The document provides information about a thermal power simulator training that took place at Essar Power Gujarat Ltd in Jamnagar, India. It acknowledges the organizers and mentors of the training. It then provides details about the Salaya power plant including its location, phases, capacity and key components. It describes the specifics of the 2x600 MW simulator used for training including its advantages. The document outlines the daily plan for the training and provides an overview of the key systems and circuits within the thermal power plant such as the boiler, turbine, generators, transformers and main circuits.

1. Thermal Power Simulator Training
Essar Power Gujarat Ltd,
Jamnagar
Vedant Pravin Sumaria (R630212061)
Ishaan (R6302120
Kanishk Anand Sharma (R630212067)
Kulkarni Singh (R6302120
Md. Amjad Hussain (R630212030)

2. Acknowledgement
At the outset, We are grateful to Mr. Indranil Ghosh, for giving us the
opportunity to do our Industrial Training in ESSAR POWER GUJARAT
LIMITED. We would like to thank our mentors Mrs. Vinti Gupta(Deputy
Manager-L&D,EPGL), Mrs. Bhakti Peshkar(Deputy Manager-L&D,EPGL)
and Mr. Vijay Anand( Manager-L&D, EPGL) for their extensive help and
guidance throughout the training. We would also like to thank Mr. N.B Soni
(Head Of Department, Electrical, Power and Energy Department, UPES)who
imparted us with his valuable guidance and suggestions during the entire
training session.

3. About Plant
• Salaya power project is located in the Jamnagar district of Gujarat, India.
• It is a 3,120MW coal-fuelled thermal power plant proposed to be built over three
phases (phase I - 1,200 MW, phase II - 1,320MW, phase III - 600 MW).
• The project is being developed by Essar Power, a subsidiary of Essar Energy.
• The 1,200MW phase I of the project, Salaya I, was completed in June 2012 with an
investment of $1.1bn.
• Salaya I includes two 600MW generating units.
• Phase II and III of the project are currently under construction.

4. Salaya Power Project Details
• The Salaya power project site is spread over an area of 330ha.
• Coal for the plant is transported through a 17km-long conveyer from Essar's own
jetty established for importing coal.
• Salaya I will use coal imported from the Aries coal mine in Indonesia, which was
acquired by Essar in April 2010.
• The proposed phase II of the project, Salaya II, will include two 660MW units.
• It will also use imported coal as fuel but the source of coal for Salaya II has not
been decided yet.
• Phase III of the project, Salaya III, will be a petroleum coke and thermal coal-based
power plant.
• It will use circulating fluidized-bed combustion (CFBC) technology and consist of
four 150MW generating units.
• The plant will use petroleum coke purchased from Essar's Vadinar refinery located
near the plant.

5. Salaya I Plant Makeup
• The two generating units of Salaya I plant feature a pulverized boiler,
cooling tower and transformer yard.
• Coal is milled and fed with air into the burners. Heated coal converts the
water passing through the boiler pipes into superheated steam. The
generated steam spins the turbine generator to create electricity, with the
low-pressure steam then sent through a condenser and converted back to
liquid water for reuse in the boiler.
• The plant uses seawater for cooling purposes. Flue gases generating by the
plant are sent through an electrostatic precipitator (ESP) that captures fly-
ash particles.
• Other facilities at the plant include a coal stockyard, coal mills, a DM plant,
a desalination plant, a 400kV switchyard, a main control room and an
administration building.

6. About The 2x600 Mw Simulator
• Simulator provides an interface to execute power plant operation on a simulated
machine. The interface is mostly graphical, which allows the users to control or
limit the execution of a command. This gives practical hands on experience to the
user. 2x600 MW Operator Training Simulator at Essar Power Learning Centre
(EPLC) is the replica of the control units running at 600MW thermal power plant.
• Thermal power plant simulator is an effective tool for operational training used for
safe, efficient and economical thermal power plant operation. The associates, who
are meant for operating 600 MW thermal power plants, can get themselves trained
in the simulator before operating an actual plant.
• The 2x600 MW Simulators installed are the replication of the Unit 1 & 2 of M/s
Essar Power Gujarat Limited, Salaya. These units were commissioned in the year
2011 and 2012 respectively and both of the units have been operating up to their
fullest capacity. These simulators, developed by ABB India, have been used to train
operating personnel of the thermal power stations located at Salaya as well as
Mahan.

7. Advantages of Simulator Training
• Highly Efficient Learning
• No Fuel Cost On Account Of Training
• No Wastage Of Equipment Time
• Risk Free Training
• High Retention Level Of Plant
• Improved Sharpness Of Operators
• Test Bed

8. Capacity 2 x 600 MW
Fuel Source Imported Coal
Fuel Requirement 4 million tone/hr.
Mode of Transportation Belt Conveyers
DM Water Source DM Plant
Land Requirement 330 Acres
Main Contractor Harbin Power, China
Power Evacuation GETCO (400kV)
Boiler 1 & 2 Harbin Boiler Group
Turbine Harbin Boiler Group
Generator Harbin Boiler Group
DM Plant Thermax
Electricity Balance of Plants AREVA
HP Heaters 3
LP Heaters 4
CEP (2 Working + 1 Stand By) 3
Super heaters 4
BFP ( 2 TDBFP + 1 MDBFP) 3
Chimney 1( 275m high)
Reheaters 2
Downcomers 6
Primary Separators 112
Secondary Separators 162
Dryers 148
Safety Valves for Drum 6
Overview of EPGL

9. Reheater Outlet 2
Reheater Inlet 7
HFO Pumps( 2W +1S) 3
LDO Pumps(1W +1S) 2
HP-IP Turbine 1
LP Turbine 2
Ball Mills(5W + 1S) 6
Periodic Blowdown Tank 2
Continuous Blowdown Tank 1
Dewatering Tank 3
Settling Tank(Ash) 1
Primary Air Fan 2
Forced Draught Fan 2
Induced Draught Fan 2
ESP Hoppers 20
CW Pump 2
Cooling Tower 24
Condensers 2
DM Water Storage Tank (2000m3) 2
DM Feed Tank (1250m3) 2
HDO Tank (1000m3) 1
LDO Tank (500m3) 1
Compressors in Compressor house 3
Surge Silos 6
Ash Silos 2
Settling Tank(DM Plant) 2

10. Types of Superheaters
• Low Temperature Superheater
• Divisional Superheater
• Pendant Superheater
• Final Superheater
Types of Reheaters
• Low Temperature Reheater
• Platen Reheater
• Final Reheater
Collection of Ash
Ash Collection (Tons) Field No.
2045 1st
365 2nd
66 3rd
18 4th
5 5th

11. Boiler
• Boiler is steam generator. It convert water into high pressure and high temperature
steam
• In Essar power plant Salaya Subcritical type of boiler is used.
• A subcritical steam generator is a type of boiler that operates at subcritical pressure
• Main steam flow:- 2060 TPH
• Main steam outlet pres.:- 17.50 MPa
• Main steam outlet temp.:- 541°C
• Feed water pres.:- 19.492 MPa
• Feed water temp. :- 281.7 °C
• Reheat steam flow :- 1725.9 TPH

12. Boiler Side View

13. Turbine
• A steam turbine is a device that extracts thermal energy from pressurized
steam and uses it to do mechanical work on a rotating output shaft
• And main output shaft is coupled with electrical generator
• Turbine divided into 3 Stage
I. HP (High Pressure Turbine)
II. IP (Intermit Pressure Turbine)
III. LP (Low Pressure Turbine)
• Rated Output :- 600 MW
• Rated Speed :- 3000 RPM
• Steam pressure :- 16.7 MPa
• Steam temperature :- 538 °C
• Direction of rotation :- Clockwise

14. Generator Specifications
Parameter Value
MW Rating 600MW
Rated Voltage 20KV
Rated Stator current 20377 A
Rated Speed 3000 RPM
Rated Frequency 50 Hz

15. Station Transformer
• ST is used supply station common load such as Coal handling, DM plant, etc.
• Transformer used in Salaya power plant is three winding transformer
• Specification
Parameter Value
Rated MVA 70 MVA
Voltage 20/11/33KV
Frequency 50Hz
Number Phase 3
Vector Group Dyn11yn11

16. Unit Auxiliary Transformer
• Unit Transformer supply separate unit load such as Boiler auxiliary, Cooling
tower and Turbine auxiliary etc.
• Specification
Parameter Value
Rated MVA 45MVA
Rated Voltage 20/11.5KV
No. Of Phase 3
Vector Group Dy11

17. Generator Transformer
• As an essential element of all nuclear, thermal or hydraulic power stations.
• GT are step-up transformer with delta connected LV side and star connected HV
side
• In Essar power Salaya OLTC is used and GT consist of three single phase
transformer unit.
 Specification
Parameter Value
Rated MVA 250MVA
Rated Voltage at no load 21/420KV
Vector Group YNd1
Type Of cooling ONAN/ONAF/OFAF

18. Day Wise Plan
• Day 1: Thermal Power Plant Theory, Main Circuits and Coal Handling Plant
• Day 2: Simulator Training- Back Charging, Lube Oil Systems, Cooling water cycle,
drum filling and other auxiliaries.
• Day 3: Simulator Training- Boiler and Turbine Start Up, Purging, Load raising,
Synchronizing; Site Visit- Scheme Tracing, Positions of different auxiliaries,
Switchyard, Control and Operation room.
• Day 4: Simulator Training: Practice with the roles of each operator changed; Expert
Session- Session on Material of Constructions from Senior Vice President of Essar;
Site Visit- Junction House 18, Metal Detector, Surge Silos, conveyer belts, settling
tank, Cation and anion exchanger, DM feed tank.
• Day 5: Simulator Training- Shutdown Process.
• Day 6: Simulator Training- Start up of Plant and load raising to 200 MW; , Trip
Conditions; Site Visit- Cooling Tower, forebay, Cooling water pumps, platen heat
exchanger; Test; Expert Session- Conversation with Chief Operating Officer of the
plant

19. Main Circuits
The main circuits in a plant include:
 Feed Water and Steam Flow Circuits
 Coal and Ash Circuit
 Air and Gas Circuit
 Cooling water Circuit

21. Feed Water and Steam Flow Circuits
Boiler feed water is the operating medium in the water-steam circuit of a thermal
power plant and consists of recycled condensate from the water-steam circuit and
conditioned makeup water. As it flows through the piping of the steam generator, it is
heated and converted into high-purity steam that drives the turbines, thus generating
electricity via the coupled generators. The very high temperatures in the steam
generator lead to corrosion and deposits that severely reduce the efficiency of the
power plant
Coal and Ash Circuit
This circuit deals mainly with feeding the boiler with coal for combustion
purposes and taking care of the ash that is generated during the combustion
process and includes equipment and paraphernalia that is used to handle the
transfer and storage of coal and ash.

22. Air and Gas Circuit
We know that air is one of the main components of the fire triangle and hence
necessary for combustion. Since lots of coal is burnt inside the boiler it needs a
sufficient quantity of air which is supplied using either forced draught or induced
draught fans. The exhaust gases from the combustion are in turn used to heat the
ingoing air through a heat exchanger before being let off in the atmosphere. The
equipment which handles all these processes fall under this circuit.
Cooling water Circuit
This part of the thermal power plant deals with handling of the cooling water
required in the system. Since the amount of water required to cool the
outgoing steam from the boiler is substantial, it is either taken from a nearby
water source such as a river, or it is done through evaporation if the quantity
of cooling water available is limited.

23. Coal Handling Plant
• Coal is brought through trucks from seashores. There is a 9 kms. Distance between plant and seashore.
• Screw Conveyers are under construction for this purpose.
• Stockyard is divided into 4 parts. It is common for both EPGL (Essar Power Gujarat Limited) and VPCL
(Vadinar Power Company Limited).
• 2 Stockyards are for EPGL
• 2 Stockyards are for VPCL
• 3 Yard Conveyers
• 18 Junction Houses
• 3 Stacker Reclaimer
Bunkers for each unit 6
Volume per Bunker 658 m3
Stacking Density of Coal 0.802 t/m3
Operating time of stored coal at BMCR 10.04 Hrs.
Boiler Coal Consumption 2668 t/hr.
Coal Amount 2630 tones
Efficient Volume Per Bunker 526 m3

24. Stacker and Reclaimer Description Rating
Rated Capacity(S) 2500 TPH
Rated Capacity(R) 1850 TPH
Design Capacity(S) 2750 TPH
Design Capacity(R) 2035 TPH
Travel Length 630 m
Stock Pile Height 10 m
Stock Pile Base 42m/64m
Rail Gauge 8 m
Boom Length 36 m
Angle of Repose 37o
Max. Sleeve Angle +_ 105o
Incoming Power 11 kV, 3 Phase, 50 Hz.
Power Feeding Mid-Point of travel

25. Junction House:-
• Hoppers
• Vibro-feeders
• Rod Gates
• Pulleys
• Motors
• Fluid Couplings
• Gear Boxes
Pulleys:-
• Bend Pulley
• Head Pulley
• Tail Pulley
• Take up Pulley
• Snub Pulley
• Drive Pulley
Conveyer Switches:-
• Pull Cord Switches
• Belt Sway Switches
• Zero Speed Switches
• Chute Jam Switches
Types of Idlers:-
• 35o Carrying Idlers
• 200 Transition Idlers
• 10o Transition Idlers
• 2 Metal Detectors and 1 Magnetic Separator
for each Conveyer Belt.
Travelling Tripper:-
• It is situated on the Bunker Conveyers
having capacity of 1000 TPH for both
conveyers.

26. Simulator Screens
Plant parameter monitoring as well as plant equipment operation can be, as
they are done in actual plant, through the following screens:-
 Steam Plant Overview
 Electrical charging of EHV Switch-yard and auxiliaries Power supply
 Boiler Water System
 Air and gas line-up
 Turbine and its auxiliaries
 Fuel oil System
 Boiler Light up

27. Opportunity of Learning
• Cold Startup procedures
• Warm Start-up
• Hot Start-up
• Steam Plant Overview
• Scheme Tracing of a Power Plant and various
equipments.
• Electrical Charging of EHV Switchyard and Aux
power supply.
• Boiler Water System
• Air and Gas path line-up
• Cooling Water path establishment
• Turbine and it's Auxiliaries
• Fuel Oil System
• Boiler Light-up
• Synchronization
• Load Raising
• Coal Mill Operation and Changeover
• Power Plant shut down
• Emergency/Special Operations

28. Power Generation Data
1st Unit
• Power Generation- 545 MW
• Coal – 218 TPH
• Coal Mills A, B, C, E, F are in Service
• Coal Bunker Level
 A- 66%
 B- 52%
 C- 66%
 D- 92%
 E- 70%
 F- 73%

29. 2nd Unit
• Power Generation- 545 MW
• Coal – 218 TPH
• Coal Mills A, B, C, E, F are in Service
• Coal Bunker Level
 A- 58%
 B- 81%
 C- 72%
 D- 63%
 E- 72%
 F- 55%
Hydrogen Pressure and Purity
3.87 kg/cm2 and 96.88%

30. Few Pictures of Essar Power, Jamnagar
Plant Layout Design

31. BTG Block
Consists of Switch Yard, TG building, Boiler Buildings
and Chimney

32. Boiler Side View

33. Boiler Pressure Parts

34. Boiler Drum and Riser Tubes

35. Furnace Levels

36. LP Heaters

37. Transformer Yard

38. SwitchYard

39. DM Plant