1.

PREFACE

A very important element in curriculum of an Engineering student is the Practical Training.

I under went practical training at SURATGARH THERMAL POWER STATION from
25-05-2015 to 24-06-2015. This is a part of total 30 days training program incorporated in
the curriculum of swami keshvanand institute of techonology,management and gramothan
for B.Tech. courses.
As I am a student of mechanical engineering, so the training at S.T.P.S. has been particularly
beneficial for me. I saw the various procedures, processes and equipment used in production
of electricity by thermal power which were studied in books and this has helped me in better
understanding of power generation and various thermal concepts.
S.T.P.S. is a very large plant and it is very difficult to acquire complete knowledge about it in
a short span. I have tried to get acquainted with overall plant functioning and main concepts
involved therein.
I have summarized all the things, which I saw & learned at S.T.P.S. in this training report.

2. ACKNOWLEDGEMENT
It is my privilege to express my deep sense of gratitude towards all those who helped me
to under take training in Suratgarh Super Thermal Power Staion.
I would like to express my sincere thank to prof. Alok mathur (reader) and Dr, N.K.
banthiya (Head Deptt. of me) for giving us permission to undergo this summer training.
Last but not the least, I would like to thank all the other STAFF MEMBER of Suratgarh
Super Thermal Power Staion whose timely help and support was needed for the
successful completion of the training.
And at last I want to thank my colleagues. Without their help, guidance and suggestions it
was not possible to produce this training report.

SAGAR CHUGH
12ESKME096

3. ABOUT PLANT

Rajasthan Rajya Vidyut Utpadan Nigam Lmd.(RVUN) established under companies Act1956 by Government of Rajasthan on 19.7.2000 is engaged primarily in the business of
GENERATION OF ELECTRICITY.
At present the total installed capacity of various Thermal and Hydel Power Stations
owned and run by RVUN is 2086.85.
The operation and maintenance of Rana Pratap Sagar(172 MW)
And jawahar Sagar (99MW) Hydel Power Stations (owned by RVUN being shared
project with MP State) is also carried out by RVUN.
With the commissioning of Unit #4 of 250MW at STPS it has become FIRST SUPER
THERMAL POWER STATION OF RAJASTAN.
W Unit #1 of STPS w as commissioned on coal firing on 4.10.1998 and commercial
operation of the unit was declared from 1.2.1999. The unit was dedicated to the Nation
by Honble Chief Minister of Rajasthan Shri Ashok Gehlot on 3.10.1999.
The foundation stone for Unit # 3 and 4STPS stage II was laid by Honble Chief
Minister of Rajasthan Shri Ashok Gehlot on 3.10.1999.
250MW Unit # 2 of STPS was commissioned on 28.3.2000 and was put on commercial
operation from 16.7.2000. It saved Rs.80 crores due to early start of generation. The Unit
was dedicated to the Nation by Honble leader of Opposition, Lok Sabha Smt. Sonia
Gandhi on 13.10.2000.
The foundation stone for 250MW Unit # 5 under STPS Stage-III was laid by Honble
Union Minister of Power Shri Suresh P.Prabhu on 12.2.2001.
250Mw Unit # 3 of STPS was commissioned on oil 29.10.2001 and was put on
commercial from 15.1.2002. The unit was dedicated to the Nation by Honble Dy. Leader
of Opposition, lok Sabha Shri Shivraj V.Patil on 17.3.2002.
250MW Unit #4 of STPS was commissioned on oil 25.3.2002
and has been put on
commercial operation from 31.7.2002. The unit was dedicated to the Nation by honble
Leader of Opposition, Rajya Sabha Dr. Manmohan Singh on10.8.2002.

4. AN INTRODUCTION
TO
SURATGARH SUPER THERMAL POWER STATION

Suratgarh Super Thermal Power Station is owned by Rajasthan Rajya Vidhyut Utpadan
Nigam Ltd. and is situated near village Raiyanwali about 25 KM from Suratgarh town, an
ideal location for setting up a thermal power station in the state having regards to the
availability of land, water, transmission network proximity to broad gauge railway and
being an important load centre for north west Rajasthan. The techno-economic clearance
for the prefect was issued by CEA in June 1991 the planning commission accorded
investment sanction for the project in Nov. 91 for a total estimated cost of Rs. 1253.31
crores on prices prevailing in Sept. 1990. The updated cost of the project is estimate at Rs.
2300 crores of including IDC.
It has generation capacity of 1250 MW and installed with five Units of 250 MW each. It
is a coal base thermal station. Water and coal required in a large amount. Coal is received
here from coal-fields of MP areas through railways and water is received from INDIRA
GANDHI CANAL. The supply of coal is from MP, Jarkhand by rail. About 18000 tonne
coal required per day for whole unit and each unit consumes 150 tonnes coal per day.
About 2x3 km2 area covered by plant and approximately 1800 employees works in a plant
including chief engineer to labour. The supply electricity to the northern Rajasthan,
ratangarh, Bikaner, ganganagar.

5. ELECTRICITY GENERATION

Indias 71% power amounting to 64151MW in a total of 89167MW comes from Thermal
Power Station. In general it burn fuels and use the resultant heat to raise steam which drive
the turbo generator.
STPS is a coal fired power station. The other raw materials are air and water. The coal,
brought to the station by trains ,travels from the coal handling plant (1) by conveyor belt to
the coal bunkers, from where it is fed to the pulversing mills (2) which grind it as fine as face
powder. The finely powdered coal mixed with pre-heated, air is then blown into the boiler (4)
by a fan called Primary Air Fan (3) where it burns, with additional amount of air called
secondary air supplied by a Forced draft Fan (3A). As the coal has been ground so finely the
resultant ash is also a fine powder. Some of it binds together to form lumps which fall into
the ash pots at the bottom of the furnace. The water quenched ash from the bottom of the
furnace is conveyed to pits (17) for subsequent disposal or sale. Most of ash, still in fine
particle form is carried out of the boiler to the Precipitators (13) as dust, where it is trapped
by electrodes charged with high voltage electricity. The dust is then conveyed by water to
disposal areas (14) or to bunkers for sale(15) while the cleaned fuel gases pass on through
I.D.Fan to be discharged up the Chimney (16).
Meanwhile the heat released from the coal has been absorbed by many kilometers of
tubing which line the boiler walls. Inside the tubes is the Boiler feed water which is
transformed by the heat into steam at high pressure and temperature. The steam, super heated
in further tubes passes to the turbine (6) where it is discharged through nozzles on the turbine
blades. Just as the energy of the wind turns the sails of the wind-mills, so the energy of
steam, striking the blades, makes the turbine rotate.

6. PLANT FAMILIARIZATION

(I) TURBINE :Introduction:

Steam turbine is a rotating machine which CONVERTS HEAT ENERGY OF STEAM TO
MECHANICAL ENERGY.
In India, steam turbines of different capacities, varying from 15 MW to 500 MW, are
employed in the field of thermal power generation. The design, materials, auxiliary systems
etc. vary widely from each other depending on the capacity and manufacturer of the sets.
Basic principles:
The Thermal Power Plants with steam turbine uses Rankine cycle. Rankine cycle is a vapour
power cycle having two basic characteristics:
1. the working fluid is a condensable vapour which is in liquid phase during part of the
cycle and
2. The cycle consists of a succession of steady flow processes, with each processes
carried out in a separate component specially designed for the purpose. Each
constitute an open system, and all the components are connected in series so that as
the fluid circulates through the power plant each fluid element passes through a cycle
of mechanical and thermodynamic stages.
The turbine is of tandem compound design with separate HP, IP and LP cylinder. The HP &
IP turbines are of single flow type while LP turbine is of double flow type; the turbine is
condensing type with single reheat. It is basically engineered on reaction principle with
throttle governing. The stages are arranged in HP, IP and LP turbines, driving alternating
current full capacity Turbo generators.

TURBINE COMPONENTS
Casing or Cylinders:
A casing is essentially a pressure vessel which must be capable of
withstanding the maximum working pressure and temperature that can be produced within it.
The working pressure aspects demand thicker and thicker casing and the temperature aspects
demand thinner and thinner casings.
1. H.P Turbine Casing: The principal parts of the HP turbine casing are and axially
split inner shell, enclosing the rotor and outer shell of a barrel-type construction. The
barrel type of cylinder construction ensures symmetry of the wall thickness around
the axis of rotation and hence the wall thickness itself is relatively less than that used
in other type of construction.
2. I.P. Turbine Casing: The IP turbine is split axially and is of single shell design. The
outer casing accommodates a double flow inner casing. The steam coming from the
reheater is passed into the inner casing via admission

branches which are symmetrically arranged in the top and bottom halves of the outer
casing.
3. L.P Turbine Casing: The LP turbine is of double flow type. The casing is of triple
shell, fabricated construction. The outer casing consists of the front and rear end
walls, two longitudinal girders and a top cover. The inner shell of the inner casing
acts as the guide blade carriers for the initial stages of the turbine. The guide blade
carriers of the LP stage groups are so designed that, together with the inner casing,
they form annular ducts which are used for extractions.

Fig.- Turbine Stages

TURBINE OIL SYSTEM

Purpose of Oil System
The turbine of system fulfils four functions. It:
1. Provides a supply of oil to the journal bearings to give an oil wedge at he shaft rotates.
2. Maintaining the temperature of the turbine bearings constant at the required level. The oil
does this by removing the heat, which is produced by, the shaft conduction, the surface
friction and the turbulence set up in the oil.
3. Provides a medium for hydraulically operating the governor gear and controlling the
steam admission valves.
Provides for hydrogen-cooled generators a sealing medium o prevent hydrogen leaking out
aling the shaft

(II) BOILER:Introduction :The boiler installed in S.T.P.S. are made by M/s BHEL . Each of the boilers are single
drum, tangential fired water tube naturally circulated over hanged, balanced draft, dry
bottom reheat type and is designed for pulverizing coal firing with a max. Continuous
steam output of 820 tons/hour at 150 kg/cm2 pressure and 540 degree cent. Temp. The
thermal efficiency of each boiler at MCR is 86.8 %. Four no. Of bowl mills have been
installed for each boiler. Oil burners are provided for initial start up and stabilization of
low load .Two E.S.P. (one for each boiler) is arranged to handle flue gases from the
respective boilers. The gases from E.S.P.are discharged through 180 meters high chimney.
I.D. fan and a motor is provided near the chimney to induce the flue gases. The boiler is
provided with a balanced draft consisting of two forced draft fans and two induced draft
fans. Flue gases are utilized to heat the secondary air for combustion in the tubular type
air heaters installed in the boilers. Since the boiler furnace is maintained at a negative
pressure, to avoid atmospheric air entering the furnace a hydraulic pressure is maintained
at the furnace bottom. The water filled in the stainless steel seal through the hydraulic seal
between the furnace ash hoppers and the water wall ring heater. Adequate clearance is
also provided for the downward expansion of the furnace. Ash is formed by the result of
burning of coal inside furnace. A small quantity of ash is collected in the bottom ash
hopper and considerable amount of ash is collected in the E.S.P. and magnetic separator
hopper. This collected ash is extract and disposed off in a slurry form in the ash disposal
arc.

Basic theory and auxiliaries :The boiler also termed, as steam generator is a container in which water can be fed and
by the application of heat evaporated continuously into steam. The heat source is obtained
by burning the fuel, which is coal here in our case .The walls contained in the boiler drum
flows through the down corner water walls and then through risers back to the drum. This
closed ckt. Movement of boiler water is termed as circulation. The heat energy applied in
the furnace is absorbed by the water walls and water in this ckt. gets heated up .This give
rise to the formation of steam bubble in the water walls and risers . The mixture of water
and steam will rises continuously and move to the steam drum due to its lightness. The
mixture of water and steam is continuously displaced by the colder water. In the drum
there by establishing a natural circulation. As the mixture of water and steam takes place
in the steam separators and the saturated steam is led into the upper heaters for further
heating and water particles fall back into the drum water. After the feed control station the
feed water enters into the economizer inlet header where the feed water is preheated
before entering the boiler drum. The economizer is located below the real horizontal super
heater in the boiler near gas pass. The economizer has a no. Of sections composed of
parallel tube ckt. The flow direction of feed water in the economizer is in counter flow
direction to the gas flow. The feed water coming out of the economizer of the outlet

header enters the boiler drum. The boiler drum is located at 44-m level. There are four
downcomers pipes
connecting the water side of the drum to the furnace lower water wall inlet headers. The
front and rear wall inlet header feed the front and rear furnace wall tubes. The furnace
sidewalls are fed by the two side walls inlet header. The heat absorption takes place in the
water walls. As a result of heat absorption there will be a mixture of water and steam in
the ckt. Which is collected in the outlet headers .A series of riser tubes are provided to
carry the water and steam mixture from the water wall header into the drum where
separation of water and steam takes place .The wet steam which enter the drum from the
riser tubes is collected in a compartment, formed by internal baffles. From here, the steam
is passed through too rows of turbo separator which has a primary and a secondary stage.
In the turbo separator water is thrown off and the steam passes through the screen
separators in the internal stage of separation.

Fig.- Boiler System

(III) E.S.P. :E.S.P THEORY

E.S.P. is a highly efficient device for extraction of suspended particles and fly ash from
the industrial flue gases. WORKING PRINCIPLE : E.S.P can handle large volume of
gases from which solid particles are to be removed Advantages of E.S.P. are :- High
collection efficiency Low resistance path for gas flow Treatment of large volumes at high
temp.Ability of cope with corrosive atm.An E.S.P. can be defined as a device which
utilized electric forces to separate suspended particles from flue gases :WORKING
STEPS :Ionization of gases and charging of dust particles Migration of dust particles.
Deposition of charge particles on collector surface. Removal of paE.S.P. consist of two
sets of electrodes, one in the form of thin wire, called discharge or emitting electrode in
the form of plates. The emitting electrodes are placed in the center or midway between
two plates and are connected to-ve polarity of H.V. D.C source of order of 37 KV
collecting electrodes are connected to + ve polarity. The voltage gradient between
electrodes creates CORONA DISCHARGE, Ionizing the gas molecules. The dust
particles present in flue gases acquire -ve charge and deposited on collecting electrodes.
The deposited particles are removed by knocking the electrode by a process called
RAPPING DONE BY RAPPING MOTORS.

10

(IV) COAL HANDLING PLANT :-

Wagon tippler has rated unloading capacity of twelve box wagon per hour, including
shunting and spotting time of haulage equipment.
For vibrating feeders of capacity 350 tons/hr. each have been provided feeding unload
coal.
A steel hopper has been provided in crusher house to receive coal and distribute it through
manually operated rack and pinion gate to three vibrating screens of 675 t/hr. capacity
each coal above 200 mm size passes on granules for crushing and reduction in size. Coal
below 20 mm size passes granular and discharged on to crushed coal conveyor belt.
Following permutation and combination of operation are possible with installed
system.To transfer all crushed coal received from crusher house to live storage pipe.To
transfer part of received crushed coal to plant and to balance to storage yard.To deliver the
raw coal bunkers part and received crushed coal mixed with balanced coal from the live
storage pipe.To transfer the plant crushed coal at 750 T/hr from the reclaim live pile and
simultaneously stock and s/ rad.The vibrating ons as stated above can be obtained by the
use of flap gates which are installed on various chute and two vibrating feeders, installed
on tower. The coal carried on various conveyers shall be main monitored to ensure proper
loading and distributing weightless and vibrating feeders.

Fig.- Wagon Tippler

11

Fig.- Conveyor

(V) ASH HANDLING PLANT :The ash handling system provide for continuous collection of bottom ash from the furnace
hearth and its intermittent removal by hydro ejectors to a common slurry sump. It also
provides for removal of fly ash to the common slurry sump. Each boiler is provided with
ash precipitator for collecting the fly ash from the flue gases with high efficiency of
collection to minimize the dust mains and to reduce the wear of induced draft fan . The fly
ash separated from flue gases in the ash precipitator is collected in hoppers at the bottom
from where it is mixed with water to form slurry and disposed off to pumping area by
means of hydro ash pumps. Bottom ash from the boiler furnace is passed through slag
crushers and then slurred to the slurry chamber at the suction of the ash disposal pumps .
These are high pressure and low pressure pumps for this purpose . At a time one pump is
working and other two are stand by . From the ash disposal pump house ash slurry is
pumped through pipe lines to the ash dump area within about 1.5 km away from

12

the ash disposal pump house . Too separate discharge lines are provided one for each unit
but only one line is used . The ash slurry from the two units is taken in one discharge line
through electrically operated valves

(VI) GENERATOR
THEORY :Turbo generator manufactured by B.H.E.L. is incorporated with most modern design
concept and constructional features which ensures reliability, easy and constructional and
operational economicity.
The generator stator is a tight construction, supporting and enclosing the stator wdgs, core
and hydrogen coolers. Cooling medium hydrogen is contained within a frame and
circulated by fans mounted at either ends of rotor. The Generator is driven by directly
coupled steam turbine at a speed of 3000 r.p.m. The generator is designed for continuous
operation at rated O/P.
Temp. detector and other devices installed or connected within the M/c, permit the
measurement of wdgs, teeth core, and hydrogen temp. hydrogen pressure and purity in
M/C under the conditions.
The Source of excitation to rotor wdgs is thyristorised D.C. supply. The Auxiliary
equipment supplied with M/C suppresses and enables the control of hydrogen pressure
and purity, shaft sealing lubricating oils.
There is a provision for cooling water in order to maintain a constant temp. of coolant
(hydrogen) which controls the temp. of wdg., core etc. as per loads.

13

Fig.- Generator

STATOR FRAME :The stator frame of welded steel frame construction which gives sufficient strength and
rigidity necessary to minimize the vibrations and to with stand thermal gas pressure.
Heavy end shields enclose the ends of frame and from mountings of generator bearings
and radial shaft seals. The frame is subdivided by ribs and axial members to form duct
from which the cooling gas passes to and from the radial ducts in the core and in
recirculated through internally mounted coolers. All the gas ducts are designed so a s to
reduce balanced distribution of hydrogen to all parts of the core. The stator, constructed in
a single piece, houses the core and wedge. The horizontally mounted water cooled gas
cooler being so arranged that it may be cleaned on the water side without opening the M/c
to atmosphere.
All welded joints exposed to hydrogen will be specially prepared to prevent leakage. The
complete frame is subjected to hydraulic test at a pressure of 7 ATM.

STATOR CORE :It is built up of special sheet steel laminations and whose assembly is supported by the
guide bass. The method of construction insure that the core is firmly supported at a large
no of points on its periphery. The laminations of high quality silicon steel which
combines high permeability with low hysteresis and eddy current losses. After stamping
each lamination is varnished. The laminations are varnished on both sides with two coals.
14

The segment of insulating material is inserted at frequent interval to provide additional

insulation. The laminations are stamped out with accurately fine combination of ties.
Laminations are assembled on guide bass of group separated by radial ducts to provide
ventilation passage. The ventilation ducts are disposed so as to distribute the gas evenly
over the core and in particularly to give adequate support to teeths. At frequent intervals
during stacking the assembled laminations are passed together in powerful hydraulic press
to ensure tight core which is finally held between heavy clamping plates which are of non
magnetic steel. Use of non-magnetic steel reduces considerably the heating of end iron
clamping to the footed region of the core is provided by pressing figures of non-magnetic
steel which are welded to inner periphery of the clamping plate.
In order to reduce the losses in the end packets special dampers are provided at either end
of core. Mostly dampers are provided to prevent hunting in AC Machines.

STATOR WINDINGS :Stator wdgs are double star layers, lap wound ,three phase ,short pitch type. The top and
bottom are brazed and insulated at either and to form turns. Several such turns form a
phase. Phases are connected to form a double star wdg. The end wdg formed on involute
shaped ends, is inclined towards M/C axis by 20, thus form a basket wdg. With total
induced conical angle of 40. Due to this stray load losses in the stator ends to zero.
The arrangement of complete stator wdg. electrical ckt. is viewed from turbine end of
generator and rotor wdgs. Slot numbering is clock wise from turbine end. The top bar in
slot no 1 is identified by the thick line. End wdgs will be sealed against movement of
short circuit by both axial and peripheral bracing. The later consist of hardened glass
laminated blocks inserted between adjacent coil sides in coil overhangs, so that with the
coils, they form a continuous rigid ring. Glass cord or top is used for lashing the packing
of blocks. The complete assembly is secured by high tensile brass blots. The wdgs. Is
designed to with stand short circuit stresses. The exposed portion of wdgs are finally
given coated. Insulation of individual bars and stator wdgs at various stages is tested with
applied high voltages AC of 50 Hz.

RESISTANCE :A resistance temp detector (R.T.D) is a pt. Resistance element operation of R.T.D is based
on the principal of electrical resistance of metallic conductor, varies linearly with temp.

APPLICATIONS :R.T.D. and its associated equipment are designed for use with generator to determine
temp. at various parts and places. The equipment consists of two parts.
The switch board equipment which usually includes a temp.
indicating meter, test resistors transfer switch and leads. Machine equipment which
usually includes the temp. R.T.D., leads and terminal block with grounding connections,
leads from R.T.D. are brought out to the terminal board by cables through a conduit to
protect them from physical damage and from contact with high voltage coils.
Such resistance detectors in stator teeth with seven spacers 7 RTDs
between the coil side in the stator slots with 7 spacers and 3 RTD are there in the stator
core with 3 spacers.
15

The location of temp. detectors are in three phases i.e. in the center of
M/C, in each region of machine and midway between them. The detectors in the stator
slots are distributed uniformly in all three phases. Measurement of temp. in hydrogen
cooling water for hydrogen coolers and metals is as :Six R.T.D.s are provided, on at the inlet of each of 6 individual
hydrogen coolers elements for measurement of temp. of hot hydrogen, similarly 6 R.T.D.s
are provided, one at outlet of each of six individual cooler elements. One R.T.D. along
with one spacer is provided in the lower part of stator frames for measurement and
signalisation of hot hydrogen.. 6 R.T.D.s are provided one at the outlet of six individual
cooler elements for measurement of cooling water at the outlet of hydrogen cooler
elements.

ROTOR :Rotor shaft consists of a single piece alloy steel forging of high mechanical and magnetic
properties performance test includes :Tensile test on specimen piece.
Surface examination
Sulphur print test.
Magnetic Crack detection.
Visual examination of the bore.
Ultra sonic examination.
Slots are milled on the rotor forging to receive the rotor wdg. Transverse slots are
machined in the pole faces of the rotor to equalize the moment of inertia in the direct and
quadrilateral axis of the rotor with a view of minimizing the double frequency vibration
of the rotor. The fully brazed rotor is dynamically balanced and subjected to 120% over
speed test at the work balancing tunnels so as to ensure reliable operation.

ROTOR WINDINGS :The rotor wdgs. of direct coil type and consists of parallel strips of very high conductivity
silver bearing copper, bent on edge to form coils.
The coil are placed in impregnated glass, laminated short shells, using glass strip inter
turn insulation and will be brazed at the ends to form a continuous wdgs.
The complete wdgs. Will be baked at high temp. and pressed to size by heavy steel
damping rings. When the wdgs have cooled, the insulation at the tap of the slot portions
will be sealed by heavy dove tail wedges of non-magnetic materials.
The cooling medium hydrogen gas will be brought in direct contact with copper by means
of radial slots in embedded portion.

Lateral movement of the coil overhang is prevented by treated glass spaces inserted in
between the coils and the solid ring. The formation and description of the spacers is such
as to leave ample space for ventilation.

16

(VII) CONDENSER
The functions of condenser are:
1. To provide lowest economic heat rejection temperature from the steam. Thus saving on
steam required per unit of electricity.
2. To convert exhaust steams to water for reuse this saving on feed water requirement.
3. Deaeration of make-up water introduced in the condenser.
4. To form a convenient point for introducing makes up water.
IN STPS RVUN SURFACE CONDESER is used.
Surface Condenser:
This type is generally used for modern steam turbine installations. Condensation of
exhaust steam takes place on the outer surface of the tubes, which are cooled by water
flowing inside them.
The condenser essentially consists of a shell, which encloses the steam space. Tubes
carrying cooling water pass through the steam space. The tubes are supplied cooling water
form inlet water box on one side and discharged, after taking away heat form the steam, to
the outlet water box on the other side.
Instead of one inlet and one outlet water boxes, the may be two or more pair of separate
inlet-outlet water boxes, each supplying cooling water to a separate bundle of tubes. This
enables cleaning and maintenance of part of the tubes while turbine can be kept running
on a reduced load.

Description of condenser:The condenser group consists of two condensers, each connected

with exhaust part of low pressure casing. A by-pass branch pipe has interconnected these
woe condensers. The condenser has been designed to create vacuum at the exhaust of
steam turbine and to provide pure condensate for reusing as feed water for the boilers.
The tube layout of condenser has been arranged to ensure efficient heat transfer from
steam to cooking water passing through the tubes, and at the same time the resistance to
flow of steam has been reduced to the barest minimum.

17

Fig.- Condenser
350% capacity condensate pumping sets are installed for pumping the condensate from
ondenser to the deaerator4 through low-pressure heaters. Two pumps are for normal
operation and one works as stand by pump.

(VIII) TRANSFORMER :GENERATOR TRANSFORMER :18

Type of Cooling
:
OFAF ONAF
ONAN
Rating of H.V.(MVA)
:
250
175
125
Rating of L.V (MVA)
:
250
175
125
No. load voltage (H.V.) (K.V.)
:
240
No. load voltage L.V. (K.V.)
:
15.75
Line current H.V. (amps)
:
602.12
Line current L.V. (amps.)
:
9175.15
Temp. rise oil (C)
:
40 C
Temp. rise wdgs. (C)
:
55
50
50
Customer
:
R.S.E.B
Phase
:
3
frequency
:
50 Hz
Connection symbol
:
yndl
Impedance volts 250 MVA NOR TAP % :
14.57%

THEORY :A X-mer may be defined as an equipment based on electromagnetic induction, alternating

voltage and current without affecting the frequency. It is an static equipment i.e. it has no
movable limbs.
The fundamental theory of X-mer is that if on a magnetic core (Iron Core), two windings
are placed then the current produced in primary wdg. On account of alternating voltage,
imposed induced voltage. E secondary and I secondary in secondary wdg.

The flux consists of two parts :MUTUAL FLUX :- When flux path is wholly limited in the core and which therefore
links the two wdgs.

LEAKAGE FLUX :- Whose path partly in air and therefore links only the primary
wdgs .
The ratio of leakage flux to mutual flux depends on the relative reluctance of their
respective paths which in turn is a function of saturation of core and the magnitude of the
current. A 1phase X-mer adopt this core. The three phase X-mer can be accomplished by
using a three phase X-mer or by interconnecting three single phase X-mers units to form a
three phase bank.

X-mer can be classified according to core construction :Core form of construction

Shell form of construction

19

In case the core form of construction Magnetic steel punching are arranged to provide a
single path magnetic circuit. High and low voltage coils are grouped on each of vertical
by of core. In this way the mean length of turn for wdg. Is comparatively short while
magnetic path is long.
For shell form of construction all wdg. of each phase are formed into a single with
magnetic punching assembled so as to encircle each side of the wdg. Rings. The mean
length of the turn is used usually linger compared to the core form of wedg. Design which
the iron path is shorter.
In the larger size of X-mer, shell construction is quite appropriate as compared to small
size transformers where core type construction is preferred.

Another type of X-mer classification is based on cooling :In a X-mer, the losses in the core and wdgs (iron and copper losses) are transferred, to the
oil in the form of oil and heat in turn is carried by ambient air either by natural or forced
convection. The overall transference of heat is by conduction, convection and radiation.
The oil in the duct and at the surface of wdg. And core takes up heat by conduction and
transform it by convection currents to the tank and supplementary coolers from which it is
dissipated by conduction and convection or by convection and radiation.

(IX) SWITCH-YARD

20

Two 220 KV buses have been provided in switchyard and are interconnected through a
bus coupler. Each of the two 110 MW generator is connected to this system through a step
up 125 MVA, 11/240 KV, yd1 gen. X-mer.
Four line feeders take off from 220 KV switch yard to Sakatpura grid substation. Two
Kota and other two to Heerapura (Jaipur) grid substation. Each of the four feeders have
been provided with a by pass isolator which is connected across the line breaker and
breaker isolator.

The outgoing feeders are :The features described above for feeders facilitates taking shut-down of any one line
breakers at a time for maintenance without power flow in line. The equipments in the
switchyard are :1. Circuit breaker
2. Isolators
3. Earthing Isolator
4. Lightening arrestors
5. Current X-mer
6. Potential X-mer

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Fig.- System overview

CIRCUIT BREAKER : Each of the G,T., S.T., line feeder and bus coupler is provided with circuit breaker with is
rated for 254 KV, 2500 amp and it can break a ckt either in load conditions or in on load
conditions. The ckt. Breaker can also interrupt fault currents, fly current automatically for
3phase system, 1phase ckt - breakers are used. Each pole of ckt. Breaker comprises of one
or more interrupters. The Interrupters are mounted on support insulators. The interrupter
encloses a set of fixed and moving contacts can be apart by means of operating medium.
The produced by the separation of current carrying contact is interrupted by a suitable
medium and by adopting suitable techniques for arc extinction. The CBs can be classified
according to the medium of are extinction. They are as follows :

AIR BREAK CIRCUIT BREAKER : In these C.B. the contact, separation and are extinction takes place in air at atm. Pressure.
The CB employs the high resistance interruption principle. The are is rapidly lengthened
by means of are runners and are chutes and the resistance of the are is increased by
cooling lengthening and splitting the arc. The arc resistance increases to such an extent
that the voltage drop across the arc becomes more than the supply voltage and arc get
extinguished

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7. CONCLUSION

It was really worth spending 30 days at STPS, Suratgarh as I went through Electricity
Generation. The practicality of the training was really fruitful as I was able to understand the
real time applications of various electronic instruments. Moreover while working over there I
also gained a very rich experience of working in a government station as well as people. It
also gave me the knowledge of professional fields.
It was a memorable experience for me to work in the station as I have been listening to it
from my childhood.
I have learned all about the wagon, wagon-tippler, side-arm-charger, conveyor, rootery-vecor
, Boiler, Turbine, Transformer and Generator.
S.T.P.S. is a very large plant and it is very difficult to acquire complete knowledge about it in
a short span. I have tried to get acquainted with overall plant functioning and main concepts
involved therein.
I have summarized all the things, which I saw & learned at S.T.P.S. in the training session.
It makes us to realize that engineering is not just learning the structured description and
working of various machines, but the greater part is of planning proper management.
It has allowed an opportunity to get an exposure of the practical implementation to
theoretical fundamentals.

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REFERENCES
1. http://en.wikipedia.org/wiki/Thermal_power_station
2.http://www.bentley.com/saIN/Promo/AutoPLANT/SKID=CEO_IN_APLANT_GOGLE
07&WT.srch=1&gclid=CMq4_uqvypcCFQEspAodrwrOSQ
3. Books : Electrical Machines (P.S. Bhimbra) 4th Edition 11th Reprint-2009
4. Electrical Machines (J.B. Gupta) 12th Thoroughly Revised Edition

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