L&T- Power

Basics of Engineering
Electrical

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Electrical System for Power Plants

Electrical System for a Power Station can be broadly classified as:

Main Power System
The Main power system deals with Generation of Power and stepping it up to a Extra
High Voltage (EHV) level. It also deals with Unit start-up power.

Plant Auxiliary Distribution System

The Auxiliary distribution system deals with supply and distribution of power to various
auxiliaries (e.g. boiler feed pump, Cooling water pumps etc) within the station boundary,
necessary for keeping the Unit up and running.

Power Evacuation System

Power evacuation system deals with receipt of power from Station at EHV level,
Export/Import of Power to the Grid and Deriving Unit start-up power.

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Typical Main Power System for Large Thermal Power Plant

Main Power System

Unit Auxiliaries
Station Auxiliaries

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Overview Main Power System

Main Power System deals with Generation of Power and steppingup this generated power to the evacuation voltage

For a 800MW Unit, power generated at 24kV and transmitted to the

Generator Transformer (GT) thru Isolated Phase Bus Duct (IPBD)

Main route of IPBD is provided with taps to feed the plant unit
auxiliaries thru Unit transformers (UTs)

Main Power system also deals with Unit start-up

For this mainly two schemes exists, Station transformer scheme

and Generator Circuit Breaker (GCB) Scheme.

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Station Transformer (ST) scheme

Start-up power derived from Grid thru Station transformer.

Unit is started by supplying power to the necessary Turbine & Boiler
auxiliaries thru Station to Unit interconnector
After start-up, unit is synchronized to the grid at EHV breaker in
switchyard. Synchronization achieved thru automatic synchronizing
equipment normally a part of turbine control equipment
After synchronization with grid, unit load are transferred to the UT by
paralleling via 11 kV interconnector
Unit supplies power to unit auxiliaries through UTs. Power is evacuated
through GT.
HV side of ST 132 kV, 220 kV, 400 kV
LV side of ST 11 kV
On load Tap Changer is required

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Station Transformer scheme

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Generator Circuit Breaker (GCB) scheme

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Generator Circuit Breaker (GCB) scheme

A switching device (GCB) introduced between generator and GT

Start-up power is derived from Grid by back charging GT and UT and

keeping GCB open

Unit is started by supplying power to the necessary Turbine & Boiler

auxiliaries

After start-up, generator is synchronized with the grid thru GCB

Once synchronized, unit supplies power to auxiliaries through UTs.

Power is evacuated through GT.

HV side of UT 24 kV
LV side of ST 11 kV
This scheme is not widely used for large thermal power plants,
However this scheme is very popular for Combined cycle plants

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Main Power System

Major Constituents of Main Power System are:

Generator with Excitation System

Station Transformer

Generator Circuit Breaker (GCB) (As applicable)

Isolated Phase Bus Duct

Generator Transformer

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Generator

Mainly comprises of:

Generator with Excitation System

Generator Control Protection & Monitoring System

Neutral Earthing Equipment

Above are in scope of Original Equipment Manufacturer (OEM) for Turbine

Generator Package

Generator stator and rotor - some of the heaviest equipment to be transported

and handled at site, with stator weighing approx. 370 MT and rotor 80 MT for
800MW generator

Major domestic suppliers - BHEL

Major international suppliers - MELCO, GE, ALSTOM, SIEMENS, HITACHI,
ABB, Toshiba
Major Chinese suppliers are Don fang Electric (DEC), Sanghai Electric, Harbin

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Major Parts of a Large Water Cooled Generator

LARGE DIAMETER ROTOR

EXCITER
SIDE

COIL END SUPPORT STRUCTURE

WITH RESIN CONE
TURBINE
SIDE

H2 GAS

BEARING

BEARING

ROTOR
BLOWER

GAS
COOLER

STATOR CORE

COOLING SYSTEM
STATOR COIL:
WATER COOLED
ROTOR COIL:
HYDROGEN INNER COOLED

STATOR
COIL

BUSHING

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Picture of a 990MVA 3000rpm MHI Generator

Turbine

Generator

Static Excitation
System

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Brushless type
Excitation system

Picture of a 1,310MVA 1,800rpm MHI Generator

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Picture of a 1,600MVA 1,800rpm MHI Generator

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Generator Excitation System

Function:
1.

SUPPLY AND CONTROL THE DIRECT CURRENT FOR THE FIELD WINDING
(FIELD CURRENT) OF THE GENERATOR.

2.

CONTROL THE VOLTAGE AND REACTIVE VOLT- AMPERE OF THE MAIN

GENERATOR BY CONTROLLING ITS EXCITATION.

Types of Excitation System:

1.

STATIC EXCITATION SYSTEM

POWER ELECTRONICS BASED
MORE ADVANCED TECHNOLOGY

2.

THYRISTOR EXCITER

BRUSHLESS EXCITATION SYSTEM

ROTATING ELECTRICAL MACHINE
CONVENTIONAL TECHNOLOGY

BRUSHLESS EXCITER

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System Configuration of Excitation System

STATIC (THYRISTOR) EXCITATION SYSTEM

Exciter Transformer
AC Bus Duct
PT

MAJOR COMPONENTS:
- EXCITER & AVR CUBICLES
- EXCITER TRANSFORMER
- AC BUS DUCT
- DC BUS DUCT
- SLIP RING & BRUSH GEAR
BRUSHLESS EXCITATION
SYSTEM
MAJOR COMPONENTS:
- BRUSHLESS EXCITER
- AVR CUBICLE

AVR

CT

Slip Ring & Brush

Gear
DC Bus
Duct

Field
Breaker

Thyristor
Rectifier

STATIC (THYRISTOR)
EXCITATION SYSTEM
PT
AVR

CT

EX

Field
Breaker

PMG

BRUSHLESS EXCITATION
SYSTEM

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Generator Circuit Breaker (GCB)

Special type of breaker, capable of withstanding the short circuit

level at Generator terminal

Requires breaking capability of a very large amount of short

circuit current, being very close to Generator

Enables power to unit auxiliaries by back charging of Generator

Transformer (as explained earlier)
Suppliers - ABB, Areva and Hitachi
ABB HEC-7 & HEC-8 more suitable for large
thermal power units

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Generator
side

Generator Circuit Breaker

Generator
Transformer side

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Isolated Phase Bus Duct

Also known as Isolated Phase type Bus Duct.

Main run connects Generator to GCB and GCB to Generator
Transformer.
Tap-off run connects main run to Unit Transformers, Excitation
transformer etc
For a 800MW unit, continuous rating of the Main run is in the range of
25,000 A and short-circuit rating of around 165 kA
Major domestic suppliers - C&S, Powergear
Major International suppliers ALFA Standard, EGE, Simelectro from
Europe, Delta Unibus from USA, Hyosung from Korea
Major Chinese suppliers - DAQO, Beijing Power Electric

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Typical IPBD Layout and connection scheme, and internal details

Tubular (hollow) conductor

Enclosure

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GE 7FA Gas Turbines Part of a 500 MW Combined Cycle Power Plant

Generator Transformer

GCB

IPBD

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Generator Transformer

Step up the generation voltage to evacuation voltage

Available in three phase bank (Single unit) up to 315 MVA rating
Single Phase banks (One transformer per phase) employed in large
thermal power plants for
a) 3-Phase transformer impose transport weight and height
limitations beyond 315 MVA
b) Failure in one bank does not affect others
Typical rating: 3 x 333 MVA for a 800 MW Unit and 3 x 260 MVA for a
660 MW Unit
One of the heaviest and largest equipment to be transported to site
Major domestic suppliers are AREVA, ABB, CGL, BHEL
Major International suppliers are GE Prolec, Fortune Electric, SPECO
(Shandong Power Equipment Company)

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View of a 290 MVA Generator Transformer

Connection with the overhead lines

IPBD
Firewall
To restrict fire
to a limited area

Transformer
Cooler banks

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Plant Auxiliary Distribution System

Plant Auxiliary Distribution is broadly divided in to following subsystems :

Normal AC System

Emergency AC System

DC System

UPS System

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Typical Unit & Station System for a 660MW Generator

Motors > 1500 kW

BFP largest motor, rating around 19 MW

typically for a 800 MW Unit
1500kW > Motors > 160 kW

Motors <160 kW

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Medium Voltage (MV) and Low Voltage (LV) Switchgear

Medium Voltage levels generally used are - 3.3 kV, 6.6 kV and 11 kV

MV switchgears comprises of SF6/VCB breakers & protective relays.

MV switchgears are used to feed HT motors and auxiliary / service transformers.

Major Manufacturers ABB, Siemens, L&T has entered in this field with a joint
venture with TAMCO, Malayasia.

Low Voltage levels generally used are - 415 V, 240 V and 110 V

LV switchgears comprises of Air Circuit Breakers & protective relays.

LV switchgears are used to feed LV loads, MCC and DB.

L&T make switchgears are used in L&T projects.

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Diesel Generator backed Emergency Power Supply

Diesel Generator provide start-up or shut-down power

In the event of total power failure, DG set provides power required for
safe shutdown of the plant like AC lube oil pumps, turning gear,
cooling water pumps/fans (as required), back-up to UPS and DC
system
DG sets also provide start-up power for combined cycle power plants
(CCPP).
Rating in the range of 1500 KVA for a 250 to 500 MW CCPP.
Normally provided at LV (415V) level.
For large thermal power plants, DG not adequate for huge start-up
power supply requirements. Hence Gas turbines may be provided.

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Diesel Generator (DG) room pictures

DG Set inside
acoustic enclosure

Auto Mains
Failure (AMF) Panel

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Plant DC Supply System

DC system
Supply power DC Emergency Oil Pumps, Control Supply to
Switchgears & Panels, Emergency Lighting
DC system mainly comprises of :

Batteries (Lead acid tubular/plante, Ni Cd type)

Battery chargers (float and float cum boost chargers)
DC distribution boards

Major local suppliers for Batteries: Exide, HBLNIFE

Major local supplier for Battery Chargers: Chhabi, Caldyne

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Battery Room Picture

Cable Trays

Operation &
Maintenance
Space

Battery Rack

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Uninterrupted Power Supply (UPS) System

UPS System
Provides uninterrupted AC power to:

DCS
Various control panels
Instrumentation System

Mainly comprises of : Battery charger, Battery, Static Inverter, Static Switches,

Isolation Transformer, UPS DB.

Major local suppliers for UPS: DB power, HIREL, Emerson, Gutor, HiRel

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Overview - Power Evacuation System

Large thermal power plants are generally located away from the
load centers
Generated power is stepped up to a suitable high voltage in step-up
substation / switchyard at generating end to minimize the
transmission losses.
Evacuation system receives power from the generating station at
high voltage level, interconnects generating station with the regional
/ National grid.
Provides power to generating station to feed plant auxiliaries during
start up, and to feed station-load during running condition.

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Connection of Generating Station with a Switchyard

Connection with
the Switchyard

IPBD
Generator
Transformer

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Outdoor (AIS) type Switchyard

Transmission Tower
& Lines

Switchyard Control
Building

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Major equipment of a Outdoor type Switchyard

Current
Circuit
Breaker (CB)

Transformer (CT)

Centre rotating
double break
isolator

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Major equipment of a Outdoor type Switchyard

Lighting
Tower

Transmission
Tower

LA
Wave Trap
CVT
CB

400 kV Circuit breaker &

Lighting tower

Wave trap, Capacitive Voltage

Transformer (CVT), Lightning Arrestor,
Double circuit Transmission tower

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33 kV Gas Insulated Switchgear (GIS)

Front View

Rear View

132 kV GIS

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BUS BAR
MODULE

VT
MODULE

CT
MODULE
CB
MODULE

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Comparison between Outdoor AIS and GIS type Switchyard

Parameters

Outdoor AIS

Indoor GIS

Layout

Occupies large space.

Hence suitable for plants in remote areas.

Occupies less than 40% space as

compared to AIS. Hence suitable for
urban area where land is at premium.

Civil & Structural

aspects

Involves construction of large number of

small foundations over a vast area, and
vast length of small cable trenches

Involves construction of a GIS building

Environmental
Considerations

Noise and electromagnetic radiation

emanating from EHV lines is a cause of
concern

Not a concern, as all the EHV

conductors are enclosed

Overall Economics

Excluding land cost, Initial capital cost is

substantially less as compared to GIS.

Approximately 2.5 to 3 times costlier

than AIS of similar capacity, for 220kV
and 400kV level

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Power System Studies

Load flow for the study of voltage regulation

Motor Starting Analysis - for the study of voltage regulation during
motor starting, constraints on motor starting current
Short Circuit / Fault Studies - for selection / verification of %
impedance of transformers, fault rating for Switchgear / MCC,
assigning short circuit rating for equipment / system

Relay co-ordination / Settings for protection co-ordination, designing

primary protections, ensuring system safety and maximum availability

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Switchgear Room Picture Showing HV Switchgear

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Switchgear Room Picture Showing LV Switchgear

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Model View of Cable Trays on Pipe rack

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Picture of Cable Trays on Pipe rack

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Picture of Cable Trays on Pipe rack

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Picture showing Under ground cable trench

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Underground Duct bank pictures

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