IN TO THE WORKING OF PLANT

BASIC PRINCIPLE INVOLVED IN WORKING: The basic principle involved is Faradays law of elec ro!"a#$e %c %$d&c %o$ i.e. w'e$e(er a co$d&c or c& s a "a#$e %c fl&) e"f %s %$d&ced across % s e$ds. BASIC IDEA OF OPERA*ION: 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. n general to rotate an ob!ect which is mounted we need to apply some torque. To produce torque we need to apply "#

force in the tangential direction. $or the purpose of application of force we chose steam as a medium of transfer. $or hydel plants water is directly allowed from a very great height to collide with the turbine blades with a great force. n the same way we need to send the steam with a greater force in turn with a greater pressure to ma%e 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. &ur target is to produce steam at a very high pressure. 'ressure of the steam can be increased by various auxiliaries through different mechanisms. So basically we need to produce steam. $or the production of steam water is to be heated to high temperatures with the help of available fuel. (ombustion 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. )nvironmental 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. BASIC RE+,IRE-EN*S: * $uel * +ater * ,eating system

* Steam circuit * -egenerating system * Steam turbine * .enerator * Transformer NO*E: AN. INFOR-A*ION DISC,SSED FRONOW ONWARDS IS -AINL. CONSERNED *O K*PS!/B S*A*ION F,EL: The available fuel for us is COAL0 (oal is transferred in lump sum from nearby coal mines popularly called as SINGERENI COLLARIES through wagons. "/

COAL 1ANDLING PLAN* 2C1P3

0aily 1 rac%s of coal will be transferred to the plant. )ach rac% consists of 2/ wagons each carrying coal around /3 tonnes. )4grade and $4grade coal is being transferred to plant whose calorific value varies in between 563341/33 7.(al87g. WAGON TIPPLER: The coal received from the collieries, is more than "33 rail wagons a day, is unloaded mechanically by two ways, wagon tipplers out of which one serves as a standby. )ach loaded wagon is emptied by tippling it in the underground coal hopper from where the coal is carried by conveyor to the crusher house. 9rrangements have been provided for weighing each rail wagon before and after tippling. )ach tippler is capable of unloading /4: rail wagons of 224/3 tonnes capacity in an hour. CONVE.OR BEL*: t is a normal rubber belt carrying the coal from one place to the other in the course of processing. The belt runs at a speed of 5.2 m8s with the help of a induction motor in connection with a speed reducing gear. MAGNETIC PULLEYS: &n belt conveyor no. #9 and #;, there have been provided high intensity electromagnetic pulleys for separating out tramp iron particles8pieces from the main stream of coal conveying. 0.(. supply for the magnet is ta%en on #"2 volt, 1phase, 23 cycles 9.(.

supply system. n addition to above high intensity suspension type electromagnets have also been provided on belt conveyors #9 and #; for separating out tramp iron pieces8particles. CRUSHER HOUSE: The unloaded coal is dragged on to mesh with slots of size 133 < 133 mm5 with the help of dozers. The filtered coal through mesh is carried through conveyor belts to hoppers from where coal is sent to crushers. Two nos. hammer type coal crushers are provided, which can crush coal to a size of 52 < 52 mm5. The crushed coal is then supplied to ;oiler -aw (oal ;un%ers =-( ;un%ers>. The surplus coal is carried to coal storage area by series of conveyors. (rushing of coal is an essential requirement for its optimum pulverizing and safe storage. NO*E: To be on safe side coal required for one month will be %ept in reserve condition in the yard, the storage yard and the raw coal is required for one day is %ept in reserve condition in the -( bun%ers. ":

COAL -ILLING PLAN*

* -aw (oal ;un%ers =-( ;un%ers> * -aw (oal (hain $eeders * 0rum ?ills or (oal ?ills * (lassifier * (yclone Separator * @apour $an * 'ulverized (ola ;un%ers ='( ;un%ers> RAW COAL BUNKER: )ach of three raw coal bun%ers is fabricated from the sheet metal and is well stiffened all around. The storage capacity of each raw coal bun%er is about 233 tones. There are four outlet gates with each bun%er. The gates are electrically operated from site. n case of failure of the electric motors the gate can be hand operated from site. 9t a time only one gate opening is suffices but should be changed so that there is no pilling within the bun%er. RAW COAL CHAIN FEEDER: The raw coal chain feeder transports coal from raw coal bun%er to the inlet chute leading to the pulverized8coal mills. There is a double lin% chain of high tensile strength steel, which moves on wheels and sweeps the raw coal falling over the top of the raw coal chute of the mill. The height of the coal bed in the chain feeder can be ad!usted manually by means of lever operated damper.

The maximum and minimum heights of the coal bed are 533mm and "53mm respectively. The signaling equipment indicates the absence of coal flow in the feeder, which is annunciated in the unit control board =A.(.;.>. The main shaft on the driving end is connected to the driving unit, consisting of variator, a gear box and a motor all mounted as a single unit. The chain wheel on the driving end shaft is provided with a shear pin, which will shear off and disconnect the driving mechanism if there is any overload on the feeder. The speed of the chain feeder is regulated automatically8remotely by actuating the control spindle of the variator through a servomotor. 9 pump for circulating the oil in 53

the gear box of variator is an integral part of variator driven by a separator motor. Some of the technical data about the raw coal chain feeder is given hereB4 ". &utput of the chain feeder "34#2 tonnes8hr. 5. Speed variations 3.323143."2"m8sec. 1. ?ain motor 6.2%+, #"2@, 23,z. #. &il pump motor 3.32%+, 553@ 2. &perating motor of each gate 1,', #"2@ and 23,z. +e can change the quantity of coal which is fed to mill in two ways. 4C ;y changing the speed of chain 4C ;y changing the depth of coal in chain Speed of chain can be changed by adding a gear system to motor. +e connect the gear system with motor with a pin called shear pin. This prevents the overloading of motor because when the coal quantity of coal on chain is greater than its capacity then the pin will brea% and prevent the pin from overloading. Speed of -aw (oal chain is 5 to /8sec. DRUM MILL: )ach mill consists of single compartment drum, bearings driving motor, coal inlet and discharge piping, ball change and lubricating equipment for mill bearings. ?ill drum is fabricated from thic% steel plates and is supported on to the anti4friction bearings. The mill is driven by an electric motor of capacity /13%+, DD3 rpm, and /./%@ through a reduction gear, which reduces the speed to "6.2 rpm. P%c &re of Ball -%ll or Coal -%ll: The ball charge for the mill consists of the three

different sizes of forged steel balls detailed as below. The capacity of each mill is 1/.6 T8hr. ". #3mm diameter 55233 %g 5. 23mm diameter 53333%g 1. /3mm diameter "3333%g 40 *o al Ball C'ar#e 565778# 0uring operation only /3mm diameter balls are added is approx. 233 %g per wee% and the guiding factor is the amperage of the coal mill, normally it should be //4ampere approx. at full 55

load and when it falls below the above value ball charging of the mill is carried out. Eubricating system consists of the oil tan%, gear pump, oil cooler and base frame to mount all these equipments. .ear pump is driven by an electric motor of rating " ,.'., #"2 @, "##3 rpm. Suction side of the gear pump is connected to the tube oil tan% and the delivery side is connected to inlet of the oil cooler and after cooling oil goes to the bearings. The oil from the bearings is cooled to the required temperature in the cooler by the means of plant bearing cooler water. CLASSIFIER: The classifier is fabricated from the steel plates. t is the equipment that separates fine pulverized coal from the coarser pieces. The pulverized coal along with the carrying as well as drying medium =flue gas> stri%es the impact plate in the classifier and the coarser pieces get separated due to the change in the direction of flow and go bac% to mill. The stream then passes to the outlet branch of the classifier through an ad!ustable telescopic tube. 9t the outlet ad!ustable vanes are provided to change the size of coal when required. CYCLONE SEPARATOR: The centrifugal type cyclone separator consists of two cyclones made up of welded sheets. t is equipment in the milling plant, which serves for separating the pulverized coal from the vapours i.e. carrying medium. The pulverized coal gets stored in the pulverized coal bun%ers and vapours go to suction of vapour fan. 9t the bottom of the cyclone separator a

rotary valve =Trin%et> is provided to transport coal from cyclone separator to '.(. bun%er on the worm conveyor as the case may be. VAPO,R FAN: 'ulverized coal from the cyclone separator is carried to the '( bun%ers by the vapour fan. This is !ust a suction fan for carrying light coal particles. $or this purpose a 1 'hase induction motor is used. @oltage applied /./ 7@ -ating #33 7+ -'? DD3 (urrent ## amps P,LVERI9ED COAL B,NKERS 2PC B,NKERS3: 9fter complete pulverizing of coal in to fine powder and separation of fine coal particles from coarse particles the final fine powder is suc%ed through vapour fan in to storage hoppers called '( ;un%ers. $rom here coal is directly sent to furnace for combustion. NO*E: *'e ac &al $eed for :&l(er%;a %o$ of coal <efore se$d%$# % o f&r$ace %s co"<&s %o$ of :owdered coal %s "ore eff%c%e$ 'a$ $or"al s%;ed coal :ar %cles0 So f%$er 'e :ar %cle %s '%#'er %s 'e eff%c%e$cy of co"<&s %o$0 So "ore %s 'e co"<&s %o$ less %s 'e e(ol& %o$ of :o%so$o&s #ases l%8e CO a$d less %s 'e :oll& %o$ a$d "ore %s 'e e$er#y collec ed0 5#

PRI-AR. AIR FAN: The pulverized coal can directly be supplied to the boiler furnace for combustion with the help of primary air fan popularly called as '9 $9F. The temperature of the coal is maintained with the help of hot air stream supplied by the '9 fan. ?&T&- 1 'hase nduction ?otor #33 7+, D33 -'?, /./ 7@, ## amps (apacity 11 m18 s Suction 0ouble WATER: Fext basic requirement water is available in lump sum from KINNERASAANI RESERVOIR=0 7innerasani is a tributary for river .odavari. 9 reservoir was constructed across this tributary from where water flows by gravity=due to difference of height in ground level> to 7T'S reservoirs. 0uring the construction of 94Station reservoir with capacity of "53 Ea%hs .allons was constructed. Eater for ;4station 5 reservoirs each with a capacity of /3 Ea%hs .allons was constructed. )ven from here water flows to clarifier naturally by gravity. 5/

WATER HANDLING SYSTEM

CLARIFIER: +ater from reservoir is directly filled in to 9EA? T9F7S in which raw water is treated with 9EA? for precipitating mud. (hlorination of water is also done here to remove different bacteria and algae present in the water. +ith the help of (entral $raculator mud in the water gets separated along with some amount of water and remaining clarified water is pumped towards 0e4?ineralizing plant through ;ooster 'umps. DE!-INERALIsING PLAN*: ,ere water is sent through a series of sand filters to remove any impurities present. Fow4a4days carbon filters are also used for this purpose. n the next step water is sent through a (9T &F ( )<(,9F.) -)S F for the removal of any metal cat ions. Fow water is passed through 0)4.9S $ )- T9F7 to remove the trace of (&5 whose output is connected to a tan% containing 9F &F ( )<(,9F.) -)S F for removal of non metallic anions. 9s a final step this water is sent through another tan% containing both the resins called mixed beds. $rom here water is sent to units for supplying to the boiler to produce steam. 56 5: NO*E: *1E -AIN REASON FOR DE-INERALIsING WA*ER IS *O PREVEN* *1E DA-AGE IF PIPE LINES CARR.ING S*EA-> *O PREVEN* *1E DA-AGE OF BOILER DR,- AND *O PREVEN* *1E DA-AGE OF *,RBINE BLADES0BECA,SE OF PRESENCE OF SAL*S IN WA*ER SCALES ARE FOR-ED ON *1E PIPE

S,RFACE AND DR,- S,RFACE0*1IS -A. DA-AGE PIPE AND DR,-0EVEN *1E BLADES OF *1E *,RBINE ARE ALSO EFFEC*ED B. *1IS0 SO *O PREVEN* DA-AGE AND CORROSION WA*ER NEED *O BE DE-INERALI9ED0

WORKING OF *1E BOILER

Ge$era %$# a$d "a%$ a%$%$# f%re: .eneration of fire is done with the help of oil and lighters. &il is sprayed from four corners of the furnace with the help of oil guns and lighters at four ends of the furnace release spar%s. This spar%s ma%e the oil to catch fire. Fow coal is carried from '( ;un%ers with the help of '9 $an. (ola is %ept hot i.e. at a temperature around 63o( for effective burning of coal. This temperature is maintained with the help of hot air from '9 fans and secondary air. (oal is released from four diagonal corners of the boiler continuously to maintain the temperature through '( in!ectors. n case of drop of temperature at any corner more amount of coal is dropped at that end through ad!ustment in the valve system. The temperature in the furnace will be around "233o(. $or the coal to be burnt effectively oxygen should be supplied uninterruptedly. $or this $0 fan is engaged. FORCED DRA,G1* FAN: This fan suc%s air from the open atmosphere and supplies it to the boiler furnace for effective combustion of coal. 9s the open air contains 5"G of oxygen this fan helps for combustion. (apacity /5 m18sec 13

"/@ control 1 'hase induction motor #33 7+, /./ 7@, DD3 -)? and ## amps. Ge$era %$# a$d :rocess%$# s ea": +ater from 0? plant is fed to the pipes that are in contact with the walls of the furnace. ,eat evolved from the burning of coal in the furnace is utilized to convert water in to steam. Steam obtained here will be at a temperature of 123o ( and at a pressure around "#3 7g8cm5. This is fed to boiler 0-A? where an interface separates water and steam. The upper part of the drum is filled with steam which is wet in nature and the down part with water from ;oiler $eed 'ump =;$'>. ;ut this steam will be wet in nature because of presence of moisture in the steam. This is called wet steam. So, to ma%e it dry this steam is passed through SA')- ,)9T)- (& ES to produce dry steam. Temperature of dry steam is around 2#3o ( and a pressure of "#3 7g8cm5. +ater from the drum is sent around the furnace and is converted to steam =wet> and brought bac% to boiler drum. 9gain from here it is sent to superheated coils to produce dry steam and the process continues. 1"

S*EA- WI*1 *1E *,RBINE

To generate )?$ the rotor of the generator need to be rotated which in turn is operated by a shaft which is rotated with the help of three turbines. * , ., '-)SSA-) TA-; F) =,' TA-; F)> * FT)-?)0 9T) 8?)0 A? '-)SSA-) TA-; F) = ' TA-; F)> * E&+ '-)SSA-) TA-; F) )ach turbine has its own operating temperature and pressure. Steam from the super heater coils is fed directly to the 1P &r<%$e at a temperature of 2#3o ( and a pressure around "#37g8cm5. The enthalpy of the steam gets converted to mechanical energy which ma%es the turbine to rotate. $rom the law of thermodynamics a perpetual motion machine of second %ind doesnHt exist, heat energy cannot be completely converted to wor%. So some amount of energy still remains in the steam. To re4utilize this energy this steam is made to interact with another turbine called I$ er"ed%a e?-ed%&" Press&re *&r<%$e. ;efore ma%ing them to interact the outlet steam from the ,' turbine is sent bac% to furnace and reheated through reheater coils .This is a part of re#e$era %(e sys e" for efficient utilization of heat energy. Steam from reheater coils is fed to ' 15

Turbine. 9gain from second law of thermodynamics some amount of energy still remains in the steam. The outlet steam from the ' Turbine is directly fed to LP *&r<%$e where maximum amount of energy is expected to be utilized. The outlet steam of the E' Turbine contains very low amount of energy as it is already used for 1 times with 1 different turbines this cannot be used for regeneration. So this steam is allowed for condensation. Turbine Lubrica in! Oi" S#$ e%: Turbine lubricating4oil system see%s to provide proper lubrication of turbo4generator bearings and operation of barring gear. The recommended wor%ing medium for governing and lubrication system of the turbine is Turbine oil4"# of F0 9F & E (&?'9FI. OIL SPECIFICA*ION: ". Specific .ravity at 23( 3.:25 5. 7inematic @iscosity at 23( 5: centisto%es 1. Feutralization number 3.5 #. $lash 'oint 53"(=min> 2. 'our 'oint 4/./(=max> /. 9sh G by +eight 3.3"G 6. ?echanical mpurities Fil The Turbine Eubricating oil system mainly consists of * ?ain &il 'ump =?&'> * Starting &il 'ump =S&'> * 9( standby &il 'umps

* emergency 0( oil pump * Jac%ing oil pump =J&'> =" per AF T> . ?ain &il 'ump is used for the Eubrication system. t is coupled with turbine rotor through a gear coupling and is used when the turbine is running at normal speed =1333 rpm> or greater than 5:33 rpm. Starting oil pump is a multi4stage centrifugal pump driven by 9.( electric motor. t is provided for meeting the requirement of oil of the turbo4set during starting or stopping and also as standby to maintain centrifugal oil pump. Standby oil pump is a centrifugal pump by an 9.( electric motor, this runs for "3 min in the beginning to remove air from the governing system and fill the oil system with the oil. )mergency &il 'ump is a centrifugal pump driven by 0.( electric motor. This automatically cuts in whenever there is a failure of 9.( supply at '&+)ST9T &F and or the pressure in lubrication system falls. 1#

Jac%ing &il 'ump enable the main bearing of the complete rotor assembly to be raised or floated in the bearing during turbine generator start up and during shut down. Oi" C&&"er$: The oil of the lubrication and governing system is cooled in the oil coolers. (irculating water is used as the cooling medium for these oil coolers. 2 oil coolers are available at the plant, out of which # are for continuous operation and one remains as standby. S ea% urbine a$ 'ri%e %&(er: The steam turbine offers many advantages over other prime movers, both thermodynamically and mechanically. $rom a thermodynamic point of view the main advantage of steam turbine over say a reciprocating steam engine is that in the turbine the steam can be expanded down to a lower bac% pressure there by ma%ing available a greater heat drop, f a reciprocating steam engine is to expand the steam down to a bac% pressure of the order of an inch or two of mercury and the low pressure cylinders would have to be a very large to deal with large volume of steam resulting from these pressures. $rom a mechanical point of view the turbine is ideal because the propelling force is applied directly to the rotating element of the machine and has not as in the reciprocating 12

engine to be transmitted to a system of connecting lin%s which are necessary to transform a reciprocating motion into a rotary motion. f the load on the turbine is %ept constant that are developed at the coupling is also constant. 9 generator at a steady load offers a constant torque. Therefore a turbine is suitable for driving a generator, particularly as they are both high speed machines. 9 further advantage of the turbine is the absence of internal lubrication. This means that the exhaust steam is not contaminated with oil vapour and can be condensed and fed bac% to the boilers without passing through filters. S ea% c#c"e: The steam plant uses a dual =vapour K liquid> phase cycle. t is a closed cycle to enable the wor%ing fluid =water> to be used again and again. The cycle used is -9F7 F. (I(E) modified to include super heating of steam, regenerative feed water heating and reheating of steam. 1/

CONDENSOR: The outlet steam of the E' Turbine is sent to condenser where steam is passed through pipe lines and cool water is allowed to be in contact with these pipes. ;ecause of the heat exchange between steam and cool water steam gets converted to water and stored in ,&T +)EE. 1O* WELL: +ater from the condenser pipes are pumped in to a sump called ,&T +)EE. +ater in this well is around 23o (. $rom here water will be sent to cooling towers for cooling. COOLING *OWERS: $rom hot well water is sent to cooling towers for the purpose of cooling. ,ere water will be ta%en to an elevation of "34"5 mts. and allowed to fall freely. +ater is allowed to fall at different points. 9t each and every falling point sprin%ling mechanism is arranged. 9t every small depth a grill arrangement is fixed to collide with the water droplets falling freely. 9 scale li%e arrangement is fixed at every small depth. This is done because to ma%e the water droplets to collide with these grills and to decrease the size of the water droplets. So smaller is the water droplet faster will be the heat exchange with the medium in which it is present. 9s heat is being evolved from every droplet of water some droplets of 1:

water may absorb the heat. This ma%es some water droplets increase their temperature rather than cooling. The heat exchange ta%es place in such a way that the temperature crosses its boiling point an even latent heat is also absorbed converting water droplets to vapour. This vapour is allowed in to the atmosphere at greater heights. So in cooling towers water gets cooled and gets converted to vapour too. To allow vapour in to free atmosphere at greater heights vapour needs to be carried to greater heights. -ather than spending energy to carry the steam to greater heights some civil engineering techniques are applied in construction of cooling tower. The construction of cooling tower involves basic laws of fluid mechanics. The walls are hyperbolic in shape following SIP1ON mechanism. These are also called 1.PERBOLIC NA*,RAL DRA,G1* COOLING *OWERS0 &nce vapour is left to the atmosphere forcibly in the beginning the process continues by itself until the vapour terminates which doesnHt happen because vapour continuously emits. This is called Na &ral Dra&#' . The other mechanism that can be followed is Forced Dra&#' @ I$d&ced Dra&#' in which fans are arranged and vapour is sent out forcibly. NO*E: KEEP I* IN -IND *1A* WA*ER COOLED IN *OWERS IS DE-INERALI9ED WA*ER0SO *1IS WA*ER S1O,LD NO* BE 1D

LEF* FREE OR WAS*ED0*1IS WA*ER CAN BE ,SED AGAIN *O PROD,CE S*EA- AND R,N *1E *,RBINES0AS PROCESS OF DE-INERALI9ING WA*ER IS VER. COS*L.> *1IS WA*E IS ,SED AGAIN0 +ater from cooling tower is sent to condensate sump. $rom here water is heated through a series a heaters called E' heaters and ,' heaters. LP 1ea er is a heater which heats the water with the help of a tapping from the steam line going to the E' Turbine. 9 series of such E' ,eaters are employed to increase the temperature. The out let of E' ,eater is fed to the 0eaerator. DEAERA*OR: 0eaerators are mechanical devices that remove dissolved gases from boiler feed water. 0eaeration protects the steam system from the effects of corrosive gases. t accomplishes this by reducing the concentration of dissolved oxygen and carbon dioxide to a level where corrosion is minimized. 9 dissolved oxygen level of 2 parts per billion =ppb> or lower is needed to prevent corrosion in most high4pressure =C533 pounds per square inch> boilers. +hile oxygen concentrations of up to #1 ppb may be tolerated in low4pressure boilers, equipment life is extended at little or no cost by limiting the oxygen concentration to 2 ppb. 0issolved carbon dioxide is essentially completely removed by the 0eaerator. #3

0eaerators use steam to heat the water to the full saturation temperature corresponding to the steam pressure in the 0eaerator and to scrub out and carry away dissolved gases. The outlet of the 0eaerator is fed to the ;& E)$))0 'A?' BOILER FEED P,-P: 9s the heart is to human body, so is the boiler feed pump to the steam power plant. t is used for recycling feed water into the boiler at a high pressure for reconversion into steam. Two nos. "33G duty, barrel design, horizontal, centrifugal multistage feed pumps with hydraulic coupling are provided for each unit. This is the largest auxiliary of the power plant driven by A577 KW electric motor. The "53 ?+ turbo set is provided with two boiler feed pumps, each of "33G of total quantity. t is of barrel design and is of horizontal arrangement, driven by an electric motor through a hydraulic coupling. #"

Type 533 7, 0elivery capacity ##2 t8hr. $eed water temperature "2:L( Speed #233 rpm 'ressure at suction :.13 %g8cm5 Stuffing box mechanical seal Eubrication of pump by oil under pressure ?otor bearing supplied by hydraulic coupling (onsumption of cooling water 513 E8min. The outlet of ;$' is around "#3 7g8cm5. This is fed to ,' ,eaters. 1P 1ea er is a heater that heats the outlet of ;$' with the help of a tapping from the steam line of ,' Turbine. 9 series of such ,' ,eaters are employed and then finally its outlet is fed to )(&F&? S)- in the furnace. ECONO-ISER: t is a part of regenerative system for efficient utilization of heat energy from the furnace. Steam from ,' ,eater is fed to the economiser tubes. ,ere steam gets heated up to 123o (. the outlet of economiser is fed to the boiler drum. n the boiler drum steam and water gets separated and steam is sent to super heater coils and same process repeats as explained earlier. #5

REGENERA*IVE S.S*E-: t is a designed loop for effective utilization of energy to increase the efficiency of the process. n general furnace is meant to produce the steam from water. ;ut total energy evolved from combustion of coal is excessive for this. So this heat energy from the furnace is repeatedly utilized wherever necessary through * SA')- ,)9T)- (& ES * -),)9T)- (& ES * )(&F&? S)-

1ANDLING OF AS1
9fter combustion of coal ash will be remained in the furnace. ,andling of ash is the ma!or problem for any thermal power plant. n the bygone ash was dumped at a far place, because of this a lot of land is being wasted. n general two types of ashes need to be handled. * ;ottom 9sh * $ly 9sh Bo o" As' is collected at the bottom of the furnace in the hoppers provided. The ash deposited at the bottom of the furnace is collected in a water impounded hopper where a continuous flow of water is maintained to limit the temperature of ash inside the hopper. The bottom ash cleaning is done in every cycle of : hours. The bottom ash system is local manually operated.

&n opening of feed gate ash is allowed to discharge into a double roll Einder grinder where it is grounded to smaller size, which can be transported through the pipe line below the lin%er grinder there is a venturi which suc%s the ground ash the vacuum created at the venturi throat by the flow of high pressure water tapped. 0awn stream of the discharge of the ash water pumps. The pressure recovered at the end of venturi is adequate to convey the slurry to disposal area. Fly As' is collected with the help of a fan called induced draught fan. ##

INDUCED DRAUGHT FAN: Two nos. axial flow nduced 0raught $ans are provided for each unit to exhaust ash laden flue gases from boiler furnace through dust extraction equipment and to chimney. The fan is driven by an electric motor through a flexible coupling and is equipped with remote controlled regulating vanes to balance draught conditions in the furnace. The fan is designed to handle hot flue gases with a small percentage of abrasive particles in suspension. This fan suc%s the ash Mparticles from the mouth of the furnace to the chimney passing through the electrostatic precipitators. 1 phase induction motor :33 7+ ELECTROSTATIC PRECIPITATORS: 'articles travelling due to the effect of 0 fan are made to enter in to )S'Hs. n this section those particles are made to travel in between two plates with a potential difference of #37@ =0( @oltage is applied>. The positive and negative ions formed by the burning of coal are precipitated here. 9t regular intervals these plates were hit by the hammers so that precipitated ions get separated from the plates in the form of powder. This powder is the byproduct and can be sold. This is used by the cement industries. #2

The un4precipitated particles are carried away by the 0 fan in to the chimney. C1I-NE.: $inally, the un4precipitated particles are left to the atmosphere from a greater height, nearly twice the height of cooling tower. The construction of chimney is also done in the same way as cooling towers. +alls are hyperbolic in nature following the S ',&F mechanism with a natural draught outlet. #/

GENERA*ING POWER: +e have gone through the process how steam is generated and interacted with turbine. 9s we have discussed the 1 turbines rotate a single shaft at a rated speed of 1333 -'?. This shaft is in turn connected to a *,RBO GENERA*OR which can generate an )?$ of "" 7@. Genera &r C&%'&nen $ : Ro or : The electric rotor is the most difficult part of the generator to design. t revolves at a speed of 1,333 rpm hence high care has to be ta%en during its design. The passage of current through the windings generates heat but high temperature results in insulation problems. To %eep the temp down rotor cross section has to be reduced but that results in mechanical wea%ness of the rotor. ,ence it has to be designed such that it carries more current at the same time it is mechanically strong. This can be achieved with good design and great care in construction. The rotor is a cast steel ingot, and it is further forged and machined. 9 hole is bored through the centre of the rotor axially from one end to other for inspection. Slots are then machined for windings and ventilation.
#6

Ro or W%$d%$#s: Silver bearings copper is used for the winding with mica as the insulation between conductors. The designs of large rotor windings incorporate combination of hollow conductors with slots or holes arranged for circulation of cooling gas. To prevent the windings from flying off away at high speeds due to centrifugal force wedges are provided. The two ends of windings are connected to slip rings. Ro or Bala$c%$#: To provide mechanical balance for the rotor , so that it rotates without vibrations arrangements have been made in all designs to fix ad!ustable balance weights around the circumference at each end. S a or: Stator comprises of an inner frame and an outer frame. The outer frame is a rigid fabricated structure of welded steel plates, within this shell is a fixed cage of grinder built circular and axial ribs. The hydrogen for cooling of stator flows through these ribs. The inner cage is usually fixed in to the yo%e by an arrangement of springs to dampen the double frequency vibrations present in 5 pole generators. #:

S a or W%$d%$#s: )ach Stator conductor must be capable of carrying the rated current without overheating. The insulation must be sufficient to prevent lea%age currents flowing between the phases to earth. &n recent generators the windings are made up from copper tubes instead of strips through which water is circulated for cooling purposes. The water is fed to the windings through plastic tubes. E)CITATION SYSTEM: The excitation system of a generator consists of B * The main exciter * The pilot and auxiliary exciters * The voltage control system De(elo:"e$ Of e)c% a %o$ sys e": nitially the dc excitation system was being used. The development of improved techniques resulted in the increased capacity of generators which in turn raised demand of excitation power. ;ut it found that dc excitation could not meet the demands of large capacity turbo4generators due to following reasons. ,igh excitation currents at comparative low voltage were required and these would entail a large number of brushes #D

operating on exciter commutator. This will create difficulties in operation and will require extensive maintenance of commutator and brush gear. The other disadvantage of dc exciter is that commutator may be satisfactory during steady state during load fluctuations there is a ris% of flash over at the commutator. The maximum peripheral speed of commutator for proper operation should not be more than #2 meters per second. -eliability is one of the main requisites of excitation system of the generator. This accelerated development of 9( excitation system, where 9( generator along with rectifier system is used for field excitation. DC EBCI*A*ION S.S*E-: 0irect current exciters are shut wound machines and compounding can be included to improve response. The open4circuit characteristics and basic diagram of a self excited compound shut wound exciter are shown in the following figure. t is important to note that the unstable voltage region ,; on open circuit characteristics of the exciter. Since &) is the excitation current when voltage ;) is across the shunt field ;)8&) is the value of the critical resistance of the circuit. The line of this critical resistance coincides with slope of voltage characteristic. Therefore, the voltage is indefinite and can vary freely between the value due to exciter permanent magnetism, 23

and value ; the voltage due to field current &). )ven small temperature increases in the field winding will contribute to voltage instability. 9 method of overcoming this effect is to insert a saturation liner behind each pole piece. ;ecause of reduced magnetic section the liner is saturated much sooner than the pole body, therebyit introducing the required non4linearity in the open4circuit characteristic. &ne adverse effect of the saturation line however, is to depress the ceiling voltage of the exciter. 2"

;asic schematic diagram of 0( excitation system )xciter field windings can compromise two or three separate windings. The main field winding are often duplicated to provide parallel current paths to reduce contact wear and field rheostat wear. The provision of a negative field gives a negative bias in the exciter by which response is improved when load is thrown off. t also improves the lowering response of the exciter system following as external fault clearance and reduces the range of main exciter field current needed for a given change in exciter voltage. ;ut this negative field constitutes a constant load on pilot exciter and necessitates a more powerful positive main field than would be the case without negative bias. These disadvantages are !ustified. ,owever, on the ground of improve 25

exciter performance, it should be noted that negative excitation li%e this cannot be achieved in present 9( exciter systems. AC e)c% a %o$ sys e": The 9( exciter for large units gained favor because it was possible to use 5 or # pole revolving field type machines possessing all the robustness associated with the generator. (ommutator and 0( brush gear were eliminated giving place to the simple rotor slip4 rings and associated brush gear. 9 pilot exciter is a necessary part of the ac exciter system. t is common practice to have pilot exciter, itself an ac machine. The pilot exciter can also be a permanent magnet generator. t must operate over a wide range with ceiling valves considerably greater than the rated full load valve. $urthermore the exciter output must respond quic%ly to excitation changes at its own rotor terminals. The excitation is controlled by the 9@-. The excitation for pilot exciter is obtained from a permanent magnet of exciter where output is rectified. The pilot output, which excites the field of 9( main exciter, is controlled by automatic voltage regulator. The rectified output of main exciter then energies the rotor of the synchronous generator. n main exciter the 9( supply can be ta%en from the grid or generator itself rectified and given to the generator field. This is called Static )xcitation. 21

;sic schematic diagram of 9( excitation system Genera &r C&&"in! * Sea"in! S#$ e% The "53 ?+ .enerator is provided with an efficient cooling system to avoid excessive heating and consequent wear and tear of its main components during operation. Ro or Cool%$# Sys e": The rotor is cooled by means of gas pic% up cooling. The ,5 gas in the air gap is suc%ed through the scoops on the rotor wedges and is directed to flow along the ventilating canals milled on the sides of the rotor coil. 0ue to rotation of the rotor, a Kve suction as well as discharge is created due to which a certain quantity of gas flows and cools the rotor. 2#

16 Cool%$# Sys e": ,ydrogen is used as cooling medium in large capacity generator due to its high capacity of heat carrying and low density. ;ut in view of its forming an explosive mixture with oxygen, proper sealing system has to be provided and see that there is no escape of hydrogen from the generator. ?ainly oil sealing is used to seal hydrogen. S a or Cool%$# Sys e": The stator winding is cooled by distillate which is fed from one end of the machine by Teflon tube and flows through the upper bar and returns bac% through the lower bar of another slot. Turbo4generators require both water cooling arrangement as well as hydrogen cooling steam .The cooling water is used for cooling of stator winding , hence high quality water=de4 mineralized water> is used for its cooling. Ge$era or Seal%$# Sys e": Seals are employed to prevent lea%age of hydrogen from the stator at the point of rotor exit. 9 continuous film between the rotor collar and the seal liner is maintained by means of the oil at a pressure which is about to start above the casing hydrogen gas pressure, which is regulated in relation to the hydrogen pressure and provides a positive maintenance of the oil film thic%ness. This "" 7@ voltage is stepped up or stepped down using different type of transformers. *RANSFOR-ERS: 0ifferent types of transformers are used for stepping

up and stepping down the generated voltage either for supplying to the grid or for self utilization. * .)F)-9T&- T-9FS$&-?)* AF T 9A< E 9-I T-9FS$&-?)* ST9T &F T-9FS$&-?)GENERATOR TRANSFORMER: +GT, .enerated "" 7@ is stepped up to 553 7@ using generator transformers for transmitting to the grid through the switch yard. The "" 7@ voltage is stepped up for transmitting because to reduce 5- losses. f voltage is maintained high then current is maintained low since the produced power remains constant. f current is low then 5 is low and loss of power is low. The produced power is in 9( 1 'hase, so we need 1 'hase transformer to step up or step down. 2/

AP'ase CC KV ? 667 KV *RANSFOR-ER0 -a$&fac &rer B1EL ,NI* A,BIALIAR. *RANSFOR-ER: 2,A*3 +e have seen that many motors need to be run in the plant such as 0, $0, '9 fans etc. and for the internal needs of the plant power is needed. So rather than collecting the power from the grid "3G off the produced power is self utilized by the 26

plant. $or this purpose produced ""7@ is stepped down to /./ 7@ using A9T. This /./ 7@ is fed to different motors as per requirement and for remaining purposes this voltage is again stepped down to required levels. S*A*ION *RANSFOR-ER: 2S*3 This is also a step down transformer 553 7@ 8 /./ 7@. The primary of the transformer is directly connected to the 5537@ bus from the grid through the switch yard and is stepped down to /./ 7@. This is a safety transformer i.e. %eeping in the view that if there is some problem with A9THs and the system getting failed by chance the required power is collected directly from the grid and is stepped down for plant requirements so that there is no obstacle for power production. 2:

K*PS SWI*C1 .ARD

IN*ROD,C*ION: 9n electrical substation is an assemblage of electrical components including bus bars, isolators, circuit brea%ers, transformers, lightning arresters, instrument transformers, etc. )lectric power between incoming and outgoing circuits, in substation ta%es place through bus bars. +e can say, the bus bars are !unction points capable of carrying huge power. ;us bars are conducting bars to which a number of incoming or outgoing circuits are connected. )lectrical components of each circuit are connected in a definite sequence such that a circuit can be switched on8off during normal operations. n 7T'S &N? we are using 0ouble ;us ;ar system with quadrantone 9(Sconductor. TASKS OF THE SWITHCH YARD : a. 'rotection of transmission system =to isolate faulty networ% from the healthy one> b. (ontrolling the exchange of power =i.e. to control the power transmission to load points as per requirements and instructions of E0(.> c. ?aintain the system frequency within targeted limits. =This can be done by raising8 lowering of generation or load shedding.>
2D

d. 0etermination of power transfer through transmission lines. e. $ault analysis and subsequent improvements. f. Co""&$%ca %o$: data transfer via power line carrier for the purpose of networ% monitoring, control and protection. ED&%:"e$ s %$ Sw% c' .ard: * nsulators * (onductors N 9ccessories * (lamps N (onnectors * (ircuit ;rea%ers * solators * )arth Switch * nstrument Transformers * Surge 9rrestors * +ave Traps I$s&la ors: /3

The flexible 9(S- conductors of transmission line and substation bus bars are supported on string insulators. The rigid tubular bus bars in SS are supported on Solid insulators8'ost insulators. Co$d&c ors @ Accessor%es: (onductor consists of several strands =individual wires> wound in layers spiraled along the length of conductor. (onsecutive layers are twisted spirally in opposite direction to provide good interlayer grip and gives strength and flexibility to the total conductor. )lectrical .rade 9luminum wires or 9l alloy wires are used for conductor for carrying current. n the core, .alvanized Steel wires are used for reinforcement .The core gives high tensile strength N conductor has low resistance. Cla":s @ Co$$ec ors: *ee!Co$$ec orsB $or connecting 9(S- conductor to 9(S- tap conductor =dropper> Parallel!Gro(e Co$$ec ors 2PG cla":3: $or connecting two 9(S- flexible conductors in parallel. F%)ed y:e <&s :os Cla":s: $or supporting tubular bus on post insulators. Pad Cla":s: $or solator to 9(S- conductor connections Spacers. /"

* $or twin conductor bundle. * $or quadruple conductor bundle ,ardware for string insulator assembly. /5

CIRC,I* BREAKERS: (ircuit brea%ers are switching devices, design to close or open contact members, thus closing or opening an electrical circuit under normal or abnormal conditions. (ircuit brea%er is automatic switching 0evice which can * carrying normal current N switching in N out normal loads * nterrupt short circuiting currents. * can able to performer auto4reclose duty. Class%f%ca %o$ of c%rc&% <rea8ers: Based o$ LOCA*ION * ndoor * &utdoor. Based o$ IN*ER,P*ING -EDI,9ir brea% 9ir ;rea% (ircuit ;rea%er =9(;> 9ir blast 9ir ;last (ircuit ;rea%er =9;(;> ;ul% oil ;ul% &il (ircuit ;rea%er =;&(;> ?inimum oil ?inimum &il (ircuit ;rea%er =?&(;> S$/ gas insulated S$/ (ircuit ;rea%er =.(;> @acuum @acuum (ircuit ;rea%er =@(;> /1

ISOLA*ORS: n sub4stations it is often desired to disconnect a part of the circuit for maintenance or repairs of conductors, clamps, (;s etc. This is accomplished by an solator = solating switch>. solators are switches operated when the line in which they are connected carry no current. solator =disconnecting switch> operates under no load condition. t does not have any specified current brea%ing capacity or current ma%ing capacity. solator is not even used for brea%ing load currents. n some cases isolators are used for brea%ing charging current of transmission line. solators used for power systems are generally 14pole isolator. The 14pole isolator has three identical poles. )ach pole consists of two or three insulator posts mounted on a fabricated support. The conducting parts are supported on the insulator posts. The conducting parts consist of conducting copper or aluminum rod, fixed and moving contacts. 0uring the opening operation the conducting rod swings apart and isolation is obtained. The simultaneous operation of three poles is obtained by mechanical inter loc%ing of the three poles. $urther, for all three poles, there is a common operating mechanism. The operating mechanism is manual plus one of the followingB /#

". )lectrical motor mechanism 5. 'neumatic mechanism $urther, the isolator can be provided with earthing switching when required. The earthing switch consists of a conductor bar. +hen the earthing switch is to be closed, these bars swing and connect the contact on line unit of isolator to earth. /2

EAR*1ING SWI*C1: )arthing switch is connected between the line conductor and earth. Formally it is open. +hen line is disconnected, the earthing switch is closed so as to discharge the voltage trapped on the line. Though the line is disconnected, there is some voltage on the line to which the capacitance between line and earth is charged. This voltage is significant in high voltage system. ;efore proceeding, with the maintenance wor% these voltages are discharged to earth by closing the earth switch. INS*R,-EN* *RANSFOR-ERS: C,RREN* *RANSFOR-ERS: 'rotective relays in a.c power system are connected in the secondary circuit of the current transformers . (urrent transformers are classified into two groups ". 'rotective current transformers 5. ?easuring current transformers -atio error and phase angle errors are the important errors of these transformers .The ratio error is very important in protective current transformers ,and phase angle error may be less important . //

Earger cores and air gaps are introduced in (TOS for fast protective relays , in order to prevent saturation of current transformer cores during sub4transient current. DESCRIP*ION OF C*ES: The current transformer types T 5#2 are out door, single phase post type with oil impregnated paper insulation and hermitically sealed enclosures. The primary winding is of eyebolt design with capacitance graded voltage insulation. 'rimary currents are more than one value is obtained by providing either primary reconnection or secondary tapping. The core is made of high4grade electrical steel through which the required numbers of secondary turns are wound torridly. This assembly is located in the eye of the primary winding. The active part is located inside tan%. There is more than one secondary, to achieve various functions li%e metering or protection. 9 high voltage porcelain insulator serves as the external insulation. &ne oil sight glass is provided and section head contains the primary terminals. 9 Fitrogen valve in the dome, Fitrogen gas which acts as a cushion for expansion and contraction of oil.The transformer is hermetically sealed to eliminate moisture absorption and oil contamination. /6

OPERA*ION: (TOS whose primary windings have been energized must not be open on the secondary side. The secondary winding should either be short4circuited or closed by a load corresponding to the rated burden indicated on the rating plate. /:

VOL*AGE *RANSFOR-ERS: @oltage transformers are used for measurement and protection. These are necessary for voltage directional, distance protection. The primary of the voltage transformer is connected directly to power circuit between phase and ground depending upon rated voltage and application. The volt ampere rating of voltage transformer is smaller. There are two types of constructionB 4 Elec ro"a#$e %c :o e$ %al ra$sfor"er, in which primary and secondary are wound in magnetic cores li%e usual transformer. 4 Ca:ac% or :o e$ %al ra$sfor"er, in which the primary voltage is applied to a series capacitor group. The voltage across one of the capacitor is ta%en to auxiliary voltage transformer. The secondary of auxiliary voltage transformer is ta%en for measurement or protection. NO*E:C*S AND P*S ARE EB*ERNALL. VISIVBLE WI*1 CO-BINA*ION OF DISC S1APED S*R,C*,RES CALLED PE**I COA*S0*1IS S*R,C*,RED IS PREFERRED *O ERADICA*E *1E S1OR* CIRC,I*IN AND EAR*1ING D,RING RAINING0WA*ER FALLS ON *1E DISC S1APED S*R,C*,RE AND IS DEVIA*ED IN I*S DIREC*ION NO* FOR-ING A CON*IN,O,S LINE OF WA*ER
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DROPLE*S W1IC1 CA,SES GRO,NDING OR S1OR* CIRC,I*ING0 A V%ew of a P*: 63

S&r#e Arres ors: ?etal oxide surge arrester also %nown as zinc oxide surge arresters are well accepted as voltage clippers for effective protection against over voltages. ?etal oxide surge arresters protect the costly outdoor electrical equipment from over voltages caused by atmospheric disturbances due to lightning and internal disturbances due to switching surges. The assembly consists of ?etal &xide elements with contact plates between discs and held rigidly by a tie rod assembly. The stri%ing aspect of this arrester is its simplicity of construction. Wor8%$#: This zinc oxide acts as an insulator up to the voltage of 553 7@ and if voltage exceeds to a greater extent due to lightening or internal disturbances brea%down of zinc oxide occurs and charge is completely passed in the ground. ,igh frequency high voltage waves are discharged in to the ground. WAVE *RAPS: t is also called PEine trapP. t is connected in series with the power =transmission> line. t bloc%s the high frequency carrier waves =5# %,z to 233 %,z> and let power waves =23 ,z 4 /3 ,z> to pass through. t is basically an inductor of rating in milli ,enry. 6"

-a%$ Co$ rol Roo" 2-CR3: )ach and every part of the switch yard can be operated with computer based software technique from ?ain (ontrol -oom. 9ny problem anywhere in the ;AS, $))0)-, (;, S&E9T)- etc., can be found out without manual effort from ?(-. ,$% Co$ rol Board 2,CB3: )ach and every unit in the thermal power station can be controlled and operated with computer based software techniques from A(;. 9ny problem anywhere in the turbine, ;$', $ans, bun%ers, boilers etc., can be found at A(; without any manual effort.