ABSTRACT

DECLARATION
This is to declare that Mini project work reported in the thesis titled
“OVER VIEW OF THERMAL POWER PLANT” submitted in the
department of electrical and electronics engineering (EEE), JNTUHUCEST,
Hyderabad in fulfillment of degree for the award of Bachelor of Technology is a
bonafide work done by us.

No part of the thesis is copied from books or journals or internet and

wherever the portion is taken. The same has been duly referred in the text.
The reported results are based on the project work entirely done by us and
not copied from any other source.

Also, we declare that the matter embedded in this thesis has not been
submitted by us in full or partial thereof for the award of any
degree/diploma of any other institution or university previously.

SIGNATURE OF THE CANDIDATES:

RATNA VANDANA (20011A0233)
VALEMONI SWETHA (20011A0242)

The above bonafide work carried out is found satisfactory and fulfilled
the project requirements.
Date:
 Acknowledgment

We whole heartedly thank the JNTUHUCEST ,Hyderabad for giving me

permission to do project work in K.T.P.P.

We all are thankful to Mr. [Link] (ADE/ HT) and Mr. G. VENU GOPAL
(AE/EE) internal guide in K.T.P.P Stage-II for his valuable academic guidance
and support. We whole heartedly thankful to Mr. [Link] (DE/ EMD,
Stage-II) K.T.P.P Stage-II, for giving us the opportunity to carry out our project
work in K.T.P.P.

We express our immense gratitude to our project guide Dr. A. RAGHU RAM,
Professor, for guiding us in every step our project. We would like to express our
deep sense of gratitude to Dr. K. NAGA SUJATHA, head of the department of
EEE in JNTUHUCESTH for her valuable guidance, inspiration and
encouragement in doing my project work. We all are thankful to Dr. A. JAYA
LAXMI, Principal, JNTUHUCESTH for her motivation during the project
work.

Lastly, we thank all those who helped me directly and indirectly in doing this
project work successfully. We should also thank my beloved parents and family
for the normal support throughout the project.

With Gratitude
R. Vandana (20011A0233)
V. Swetha (20011A0242)
 TABLE OF CONTENTS
CHAPTER TITLE PAGE NO.
NO.
1. INTRODUCTION 1-3
2. COAL HANDLING PLANT 4-6
2.1 OVERVIEW OF CHP
2.2 PROCESS
2.3 CRUSHER PICTURE
2.4 BUNKERS
2.5 STACKER AND RECLAIMER
3. BOILER 7-14
3.1 PULVERISERS
3.1.1 BOWL MILL
3.1.2 BALL MILL
3.2 DRUM
3.3 DRUM LEVEL INDICATOR
3.4 BOILER3
3.4.1 INTRODUCTION
3.4.2 DIMENSIONS
3.5 VARIOUS COMPONENTS OF BOILER
3.5.1 SUPER HEATER
3.5.2 REHEATER
3.5.3 DESUPER HEATERS
3.5.4 FUEL OIL PUMPING
3.5.5 FUEL HANDLING SYSTEM
3.5.6 SOOT BLOWERS
3.6 SAFETY VALVES
3.7 ECONOMISER
3.8 AIR PREHEATER
4. FANS 15-17
4.1 FORCED DRAFT FAN
4.2 INDUCED DRAFT FAN
4.3 PRIMARY AIR FANS
4.4 FANS SPECIFICATIONS
5. ASH HANDLING PLANT 18-20
5.1 INTRODUCTION
5.2 PROCEDURE OF COLLECTION
5.2.1 FLY ASH
5.2.2 BOTTOM ASH
5.3 ELECTRO STATIC PRECIPITATORS
6. WATER TREATMENT SYSTEM 21-22
6.1 WATER TREATMENT PLANT CONSISTS
6.1.1 PRE TREATMENT PLANT
6.1.2 DE MINERALISING PLANT
6.2 COOLING TOWER
7. TURBINE 23-29
7.1 INTRODUCTION
7.2 CONSTRUCTION, STEAM FLOW
7.3 HP TURBINE
7.4 INTERMEDIATE PRESSURE TURBINE
7.5 LOW PRESSURE TURBINE
7.6 MAIN OIL TANK
7.7 DE-AERATING HEATERS
7.7.1 LP HEATERS
7.7.2 HP HEATERS
7.8 GOVERNING SYSTEM
7.8.1 HYDRAULIC GOVERNING SYSTEM
7.8.2 ELECTRO-HYDRAULIC GOVERNING
SYSTEM
8. GENERATOR 30-41
8.1 STATOR
8.1.1 STATOR FRAME
8.1.2 STATOR END SHIELDS
 8.1.3 GENERATOR TERMINAL BOX
8.1.4 STATOR CORE
8.1.5 STATOR WINDING
8.2 ROTOR
8.2.1 ROTOR SHAFT
8.2.2 ROTOR WINDING
8.2.3 ROTOR SHAFT
8.3 GAS SYSTEM
8.4 TERMINAL BUSHINGS
8.5 GENERATOR TERMINAL BOX
8.6 CONSTRUCTION OF BUSHINGS
8.7 DISSOLVED GAS ANALYSIS
8.8 TESTS PERFORMED ON INSULATING FLUIDS
8.8.1 REASONS FOR TESTS
8.8.2 REASONS FOR DGA USAGE
8.8.3 DISSOLVED GAS IN OIL ANALYSIS
8.8.4 DGA TECHNIQUE INVOLVES
8.8.5 GAS DETECTED AND THEIR RELEVANCE
9. TRANSFORMER 42-45
9.1 INTRODUCTION
9.2 WORKING PRINCIPLE OF A TRANSFORMER
9.3 POWER TRANSFORMERS USED IN KTPP
9.3.1 GENERATING TRANSFORMERS
9.3.2 UNIT TRANSFORMERS
9.3.3 UNIT AUXILIARY TRANSFORMERS
9.3.4 STATION TRANSFORMERS
9.3.5 STATION AUXILIARY TRANSFORMERS
10. SWITCH YARD SYSTEM OF KTPP 1X500 MWATTS 46
11. CONCLUSION 47
12. REFERENCES 48
 CHAPTER 1

INTRODUCTION TO K.T.P.P

With increase in demand of power in India, new power projects are being
constructed with higher capacity and advanced technology for the better economy and
reliability of operation.

 The govt. of AP accorded approval on Feb 28th 2005 for setting of one 500MW
(STAGE-I) Thermal Power Project at Bhuplapally vide Lr No.4033/Pr.191/2001-2005
 Govt. of AP has also approved a 600MW (STAGE-2) at the same Thermal Power
project.

LOCATION

 Chelpur (V), Ghanpur (M), Jayashankar Bhupalpally (Dist.), Telangana, India.

Nearest Highway SH-7 connecting parkal with mahadevpur

Major crops Rice in rainy season, cash crops such as
Maize, Ground nut, Cotton etc in other
seasons
Nearest City Warangal(60km)SW
Nearest Railway Uppal Railway Station(40km)
Nearest Airport Hyderabad(170km)
Latitude 18026’54”N
Longitude 79045’32”E

Objectives: One of the important objectives of K.T.P.P. is to generate thermal power

efficiently and economically. It is also fulfilling the role of social responsibility objective by
encouraging local small-scale industries, providing employment to the people of the
backward and tribal areas. It has crores of rupees controlling pollution by installing
Electrostatic Precipitators (ESP).
BASIC IDEA OF OPERATION:

The basic principle involved is Faraday’s law of electro-magnetic induction i.e.

“whenever a conductor cuts a magnetic flux emf is induced across its ends”.

Fig 1.1. Coal Fired Power Plant

The very first thing we need to provide is a conductor cutting magnetic flux. So this can
be done in two basic ways i.e. either the conductor can be moved in the magnetic field or the
field can be varied according to the required emf that is to be generated. The process we
follow here is we rotate the rotor of a generator in the magnetic field and emf is generator at
the stator and this generated emf is further utilized according to the purpose.
To meet the purpose of rotating the rotor of a generator, the rotating shaft is in turn
connected to a turbine which is made to rotate at a rated speed by an external energy source.
So we need an energy source to rotate the turbine. To rotate the turbine energy must be
transferred from a medium to the turbine so that energy from the external source is converted
to rotational energy of turbine. In general to rotate an object which is mounted we need to
apply some torque. To produce torque we need to apply force in the tangential direction. For
the purpose of application of force we chose steam as a medium of transfer. For hydel plants
water is directly allowed from a very great height to collide with the turbine blades with a
great force.
In the same way we need to send the steam with a greater force in turn with a greater pressure
to make the turbine rotate. The basic physics involved in this is the internal energy and
enthalpy of the steam gets converted to mechanical energy that rotates the turbine.
Our target is to produce steam at a very high pressure. Pressure of the steam can be increased
by various auxiliaries through different mechanisms. So basically we need to produce steam.
For the production of steam water is to be heated to high temperatures with the help of
available fuel. Combustion of fuel is done and evolved heat is utilized for production of
steam.
Total idea is to be implemented in a highly efficient way to balance the finance and economy.
Environmental protection should also be the point of concern because burning of fuel may
evolve gases which are responsible for harmful effects that distract our ambience
 CHAPTER 2
COAL HANDLING PLANT

2.1 OVER VIEW OF CHP:

The coal handling plant for the station is designed to operate with coal from Kakatiya mines
of SCCL (Singareni Coal Company limited) to be transported from Bhoopalpally by
conveyor. This is the only plant carry the coal by road transportation.

Table 1: COAL CHARACTERISTICS

Total moisture % : 9
Ash % : 34
Sulphur % : 0.5
HHV K. cal/kg. : 4400
Ash softening temperature
(at reducing atmosphere) : 1400^0 c
Sodium content in ash as Na2O % : 01
Grindability (HGI) : 52

2.2 PROCESS:
The lumped coal is collected from coal mines through Lorries and stored in coal yard. By using
bulldozers coal is dumped in ground hopper. Coal from the ground hopper gets loaded on the
conveyor belt system. The received coal is fed to the surge hopper of the crusher house. In the
crushers coal would be sized in 20mm.

Mainly 2 types of crushers are used.

They are
- Swing hammer type.
- Ring granulator crushers.
 Fig 2.1. Crusher

Fig 2.2. Bunker

In this plant we have 7 bunkers. Among this 5 will be in service, remaining 2 are standby
mode.

2.3STACKER AND RECLAIMER :-

Excess of crushed coal is stored at Stacker for usage during non availability of
coal at hopper house. The crushed coal from stacker is sent to bunkers by reclaimer.
Fig 2.3. Stacker and Reclaimer
 CHAPTER 3
BOILER:
3.1 PULVERISERS:

Pulverisers are basically classified into two types

3.1.1BOWL MILL:

The bowl mill is one of the most advanced designs of coal pulverisers,
presently manufactured by m/s BHEL. The advantages are

1. Low power consumption.

2. Reliability.
3. Minimum maintenance.
4. Quiet and vibration less operation.

OPERATION OF BOWL MILL:

The raw coal is fed in to the mill near the canter of the revolving bowl. The drying
and transport of pulverised material from the mill is done by the hot air entering the mill side
below the bowl.
As the air pass upwards around the bowl, it picks up the pulverised coal. The
scraper pivoted to the skirt sweeps this material into the tramp iron discharge spout.
In order to get the rated capacity from the mill, it will necessary to have sufficient
hot air entering the mill to dry the material. Sufficient spring pressure to pulverize it.
And classifier deflector vanes set to obtained the required fineness.
For best operation the mill outlet temperature should be maintained as high as
possible without exceeding the safe limits. The safe limit is 90 %, but the minimum mill
temperature should not less than 650 c.
The mill is equipped to operate under pressure and the vertical shaft is air sealed to
prevent hot air and dust from leaking into the gear housing. Seal air is also supplied through
center of each trunion shaft to prevent material from entering the journal bearings.

3.1.2 BALL MILL

Ball mills come under the categorisation of low speed mills .In this mills grinding
takes place by friction of the balls on the raw coal in stage 2 and stage 3 of Dr. NTPPS low
speed mills are in service and are of direct pulverised fuel firing type i.e, pulverised coal is
directly taken from the mill to the burners via classifier and pulverised fuel pipe.
With respect to the speed of mills, the mills are classified into three types:

1. LOW SPEED MILLS

 Tube ball mill (generally suction type) - 17 to 20 rpm
 High availability/ no spare mill required.
 2. MEDIUM SPEED MILLS
 Vertical spindle design – 30 to 100 rpm pressurised and suction
tube.
3. HIGH SPEED MILL
 Beater mill, impact mill – 500 to 1000 rpm

Now the pulverised coal is sent through the 4 pipe lines to boiler.

Fig 3.1. Pulveriser

3.2 DRUM:
The function of steam drum is to separate the water from the steam generated in the
furnace walls and to reduce the dissolved solid contents of the steam generated in the furnace walls
and to reduce the dissolved solid contents of the steams to below the prescribed limits of 1ppm. The
drum is located into the steam drum by recovering heat from the gases leaving the boiler.

3.3 DRUM LEVEL INDICATOR:

The objective of this control system is to maintain the drum level to the normal water level of the
drum at all loads. At low loads (<30%), the start up feed control valve will be used as final control
element and at higher loads, speed control of boiler feed water pumps will be used. Drum level is
measured by 3transmitters through temperature compensated constant head unit. The pressure
compensated drum level signal may be selected by Mid Valve Auto Selection (MVAS) circuit of
controlas pass below the rear horizontal superheater.

DRUM specifications:

Material specification : SA-299

Design pressure Kg/cm2 (ABS) : 204.9

Design metal temp OC : 366

Max operating pressure Kg/cm2 (ABS) : 192.4

Actual thickness used for dished ends : 152.4

Overall length of Drum (MM) : 22070

OD of Drum (MM) : 2130

Internal diameter (MM) : 1778

Corrosion allowance (MM) : 0.75

Number of distribution headers :6

No. of Cyclone separator : 96

No. Of Secondary driers : 96

Shroud material : Carbon Steel

Max permissible temp differential between any two parts of the

drum (oC). : 50

Water capacity at MCR conditions (in seconds) between

normal and lowest water level permitted(up to LL trip) : 10

Drum wt. with internals (ton’s) : 237.00

Drum wt. without internals (ton’s) : 215.00

3.4 BOILER:

3.4.1 INTRODUCTION:
In boiler heat energy is released from the combustion of fossil fuels and the heat is
transferred to different fluids in the system and a part of it is lost or left out as unutilized.

Heat transfer modes

There are three modes of heat transfer like conduction, convection and radiation.

- Conduction is the heat transfer from one part of a body to another part of the same
body or from one body to another body in physical contact without appreciable
displacement of the particles of the body.
- Convection is the transfer of heat from one point to another within a fluid by the
mixing of one part with another due to the movements of the fluids.
- Radiation is the transfer of heat energy from one body to another by electro magnetic
waves
3.4.2DIMENSIONS:-

The dimensions of boiler are

Furnace width : 18034mm

Furnace depth : 15797mm

Furnace volume : 14272m3

3.5 VARIOUS COMPONENTS OF BOILER:

3.5.1 SUPER HEATER:
Super heaters are mean to raise the steam temperature above the saturation
temperature by absorbing heat from flue gas. Thus in modern boilers super heaters are
widely used to increase the cycle efficiency economically present trend is to limit the
steam temperature value at 540 degrees temperature.

Specifications:

Type: LTSH Horizontal and Pendant

Area:10843 m-sq

3.5.2 REHEATER:
Reheater is used to raise the temperature of steam from which part of the energy has
been extracted in high pressure turbine. This is another method of increasing the cycle
efficiency which increases the number of stages of reheating. Present trend is to limit the
steam temperature at 540 degrees in reheater.

Specifications:

Type: Front: Pendant Platen

Rear: Pendant Spaced

Area: 6298 m-sq

3.5.3 DESUPER HEATERS:

Desuperheaters of contact spray type are commonly used to reduce the super
heated steam temperature as a means of controlling the final super heated steam temperature.
Even though the temperature can be controlled by other means like tilting burner, gas by-pass
this is widely used to control super heated steam temperature because of simpler system, low
initial and maintenance cost, flexibility and effective control in operation.
 The only disadvantage is the purity of super heater steam may go down if the de
super heater spray water is of poor quality. But in the case of reheaters this method can be
used only as an emergency purpose and not as a regular means as direct admission of water in
reheater adversely affects the system efficiency. Hence other methods mentioned above are
utilizing for reheater temperature control oil.

3.5.4 FUEL OIL PUMPING:

i. Heavy oil pumping: Heavy Fuel oil from storage tank is led to the fuel oil pumps
located in a pump house at a pumpable temperature of 400 to 600 c .The heavy fuel oil
passé through the oil strainer on the suction side of the high pressure pump and gets
pressurised to high pressure required of oil atomisation.
ii. Light oil pumping: Light oil is required for use with eddy plate oil side
iii. Igniters: Light oil is required for warming up guns to start up the boiler from cold
condition when steam is not available for heating Heavy fuel.

3.5.5 FUEL HANDLING SYSTEM:

The principal function of pulverised coal burners is to distribute fuel and air evenly
in a furnace. Even distribution of fuel and air means that every square of the cross section of
steam from burning mixture in the furnace gets it share of fuel and air. This uniformity of
distribution is maintained along the full length of path of the burning mixture through the
furnace. If the distribution is not uniform certain part of furnace get too much fuel, so the
temperature is high and there may be heavy deposit of slag in the furnace.

3.5.6 SOOT BLOWERS

Both primary and secondary airpreheaters are provided with twin nozzle swiveling
arm type electric driven soot blowers for on load cleaning at gas outlet end only. On load, gas
side cleaning of boiler tubes and regenerative airheaters is achieved using 126 microprocessor
controlled soot blowers which are disposed around the plant as follows :
1. 88 -Furnace Wall Blowers – Steam
2. 40 - Long Retractable Soot Blowers - Steam
3. 4 - Airheater Soot Blowers for Primary and Secondary Airheaters – Steam

The boiler water wall panels are provided with suitable wall boxes four for future
accommodation of an extra sixteen furnace wall blowers and twenty-four long retractable
soot blowers for upper furnace, arch and rear pass zone, if necessary.

3.6 SAFETY VALVES:

Safety valves on the superheater main steam lines set below the low set drum
safety valve, provide another means of protection by assuring adequate flow through the
superheater if the steam demand should suddenly and unexpectedly drop Reheter safely
valves, located on the hot and cold reheat piping serve to protect the reheater if steam flow
through the reheater is suddenly interrupted.
 A power control valve on the superheater main steam line set below the low set
superheater safety valve is provided as a working valve to given an initial indication of
excessive steam pressure. This valve is equipped with a shut off valve to permit isolation for
maintenance. The relieving capacity of the Power Control Valve is not included in the total
relieving capacity of the safety valves required by the Boiler Code. During all start-ups, care
must be taken not to overheat the superheater or reheater elements. The firing rate must be
controlled to keep the furnace exit gas temperature from exceeding 5400C. A thermocouple
probe normally located the upper furnace sidewall should be used to measure the furnace exit
gas temperatures.

Specifications of Safety Valves:

LOCATION TYPE MAKE NO SET [Link]/cm2(g) SIZE in/out
(mm)
Drum 1750 WB BHEL 6 209.0,211.1 76.2/152.4
1740WB 213.2,213.2
215.3,215.3
SH SV 1740WD BHEL 2 188.5,188.5 76.2/152.4
Outlet 1538 VX-10W 2 184.7,184.7 63.5/101.6
ERV
RH 1786WB BHEL 4 52.4,52.4,54.0,54.0 152.4/254
Inlet 1786WD BHEL 4/18 49.0,49.0,50.5,50.5 152.4/203.2

Outlet

3.7 ECONOMISER:
The function of an economizer in a steam generating unit is to absorb heat from the
gases And this as sensible heat to the feed water before the water enters the evaporative
circuit of boiler

Earlier the economizers was introduced mainly to recover the heat available in the
flue gas That leaves the boiler and provision of this additional heating surface increased the
efficiency of steam generation saving the fuel consumption, that’s why it was named as
“ECONOMISER”.

Now a days economizer is used to improve the efficiency of turbine unit.

This is a good proposition as the heat available in boiler exit flue gases can be economically
recovered using air heater which is essential for pulverised fuel fired boilers.

Economiser location and arrangement:

It is usual to locate economizer, ahead of airheaters and following the primary super
heater or re heater in the gas tube hence it will be generally be contained in the same casing
as the primary super heater or reheater.

Counter flow arrangement is normally selected so that heating surface requirement is

kept minimum for the same temperature drop in the flue gas. Economiser coils are designed
for the horizontal placement , which facilitate draining of the soil and the favour the
arrangement in the second pass the boiler.
 Water flow is from the bottom to top so that steam if any formed during the heat transfer and
move along with water and prevent the lock up steam, which will cause overheating,and
failure of economizer tube.

Economiser tubes are supported in such a manner that sagging undue deflection and
expansion prevention will not occur at any condition of operation. A recirculation line with a
stop valve and n-return valve may be incorporated to keep circulation in economizer in to
tseam drum when there is fire in furnace but no feed flow

3.8 AIR PREHEATER:

Air preheater is an heat recovery unit used in the last stage in boiler. It is a heat
exchanger that absorbs waste heat from exit flue gas in boiler and transfers the heat to the
incoming cold air.
In utility boilers it is used to heat the air required for combustion purpose as well as dry and
transport coal.

3.8.1 AIRPREHEATER WORKING PRINCIPLE

- As the rotor revolves, waste heat is absorbed from the hot exhaust gas passing through
one-half of the rotor. This accumulated heat is released to the incoming air as the
same surfaces pass through the other half of the rotor.
- The heat transfer cycle is continuous as the surfaces are alternately exposed to the
outgoing gas and incoming air streams.

TYPES OF AIRPREHEATER
1. Recuperative
2. Regenerative

1. RECUPERATORS
In Recuperates gas and air are allowed to flow in separate channels and heat is
continuously transferred from gas to air through the walls of the flow channels.
2. REGENERATORS
In Regenerator type gas and air allowed to flow alternatively in the same channels
to store and retrieve heat respectively channels are made in matrix form to achieve the heat
transfer.

3.8.2 ADVANTAGES OF USING AIR PREHEATER IN A BOILER:

1. The efficiency of boiler is increased by 1 % for every 20 °C drop in flue gas

temperature.

2. Saves as much as 15% on fuel costs.

3. Enables efficient burning of lower grade fuels.

4. Permits faster load variation.

5. Preheats air for coal drying and transporting the pulverised coal to burners.

6. Reduced flue gas volume leads to size reduction in pollution control equipment.
 CHAPTER 4

HT AND LT MOTORS

4.1 HIGH TENSION MOTORS:

4.1.1 MAIN BOILER FEED PUMPS:

High-capacity HT motors are used to drive the main boiler feed pumps. These pumps
are responsible for supplying water to the boiler at high pressures, and they require
high power to perform this task efficiently.

4.1.2 FORCED DRAFT FAN:

1. Take air from atmosphere at ambient temperature to supply essentially all the
combustion air.
2. Can be either be sized to overcome all the boiler losses (pressurised firing) or just to
put the air in the furnace(balanced draft fan)
3. The system resistance includes losses in the cold air duct, airheater, the hot air duct
and the wind box in the balanced draft units.

Fig 4.1. Forced Draft Fan

4.1.3 INDUCED DRAFT FAN:

1. Used only balanced draft units, these fans literally suck the gases out of the furnace
and throw then into the stack.
2. Handle dirty gases at temperature of 125 to 200°C.
3. Speeds seldom exceed 1000 rpm.
4. System resistance includes losses in the Furnace , superheaters, reheaters, economiser,
water wall sreens, airheater, gas ducting and electrostatic precipitators (the entire gas
path).

Fig 4.2(a) Induced Draft Fan Fig 4.2(b) Induced Draft Fan

4.1.4 PRIMARY AIR FANS:

1. Used for coal fired boilers only.
2. Sized to handle clean air for the pulverisers
3. Two function are drying the coal and transporting it into furnace.
4. Similar to FD fans but much higher pressure boots.
5. System resistance includes losses in the cold air duct , pulveriser, fuel piping and
burners
6. Usually sized for 1500 rpm due to the higher pressure.
 Fig 4.3. Primary Air Fan

4.1.5 FANS SPECIFICATIONS:

Fans Frame Manu Num Voltage Tempera Drive Speed Power
factur ber ture 0c RPM Kw
er of
units
FD 1LA7714 BHEL 2 3.3KV 50 Motor 990 1025
FAN -6
PA 1LA7904 BHEL 2 11KV 50 Motor 1490 2650
FAN -4
ID 1DQ434 BHEL 2 2.3KV 150 Motor 580 3000
FAN 4

4.1.6 HIGH VOLTAGE SWITCHYARD:

The power generated in a thermal power plant is typically transmitted at high voltages
(HT) to minimize transmission losses. HT motors are used in the switchyard for
various operations, including controlling circuit breakers and disconnect switches.

4.2 LOW TENSION MOTORS:

4.2.1 AUXILIARY SYSTEMS:

LT motors are used in various auxiliary systems of a thermal power plant. These
systems include conveyor belts, pumps for cooling water, lubrication systems, and
other equipment that support the plant's operations.

4.2.2 CONTROL ROOM AND OFFICE BUILDINGS:

LT motors are used for HVAC systems, elevators, and other electrical systems in
control rooms, office buildings, and other non-industrial areas of the power plant.

4.2.3 LIGHTING:
LT motors are used for lighting throughout the power plant, including indoor and
outdoor areas, providing illumination for safety and operational purposes.
 CHAPTER 5

ASH HANDLING PLANT

5.1 INTRODUCTION:

- Ash is the residue remains after combustion of coal.

- Major part of ASH is SiO2 (60% APPROX), Which adds the property of abrasiveness
in the ash.
- Indian ash contains approximately 40-50 % of ash.

5.2 Procedure of collection:

TYPES OF ASH:

In general there are two types of ash produced in Boiler, they are

1. Fly Ash:-It is minute particles which can be collected with ID fan.

2. Bottom Ash:-It is solid form of ash and can be collected at bottom of Boiler with the
help running water.

5.2.1FLY ASH:
- About one hundred and forty four(144) Electro Static Precipitator Hopers are
used for the extraction of Fly Ash from Boilers.
- First the Fly Ash is sucked by the help of Induced Draft Fan to Electrostatic
Precipitators.
- Electrostatic Precipitators consists of series of highly charged electrodes which
precipitates ash from the Fly ash.
- Vacuum pumps create vacuum and send it to Auxiliary Buffer.
- From the Auxiliary Buffer by using high pressure air the ash is collected in Silo.
- Silo is the storage structure for Fly Ash.
 Fig 5.1 Silos of KTPP

5.2.2BOTTOM ASH:
- The bottom ash is collected from boiler will be removed by 2 sets of unloading
equipment.
- The unloading equipment consists of feed gate, clinker grinders, and jet pumps.
- The bottom ash hopper will be provided with seal through on top to prevent
ingress of outside air into the furnace. The hopper will be of ‘w’ shape.
- Each v shape consists of two outlet openings at the bottom. One opening of each
compartment will be normally used for removing ash and other will be standard.

Sequence of operation for bottom ash evacuation system:

- Start HP ash water pump.
- Select the desire jet pump from each v section.
- Open jet pump inlet valve.
- Check water pressure is above preset pressure (>6.5kg/cm2).
- Open gate valve of ash slurry disposal sump of desire compartment.
- Open seal water line valve of clinker grinder.
- Check seal water pressure is normal.
- Start clinker grinder.
- Open B.A hopper discharge gate.
- Open the jetting line valve sequentially as required.
- Once the hopper is emptied, close the feed gate start the grinder and also close the
jet pump inlet valve.
- Start BA/CA LP water pump for fast filling of hopper.
- Ensure over flow of water from BA hopper.
- Stop the BA/CA lp water pump.
- Start the refractory cooling water pump.
- Open the makeup by filling line valve for normal makeup through RCW line.

5.3ELECTRO STATIC PRECIPITATORS (ESP):

- Electrostatic precipitator mainly consists of series of electrodes.

- These electrodes are charged by High Voltage step up transformers.
- Due to the high charge when Fly Ash pass through these electrodes they get charged
and gets attached on electrodes by attraction principle.
- This Ash is removed from electrodes by Constant hammering.
the maximum amount of ash is collected at starting electroads of “ESP” as all the

ash pass through the “ESP” from starting to end point.

Principle of electro static precipitator:

The electrostatic precipitator utilizes electrostatic forces to separate dust from the
gas to be cleaned. The gas is conducted to a chamber containing “curtains” of vertical steel
plates. These curtains divide the chamber into a number of gas passages. A frame with
secured wires is located within each passage. All the frames are linked to each other to form
rigid framework. The entire framework is held in place by four support insulators, which
insulate it electrically from all parts which are grounded.

A high voltage direct current is connected between the framework and the
ground, thereby creating a strong electrical field between the wires in the framework and the
steel curtains. The electrical becomes strongest near the surface of the wires. So strong near
the surface of the wires. So strong that an electrical discharge “the corona discharge”
develops along the wires the gas is ionized due to the corona discharge and large quantities of
positive and negative ions are formed. The positive ions are immediately attracted towards
the negative wires by strength of the field. The negative ions however, have to traverse the
entire space between the electrodes to reach the positive curtains.

Enroute towards the steel curtains, the ions collide with and adhere to the
particles in the gas. The particles thereby become electrically charged and begin to migrate in
the same direction as the ions towards the steel curtains and stick on to them. These curtains
are rapped periodically to dislodge the deposited dusts, which are collected in the hoppers.
The precipitation process involves 4 main functions

1) Corona generation
2) Particle charging
3) Particle collection
4) Removal of particles
 CHAPTER 6

WATER TREATMENT SYSTEM

The importance of water treatment plant is to remove the suspended and dissolved
impurities in natural water and feed de mineralised water to boiler.

6.1 Water treatment plant consists of two major divisions

1) Pre treatment plant(PTP)
2) De Mineralising plant(DMP)

6.1.1 PRE TREATMENT PLANT:

PURPOSE: The Pretreatment Plant is the initial stage of water treatment in a thermal
power plant.
FUNCTION: It is primarily responsible for removing large impurities and suspended
solids from the raw water source (such as river water or groundwater). These impurities
could damage downstream equipment if not removed.
PROCESSES: Pretreatment typically involves processes like screening, sedimentation,
and filtration to remove debris, sand, and other coarse particles.
CHEMICAL ADDITION: Sometimes, chemicals are added at this stage to aid in
flocculation and settling of suspended solids.

6.1.2 DE MINERALISING PLANT:

PURPOSE: The Deionizing Plant is a crucial part of the water treatment process,
particularly for boiler feedwater.
FUNCTION: It is designed to remove dissolved minerals and ions from the water, which
can lead to scale formation and corrosion in the boiler and other equipment.
PROCESSES: Deionization often employs ion-exchange resins or membranes to
selectively remove ions like calcium, magnesium, sodium, and chloride from the water. This
results in highly purified or "de ionized" water.

Demineralised Cooling Water Steam Generator Pump is used to circulate cooling

water to main and high rating motor on steam generator side. This circulating water travels
through the circumference of motor. The Demineralised Cooling water steam generator
shown in fig.6.1 has power and voltage ratings of 150KW and 3.3KV respectively and
manufactured by BHEL. There are 2 units of Demineralised Cooling Water Steam
Generator, out of which one unit is in running condition and other is kept in standby. For
cooling of its own winding temperature , fan blades are mounted on non driving end of shaft.
 Fig 6.1 De Mineralised Cooling Water Steam Generator

6.2 COOLING TOWER

Cooling tower is the crucial component of cooling system used to dissipate heat from
circulating water by transferring it to atmosphere through evaporation and convective heat
transfer process. Its primary function is to cool down the heated water before it is re-
circulated back to the power plant. Inside the cooling tower shown in fig.6.2, the heated
water is distributed over a fill material. The fill material helps increase the water's surface
area, allowing for enhanced contact with air. The Natural draft air cooling mechanism is
used here. The height of cooling tower helps in better air circulation and provides a larger
surface area for heat transfer. It even minimize the possibility of recirculation of water .

Fig 6.2. Cooling Tower

 CHAPTER 7
TURBINE
7.1 INTRODUCTION:

The steam turbine would be standard multi-cylinder; tandem compound, single reheat,
condensing type machine operating at 3000 rpm with five to seven uncontrolled extractions
for regenerative feed heating. The turbine will be designed for main steam inlet parameters of
170 kg/cm2 .

7.2 CONSTRUCTION, STEAM FLOW:

Depending on the pressure main steam turbine splitted are as follows

[Link] pressure turbine(HP-T)

[Link] pressure turbine(IP-T)

[Link] pressure turbine(LP-T)

The HP turbine is a single-flow cylinder and the IP and LP turbines double flow
cylinders. The turbine and rotors and the generator rotor are connected by rigid couplings.
The HP turbine is throttle controlled. The initial steam is admitted ahead of the blading via
two main stop and control valve combinations. A swing check valve is installed in the line
leading from HP turbine exhaust to the Reheater to prevent hot steam from the reheater
flowing back into the Hp turbine.

The steam coming from the Reheater is passed to the IP turbine via two reheat stop and
control valve combinations. Cross around pipes connect the IP and LP cylinders. Connections
are provided at several points of the turbine for feedwater extraction purpose. Before the
emergency stop valves of the HP turbine reheat steam temperature of 537 degree centigrade
(+/-5 degree centigrade),Ip turbine inlet with condenser pressure of 76mm Hg (abs.)with
design condenser cooling water temperature. Though indigenous steam turbine of 500MW set
size normally has a Barrel type HP cylinder

7.3 HP TURBINE (BARREL TYPE CASING):

The outer casing of the HP turbine is of the barrel type and has neither an axial
nor a radial flange. This prevents mass concentration which would have caused high thermal
stresses. The almost perfect asymmetric design of the casing permits moderate and nearly
uniform wall thickness at all sections. The inner casing is axially split and supported so as to
be free to move in response to thermal expansion. As only slight pressure differences are
effective, the horizontal flange and joint botts of the inner casing can be kept small. The
barrel type casing permits of operation in the form of short start-up times and a high rate of
change of load even at high initial steam conditions.

7.3.1 BLADING:
 The entire turbine is provided with reaction blading. The stationary and moving
blades of the HP and IP sections and the front rows of the LP turbine are designed with
integrally milled inverted T-roots and shrouds. The iast stages of the LP turbine are fitted
with twisted drop –forged moving blades with fir-tree roots engaging in grooves in the shaft
with last stage stationary blades made from sheet steel.

Moving and stationary Blades

The HP turbine with advance blading consists of 17 drum stages. All stages are
reaction stages with 50% reaction. The stationary and moving blades of all stages are
provided the inverted T-roots which also determine the distance between the blades.

7.4 INTERMEDIATE PRESSURE TURBINE:

The IP turbine section is of double flow construction with horizontally split casings.
Allowance is made for thermal movement of the inner casing within the outer casing. The
inner casing carries the stationary [Link] reheated steam enters the inner casing from
top and bottom. The provision of an inner casing confines high steam inlet conditions to the
admission selection of this casing, while the joint flange of the outer casing is subjected only
to the lower pressure and temperature effective at the exhaust from the inner casing.

7.4.1 VALVES:
The IP turbine has two reheat stop and control valves. The reheat stop valves are
spring-action single-seat valves. The control valves, also spring-loaded, have diffusers. The
control valves operate in parrel and are fully open in the upper load range. In the lower load
range, they control the steam flow to the IP turbine and ensure stable operation even when the
turbine generator unit is supplying only the station load.

The reheat stop and control valves are supported free to move in response to thermal
expansion on the foundation cover plate below the operating floor and in front of the turbine
–generator unit. All valves are actuated by individual hydraulic servomotors.

7.5 LOW PRESSURE TURBINE:

The casing of the double-flow LP cylinder is of three-shell design .The shells are
horizontally split and are of rigid welded construction. The innermost shell, which carries the
first rows of stationary blades, is supported so as to allow thermal expansion within the
intermediate shell.

7.5.1 BLADING:
The blading stages 1 to 3 of the double flow LP turbine are of reaction type with
50% reaction. They are located in the inner-inner casing and form the initial stages of the LP
blading

a. LP bypass de superheating spray

b. Turbine exhausts hood spray

c. Gland sealing system de superheating.

Condensate will then pass series through the gland steam condenser and drain
cooler before being passed through the low pressure feed water heaters.

7.6 MAIN OIL TANK :

The main oil tank contains the oil necessary for the lubrication and cooling of the bearings, It
not only serves as a storage tank also for dearating the oil. The capacity of the tank is such
that the full quantity of oil is circulated not more than 8 times per hour.

Oil returning to the tank from the oil supply system first flows through a section of
the tank Where It is then drawn off on the opposite side the top of the tank. Oil over flows
from the riser section through the oil strainer into the adjacent submerged inlet into the riser
section of the tank where the first stage of deaeration takes place as the oil rises to the
TURBINE DRIVEN FEED WATER PUMP
7.6.1 CONDENSATE EXTRACTION PUMP:

The condensate /feed water cycle would also comprise there 50% capacity motor-
driven, vertical condensate extraction pumps of CAN-type construction. Connection between
condenser and each pump will be through a block valve and removable strainer .The pumps
will discharge through check valve and motor operated stop valves into a common discharge
header. Connection for condensate supply to the following major services will be tapped off
from this condensate discharge header.

7.7 DE-AERATING, HEATERS:

The regenerative feed heating system would comprise vertical or horizontal shell and
tube type high pressure feed water heaters with bypass arrangement. Three /four stages of
horizontal U-tube type Low pressure heaters equipped with drain cooling and condensing
zones and individual bypass system is envisaged. Besides these, separate drain cooler, gland
steam condenser etc…as per suppliers standard, horizontal spray or spray-cum tray type de-
aerater with integral vent condenser to limit oxygen content to a maximum limit of
0.0-5cc/litre at all operating conditions with minimum loss of steam are envisaged .The
storage tank should be adequate sized to accommodate at least10 minutes water requirement
to provide feed water to respective boiler at the BMCR condition. Two 50% capacity parallel
train of high-pressure feed water heater streams would be considered. Each feed water heater
stream will consists of two high pressure heaters in series. The heaters will be of horizontal
U-tube type having de superheating, condensing and drain cooling zones .All steel
construction of condensate/feed water wetted surfaces is desired to facilitate uniform
chemical conditioning of steam condensate feed water system

7.7.1 L.P HEATERS :

During normal operation, condensate passes through the LP heaters 1, 2 & 3.
However, in the event of very high level in individual heater the condensate is automatically
bypassed by interlock action. For this reason motor operated. By pass valves are placed
across LP Heater respectively. In the event of very high water level in each LP Heater, sensed
by level switches, the individual bypass valve opens and inlet-outlet motor operated isolation
valves in each heater gets closed. Restoration of the heater level to normal will not
automatically restore the heater to service. The return to normal operation must be initiated
by operator action.

NAME PLATE DETAILS OF LP HEATERS

LP HEATER-2
Serial no 01228
Design pressure Shell Side 3&F.V kg/cm2
Design pressure Tube Side 40&F.V kg/cm2
Surface Area 1337 m2
 Division Hyderabad
Type SHELL&TUBE
Design Temp. Shell Side 1560c
Design Temp. Tube Side 1520c
Weight 26000kg
Year 2007
Design As Per: ASME. SEC.8 DIV.1 2004+ADD NIL&HEI 6TH EDN

LP HEATER-3
Serial no 01229
Design pressure Shell Side 4&F.V kg/cm2
Design pressure Tube Side 40&F.V kg/cm2
Surface Area 847 m2
Division Hyderabad
Type SHELL&TUBE
Design Temp. Shell Side 2160c
Design Temp. Tube Side 1520c
Weight 18000kg
Year 2007
Design As Per: ASME. SEC.8 DIV .1 2004+ADD NIL&HEI 6TH EDN

7.7.2 HP HEATERS:
- In regenerative system of 210MW, KWU units two HP heaters are provided in feed
water line after BFP CRH line.
- AT 40% Turbine load, combustion controls can be put on auto. HP Heaters 5 &6 can
be taken into service.
- Work permit on various HP heaters, drip system, deaerator, etc. cancelled and Men,
material removed from these areas.
- Ensure that HP heaters are bypassed (valve FW-14 should be opened). Check the
analogue indication in UCB.
- Check HP heaters feed water bypass valve full open (FW - 14).
- Minimum one BFP is running with feed water charged upto the feed control Station
after HP heaters.
- Watch the trend of main steam and reheat temperature, it may come down
- since HP heaters are charged, however same shall be controlled as spray controllers
are in auto.

NAME PLATE DETAILS OF HP HEATERS

HP HEATER-5A
Serial no 01238
Design pressure Shell Side 24 kg/cm2
Design pressure Tube Side 330 kg/cm2
Surface Area 964 m2
Division Hyderabad
Type HPH-U
 Design Temp. Shell Side 2240c
Design Temp. Tube Side 2440c
Weight 44500kg
Year 2007
Design As Per: [Link].8 [Link]&IBR

HP HEATER-5B
Serial no 01239
Design pressure Shell Side 24 kg/cm2
Design pressure Tube Side 330 kg/cm2
Surface Area 964 m2
Division Hyderabad
Type HPH-U
Design Temp. Shell Side 2240c
Design Temp. Tube Side 2440c
Weight 44500kg
Year 2007
Design As Per: ASME. SEC.8 [Link]&IBR

HP HEATER-6A
Serial no: 01240

Design pressure Shell Side 57 kg/cm2

Design pressure Tube Side 330 kg/cm2
Surface Area 1145 m2
Division Hyderabad
Type HPH-U
Design Temp. Shell Side 2730c
Design Temp. Tube Side 2930c
Weight 54000kg
Year 2007
Design As Per: ASME. SEC.8 [Link]&IBR

HP HEATER-6B
Serial no -
Design pressure Shell Side 57 kg/cm2
Design pressure Tube Side 330 kg/cm2
Surface Area 1145 m2
Division Hyderabad
Type HPH-U
Design Temp. Shell Side 2730c
Design Temp. Tube Side 2930c
Weight 54000kg
Year 2007

7.8 GOVERNING SYSTEMS:

 Speed control of the steam turbine, make use of two types of governing systems

7.8.1 Hydraulic governing system:

7.8.2 Electro-hydraulic governing system :

The steam turbine will be equipped with hydraulic/motorised turning gear for
uniform heating/cooling of the rotor during start up/shut down. Highly sensitive electro-
hydraulic governing system would be provided with suitable hardware to ensure fast speed of
operation and safety. The electro-hydraulic governing system would be backed by
conventional mechanical governing and safety system ensuring stable operation under any
grid fluctuation and load throw off condition.
 CHAPTER 8
GENERATOR
An electrical generator is a machine which converts mechanical energy into
electrical energy based on the principle:

“Whenever a conductor cuts magnetic flux, dynamically e.m.f is induced in it

according to Faraday’s law of electromagnetic induction”.

The generator consists of the following components:

 Stator
 Stator frame
 End shields
 Stator core
 Stator winding
 Hydrogen coolers
 Rotor
 Rotor shaft Rotor winding
 Rotor retaining rings
 Field connections
 Bearings
 Shaft seals

The following additional auxiliaries are required for generator operation:

 Oil system
 Gas system
 Primary water system
 Excitation system

8.1 STATOR
 Fig 8.1. Stator

Construction:

Stator bars, phase connectors and bushings are designed for direct water cooling. In order to
minimize the stray losses, the bars are composed of separately insulated strands which are
transposed by 540 deg. In the slot portion and bending, the end turns are bonded together
with baked synthetic resin filters.

The bars consists of hollow and solid strands distributed over the entire bar cross-
section so that good heat dissipation is ensure.

The stator consists of the following main components:

 Stator frame
 End shields
 Bushing compartment

8.1.1 STATOR FRAME:

The stator frame with flexible core suspension components, core, and stator winding is the
heaviest component of the entire generator. A rigid frame is required due to the forces and
torques arising during operation.

The welded stator frame consists of the cylindrical frame housing, two flanged rings
and axial and radial ribs. Housing and ribs within the range of the phase connectors of the
stator winding are made of non-magnetic steel to prevent eddy current losses, while the
remaining frame parts are fabricated from structural steel.

The arrangement and dimensionally of the ribs are determined by the cooling gas
passages and the required mechanical strength and stiffness.

Two lateral supports for flexible core suspensions in the frame are located directly
adjacent to the points where the frame is supported on the foundation. Due to the rigid design
of the supports and foot portion, the forces due to weight and short-circuits will not result in
any over-stressing of the frame.
 Manifolds are arranged inside the stator frame at the bottom and top for filling the
generator with carbon dioxide and hydrogen.

Additional openings in the housing, which are sealed gastight by pressure-resistant

covers, afford access to the core clamping flanges of the flexible core suspension system and
permit the lower portion of the core to be inspected.

In the lower part of the frame at the exciter and an opening is provided for bringing
out the winding ends. The generator terminal box is flanged to this opening.

8.1.2 STATOR END SHIELDS:

The ends of the stator frame are closed by pressure containing end shields. The end
shields feature a high stiffness and accommodate the generator bearings, shaft seals and
hydrogen coolers. The horizontally split to allow for assembly.

The end shields contain the generator bearings. This results in a minimum distance
between bearings and permits the overall axial length of the TE end shields to be utilized for
accommodation of the hydrogen cooler sections Cooler wells are provided in the end shield
on both sides of the bearing compartment for this purpose.

The bearing oil is supplied to the bearing via a pipe permanently installed in the end
shield and is then passed on to the lubricating gap via ducts in the lower bearing sleeve.

8.1.3GENERATOR TERMINAL BOX:

The phase and neutral leads of the three-phase stator windings are brought out of
the generator through six bushings located in the generator terminal box at the exciter end of
the generator.

The terminal box is a welded construction of non-magnetic steel plate. This

material reduces stray losses due to eddy currents.

8.1.4 STATOR CORE:

In order to minimize the hysteresis and eddy current losses of the rotating
magnetic flux which interacts with the core, the entire core is built up of thin laminations.
Each lamination layer is made up from a number of individual segments. The segments are
punched in one operation from 0.5 mm (0.02 in.) thick electrical sheet-street laminations
having high silicon content. The stator frame is turned on end while the core is stacked with
lamination segments in individual layers. The segments are staggered from layer to layer so
that a core of high mechanical strength and uniform permeability to magnetic flux is
obtained.
 To obtain the maximum compression and eliminate undue settling during operation,
the laminations are hydraulically compressed and heated during stacking procedure when
certain heights of stack are reached. The complete stack is kept under pressure and located in
the frame by means of clamping bolts and pressure plates.

The clamping bolts running through the core made of non-magnetic steel and are
insulated from the core and the pressure plates to prevent the claiming bolts from short-
circuiting the laminations and allowing the flow of eddy currents.

8.1.5 STATOR WINDING [Corona Protection]:

To prevent potential differences and possible corona discharges between the

insulation and the slot wall, the slot selections of the bars are provided with an corona
protection. This protection consist of a wear-resistant, highly flexible coating of conductive
alkyd varnish containing graphite

A final wrapping of glass fabric tapes impregnated with epoxy resin serves as
surface protection.

High-Voltage Insulation:

High-voltage insulation is provided according to the proven Micalastic system. With

this insulating system, several half-overlapped continuous layers of mica tape are applied to
the bars. Mica tape is built up from large area mica splitting which are sandwiched between
two polyester backed fabric layers with epoxy adhesive.

The high-voltage insulation obtained is nearly void-free and is characterized by its

excellent electrical, mechanical and thermal properties in addition to being fully waterproof
and oil-resistant.

To minimize corona discharges between the insulation and the slot wall, a final coat
of semi conducting varnish is applied to the surfaces of all bars within the slot range. In
addition all bars are provided with an end corona protection, to control the electric field at the
transition from the slot to the end winding.

Bar Support System:

To protect the stator winding against the effects of magnetic forces due to load and
to ensure permanent film seating of the bars in the slots during operation, the bars are inserted
with a top ripple spring located beneath the slot wedge. The gaps between the bars in the
stator end windings are completely filled with insulating material which in turn is fully
supported by the frame.
 The stator winding connections are brought out to six bushings located in a
compartment of welded non-magnetic steel below the generator at the exciter end. Current
Transformer for metering and relaying purposes can be mounted on the bushings.

8.2 ROTOR

8.2.1 ROTOR SHAFT:

The rotor shaft is a single-piece solid forging manufactured from a vacuum casting.
Slots for insertion of the field winding are milled into the rotor body. The longitudinal slots
poles are obtained. The rotor poles are designed with transverse slots to reduce twice system
frequency rotor vibrations caused by deflections in the direction of the pole and the neutral
axis

8.2.2 ROTOR WINDING:

The rotor winding consists of several coils which are inserted into the slots and
series connected such that two coil groups form one pole. Each coil consists of several series
connected turns, each of which consists of two half turns which are connected by brazing in
the end section. The slot wedges are made of high-conductivity material and extend below
the shrunk seat of the retaining ring which is silver-plated to ensure a good electrical contact
between the slot wedges and rotor retaining rings which is proved to be a good damper
winding.

8.2.3 ROTOR SHAFT:

 The high mechanical stresses resulting from the centrifugal forces and short-
circuit torques call for high-quality heat-treated steel. Therefore, the rotor shaft is forged from
a vacuum cast steel ingot.

The root shaft consists of an electrically active portion the so-called rotor body,
and the two shaft journals.

Approximately two-thirds of the rotor body circumference is provided with

longitudinal slots which hold the field winding.

Slot pitch is selected so that two solid poles are displaced by 180 degrees.

The solid poles are also provided with additional longitudinal slots to hold the
copper bars of the damper winding. The rotor wedges act as a damper winding in the area of
the winding slots.

Retaining rings:
The centrifugal forces of the rotor end windings are contained by single-piece rotor
retaining rings. The retaining rings are made of non-magnetic high-strength steel in order to
reduce stray losses. The retaining ring is secured in the axial position by a snap ring.

Field Connections:
The field current is supplied to the rotor winding through radial terminals bolts and
two semi-circular conductors located in the hollow bores of the exciter and rotor shafts. The
field current leads are connected to the exciter leads at the exciter coupling with multi contact
plug-in contact which allow for unobstructed thermal expansion of the field current leads.

Hydrogen Cooler:
The hydrogen cooler is a shell and tube type heat exchanger which cools the
hydrogen gas in the generator. The heat removed from the hydrogen is dissipated through the
cooling water. The cooling water flows through the tubes, while the hydrogen is passed
around the finned tubes. The hydrogen cooler is subdivided into identical sections which are
vertically mounted in the turbine-end stator end shield. The required cooling water flow
depends on the generator output and is adjusted by the control valves on the water side.
Controlling the cooling water flow on the outlet side ensures an interrupted water flow th

Bearings:
The sleeve bearings are provided with hydraulic shaft lift oil during start-up and
turning gear operation. To eliminate shaft currents, all bearings are insulated from the stator
and base plate respectively.

8.3 GAS SYSTEM:

 In general the gas system contains all equipment necessary for filling the generator
with carbon dioxide, hydrogen or air and removal of these media and for operation of the
generator filled with hydrogen. The gas system consists of:

 Hydrogen supply
 Carbon dioxide supply
 Nitrogen supply
 Pressure reducer Pressure gauges
 Miscellaneous shutoff valves
 Purity metering equipment
 Gas dryer
 Carbon dioxide flash evaporator
 Flow meters

Hydrogen Supply:
The heat losses arising in the generator are dissipated through hydrogen. The heat
dissipating capacity of hydrogen is eight times higher than that of air.

rough the cooler sections so that proper cooler performance will not be impaired.

Carbon Dioxide Supply:

The generator must be filled with an inert gas carbon dioxide prior to hydrogen
filling and hydrogen removal as it is considered as a protection against explosive hydrogen
air mixtures. Carbon dioxide mixtures filled in the generator until it is positively ensured that
no explosive mixture will form during the subsequent filling or emptying procedures.

Compressed Air Supply:

To remove carbon dioxide from the generator, compressed air (clean & dry) is to
be admitted into the generator in the filter line.

Nitrogen Supply: Nitrogen is required for removing the hydrogen or air during primary
water filling and emptying procedures

PRIMARY WATER SYSTEM:

The primary water required for cooling is circulated in a closed circuit by a separate
pump. Two full capacity pumps (1 running+1 stand-by driven by separate motor) are
provided to ensure uninterrupted generator operation.

The primary water system consists of the following principal components:

Primary water tank:

Location: on the top of the stator frame on an electric support.
Need: forming highest point of entire primary water circuit in terms of static head.

Compulsive need:

A small conductivity of the primary water flow should be passed through the ion
exchanger located in the bypass of the main cooling circuit.

 Cooler:
 Primary water filter
 Fine filter
 Ion exchanger
 Alkalyser unit

8.4 TERMINAL BUSHINGS

ARRANGEMENT OF TERMINAL BUSHINGS:

The beginnings and ends of the three phase windings are brought out from the
stator frame through terminal bushings which provide for high-voltage insulation and seal
against hydrogen leakage.

Location: Bolted to the bottom plate of the generator terminal box by the mounting
flanges.

8.5 GENERATOR TERMINAL BOX:

Location: Beneath the stator frame at the exciter end.

Material: Non-magnetic steel

Advantage: Avoid eddy current losses resulting in temperature rise.

Bushing-type generator current transformers, for metering and relaying are

mounted on the bushings outside the generator terminal box

8.6 CONSTRUCTION OF BUSHINGS:

The cylindrical bushing conductor consists of high-conductivity copper with a
central bore for direct primary water cooling.

The insulator is wound directly over the conductor. It consists of impregnated

capacitor paper with conducting fillers for equalization of the electrical direct-axis and
quadrature-axis fields.

The cylindrical connection ends of the terminal bushing conductors are silver-
plated and designed to accommodate bottle two-part cast terminal connectors.

8.7 DISSOLVED GAS ANALYSIS:

 The analysis of gases from petroleum products has been performed for decades
using gas chromatography. However this technique was not applied to transformers mineral
oil until the late 1960’s and is now commonly called dissolved gas in oil analysis (DGA).
Some of the early developers of the technique were [Link] Morgan Schaffer Systems,
Canada, and researchers [Link], [Link] and [Link] from the Canadian utility Hydro-
Quebec.

8.8TESTS PERFORMED ON INSULATING FLUIDS:

Insulating fluid analysis is performed using an array of physical, chemical and

electrical tests. Physical tests include analysis for interfacial tension, pour point, relative
density, viscosity, color and others. Tests such as water content, neutralization number,
oxidation inhibitor and polychlorinated biphenyls (PCBs) are considered chemical tests.
Electrical tests consist of analyses for dielectric breakdown voltage and power factor.

8.8.1 REASONS FOR TESTS:

Because oil and solid insulation degrade with service in electrical apparatus, periodic
sampling and testing are necessary to ensure that deterioration is detected before it become
excessive. The rate at which the insulating materials degrade depends on several factors, such
as the type of the insulation, and the amounts and types of contaminants.

8.8.2 REASON FOR DGA USAGE:

The tests mentioned above provide information on the oil quality itself but fail to in
depth diagnostic information on the operating condition or health of the electric apparatus.
There is one test namely DGA however, also performed on the insulating oil of the
transformer, which provides information for diagnosing the operating condition of the
electrical apparatus.

8.8.3 DISSOLVED GAS IN OIL ANALYSIS:

Transformer oil sample analysis is useful, predictive, maintenance tool for

determining transformer health. Along with the oil sample quality tests, performing a
dissolved gas analysis (DGA) of the insulating oil is useful in evaluating transformer health.

The breakdown of electrical insulating materials and related components inside a

transformer due to thermal or electrical stress, gaseous by products are formed with in the
transformer. There are several techniques for detecting those gases and DGA is recognized as
the most informative method.

8.8.4 DGA TECHNIQUE INVOLVES:

- Sampling the oil

- Testing the sample to measure the concentration of dissolved gases,
- Extracting the gases from the oil and injecting them into a gas chromatograph (GC )
- Detection of gas concentration usually involves the use of a flame ionization detector
(FID) and a thermal conductivity detector (TCD).
- Most systems also employs methanizer, which converts any carbon monoxide and
detected on FID, a very sensitive sensor.

Removing the gas from the oil is one of the more difficult and critical portions of the
procedure. To remove most of the gas from the oil, the oil is subjected to a high vacuum in an
elaborate glass-sealed system. The gas was then collected and measured in a graduated tube
by breaking the vacuum with a mercury piston. The gas was removed from the graduated
column and immediately injected into a GC. In present modern day laboratory, however,
mercury is not a favourite material of chemists. For this reason, two additional extraction
techniques have been developed to eliminate mercury.

One is direct injection technique (ASTM D3612B). In this method, the stripping of
gases from the oil and the gas analysis takes place inside the GC. Another method is newest
method, Headspace method (ASTM D3612C).

8.8.5GAS DETECTED AND THEIR RELEVANCE:

Insulating mineral oils for transformers are mixture of many different hydrocarbon
molecules, and the decomposition process for these hydrocarbons in thermal or electrical
faults are complex.

Typical gases generated from insulating mineral oil are:

Hydrogen, H2

Methane, CH4

Ethane, C2H6

Ethylene, C2H4
 Acetylene,C2H2

Carbon Monoxide, CO

Carbon dioxide, CO2

Additionally, O and N are always present; their concentrations vary with the type of
preservation system used on the transformers. These gases are generally referred to as key
gases. The concentration of the different gases provides information about the type of
incipient fault condition present.

Key gases General fault condition

Methane, ethane, ethylene, and small Thermal condition involving the oil
amount of acetylene

Hydrogen, methane, small amount of Partial discharge

acetylene and ethane

Hydrogen, acetylene, ethylene Sustained arcing

Carbon monoxide and carbon dioxide Thermal condition involving the paper

These key gases (except CO2 ) are combustible. The total combustible gases may
indicate the existence of any one or a combination of thermal, electrical, or corona faults. The
rate at which each gases are produced depends largely on the temperature and directly on the
volume of material at that temperature.

The concentration levels of different key gases are given below:

Gases description Key gas concentration (in PPM)

 Normal Action limits Potential fault type
limits (<) (>)

Hydrogen H2 150 1000 Corona, arcing

Methane CH4 25 80 Sparking

Acetylene C2H2 15 70 Arcing

Ethylene C2H4 20 150 Severe overheating

Ethane C2H6 10 35 Local overheating

Carbon monoxide CO 500 1000 Severe overheating

Carbon dioxide CO2 10,000 15000 Severe overheating

Total combustibles TDCG 4,630 4630

As the values exceed this limit, sample frequency should be increased with
consideration given to planned outage in near term for further evaluation.

As value exceeds this limit, removal of transformer from service should be

considered.

As key gases concentration levels approach the action levels, consideration should be
given to taking the transformer out of service for further testing and inspection.

CHAPTER 9
TRANSFORMER
9.1 INTRODUCTION:
Transformers are static devices used for transferring power from one circuit to
another without change in frequency.

Different types of transformers are used for stepping up and stepping down the
generated voltage either for supplying to the grid or for self utilization.

1. GENERATOR TRANSFORMER

2. UNIT TRANSFORMER

3. STATION TRANSFORMER

9.2 WORKING PRINCIPLE OF A TRANSFORMER:

The physical basis of a transformer is mutual inductance between two circuits linked by a
common magnetic flux through a path of low reluctance. The two coils named primary and
secondary posses high mutual inductance. If one coil connected to a source of alternating
voltage, alternating flux is set up in laminated core, most of which is linked up with the other
coil in which it produces mutually induced emf according to the faradays law of
electromagnetic induction, ie

E=M*(di/dt)

Where E=induced emf,

M=mutual inductance.

EMF induced in a transformer is given by

the equation

E=4.44 ɸm f N volts, ɸm=Bm×A

If second circuit is closed, a current flow in it and so electrical energy is transferred entirely
magnetically from the first coil to the second coil.

9.3 POWER TRANSFORMERS USED IN KTPP:

The critical application of transformers in thermal power plant divided into 5 major groups.

They are

1. Generating Transformers
2. Unit Transformers
3. Unit Auxiliary Transformers
4. Station Transformers
5. Station Auxiliary Transformers

9.3.1 GENERATING TRANSFORMERS:

The Generating Voltages are normally varies from 11 KV to 21 KV. In our station,
the Generating voltage is 21 KV. The generating voltages shall be raised to the transmission
voltages ( 400 KV ).

Name Plate Particulars:

 MVA Rating : 207 MVA

 HV / LV Voltage : 400KV / 21 KV

 Vector Group : YNd1

 Phase :1

 Frequency : 50 Hz

 Cooling : ONAF/ONAF/OFAF ( 124.2 MVA/ 165.6 MVA/ 207 MVA )

9.3.2 UNIT TRANSFORMERS:

 The Unit Transformer is connected to the generator output by a tap off of the Isolated
Phase Bus Duct. The HV winding of the transformer is designed to match the
generator output voltage.

 This Unit Transformer is also used when the plant is being in service to power the
Unit equipment and Auxiliaries.
Name Plate Particulars:

 MVA Rating : 25MVA

 HV / LV Voltage : 21 / 11 KV

 Vector Group : Dyn1

 Phases :3

 Frequency : 50 Hz

 Cooling : ONAN/ONAF

9.3.3 UNIT AUXILIARY TRANSFORMERS:

 The Unit Auxiliary Transformer is also step down transformer and designed as per the
auxiliary voltages required for the power station.

 The HV side of the transformer is tapped from the Unit Transformer output . The LV
side of the transformer is connected to the Unit Switch Board with 3.3KV Loads.

 For every Unit there will be 2 Nos. Unit Auxiliary Transformers.

Name Plate Particulars:

 MVA Rating : 12.5 MVA

 HV / LV Voltage : 11 / 3.3 KV

 Vector Group : Dyn11

 Phases :3

 Frequency : 50 Hz

 Cooling : ONAN/ONAF

9.3.4 STATION TRANSFORMERS:

 The Station Transformer is a step down transformer used to connect the power
station to the transmission system so that power is available for the plant equipment
when the plant is being started.

 This particular transformer is a three winding transformer. This has one primary
winding and two separate secondary windings at same voltages.

Name Plate Particulars:

  MVA Rating : 80 MVA

 HV / LV Voltage : 400 / 11.5 /11.5KV

 Phases :3

 Frequency : 50 Hz

 Cooling : ONAN/ONAF/OFAF

9.3.5 STATION AUXILIARY TRANSFORMERS:

To start up a Thermal Power Unit, various auxiliary equipments are to be taken into service
to meet the required parameters. This power has to be drawn from the EHV substation (Grid)
through the Station Transformer. These transformers are step down type and designed as per
the auxiliary voltages required for the power station.

 It is also useful to provide uninterrupted supply to the auxiliary equipment in case of

tripping of the unit.

 The Station Transformer is connected between the EHV substation ( grid ) and Station
Service Switch Board. The Input for this Transformer is taken from The Output of
Station Transformers.

Name Plate Particulars:

 MVA Rating : 16 MVA

 HV / LV Voltage : 11/ 3.6 KV
 Vector Group : Dyn11
 Phases :3
 Frequency : 50 Hz
 Cooling : ONAN/ONAF
 CHAPTER 10
SWITCH YARD SYSTEM OF KTPP 1 X 500 MWATTS
- 21 KV Produced in the generator is step-up to 400KV with the help of Generator
Transformers (GT) and transmitted to sub stations through two bus bars.
- One bus bar is sent to Warangal Line 1 and another to Warangal Line 2.

CHAPTER 11
 CONCLUSION

In the conditional monitoring, we test the equipment to avoid the forced outage. If faults are
found to be occurring outages can be planned and the fault can be rectified before major
occur. With strict monitoring, accurate diagnostics interpretations and realistic operational/
maintenance
Strategies implementation the following would be achieved effectively:
• Asset economic loading conditions identification and assessment for maximum practicable
operating efficiency.
• Premature failures risk minimization.
• Remnant life estimation and timely asset replacement/ retiring planning.
• Asset life extension by implementing correct operational and cost effective maintenance
strategies
• Improvement in the system performance ensuring good reliability as well as plant
availability.
• Minimization of the long-term operational cost.
• Cost saving by eliminating the unplanned maintenance.
• Minimizing the outage period.
• Relocation/ retirement planning.
• In time procurement of spare parts.
 CHAPTER 12
REFERENCES

1. Power System Protection and Switchgear by Badri Ram and D N

Vishwakarma, Second Edition, Tata McGraw Hill Education Private Limited,
2011.

2.C.L. Wadhwa: Electrical Power Systems, Third Edition, New Age

International Publishers, 2001.

3. Switchgear protection and power systems by Sunil S Rao, Thirteenth

Edition, KHANNA PUBLISHERS, 2008