PROJECT REPORT ON

AND OVERVIEW OF POWER PLANT

And
TRANSFORMERS
AKASH SRIVASTAVA
12BEE0019
PROJECT REPORT ON
AND OVERVIEW OF POWER PLANT
And
TRANSFORMERS
AKASH SRIVASTAVA
12BEE0019
PROJECT REPORT ON
AND OVERVIEW OF POWER PLANT
And
TRANSFORMERS
AKASH SRIVASTAVA
12BEE0019
ACKNOWLEDGEMENT:
Our report will remain incomplete if we do not mention the efforts of
those people who helped us in completing this project.
Firstly we want to thank Mr. Binay Khalkho Manager-H.R. and
Deepu Minz H.R. Dept TATA POWER Jamshedpur and the electrical
department for letting us use the department data and carry out the
necessary field work.
We would like to express our gratitude to Mr.G.P.Shastry,
Department Head, EMD, for his support, encouragement and all the
technical help without which the completion of this project would
have been impossible.
We are also deeply indebted to Mr. Soumendra Mandal, EMD Project
coordinator, whose technical input, stimulating suggestions and
encouragement helped us in completion of report and provided us
with practical on field knowledge of the subject.
We also want to thank my co-trainees from various colleges who
supported us in work. Their presence made our stay at TATA
POWER a pleasant and learning experience in all aspects of life.
CONTENTS
Tata power
Jojobera Thermal Power Plant
Areas of operation
Coal Handling Plant
Boiler & Turbine Area
Transformer Yard
Electrical Switchyard
Electrostatic Precipitator
Transformers
Conclusion
Bibliography
Jojobera Thermal Power plant
The Jojobera Thermal Power Plant, in Jamshedpur has an installed capacity of
547.5MW. It has a 5 generating units comprising of a single 67.5MW unit and
four units of 120MW each.
Units:
Unit#1: 67.5MW (commissioned in 1996)
Unit#2: 120MW (commissioned in 2000)
Unit#3: 120MW (commissioned in 2001)
Unit#4: 120MW (commissioned in 2005)
Unit#5: 120MW (commissioned in 2011)
In total there are total 9 number of transmission lines going to various
substations in the city.
Transmission Lines (each 132kv):
Line 1: Golmuri
Line 2: Golmuri
Line 3: Golmuri
Line 4: Main Ring Substation (MRSS 4)
Line 5: Blower House (TATA STEEL)
Line 6: Bara, Sonari
Line 7: Main Ring Substation (MRSS 2)
Line 8: Main Ring Substation (MRSS 2)
Line 9: Tata Growth Shop
Total number of bus couplers and bus sectionalizers used for transmission are:
Bus sectionalizers: 4
Bus couplers: 3
Total bus sections: 6
The transmission line diagram of the plant is as follows:
RAW MATERIAL
(COAL)
CHP
BOILER AND
TURBINE
TRANSFORMER
YARD
SWITCHYARD
ELECTROSTATIC
PRECIPITATOR
FLY ASH
AS SIDE
PRODUCT
TO DIFFERENT
PLACES BY
TRANSMISSION
LINES
Areas of operation
The main area of operation or the division of the thermal power
plant is into the following areas:
Coal Handling Plant
Boiler & Turbine Areas
Transformer Yard
Electrostatic Precipitator
Switchyard
COAL HANDLING PLANT
Coal Handling Plant is the most essential part of any thermal plant. CHP is
responsible for the procurement and the supply of the coal to the coal mill
bunkers so that the required supply of pulverized coal is obtained for the
generation of power. CHP in thermal power plant comprises the process from
the unloading till filling bunkers of respective coal mills in different units.
Function and Capacity
Procurement of coal
Unloading , sizing and storing of coal
Feeding of coal
The design capacity of CHP is 1176TPH and rated capacity is 100TPH
Middling coal from TISCO West Bokaro Collieries
IB Valley coal from Mahanandi Coalfields Ltd.
Coals are crushed by primary crusher and secondary crusher.
PROCESS FLOW CHART OF CHP
Step 1 Railway Rakers
Step 2 Wagon Tipplers
Step 3 Hopper
Step 4 Apron Feeder
Step 5 Primary Feeder
Step 6 Eccentric Disk Screen
Step 7 Secondary Crusher
Step 8 Conveyer
Step 9 Bunker
Specifications of Jojobera CHP plant:
Capacity of CHP 1176 ton/hr
Capacity of Wagon Tippler 105 ton
Coal carrying capacity of one wagon 58-60 ton(approx.)
Coal carrying capacity of one rake 3500 ton(approx.)
Charging rate of side arm charger 20 wagon/hr
Capacity of primary crusher 1176 ton/hr
Capacity of secondary crusher 1176 ton/hr
Total length of conveyer 3km(approx.)
Input/ Output coal size primary crusher 600mm/150mm
Input/ Output coal size secondary crusher 300mm/25mm
Average coal consumption per day 3000 4000 ton
Coal storage capacity of stockyard 1000 tons
Major auxiliaries of CHP are:
1. Wagon Tipplers:
The wagon tippler is driven by 110KV motor and the top lamping device is
actuated by hydraulic cylinders. Cylinders are operated by a hydraulic power
pack which gives necessary fluid flow and pressure by means of 30KV
hydraulic motor to operate the hydraulic cylinder. All these motors are PLC
controlled.
Wagons arriving at CHP are placed by hydraulic operated side arm charger
on wagon tippler which is driven by 415V ac, 125KV induction motor.
TATA Honeywell PLC performs the entire of wagon tippling.
Individual coal loaded wagons are placed on wagon tippler cradle. Wagon
tippler raise command is given by operator and sequence of tippling
operation starts in auto mode controlled by PLC.
During tippling operation the along with loaded wagons rotates for 135
140 degrees and dumps the coal into the hooper.
2. Side Arm Chargers
It is hydraulic equipment provided at wagon tippler to place coal wagons as
per requirement avoiding the engagement of the locomotive during
unloading operation. A batch of 20 22 coal loaded wagon can be handled
at a time. A 450KW motor in side arm chargers is connected with the SAC
hydraulic power pack which delivers necessary torque to the SAC. SAC in
each operation gets connected to the rack of the loaded wagon by swing arm
and brings the individual wagon to cradle for tripling.
3. Conveyer Belts:
A conveyer belt (or belt conveyer) consists of two or more pulleys, with a
continuous loop of material the conveyer belt that rotates about them.
One or both of the pulleys are powered, moving the belt and the material on
the belt forward. The powered pulley is called the drive pulley while the
unpowered pulley is called the idler.
4. Primary Crusher:
It is also known as rotator breaker. It is a horizontal drum having perforated
screen plates inside the drum and is supporting rollers along with two guide
rollers. Lifting shelves are fitted inside the drum which lifts up coal fed at
one end during its rotation the coal is reduced in size and passes through the
perforated screened plates having 150mm diameter holes. The uncrushed
BOILER AND TURBINE AREA
Boiler, also called the steam generator is the engineering device which
generates steam at constant pressure. It is a closed vessel, generally made of
steel in which vaporization of water takes place. Heat required for vaporization
may be provided by the combustion of fuel in furnace, electricity, nuclear
reactor, hot exhaust gases, solar radiations etc.
Boiler mainly works on the principle of Rankine cycle.
RANKINE CYCLE
Rankine cycle is thermodynamic cycle derived from Carnot vapour power
cycle for overcoming its limitations. Carnot cycle cannot be used in practice due
to certain limitations. Rankine cycle has the following thermodynamic
processes.
1 2: Isobaric heat addition
2 3: Adiabatic expansion
3 4: Isobaric heat release
4 1: Adiabatic pumping
T S, H S and P V representations are as shown below
Practical arrangement in a simple steam power plant working on Rankine cycle
is shown ahead.
Thus in Rankine cycle, isothermal heat addition and heat rejection processes
have been replaced by isobaric processes. Realization of isobaric heat addition
and heat rejection in boiler and condenser respectively is in conformity
with nature of operation of these devices. Isobaric heat addition can be had in
boiler from sub cooled liquid to superheated steam without any limitations.
Boiler mountings:
Water level indicator
Safety valve
High steam and low pressure safety valves
Fusible plugs
Pressure gauge
Stop valve
Feed check valve
Blowof cock
Manhole and Mudbox
Boiler accessories:
Super heater
Economizer
Air preheater
Feed pump
N.B :- Boiler mountings and accessories may vary for different types of boilers.
Some of the boiler accessories and mountings are described below.
Super Heater: Its purpose is to super heat steam and is a type of heat
exchanger in which steam flows inside tubes and hot gases surround it.
Economizer: It is also a heat recovery device in which feed water is
heated from heat available with exhaust gases. Thus hot feed water
available from economizer lowers the fuel requirement in combustion
economizer also helps in removal of dissolved gases by preheating of
water and thus minimizes tendency of corrosion and pitting.
Feed pump: Feed pump is used for sending water into boiler at the
pressure at which steam generation takes place. It is generally of three
types i.e. centrifugal pump, reciprocating pump and injectors.
Safety valve: Its function is to prevent the steam pressure from
exceeding a limiting maximum pressure value. Safety valve should
operate automatically by releasing excess steam and bring pressure
down within safe limits.
Pressure gauge: It is used for pressure measurement. Pressure is
continuously monitored so as to avoid occurrence of over shooting of
boiler pressure, although safety devices to protect boiler against pressure
rising beyond a limit is provided but pressure gauges are also used for
monitoring pressure.
Stop valve: It regulates the flow of steam from the boiler. The is
generally mounted on highest part of boiler shell and performs function
of regulating the flow of steam from boiler. Stop valve generally has
main body of cast steel; valve, valve seat and nut etc. are of brass.
Manhole and Mudbox: Manhole provides opening for cleaning,
inspection and maintenance purpose. Mudbox is a collection chamber
for collecting the mud.
TURBINE AUXILLARIES:
A steam turbine is a prime mover in which rotary motion is obtained by the
gradual change of momentum of the steam. In a steam turbine following are the
main parts:
The nozzle in which energy of high pressure is converted in to kinetic
energy, so that steam issues from nozzle at high velocity.
The blade which change the direction of motion of steam issuing from
the nozzle that force acts on the blade to change momentum and propel
them.
The auxiliaries are:
Condensate extraction pump
Hot well make up pump
Grand stream condenser
Surface condenser
Extraction steam system
LP Heater: A heater located between the condensate pump and either the
boiler feed pump.
HP Heater: A heater located downstream of the boiler feed pump.
De aerator: It is a device that is widely used for the removal of oxygen
and other dissolved gases from the feed water to steam- generating
boilers
Operation:
The steam cycle is working on a heat regeneration cycle. Feed water is supplied
to the drum through the economizer outer limbs. Water in the boiler tubes
absorbs heat from the furnaces. The mixtures of the water and steam is
discharged into the boiler drums. The separated saturated steam is led to super
heater where it is heated to about 810K.
Superheated steam from the boiler is fed to the turbine via the turbine top valve,
emergency stop and governing valve. Steam first enters the HP turbine, gets
expanded here and then it is directed to the inlet of the LP turbine for further
expansion. In the process the turbine starts rotating which in turn rotates the
prime mover of the generator, thus producing electricity.
Steam undergoing expansion in the allowed to flow through the condenser
where the steam is condensed by cooling water supplied by C.W pumps. The
condensate collected in the hot wells and pumped by vertical condensate
extraction pumps to the de aerator through air ejector, gland steam condenser,
drain cooler and LP heater. From the de aerator feed water storage tank, feed
water is pumped to the economizer inlet header through two HP heater. During
this process, the condensate steam is collected in different system. Heat is
recovered at various points and is fed to the main feed water system.
The ratings of UNIT #2 turbo generator of TATA Power Jojobera Power Plant
is given below:
1. K.W : 120000
2. P.F : 0.8
3. KVA : 150000
TURBO GENERATOR
A turbo generator is a combination of a turbine directly connected to an electric
generator for the generation of electric power. Large steam powered turbo
generators provide the majority of the worlds electricity and are also used by
steam powered turbo electric ships.
Smaller turbo generators with gas turbine is often used as auxiliary power
units. For base loads diesel generators are usually preferred, since they offer
better fuel efficiency, but on the other hand diesel generator have a lower power
density and hence require more space.
The efficiency of larger gas turbine plants can be enhanced by using a combined
cycle, where the hot exhaust gases are used to generate steam which drives
another turbo generator.
Generator produces alternating current:
The generator is connected to the turbine drive shaft. It has a moving part the
rotor and a fixed part the stator. The rotors outer surface is covered with
electromagnets. The stators inner surface, or cylinder wall, is made up of
copper windings. When the rotor turns inside the stator, the electrons in the
copper windings vibrate. Their movement generates an electric currents,
similar to the one created by Michael Faraday in his 1831 experiment on
electromagnetic induction, but on a much larger scale.
Turbine have a constant rotation speed:
All the generators units in a power system must be synchronised. In other words
its essential that they maintain an exact rotation speed. To ensure adequate
power quality. Equipment that runs on electricity is designed to use alternating
current of specific frequencies. This frequency depends on the generating units
rotation speed i.e. the no of times per second that rotor magnet travel past the
stator winding. This frequency is expressed in cycles per second, or hertz(Hz),
named after the German physicist Heinrich Hertz, to prove the existence of
radio waves.
Stator :-
The stator consists of two party viz. The outer casing and inner frame
supporting the core the winding outer casing is of welded construction welded
tubes and ducts provide flow path for cooling. Inner stator consists of stator and
core windings. Stator core stacked with insulated electrical sheet steel
lamination clamping fingers ensures a uniform pressure and intensive cooling of
stator core ends. Stator winding fractional pitched, two layers consisting of
individual bars. To minimize the losses, the bars are separately brazed together
and insulated from each other
TRANSFORMER YARD
The transformer yard of Jojobera thermal plant comprises of following
transformers:
TYPE OF TRANSFORMER QUANTITY
1. Generating transformer (GT) 5
2. Unit Auxiliary transformer (UAT) 5
3. Station transformer (ST) 3
4. Sub station transformer (SST) 8
Generating Transformer (GT)- 11KV/132KV
The generating transformer is used as a step up transformer which produces
11KV and steps up this voltage to 132KV for transmission. Electricity produced
at 11KV cannot be transmitted owing to large losses due to heavy current at the
voltage level. A generating transformer is used to increase the voltage level to
132KV to meet the transmission requirements GTs are step up transformers
with delta connected LV windings are connected to the transmission lines.
Specifications:
GT#1
Make BHEL
Rating 90MVA
Voltage 11/132KV
Cooling
HV
LV
ONAF ONAN
30MVA 55MVA
90MVA 55MVA
No Load Voltage
HV
LV
ONAF ONAN
133V 139V
10.5V 10.5V
Line Current
HV
LV
ONAF ONAN
373.8A 228.4A
4943.7A 3024.5A
Phase 3
Connection Y
Frequency 50Hz
Insulation level
HV
LV
ONAF ONAN
660KV 275KV
75KV 25KV
Weight (of oil)
(total)
30500Kg
116000Kg
GT#2, GT#3, and GT#4
Make BHEL
Rating 90/120/150 MVA
Voltage 11/132KV
Cooling
HV
LV
ONAF ONAN
30MVA 55MVA
90MVA 55MVA
No Load Voltage
HV
LV
ONAF ONAN
133V 139V
10.5V 10.5V
Line Current
HV
LV
ONAF ONAN
373.8A 228.4A
4943.7A 3024.5A
Phase 3
Connection Y
Frequency 50Hz
Insulation level
HV
LV
ONAF ONAN
275KV 650KV
28KV 75KV
Weight (of oil) 30500Kg
(total) 116000Kg
Unit Auxiliary Transformer (UAT) 11KV/6.6KV
UAT is a power transformer that supplies power to the auxiliary equipment of
the power generating station during its normal operation. This transformer is
connected directly to the generator output by a tap off of the isolated phase
bus duct and thus becomes the cheapest source of power to the generating
station.
It is generally a three winding transformer where the primary winding is equal
to the main generator voltage rating. The UATs are connected to the generators
as step down transformers. Rated KVA of UAT is approximately 15% of the
generator rating.
Specifications:
UAT#1
Make BHEL
Rating 11/6.6KV
No Load Voltage
HV
LV
11000V
6600V
Line Current
HV
LV
656.1/787.3A
1045.9/1255.1A
Phase 3
Vector group DdO
Cooling ONAF/ONAN
Impedance at normal temperature 8.76%
Impedance at extreme temperature 8.05%
Weight (of oil )
(total)
6265Kg
16500Kg
Station Transformer (ST) 132KV/33KV/6.6KV
A critical function of any electricity generation and distribution system is
stepping up or down of voltage at various points in the delivery network. The
voltage is stepped up or down at substations using station transformers. The se
may come in various sizes, depending upon the site transformers, but are
normally connected to the network through overhead connections which results
in exposed HV or LV bushings that necessitate a fence or other protective
enclosure for personnel safety and security.
At Tata Power Jojobera plant, there are three numbers of 3 winding
132/22/6.6KV station transformers (ST#1, ST#2, ST#3) to cater to station loads
such as CHP,DM water plant, AIC plant, ESP unit etc. These also supply power
to the customers as Tata Motors, Tata Cummins, and Lafarge Cement at 33KV.
There are two numbers of feeders for each recipient, normally which are kept
ON from the Jojobera plant end.
Specifications:
ST#1, ST#2, ST#3
Make BHEL
Rating 75MVA
Voltage 132/33/6.6KV
Oil quantity 32250 Lts
Cooling ONAF/ONAN
Connection HV Star, MV Star, LV Delta
Vector group HV MV: YNyno
HV LV: YNd1
Insulation level
1.) Impulse withstand voltage
2.) 1 min. Power frequency
withstand voltage
HV MV LV
550 75 60
230 28 20
No load losses at rated voltage and
frequency
42 KW
Load losses at principal tap and rated
output
268 KW
Auxiliary losses 5.2KW (Max.)
Weight (of oil )
(total)
30500Kg
116000Kg
TRANSFORMERS AT JOJOBERA PLANT AND THEIR USES:
USTs are located in power plant to step down the voltage level from
6.6KV to 415V. The rating for this transformer corresponds to the rating
of the auxiliary load to be borne. Generally, these are stationed indoor
and are dry type transformers.
Power at Jojobera plant of Tata Power is evacuated at 132KV
33KV system supplies power to Lafarge cement plant, Tata Cummins and
TELCO. For each of the aforesaid units, there are two feeders of 33KV
each. To facilitate this is a 33 kV bus with two incomers and one bus
couplers. Each incomer is capable of bearing the full load.
There are six 6.6 kV buses. All the HT motors, 6.6kV/440V transformers
are connected to the 6.6kV buses employ SF
6
breakers. If the unit trips
then all the load gets transferred to the station transformer automatically.
There are 14 415 V buses, all the 415V motors like ACW pumps, CCW
pumps, valves, blowers, ACs are connected to the 415V bus system.
SWITCHYARD
Switchyard is protected area where all the switchgears and its equipment are
installed power transmission. Switchgear is used for switching, controlling and
protecting device. Switchgear equipment is essentially concerned with
switching and interrupting currents either under normal or abnormal operating
conditions. Switchyard is hub for electrical power sources, transformers,
remotely controlled arc snuffing breakers, metering devices etc.
Switchyard forms the integral part of any power plant. These power plants have
their main plant equipment integral controls as well as Plant Distributive
Control System (DCS). While the entire plant is integrated at the DCS level,
true unification is achieved by incorporating/integrating switchyard controls.
Features:
1.) Monitoring of status of switchyard equipment like isolators, circuit
breakers etc.
2.) Issue of close/open commands to isolators, breakers, etc.
3.) Monitoring of system parameters like voltage, current, frequency, MW,
MVAR, energy.
4.) Controlling operations of protective relays.
5.) Presentation of information useful to operator in different forms.
6.) Generation of reports.
7.) Storage and revival of reports.
8.) Remote control and monitoring of different kinds of frequencies
through fibre optics/PLCC communication like wave traps.
Switchyard Equipments
CURRENT TRANSFORMER (CT)
Current transformer is used to measure current at reduced current as well as for
the protection of the system. It is mainly a step down current to known ratio.
The primary of this transformer consists of one or more turns of thick wire
connected in series with the line. The secondary consists of large number of
turns of fine wire which provides measuring instrument and relay a current
which is a constant fraction of current in the line. It reduces heavy current
flowing in the element of a power system to low values that are suitable for
relay operation. Nickel iron is used for the construction of CT because it gives a
good accuracy up to 5 times the rated current.
Types of CT:
a) Live Tank Current Transformer: In the live tank design, active part (i.e.
core with secondary and primary duly insulated) is in the top tank. Top
tank is live and secondary is insulated and taken to the bottom tank.
b) Dead Tank Current Transformer: in dead tank design, active part is in
bottom tank is in ground potential (i.e. dead) and the primary is insulated
and taken to the top tank for primary termination.
POTENTIAL TRANSFER (PT)
Potential transformer is mainly a step down transformer which steps down the
voltage to known ratio. It is used for protection as well as measurement of
voltage in the system. The primary of this transformer consists of a large
number of turns which provides measuring instruments and relays, a voltage
which is known fraction of line voltage.
Types of PT:
a) Capacitive Voltage Transformer (CVT): CVT is used to measure high ac
voltage. It consists of capacitive potential divider and step down
transformer. Primary side of transformer is connected to the high voltage
side together with capacitive and secondary side of transformer is having
measuring instrument.
Advantages of CVT are:
Low impedance measuring device is used in CVT
Cost of device reduced
Loss is less
b) Inductive Voltage Transformer (IVT): IVT are used for voltage metering
and protection in high voltage network systems. They transform the high
voltage into low voltage adequate to be processed in measuring and
protection instruments secondary equipment, such as relays & recorders.
ISOLATORS
It is a disconnection switch which operates at no load condition both manually
as well as remote. During faulty conditions circuit breaker operates first and
then isolator is opened. After getting recovered from the fault, the isolator is
closed first then the circuit breaker in order to avoid flashover.
Isolators have provisions for a padlock so that inadvertent operation is not
possible. In high-voltage or complex systems, these padlocks may be part of
a trapped key-interlock systemto ensure proper sequence of operation. In some
designs, the isolator switch has the additional ability to earth the isolated circuit
thereby providing additional safety. Such an arrangement would apply to
circuits which inter-connect power distribution systems where both ends of the
circuit need to be isolated.
So definition of isolator can be rewritten as Isolator is a manually operated
mechanical switch which separates a part of the electrical power system
The main difference in isolator and a circuit breaker is that an isolator is an off
load device intended to be opened only after a current has been interrupted by
some other control device. Safety regulations of the utility must prevent any
attempt to open the disconnector while it supplies current.
Classification of isolators
Isolators are classified into three categories based on its breaking method.
Horizontal break: In these isolators the operating arm moves in a
horizontal plane. It can be further classified into:-
1. Centre break
2. Double break
Vertical break
Pantograph
CIRCUIT BREAKER
The circuit breakers are the device, which is capable of making and breaking of
an electrical circuit under normal and abnormal conditions. During normal
operating condition the Circuit Breaker(CB) can be opened or closed by a
station operator for the purpose of switching and maintenance. During the
abnormal or faulty conditions the relays senses the fault and closes the trip
circuit breaker. Thereafter the circuit breaker opens. The circuit breaker has two
working positions, open & closed. These correspond to open circuit breaker
contact and closed circuit breaker contact respectively. The operation of
automatic opening and closing the contact is achieved by means of operating of
the circuit breaker. As the relay contact closes the trip circuit is closed and the
operating mechanism. In Tata Power, the 132kV breakers for GT#1,2,3 all ABB
and arc SF
6
circuit breaker in which closing and tripping charged spring.
Classification of Circuit Breaker
a) Oil Circuit Breaker: It employs the basic technique of oil for arc
extinction. Upon interruption of the electric circuit, an electric arc forms
between the contacts of the circuit breaker. Because of the high
temperature of the arc the oil is evaporated and oil vapours are partially
decomposed liberating ethylene, methane and other gases. A gas bubble
is formed in the arcing zone; the pressure in the bubble may be as high as
several dozen mega N/m
2
. The arc is then extinguished, both because of
its elongation upon parting of contacts and because of intensive cooling
by the gases and oil vapour.
b) Vacuum Circuit Breaker: Vacuum circuit breakers are circuit breakers
which are used to protect medium and high voltage circuits from
dangerous electrical situations. A vacuum circuit breaker is such kind of
circuit-breaker where the arc-quenching takes place in vacuum. The
technology is suitable for mainly medium voltage application. For higher
voltage vacuum technology has been developed but not commercially
viable. The operation of opening and closing of current carrying contacts
and associated arc interruption take place in a vacuum chamber in the
breaker which is called vacuum interrupter. The vacuum interrupter
consists of a steel arc chamber in the centre symmetrically arranged
ceramic insulators. The vacuum pressure inside a vacuum interrupter is
normally maintained at 10
- 6
bar.
c) Air Blast Circuit Breaker: It uses compressed air or gas as the interrupting
or the breaking medium. Gases such as hydrogen, carbon-dioxide,
nitrogen and Freon can be used as arc interrupting medium, but
compressed air is the most suitable arc interrupting medium. The reason
is nitrogen has the similar circuit breaking properties as that of
compressed air medium. Carbon-dioxide has a drawback that is difficult
to control owing to the freezing at valves and other restricted passages.
Hydrogen has increased breaking capacity bit it is costlier. The air blast
circuit breaker requires an auxiliary compressed air system which
supplies air to the breaker air receiver.
d) SF
6
Circuit Breaker: A circuit breaker in which the current carrying
contacts operate in sulphur hexafluoride or SF
6
gas is known as an
SF
6
circuit breaker. SF
6
has excellent insulating property. SF
6
has high
electro-negativity. That means it has high affinity of absorbing free
electron. Hence, for heavier and less mobile charged particles in SF
6
gas,
it acquires very high dielectric strength. Not only the gas has a good
dielectric strength but also it has the unique property of fast
recombination after the source energizing the spark is removed. The gas
has also very good heat transfer property. Due to its low gaseous
viscosity (because of less molecular mobility) SF
6
gas can efficiently
transfer heat by convection. So due to its high dielectric strength and high
cooling effect SF
6
gas is approximately 100 times more effective arc
quenching media than air. Due to these unique properties of this
gas SF
6
circuit breaker is used in complete range of medium voltage and
high voltage electrical power system. These circuit breakers are available
for the voltage ranges from 33KV to 800KV and even more.
LIGHTNING ARRESTER
A lightning arrester is a device used electrical power systems and
telecommunications systems to protect the insulation conductors of the system
fromthe damaging effects of lightning. The typical lightning arrester has a high
voltage terminal and a ground terminal. When a lightning surge (or switching
surge, which is very similar) travels along the power line to the arrester, the
current from the surge is diverted through the arrester to earth.
If protection fails or is absent, lightning that strikes the electrical system
introduces thousands of kilovolts that may damage the transmission lines, and
can also cause severe damage to transformers and other electrical or electronic
devices. Lightning produced extreme voltage spikes in incoming power lines
can damage electrical home appliances.
Here zinc oxide arresters are used. Zinc oxide arresters have energy absorption
level.
Types:
1. Rod gap arrester
2. Horn gap arrester
3. Multi gap arrester
4. Expulsion type lightning arrester
5. Valve type lightning arrester
RELAYS
A relay is an electrically operated switch. Many relays use an electromagnet to
mechanically operate a switch, but other operating principles are also used, such
as solid-state relays. Relays are used where it is necessary to control a circuit by
a low-power signal (with complete electrical isolation between control and
controlled circuits), or where several circuits must be controlled by one signal.
The first relays were used in long distance telegraph circuits as amplifiers: they
repeated the signal coming in from one circuit and re-transmitted it on another
circuit. Relays were used extensively in telephone exchanges and early
computers to perform logical operations.
A type of relay that can handle the high power required to directly control an
electric motor or other loads is called a contactor. Solid-state relays control
power circuits with no moving parts, instead using a semiconductor device to
perform switching. Relays with calibrated operating characteristics and
sometimes multiple operating coils are used to protect electrical circuits from
overload or faults; in modern electric power systems these functions are
performed by digital instruments still called "protective relays".
BUS COUPLER
The main function of bus coupler is to couple the busses. For each and every
instrument a cable comes at the input terminal of bus coupler. Output terminal
of this coupler goes to the control room. Thus each equipment can be controlled
either manually or by control room. It comes into action if any fault occurs in
the bus.
Bus coupler configurations are available as non-terminated or internally
terminated. If two or more non-terminated couplers are used on a bus, then the
couplers at each end of the bus must be terminated externally with 78
ohmterminators on the unused bus connections of the end couplers. Alternately,
internally single terminated couplers (with or without the non-functional bus
connectors) can be supplied.
BUS SECTIONALIZERS
The sectionalizer is a self-contained, circuit-opening device used in conjunction
with source-side protective devices, such as reclosers or circuit breakers, to
automatically isolate faulted sections of electrical distribution systems. Power to
operate the control circuitry and the mechanism is obtained from the line
ELECTROSTATIC PRECIPITATOR
(E.S.P)
An electrostatic precipitator (ESP) is a highly efficient filtration device that
removes fine particles, like dust and smoke, from a flowing gas using the force
of an induced electrostatic charge minimally impeding the flow of gases
through the unit.
In contrast to wet scrubbers which apply energy directly to the flowing fluid
medium, an ESP applies energy only to the particulate matter being collected
and therefore is very efficient in its consumption of energy (in the form of
electricity
Exhaust gases contain large quantity dust particles which are emitted into the
atmosphere. This poses threat to mankind as devastating health hazard.
The dust issuing from exhaust of the plant can most effectively be prevented
from entering into atmosphere by employing ESP.
Here de dusting of exhaust gases from boiler is done.
Exhaust gases contain large quantity dust particles which are emitted into the
atmosphere. This poses threat to mankind as devastating health hazard.
E.S.P advantages:
Ability to treat volume of gases at high temperature.
Ability to cope up with corrosive atmosphere.
Offers low resistance path to gas flow.
E.S.P uses intense electric forces to separate suspended particles from the
flue gases.
Processes involved:
Electric charging of suspended particles.
Collection of charged particles on collecting diodes.
Removal of particles from collecting diodes.
Five fields to keep emission within limits.
Electromagnetic control system is used.
TRANSFORMERS
A transformer is an electrical device that can change electrical energy of a
given voltage into electrical energy at a different voltage level. It consists of two
coils arranged in such a way that the magnetic field surrounding of one coil cuts
through the other coil. When an alternating voltage is applied to (across) one
coil induces an alternating voltage in the other coil. Transformers will not work
with direct current, since no changing magnetic field is produced, and therefore
no current can be induced. The factor which determines whether a transformer
is a step up or step down type is the turns ratio. The turns ratio in the primary
winding to the number of turns in the secondary winding.
The TATA power Jojobera division has got the following types of transformers:
Generating Transformer (GT) 5
Station Transformer (ST) 3
Substation Transformer (SST) 8
Unit Auxiliary Transformer (UAT) 5
Essential parts of a Transformer:
LV Winding:
The LV Winding or Low Voltage winding is that winding of a
transformer which has less number of turns compared to the high
voltage winding. As a result, the voltage generated in this winding i.e.
LV winding, also the LV winding is generally Delta connected.
HV Winding:
The HV winding or High Voltage winding has more number of turns
as compared to the LV winding so voltage regulation is better. So the
voltage required in this type of winding is more than the LV side. The
HV winding is generally Star connected.
Transformer Core:
The core makes up the bulk of the transformer and so selection of proper
material plays an important role in the transformers overall function,
working and efficiency. A range of different cores exist viz... steel
laminated, solid, toroidal and air cores as well as variation of each within
their respective categories. The core thus serves to greatly reduce the
magnetizing current and confine the flux to a path which closely couples
the windings. Generally all transformers are made of CRGO (Cold
Rolled Grain Oriented Silicon Steel)
The salient features of CRGO Transformer cores are:
Unmatched quality
High strength
Corrosion resistant
Long lasting
Reliable
Moisture resistant
High permeability
Electrical bushings:
It is an insulated device that allows safe passage of electrical energy
through an earth field.
If the strength of the electric field increases, it may be attracted to the
earthed material and if sufficient voltage is present, leakage paths may
develop within the insulation. If the energy of the leakage path
overcomes the dielectric strength of the insulation, it may puncture the
insulation and allow the electrical energy to conduct to the nearest
earthed material causing burning and arcing. Thus, it should be so
designed that it has the capability of enduring occasional and exceptional
high voltage moments as well as the normal continual service withstand
voltage.
Transformer tank:
Most power transformers are filled with transformer oil, a high dielectric
fluid that both cools and insulates the windings. Transformer oil is a
highly refined mineral oil that cools the windings and insulation bu
circulating within the transformer tank.
Radiator:
Radiators are used to circulate the oil in a transformer by natural
convection.
Conservator:
A conservator as the name suggests is a reservoir used in conserving or
storing oil. If the transformer tank oil reduces due to a kind of overload
or any other ambient conditions, the conservator will feed the oil into the
main tank and if expansion occurs in the transformer oil, that oil will go
to the conservator.
Buchholz relay:
In the field of electric power distribution and transmission, a buchholz
relay is a safety device mounted on some oil filled transformers
equipped with an external overhead oil reservoir/conservator. It is used
as a protective device sensitive to the effects of dielectric failure inside
the equipment.
On a slow accumulation of gas, due to slight overload or any ambient
condition, gas produced by decomposition of insulating oil accumulates
in the top of the relay and forces the oil level downward.
On load Tap Changer (OLTC):
The OLTC is located in HV winding of a transformer. The tapping is
taken from HV winding because..
In HV winding, no. of turns is more, so voltage regulation is good.
The LV winding is nearer to the core, so that less insulation can be
provided between core and winding.
In HV winding, current carrying capacity is less than LV winding.
The function of OLTC is to give constant voltage to the secondary
winding, rather maintain/regulate the output voltage of a transformer.
Breather:
When load on transformer increases or when the transformer is under full
load, the insulating oil in the transformer gets heated up, expands and
gets expelled out into the conservator, thus subsequently pushing the dry
air out of the conservator tank through the silica gel breather.
When the oil cools down, air from the atmosphere is drawn into the
transformer. This is called Breathing in of the transformer.
During the breathing process, the incoming air may contain moisture and
dirt which should be removed in order to prevent any physical damage.
Hence the air is made to pass through Silica gel breather, which will
absorb the moisture in the air and ensure that only dry air enters into the
transformer.
Silica gel in the breather is blue when installed and they turn to pink
colour after absorbing moisture, thus indicating replacement of the
crystals. Thus silica gel breathers provide an economic and efficient
means of controlling the level of moisture entering into the conservator
tank during the breathing process.
Neutral Grounding Resistor:
The purpose of a Neutral Grounding Resistor (NGR) is to limit the
ground fault current to a safe level so that all the electrical equipment in
the power system is protected. The resistor should be the only current
path between the neutral of the power transformers and ground.
Cooling Fans:
Oil Natural Air Forced (ONAF):
For oil filled transformers, the cooling ducts in the coils must be in
sufficient number and size to allow dielectric fluid to flow through
the coils to remove heat. This oil can move by simple convection
(Oil Natural Air Natural) or it can be forced cooled by pumping
fluid. Additionally, the tank surface must be large enough to
transfer heat away from the fluid by the combined actions of
conduction, convection or radiation. To maximise the cooling
effect, cooling fans are added to expedite the heat removal through
radiators.
Thus ONAF uses natural circulation of the oil with the help of fans
to increase the air flow and thus increase the rating of the
transformer.
Oil Natural Air Natural (ONAN):
This is the simplest transformer cooling system. The full form of
ONAN is "Oil Natural Air Natural". Here natural convectional
flow of hot oil is utilized for cooling. In convectional circulation
of oil, the hot oil flows to the upper portion of the transformer tank
and the vacant place is occupied by cold oil. This hot oil which
comes to upper side, will dissipate heat in the atmosphere by
natural conduction, convection & radiation in air and will become
cold. In this way the oil in the transformer tank continually
circulate when the transformer put into load. As the rate of
dissipation of heat in air depends upon dissipating surface of the
oil tank, it is essential to increase the effective surface area of the
tank. So additional dissipating surface in the form of tubes or
radiators connected to the transformer tank.
Oil Forced Air Forced (OFAF):
OFAF means "Oil Forced Air Forced" cooling methods of
transformer. In oil forced air natural cooling system of
transformer, the heat dissipation is accelerated by using forced air
on the dissipating surface but circulation of the hot oil in
transformer tank is natural convectional flow.
The heat dissipation rate can be still increased further if this oil
circulation is accelerated by applying some force. In OFAF
cooling system the oil is forced to circulate within the closed loop
of transformer tank by means of oil pumps.
Minimum Oil Gauge (MOG):
MOG in transformer is used to show analogic indication of oil level
inside the conservator tank and upon requirement; it also gives alarm
signals when the oil level reduces below minimum/maximum level.
Oil Temperature Indicator (OTI) & Winding Temperature
Indicator (WTI):
Oil Temperature Indicator (OTI): The OTI measures the Top Oil
Temperature. It is used for control and protection for all
transformers. This device measures top oil temperature with the
help of sensing bulb immersed in the pocket by using liquid
expansion in the bulb through a capillary line to operating
mechanism. A link and lever mechanism amplifies this movement
to the disc carrying pointer and mercury switches. When volume
of the liquid in operating mechanism changes, the bellow attached
to end of capillary tube expands and contracts. This movement of
bellow is transmitted to the pointer in temperature indicator of
transformer through a lever linkage mechanism.
Winding Temperature Indicator (WTI):
This device measures the LV and HV winding temperature. A
winding temperature indicator or WTI is also used as protection of
transformer. The basic operating principle of WTI is same as OTI.
But only difference is that the sensing bulb pocket on transformer
top cover is heated by a heater coil surrounded it. This heater coil
is fed by secondary of current transformers associated with
transformer winding. Hence the current through the heater coil is
directly proportional to the electric current flowing through
transformer winding.
CONCLUSION
This vocational training helped us in knowing what it takes to be in a
corporate section. Working in an industry requires soft skills, patience
and the power of making adjustments. We got a good view of the
working and use of different electrical machines and other equipments,
understood the need of control rooms in every realm of the power plant
and above all learned that SAFETY IS IN YOUR OWN HAND,
without it we can suffer major consequences and it can even risk ones
job and life. Also, we could relate my theoretical knowledge with the
practical field and got to know that both practical as well as theoretical
knowledge has its own experience and they run in parallel tracks.
Undergoing this training helped us to develop our inner self confidence
and interactions with people in the plant premises thus giving me an
interest in understanding basic engineering work. Through this training,
we met people who shared their views, thoughts and outlooks required
for working in an industry. Apart from the training, the culture Tata
Power inculcates in each and every employee and even their trainees is
really commendable.