0 - Kota Tharmal Plant New PDF

PT&IV at KOTA SUPER THERMAL POWER STATIONS GIT DEE
Chapter 1
INTRODUCATION
1.1 Basic View Of K.S.T.P.S.
Rajasthan RajyaVidyut Utpadan Nigam Limited (RVUNL) has been entrusted with the
job of development of power projects under state sector, in the state along with
operation & maintenance of state-owned power stations. The government of Rajasthan
constituted the Rajasthan RajyaVidyut Utpadan Nigam Ltd.
(RVUNL) under Companies Act-1956 on 19th July 2000. The Nigam is since playing
thelead role in giving highest priority to the power generation for themanifold and rapid
development of the state.
The generating Stations of RVUN have acquired a distinctive reputation in the country
for their efficient and economic power generation. RVUNL has a track record of
completing the generation projects ahead of schedules.The present installed capacity of
RRVUNL is 4097.35 MW.
Fig. 1.1 K.S.T.P.S. Layout
Session 2015-2019 Page 1

For the power generation with 2x110 MW, 3x210 MW and 2X195 MW of K.S.T.P.S.
authorities are required to be operative to active full operation. The auxiliaries are
basically operation either on L.T. System i.e. 415 V 3-Ø power supply is made available
to the system after providing the station transformer of 3x50 MVA capacity with
voltage 220 KV/ 7.2/7.2 KV & different service transformers of capacity 1.0 MVA, 1.5
MVA, 2.0 MVA, which are located near the load centre as the transformer having the
voltage of 6.6 KV /415 V. The 6.6 KV power is distributed through 6.6 KV
interconnected Bus System for all the 5 units with a control through DC of 220 V.
The 415 V power supply is done through a L.T. SWGR (Switchgear) which are located
nearby the distribution transformer as well as the load centers. The all incomers, which
are breaker controlled , are having the control the L.T. SWGR are having the control
system on 110/ 220 V AC. The 6.6 KV power supply which are either MOCB
(Minimum Oil Circuit Breaker) of JYOTI MAKE or Air Circuit Breakers.
The 6.6 KV power supply to various draining equipment’s i.e. more is made through
breakers which are either MOCB of Jyoti make air circuit breaker which are either of
voltage makers as well as SF 6 of NGEF make. The LT supply is also controlled through
air break circuit breaker which are either L&T make or English Electric Company of
India. TheKota Super Thermal Power Station (K.S.T.P.S), Kotavarious H.T. motors are
switched on started through on direct ON line (DOL) in order to inverse the availability
of equipment at full efficiency without time gap.
Further , the 6.6 KV system which is normally in delta configuration and terms as an
unearthed system so also to keep the running motor complete in operating condition in
case of any one .phase of motor winding is earthed due to any one reason. Earthling is
detected by an protection system with alarm facility to take remedial measures
immediately and at the same time to maintain the generation level in the same condition,
prior to occurring the earth fault the single phase earth fault is detected in due course
till the motor is not earthed to other or another phase. “PUBLIC ADDRESS SYSTEM”
is available through in area of each unit which helps in fast communication for prompt
remedial measure.
Soot Blowers are there in the boiler area on the furnace side or Zone which helps in
blowing the soot / ash deposition regularly of the furnace wall / economizer tubes to
keep heat transfer at the required parameter.
1.2 Salient Feature Of K.S.T.P.S.

1. Location Sakatpura kota

2. Capacity
A) 1st stage 2 x 110MW
B) 2nd stage 2 x110MW
C) 3rd stage 1 x 210MW
4th
D) stage 1 x195 MW
E) 5th stage 1 x 195MW
3. Source of water Chambal river
4. Boiler
a) Type Tangentially fired natural
Circulation , Balance draft,
Direct fire radiant, Water tube boiler
b) No. Of Unit 7
c) Maximum efficiency BHEL(86.6+1)%
d) Capacity 375 t/Hr ,710 t/Hr
(110 mw) / (210 MW)
e) Steam pressure 139 kg/cm2 / 150 kg/cm2
f) Steam temperature 540 0c
g) No. Of draft fan in service (i) FD Fan 2 unit (Each boiler)
ii) ID Fan 2 unit (Each boiler)
h) No. Of air fan in service
(i) Primary 2 Unit
(ii) Seal Air fan 1 Unit
(iii) Scanner 1 Unit
i) No. Of coal mills in service 3 Unit
j) No. Soot blower in service 68
k) No. Of oil 8
5)Fuels
(A)Coal :
i) Type stack coal
ii) Calorific value 3300k.cal. /kg
iii) Qty used 80 t/Hr

iv) Ash content 40%
v) sulphur content 0.5%
vi) Type of handling Belt conveyor
Chapter 2

SITE FOR THERMAL POWER PLANTS

The following factor should be considered while selecting a site for a steam power plant
for economical and efficient generation:-
2.1 Supply Of Water
A large quantity of water is required in steam power plants. It is required
1. It raises the steam in the boiler.
2. For cooling purposes such as in condensers.
3. As a carrying medium such as in disposal of ash.
4. For drinking
The efficiency of thedirectcooling plant is about 0.5% higher than that of the plant in
which cooling towers are used. This means a saving of about Rs. 7.5 Lakhs per year in
fuel cost for a 2000 MW station.
Huge amounts of coal are required for raising the steam (20,000 tonnes per day for a
2000 MWs). Since the Government policy is to use only low-grade coal with 30to 40%
ash content for the power generation steam power plant should he located near the coal
mines to purpose, the avoid the transport of coal and ash.
2.2 Requirement Of Land
The land is required not only for setting up of the plant but also for another purpose
such as staff colonies, coal storage, ash disposal etc. The cost of land adds to the final
cost of theplant. So it should be available at a reasonable cost. Land should be good
bearing capacity since it has to withstand about 7Kg./Sq. Cm. Moreover, land should
be reasonably level. it should not below lying.
2.3 Labour Supplies
Skilled and unskilled labourers should be available at reasonable rates near the site of
thepower plant.
2.4 Transportation Facility
The land and rail connections should be proper and capable of taking heavy and over
dimensioned loads of machines etc. To carry coal, oil etc. Which are daily requirements,
we need these transport linkages.
2.5 Ash Disposal

Ash is the main waste product of the steam power plant. Hence some suitable means
for disposal of ash should be applied. Ash can be purchased by building contractors,
cement manufacturers or it can be sued for brick making near the plant site. Otherwise,
wasteland should be available near the plant site for disposal of ash.
2.6 Distances From The Populated Area

Since most of the modem generating stations employ pulverized fuel residues and
fumes of them are quite harmful. Therefore the site for the plant should be away from
the populated area.
The factors to be considered while selecting a site for a steam power plant for the
efficient generation are:
2.7 Near Of The Load Centre

The power plant should be as near as possible to the centre of theload so that
transmission cost and losses are minimum. This factor is most important when dc
supply system is adopted.
Chapter 3

PLANT FAMILIARIZATION
3.1 Turbine
3.1.1 Introduction
The steam turbines and their auxiliaries installed have been manufactured by BHFL.
The turbines are three cylinders, compound 3000 rpm, double-flow exhaust type reheat
units with initial parameters of 13 Kg/cm2. And five low-pressure heaters are fed. The
high-pressure heaters are fed. The high-pressure cylinder comprises of two courts is
wheels as a regulation stage. Intermediate pressure cylinder comprises of twelve stages
and each of the double flow section of the L.P. cylinder consists of four stages.
3.1.2 Operation
There are two live steam lines connecting the boiler to the turbine. The superheated
steam enters the H.P. turbine and strikes its blades hence heat energy of steam is
converted into mechanical energy. The steam from H.P. turbine is reheated in reheaters
and reheated steam is sent to L.P. turbine through hot steam lines. Here the second stage
of energy conversion takes place. Then steam is sent to L.P. turbine from where it is
ejected by vacuum ejectors and condensed. Here are low cold reheaters and two hot
reheat lines connecting the reheater and turbine. In each of the two steam lines, one
electricity operated isolating valve, one water separator, and one quick closing stop
valve is mounted. The direction of revolution of the turbine is clockwise when looking
at turbine from the front bearing pedestal. For the oil lubrication of bearings and for
governing, the main oil pump is driven shaft is assembled into the front bearing pedestal
of the turbine itself.

Figure.3.1 Thermal Power Plant Layout
3.1.3 Components of Turbine
3.1.3.1 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 me 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 another 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 on 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 thetriple
shell, fabricated construction. The outer casing consists of the front rear end walls, two
lonGCTudinal 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
3.1.4 Turbine Specification:-
Reted output 110MW

Economic output 95MW
Rated speed 3000rpm
Direction of rotation viewing front pedestal clockwise
Maximum pressure of steam before the stop valve 145 atm
Maximum temperature of steam before the stop valve 545degree Celsius
Maximum pressure of steam before Mp casing 35atm .
Maximum temperature of steam before MP casing 545 degree celsius
3.2 Boiler
The boiler is installed in KSTPS are made by BHEL. Each of the boilers is asingle
drum, tangentially 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 375 Hour/hour at 138 Kglcm2 pressure and 540°C temperature. The
thermal efficiency of each boiler at MCR is 86.8%. Four number 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 are provided near the chimney to induce the
flue gases. The boiler is provided with a balanced draft consisting of tow forced draft
fans and two induced draft fans. Flue gases are utilized to heat the secondary air for
combustion tin the tubular type air heaters installed in the boilers. Since the boiler
furnace is maintained at t 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 coal inside thefurnace. A small

quality or ash is collected in the bottom ash hopper and aconsiderable amount of ash is
collected in the E.S.P. and magnetic separator hopper.
Boiler are classified as:-
3.2.1FireTube Boiler:- In this type the product of combustion pass through the
tubes which are surrouneded by water These are economical for low pressure .
3.2.2Water Tube Boiler:- In this type of boiler water flow inside the tubes and
hot gases flow outside the tubes .These tubes are interconnected to common water
channels and to steam outlet .
• The wter tube boiler have many advantage over the fire tube boiler.
• High evaporation capacity due to availability of large heating surface .
• Better heat transfer to the mass of water.
• Better effiency of plant owing to rapid and uniform circulation of water in tubes
.
• Better overall control
• Easy removal of scale from inside the tubes.
Figure 3.2 Boiler

This collected ash is extracted and disposed of in as slurry from in the ash disposal arc.
For the central steam power plants o large capacity water tube are used. Water tube
boiler essentially consists of drums and tubes. The tubes are always external to drum
.In comparison to fire tube boilers the drum in such boiler do not contain any tubular
heating surface, so they can be built in asmaller diameter and consequently they will
withstand high pressure. The water tube boilers have got thefollowing advantage over
the fire tube boiler.
Fig 3.3 Internal Structure Of a Boiler

The selection of the size and type of boiler depends on upon –
The output required in terms of amount of steam per hour, operating
1. Temperature and pressure.
2. Availability of fuel and water.
3. The probable load factor.
4. Initial costs, maintenance costs, labour costs

5. Space requirement and availability.

3.3 Boiler Furnaces
A boiler furnace is a chamber in which fuel is burnt to liberate the heat energy. It
provides support and enclosures for the combustion equipment. The boiler furnace
walls are made of refractory materials such as fire clay, silica. kaolin etc. Such materials
have the property of resisting change of shape, weight or physical properties at high
temperatures. The construction of boiler furnace varies from plain refractory walls to
completely water cooled walls, depending upon characteristics offuel used and ash
produced. Firing method, nature of load demand, combustion space required. Excess
air used operating temperature, initial and operating costs.
The plain refractory walls are suitable for small plants where the furnace temperature
may not be high. For larger plants, where the furnace temperature is quite high,
refractory walls are made hollow and theair is circulated through hollow space to keep
the temperature of the furnace walls low.
The recent development is to use water walls. Water walls are built of tubes of diameters
ranging from 25mm to 10mm variously spaced with or without fins or studs and bare
or with different thickness of mouldable refractory on the inner face. Heat transfer rates
run from 0.5x 10^6 to 104x10^6 Kilocalories per cubic metre of surface. To meet these
requirements of heat transmission, circulation on the water side must be adequately
obtained by convection or by pumps. This type is suitable for pulverised fuel-fired
boilers and high steaming rates can be maintained.
3.4 Super-Heater and Re-Heater

A Superheater is a device which removes the last traces of moisture from the saturated
steam leaving the boiler tubes and also increases its temperature above the saturation
temperature. For this purpose, the heat of combustion gases from the furnace utilised.
Super-heaters consists of groups of tubes made of steel (carbon steel for steam
temperature up to 950 degrees F carbonmolybdenum steel for thesteam temperature of
1,050 degrees F and stainless steel for thesteam temperature of 1,200 degrees F) with
an outside diameter ranging from 25mm to 64mm. The superheater tubes are heated by
the heat of combustion gases during their passage from the furnace to the chimney.
Superheaters are classified into two parts.

3.4.1 Radiant Super-Heater:-it is located in the furnace between the furnace

waterwalls and absorbs heat from the burning fuel through radiation. It has two main
disadvantages firstly, owing to high furnace temperature; it may get overhead and
therefore, requires a careful design. Secondly, it gives drooping characteristics i.e. the
increases in steam output and radiant heat transfer being a function of furnace
temperature increases slowly with thesteam flow or the steam temperature falls.
Fig 3.4Superheater
3.4.2 Convection Super-Heater:- It is located well back in the boiler tube bank,
receives its heat entirely from fuel gases through convection. It gives rising
characteristics i.e. the temperature of superheat increases with the increase in steam
output because with the increase in steam output both gas flow over the super-heater
tubes and steam flow within the tubes increase with causes increase in the rate of heat
transfer and mean temperature difference. Convection super-heaters are more
commonly used.
The function of the reheater is to re-superheat the partly expanded steam from the
turbine. This is done so that the steam remains dry as far as possible through the last
stage of the turbine. Modern plants have re-heaters as well as super-heaters in the same
gas passage of the boiler. They can also be of combination type using both radiant and
convective heating.

3.5 Economizer
When the combustion gases leave the boiler after giving most of their heat to water
tubes. Superheater tubes and reheated tubes, they still possess alot of heat which if
not recovery means of some devices, would go waste. Economiser and air pre-heater
are such devices which recover the heat from the flue gases on their way to the
chimney and raise the temperature of feed water air supplied for combustion
respectively.
Fig.3.5 Economizer
3.6 Air Preheater
Air preheaters are employed to recover the heat from the flue gases leaving the
economiser and heat the incoming air required for combustion. This raises the
temperature of the furnace gases, improves combustions rates and efficiency. And
lowers the stack temperature. Thus improving the overall efficiency of the boiler. It has
been found that a drop of 20-22c in the fuel gas temperature increases the boiler
efficiency by about 1%. An air preheater should have high thermal efficiency, reliability
or operation, fewer maintenance charges should occupy small space, should be
reasonable in initial cost and should be accessible.
Air preheater is two types:
3.6.1 Recuperative Air Preheater: - These types of airpreheater are continuous in

action while the regenerative type is discontinuous in action and operates on acycle. In
therecuperative type of heaters, the two fluids ate separated by heat transfer surface,
one fluid flowing constantly on one side and the other fluid on the other side or the
surface.In the recuperative type of heaters, the rate of heat transfer is low, space
occupied in large and cleaning of thesurface is difficult. The plate type recuperative

heater consists of rectangular flat plates spaced from 12.5mm to 25mm apart,leaving
alternate air and gas passages.
3.6.2 Regenerative Airpreheater:-It consists of a rotor made up of corrugated

elements. The rotor is placed in a drum which has been divided into two compartments.
Air and gas compartments. To avoid leakage from one compartment to the other seal
share provided. The rotor rotates at a very slow speed of 3-4rpm. As the rotor rotates,
it alternately passes through flue gases and air zones. The rotor elements are heated by
the flue gases in their zone and transfer this heat to air when they are in air zone.
3.7 Condenser
Steam, after expansion through the prime mover, goes through the condenser which
condenses the exhaust steam and also removes air and other non-condensable gases
from steam while passing through them. The recovery of exhaust steam in the
condenser reduces the make-up feed water that must be added to the system, from 100%
when exhausted to theatmosphere to about 1-5% and thereby reduces considerably the
capacity of water treatment plant. The exhaust pressure may be lowered from the
standard atmospheric pressure to about 25mm of Hg absolute and thereby permitting
expansion of steam. In the prime mover, to a very low pressure and increasing plant
efficiency operation.
Any leakage of air into the condenser destroys the vacuum and causes
1. An increase in the condenser pressure which limits the useful heat The prime mover
2. A lowering of the partial pressure or the steam and of the saturation temperature
along with it. This means that the latent heat increases and therefore, more cooling
water are required.
Fig. 3.6 Condenser

3.8 Evaporator
Evaporators rate employed for supplying pure water as make-up feed water in steam
power plants. In an evaporator raw water is evaporated by using extracted steam and
the vapours so produced may vex condensed to give a supply of distilled or pure feed
water. These vapours can be condensed in feed water heaters by the feed water or in
separate evaporator condensers using feed water as the cooling medium. There are two
main types of evaporators-
3.8.1 Film or Flash Type Evaporator: - In this kind of evaporators, there are tubes or
coils through which the steam is passed. Raw water is sprayed by means of nozzles on
the surface of these tubes and some of the raw water will be converted into vapours.
These vapours ate collected from the evaporator and are condensed to give pure and
distilled waterfor boilers.
3.8.2 Submerged Type Evaporator: - In this kind of evaporators, the tubes through
which the steam is passed are submerged in raw water. The vapours rising from the raw
water are collected and condensed to provide a supply of pure make-up feed water.
Because of continuous operation of raw water, concentration or impurities goes on
increasing, so periodic blowing down of raw water is essential. Scales formed on the
surface of the tubes will retard the heat transfer rate and so it's removed is very
necessary. This is removed by draining the raw water from the shell and then spraying
the tubes with cold water while the tubes arc kept hot by theflow of steam through them.
The scale is cracked off and is washed away by the spray.
3.9 Feed Water Heater
Heaters are used to heat the feed water by means of bled steam before it is supplied to
the boiler. Necessity of heating feed water before feeding it back to the boiler arises
due to the following reasons:
1. Overall power plant efficiency is improved.

2. Thermal stresses due to cold water entering the drum of boiler are avoided.
3. There is an increase in the quantity of steam produced by the boiler.

4. The dissolved oxygen and carbon dioxide which would otherwise cause boiler
corrosion is removed in the feed water heaters.
5. Some other impurities carried by steam and condensate, due to corrosion in the boiler
and condenser, ate precipitated outside the boiler
Feed water heaters are two types:
3.9.1 Open or Contact Heaters:-These are usually constructed to remove no

condensable gases from water and steam along with raising the feed water temperature.
Such heaters are also called the desecrator. The amount of gas dissolved in water
depend on upon its temperature, this decreases sharply with the increasing temperatures
and falls to almost zero at the boiling point. Such feed water heaters are used in small
power plants.
3.9.2 Closed or Surface Heaters:-These heaters consist of closed shell in which there
are tubes or coils through which either steam or water is circulated. Usually, the water
is circulated through the tubes and the steam and water may flow either in the same
direction or in opposite directions. Such heaters may be the temperature of thesteam.
For maintaining a high overall heat transfer for the heater, the water velocity should be
high but pumping costs limit the velocity to about l-2.5m/s.

Fig. 3.7Internal Structure of feed water heater
3.10 Cooling Towers
A cooling tower is a wooden or metallic rectangular structure inside of which is packed

with baffling devices. The hot water is led to the tower top and falls down through the
tower and is broken into small particles while passing over the baffling devices. Air
enters the tower from the bottom and flows upward. The air vaporises a small
percentages or water, thereby cooling the remaining water. The air gets heated and
leaves the tower at the top.

Fig 3.8 Internal structure of a cooling tower
3.11 Turbo Alternator
In a central power station, the system turbine and alternator arc directly coupled to avoid
transmission losses. Turbo-alternator ishigh-speed machines (3,000 or 5,000RPM)
for50Hz systems. These machines have horizontal configurations and smooth
cylindrical (or no salient pole) type field structure wound usually for 2 or 4poles. To
reduce the peripheral speed (maximum peripheral speed should not exceed 175 m/s)
ten diameter of the rotor is kept small and axial length is increased. The ratio of diameter
to axial length ranges from 1/3 to ½.
Due to high peripheral speed, the rotating part of the turbo-alternator is subjected to
high mechanical stresses. As a result, the rotor of large turbo-alternator is normally built
from solid steel forging. Chromium-nickel-steel or special chrome-nickelmolybdenum
steel is used for rotors of turbo-alternators. The coils are held in place by steel or bronze
wedges and the coil ends are fastened by metal rings. Normally two-third of the rotor
is slotted for the field winding and one-third is left without slots so as to form the pole
faces. 500MW units generally use hollow stator conductor. The short-circuit ratio is 0.4
to 0.6.
The non-salient field structure used in turbo-alternators has the following special
features:
1. They are of smaller diameter (maximum 1m in the2-polc machine) and of very long
axial length.
2. Robust construction and noiseless operation.

3. Less winding (air-resistance) loss.

4. Better in dynamic balancing.
5. High operating speed (3,000 or 1,500).
6. Nearly sinusoidal flux distribution around the periphery, and therefore, Gives a better
emf waveform than obtainable with salient pole field Structure.
7. There is no need of providing damper windings (except in special cases assist in
synchronising) because the solid field poles themselves act as efficient dampers.
3.12 Generator
3.12.1 Introduction
Generator is the electrical end of turbo generator set. It is a cylindrical polesynchronous
generator. It is generally known as a piece of equipment thatactually converts the
mechanical energy of turbine into electricity. Thegeneration of electricity is based on
the principle of electromagneticinduction.
A generator consists of the following main components and associated system:-

(1). Stator
(2). Rotor
(3). Excitation system
(4).Cooling system
(5).Sealing system
Fig. 3.9 Generator

3.12.1.1 Stator
The stator is the component that embodies the armature core and armaturewinding. It
is totally enclosed gas tight fabricated structure. It is the singleheaviest load in the whole
turbo generator. The major part of this load isstator core. The stator comprises of an
inner frame and outer frame. Theouter frame is a rigid fabricated structure of welded
steel plates. Within this shell is fixed cage of girder built circular and axial ribs. The
ribs divides the yoke into, compartments throw which hydrogen/air flow into radial
ducts in the stator core and circulates throw the gas coolers housed in the frame. The
inner cage is usually fixed to the yoke by an arrangement of springs to dampen the
double frequency vibration inherent in 2-pole generator. The details of the stator have
been shown in the figure on the next page. In large generators (500MW etc.), the frame
is constructed as two separate parts. The fabricated inner cage is inserted in the outer
frame after the stator has been assembled and the winding completed.
3.12.1.2 Stator Core
The stator is built up from a large no of vanished insulated punching or thinsections of

thin (generally 0.35 mm to 0.5 mm) steel plates. The use ofcooled rolled grain-oriented,
loss less steel iron which the punching aremade can contribute to reduction in the
weight of stator core for two main reasons.
(1). There is an increase in core stacking factor which improvement inlamination, cold
rolling and in core building techniques.
(2). The advantage can be taken of the high magnetic presence of grain oriented steel
to work the stator core at comparatively high magneticsaturation without fear of
excessive iron loss or too heavy a demand for excitation ampere-turns from the
generator rotor.
The slot ventilation holes etc. are punched out in one operation in thestampings and as
such the stampings are rather complicated or accounts of holes and the slots that have
to be produced. The core stampings areassembled in an inner leaved manner on core
bars. The core consists ofseveral pockets separated by steel spacer for radial cooling of
the core byhydrogen. To ensure a tight and monolithic core, pressing of the punching
is done in several stages and completely built, the core us help in pressedcondition by
mean of heavy non-magnetic steel press rings which are bolted to the end of core bars
as additional support is provided to the teeth portion by means of non-magnetic fingers
held between the core and the press ring. The press rings are tempered on the face

toward the core, so that an even pressure is exerted over the end surface of the core
when core bars are tighten. Copper screens provided between the end packets and press
rings reduce the end zone heating. The core bars are designed to provide
elasticsuspension of core in the stator.
3.12.1.3 Stator Winding & Insulation
Stator core carries the armature winding where the voltage is generated due to
electromagnetic induction. Each stator conductor must be capable ofcarrying the rated
current without overheating and the insulation must besufficient to prevent leakage
current flowing between earth and phase.
The stator has a three phase double layer short core type bar winding having two parallel
paths. Each coil side consists of glass insulated solid and hollow conductor with cooling
water passing through the latter in case of water cooled conductors being used in higher
capacity units. Water is fed to and fro the winding throw Teflon tubes.
The stator winding conductors, both solid and hollow, are transposed aboutanon-
magnetic duct, which provide the flow path for the coolant gas in case of H2 cooled
generator. In liquid cooled windings the transposed conductors are rectangular tubes.
The transposition can be done in no. of ways but most commonly used method of
transposition is Rebel arrangement.
The rotor is cast chromium, nickel, molybdenum and vanadium steel ingotand it is
further forget and machined. The rotor forging is then planed andmilled to form the
teeth. Very often a hole is bored throw the centre of theaxially from one end to the other
for inspection. Slots are then machined forwinding and ventilation.
3.12.2 Rotor Winding & Retaining Rings
The rotor carries the field windings. Silver bearing copper (containing 0.03to 0.1 %
silver) is used for the winding with mica as the insulation betweenconductors. A
mechanically strong insulator such as micanite is used forlining the slots. Later designs
of windings for circulation of the cooling gases throw the actual conductors. When
rotating at high speed, centrifugal force tries to lift the winding out of the slots and
duralumin wedges contain them.
The end turns outside the slots are covered by non-magnetic steel retainingend rings are
secured to a turned recess in the rotor body. By shrinking orscrewing and support at the
other end by fitting the rotor body.

Chapter 4
FUEL HANDLING and FEED WATER
4.1 Fuel Handling
Coal can he handled manually or mechanically. Mechanical adopted as it is reliable,

expeditious and economical. Owing to thelarge quantity of coal required to be handled
everyday, mechanical handling has become absolutely necessary.
The main required of a coal handling plant are reliability, soundness and simplicity
requiring a minimum of operatives and minimum of maintenance. Besides, the plant
should be able to deliver the required quantity of coal at destination during peak hours
.
4.1.1 Transportation or Delivery of Coal
There are three ways of transporting coal from coal mines to the site of power plant i.e.
by sea or river, byroad, and by rail. If the power plant is situated on the bank of a river
or near the sea-shore, it often economical to transport coal in boats or barges, unload
mechanically by cranes or grab buckets and place in the storage yard or directly to the
conveyor system to be carried to the power plant. Transportation by road is possible for
small and medium size plants only. The chief advantage of this system is thepossibility
of carrying coal directly into the powerhouse up to the point of consumption. Moreover
due to fewer traffic restrictions it is considered abetter system in comparison to rail
transport. Transportation of coal by rail, particularly for station located interior, is still
the most important mean of transportation in common use.
4.1.2 Methods of Coal Handling
Irrespective of the method of transportation of coal adopted, the coal has to be carried
to the boiler stokers or the coal preparation plant in the case of pulverised fuel firing.
The various stages in coal handling are:

4.1.2.l Unloading Stage:- The coal is unloaded from the point of delivery by means of
1. Coal shakers or coal accelerators
2. Rotary car dumpers or wagon tipplers and

3. Grab buckets

The choice equipment will depend on upon the method of transportation adopted. The
main equipment employed for taking the coal from the unloading site to the dead
storage are belt conveyors,screw conveyors, bucket elevators, skip hoist, grab bucket
conveyorsand flight conveyors.
4.1.2.2 Reclamation is the process of taking coal from dead storage for preparation or
further feed into hoppers or live storage.
4.1.2.3 Live storage consists of about one-day requirement of coal of power plant and
is usually covered storage in the power Station near the boiler furnace.it can be provided
withbunker and coal bins.
4.1.2.4 Input handling refers to the handling of coal between the live storage and firing
equipment. In thecase of simple stoker firing only chutes may, be required feeding the
coal from storage bunkers to the firing units.
4.1.2.5 Coal weighing enables one to have an idea of thetotal quantity of coal delivered
to the site and also whether or not proper quantity has been burnt as per load on the
plant.
It can be accomplished by
1. Weighing bridge,
2. Belt scale and
3. Automatic recording system.
The wagon can be unloaded either manually or by using rotary wagon tipplers.
4.2 Feed Water
The system coming out the turbine is condensed and the condensate is feedback to the
boiler as feed water. Some water may be lost due to blow-down, leakage etc. and to
make up these losses additional water, called the make-up water, is required to be fed
to the boiler. The make-up water in a modem thermal plant is about 1-4%. The sources
of boiler feed water is generally a river or lake which may contain suspended and
dissolved impurities, dissolved gases etc. It is necessary to heat and purify the water
before feeding to the boiler .
The heating of feed water:

1. Improves the overall efficiency of the plant

2. Removes dissolved oxygen and carbon-die-oxide

3. Causes precipitation of other impurities carried by steam and Condensate Outside
the boiler
4. Avoid thermal stresses owing to entry of cold water intothe boiler.
The water is treated for removal of suspended and soluble solids and removal of gases.
The various methods used for water treatment are:
1. Mechanical (sedimentation and filtration)
2. Thermal (distillation and de reactive heating)
3. Chemical (lime treatment, soda treatment, lime soda treatment, zeolite treatment and
demineralisation).
Lime treatment is suitable for the treatment of carbonate hardness, carbon-die-oxide in
the water, either in a free state or in bicarbonate combination.
Chapter 5
ASH HANDLING and DROUGHT SYSTEM

5.1 Ash Handling
Coal contains a considerable amount of ash. The percentage of ash in the coal varies
from about 5% in good quantity coals to about 40% in poor quantity coals. Generally,
poor quality coal is used in steam power plants and, therefore, a system power plant
produces hundreds of tonnes of ash daily (a modern2.000MW steam power plant
produces about 5,000 tonnes of ash daily).For removal of ash from the boilers and its
disposal to the suitable site is quite difficult and quite elaborate equipment is required.
Ash handling comprises the following operations:

1. Removal of ash from the furnace ash hoppers.
2. Transfer of this ash to a fill or storage and
3. Disposal of stored ash
4. The ash can be disposed of in the following ways.
5. Wasteland sites may be reserved for the disposal of ash
6. Building contractors may utilize it to fill the low-lying areas.
7. Disused quarries within a reasonable distance of the power plant may be employed
for dumping the ash into the evacuated land.
8. Deep ponds may be and the ash can be dumped into these ponds to fill them
completely. When such ponds are completely filled, they may be covered with soil and
seeded with grass.
9. When seaborne coal is used, barges may take the ash to sea for disposal to a water
grave.
5.2 Dust Collection
The exhaust gases leaving the boiler contain particles of solid matter in suspensions
make, dust, soot, flash or carbon as a material called "cinder". The quantity of these
solid particles largely depends on upon the method of fuel firing. Flue dust is greatest
with pulverised fuel and spreader stoker firing systems. In the case of pulverised fuel
firing, 60 to 80 percent of the total ash produced in the furnace escapes through the
chimney as fuel dust.
Gas cleaning devices make use of certain physical/electrical properties of the particular
matter for gas steam. Basically, gas cleaning devices called the dust collectors may be
classified into mechanical and electrical ones (electrostatic precipitators).

Mechanical dust collectors can be further classified as wet dry dust collectors. In wet
type units, dust is washed away from the flue gases by spraying water on it. This system
is usually because it needsa large amount of water.
5.3 Drought System
In a boiler, the combustions of the fuel require asupply of sufficient quantity of air and
removal of exhaust gases and this is achieved by draught system.
The circulation of air is caused by the difference in pressure, known as draught. Thus
be drought is difference in pressure between the two i.e. atmosphere and inside the
boiler.
5.3.1 Natural Draught: -The natural draught is provided by the action of chimney or
stackisused only 111 small boilers. Its intensity depends onupon the average
temperature ( the difference between theflue gases within the chimney and the outside
air (the gases within the chimney are at as higher temperature than that of the
surrounding air) and also on the height of the chimney above the level of the furnace
grate.
5.3.2 Mechanical Draught: - Artificial or mechanical draught is provided when the

natural draught caused by a chimney is not sufficient or where a certain draught is
required to be maintained irrespective of weather conditions or boiler operating
conditions. In thecase of large steam boilers where economisers and air pre -·heaters
are employed, the exit temperature of the flue gases is sufficiently lowered and also the
volume of air required is tremendously high. In such cases, the height of the chimney
to cause the required draught may be excessive in height and cost.
In a mechanical draught system, the movement of air is due to the action of a fan. A
mechanical draught may consist of induced draught or forced draught or both.
5.4 Steam Power Plant Controls
In the case of the large power plant, the various controls used to be accomplished
manually on the basis of instrument reading.

Now the various controls involved in the power plant operation have been completely
automated resulting in
1. Increased labour productivity
2. Improvement in the safety of operation and reliable functioning of the various
instruments and equipment
A number of controls, such at the boiler, turbine and generator unit are provided ina
steam power plant so as to maintain the best conditions at all load. Turbine governing
is affected by throttling the steam at the main valve or by reducing only the steam mass
flow by cutting off one or more nozzles through which the steam enters the blades. The
first method ofgoverning, known as throttle governing or qualitative governing is used
in case of small turbines and the second method of governing, known as nozzles
governing or cut-off governing or quantitative governing, is used to large turbines.
Maintenance or proper vacuum in the condenser, enough circulating water, a number
of pumps, oil pressure for control of circuits, steam bleeding if any and the heater and
feed water control are another requirement of the turbine.
In the case of an isolated generating unit, an increase in load causes reduction and the
speed of the unit and hence a reduction in frequency. However, in the case of generating
connected to infinite bus bars, the load shared by the unit can be adjusted the turbine
speed. In this case, frequency remains constant.
In general, centralized control is employed for modern steam power plants. the boiler
and turbine control being at one place in the turbine room and the generator and feeder
controls in the control room, in some cases all controls are centralized in one room,
called the control room.
Chapter 6
PLANT AUXILIARIES THERMAL POWER

The equipment which helps in the proper functioning of the plant are called plant
auxiliaries.The various plant auxiliaries can be grouped under the subheading of boiler
auxiliaries, coal and ash auxiliaries, turbo-alternator auxiliaries and miscellaneous ones.
6.1 Boiler Make-Up Water Treatment Plant and Storage
Since there is the continuous withdrawal of steam and continuous return of condensate
to the boiler, losses due to blow down and leakages have to be made up to maintain a
desired water level in the boiler steam drum. For this, continuous make-up water is
added to the boiler water system. Impurities in the raw water input to the plant generally
consist of calcium and magnesium salts which impart hardness to the water. Hardness
in the make-up water to the boiler will form deposits on the tube water surfaces which
will lead to overheating and failure of the tubes. Thus, the salts have to be removed
from the water, and that is done by water demineralizing treatment plant DM plant
generally consists of cation, anion, and mixed bed exchangers. Any ions in the final
water from this process consist essentially of hydrogen ions and hydroxide ions, which
recombine to form pure water.Very pure DM water becomes highly corrosive once it
absorbs oxygen.
The capacity of the DM plant is dictated by the type and quantity of salts in the in the
raw water input. However, some storage is essential as the DM plant may he down for
maintenance. For this purpose, a storage tank is installed from which DM water is
continuously withdrawn for boiler make-up. The storage tank for DM water is made
from materials not affected by corrosive water, such as PVC. The piping and valves are
generally or stainless steel. Sometimes, a steam blanketing arrangement or stainless
steel doughnut float is provided on top of the water in the tank to avoid contact with
air.
6.2 Fuel Preparation System
In coal-fired power stations, the raw feed coal storage area is first crushed into small
pieces and then conveyed to the coal feed hopper at the boiler. The coal is next

pulverized into a very line powder. The pulverizers may be ball mills,rotating drum
grinders,or other types of grinders.
Oil must keep warm (above its pour point) in the fuel oi1 storage tanks to prevent the
oil from congealing and becoming pumpable. The oil is usually heated to avoid 100
degrees C before being pumped through the furnace fuel oil spray nozzles.
Boilers in some power stations use processed natural gas as their mainfuel. Other power
stations may use processed natural gas as auxiliary fuel in the event that their main fuel
supply (coal or oil) is interrupted. In such cases, separate gas burners are provided on
the boiler furnaces.
6.3 Barring Gear
Barring gear or ("turning gear") is the mechanism provided to rotate the turbine
generator shaft at a very low speed after unit stoppages. Once the unit is "tripped" (i.e.
the steam inlet valve is closed), the turbine-coasts down towards standstill. When it
stops completely, there is a tendency for the turbine shaft to deflect to bend if allowed
to remain in one position too long. This is because the heat inside the turbine casing
tends to concentrate in the top of half of the casing, making the top half portion of the
shaft hotter than the bottom half. The shaft, therefore, could wrap or bend by millionths
of inches.
This small shaft deflection, only detectable by eccentricity meters, would be enough to
cause damaging vibrations to the entire steam turbine generator unit when it is restarted.
The shaft is therefore automatically turned at low speed (about one percent rated speed)
by the barring gear until it has cooled sufficiently to permit a complete stop.
6.4 Oil System
An auxiliary oil system pump is used to supply oil at the start-up of the steam turbine
generator. it supplies the hydraulic oil system required for Steam turbine’s main inlet
steam stop valve, the governing control valve, the bearing and seal oil systems, the
relevant hydraulic relays and other mechanisms.
At a present speed of the turbine during start-ups, a pump driven by the turbine main
shaft takes over the functions of the auxiliary system.
6.5 Generator Cooling

While small generators may be cooled by air drawn through filters at the inlet, larger
units generally require special cooling arrangements. Hydrogen gas cooling, in an
oilseed casing, is used because it has the highest known heat transfer coefficient of any
gas and for its low viscosity which reduces winding losses. This system requires special
handling during start-up, with air in the generator enclosure first displaced by carbon
dioxide before filling with hydrogen. This ensures that the highly flammable hydrogen
does not mix with oxygen in the air.
The hydrogen pressure inside the casing is maintained slightly higher than atmospheric
pressure to avoid air ingress. The hydrogen must be sealed against outward leakage
where the shaft emerges from the casing. Mechanical seals around the shaft are installed
with a Very small annular gap to avoid rubbing between the shaft and the seals. Seal
oil is used to prevent the hydrogen gas leakage to atmosphere.
The generator also uses water cooling. Since the generator coils are at a potential of
about 22kV, an insulating barrier such as Teflon isused to interconnect the water line
and the generator high-voltage windings. Demineralised water of low conductivity is
used.
6.6 Generator High-Voltage System
The generator voltage for modem utility-connected generators ranges from 11kV in
smaller units to 22 kV in larger units. The generator high-voltage leads are normally
large aluminium channels because of their high current as compared to the cables used
in smaller machines.They are enclosed in well-grounded aluminium bus ducts .
and are supported on suitable insulators. The generator high-voltage leads are
connected tostep-up transformers for connecting to a high-voltage electrical substation
(usually in the range of 115 kV to165 kV)for further transmission by the local power
grid.
The necessary protection and metering devices are included for the high-voltage leads.
Thus, the steam turbine generator and the transformer form one unit. Smaller units may
share a common generator step-up transformer with individual circuit breakers to
connect the generators to a common bus.
6.7 Monitoring and Alarm System
Most of the power plant operational controls are automatic. However, at times,manual
intervention may be required. Thus, the plant is provided with monitors and alarm

system that alert the plant operators when certain operating parameters are seriously
deviatingfrom their normal range.
Chapter 7
MAJOR EQUIPMENT IN POWER PLANT

7.1Power Transformers

The power transformer is used for steppingup the voltage for transmission at generating
station and further distribution at the main step-down transformer substations. Usually
naturally cooled, oil immersed, known as ON type, two winding, three-phase
transformers, are used up to the rating of MVA.
They are put in operation during load hours and disconnected during light load hours
i.e. they are usually operated at approximately full load. This is possible because they
are arranged in banks and can be thrown in parallel with other units or disconnected at
will. So power transformers are designed to have maximum efficiency at or near full
load.
7.2 Voltage Regulators
Every alternator in modern power plants is provided with an automatic voltage

regulator.
This performs the following functions:
1. Control of system voltage within prescribed limits.
2. Proper division of reactive power between the alternators operating in Parallel.
3. Prevention of dangerous over-voltages on the occurrence or sudden loss of load
system.
4. The increase of excitation under system fault conditions so that maximum
synchronism.
7.3 Bus-Bars
Bus-bar (or bus in short) term is used as a main bar or conductor carrying an electric
current to which many connections may be made.
Bus-bars are merely convenient means of connecting switches and other equipment into
various arrangements. The usual arrangement of connections in most of the substations
permits working on almost any piece of equipment without interruption to incoming or
outgoing feeders.
In some arrangements, two buses arc provided to which the incoming or outgoing
feeders and the principal equipment may be connected. One bus is usually called the
"main” bus and the other "auxiliary" or "transfer" bus. The main bus may have a more
elaborate system of measuring instruments, relay etc. associated with it.
7.4 Reactor

A reactor is a coil having large inductive reactance in comparison to its ohmic resistance
and is induced in a circuit or system to limit the short-circuit currents to a self-value in
order to protect the electrical installation. As the resistance of the reactor in comparison
with their reactance is very small, the efficiency of the system is not affected
appreciably. The reactors localise the fault by limiting the current that can flow into it
other from healthy parts of the system.The reactors are also employed to protect the
circuit breakers of inadequate.
The reactors are of two types namely
1. Open type
2. Oil immersed type
Reactors in a power system can be located
1. in series with generators
2. In series with feeders or
3. Indus-bars (in ring system or in tie-bar system).
7.5 Insulators
The porcelain insulators employed in substations are of the post and bushing type. They
serve as supports and insulations of the bus-bars.
A post insulator consists of porcelain body, cast iron cap, and flange cast iron base. The
hole in the cap is threaded so that the bus-bars are either directly bolted to the cap or
fixed by means of abus -bar clamp. Post insulators are available with oval and square
flanged bases for fixing respectively, with aid of one, two or four bolts. Each basein
addition also has anunearthing bolt.
A bushing or through insulator consists of porcelain-shell body upper and lower
location washers used for fixing the position of abus bar or rod in theshell, and mounting
flange with holes drilled for fixing bolts and supplied with an earthing bolt. For current
rating above 2,000A, the bushings are designed to allow the main busbars to be passed
directly through them.

Fig. 7.1 Types of Insulators
7.6 Switchgears
During the operation of the power system the generating plants. Transmission lines.
Distributors and other electrical equipment are required to be switched on or off under
both normal and abnormal operating conditions. The apparatus including its associated
auxiliaries employed for controlling, regulating or switching on or off the electrical
circuits in the electrical power system is known as switchgear.
Broadly speaking switchgear is of two types
1. Outdoor type
2. Indoor type
For voltage above 66kV outdoor type is almost universally used because for such
voltages building work will unnecessarily increase the installation cost owing to large
spacing between conductors and large size insulators.
7.7 Switches

A switch is used in an electric circuit as a device for making or breaking the electric
circuit in a convenient way i.e. by the simple motion of a knob or handles to connect
together or disconnect into
1. Air switches and

2. Oil switches
7.7.1.Air Switches
As its names imply. Air switches are those whose contacts areopened in air, while
switches arc those whose contacts are opened under oil. Oil switches areusually
employed invery high voltage heavy current circuits.
Air switches are further classified as air-break switches and isolators
7.7.1.1 Air Brake Switch
The air-break switch has both the blade and light contact equipped with arcing horns.
Arcing horns are piece of metal between which the arc resulting from opening a circuit
carrying current is allowed to form
7.7.1.2 Isolators
Isolators are not equipped with are quenching and, therefore.not used in circuits
carrying. As the name implies isolators isolate one portion of the circuit from another
and is not intended tone opened while current is flowing.
7.7.2 Oil Switch
The oil switches arc those whose contacts are opened under oil. Oil switches areusually
employed invery high voltage heavy current circuits.
The oil switch has both the blade and the contact mounted in an oil-filled tank. The
switch is usually operated from a handle on the outside of the case. As the switch opens,
the arc formed between the blade and contact is quenched by the oil.
7.7.3 Load-Interrupter Switch
The switches are designed and used to close and open high voltage circuits under
nom1al working conditions. The arc extinguishing device ofthe load interrupter is made
in the form of as split, moulded plastic chute fitted with organic glass insets. This chute
surrounds the moving knife of the arc extinguishing system. The stationary acting
contact is located in the lower part of the chute.

7.8 Protective Equipment
Protective equipment is an extremely important item in system design as it is installed

to function under abnormal conditions to prevent failure or isolated trouble and limit its
effect.It much functions reliably and quickly. It should be selected for greatest
reliability, the speed of operations, and simplicity and should be consistent with the
system design.
7.8.1 Fuses
Fuse is a wire of short length or thin strip of material having low melting point and is
inserted in an electric circuit as aprotective device to the flow of an excessive current
through the circuit. Under normal working conditions, the such as short-circuit ,occurs
or when to load more than circuit capacity is connected to it, the current exceeds the
limiting valve, the fuse wire gets heated, melts and breaks the circuit. It thus protects a
machine or apparatus or ,aninstallation from damage due to excessive current.
Advantages:
1. it is thecheapest type of protection.

2. It needs no maintenance.
3. It interrupts enormous short-circuits current without noise, flame, gas or Smoke.
4. The minimum type of operation can be made much smaller than that with circuit
breakers.
5. It affords current limiting effect under short-circuit conditions.
6. Its inverse time-current characteristic enables its use for overload protections.
Disadvantages:
1. Time is lost in re-wiring or replacing of fuse after theoperation.

2. Discrimination between fuses in series cannot be obtained unless there is a
considerable differencein the relative sizes of the fuses concerned.
7.8.2 Circuit Breakers

Circuit breakers is a mechanical device designed lo close or open contact members.

Thus closing or opening an electrical circuit under normal or abnormal conditions. It is
so designed that it can be operated manually under normal conditions and automatically
under fault conditions. An automatic circuit breaker is equipped with a trip coil
connected to are lay or other means, designed to open or break automatically under
abnormal connected to a relay or other means.
A circuit breaker must carry normal load currents without overheating or damage and
must quickly open short-circuit currents without serious damage to itself and with a
minimum burning of contacts.
Air circuit breakers are often employed instead of oil up to 15kV in these units and oil
reclose is sometimes employed to cut cost in small rural substations.
7.9 Protective Relays
The protective relay is an electrical device interposed between the main circuit and the
circuit breaker in such a manner that any abnormality in the circuit acts on the
relay, which in turn, ifthe abnormality is a dangerous character, causes the breaker to
open and so to isolate the safety of the circuit equipment from any damage which might
otherwise cause by the fault.
All the relays have essential fundamental elements, as illustrated:
1. The sensing element, sometimes also called the measuring element, responds to the
change in the actuating quantity, the current in a protected system in case of theover-
current relay.
2. Comparing element serves to compare the action or the actuating quantity on the
actuating quantity on the relay with a pre-selected relay setting.
3. Control element on a pick-up of the relay accomplishes a sudden change in thecontrol
quantity such as theclosing of the operative current circuit.
7.10 Current Transformers
These instrument transformers are connected in power circuits to feed the current
coilsof indicating and metering instruments and protective relays. Thus the CTs in
broaden the limitsof measurements and maintain a watch over the currents flowing in
the circuit and over the power loads. In high voltage installations CTsin addition to
above ,also isolatetheindicating metering instruments from high voltage.

The primary winding is usually single turn and the number of turns on secondary
winding depends on upon the power circuit current to be measured. The larger amount
of current to be measured by more the number of turns on secondary.
The ratio of primary current to the secondary current is known as transformation ratio
of the CT.
A transformer is a device for changing the voltage in an a.c. circuit. It basically
consistsof two conductor coils that are connected not electrically but through
magneticflux. As a result of electromagnetic induction, an alternating current in one
coil willset up an alternating current in the other. However, the comparative magnitude
ofthe current and voltage on each side will differ according to the geometry, that is,the
number of turns or loops in each coil.
Consider the diagram of a very simple transformer. The coil on theleft-hand side, which
we will label as the primary side, might be connected to apower source such as a
generator, while the right-hand or secondary coil wouldsupply a load.
Transformers are often used in instrumentation applications to match the magnitudeof
a voltage or current to the range of a meter or other instrumention.
For example,most 60-Hz power-systems' instrumentation is based upon voltages in the
range of0-120 V rms and currents in the range of 0-5 Arms. Since power system
voltagesrange up to 765-kV line-to-line and currents can be 10's of kA, some method
ofsupplying an accurate, low-level representation of these signals to the
instrumentationis required.
One common technique is through the use of specialized transformers knownas
potential transformers or PT's and current transformers or CT's. If constructedwith a
turns ratio of Nl :N2, an ideal potential transformer would have a secondaryvoltage
equal in magnitude to N2/N1 times that of the primary and identical in phase.
Similarly, an ideal current transformer would have a secondary output current equal
toNl/N2 times the current input to the primary, again identical in phase. In other
words,potential and current transformers (also referred to as instrumentation
transformers)are designed to approximate ideal transformers as closely as is practically
possible.

7.11 Potential Transformers
The potential transformers are employed for voltages above 380 volts to feed the
potential coils of indicating and metering instruments relays. These transformers make
the ordinary low voltage instruments suitable for measurement of high voltage and
isolate them from high voltage.
The potential transformers arc rated for primary and secondary rated voltage, accuracy
class, thenumber of phases and system of cooling.
When the rated high voltage is applied to the primary of 110 volts the appears across
the secondary winding. The ratio of the rated primary voltages to the rated secondary
voltage is known as turn or transformation ratio.
A transformer is a device for changing the voltage in an a.c. circuit. It basically
consistsof two conductor coils that are connected not electrically but through
magneticflux. As a result of electromagnetic induction, an alternating current in one
coil willset up an alternating current in the other. However, the comparative magnitude
ofthe current and voltage on each side will differ according to the geometry, that is,the
number of turns or loops in each coil.
Consider a very simple transformer. The coil on theleft-hand side, which we will label
as the primary side, might be connected to apower source such as a generator, while the
right-hand or secondary coil wouldsupply a load.
Transformers are often used in instrumentation applications to match the magnitudeof
a voltage or current to the range of a meter or other instrumention.
For example,most 60-Hz power-systems' instrumentation is based upon voltages in the
range of0-120 V rms and currents in the range of 0-5 Arms. Since power system
voltagesrange up to 765-kV line-to-line and currents can be 10's of kA, some method
ofsupplying an accurate, low-level representation of these signals to the
instrumentationis required.
One common technique is through the use of specialized transformers knownas
potential transformers or PT's and current transformers or CT's. If constructedwith a
turns ratio of Nl :N2, an ideal potential transformer would have a secondaryvoltage
equal in magnitude to N2/N1 times that of the primary and identical in phase.
Similarly, an ideal current transformer would have a secondary output current equal
toNl/N2 times the current input to the primary, again identical in phase. In other
words,potential and current transformers (also referred to as instrumentation

transformers)are designed to approximate ideal transformers as closely as is practically

possible.
7.12 Lightning Arresters
The lightning arrester is a surge diverter and is used for the protection of power system
against the high voltage surges .It is connected between the line and earth and so diverts
the incoming with voltage wave to the earth.
Lightning protection by means of lightning arresters and gaps and overhead ground
wires is a means of reducing outages and preventing damage to station equipment from
lightning disturbances. The amount and kind of protection vary in different
applications, depending upon the exposes of the lines, the frequency and the severity of
lightning storms, the cost of the protection as an insurance value against damage to
equipment and the value of reduced line outages.
The transmission line is protected from direct strokes by running conductor, known as
theground wire, over the towers or poles and earthed at regular intervals preferably at
every pole/tower.
Substations, interconnectors, and powerhouses are protected from direct strokes by

anearthing screen that consists of a network of copper conductors. Earthed at least on
two points, overall the electrical equipment in the substation.
There are following types of lightning arresters
Rod gap is thevery inferior type of surge diverter and is usually employed as a second
line of defence in view of its low cost.
Horn gap arrester was one of the earliest types of surge diverters to be developed and
is still used to a certain extent on low voltage lines on account of its great simplicity.
Electrolytic arrester operates on the fact the thin film of aluminium hydroxide
deposited on the aluminium plates immersed in electrolyte acts as high resistance to
low voltage but a low resistance to avoltage above a critical value.
Valve type lightning arrester is very cheap, effective and robust and is therefore
extensively used nowadays for high voltage systems. This consists of a number of discs
of a porous material stacked one above the other and separated by their mica rings.
7.13 Earthing Of Power System

The term 'earthing' means connecting of the non-current carrying parts of the electrical
equipment or the neutral point of the supply system to the general mass of earth in such
a manner that at all times an immediate discharge of electrical energy takes place
without danger.
The earthing is provided with the following objective:
1. For the safety of personnel from the electric shock-insuring that noncurrent carrying
parts, such as equipment frames are always safely at ground even through insulation
fails.
2. For providing the ground connections for grounded neutral system.
3. For providing a means of positively discharging and de-energizing feeders equipment
before proceeding with maintenance on them.
The earthing can be divided into neutral and equipment earthing. Natural earthing of
the system neutral to ensure system security and protection.
Equipment Earthing:-It also helps in the earth fault protection. The earth fault current
from the equipment flows through the earthing system tothe earth and issensed
protection system and circuit breakers are opened. The faulty equipment is then repaired
and decommissioned. The earthed parts remain at approximately earth potential even
during theflow of fault current.
Neutral Earthing(Neutral grounding):- The natural point of star connected 3-phase

winding of power transformers, generators, motors, earthing transformer share
connected to low resistance ground.
The chief advantages of neutral earthing are:
1. Persistent arcing grounds can be eliminated by employing suitable Protective gear.

2. Earth faults can be utilised to operate protective relays to isolate the fault.
3. The voltage of healthy phases remains nearly constant.
4. Induced static charges are aconductor to earth without disturbance.
5. There is a possibility of installing discriminative protective gear on such systems.
6. This system gives reliable service and greater safety to personnel and equipment.
7. Maintenance and operating cost of such systems over theisolated system are
comparably less.

A number of methods exist for neutral earthing. At one extreme is the isolated solidly
earthed neutral. In between there are various degrees of earthing through resistance,
reactance or arc suppression coil.
Solid Grounding:-It (are known as effective earthing) means thedirect connection of

the neutral to earth. Solid grounding reduces the voltage strain to the minimum and
permits the lowest setting of protective gaps and voltage rating of lightning arresters.
The only drawback of solid grounding is that is that in the event of a fault involving
ground, the fault current is high. However, due to theadvent of high-speed protection
systems and high rupturing capacity fuses this drawback has been, more or less
overcome. There foremost of the systems operate with asolid earthling.
There are following methods of grounding:-
1.Grounding through a resistance or reactance limits the fault current and resulting
system disturbance in case of line-to-ground failure but increases through animpedance,
the value must be low enough to permit adequate ground current for reliable relaying
and to prevent dangerously high voltages due to resonant or arcing conditions.
2. Arc suppression or Peterson coil earthing is also reactance earthing but the value
of reactance is tuned with the line- toground capacitance. In this method or neutral
grounding, the acting grounds danger has been eliminated and the system is
approximated to the isolated neutral systems, in which one or two healthy phases
continue to supply power and complete shutdown is avoided.
7.14 Control Rooms
The control room is the nerve centre or a power station. Thevarious controls performed
from here are voltages adjustment. load control, emergency tripping of turbines etc. and
the equipment and instruments housed in a control room are synchronising equipment,
voltages regulators, relays, ammeters, voltmeters, wattmeters, kWh meter, kVARh
meters, temperature gauges, water level indicators and other appliances, as well as a
mimic diagram and suitable indicating equipment to show the opened or closed position
of circuit breakers, isolators etc.

Fig 7.2 Control room of a thermal power plant
Control Panel Room
Fan Generator
control Control
desk Desk
Turbine
Fuel
Steam & Desk
control
Water
desk
Desk
Fig 7.3 : Schematic diagram of contol room
Chapter 8

Electric Power Transmission

8.1 Introduction
Electric power transmission is the bulk transfer of electrical energy a process in the
delivery of electricity to consumer . A power network typically connect power plant to
multiple substation near a populated area .The wiring from substation to consumer is
referred to electricity distribution ,following the historic business model separating the
wholesale electricity transmission business from distributor who deliver to electricity
to the home . Electric power transmission allows distant energy source (such as
hydroelectric power plant ) to be connected to consumer in population centre and may
allows exploitation of low –grade fuel resource such as coal that would otherwise be
too costly to transport to generating facility .
Fig 8.1Power system network layout
8.2 Transmission line
Usually transmission line use three phase alternating current (AC) . Single phase AC
current is sometime used in a railway electrification system . High voltage direct
current sustem are used for long distance transmission line or some undersea cable or
for connecting different ac networks.
Electricity is transmitted at high voltage ( 110kv or above ) to reduce the energy lost in
transmission . Power is usually transmitted as alternating current through overhead
power line . Underground power transmission is used only in density populated areas
because of its higher cost of installation and maintence when compared with overhead
wire and the difficulty of voltage control on long cable.

Fig 8.2 Transmission line
8.2.1 Overhead Transmission line
Overhead conductor are not covered by insulation . The conductor material is nearly
always an aluminium alloy ,made into several strands and possibly reinforced with steel
strands .Copper was sometime used for overhead transmission line but aluminium is
lower in weight for equivalent performance and much lower cost . Overhead conductor
are a commodity supplied by several companies worldwide . Improved conductor
material and shapes are regularly used to allow increased capacity due to the the skin
effect that cause most of the current to flow close the surface of the wire.
8.2.2 Underground Transmission line
Electric power can also be transmitted by underground power cable intsead of overhead
power line they can assist the transmission of power across. Densely populated areas
where land is unavaible or planning consent is difficult . River and other natural
obstacle land with outstanding natural or heritage areas of significant or prestigious
infrastructure development land whose value must be maintained for future urban
expansion and rural development .

Chapter 9
ELECTROSTATIC PRECIPITATOR
If suspended partical are not removed from the flue gases and it is allowed to released
in environment ,then it would be cause a serious threat to the environment ,so it become
necessary to extact suspended particle from flue gases and for this puspose ESP isa
widely used.
9.1WORKING PRINCIPLE:- An electrostatic precipitor is define as a device

which utilize electrical force to seprate suspended particle. The electroststic precipitor
consist of two sets of electrode , one in form of thin wire called “ discharge or emmiting
electrode” And other set is “collecting electrode” in there form of plate.
9.2Construction :-
The Main Part Of ESPAre As Follows

• Casing
• Hopper
• Collecting system
• Emitting system
• Rapping mechanism for collecting system
• Rapping mechanism for emitting system
• Insulator housing
Casing:- It is designed for horizontal gas flow to provide for heat expansion the casing
is supported bu roller bearing support.
Hopper:- they are of pyramidal shape .Angle between hopper corner and Hz is never
less than 55 degree.
Collector system;- The profied collecting electrode is based on the concept of
dimensioned electrode stability .
Emitting System:- The framework is thoroughly braced and forms a rigid box like
structure ,the emitted electrode is made of hard staineless steel wire.
Rapping Mechanisms For Collecting System;- the system employe fumbling which
are mounted on Hz shaft in a staggered fashion. A uniform rapping effect is provide for
all collecting rapping effect is provide for all collecting plate in one row rapping
frequency is very low to minimize the dust loss.

Chapter10
SUPER-CRITICAL TECHNOLOGY
10.1 Efficiency Of Thermal Power Plants
The thermal efficiency of thermal power plants, defined as the ratio of the heating
equipment of the mechanical energy transmitted to the turbine shaft and the heat of
combustion is quite low (about 30%). The overall efficiency of the power plant,
defined as the ratio of heat equipment of electrical output to the heat of combustion, is
about 29%. The overall efficiency is determined by multiplying the thermal
efficiency of thepower plant by the efficiency of generation.
Table 10.1 The overall efficiency of thermal power plant
Installed plant capacity Average Overall Thermal Efficiency
Upto 1 MW 4%
1MW to 10 MW 12%
10 MW to 50 MW 16%
10 MW to 50 MW 24%
Above 100 MW 27%
Plant Efficiency:-
we will divide whole plant efficiency in four component efficiency
1) Cycle efficiency
2) Turbo generator efficiency
3) Boiler efficiency
4) Auxiliary efficiency
Overall efficiency = boiler efficiency * turbine efficiency * cycle efficiency*

generator efficiency
1.Cycle efficiency
Cycle efficiency being the maximum possible heat energy that could be
obtained from any particular set of steam condition employed .The operarion of
heat reduction of condenser which is almost 50% of the total available heat
makes ranking cycle relatively inefficient.

Cycle efficiency = energy available for conversion in work

Energy given in boiler as heat
2.Alternator Efficiency
The alternator efficient machine at about 98% efficiency .The losses are
(a) Copper and irion loss
(b) Wind age losses
Operationally the plant is governed by the grid requirement . for voltage we use the
set out from generator transformer
3.Boiler efficiency
It depend on :
(a) dry flue gas loss: increase by excess air in boiler
(b) Wet flue gas loss: Moisture in coal
(c) Moisture in combustion loss: Hydrogen gas
(d) Radiator and in accounted loss
4. Turbine efficiency
It means the efficiency of steam turbine in converting the heat energy made
available in the cycle into actual work.
Turbine losses falls into the one or two groups either losses external to the
turbine or losses directely related to the expansion of the steam in the cylinder.
10.2 Advantages Of Thermal Power Plants

1. They can respond to rapidly changing loads without difficulty.
2. Absorption of the steam generated can be used as a process steam in Different
industries
3. Steam engines and turbines can work under 25% of overload continuously
4. Fuel used is cheaper
5. Cheaper in production cost in comparison with that of diesel power stations
10.3 Disadvantages Of Thermal Power Plant
1. Maintenance and operating costs are high

2. Long time required for erection and putting into action
3. A large quantity of water is required
4. Great difficulty experienced in coal handling
5. Presence of troubles due to smoke and heat in the plant
6. Unavailability of good quality coal
7. Maximum of heat energy lost 8. Problem of ash removing

10.4 Supercritical Technology
At a temperature of about 600°C and pressure or 30N/mm^2, water enters a

supercritical phase and has properties between those of liquid and gas. Water in
thesupercritical stage can dissolve a number of organic compounds and gases and on
theaddition of hydrogen peroxide and liquid oxygen combustion process starts. The
steam power plants operating on this principle are called supercritical plants.
The advantages of such plants are that low-grade fossil fuels (e.g. lignite) can be used
NO^2 emissions are completely eliminated and S02 emission are reduced and complete
burning of coal occurs. So the plant has no need of desulphurisation and equipment and
soot collector. With this system, the cost of processing flue gas emissions (electrostatic
precipitator etc.) is eliminated and cooling water requirements arc also reduced. So the
system becomes more economical and efficient. Supercritical power plants, these days
have an overall efficiency of just over 40%. With the use of temperature around 700°C
(known as aultra-supercritical condition), the overall efficiency of the system may be
improved to around 50%.

CONCLUSION
Summer training at the end of VI semester is an integral part of B. tech curriculum,

which gives the practical knowledge of the current technologies and future aspects of
this & gets as a link in between the theoretical input and practical application. To get a
practical knowledge of the practical field in electrical engineering is very important.
Doing summer training in such a professionally managed and well known organization
KOTA SUPER THERMAL POWER STATION helped me a lot to achieve the aim of
summer training.
During the training I have gained deep and practical knowledge about Thermal Power
Plant as well as with its main components like Turbine, Boiler, and Generator etc.
During the whole process of training we have learnt how to work in team.

REFERENCES
1. KOTA Super Thermal Power Station" Rajasthan Rajya Vidyut Utpadan Nigam Ltd
2. A course in Electrical Power by J.B.Gupta
3. Maury Klein, The Power Makers: Steam, Electricity, and the men who Invented
Modem America Bloomsbury Publishing USA, 2009 ISBN 159691-677-X
4. J.C. Hensley (Editor) (2006). Cooling Tower Fundamental (2nd Ed.ed.). SPX
5. Various information from www.google.com
6. http:/www.energymanagertraining.com/powerplant/thermalpowerplant.htm
7. www.geocities.com

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PT&IV at KOTA SUPER THERMAL POWER STATIONS GIT DEE

Fig. 1.1 K.S.T.P.S. Layout

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1.2 Salient Feature Of K.S.T.P.S.

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1. Location Sakatpura kota

i) Type stack coal

ii) Calorific value 3300k.cal. /kg

iii) Qty used 80 t/Hr

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iv) Ash content 40%

v) sulphur content 0.5%

vi) Type of handling Belt conveyor

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SITE FOR THERMAL POWER PLANTS

2.2 Requirement Of Land

2.4 Transportation Facility

2.5 Ash Disposal

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2.6 Distances From The Populated Area

2.7 Near Of The Load Centre

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Figure.3.1 Thermal Power Plant Layout

3.1.3 Components of Turbine

3.1.3.1 Casing or Cylinders:

A casing is essentially a pressure vessel which must be capable of withstanding the

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3.1.4 Turbine Specification:-

Reted output 110MW

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Figure 3.2 Boiler

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Fig 3.3 Internal Structure Of a Boiler

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5. Space requirement and availability.

3.4 Super-Heater and Re-Heater

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3.4.1 Radiant Super-Heater:-it is located in the furnace between the furnace

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3.6 Air Preheater

Air preheater is two types:

3.6.1 Recuperative Air Preheater: - These types of airpreheater are continuous in

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3.6.2 Regenerative Airpreheater:-It consists of a rotor made up of corrugated

Fig. 3.6 Condenser

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3.9 Feed Water Heater

1. Overall power plant efficiency is improved.

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3.9.1 Open or Contact Heaters:-These are usually constructed to remove no

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Fig. 3.7Internal Structure of feed water heater

3.10 Cooling Towers

A cooling tower is a wooden or metallic rectangular structure inside of which is packed

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Fig 3.8 Internal structure of a cooling tower

3.11 Turbo Alternator

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3. Less winding (air-resistance) loss.

A generator consists of the following main components and associated system:-

Fig. 3.9 Generator

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