.
The Station Transformers are ONAN/ONAF cooled, 3 phase, with on load
tap changer of ±10 % in steps of 1.25%. For sizing of ST-1 & ST-2, station
load of 3 x 660 MW.
ST sizing also considers half the Unit load minus BFP load (during outage
of one of the UTs) while feeding half the station load.
The ratings and details of the station transformers are as given in Table
below

39
STATION TRANSFORMER(ST)
UNIT TRANSFORMERS (UT)
UNIT TRANSFORMER

40
Two (2) nos. of two winding unit transformers are provided for each unit.
These are of 45 MVA rating, 20/11.5 kV, 3 phase, 50 Hz, with on load tap
changer of ±10 % in steps of 1.25% on the HV side.
The transformers had been ONAN/ONAF cooled with a vector group of
Dyn11. The MV side is medium resistance earthed.
The details of UT are indicated in Table below
UNIT TRANSFORMER
The unit transformers supply power to the 11kV unit switchgear.
As far as possible, the unit loads distributed equally on each 11kV unit
switch gear so that in case of outage of any one bus, it will still be possible
to operate the unit at partial load in worst situation.

41
UNIT AUXILIARY TRANSFORMERS (UAT)
AUXILIARY TRANSFORMER
Two (2) nos. unit auxiliary transformers are provided for each unit to feed
6.6kV unit auxiliary motor loads. These are 11/6.9 kV, 3 phase, 50 Hz, with
+5% off-circuit taps in steps of 2.5% on the HV side. The transformers are
ONAN cooled with a vector group of Dyn11. The 6.6kV system is medium
resistance earthed. 11kV feeders from station switchgear are provided for
Coal Handling system, Ash Handling System and other station loads.
AUXILIARY / SERVICE TRANSFORMERS
These transformers are rated at 2500 / 2000 / 1600 / 1000 kVA,
11kV/433V with a vector group of Dyn11 as per actual requirement. Supply
power to the 415 V auxiliaries of the unit and station loads. The neutral of
these Transformers are solidly earthed. The transformers are provided with
+ 5% off-circuit taps in steps of 2.5% on the HV side. The service
transformers may be dry type or oil filled.

42
SWITCHGEAR
Switchgear is one which makes or breaks an electric circuit. The
equipment’s which normally fall in this category are:-
Isolators
Switching Isolators
Circuit Breakers
Load Break Switches
Earth Switches
11 kV SWITCHGEAR
The 11kV switchgear comprise draw-out type Vacuum circuit breakers
housed in indoor, metal-enclosed cubicles and cater to all 11kV motors,
11kV/415V and 11/6.9KV transformers.
The switchgear is been equipped with control, protection, interlock and
metering communication features as required. Technical parameters of
11kV switchgear are given in Table-below Ties from station to station and
from station to unit switchgear are provided.
6.6 KV SWITCHGEAR
The 6.6 kV switchgear comprise draw-out type Vacuum circuit breakers
housed in indoor, metal-enclosed cubicles and cater to 6.6 kV motors. The
switchgear is been equipped with control, protection, interlock and metering
features as required. Technical parameters of 6.6 kV switchgear are given
in Table-below.

43

44
DISTRIBUTED CONTROL SYSTEMS
Introduction
Generally, the concept of automatic control includes accomplishing two
major operations; the transmission of signals (information flow) back and
forth and the calculation of control actions (decision making). Carrying out
these operations in real plant requires a set of hardware and
instrumentation that serve as the platform for these tasks. Distributed
control system (DCS) is the most modern control platform. It stands as the
infrastructure not only for all advanced control strategies but also for the
lowliest control system. The idea of control infrastructure is old. The next
section discusses how the control platform progressed through time to
follow the advancement in control algorithms and instrumentation
technologies.
Description of the DCS elements
The typical DCS system shown in Figure 1 can consists of one or more of
the following elements:
 Local Control Unit (LCU). This is denoted as local computer in Figure
1. This unit can handle 8 to 16 individual PID loops, with 16 to 32
analog input lines, 8 to 16 analog output signals and some a limited
number of digital inputs and outputs.
 Data Acquisition Unit. This unit may contain 2 to 16 times as many
analog input/output channels as the LCU. Digital (discrete) and
analog I/O can be handled. Typically, no control functions are
available.
 Batch Sequencing Unit. Typically, this unit contains a number of
external events, timing counters, arbitrary function generators, and
internal logic.
 Local Display. This device usually provides analog display stations,
analog trend recorder, and sometime video display for readout.
 Bulk Memory Unit. This unit is used to store and recall process data.
Usually mass storage disks or magnetic tape are used.

45
Figure 1 The elements of DCS network
 General Purpose Computer. This unit is programmed by a customer
or third party to perform sophisticated functions such as optimization,
advance control, expert system, etc.
 Central Operator Display. This unit typically will contain one or more
consoles for operator communication with the system, and multiple video
color graphics display units
 Data Highway. A serial digital data transmission link connecting all
other components in the system may consist of coaxial cable. Most
commercial DCS allow for redundant data highway to reduce the risk of
data loss.
 Local area Network (LAN). Many manufacturers supply a port device
to allow connection to remote devices through a standard local area
network.

46
Network architecture
Metso DNA has a decentralized structure and allows for later extensions
without disturbing existing system parts. Different sub-processes are
divided into different controllers. If one controller stops or fails, this will not
affect other process parts.
Ring topology is recommended for the Metso DNA network structure, but
also star (switched Ethernet) topology is possible. All connections are
normally redundant. Process controllers, user interface computers, history
database and engineering servers are connected to the network without
additional gateways. The process network is based on 100 Mbit/s
communication, and in special cases even higher speeds may be attained.
The communication protocol is UDP/IP combined with a Metso DNA
specific application protocol.
Both network topologies provide robust and redundant network structure,
as well as rapid switching to backup connections. Network connections
between PCs and ACN controllers are redundant, so a backup path is
always available. Main and backup connections use different Ethernet

47
cards and switches. If the main connection fails, the hot backup connection
automatically takes over.
The name-based communication protocol ensures flexible, address-
independent interfaces between applications, within each controller and
between controllers. The advantage of name-based communication also
results in flexible and user-friendly application engineering. Communication
between the process control environment and the information management
environment is also based on the same name-based protocol, allowing a
seamless link between these areas and resulting in a high level of flexibility.
There is also no need to configure data transfers between controllers.
An additional security solution is network perimeter security with Metso
DNA Security Frontier, known as Automation DMZ. This is a way to setup
the firewall/router environment to effectively isolate the Metso DNA servers
that provide services to the office network users from the Metso DNA
network. It provides a solution for connecting Metso DNA to different
customer network infrastructures, and a way to allow office users to share
Metso DNA information services more securely

48
Network and peripheral hardware
Switches used in the Metso DNA
network are either industrial ACN
switches or commercial switches, such
as Cisco or HP. ACN switches provide a
redundant industrial solution with faster
switchover time. The routers and
firewalls are from commercial brands.
User Interaction activity
User interface
DNA Operate is the user interface of Metso DNA, used for operating and to
viewing all process events. Easy-to-use, obvious operations and clear
pictures ensure that the user has instantly accessible, accurate information
about the task in hand. Flexible alarm handling enables users to solve
problems and leads right to the roots of the problem. The versatile trending
feature fulfills even the most demanding requirements. Process control
user interface is a linking center for all process and field device information.
Integrated tools such as alarm analyzing tools, field device status and
F ACN SWITCH

49
diagnostics, as well as reports, ensure that all the information needed to act
immediately in all process situations is available to the user. It is available
for both controls room and offices.
From each user interface workstation, the entire process can be controlled
and supervised. DNA Operate can retrieve process pictures and alarm from
the other control room (other Metso DNA subsystem). Thus central control
room can be made easily without additional configuration of process
pictures.
DNA Operate has a built-in feature to show processdata in history mode in
a normal process picture. In history mode, the production data is retrieved
from the history database and it can step forward automatically. Thus user
can all replay processes later on. User can run the same process picture in
parallel in both real-time mode and in history mode. Thus the user can
compare the current process situation to the earlier one.
Field interfaces
Metso DNA provides solutions for all kind of process interfacing needs.
These solutions cover:
• centralized or distributed I/O solution with ACN I/O
• Standard buses like Foundation Fieldbus, PROFIBUS, AS-i interface,
OPC and Can Open
• Serial and Ethernet links to third-party systems.
ACN I/O
The ACN I/O is a modern I/O family used with ACN process controllers. An
ACN I/O is suitable for both centralized and distributed I/O solutions. An
ACN I/O is mounted on a DIN rail and thus is easy to install onto a cabinet
or wall.
An ACN I/O group consists of Power Supply Unit (IPSP), the Bus Controller
Unit (IBC), and I/O units. One ACN I/O Ethernet field bus can have up to 16
I/O groups connected. Up to 32 I/O units can be connected to one I/O
group. Power supplies, bus controllers and field buses can be single or
redundant.

50
I/O units are mounted
onto the I/O Mounting
Base (MB). There are
several I/O units
available. Analog units
provide high resolution:
16 bits for analog input
units, and 14 bits for
analog output units.
Analog inputs and analog
outputs are HART-
capable without requiring
additional multiplexers.
For all digital inputs, 1 ms
time stamping (SOE) is
available automatically
without additional
configuration. Units can
be coated to meet G3
environmental conditions.
There is an Ethernet connection to the ACN controller.
ACN cabinets and power supplies
ACN cabinets are compact industrial solutions
with high packing density. There are several
ready-made solutions available, as well as
custom-built cabinets for special use.
As a standard, every ACN controller or I/O
group is provided with a power supply unit.
Additionally, every cabinet (including each I/O
cabinet) is equipped with a stand-by power
unit, which can keep the whole cabinet working
for 30 min after the main power is shut off.
When even more operating time in blackout
situations is required, separate UPS/backup
batteries can be supplied. Also existing
LARGE CENTRALIZED CONTROLLER
CABINET

51
customer DC-standby units can be
utilized.
The standard power supply
arrangement for the system is based
on 230/120 VAC for control room
equipment and for controller and I/O-
cabinets. It is also possible to use
direct 28 VDC, in case there is a larger
DC-supply with batteries available on
site. Other power supply possibilities
are also available.
Control room equipment (user interface
nodes, printers, the information
management server, etc.) is normally
powered from a UPS.
FIELD CABINET WITH I/0 AND CONTROLLER

52
ELECTROSTATIC PRECIPATATOR
It is a device which captures the dust particles from the flue gas thereby reducing
the chimney emission. Precipitators function by electrostatically charging the dust
particles in the gas stream. The charged particles are then attracted to and
deposited on plates or other collection devices. When enough dust has
accumulated, the collectors are shaken to dislodge the dust, causing it to fall with
the force of gravity to hoppers below. The dust is then removed by a conveyor
system for disposal or recycling.
Electrostatic precipitation removes particles from the exhaust gas stream of Boiler
combustion process. Six activities typically take place:
Ionization - Charging of particles
Migration - Transporting the charged particles to the collecting surfaces

Collection - Precipitation of the charged particles onto the collecting surfaces
Charge Dissipation - Neutralizing the charged particles on the collecting
surfaces
Particle Dislodging - Removing the particles from the collecting surface to
the hopper

53
Particle Removal - Conveying the particles from the hopper to a disposal
point
MOTOR
A 3-φ induction motor, stator connected 2 or 3φ supply produces a rotating
magnetic field. Speed of rotation is proportional to the main frequency and
inversely proportional to the no. of pair of poles. Stator can have single
layer windings with each coil side occupying one stator slot. Many type of
stator windings are encountered. 2 most common types are:-
1. Single Layer winding – Each winding is distributed over a number
of stator slots.
2. Double Layer winding – Each stator slot contains sides of two
separate coils.
Definition: Motor form the single largest prime mover found in power
stations and are used for multipurpose.
Induction motor: There are various types and sizes of motors used in
the power stations. These are used for various purposes as prime movers.
Apart from the simple motor used in different areas, these HT motors used
in the various heavy duty equipment’s. These are FD, ID, PA fans, boiler
feed pumps, CW pumps, etc. These motors have certain special features
like cooling, auto starting, inter locks and control. These are generally
squirrel cage motors. The rotor never rotates at the synchronous speed. Off
load, the induction motor has poor efficiency and power factor. On load we
get an efficiency of 85% and 0.8 power factor.
Synchronous Motor: These are motors which always run at
synchronous speed and speed of rotation depends upon the pair of poles.
Synchronous motors do not start on their own they need an external
exciting system which gives it an initial rotation. Generally an induction
motor is used for this purpose. As the load increases, load angle increases
and power drawn from the supply increases. With an excessive load, the
rotor pulls out of synchronism. When operating at synchronous speed the
power factor can be changed by varying the degree of excitation.
The motors are generally started using DOL (Direct Online Starters)

54
ENVIRONMENTAL ASPECTS
TYPE OF POLLUTION
1. The various types of pollutions likely to be created by the proposed
power plant can be broadly
Classified into the following categories:
- Air pollution
- Water pollution
- Noise pollution
- Sewage pollution
AIR POLLUTION
2.1 Source of Air Pollution
The source of air pollution from the proposed plant is:
a) Dust particulates from fly ash in flue gas
b) Sulphur dioxide in flue gas
c) Nitrogen oxides in flue gas
d) Coal dust particles during storage/handling of Coal
e) Dust in the ash disposal area
2.2 Regulations for Limiting Air Pollution
2.2.1 Indian Standards:
(a) As per notification by Ministry of Environment and Forests dated
19th May 1993, the emission limits for :
(i) Suspended particulate matter (SPM) emission (dust particulate
from fly ash) : < 100 mg/Nm3
(ii) Sulphur di-oxide *: < 100 ppm
(iii) Nitrogen oxides : < 50 ppm

55
(iv) Coal dust particles during storage/handling of coal : Not
specified
(v) Dust in the ash disposal area : Not specified
Note: * Sulphur di-oxide emission would be controlled by provision of stack
of suitable height as per the formula given below.
3.0 WATER POLLUTION
3.1 Source of Water Pollution
The water pollutants are:
• Cooling tower blow down water
• Water treatment plant effluent
• Effluent from ash handling system.
• Effluent from coal pile run off area
• Air pre-heater wash water effluent
• Plant wash down water
• Floor and equipment drainage effluent
• Rain water drainage
• Sewage from various buildings in the plant

56

57
4.0 NOISE POLLUTION
4.1 Source of Noise Pollution
The source of noise in a power plant is:
- Steam turbine generator
- Other rotating equipment
- Combustion induced noises
- Flow induced noises
- Steam safety valves

58
CONCLUSION
Industrial training being an integral part of engineering
curriculum provides not only easier understanding but also
helps acquaint an individual with technologies. It exposes an
individual to visualize practical aspect of all processes which
differ considerably from theoretical models. During my
training, I gained a lot of practical knowledge which otherwise
could have been exclusive to me. The practical exposure
required here will pay rich dividends to me when I will set my
foot as an Engineer.
The training at LPGCL was altogether an exotic experience,
since work, culture and mutual cooperation was excellent here.
Moreover fruitful result of adherence to quality control
awareness of safety and employees were fare which is much
evident here.

59
Reference

WEBSITES VISITED:
 www.google.com
 www.lpgcl.com
 LPGCL/ LSTPP (Intranet)
 www.wikipedia.com

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