Training Report

On
‘Captive Power Plant ‘
(HEG Ltd. Mandideep)

Duration: 15 days

21 June 2018 to 5 July 2018

Guided by: Submitted By:

Mr. Shartendu Sharma Sourabh Sen

University Institute of Technology , Rgpv

Bhopal
 Certificate

This is to certify SOURABH SEN , student of 3rd year (B.E.) , Electrical & Electronics
Engg. , UIT RGPV , Bhopal has successfully completed his Minor training in “Captive
Power Plant Department (CPP)” in H.E.G .

The training at HEG LTD. Mandideep is of 15 days from 21 June 2018 to 5 July 2018
and has submitted a satisfactory report in a partial fulfillment of requirement pf the
award of B.E. in Electrical and Electronics Engg.

The project report hence made for Academic purpose.

Place – Bhopal

Date - Mr. Sanjay Singh

Sr. Manager L&D (HR)

ACKNOWLEDGEMENT
I would like to express my gratitude to the Engineers and Officials of the HEG for
providing us valuable information about the different facts .

I would like to express my sincere gratitude to Mr. Sanjay Singh Sir , Sr Manager , for
his simulating guidance , continuous encouragement and supervision throughout the
training . I would also like to thank the department of CPP for giving valuable
information. I thank to my training coordinator Mr. Shartendu Sharma Sir , Dy.
Manager (CPP) , for providing all the materials possible and encouraging me
throughout the course for being supportive throughout and providing me with all the
necessary advice and tools which helped me pursue this project in a healthies way .

I am also grateful , beyond my sense of gratitude , to Mr. Abhishek Yadav Sir for
sharing his valuable knowledge to us . And also to Mr. Pradyumn Thakur sir for
sharing his informations . I am deeply thanking to Mr. Mohit Sharma Sir , CPP for
giving the wisdom to us .

Lastly , I would like to express heartiest gratitude to everyones support and blessings
to complete this training successfully .
 Declaration

I SOURABH SEN student of B.E. , Electrical & Electronic Engg. , UIT RGPV , Bhopal ,
hereby declare that work presented in the training report is outcome of my own
work , iis bona-fide , correct to the best of my knowledge and this work has been
carried out taking care of Engineering ethics . The work presented does not infringe
any patented work and the same has been submitted to university for award of
degree .

Place – Submitted By,

Date – Sourabh Sen

 Preface
Today our country is passing through a critical stage , where unemployement is
expandind itself day by day . The growing number of educated people remain
unemployed for a long time . Our Govt. is trying to do its best to provide
employement opportunities , but they have there own limitations . So self
employement is an important aspect accordind to present scenario .

To provide one suitable guidance in this direction , training work has been included
in our curriculum of engineering courses . This training will reflect the theoretical and
practical knowledge acquired by students during their visit in thir industry . It deals
with an aspect in curriculum of students .

The industrial training report is about HEG , its workin and electrical maintenance in
the plant . I have tried my level best to make it error free .
 Contents

 About HEG
 Main Equipments of Thermal Power Plant
 Boiler
 Turbine
 Turbogenerator
 About HEG

HEG Ltd, a premier company of the LNJ Bhilwara group, is today India’s
leading graphite electrode manufacturer. It has one of the largest integrated
Graphite Electrode plants in the world, processing sophisticated UHP (Ultra
High Power) Electrodes.
The company exports over 70% of its production to more than 30 countries of
the world.
The position the company enjoys today in India and abroad is largely due to
its commitment to constant upgradation of its product quality to match
international standards and to meet new challenges to win and excel in all
situations.
In the 1990s, we set our “Vision” to be : “ A vibrant globally acknowledged top
league player in Graphite Electrodes and allied businesses with commitment
to growth, innovation, quality and customer focus.”
In Graphite, our focus is on UHP grade electrodes, and we have expanded
our product range and established the same on some of the toughest furnaces
of our customers. Today, we have years of experience supplying quality UHP
grade electrodes all over the world.
The encouragement from our customers has led us to increase production
capacity and become a significant global producer of quality UHP grade
electrodes for EAF application. Our ability to source the best raw material from
sources worldwide and the skills of our human resources has been the key to
our growth.
To maintain our competitiveness, we have set up a Captive Power Plant
totaling more than 77 MW.
As a responsible graphite electrode manufacturer, we continue to invest in
technology, development of new products environment and in our human
resources.
 Main Equipment of Power Plant

1. Boiler
2. Turbine
3. Generator
4. Balance of plant
5. Compressed Air System
6. Ash Handling System
7. Coal Handling System
8. DM Plant
9. Water Plant
 Boiler

A boiler is defined as a close vessel in which steam is produced from water by combustion of
fuel .
In Captive Power plant (CPP) , CBFC (Circulating Fluidizing Bed Combustion ) boiler is used
for production of steam .

How Does a CBFC Boiler work ?

CBFC has given boiler and power plant operators a greater flexibility in burning a wide range
of coal and other fuels . All this without compromising efficiency and with reduced
pollution . How does the boiler work with this technology ?

At the bottom of the boiler furnance there is a bed of inert material . Bed is where the coals
or fuels spreads . Air sipupply is from under the bed at high pressure . This lifts the bed
material and the coal particles and keeps it in suspension . the coal combustion takes place
in this suspended condition . This is Fluidized bed .

Special design of the air nozzles at the bottom of the bed allows air flow without clogging .
Primary air fans provide the preheated Fluidizing air . Secondary air fans provide preheated
combustion air in the furnance .

Circulation

Fine particles of partly burned coal , ash and bed material are carried along with the flue
gases to the upper areas of the furnances and then into a cyclone . In the cyclone the
heavier particles separate from gases and falsls to the hopper of the cyclone . This returns to
the furnance for recirculation . Hence the name Circulationg Fluidizing Bed Combustion
(CFBC) . The hot gases from the cyclone pass to the heat transfer surfaces and go out of the
boiler .

Bed Material

To start with the bed material is Sand . Some portion is lost in the ash during the operation
and this has to be made up . In the coal fired boilers , the ash from the coal itself will
makeup material . When firing biofuels with very low ash content sand will be the makeup
bed material . For high Sulphur coals , limestone addition t the bed materioas reduces SO2
emissions .

CFBC uses crushed coals of 3 to 6 mm size . This requires only a crusher not a pulverizer .
From storage hoppers c, conveyor and feeders transport the coal to feed chutes in the
furnance . Start up is by the oil burners in the furnance . Ash spouts in the furnance removes
the ash from bottom of the furnace .
Specifications of Boiler

Steam flow - 140TPH

Temperature - 4850C

Pressure - 66 kg/cm2

Efficiency - 88%

Major Equipments

1. PA Fan - Primary Air fan are used to transport and preheat pulverized coal to
burners .

2. SA Fan - Secondary Air Fan provide air to boiler for help in firing which is
called secondary air .

3. ID Fan - Induced Draught fan are used to exhaust flue gases to Chimney and
create vacuum in Furnace .

4. Ball Mill - Ball mill or Bowl mills are used for pulverization of coal in powder
form for efficient firing in the boiler .

5. Coal Feeding - Raw Coal feeders are used to supply coal to ball mills in
controlled quantity .

6. ESV - Emergency Stotators Valve are used to stop supply of steam to turbine
when unit trips .
7. ESP - Electrostatic Precipitators are used to separate ash particles from flue
gases to control pollution . Here collecting electrode , emmiting electrode and
rapping mechanism used to dislodge fly ash particles .

8. Dearator – Dearator is used to separate dissolved air from feed water to

reduce corrosion at high temperatures and pressures . It is also dosed with pH
control agents such as ammonia or morpholine to keep the residual acidity low
and thus non corrosive .

Air from feed water is separated bt Dearator . Hydrazine is dosed here so that
oxygen is removed from feed water . Phosphate dosing is done in Boiler drum
to separate Silica particles from feed water . Dosing of Phosphate and
Hydrazine must be properly monitored .Sample of water must be timely get
checked from lab so that deposition of silica in boiler tubes and turbines
blades may be avoided .

9. Cyclone Ash Collector – Cyclonic separation is a method of removing

particulatesfrom an air , gas or liquid stream , without the use of filters ,
through the vertex separation . Rotational effects of gravity are used to
separate mixtures of solid and fuels . this method can also be used to separate
fine droplets of liquids from gaseous steam .

A high speed rotating (air) flow is eastablished within a cylindrical or conical

container called a cyclone . Air flows in a helical pattern , beginning at the top
(wide end ) of the cyclone and ending at the bottom (narrow) end f=before
exciting the cyclone in a straight stream through the center of the cyclone and
out of the top . Larger (denser) particles in the rotating stream have too much
inertia to follow the tight curve of stream , and strike the outside wall , then
falling t the bottom of the cyclone where they can be removed .

10.Economizer – Economizers are used to heat feed water by flue gases to

increase efficiency of water flue gas is utilized here .
11.Super Heater – Steam produced in Boiler is further superheated in
Superheaters . The superheated steam is then piped through the main steam
lines to valves before the high pressure turbines .
Plants –

DM Plant –
Water treatment plant is used to produce Demineralized water for the steam
generation . Cation , anion and degassifier tower used to separate mineral and
gases from water . PAC or Alum used to separate mud and Silica from water . Here
minerals removed from water and pH value is maintained near 7 and Silica value
must less than 0.02 ppm .

Coal Handling Plant –

Coal Handling plant supplies coal to boiler . Waggon trippler is used to unload coal
into hoppers . Coal is crushed in crusher to crush it in 25mm size . Magnetic
separators used to separate metallic particles from coal .
 Steam Turbine

Turbine converts the heat energy of steam into Mechanical energy .

The turbine generator consists of a series of steam turbines interconnected to each

other and a generator on a common shaft . There is a high pressure turbine at one
end , followed by an intermediate pressure turbine , two low pressure turbines , and
the generator . As steam moves through the system and loses pressure and thermal
energy it expands in volume , requiring increasing in diameter and longer blades at
each succeeding stage to extract remaining energy . The entire rotating mass may
be over 200 metric tons and 100 feet (30m) long . It is so heavy that it must be kept
turning slowly even when shut down (at 3 rpm) so that ths shaft will not bow even
slightly and become unbalanced .

Impulse Reaction turbine is used in CPP .

Impulse Reaction Turbine – A form of turbine in which hot , high velocity gases
produces an aerodynamic force as an impulse force as they movie the turbine
blades in the direction needed to spin the turbine blades . In this type of turbine ,
there is a stator vane and a rotor blade arrangement whereby the base area is an
impulse design and the top is reaction turbine .

Specs of 33MW Steam Turbine –

Inlet Pressure - 65 atm

Inlet Temperature - 4800C

Output - 33MW

Speed - 3000rpm

Exhaust Air - 0.1 atm

 Turbine Auxiliary

 BFP – Boiler feed Pump is used to provide water to boiler drum .

 Condensor – Condensor is used to condense the steam exhausted from
turbine .
 CEP – Condensate Extraction Pump are used to supply water to Dearator from
condenser hot well .
 LP & HP Heater – LP and HP heaters are used to heat condensate and feed
water supplied to boiler to increase efficiency by steam bled from turbine
extraction .
 CW Pump – Raw water is circulated by CW pump in condensr tube , hence
leakage from condenser tubes must be checked to avoid mixing of raw water
into hot well .
 Cooling Tower – To condensate the steam coming out from the turbine the
flow of cooled water in condenser tube is necessary .
The water coming out from the condenser tube is hot , so it is cooled in cooling
tower and after cooling , Water is recirculated in condenser tubes .
 Main Oil Pump (MOP) – MOP supply oil to bearing of the turbine and its
governing system JOP supply oil to lift the turbine rotor when turbine is
tripped .
 DC EOP & DC JOP – During black out condition if DG SET power is not available
then above work is done by DC EOP (Emergency oil pump) & DC JOP .
 Turning Gear - Barring Gear or shaft turning gear is used to rotate turbine
rotor at 3.15 rpm when turbine is not running to check bending of rotor due to
its own weight .

Barring Gear or Shaft turning gear must be immediately engaged when turbine
rotor speed reaches to zero to avoid its bending
 Turbogenerator
(AC generator or Alternator 2 pole Cylindrical Rotor)

TurboGenerator converts mechanical energy in Electrical energy .

CPP of HEG Ltd. has 2 units of turbogenerator (Unit 1 -30 MW , Unit 2 – 33MW)

Turbogenerator Description

Unit 1

Drive - ST
KVA - 35,294
KW- 30000
P.F.- 0.85(lag)
Frequency- 50Hz
Rpm- 3000
Phase- 3AC
Stator Winding- Y(Star)
Volts - 11000
Ampere- 1852

Rotor
Volts - 186
Ampere- 642
Ambient air- 420C
Cooling- CACW
Altitude- <1000 m
Total Weight- 76000kg
Overspeed- 10% max
Insulation- Class-F
Unit 2

Apparent Power- 37 MVA

Active Power- 33MW

Current- 1942Amps

Voltage- 11KV

Speed - 3000rpm

Frequency- 50Hz

P.F.- 0.89(lag)

Connection of Stator Winding- Star(Y)

Unbalanced Loading- 10%

Field Current For Rated output - 646Amp (approx)

Cooling - CACW

Insulation- Class-F
Excitation System

The excitation used in turbogenerator in CPP of HEG is brushless excitation system.

Brushless Exciter (Main Exciter)

Type- EAR 50/15-30/8-3

Insulation- Class-F
Rated Output- 224KW
Rated Voltage- 280V
Rated Current- 800Amp
Rated Speed- 3000 rpm

Pilot Exciter

Type- EAP 22/3-30/12

Rated Output- 5KVA
Rated Voltage- 100V
Rated Current- 28.9Amp
Frequency- 300Hz
Phase- 3 (AC)
Speed- 3000 rpm

A common shaft carries the rectifier wheels the rotor of the main exciter and the permanent
magnet rotor of the pilot exciter. The shaft is rigidly coupled to the generator rotor and
exciter rotors are then supported on the three bearings.
 Brushless Exciter Consists of-

- Rectifier Wheels
- Three phase Main Exciter
- Three Phase Pilot Exciter
- Metering & Supervising Equipment – AVR & PT(Potential Transformer)

Main Exciter

Main Exciter is rotating armature type , in which armature is rotating & field is stationary
.
And armature is connected to rotating rectifier bridge for rectifying AC voltage induced in
the armature to DC voltage .

Pilot Exciter

The pilot exciter permanent magnet generator (PMG) AC machine with stationary
armature & rotating field (permanent magnet) it has 12 poles.
When the generator rotates at a rated speed the PMG generates 100V at 300Hz to
provide power supply to AVR (Automatic Voltage Regulator).
~AVR gives the DC supply to field winding of the main exciter .

AVR (Automatic Voltage Regulator)

An AVR is a device used for control the field current of the generator to keep output
voltage constant . If the output voltage from the stationary armature coil drop due to
increase in demand . More current is fed into rotating magnetic field coil through AVR ,
this increase the magnetic field around the field coil which induce a greater voltage in
armature coil.
Thus the output voltage comes into its original position.
Thank You