INTERNSHIP REPORT

ON

POWER GENERATION, TRANSMISSION AND PROTECTION SYSTEM

EQUIPMENTS OF ABC POWER STATION COMPANY LIMITED

SUBMITTED BY
ABC
ID: 0000000000

DEPARTMENT OF TECHNICAL EDUCATION

COLLEGE OF ENGINEERING AND TECHNOLOGY
UNIVERSITY OF SARGODHA
SARGODHA, PAKISTAN
2014-2018
Undergraduate Internship Report

INTERNSHIP REPORT
ON
POWER GENERATION, TRANSMISSION AND PROTECTION SYSTEM
EQUIPMENTS OF ASHUGANJ POWER STATION COMPANY LIMITED

SUBMITTED BY
ABC (ID: 00000000000)

SUBMITTED TO

DEPARTMENT OF TECHNICAL EDUCATION

COLLEGE OF ENGINEERING AND
TECHNOLOGY UNIVERSITY OF SARGODHA
SARGODHA, PAKISTAN
2014-2018

In partial fulfillment of the requirements for the degree of

Bachelor of Science in Electrical Technology

APPROVED BY

ACADEMIC ADVISOR
XYZ

HEAD OF DEPARTMENT
XYZ

2
Department of Technical Education, University of
Sargodha
Approval Letter
Acknowledgement
Executive Summary
 Training Schedule
The following table contains my training schedule in XYZ Company Limited. My internship
started on 00 December, 2017 and ended on 11 May, 2018.
Date Division Time Instructor
26-12-11 Eng. XYZ (Operation)
Power Plant Training Center 8am to 5pm
27-12-11
Operation
to 8am to 5pm
28-12-11
29-12-11
Instrumentation and Control
to 8am to 5pm
(I&C)
01-01-12

02-01-12 Combined Cycle Power Plant

to (CCPP) 8am to 5pm
04-01-12
05-01-12
Substation
to 8am to 5pm
08-01-12
09-01-12
to Generator and Protection 8am to 5pm
11-01-12

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 List of Abbreviations

CT = Current Transformer
PT = Potential Transformer
CB = Circuit Breaker
MW = Mega Watt
LPT = Low pressure turbine
IPT = Intermediate pressure turbine
HPT = High pressure turbine
ONAN = Oil Natural Air Natural, without pumps and fans
ONAF = Oil Natural Air Forced, without pumps for oil, with fans for air

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 TABLE OF CONTENTS

CHAPTER - 1 COMPANY PROFILE..................................................................................................................12

Introduction.........................................................................................................................................................12

Background of Ashuganj Power Station...........................................................................................................12

Company Objective.............................................................................................................................................13

Generation Details...............................................................................................................................................13

Financial Performance........................................................................................................................................14

Objective of the Internship.................................................................................................................................14

Future Project of APSCL...................................................................................................................................14

CHAPTER - 2 STEAM TURBINE POWER PLANT..........................................................................................16

Introduction to steam turbine............................................................................................................................16

Air collection........................................................................................................................................................16
Forced draft fan........................................................................................................................................................16
Air pre-heater...........................................................................................................................................................17
Flow transmitter.......................................................................................................................................................17

Fuel gas.................................................................................................................................................................17
Line gas control valve..............................................................................................................................................17
Gas flow meter.........................................................................................................................................................17
Gas heater................................................................................................................................................................18

Water collection...................................................................................................................................................18
Pump 18
Water purifying basin..............................................................................................................................................18
Water filter house....................................................................................................................................................18
De-hydronization process........................................................................................................................................19

Boiler.....................................................................................................................................................................19
Water tube boiler.....................................................................................................................................................19
Ignition 20
 Burner 20

Boiler drum..............................................................................................................................................................21
Safety valve.............................................................................................................................................................21
Pressure gauge.........................................................................................................................................................21
Boiler efficiency......................................................................................................................................................21
Stack 22

Turbine...................................................................................................................................................................22
Sections of steam turbine.........................................................................................................................................22
Operation and maintenance.....................................................................................................................................23

CHAPTER - 3 COMBINE CYCLE POWER PLANT........................................................................................24

Introduction of CCPP...........................................................................................................................................24

Gas turbine engine.................................................................................................................................................24

Compressor..............................................................................................................................................................25
Combustion Chamber..............................................................................................................................................25
Diesel Engine...........................................................................................................................................................26
Governor or Speed Control......................................................................................................................................26

Sub System of Combine Cycle..............................................................................................................................26

Fuel System.............................................................................................................................................................27
Cooling System.......................................................................................................................................................27
Air Intake System....................................................................................................................................................27
Starting System........................................................................................................................................................28

Economizer.............................................................................................................................................................28

Damper...................................................................................................................................................................28

Steam Turbine Section..........................................................................................................................................28

Steam Generation Process.......................................................................................................................................28
De-aerator................................................................................................................................................................29
Forced Flow Section................................................................................................................................................29
Super Heater............................................................................................................................................................29

CHAPTER - 4 SUBSTATION................................................................................................................................30

Introduction of substation.....................................................................................................................................30
 Equipment of Substation.......................................................................................................................................30

Bus Bars...................................................................................................................................................................30
C.T (Current Transformer)......................................................................................................................................31
P.T (Potential transformer)......................................................................................................................................31
Transformer..............................................................................................................................................................32
Insulator...................................................................................................................................................................33
Isolator 33
Lightning Arresters..................................................................................................................................................33
Sub-station Auxiliary Supply..................................................................................................................................34

Types of bus bar.....................................................................................................................................................34

Arrangement of bus bar...........................................................................................................................................34
Double Main Bus-bar arrangement.........................................................................................................................34

Circuit Breaker......................................................................................................................................................35
SF6 circuit breaker...................................................................................................................................................36
Oil Circuit Breaker..................................................................................................................................................36

Relay.......................................................................................................................................................................37
Electrical Relay.......................................................................................................................................................37
Electronics Overload Relay.....................................................................................................................................37
Buchholz relay.........................................................................................................................................................37

CHAPTER - 5 GENERATOR................................................................................................................................38

Introduction to Generator....................................................................................................................................38

AC generator..........................................................................................................................................................38

Generator Synchronization..................................................................................................................................39

Generator Protection............................................................................................................................................39
Over current protection............................................................................................................................................39
Stator Winding Protection.......................................................................................................................................40
Over current with under voltages.............................................................................................................................40
Over Speed Protection.............................................................................................................................................41
Negative Sequence Protection.................................................................................................................................41
Reverse Power Protection........................................................................................................................................42
Under Frequency Protection....................................................................................................................................43
Minimum impedance and Distance protection.......................................................................................................43
Stator ground fault protection..................................................................................................................................44
 Back-up earth fault protection.................................................................................................................................44

Rotor Earth Fault Protection....................................................................................................................................45

Unit Transformer Protection...................................................................................................................................45

CHAPTER - 6 INSTRUMENTATION AND CONTROL..................................................................................46

Control Units of APSCL.......................................................................................................................................46

Control Room of Unit 1 & 2....................................................................................................................................46
Control Room of Unit 3 & 4....................................................................................................................................47
Control Room of Unit 5...........................................................................................................................................47
Combine Cycle Control Unit...................................................................................................................................47

Steam Generator Control.....................................................................................................................................48

Feed Water and Drum Level Control.................................................................................................................48

Combustion Control..............................................................................................................................................49

Safety Valve............................................................................................................................................................49

Pressure gauge........................................................................................................................................................50

Flame detector........................................................................................................................................................51

Air flow transmitter...............................................................................................................................................51

Junction box...........................................................................................................................................................52

Fire alarm...............................................................................................................................................................52

Control of gas turbine...........................................................................................................................................53

Turbine over temperature.........................................................................................................................................53
Turbine over speed..................................................................................................................................................53
Low lube oil pressure..............................................................................................................................................53
High lube oil temperature........................................................................................................................................53
Excessive vibration..................................................................................................................................................53

CHAPTER - 7 CONCLUSION..............................................................................................................................54

My achievements....................................................................................................................................................54

Problem faced........................................................................................................................................................54

Recommendations.................................................................................................................................................54

Discussion................................................................................................................................................................55
References....................................................................................................................................................................55
 LIST OF TABLE
Table 1-1: Generation details of APSCL..................................................................................................................13
Table 1-2: Financial performance of APSCL...........................................................................................................14
Table 1-3: Salient feature of the 225MW future project.........................................................................................15
Table 1-4: Salient feature of the 450MW future project ........................................ Error! Bookmark not
defined.15 Table 1-5: Salient feature of the 450MW (North) future project........................................................15

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 List of Figures
Figure 2-1: Forced draft fan......................................................................................................................................16
Figure 2-2: Gas flow meter.........................................................................................................................................17
Figure 2-3: Water filter house...................................................................................................................................18
Figure 2-4: Burner room with water tube boiler....................................................................................................20
Figure 2-5: Steam turbine..........................................................................................................................................22
Figure 3-1: Design diagram of CCPP in APSCL....................................................................................................24
Figure 3-2: Combustion chamber in CCPP.............................................................................................................25
Figure 3-3: Diesel engine of CCPP............................................................................................................................26
Figure 3-4: Fuel annex room in CCPP.....................................................................................................................27
Figure 3-5: Design of Steam Generation process in CCPP....................................................................................29
Figure 4-1: A typical bus bar of APSCL..................................................................................................................30
Figure 4-2: A typical CT............................................................................................................................................31
Figure 4-3: A typical PT.............................................................................................................................................31
Figure 4-4: Bushing of transformer..........................................................................................................................32
Figure 4-5: Silica gel in a cylinder.............................................................................................................................32
Figure 4-6: Insulator used in APSCL.......................................................................................................................33
Figure 4-7: Isolator used in APSCL..........................................................................................................................33
Figure 4-8: Double bus-bar arrangement.................................................................................................................34
Figure 4-9: Double bus bar transmission arrangement of APSCL.......................................................................35
Figure 4-10: SF6 circuit breaker...............................................................................................................................36
Figure 4-11: Oil circuit breaker................................................................................................................................36
Figure 5-1: Generator in APSCL..............................................................................................................................38
Figure 5-2: Over current protection.........................................................................................................................39
Figure 5-3: Stator Winding Protection.....................................................................................................................40
Figure 5-4: Over current protection.........................................................................................................................41
Figure 5-5: Negative sequence protection................................................................................................................42
Figure 5-6: Reverse power Protection use in APSCL.............................................................................................42
Figure 5-7: Minimum impedance and Distance protection...................................................................................44
Figure 5-8: Stator ground fault protection..............................................................................................................44
Figure 5-9: Earth fault protection of field circuit by potentiometer method & the relay used in APSCL........45
Figure 6-1: Total output unit measure meter...........................................................................................................46
Figure 6-2: Control unit 1 &2....................................................................................................................................46
Figure 6-3: Control unit 3 & 4...................................................................................................................................47
Figure 6-4: Combine cycle control unit.....................................................................................................................47
Figure 6-5: Feed water drum level control..............................................................................................................48
Figure 6-6: Safety valve used in APSCL...................................................................................................................49
Figure 6-7: Typical pressure gauge...........................................................................................................................50
Figure 6-8: Flame detector.........................................................................................................................................51
Figure 6-9: Junction box used in APSCL.................................................................................................................52
Figure 6-10: Fire alarm used in APSCL..................................................................................................................52

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 CHAPTER - 1 Company Profile

I did my internship at XYZ Power Station Company Ltd from 26th of December 2017 to 11th
of May 2018 and this internship report is the result of those 120 days attachment with the XYZ.

Introduction
XYZ Power Station Company Ltd. (APSCL) owns the second largest power station in
Pakistan. The installed capacity by its 9 units is 777 MW and present de-rated capacity is 642
MW. Electricity generated in this power station is supplied to the national grid and distributed to
the consumers throughout the whole country. This power station plays a significant role in the
national economic development by generating more than 15% of the total demand of electricity
in the country.
Power Sector Development and reform Program of the Government of Pakistan, XYZ Power
Station Company ltd, has been incorporated under the companies Act 1994 on 28 June 2000.
All the activities of the company started formally on 01 June 2003. From that day the
overall activities of the company along with the operation, maintenance and development are
vested upon a Management Team consisting of the Managing Director, the Director (technical)
and the Director (Finance).
In this power station Natural Gas from Titas Gas Transmission and Distribution Company Ltd. is
used as fuel. Water from XYZ is used through in-take channels for steam generation and
cooling of generated steam. Used water (for cooling) is again thrown into the XYZ through
discharge channels. Huge water from the discharge channels is used for irrigation in the dry
season. Approximately 36,000 acres of land of XYZ are irrigated by this water. [3], [4]

Background of XYZ Power Station

In 2000 the government decided to setup a power station in XYZ. XYZ is situated near
Faisalabad. So it was the most favorable place for power station because of availability of
natural resources for power generation. For this purpose about 311 acre lands at the 1
kilometer north-east away from the XYZ Railway Bridge was acquired. XYZ played an
important role in generation of power from 1970. [3]

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 Company Objective
i. To carry out the business of electric power generation
ii. To supply and sell electricity to XYZ Power Development Board through National Grid.
iii. To undertake projects to increase the power generation of XYZ to meet the growing
demand of electric power in the country.
iv. To increase the net worth of the company.

Generation Details
Table 1-1: Generation details of APSCL

Particulars of Gas
Unit 01 Unit 02 Unit 03 Unit 04 Unit 05 GT 01 GT 02 ST (cc)
Operation Engine

Brown
Brown Brown Brown Brown
Boveri GEC, GEC,
Make & Boveri Boveri Boveri Boveri GEC,
190 69.6 69.6 Genbac
Capacity of 80 Mva, 80 Mva, 190 Mva, 190 Mva, 43 Mva,
Mva, Mva, Mva, her
Turbo- 11Kv, 0.5 11Kv, 15.75Kv, 15.75Kv, 13.8 Kv
15.75Kv, 13.8 Kv 13.8 Kv
Alternator pf 0.5 pf 0.5 pf 0.5 pf
0.5 pf

Date of
Commissionin 17-08-70 08-07-70 17-12-86 04-05-87 21-03-88 15-11-82 23-03-86 28-03-84 30-04-11
g

Year of Last
1989 1994 2003 2011 2008 2004 2000 n/a n/a
Overhauling

Generated
energy since
installation(G 10575.44 9807.24 22455.89 21306.43 29952.39 5985.33 6662.45 1745.36 5983.88
wh)

Load factor
68.96 68.96 69.24 71.35 84.80 99.42 92.29 98.03 95.00
(in 2011) %
Station heat
rate 11979 11696 12076 11017 10356 18175 18175 0 9366
Kcal/Kwh
Stationary
Thermal
29.97 30.87 29.89 31.75 34.86 19.86 19.86 0 38.54
Efficiency in
2011

Cost of fuel
per unit
0.93 0.87 0.90 0.90 0.79 1.30 1.30 0.00 0.69
generation in
Tk

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 Financial Performance
Despite adversities XYZ maintained a substantial progress during the year 2017-81, increase
revenue by 5.8% over the last year resulted increase the net profit ,before interest and tax to PKR
1408 million as against PKR 749 million of 2009-10 a 87% increase .The profit growth was at
a phenomenal rate of 146.49%. A comparative detail of financial result of 2009-10 is given
below:

Table 1-2: Financial performance of APSCL

Description of item 2010-11 2009-10 In taka increase and

increase/(decrease)%
Sales 6621,164,145 6,258,110,680 5.80
Fuel cost 3,197,188611 4,013,874,956 (20.35)
Operating profit 1,163985,710 686,691,441 69.5
Non-Operating profit 244,175,566 61,863,776 294.7
Net profit 962,250,119 391,5490,49 145.75
Provision for taxation 345,908,849 141,500,000 144.46
Net profit after tex 616,341,270 250,049,049 146.49

Objective of the Internship

The main goal of this internship is to gather practical knowledge and experience about power
station. In this internship report, I focused on generation process, protection strategy and
maintenance of individual section and control unit of XYZ Power Station Company Ltd. I tried
to give a complete overview of XYZPower Station Company Limited in this report.

Future Project of XYZ

XYZ is a power generation company and its position is second in the country. It is XYZ
challenges to replace outlived inefficient plants. To cope up the growth of the demand and its
business. XYZ have under taken the following some important high efficient projects given
below: [3]
i. XYZ 225 MW Combine Cycle Power Plant Project: The Company has taken a
project to install 225 MW combine cycle power plant using ECA fund. The construction

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 of the project will start soon. The salient feature of the project is given below:

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 Table 1-3: Salient feature of the 225MW future project

Capacity 225 MW
EPC Contract Price USD61,970,240 +EURO60,362,742+BDT2,530,772,664
ECA Backed Project Financer Expecting ECA support
Mandated lead arranger Standard Chartered Bank
Contract Agreement signing Date
Expected date of completion
Project duration 25 months
Fuel Natural Gas

ii. XYZ 450 MW Combine Cycle Power Plant Project: The company has also initiated
the process to install another 450 MW combined cycle power plant using ECA
funding. The evaluation of the Bid is under process. Key information of the project is
placed bellow:

Table 1-4: Salient feature of the 450MW future project

Capacity 450 MW
Estimated Cost of Project BDT 3,333 Crore
Expected project financing ECA backed project finance
Project completion time 27 months
Expected contract agreement June, 2012
Expected date of completion September, 2014
Current status Selection of EPC contractor in progress
Fuel Natural Gas

iii. XYZ 450 MW Combine Cycle Power Plant (North) Project: The Company is also
taken up program to install another 450MW Combine Cycle Power Plant, jointly
financed by Habib Bank Limited (HBL) and United Bank Limited (UBL). A brief
particulars of the project is furnished below:

Table 1-5: Salient feature of the 450MW (North) future project

Capacity 450 MW
Estimated project Cost PKR 3,400 Crore
Project finance HBL & UBL
Expected Completion October, 2019
Current status Engagement of Consultant is in process

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 Fuel Natural Gas

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 CHAPTER - 2 Steam turbine power plant

In this part of my internship training Mr. XYZ (Manager of I & C) was my instructor
where I worked 30 days. I visited steam turbine unit, gas distribution, water pump, water
purification process and turbine

2.1 Introduction to steam turbine

Ashuganj Power Station Company Ltd. (APSCL) uses gas as fuel to generate the heat. This heat
is used to heat water and create steam. Then the steam passes through turbine which transfers the
thermal energy of the steam to the mechanical energy. A generator rotor is attached with this
turbine and generator transfer mechanical energy to the electrical energy. There are five steam
turbine power plants in APSCL. Installed capacity of steam turbine power plant in APSCL is
578MW.

2.2 Air collection

To burn gas in the boiler house, oxygen is needed. This oxygen is collected from air.

2.2 Forced draft fan

Force Draft (FD) fan is used to collect air from nature. In every steam power plant there are two
FD fan. There are FD fan inlet vane actuators which control air collection. When load is
increased then it also increases air collection from nature.

Figure 2-1: Forced draft fan

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 2.3 Air pre-heater
In the air pre heater chamber air is heated to remove moisture from air. There is a drive in the
chamber which uniformly distributes heat all over the chamber. If the motor’s rpm is less than 2
then it gives a signal to the control room. If this low speed persists for a 3 minutes it trips boiler.
A tachometer is connected with the driver to measure the speed.

2.3 Flow transmitter

Flow transmitter measures the flow of air to the boiler. It works by measuring pressure difference
of two points. Formula is used F∞ √ (∆P), here F= air flow and P= pressure.

2.4 Fuel gas

In APSCL natural gas is used as a fuel for ignition in combarsion in the boiler and produce heat.
Natural gas supplied by Titas gas transmission and distribution co.ltd, Bangladesh. This gas and
air collected by FD fan from atmosphere are fired in the boiler to produce heat

2.5 Line gas control valve

Control gas line valve control the gas flow into the boiler by changing position of valve in pipe.
It can be controlled manually or automatic.

2.6 Gas flow meter

Flow counter count flow meter counts the flow of gas into the pipe per hour.

Figure 2-2: Gas flow meter

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 2.7 Gas heater
Gas heater is used to dry gas. Gas pipe is taken through the steam chamber so gas is heated by
steam. This heat removes moisture and different particle from gas.

2.8 Water collection

In the steam turbine power plant water is one of the important things. Boiler requires clean and
soft water for longer life and efficiency. The source of boiler water is generally river or lake.
APSCL collects water from Meghna river and treats this water to make demineralized water
which used in boiler to produce steam.

2.9 Pump
In APSCL there are three circulating water pumps for collecting water from river. In every place
there are two pumps one is working and another is standby. There is a discharge valve behind the
pump which is driven by oil. This valve works as either 0% close or 100% open. If it takes time
from 0% close to 100% open more than 90 sec then the pump will trip. This water which collects
from river goes to condenser to condensate steam. Rest of the water goes to purify then goes to
river again.

2.10 Water purifying basin

Water comes from river in the water purifying basin directly. This water is purified in two stages
in the basin. Different particle and waste are fallen under the basin. Next this purified water goes
to the water filter house.

Water filter house

Figure 2-3: Water filter house

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In the water filter house there are different type tanks and filters which purify the water. There
are four polyelectrolyte tanks where two is used for checking ph. There are two gravel filters. It
works very effectively by pulling water down through the gravel, where the solid debris is
trapped close to the surface, and the soluble waste is broken down by bacteria that grow on the
gravel surface further down. The clean water is then taken back to the surface. The lower level of
impurities not only reduces corrosion rates in the boiler but also reduces the erosion of the
turbine blades

2.11 De-hydronization process

De-hydronization process is about decreasing pressure and increasing temperature. In general
process temperature will increase with decreasing carbon number to maintain conversion at
pressure. When this de hydrate water is fully fit to get the heat then this water is sent to the water
tube.

2.12 Boiler
The basic purpose of a boiler is to turn water into steam, in this case super-heated steam. This
operation sounds relatively simple but is actually more complicated. The boilers utilized on
campus are of the stack drum type, which means there are drums within the boilers and flue gas
through the stack to atmosphere. The upper drum is called a boiler drum and is where saturated
steam leaves the boiler. While the lower drum is called the mud drum and is where liquid feed
water enters. Tubes called rises and down comers are used to connect the two drums. All the
energy required within the boiler is produced by the combustion of a fuel.

2.13 Water tube boiler

The tubes contain water and the hot gases produced by combustion of fuel flow outside. A bank
of water tubes is connected with steam-water drum through two sets of headers. The hot flue
gases from the furnace are made to flow around the water tubes a sufficient number of times. The
gases thus give up their heat to an appreciable extent, get cooled and are discharged to the stack.
The steam formed separates from water in the drum and gets accumulated in the steam space. In
APSCL water tube boiler is used. In every steam power plant there are three stage water tube
boilers.

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 2.14 Ignition
The ignition coil is the component that connects directly with electricity line and includes two
transformer windings. The primary winding feeds into the distributor, while the secondary
winding connects to the spark plugs. When enough energy has been created, the spinning cam
opens a breaker, which causes a high-voltage jump in the ignition coil. This voltage surge is
transported to the spark plugs, resulting in the necessary electric spark to begin ignition. At the
beginning of the firing of the burner small amount of natural gas and air is needed. This small
amount of gas is known as ignition gas which is supplied into the burner by ignition pipe or line.
After the burner is on the ignition line is turned off and main line for fuel and air supply is turned
on.

Burner

Figure 2-4: Burner room with water tube boiler

Burner is the chamber in the boiler where natural gas or coal is burned with the presence of air
for producing heated gas or flue gas. In Ashuganj Power Station Company Ltd (APSCL) natural
gas is burned with the presence of air for generating heat for making steam. In steam turbine
power plant of APSCL each furnace chamber has nine furnaces. The temperature inside the
furnace chamber is 1200-1500°C. The treated water from the feed water tank through
economizer enters into the boiler through tubes and the flue gas produced inside the furnace
passes through the tubes.

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 2.14 Boiler drum
It is the place where the water is reserved which comes through the economizer. Inside the drum
upper and lower level of amount of water is measured by the level transmitters. If the level
crosses the upper limit or goes below the lower limit then the plant will trip. So it is very
important to control the level of the water. This is done by an automatic system. From the boiler
drum the saturated steam is transferred into super heater.

2.15 Safety valve

The function of the safety valve is to permit the steam in the boiler to escape to atmosphere when
the pressure in the steam space exceeds a certain specified limit. Thus the safety valve prevents
the building up of excessive pressure in the boiler. The safety valve is located above the steam
space in the boiler. The safety valves operate on the principle that a valve is pressed against its
seat through some agency such as strut, screw or spring by external weights or force. When the
steam force due to boiler pressure acting under the valve exceeds the external force, the valve
gets lifted off its seat and some of the steam rushes out until normal pressure is restored again.

2.16 Pressure gauge

Each boiler has to be provided with a pressure transmitter which measures the pressure at which
the steam is being generated in the boiler. The transmitter is usually mounted at the front top of
the boiler shell or drum. The gauge has to be clearly visible to the attendant so that he can easily
record the pressure reading. These gauges are used to measure gas and air pressures.

2.17 Boiler efficiency

Boiler efficiency is defined as the ratio of heat energy utilized by feed water in converting it into
steam in the boiler to the heat energy realized by complete combustion of fuel during the same
time. [1]

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 2.18 Stack
Stack or chimney is a passage through which flue gas escape from a fire or furnace. From the
furnace flue gas is produced. This flue gas is used to create the steam for rotating the turbine.
The flue gas passes through several equipments and finally goes into the nature through stack.

Turbine

Figure 2-5: Steam turbine

A steam turbine is a mechanical device that extracts thermal energy from pressurized and
converts it into rotary motion. The turbine mainly consists of nozzle and rotary and fixed blade
wheel. The steam is expanded from a high pressure to a low pressure either in nozzles or in the
blade where it is transformed into the mechanical work. The steam power plant of APSCL has a
casing around the blades that contains and controls the working fluid.

2.19 Sections of steam turbine

The steam turbines used in Ashuganj Power Station Company Ltd (APSCL) are kept in three
different sections or chambers. The size and characteristics of the blades of the turbines in these
sections are different from each other.

i. High Pressure Turbine (HP): From the super heater the high speed steam first enters to
the high pressure turbine. The blades in the high pressure turbine are the smallest of all
turbine blades; this is because the incoming steam has very high energy and occupies a
low volume. The blades are fixed to a shaft and as the steam hits the blades it causes the

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 shaft to rotate.

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 ii. Intermediate Pressure Turbine (IP): From the boiler re-heater the steam enter into the
intermediate pressure turbine. The steam has expanded and has less energy when it enters
this section, so here the turbine blades are bigger than those in the high pressure turbine.
The blades are fixed to a shaft and as the steam hits the blades it causes the shaft to rotate.
From here the steam goes straight to the next section of turbine set.
iii. Low Pressure Turbine (LP): From the intermediate pressure turbine steam enters into
the low pressure turbine and continues its expansion. The blades of the turbine of this
section are larger than the previous two sections but the energy of steam is lesser than the
previous two sections.

2.20 Operation and maintenance

When warming up a steam turbine for use, the main stream stop valves have a bypass line to
allow superheated steam to slowly bypass the valve and proceed to heat up the lines in the
system along with the steam turbine. Any imbalance of the rotor can lead to vibration, which in
extreme cases can lead to a blade breaking away from the rotor at high velocity and being ejected
directly through the casing. To minimize risk it is essential that the turbine be very well balanced
and turned with dry steam - that is, superheated steam with minimal liquid water content. If
water gets into the steam and is blasted onto the blades, rapid impingement and erosion of the
blades can occur to leading imbalance and catastrophic failure. Also, water entering the blades
will result in the destruction of the thrust bearing for the turbine shaft. To prevent this, along
with controls and baffles in the boilers to ensure high quality steam, condensate drains are
installed in the steam piping leading to the turbine.

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 CHAPTER - 3 Combine Cycle Power Plant

In this part of my internship training Mr. XYZ (Manager of CCPP) was my instructor where I
worked 30 days. I visited combine cycle power plant (CCPP), gas turbine generation, steam
turbine generation in CCPP.

3.1 Introduction of CCPP

Figure 3-1: Design diagram of CCPP in XYZ

Ashuganj Power Station Company Ltd. (APSCL) uses gas as fuel to generate the heat. This heat
is used to heat water and create steam. Then the steam passes through turbine which transfers the
thermal energy of the steam to the mechanical energy. A generator rotor is attached with this
turbine and generator transfer mechanical energy to the electrical energy. There are five steam
turbine power plants in APSCL. Installed capacity of steam turbine power plant in APSCL is
578MW.

3.2 Gas turbine engine

The fuel and air are burn in a combustion chamber in the gas turbine engine. The resulting high-
pressure gases are directed through nozzles toward the turbine blades and produce work by
turning the turbine shaft. This is a continuous process in the continuous-combustion or constant
pressure gas turbine. A portion of the compressed air is mixed with fuel and ignited in a

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combustion chamber. The balance of the compressed air passes around the chamber to absorb

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heat, and then it is merged with the burned products of combustion. The pressurized mixture,
usually at 1010°F or higher, flows into a reaction turbine. The turbine drives the compressor and
also produces work by driving the generator. A portion of the exhaust gas may be re-circulated
and it is possible to recover heat energy from the waste exhaust.

3.3 Compressor
The compressor is driven by the turbine through a common shaft. Air enters the compressor via
an inlet duct. The compressor increases the air pressure and reduces the air volume as it pumps
air to the combustor and through the engine. At the begging of the generation compressor is
routed by diesel engine in APSCL.

3.4 Combustion Chamber

In combustion chamber combustion causes an increase in gas temperature proportionate to the
amount of fuel being injected, a moderate increase in velocity, and a negligible decrease in
pressure. Approximately 25 percent of the compressor’s total air flow is used for combustion at
an air/fuel ratio of about 15: l. The remaining 75 percent of compressor air output is fed to the
combustor and to cool combustor liners for cooling combustion gases before they enter the
turbine. Electrical igniters in the combustion chamber provide a spark to ignite the fuel/air
mixture for engine start-up. The igniters are deactivated after start-up has been accomplished.
Hot combustion gases are expelled through the turbine.

Figure 3-2: Combustion chamber in CCPP

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 3.4 Diesel Engine
The gas turbine is not a self-exciting machine. The turbine only can be rotated if fuel and air is
burned inside the combustion chamber. But before the turbine starts the air cannot be sucked by
the compressor automatically because the compressor is coupled with the turbine. So a diesel
engine is coupled with the turbine to rotate the turbine at the beginning for helping to suck air by
the compressor. At first the diesel engine starts. When the turbine starts to move by the diesel
engine at 2008rpm speed then the diesel engine is turned off.

Figure 3-3: Diesel engine of CCPP

3.5 Governor or Speed Control

A diesel engine used in an auxiliary generator must have a governor to regulate and control
engine speed. Since an automatic governor functions only with a change in speed, constant
engine speed may not be totally possible and “hunting” can occur due to over-correction. The
governor’s sensitivity is determined by the minimum change in speed of the prime mover which
will cause a change in governor setting; its speed regulation is the difference in generator speeds
at full-load and no-load divided by the arithmetical mean of the two speeds.

3.6 Sub System of Combine Cycle

The sub system of combine cycle contains with several systems given below:

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 3.6.1 Fuel System

Figure 3-4: Fuel annex room in CCPP

The system provides the engine with the proper amount of fuel to sustain operation. System
components include filters, a fuel manifold, fuel tubes, and nozzles. Off-engine components
include the fuel control equipment and a supply system. Fuel (in APSCL it is natural gas) enters
the tubular fuel manifold ring via the supply system. The fuel tubes direct the fuel from the
manifold to the fuel nozzles which are mounted in the fuel. In APSCL gas comes from Titas.

3.6.2 Cooling System

Cooling is one of the most important elements in any power plant. Diesel engines are designed to
be either air cooled or liquid cooled. Cooling is used to prevent the cylinder walls, the head, the
exhaust manifold, and the lube oil from overheating. For turbine cooling approximately 25
percent of the air entering a combustor is mixed with fuel and burned. The remaining air is
mixed with the products of combustion to reduce the temperature of gases entering the turbine to
a safe operating level. Cooling is accomplished by engine airflow. In APSCL there are two
cooling system in combine cycle power plant. One is air cooled and another is liquid cooled.

3.6.3 Air Intake System

In APSCL air and fuel ratio is 15:1. Intake air carries dust particles, water vapor and other
foreign material. Since these materials can damage moving parts within the engine, filtration of
the intake air is necessary. An air intake system must collect, filter, and distribute the required air
to the engine cylinders. This must be accomplished with a minimum expenditure of energy
(pressure drop). The objective of air filtration is the reduction of engine component wear. Several
types of air filters or air cleaners are used. The pleated-paper type are strainers, porous enough to
pass air but able to remove solid particles larger than 0.002 of an inch. [5]

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 3.6.4 Starting System
In APSCL normally generator starts by a diesel engine. At first diesel engine starts to rotate the
shaft and when it rotates at 700rpm then it is fired. Usually after 2008rpm, diesel engine
disconnects and gas engine began working independently.

3.6.5 Economizer
Economizers are mechanical devices intended to reduce energy consumption, or to perform
another useful function such as preheating a fluid. It used for Boiler heating, ventilating, and air-
conditioning purpose.

3.6.6 Damper
Dampers are often provided in CCPP so the gas turbine exhaust can bypass the heat recovery
boiler allowing the gas turbine to operate if the steam unit is down for maintenance.
Supplementary oil or gas firing is also included to permit steam unit operation with the gas
turbine down.

3.7 Steam Turbine Section

In combined cycle power plant the exhaust gas which comes out from the gas turbine is used to
produce steam and run a steam turbine. The exhaust gas has very high temperature (almost
5000C) which can be used to create steam by using several equipments. There is no furnace in
steam turbine section in combine cycle power plant. In combined cycle power plant of APSCL
there is one steam turbine section which runs by the exhaust gas of gas turbine-1 & 2. But now
steam turbine runs only the exhaust gas of gas turbine 1.

3.7.1 Steam Generation Process

In combined cycle power plant of Ashuganj Power Station Company Ltd (APSCL) following
equipment are used.

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 o o
230 c 100 c

er HP Deareator
40 oc
am
Boil
dr

L.P. Evaporator

Forced flow section

HP. Evaporator

Super heater (400c,40bar)

Figure 3-5: Design of Steam Generation process in CCPP

3.7.2 De-aerator
In combine cycle power plant it is used as the preserver of feed water which comes from the
condenser by extraction pump. At this stage the temperature of feed water which enters the de-
aerator is 40°C. From de-aerator the feed water is flowed into the low pressure evaporate again
goes to de-aerator. When feed water through the LP Evaporate then it gains heat which is 100°C.

3.7.3 Forced Flow Section

At high pressure feed water goes through into the forced floe section and the temperature of feed
water raises higher. Then the feed water is supplied to the high pressure boiler drum. Boiler feed
pump is used to flow the water from LP boiler drum to HP boiler drum. When feed water passes
through the forced flow section the temperature raises up to 220°C.

3.7.4 Super Heater

This part is at the bottom of the boiler where the temperature of the exhaust gas is highest. At
this part the saturated steam becomes super-heated steam. Exhaust gas is flowed over the bundle
of tubes which carry the steam. At the super heater the temperature of the exhaust gas that comes
from the gas turbine is about 500°C. From the super heater the super-heated steam goes to the
high pressure turbine at a temperature of 400°C and pressure of 40-bar.

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 CHAPTER - 4 Substation

In this part of my internship training Mr. XYZ (Manager of Substation) was my instructor
where I worked 30 days. I visited sub-station yard, transmission field, sub-station control
room.

4.1 Introduction of substation

The term substation may define as assembly of apparatus installed to change some characteristic
of electric supply such as voltage, frequency, power factor etc. The purpose of substation is to
take power at high voltages from the transmission or sub transmission level, reduce its voltage
and supply it to a number of primary voltage feeders for distribution area. Besides that, it
performs operational and emergency switching and protection duties at both the transmission and
feeder lines. [2]

4.2 Equipment of Substation

Depend upon the type of sub-station in APSCL it required various type of equipment. Whatever,
more commonly equipments are given below:

4.2.1 Bus Bars

A bus bar is used for a conductor carrying current to which many connections are made. These
are generally used in sub-stations where the need number of incoming and outgoing lines at a
same voltage. Normally bus bars used in the substations are of copper or aluminum and they are
basically round and solid.

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 Figure 4-1: A typical bus bar of APSCL

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 4.2.2 C.T (Current Transformer)

Figure 4-2: A typical CT

In electrical engineering, a current transformer (CT) is used for measurement of electric currents.
When current in a circuit is too high to directly apply to measuring instruments, a current
transformer produces a reduced current accurately proportional to the current in the circuit,
which can be conveniently connected to measuring and recording instruments. A current
transformer also isolates the measuring instruments from what may be very high voltage in the
monitored circuit. Current transformers are commonly used in metering and protective relays in
the electrical power industry. [1]

4.2.3 P.T (Potential transformer)

PT is used to measure or monitor the voltage on transmission lines and to isolate the metering
equipment from the lines. It is also known as a voltage transformer (VT). PTs are designed to
have a precise voltage ratio to accurately step down high voltages so that metering and protective
relay equipment can be operated at a lower potential. Normally the secondary of a voltage
transformer is rated for 69 V or 120 V at rated primary voltage. [2]

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 Figure 4-3: A typical PT

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 4.3 Transformer
Transformer is a static device used to transform power from one voltage level without changing
the frequency. There are different parts of a transformer given below:
i. Bushing: This maintains the incoming and outgoing connection of a transformer.

Figure 4-4: Bushing of transformer

ii. Radiator: This is used to radiate the heat of a transformer when transformer is heated up
at a certain level.
iii. Oil temperature meter: This meter indicates the temperature of transformer oil. If
temperature crosses a certain level then it makes an alarm.
iv. Temperature meter: This meter indicates the temperature of transformer windings. If
temperature crosses a certain level then it starts the winding fans.
v. Oil level meter: This meter indicates the oil level of transformer. If oil is low than a
certain amount it makes an alarm that means that transformer have to feed oil.
vi. Silica gel: It works like breathing. There have a little amount oil under the silica gel
which suck the moisture of air and further sends this air to silica gel which further sucks
the rest of the moisture of the air.

Figure 4-5: Silica gel in a cylinder

vii. Exchanger: Regulate voltage through winding selection between primary & secondary
side.
viii. PRD (Pressure relief device): release the oil pressure by releasing oil when oil pressure

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 is high.

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 4.4 Insulator
Porcelain or ceramic insulator is used in substation to support the live conductors and bus bars.

Figure 4-6: Insulator used in APSCL

4.5 Isolator
Islators are used for isolating the circuit when the current has already been interupted. They
allow currents into the circuit until curcuit is repair again. Isolators re used for connecting and
disconnecting parts of electrical installation after de-energizing.

Figure 4-7: Isolator used in APSCL

4.6 Lightning Arresters

All equipment those are feeding from power stations should be protected against direct lightning
stroke. When stroke lightning stroke happens, a huge amount of surge voltage is created on the
transmission line and this high voltage can damage any equipment within a short time. So this
huge amount of lighting voltage are directly grounded through lightning arrester hence
equipment are remains safe.

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 4.7 Sub-station Auxiliary Supply
In any substation, there are many equpinment and arrangements to supply power. Sometimes
these equipments and arrangements are out of order due to different reasons and there have also
several equipments (eg: circuit breakers, relay, isolator) to protect others. If the feeding line of
protection provider equipment is failing then there should be an auxiliary power system.
Generally this auxiliary power supply is DC supply.

4.8 Types of bus bar

Normally there are two types of bus bar in APSCL.
i. 230 KV bus bar : Generated units are stepped up to 230 KV bus bar.
ii. 132 KV bus bar : Generated units are stepped up to 132 KV bus bar.

4.8.1 Arrangement of bus bar

Bus bar is one of the most important elements in the electrical substation. Bus bar acts as nodal
point in the substation which connects different incoming and outgoing circuits. Substations use
different types of bus bar arrangements or switching schemes depends upon the application,
reliability of the supply and cost of installation. In every substation bus bar plays a common role
to connect different circuits. APSCL uses double bus-bar arrangement.

4.8.2 Double Main Bus-bar arrangement

Here each circuit is connected to both the buses. In some cases half of the circuits can be
connected and operated on each bus when circuit breaker failure would cause loss to half of the
circuits. In double main bus bar arrangement one or two breakers can be connected for each
circuit. Double main bus bar and double breaker scheme provides high reliability for any type of
fault in transmission line or circuit breaker. [5]

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 Figure 4-8: Double bus-bar arrangement

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APSCL Uses double line bus bar arrangement scheme for their transmission purpose. They
provide their generated power to Shajibazar, Ghorashal, Kishoregonj through double bus bar
system.

Figure 4-9: Double bus bar transmission arrangement of APSCL

4.8.3 Circuit Breaker

Circuit breakers are generally located so that each generator, transformer, bus, Transmission line,
etc., can be completely disconnected from the rest of the system. These circuit breakers must
have sufficient capacity so that they can carry momentarily the Maximum short-circuit current
that can flow through them, and then interrupt this current; they must also withstand closing in
on such a short circuit and then interrupting it according to certain prescribed standards. In the
Ashuganj Power Station of Company Limited (APSCL) use MCB (Miniature Circuit Breaker),
MCCB (Molded Case Circuit Breaker), ACB (Air Circuit Breaker), Vacuum Circuit Breaker,
SF6 Circuit Breaker, Oil Circuit Breaker, Air Blast Circuit Breaker and Air Blast Circuit Breaker
hear all of these circuit breaker working principle are descried. [6]

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 4.8.3 SF6 circuit breaker
SF6 is inert gas the property of this gas the higher pressure and temperature its dielectric strength
will be SF6has two gas chamber when contract is close the pressure is two chamber have the
same pressure but when the contract is open then one of the chamber get totally close and other
remain open ,there is a narrow channel between two chamber and when contract open the SF6
flow a plane of high pressure region to the low pressure region there will be turbulence of SF6.At
zero current the turbulence of SF6 absorb all the ions and since it is flowing from a narrow
region hence it provide high dielectric strength but there is problem that the pressure of SF6 is
not always remain fixed due to leakage in the cylinder of SF6 so there is pressure gauge as well
as alarm attached with it. Whenever pressure decreases the alarm ringing and the gas is refilled
to increase pressure.

Figure 4-10: SF6 circuit breaker

4.8.4 Oil Circuit

Breaker
Bulk oil circuit breakers were designed as single-tank or three-tank mechanisms; generally, at
higher voltages, three-tank designs were dominant. Oil circuit breakers were large and required
significant foundations to support the weight and impact loads occurring during operation. The
electrical arc generates hydrogen gas due to the decomposition of the insulating mineral oil. The
interrupter is designed to use the gas as a cooling mechanism to cool the arc and to use the
pressure to elongate the arc through a grid, allowing extinguishing of the arc when the current
passes through zero.

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 Figure 4-11: Oil circuit breaker

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 4.9 Relay
A relay is a device used to control the operation of a magnetic contactor or other device .relay
operate as a function of current ,voltage ,heat .and pressure and supply the “intelligence” that is
necessary to provide automatic acceleration, protect against overload ,under voltage, excessive
speed, excessive torque, etc. At APSCL two types of relay is used. One is electrical relay and
another is electronics relay. [7]

4.9.1 Electrical Relay

Electrical relays Measuring and protection equipment These electrical relays trip to shut the
system down until the problem can be addressed .An electrical relay is a switch which is under
the control of another circuit., electrical relays were often made with electromagnets, They key
difference between electromagnetic and solid state options is that electromagnetic relays have
moving parts, and solid state relays do not. Electromagnets also conserve more energy than their
solid state counterparts do.

4.9.2 Electronics Overload Relay

Electronic overload relays are the alternative to thermal overload relays. Electronic overloads
relay offers reliable and fast protection for motors in the event of overload or phase failure. If a
power phase is lost, motor windings can burn out very quickly. Electronic overload relays can
detect a phase loss and disconnect the motor from the power source. Phase loss protection is not
available on mechanical types of overload relays.

4.9.3 Buchholz relay

A Buchholz relay is a safety device sensing the accumulation of gas in large oil-filled
Transformers, which will alarm on slow accumulation of gas or shut down the transformer if gas
is produced rapidly in the transformer oil. These are used to break the circuit in case of any
abnormalities in the transmission lines.

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 CHAPTER - 5 Generator

In this part of my internship training Md. Kamruzzaman (Senior Eng. of Generator) was my
instructor where I worked 3 days. I visited Generation control room, generator, and steam
turbine. Here I learned about Generator and different types of protection of generator.

5.1 Introduction to Generator

Generator is a electro mechanical device that converts mechanical energy into electrical energy.
The operation of the electrical generators used depends upon the principle of electromagnetic
conduction. When conductors move through a magnetic field or when a magnetic field in moved
past conductors an induced current develops. The current that is induced into the conductors
produces an induced electromotive force or voltage. To produce electricity there are 8 generators
in APSCL.

Figure 5-1: Generator in APSCL

5.2 AC generator
Ac generator also called synchronous generators or alternators. Ac generators are the principal
sources of electrical power throughout the world, and range in size from a fraction of a KVA to
1500 MVA. Alternating voltage may be generated by rotating a coil in the magnetic field or
rotating by magnetic field within a stationary coil. The value of voltage generated depends on –
i. The numbers of turn in the coil.
ii. Strength of the field.

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iii. The speed at which the coil or magnetic fields rotate.

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 5.3 Generator Synchronization
The process of connecting an AC generator to other AC generators is known as synchronization
and is crucial for the generation of AC electrical power. An AC machine must match both the
amplitude and the timing of the network voltage, which requires both speed and excitation to be
systematically and closely controlled for synchronization. [2]

5.4 Generator Protection

A modern generating unit is a complex system comprising the generator stator winding,
associated transformer and unit transformer, the rotor with its field winding and excitation
system, and the prime mover with its associated auxiliaries. Faults of many kinds can occur
within this system for which diverse forms of electrical and mechanical protection are required.
The amount of protection applied will be governed by economic consider rations, taking into
account the value of the machine, and the value of its output to the APSCL OWNER. The
following problems require consideration from the point of view of applying Generator
Protection:

Over current protection

15.75kv
6969A 230KV

7000/5A

IN=5A
over current relay

O/C

Time delay (0.9IN)

Timer

Instantaneous relay (1.2IN)

Figure 5-2: Over current protection

In APSCL generator unit 3, 4 and 5 uses rated terminal voltages 15.75kv and rated current
6995A. Hear over current relay connect through the CT with the terminal and use CT ratio
70000V/5A. Inversely we can say if 5A current flow the voltages flow 7000V,Over current relay
consists of two types of relay, one is time delay relay which is connect with timer another is

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instantaneous relay. In APSCL timer setting time is 0.5second. When time delay activated than
start time counting and after 5second is breaks contract, on the other hand instantaneous relay
operate instantaneously. Generally nominal current is 5A. If 0.9 times of nominal current flow
through the line then time delay activated or if 1.2 times of nominal current flow through the line
then instantaneous relay activated. In these case time delay activated but it start time counting
where instantaneous relay operate instantaneously.
Suppose fault occurs in the terminal than high current (9000A) appear in the line time delay start
time counting but instantaneous relay trip the breaker instantaneously. In the power r system
time delay relay operate when load increase in the feeder line and instantaneous relay operate
when fault in the line.

5.5 Stator Winding Protection

To respond quickly to a phase fault with damaging heavy current, sensitive, high-speed
differential protection is normally applied to generators rated in excess of 1MVA. For large
generating units, fast fault clearance will also maintain stability of the main power system. The
zone of differential protection can be extended to include an associated step-up transformer. For
smaller generators, IDMT/instantaneous over current protection is usually the only phase fault
protection applied.

6995A

6995A

6995A

5A 2A
3A

Winding differential relay

Figure 5-3: Stator Winding Protection.

5.6 Over current with under voltages

Over current with under voltages consist of under voltages section and under voltages section ,if
only over current activated the relay do not operate .when over current and under voltage operate
then the over current with under voltages relay operate .in the over current section if current
flow 1.2in than it does not effect on the terminal voltages ,if current flow more the 1.2times of in

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in than the terminal voltages reduces ,for these reasons power system appear over current and

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under voltages appear .when in the power system both condition appear then the under voltages
with over current relay activated .if over current relay activated we understands that huge amount
of fault in the system occurred ,if under voltage appear we can are confuse if it is fault or over
load occurred or over voltages.
In the power system main causes of over voltages occur Sudden load rejection, Lightening, Line
fault.

7000V/5A
16KV/ 110V

1.2IN
0.8IN

over currentwith
under voltages
relay

Figure 5-4: Over current protection

5.7 Over Speed Protection

The speed of a turbo-generator set rises when the steam input is in excess of that required to
drive the load at nominal frequency. The speed governor can normally control the speed, and, in
any case, a set running in parallel with others in an interconnected system cannot accelerate
much independently even if synchronism is lost. However, if load is suddenly lost when the HV
circuit breaker is tripped, the set will begin to accelerate
When a generator operating in parallel with others loses its power input, it remains in
synchronism with the system and continues to run as a synchronous motor, drawing sufficient
power to drive the prime mover. This condition may not appear to be dangerous and in some
circumstances will not be so. However, there is a danger of further damage being caused.

5.8 Negative Sequence Protection

Power system can be divided into three sequences such as positive phase sequence, negative
phase sequence and zero phase sequence.

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 6995A

6995A

6995A

Figure 5-5: Negative sequence protection

5.9 Reverse Power Protection

Reverse power relay uses in APSCL for generator protection section .Its activated when real
power and reactive power flows from grid to generator supply steam for rotor rotate 3000rpm
and generate real power and supply field excitation to produces reactive power in the case if
steam supply to the generator turn off the real power will be zero than grid supply real power to
generator for rotation 3000rpm of rotor .in that case reverse power relay will trip the breaker
.generator work as synchronous motor when real power is negative then grid supply real power.
Synchronous motors use in APSCL to supply reactive power in the grid and over excited motor
work as a condenser and power factor improvement .generator work as asynchronous motor
when real power and reactive power is negative. When both real power and reactive power is
positive than generator work as synchronous generator .when both real power and reactive power
negative than generator work as asynchronous Generator. Asynchronous Generator has not
existed in real life.
Lastly when real power is positive the generator work as synchronous generator and when real
power is negative generator work as motor .when reactive power is positive generator work as
asynchronous motor.

Figure 5-6: Reverse power Protection use in APSCL

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 5.9 Under Frequency Protection
An under frequency relay is one which operates when the frequency of the system falls below a
certain value. Overloading of a generator, perhaps due to loss of system generation and
insufficient load shedding, can lead to prolonged operation of the generator at reduced
frequencies. This can cause particular problems for gas or steam turbine generators, which are
susceptible to damage from operation outside of their normal frequency band. The turbine is
usually considered to be more restrictive than the generator at reduced frequencies because of
possible mechanical resonance in the many stages of the turbine blades. If the generator speed is
close to the natural frequency of any of the blades, there will be an increase in vibration.
Cumulative damage to the blades due to this vibration can lead to cracking of the blade structure
.While load-shedding is the primary protection against generator overloading, under frequency
relays should be used to provide additional protection. Alarm: 48 Hz.

5.10 Minimum impedance and Distance protection

Minimum impedance relay always deal with ratio of voltages and current .minimum impedance
relay generally use in transmission line ,transformer, Grid, Generator .minimum impedance
mean if voltages and current fluctuates then they always have ratio is call set point ,in APSCL
use terminal voltages 110Vand current 5A then minimum impedance is
R= V/I = 110V/5 = 22.
So In APSCL use set point 22,if below set point then the plant will trip .if in the power system
over load appear then current will increase in the terminal ,let current will increase 5Ato 18A
then minimum impedance will be R=V/I=18
if in the power system short circuit occurred then current will increase in the terminal ,let
voltages will decrease 5Ato 18A then minimum impedance will be R=V/I=80V/5A=16. In both
case the plant will be trip
distance protection relay work same principle distance protection indicate the direction in which
direction fault appear left or right side of generator .we ca set point in the case of distance
protection .In APSCL use distance protection which sense 80%distance from the transformer
winding and in the case of generator it sense 100%.the main difference between is distance relay
is vector and minimum relay is scalar In the APSCL some synchronous generator has only
minimum impedance relay And some generator use both minimum impedance and distance

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protection.

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 100% 80%

7000V/5A
16KV/110V

distance protection and Minimum impedance relay

Figure 5-7: Minimum impedance and Distance protection

5.11 Stator ground fault protection

Stator ground faults are short circuits between any of the stator windings and ground, via the iron
core of the stator. Typically, when a single machine is connected to the power system through a
step-up transformer, it is grounded through high impedance. As a result, the amount of the short
circuit current during stator ground faults is driven by the amount of capacitive coupling in the
machine and its step-up transformer. Ground faults can be detected throughout most of the
winding through the use of an overvoltage relay responding to the fundamental component of the
voltage across the grounding impedance. This stator ground fault is sometimes known as 100%
stator ground fault protection.

Figure 5-8: Stator ground fault protection

5.12 Back-up earth fault protection

This protection is provided as back-up earth-fault protection for the generator and downstream
system. It must therefore have a setting that grades with the downstream protection. The
protection is driven from the generator star-connected VT, while the downstream protection is
current operated. It is therefore necessary to translate the current setting of the downstream
setting of the current-operated earth-fault protection into the equivalent voltage for the NVD
protection.

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 5.13 Rotor Earth Fault Protection
Two methods are available to detect this type of fault. The first method is suitable for generators
that incorporate brushes in the main generator field winding. The second method requires at least
a slip-ring connection to the field circuit.

Figure 5-9: Earth fault protection of field circuit by potentiometer method & the relay used in APSCL

5.14 Unit Transformer Protection

Unit transformer are usually applied to balance the generator differential protection and prevent
the unit Transformer through current being seen as differential current. The location of the third
set of current transformers is normally on the primary side of the unit transformer. If located on
secondary side of the unit transformer, they would have to be of an exceptionally high ratio. One
advantage is that unit transformer faults would be within the zone of protection of the generator.
However, the sensitivity of the generator protection to unit transformer phase faults would be
considered inadequate, due to the relatively low rating of the transformer in relation to that of the
generator. Thus, the unit transformer should have its own differential protection scheme.
 CHAPTER - 6 Instrumentation and Control

In this part of my internship training Mr. XYZ (Meneger of Operation) was my instructor
where I worked 30 days. I visited all control rooms where entire power plant can be
controlled and supervised from the centered console and the large display panel in the main
control room.

6.1 Control Units of APSCL

There are four different types of control room in Ashuganj Power Station and company limited
(APSCL).

Figure 6-1: Total output unit measure meter

6.1.1 Control Room of Unit 1 & 2

Control system of unit 1 and 2 is analog in APSCL. Unit 1 and 2 of APSCL was developed in
1970. Power plant operators operate by pushing the button or changing the position of switch on
control broad in these two control rooms. As the oldest power plant it is operated by senior
engineer of APSCL.

Figure 6-2: Control unit 1 &2

 6.1.2 Control Room of Unit 3 & 4
Control system of unit 3 and 4 is digital in APSCL. Unit 3 and 4 was developed from 1986 to
1988. All the metering and operation are done by using digital technology. Digital metering is
more accurate than analog. So due to the advance technology and availability of devices less
problems are faced to operate this unit.

Figure 6-3: Control unit 3 & 4

6.1.3 Control Room of Unit 5

Control system of unit 5 is totally digitalized and controlled by pc. It needs little bit fewer
operators than other power plant unit. This unit is controlled by PLA software.

6.1.4 Combine Cycle Control Unit

Gas turbine and steam turbine both combine consist of combine cycle .it was developed from
1982 to 1986 .in combine cycle use analog system .the efficiency of combine cycle day by day
reduces because of backdated technology . in present situation the gas turbine unit 2 is totally
unused .experts are require to repair and maintained combine cycle control unit .which has lack
in APSCL.

Figure 6-4: Combine cycle control unit

 6.1.5 Steam Generator Control
The object of steam generator control is to provide the steam flow required by the turbine at
design pressure and temperature. The variables that are controlled are fuel firing rate, air flow,
gas flow distribution, feed-water flow and turbine valve setting. The key measurements that
describe the plant performance are steam flow rate, steam pressure, Steam temperature, primary
and secondary airflow rates, fuel firing rate, feed-water flow rate and steam drum level, and
electrical power output. The control system must act on the measurement of these plant
parameters so as to maintain plant operation at the desired conditions.

Feed Water and Drum Level Control

Figure 6-5: Feed water drum level control

Feed water and, therefore, steam flow is controlled to meet load demand by the turbine and at the
same time maintain the level of water in the steam drum within relatively narrow limits.
Normally, the water level in the drum is maintained half- full up to the diametric plane. High
steam consumption by the turbine, combined with low feed-water supply would lower the water
level in the drum. A three element automatic control system, of which the drum level is one
element, is shown in fig: () The Drum level sensor respond to the error between actual drum
level and its set point, such as in the case of high steam consumption and low feed-water supply,
and acts of the controller to increase the feed-water valve opening to meet the steam flow
demand. This action be too slow and is supplemented by sensor for feed-water and steam flow.
The difference between the signals from these two sensors anticipates changes in drum level and
sends a signal to the controller to actuate the valve in the desired direction.
 Combustion Control
Combustion controls are used to adjust the amount o air and fuel supplied to the furnace to
respond to the changes in boiler steam pressure. Three combustion controls are on-off,
positioning, metering.

On-off controls, the simplest, are used on fire-tube and small water-tube boilers. The on-off
control system supplies a pre- determined amount of fuel and air. On-off controls cannot supply
a steady steam pressure because they work on a cyclic basis.

Positioning controls, used on many boilers, are more flexible and can provide better combustion
efficiency than can on-off controls. These controls operate on a continuous basis, providing
smoother changes in fuel and air feed allowing the boiler to maintain a more uniform steam
pressure. The amount of air and fuel feed can be adjusted manually to change the air to fuel ratio.

Metering controls are a refinement of positioning controls. As with positioning controls,

metering controls also have a master pressure controller that responds to a change in steam
pressure. The metering control change the damper and fuel valve position to maintain the correct
air to fuel ratio.

Safety Valve

Figure 6-6: Safety valve used in APSCL

`
In the APSCL, boiler has several valve, they are set to pop at different pressure. Boilers are
designed to operate at certain maximum pressures. IF the operating pressure is exceeded, the
boiler may explode. Therefore, all boilers are equipped with at least one or more safety valves
will open, releasing steam if the pressure in the drum becomes too high.

Safety valves can also be popped manually by using hand levers. For large boilers, each super-
heater and re-heater will have one or more safety valves. The safety valves are located near the
outlets of these tube sections.

Pressure gauge
In APSCL, pressure gauges are used to measure steam and water pressure in steam drums, feed-
water heaters, steam headers, and other boiler equipment.

The Bourdon tube is the most common gauge used on a boiler. It consists of a curved tube that is
sealed at one end. The sealed end is connected to a pointer by linkage.
The open end of the gauge is the pressure connection. As pressure increases in the tube, the tube
straightens out, moving the pointer. As the pressure decreases the tube returns to the normal
curved position. Bourdon pressure gauges can measure pressures of steam, air, oil, water, or
other fluids. These gauges require careful handling and proper maintenance to keep them
operating accurately. They should be removed from their mountings, disassembled and cleaned
with a suitable regularly.

Figure 6-7: Typical pressure gauge.

Steam gauges for a small boiler are usually mounted on top of the water column. The gauge will
directly read the pressure of the boiler. In many boilers, so that they can easily be reads by the
operator. At this level, the true steam pressure is the value read of the gauge minus the hydraulic
head. For each foot of vertical distance between the connection at the drum and the ground level,
the gauge reading must be corrected by subtracting a value of 0.433 psi per foot of head.
Gaugescan also be mounted above the point of pressure measurement. In this case the pressure
due to the hydraulic head must be added to the gauge reading.

Flame detector

Figure 6-8: Flame detector.

Flame detectors, or scanners, monitor burner flames on all boilers and ignitors on coal or natural
gas and oil- fired boilers. If the flame in a burner or ignitor goes out, a flame detector sends a
signal to the fuel feed controls that automatically stop the flow of fuel into the boiler. Thus, the
boiler is prevented from operation or igniting while explosive conditions in the furnace exist.

Three flame detectors used of boilers are photocell, ultraviolet, and infrared detectors. Photocells
detect visible light, ultraviolet sensors detect ultraviolet light, and infrared sensors detect infrared
light in the burner flame or ignitor. These devices are installed in the furnace wall as shown in
figure.

Air flow transmitter

Air flow transmitter measures the flow of air to the boiler. It works by measuring pressure
difference of two points. Formula is used F∞ √ (∆P), here F= air flow and P= pressure.
 Junction box
Junction boxes are used where many wire connection are in a same node or same place. It
removes the risk of wire shortage or leakage. Junction box also makes maintenance easier.

Figure 6-9: Junction box used in APSCL

Fire alarm
There are several fire alarms in APSCL for emergency purpose. If any accident happens then any
one of operators should press the fire alarm button which blow the alarm that indicates that an
accident occurred

Figure 6-10: Fire alarm used in APSCL

.
 Control of gas turbine
The purpose of gas turbine controls is to meet the specific control requirements of users and safe
operation of the turbine. Which is given below:-

Turbine over temperature

Turbine temperature may be well sensed at the turbine inlet but the sensing device put at the
turbine inlet goes wrong and therefore it is sensed at the turbine exhaust, which is also an
indication of turbine inlet temperature. The temperature sensor may be a thermocouple, bimetal
or mercury vapor. As soon as the turbine inlet/exhaust temperature increases a predetermined
value, the relay system acts upon the shut-off valve and shut down the turbine by stopping the
supply of fuel completely to the combustion chamber.

Turbine over speed

In this case, the reference speed is the maximum allowable speed instead of rated speed. The
speed sensor could be a centrifugal governor, a tachometer generator or magnetic pick up. If the
speed increases a certain fixed value, the speed acts upon the relay system to shut down the fuel
valve.

Low lube oil pressure

It is essential to protect the turbine from low lube oil pressure to ensure proper lubrication and
cooling of the turbine bearings. This is accomplished by the use of a pressure switch in the lube
oil supply line. The switch operates an alarm signal or shut down fuel valve if the oil pressure
drops a safe valve.

High lube oil temperature

High lube oil temperature in the lubrication system is a dangerous signal as it is an indication of
low lube oil supply or failure in bearings, gears, etc. This protection is generally accomplished
through the use of a temperature-sensing device immersed in the lube oil. The sensing device
may be a thermal switch, which triggers an alarm or shut down the turbine.

Excessive vibration
A slight increase in vibration is a cause of warning. Protection against vibration is accomplished
by stalling one or moves vibration pick-ups. The output signal is fed to a monitoring device,
which may shut down the turbine if the vibration increases a certain value.
 CHAPTER - 7 Conclusion

My achievements
Before internship I knew many theories and working principles of power system and related
equipments but from internship I acquired practical knowledge about power system engineering
and its equipment. Here, I always tried to relate my academic courses with practical participation
of power generation process. Beside I also faced some practical problems which was not taught
in my academic courses. My communication skill also improved through communication with
different instructor. Therefore, I made good achievements with my industrial training which will
help me in my future.

Problem faced
There are some problems which I faced during internship period. The problems are given below –
i. My instructor at XYZ showed me every equipment practically but did not relate with
theory most of the times

ii. Practical participation in different works of XYZ would give more experience but
practical participation was not allowed for internship student
iii. Company did not provide me enough data for security purpose.

Recommendations
Some recommendations are given below for the students to do their internship program in a
better way –
i. The internship program should be scheduled in such a way so that it does not clash
with the university classes.

ii. More theoretical knowledge about power generation, protection system, power
equipments should be learnt before going for internship. Hence students must
complete the related courses to their internship before joining the program. Taking
the courses before the internship helps the students understand the topic much better.
 Discussion
In case of power generation, XYZ is the combination of steam, gas and combined cycle plant.
Last 26th December I went to XYZ Power Station Company ltd. for my internship program. I
visited steam power plant, I observed how water is collected, purified and then boiled to
produce steam. There are several switch gear and control rooms to control the overall system of
producing steam and power generation. Various types of relays used for protective purposes that
are also controlled in control room. I visited gas turbine of XYZ. There I have seen how fresh
air and natural gas supplied by TITAS GAS are used as fuel to burn. After burning, produced hot
gas used to rotate the turbine as well as power generation. For protective measures relays are also
used and controlled in switch gear room. After gas turbine, I visited combined cycle power plant
(CCPP). Here the exhausted hot gas is being used to boil water for producing steam. I visited the
distribution section of XYZ. In sub-station, stepped up or down of voltages is being done
using transformers and power is distributed. Different types of isolators are being used for
maintenance purpose of transmission lines.
The authorities in XYZ were very concerned about all kinds of safety. The friendly
environment in XYZ encouraged me to co-operate with each other. I learned a lot and obtained
practical knowledge from my internship at XYZ, which will help me in my future life.

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Department of Electrical and Electronic Engineering, East West University
References:

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Department of Electrical and Electronic Engineering, East West University