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INTERNSHIP REPORT
On
POWER GENERATION, DISTRIBUTION, CONTROL AND PROTECTION SYSTEM OF
OPEX AND SINHA POWER STATION

Submitted by

Md Rasel (2016-1-80-015)
Md. Abdul Gaffar (2015-3-80-003)
Nahian Maisha (2016-3-80-016)

Submitted to the
Department of Electrical and Electronic Engineering
Faculty of Sciences and Engineering
East West University

In partial fulfillment of the requirements for the degree of Bachelor of Science in

Electrical and Electronic Engineering
(B.Sc. in EEE)

Spring, 2018

Approved by

_______________ ________________
Academic Advisor Department Chairperson
Rishad Raiyan Joardar Dr. Mohammad Mojammel Al Hakim
Lecturer, EEE Chairperson & Professor, EEE

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Training Certificate

Md. Abdul Gaffar Md. Rasel Nahian Maisha

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Md. Abdul Gaffar Md. Rasel Nahian Maisha

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Authorization letter
We are reported that we are the sole authors of this internship report. We authorize East West
University to allow other institution or persons to use this internship report for industrial
attachment and similar purposes. Again, we authorize the Department of Electrical and
Electronics Engineering of East West University to reproduce this internship report by
photocopy or other means, at the request of other institution or individuals for the purpose of
industrial attachment.

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Md. Abdul Gaffar Md. Rasel Nahian Maisha

Md. Abdul Gaffar Md. Rasel Nahian Maisha

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APPROVAL LETTER

Md. Abdul Gaffar Md. Rasel Nahian Maisha

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Acknowledgment
At first, we wish to express our gratitude to the Almighty ALLAH for giving us the strength to perform
all responsibilities as an intern and complete the report within the restricted time.

We are deeply indebted to our supervisor Rishad Raiyan Joardar, Lecturer of Department of Electrical
and Electronic Engineering of East West University, for his whole-hearted supervision, constant support,
and co-operation. It would be very difficult for us to prepare successfully this report without his guidance.

We would also like to thank our honorable Chairperson Dr. Mohammad Mojammel Al Hakim, Professor,
and Chairperson, Department of Electrical and Electronic Engineering at East West University, for his
support and gesture of goodwill and generous help.

We would also like to thank Engr. Kazi.Shariful Islam, General Manager for arranging the internship, and
the management of OPEX and Sinha textile Factory, Engr. K.M Ismail Hossain, Manager of Utility
Sector,and Marufur Rahman, Assistant Engineer, for helping us learn throughout this internship. We are
also very much thanked you to all the engineers and members of OPEX and Sinha textile Factory for their
suggestion, hard work, and direction.

At last, we would like to convey our gratitude to all of our faculty members, family, and friends for their
inspiration and co-operation, who gave us good advice, suggestions, inspiration, and support. We are also
very grateful to our EEE department for giving us the opportunity to perform 15 days (100-hour)
internship program that guides us to gather some practical knowledge necessary to prepare ourselves for
the future.

Finally, we want to thank all of our teachers, friends and family for their inspiration and co-operation
throughout our whole academic life in EWU including complete our internship.

Executive Summary
As Bangladesh is a developed country, the power sector plays a vital role in development country. Opex
and Sinha textile group of utility sector is to concern about to fulfill the demand of Opex and Sinha
textile group Ltd, and garments factory. This 28MW power plant consists of three types of generator
which name is Janbechar,Wakesha and caterpillar. There is different type of air compressor ATLAS
COPCO ZT-200 and ZEIDLER & UHL GMBH. There is different type of Boiler. The installation
capacity of Opex and Sinha textile group is 28 MW. In recent year, 23 MW electricity is produced from 7
power house. The power plant has future plans to increase the capacity of the entire power plant up to
40MW.

We have joined the internship program in this sector of Opex and Sinha textile group on 15 thDecember
2019 to 2nd January of 2020 complete at least 100 hours. During the internship program, we have visited
the all control room (7 power house), substation unit, engine unit, boiler section, water treatment
plant(WTP), ETP (Effluent treatment plant, workshop. We were able to learn, observe, and operate the

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process and equipment of the power plant that we studied in the academic courses. We were able to
gather knowledge on the components of the gas-based plant- generator, alternator, rotor, condenser,
combustion chamber, exhaust module, boiler, pre-lube operational driver, and cooling system. In the
control room, there are many type control panel. We have also worked extensively in the substation,
which is one of the major parts of the power plant, and during our visit to the substation unit, we learned
about transformers (STEP DOWN), circuit breakers (ACB, VCB. MCB, MCCB, ACB), lightning
arresters, bus bars, feeder lines, potential transformer, current transformer, protection relays, trucking and
other equipment of the substation, and we have observed how the circuit breakers and relays are switched
on/off and operated. so we can say that in this internship we saw some practical activities that we learn in
our theory class which is very important for different sector in future.

Training Schedule
Training Schedule The training schedule of Opex and Sinha Textile Group (power
Generation Section) is given below.
day& Date Subject Trainer
15-12-2019 Visit whole Power plant and Discuss whole power plant K.M Ismail Hossain
(Sunday) working system and safety system. (Utility Manager)
17-12-2019 Visit Power house-1 & Power house-7 and Waukesha K.M Ismail Hossain
( Tuesday) Gas Generator operating principle, and relevant (Utility Manager)
mechanical equipment observation
18-12-2019 Visit Substation and Control panel of the Substation and K.M Ismail Hossain
(Wednesday) seen that relevant auxiliary modules (Utility Manager)
19-12-2019 Visit the Transformer, H.T switchgear, L.T switchgear K.M Ismail Hossain
(Thursday) and seen how to control the whole system. (Utility Manager)
21-12-2019 Visited to Boiler House and seen how to Fire tube boiler MD. Mozammel Hoque
( Saturday) and maintenance Fire Tube Boiler. (Assistant Manager)
22-12-2019 Maintenance Fire Tube Boiler and Control Panel and MD. Mozammel Hoque
(Sunday) visit Steam distribution system in whole company. (Assistant Manager)
23-12-2019 Visit and maintenance Compressor room and their SK. Redwan Ahmed
(Monday) working principle. (Assistant Engineer)
24-12-2019 Visited to Effluent treatment plant (ETP) and Water Mohammad Alamgir
(Tuesday) treatment plant (WTP) and seen how to process the plant. Hossain
(Senior Engineer)
26-12-2019 Visit and maintained the Exhaust gas Boiler plant and Kartik Chandra das
(Wednesday) chiller system. (Senior Engineer)
28-12-2019 Visit the Diesel Generator and maintenance the generator Eng. Ratan
(Saturday) plant. (Senior Engineer)

29-12-2019 Visited to Safety protection system and REB distribution K.M Ismail Hossain
(Sunday) and LPS system and Voltage Regulation system and REB (Utility Manager)
substation.
30-12-2019 Visit and operation of the Jenbacher Gas Generator Marufur Rahman
(Monday) operating principle, and relevant mechanical equipment (Assistant Engineer)
observation.

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31-12-2019 Visit Cater pillar Gas Generator (Rope denim Power Marufur Rahman
(Tuesday) House) and working properly of this system and different (Assistant Engineer)
type of Substation.
01-01-2020 Visit Power distribution system in whole company and ShamserAlam
(Wednesday) mechanism. (Electrical In charge)
02-01-2020 Visit Fire system Pump control room ,Humidification Suzan Biswas
(Thursday) plant and AC system and maintenance (Sub-Assistant Engineer)

Table of Contents
Intern Certificate ………………………………………………………………………………….01-03
Authorization Page ……………………………………………………………………….………04
Approval letter…………………………………………………………………………………….05
Acknowledgment…………………………………………………………………………………06
Executive Summary ………………………………………………………………………….….06-07
Training Schedule…………………………………………………………………………………07-08

Chapter 1: Introduction
1.1 Objective of Internship……………………………………………………………………15
1.2 Company Profile of Opex and Sinha Textile Group………….………………….……….15
1.3 Generation Capacity of OPEX and Sinha Textile Group…………………………………16
1.4 Report Organization…………………………………………………………………….….16

Chapter 2: Power Plant System and Using Equipment

2.1 Introduction………………………………………………………………………………
2.2 Working Principle of Gas Power Plant……………………………………………………......
2.3 Diesel Generator………………………………………………………………………….
2. 4 Boiler…………………………………………………………………………………. …..
2. 5 Compressor………………………………………………………………………………
2.6 Water treatment plant…………………………………………………………………….
2.7 Effluent treatment plant………………………………………………………………….
2.8 Water cooling System……………………………………………………………………
2.9 Sub-station……………………………………………………………………………….
2.10 REB power system……………………………………………………………………...

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2.11 Transformer………………………………………………………………………………
2.12 Protection System of Sub-station……………………………………………………….
2.13 Excitation System……………………………………………………………………….
2.14 Control room…………………………………………………………………………….
2.15 Chiller……………………………………………………………………………………
2.16 Humidification plant…………………………………………………………………….
2.17 Fire alarm system……………………………………………………………………….

Chapter 3: generator
3.1Major Components of Generator
1.Alternator……………………………………………………………
a. Stator………………………………………………………………
b. Rotor……………………………………………………………..
c. Slip Ring…………………………………………………………
d. Carbon Brush……………………………………………………
e. Armature Winding………………………………………………
2 Engine ……………………………………………………………
a. Crankshaft and Bearings ……………………………………….
b. Camshaft ……………………………………………………….
c. Connecting Rod ………………………………………………..
d. Flywheel ……………………………………………………….
e. Piston…………………………………………………………...
f. Cylinder…………………………………………………………
g. Inlet Filter………………………………………………………
h. Radiator
i. Combustion chamber………………………………………….
j. Filter……………………………………………………………
k. Oil Bath Filter…………………………………………….
3.2 Generator Rating……………………………………………………………….
3.3 Excitation system of Generator………………………………………………..
1. Initial Excitation……………………………………………….
2. Excitation During Operation………………………………….
3.4 Generator Protection
1. Phase to Phase Fault Protection………………………….
2. Phase to Earth Fault Protection………………………….
3. Over Voltage Protection…………………………………
4. Over Current Protection…………………………………
5. Frequency Protection……………………………………
6. Temperature Protection…………………………………..
7. Reverse Power Protection………………………………..
3.5 Cooling System of Generator

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a. Water Cooling……………………………………….

3.6 Fuel supplying system…………………………………………………………...

3.7 Lube Oil System …………………………………………………………………
3.8 Exhaust Module …………………………………………………………………
3.9 Main Control Module…………………………………………………………….
3.10 Monitoring modules…………………………………………………………….

Chapter 4: Boiler and Compressor

4.1Boiler……………………………………………………
4.1Main Components of Boiler………………………………………………

Boiler Drum……………………………………………………………
Furnace……………………………………………………………….
Burner…………………………………………………………………
Super Heater………………………………………………………….
Economizer……………………………………………………………
Chimney……………………………………………………………….
Pressure Gauge…………………………………………………………
Water Level Indicator…………………………………………………
Safety Valve……………………………………………………………
Feed Check Valve…………………………………………………………
Regenerator Air Heater………………………………………………….
Forced Draft Fan…………………………………………………………
Condense ……………………………………………………………….

4.3 Boiler Protection

Temperature Control………………………………………………………........
Lube Oil Flow Control………………………………………………………….
Air Pressure Control…………………………………………………………….
Drum Level Feed Water Control………………………………………………..
4.4 Compressor
Air Compressor Working Principle

The main component of Air Compressor

Actuators…………………………………………………………………….
Belts…………………………………………………………………………..
Bumpers……………………………………………………………………..
Bushings………………………………………………………………………
 Couplings…………………………………………………………………….

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Dryers………………………………………………………………………
 Gauges……………………………………………………………………..
Motors……………………………………………………………………..
 Piston Ring…………………………………………………………………
Rotors………………………………………………………………………
Springs………………………………………………………………………
Valves………………………………………………………………………

Chapter 5: Sub-station of OSTG

5.1Introduction…………………………………………………………………………………
5.2Transformer…………………………………………………………………………………
1. Instrument Transformer……………………………………………………………

a. Current Transformer (CT)………………………………………

b. Potential or Voltage Transformer (PT)…………………………………

2. Auxiliary Transformer……………………………………………………………..
3. Coupling Transformer……………………………………………………………...

4.Cooling System of Transformer…………………………………………………………….

a. Oil Natural Air Forced Cooling System…….………………………………
b. Oil natural air natural Cooling System…………………………………….
5. Silica Gel Breather………………………………………………………………………….

6. Transformer Tap Changer…………………………………………………………………..

7.Megger Test………………………………………………………………………………...
7.Bay………………………………………………………………………………………….
5.3 Protection System of Sub-station…………………………………………………………...

Relay……………………………………………………………………………….
a. Differential Relay Protection…………………………………………………...
b. Buchholz Relay Protection……………………………………………………...
c. Distance Relay Protection………………………………………………………
Circuit Breaker……………………………………………………………………..
a. Oil Circuit Breaker……………………………………………………………...
b. Air Break Circuit Breaker……………………………………………………….
Insulator……………………………………………………………………………
Isolator……………………………………………………………………………..
Lighting Arrester…………………………………………………………………...
Feeder………………………………………………………………………………
Earthling Switch…………………………………………………………………….
Transmission Equipment……………………………………………………………………
Bus Bar……………………………………………………………………………..
a. Single Bus Bar System………………………………………………………….
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b. Double Bus Bar System…………………………………………………………

Wave Trapper………………………………………………………………………
Transmission System………………………………………………………………
Switchgear…………………………………………………………………………
a. L.T switchgear……………………………………………………………
b. H.T switchgear…………………………………………………………..
BBT………………………………………………………………………………

Chapter 6: WTP and ETP

Water Treatment Plant
Water Treatment Procedure………………………………………………………………...
Clarifier ………………………………….……… ……………………………......
Mechanical Filter...…………………………………………………………….…..
Cation Exchanger……………………………………………………………….…
Degasifier……………………………………………………………………….….
Anion Exchanger………………………………………………………………….
Mixed Bed Exchanger……………………………………………………………...
Effluent Treatment Plant
Bar Screen:

Collection Tank:
Equalization Tank
Biological Oxidation Tank:

Chapter 6: Conclusion
6.1 Discussion………………………………………………………………………………….
6.2 Limitations………………………………………………………………………………….
6.3 Recommendations………………………………………………………………………..

Reference………………………………………………………………………………………
Appendix……………………………………………………………………………………….

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Chapter 1: Introduction
1.1 Objective of Internship
The objective of our internship is to relate the basic theoretical knowledge anddeeply the practical. To do
the internship and thereby, to fufill our academic requirements, we have chosen OPEX and Sinha Textile
Factory (Utility Sector). By this power station, as an intern, there is an opportunity to visit the whole
power station and gather practical knowledge on a gas-based power plant, an open cycle, and an
electrical substation.

1.2 Company Profile

OPEX and Sinha textile group, a Bangladeshi Conglomerate of manufacturing Readymade garments,
Textile, Accessories and have power Plant. It is the largest Garments and Textile industries in Asia; which
is set up in four massive industrial complex in Bangladesh. Founded in the 1984, OPEX and Sinha Textile
Factory. a registered captive power plant, is producing power to meet the demand of OPEX and Sinha
Textile Factory.
OPEX and Sinha Textile Factory has developed 28 MW of natural gas-fired Power generation plant in
Kanchpur, Bangladesh. Currently, OPEX and Sinha Textile Factory is leading the development of
additional gas-fired power projects. he main product of Opex are in both woven and knit fabrics; such as
– shirts, pants, shorts, short – all, jumpers, overalls, jackets, vests, sportswear, sleep wear, ladies’ dresses,
T-shirts, and fleece items, with imported fabrics from all over the world.

Figure 1.1: Opex and Sinha Power Plant Sector (inside view)

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Mission, and Vision of Opex and Sinha

Mission:To deliver uninterrupted quality power for sustainable development.

Vision: To serve our clients with the finest quality industrial product and innovative product solutions
and ensure customer satisfaction.
1.3 Generation Capacity of Opex and Sinha textile Group
OPEX and Sinha Textile Factory was founded in 1984 which is a registered captive power plant. It is
producing power to meet the demand of OPEX and Sinha Textile Factory. OPEX and Sinha Textile
Factory has developed 23 MW of natural gas-fired power generation plant in Kanchpur, Bangladesh.
Currently, OPEX and Sinha Textile Factory is leading the development of additional gas-fired power
projects. Its total generation capacity is 28 MW which is generated by 7 units.

Table 1.1: The Profile of Opex and Sinha Textile Factory

Name OPEX and Sinha Textile Factory
Year of Establishment 1984
Corporate Office : Mohakhali Tower, 82, Mohakhali C/A, Dhaka

Company Name OPEX and Sinha Textile Factory

Main Work manufacturing Readymade garments, Textile,
Accessories and Power supply
Installed Capacity 28MW
Regular Employee 72(power Sector)

Table 1.2: Generation Capacity of All Units of Opex and Sinha Textile Factory
Unit No Production Capacity Generating Voltage (V) Current Condition
(MW)
Power House-01 3 400 Running
Power House-02 5 400 Running
Power House-05 6 400 Running
Power House-06 3 400 Running
Power House-07 3 400 Running
Power House-08 3 400 Running
Power House-09 5 400 Running

1.4 Report Organization

Chapter 1 contains objective of the internship, company profile, mission, vision, and objective of the
company, and generation capacity of Opex and Sinha textile Group Chapter 2 contains about Gas based
power plant of the power station, working principle, cooling system, generator, rotor, compressor,
combustion chamber, radiator, boiler, exhaust module, different types of protection system, and its
control room. Chapter 3 contains details about substation, Switchgear, and the SLD of the control system
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of Opex and Sinha Textile Group. It also elaborates details on the major equipment of a substation;
transformer and its different equipment, protection system, relay, circuit breaker, isolator, insulator,
lightning arrester, and bus bar. Chapter 4

Chapter 2: Power Plant and Using Equipment

2.1 Introduction
Opex and Sinha Power station is a captive power plant that consumes most of their generated power. It
has 7 power house and all power house produce power. To produce electricity Opex and Sinha Power
uses raw materials such as natural gas (CH4), and air. The source of natural gas is Titas Gas Transmission
and Distribution. Natural gas is used as a fuel in the power plant. They also need water and lubrication oil
for different purposes while producing electricity, for example, cooling and anti-friction purposes.

2.2 Working Principle of Gas Power Plant

In the engine, the gas is supplied through common pipes running along with the engine, continuing with
individual feed pipes to each main gas admission valve located on each cylinder head. The external
pressure regulator regulates the gas pressure under different loads. The maximum pressure needed is not
more than 4.5bar (a) under full load. There are two common pipes per bank, one for the main and one for
the pre-chamber gas supply. A filter is placed before every gas admission valve to prevent particles from
entering the valve.

Figure 2.1: Block Diagram of Gas Power Plant

power plants mainly use gas as a fuel. In Opex and Sinha, all engines are gas engines which are
generating 400V each. The 400V power is supplied through the bus bar after synchronization. The gas
power plant engine has turbo charger where the exhaust gases of engines are forced through to make the
wheel (inside the turbo charger) spin. Due to this, another wheel in turbo charger rotates and sucks air
from the atmosphere. Then the air is passed to the pre combustion chamber where fuel is mixed with the
compressed air in order to have an initial combustion in the chamber. Afterwards, the charged air is
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passed to the engine cylinders and creates combustion and exhaust is produced. Each cylinder is a four-
stroke engine where piston rotates the crankshaft, and crankshaft rotates the flywheel. Alternator rotor
spins because of the flywheel. The electricity is produced through the alternator mechanism.

2.3 Diesel Generator

AtOpex and Sinha, a diesel generator is used for the auxiliary module of the engine. When the engine is
at a blackout position, there is no current for auxiliary equipment to run. During this time, a 250KVA
generator is used to start the engine. Before starting the engine, a few mechanical pumps and valves are
needed to operate so these operations are made by this generator. The main fuel of this generator is
diesel.

Figure 2.10: Diesel Generator at Opex and Sinha

2.4 Boiler
A closed vessel made up of steel to transfer heat produced by the combustion of fuel to water and
ultimately generate steam. Industrially, there used two types of boiler.

1. Exhaust Gas Boiler

2. Fire-tube Boiler
During our internship, we saw a fire tube boiler in the plant. A boiler is an outside part of the plant. In
OPEX AND SINHA plant, we saw a big boiler that generates steam for their other factories. They are
using a fire tube boiler and using the exhaust gas they are generating steam.

Fire-Tube Boiler: A fire-tube boiler is a type of boiler in which hot gases pass from a fire through one
or more tubes running through a sealed container of water. The heat of gases is transferred through the
walls of the tubes by thermal conduction heating the water and ultimately creating steam.

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Figure 2.3: Fire Tube Boiler layout Opex and sinha

Exhaust Gas Boiler

An Exhaust Gas Boiler is a type of heat recovering system on ships which allows the exhaust heat of the
main engine to produce steam while going out in the atmosphere. Every system, which is operated at high
temperature, always has a risk of fire. This applies to EGB which has the inlet temperature of exhaust
gases @ 300-400 deg. C. The most common type of Exhaust Gas Boiler (EGB) used on ships are water
tube boiler.

2.5 Compressor
A compressor is a mechanical device that increases the pressure of a gas by mechanically decreasing its
volume. This power plant uses natural gas as fuel. The compressor reduces the volume of the gas. The
pressure of the natural gas increases from 7 bar to 30 bar using an air compressor.

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Figure 2.3: Air Compressor of Opex and Sinha

2.6 Water Treatment Plant
Water is needed for production of steam and cooling purpose. Steam is used as the main fluid to rotate the
steam turbine. Huge amount of water is needed for running the power plant. The main source of water is
the river water of Shitalakshya. Water of the river contains many minerals and suspended substances and
it is harmful for the boiler and turbine. On the other hand, the natural water or mineral water has bad
effect of “Scale Decomposition” which can block the pipeline of water of the boiler. The impure water is
purified through some chemical steps and stored in a tank. The purified water is called “Demi-water or
Demineralized water”. The quality of demi-water is maintained very carefully.

2.7 Effluent Treatment plant

Effluent is an outflowing of water or gas to a natural body of water, from a structure such as a wastewater
treatment plant, sewer pipe, or industrial outfall. Effluent, in engineering, is the stream exiting a chemical
reactor
Fossil-fuel power stations, particularly coal-fired plants, are a major source of industrial wastewater.
Many of these plants discharge wastewater with significant levels of metals such
as lead, mercury, cadmium and chromium, as well as arsenic, selenium and nitrogen compounds
(nitrates and nitrites). Wastewater streams include flue-gas desulfurization, fly ash, bottom ash and flue
gas mercury control. Plants with air pollution controls such as wet scrubbers typically transfer the
captured pollutants to the wastewater stream. [2]
Ash ponds, a type of surface impoundment, are a widely used treatment technology at coal-fired plants.
These ponds use gravity to settle out large particulates (measured as total suspended solids) from power
plant wastewater. This technology does not treat dissolved pollutants. Power stations use additional
technologies to control pollutants, depending on the particular wastestream in the plant. These include dry
ash handling, closed-loop ash recycling, chemical precipitation, biological treatment (such as an activated
sludge process), membrane systems, and evaporation-crystallization systems. [2] Technological
advancements in ion exchange membranes and electro dialysis systems has enabled high efficiency
treatment of flue-gas desulfurization wastewater to meet recent EPA discharge limits. [3] The treatment
approach is similar for other highly scaling industrial wastewaters
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2.8 Water Cooling System

The engine cooling system is very important for a smooth operation. When the combustion happens, the
temperature of the cylinder becomes very high. This heat affects engine performance. Also, the engine is
surrounded by lube oil. At higher temperatures, lube oil is affected. At Opex and Sinha, the closed-loop
water cycle system maintains the perfect temperature of the engine. They maintain the temperature
between 50 and 55-degree Celsius. There were two lines- one is input another is output. Water at
45degree Celsius temperature enters the engine from the input line and it becomes 90 degrees after
coming across the engine. The temperature is reduced by sending the heated water to the radiator by the
output pipe. The radiator cools the high-temperature water and prepares the water for passing through the
engine section again. This is the proper water cooling system of this engine.
2.9 Sub-Station
A substation is a part of an electrical generation, transmission, and distribution system. Substations
transform voltage from high to low, or the reverse, or perform any of several other important functions.
Between the generating station and consumer, electric power may flow through several substations at
different voltage levels. A substation may include transformers to change voltage levels between high
transmission voltages and lower distribution voltages, or at the interconnection of two different
transmission voltages.
Substations may be owned and operated by an electrical utility, or may be owned by a large industrial or
commercial customer. Generally substations are unattended, relying on SCADA for remote supervision
and control.
The word substation comes from the days before the distribution system became a grid. As central
generation stations became larger, smaller generating plants were converted to distribution stations,
receiving their energy supply from a larger plant instead of using their own generators. The first
substations were connected to only one power station, where the generators were housed, and were
subsidiaries of that power station.

2.10 REB power system

Opex and Sinha Textile group mainly uses REB as an alternative power. When Sinha power plant face
any problem and inactive any power house then uses REB as an alternative power. REB power is mainly
11KV power but Opex and Sinha use 400V power. So REB power convert 400V using
Transformer

2.11 Transformer
A transformer is a static device that converts ac electric power at a particular voltage level to the same ac
electric power at another voltage level at constant frequency. It is the major equipment in a sub-station.
Varies types of transformers like power transformer, auxiliary transformer, coupling transformer and
instrument transformer such as current transformer and potential transformer were observed in OPEX

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AND SINHA power station. Different types of transformers at OPEX AND SINHA are discussed in this
section.

Figure 4.2: Transformer at Opex and sinha

2.12 Excitation system

The excitation system is mounted on the side opposite the coupling. The excitation system comprises two
assemblies:

The excitation armature, generating a three-phase current, coupled with the three-phase rectifier bridge
(comprised of six diodes) supplies the excitation current to the generator revolving field. The excitation
armature and the rectifier bridge are mounted on the synchronous generator rotor shaft and are
interconnected electrically with the revolving field of the machine. The excitation field winding (stator)
is supplied by the control (indirect current).

2.13 Protection System of Sub-station

Most of the sub-station equipment are expensive. To protect electrical equipment from damage, the
protection system plays an important role. The protection system of substation isolates the faulty parts
from the working system and minimizes the losses. Circuit breaker, isolator, insulator, relay lightning
arrester, etc. are used to protect the power system. The protection system of a sub-station should be
strong to supply power safely and continuously.

2.14 Control room of power plant

In OPEX AND SINHA, every generation unit has individual control unit. And each control unit has
three section generator, compressor and boiler. From control unit, control engineers can observe the
working function of each section and control the input and output function according to demand. From
control room they also can control auxiliary parts of each unit like condenser, feed water pump,
pressure, heater, manually tripping etc. and engineers from the control room can also take reading and
observe about condition of each section.

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Distribution SystemIt is not possible to connect the consumers directly to the generator of a power
station. To supply the electricity to the consumers a system is needed by which electricity can be
transmitted to the consumers at their desired quality. This is accomplished by suitable apparatus in a
substation. Substation transmits the generated power to the consumers by transmission and distribution
system. At Opex and Sinha Power Ltd., the generated voltages are 400V at engine . They are stepped
down to 400V by using unit transformers and do not supply power to the grid line. Then the electricity
produced here is supplied to different factories through distribution.

Boiler Desk
Boiler of a power station is controlled from boiler desk. From here engineers can control demineralized
water level, gas pressure, temperature of boiler etc. Here all switches are operated manually.

Figure 5.1: Boiler desk of unit-3 at OPEX AND SINHA

Generator Desk
From the generator desk, generator is controlled. All the controlling task, which are related to the
generator such as controlling the hydrogen pressure, excitation voltage, synchronous speed etc. are done
from here. The engineers do all of the controls manually.

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Figure 5.3: Generator desk of unit-3 at OPEX AND SINHA

2.15 Chiller
A chiller is a machine that removes heat from a liquid via a vapor-compression or absorption refrigeration
cycle. This liquid can then be circulated through a heat exchanger to cool equipment, or another process
stream (such as air or process water). As a necessary by-product, refrigeration creates waste heat that
must be exhausted to ambience, or for greater efficiency, recovered for heating purposes. Chillers may
use hermetic scroll, or semi hermetic screw, or centrifugal compressors.
Chilled water is used to cool and dehumidify air in mid- to large-size commercial, industrial, and
institutional facilities. Water chillers can be water-cooled, air-cooled, or evaporatively cooled. Water-
cooled systems can provide efficiency and environmental impact advantages over air-cooled systems.
2.16 Humidification plant
The process in which the moisture or water vapor or humidity is added to the air without changing its dry
bulb (DB) temperature is called as humidification process. This process is represented by a straight
vertical line on the psychrometric chart starting from the initial value of relative humidity, extending
upwards and ending at the final value of the relative humidity. In actual practice the pure humidification
process is not possible, since the humidification is always accompanied by cooling or heating of the air.
Cooling and humidification process is one of the most commonly used air conditioning application for the
cooling purposes. In this process the moisture is added to the air by passing it over the stream or spray of
water which is at temperature lower than the dry bulb temperature of the air. When the ordinary air passes
over the stream of water, the particles of water present within the stream tend to get evaporated by giving
up the heat to the stream. The evaporated water is absorbed by the air so its moisture content, thus the
humidity increases. At the same time, since the temperature of the absorbed moisture is less than the DB
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bulb temperature of the air, there is reduction in the overall temperature of the air. Since the heat is
released in the stream or spray of water, its temperature increases.

2.17 Fire alarm system

A fire alarm system has a number of devices working together to detect and warn people through visual
and audio appliances when smoke, fire, carbon monoxide or other emergencies are present. These alarms
may be activated automatically from smoke detectors, and heat detectors or may also be activated
via manual fire alarm activation devices such as manual call points or pull stations. Alarms can be either
motorized bells or wall mountable sounders or horns. They can also be speaker strobes which sound an
alarm, followed by a voice evacuation message which warns people inside the building not to use
the elevators. Fire alarm sounders can be set to certain frequencies and different tones including low,
medium and high, depending on the country and manufacturer of the device. Most fire alarm systems
in Europe sound like a siren with alternating frequencies. Fire alarm electronic devices are known as
horns in the United States and Canada, and can be either continuous or set to different codes. Fire alarm
warning devices can also be set to different volume levels.

Chapter 3: generator

3.1 Major Components of Generator

The major components of generator are given below:

1. Alternator
a. Stator
The stator is the important element of a generator which is the armature of generator. It is the stationary
part where the rotating magnetic field converts to induce voltage. When the magnetic field of the rotor
cuts the stator windings, an EMF (Electromotive Force) is produced in the stator windings. In OPEX
AND SINHA, the stator has 30 slots and each slot has 2 windings. The stator windings are designed in
such a way that each phase has 20 windings.

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Figure 2.15: The stator of unit-6 at OPEX AND SINHA

b. Rotor
Rotor is the rotating part of generator and it is situated inside the stator. Rotor is coupled with the turbine
and works as the prime mover of rotor. DC excitation is provided in the rotor for generating an electric
current in the rotor windings. In OPEX AND SINHA, the rotor has two poles and it rotates at 3000 rpm.

Figure 2.16: The rotor of unit-6 at OPEX AND SINHA

c. Slip ring

Slip-ring provides an electrical connection to the rotor windings and provides a continuous electrical
power through brushes to the generator rotor. The brush holder gear is fitted on slip-rings and slip-ring
are fitted on to rotor shaft. It is insulated from the shaft. Slip rings improve mechanical performance and
simplify system operation. In OPEX AND SINHA, there has two slip-rings.

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Figure 2.17: Carbon brush and slip ring chamber (Unit-4)

d. Carbon Brush
Carbon brush remains in contact with the slip ring and provides power to the rotor of the generator from
external DC source for field excitation. The carbon brushes are also fitted with springs, so that when
brushes go down by friction over time, carbon brushes will still remain in contact with the slip rings. In
OPEX AND SINHA, there are total 208 carbon brushes. 104 carbon brushes are connected to positive
terminal and 104 brushes for connected to negative terminal of supply.
e. Armature Winding
Armature winding is a part of a stator. It is the main current-carrying winding in which the electromotive
force is induced. Current in the armature winding is called armature current.

2 Engine Mechanical Parts

Figure 2.6: Engine’s Mechanical Parts Inside

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a. Crankshaft and Bearings

The latest advance in combustion development requires a crank gear that can operate reliably at high
cylinder pressures. A crankshaft is a rotating shaft that converts reciprocating motion of the pistons into
rotational motion. The crankshaft is supported by the engine block, with the engine's main bearings
allowing the crankshaft to rotate within the block. The up-down motion of each piston is transferred to
the crankshaft via connecting rods. A flywheel is often attached to the front end of the crankshaft, in
order to smoothen the power delivery.

b. Camshaft

The camshaft is a mechanical component of an internal combustion engine. It opens and closes the inlet
and exhaust valves of the engine at the right time, with the exact stroke and in a precisely defined
sequence. The camshaft is driven by the crankshaft with gearwheels, a toothed belt or a timing chain.

c. Connecting Rod

A connecting rod is the part of a piston engine that connects the piston to the crankshaft. Together with
the crank, the connecting rod converts there Cipro catting motion of the piston into the rotation of the
crankshaft. The connecting rod is required to transmit the compressive and tensile forces from the piston,
and rotate at both ends.

d. Flywheel

It is working like a coupler. It basically connects the engine with the alternator. It is situated between the
alternator’s rotor end and the engine’s crankshaft end. The RPM of this flywheel is 750.

e. Piston

The piston is the moving component that is contained by a cylinder and is made gas-tight by piston rings.
In an engine, its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a
connecting rod.

f. cylinder 

A cylinder is one of the most basic curved geometric shapes, with the surface formed by the points at a
fixed distance from a given line segment, known as the axis of the cylinder. The shape can be thought of
as a circular prism. Both the surface and the solid shape created inside can be called a cylinder.
The surface area and the volume of a cylinder have been known since ancient times.
In differential geometry, a cylinder is defined more broadly as any ruled surface which is spanned by a
one-parameter family of parallel lines. A cylinder whose cross section is an ellipse, parabola,
or hyperbola is called an elliptic cylinder, parabolic cylinder, or hyperbolic cylinder respectively.
g. Combustion chamber
The combustion chamber is the area inside the engine where the fuel/air mixture is
compressed and then ignited. It is generally formed on one side by the shape cast into
the cylinder head, and on the other side by the top of the piston. When the piston is at
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top-dead-center the chamber is at its smallest dimension, and this is the time when the
fuel/air mixture is at its most unstable condition and ready to be ignited. The better the
combustion chamber is designed the better the engine "breathes;" that is, the more
efficient the overall flow of air through the engine
h. Filters

In the Opex and sinha plant, the engine has many types of filters of the engine. Generally, they are
auxiliary equipment. These are air inlet filter, auxiliary ventilation filter, oil bath filter.

i. Air Inlet Filter

Many types of filters are used in OPEX AND SINHA. Air filters are one of the most important
equipment. Air inlet is a device which is used to remove unfamiliar particle from the air. Air contain
various small particles and if this air is mixed with fuel and produces fuel gas, it can damage turbine
blades. For this reason, the air is filtered by this auxiliary machine.

Figure 2.4: Air inlet pre-filter and filter of OPEX AND SINHA

j. Oil Bath Filter

Oil bath filters are used for lube oil. These filters are used to remove heavy particles and dust from the
lube oil. The engine chamber is fully surrounded by lube oil so if lube oil carries any dust or particles it
can create abrasion with metal.

k. Radiator
Radiators are heat exchangers used to transfer thermal energy from one medium to another for the
purpose of cooling and heating. A radiator is a machine which contains few numbers of the fan. It
reduced the temperature of hot water for passing to the engine.

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Figure 2.7: Radiator for OPEX AND SINHA Gas Plant

3.2 Generator Rating
There are 3 types of generator at OPEX AND SINHA. The ratings of these generators are given in Table
1.1.
Table 1.1: Rating of Generator
specification

Model wakesha jenbechar catterpiller

Output Power 1MW 1MW 1MW
Pole 2 2 2
Phase 3 3 3
Terminal 400V 400V 400V
voltage
Stator current 4550A 4750A 4500A
Rotor excitation 1650A 1445 A 1550A
current (DC)
Frequency 50 Hz 50 Hz 50Hz

3.3 Excitation of Generator

Excitation is the process by which magnetic field is created in the rotor winding. Carbon brush and slip
rings are used to supply the DC voltage during rolling. All the six units of OPEX AND SINHA use DC
excitation system and DC power is used for that. For large generators, high amount of DC power is
needed. This excitation process has two parts,
a. Initial Excitation
b. Excitation During Operation
a. Initial Excitation

Initially the generator is excited by providing DC power supply from battery, when the generator is not
synchronized with the grid. In OPEX AND SINHA, a number of electrolytic cells are connected in series
and used as a battery bank. This battery bank is placed in the substation.

b. Excitation During Operation

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When the generator is synchronized with the grid, the battery is disconnected by a circuit breaker and dc
excitation is given from the grid line. For this purposeOPEX AND SINHA uses AC power from the grid,
which is stepped down by a rectifier transformer and the secondary winding of the rectifier transformer is
connected to a thyristor. This thyristor converts the AC power to DC power and supplies DC power to the
rotor through slip-rings. Voltage regulator is used to control the dc excitation current. The output voltage
of the generator is controlled by controlling the excitation current. The battery is disconnected
automatically after few seconds of generator synchronization with the grid. In OPEX AND SINHA, from
15.75 KV line, voltage is stepped down to 580 V by the rectifier transformer and the thyristor converts
the AC current to DC current and This DC voltage is supplied to the rotor winding.

3.4. Generator Protection

Generator is the most expensive and important part of the power plant. Various types of electrical and
mechanical faults can affect the performance and reduce the longevity of the generator. So, for safe and
long lasting operation, it is necessary to take adequate protection for generator. Due to the failure of 230
kV breaker, generator of unit-6 at GSP was damaged and the blades of low pressure turbine were bend in
2010 which is observed in practical visit.
a. Phase to Phase Fault Protection.
Due to insulation breakdown of stator windings, the phases of the stator come in contract and the
generator damage by flowing a huge current through the stator. Depending on circulating current
principle, differential protection system like differential relay is used between the phases of the stator to
protect the generator. In this protection system, current is measured at the two end of differential relay
and compared them. If there has difference of current at the two end, then this difference current will flow
through relay operating coil. Then the relay closes its contract and isolates the faulty section by making
the circuit breaker to trip.

Figure 2.18: Differential protection scheme for stator protection [11]

b. Phase to Earth Fault Protection
This fault occurs, when any phase of the stator meet the ground or body of the generator. To detect this
fault differential protection like inverse time relay is provided. A current transformer (CT) is connected
in the neutral to earth connection. When the generator is connected directly to the bus bar, an inverse time
relay is used across the CT secondary.
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c. Over Voltage Protection

Over voltage occurs because of the increase in the speed of the prime mover due to sudden loss in the
load on the generator. The over voltage protection is provided by two over voltage relays have two units –
one is the instantaneous relays which is set to pick up at 130 to 150% of the rated voltage and another unit
is IDMT (Inverse Definite Minimum Time) relay which is set to pick up at 110% of rated voltage. Due to
controlling the speed variation with very sensitively, over voltage does not occur in turbo generator. But
in Hydro generator and Gas generator, over voltage protection is needed to protect the generator.
d. Over Current Protection
In a system more than one generators supply the load and if for any reason one or more generators
suddenly trip, other generators try to supply the load. Each of these generators will experience a sudden
increase in current and thus decrease in voltage. At OPEX AND SINHA, automatic voltage regulator is
connected to the system which tries to restore the voltage. Under voltage relay is also used for the under-
voltage protection. Over current relay is used for over current protection.
e. Frequency Protection
Frequency is a major parameter in power generation. The generator operates at a certain range of
frequency. In GSP, the generator frequency range is 50±2 Hz. If the generator operates over or under this
limit, then vibration occurs in the generator which can damage the rotor. This fault occurs because of
sudden load change in the grid. Due to over loading in national grid, under frequency fault is occurred. In
OPEX AND SINHA, under frequency relay is used to detect under frequency condition which activates
under 48 Hz. Due to increasing the speed of prime mover over generator speed, then frequency of
generated voltage also be increased. If the frequency of generated voltage is increased 52 Hz, then over
frequency relay will activate and trip the circuit breaker of the generator.
f. Temperature Protection
Stator overheating protection is required to protect the generator from overheating. Stator is over heated,
due to the overloads and also failure in cooling system. Due to the short circuiting of the lamination, it is
very difficult to detect the overheating before serious damage is occurred to the stator. To detect thermal
overloading temperature detectors like embedded resistance temperature detector or thermocouples are
used in different points of generator, especially near the bearings. In OPEX AND SINHA, thermocouple
is used to detect temperature rise. A relay triggers an alarm on if the temperature is very high.
g. Reverse Power Protection
The generator is driven by the prime mover (engine or turbine) and supplies power to the grid directly. In
generation mode, the prime mover maintains enough torque to control the generator. If the prime mover
fails to maintain torque or the prime mover is stopped but generator is connected to grid, then reverse
power will flow to generator from grid and the generator shifts from generating mode to motoring mode.
This type of problem occurred in OPEX AND SINHA at unit 6. In OPEX AND SINHA, reverse power
relay and unit circuit breaker are used between transformer and the generator to detect reverse power
flow.
3.5 Cooling System of Generator
Generator cooling is very necessary for safe operation. Due to rotation and dc current supply, rotor is
heated. Stator is the conducting part of generator and due to continuous flow of electricity stator is heated.
High heat affects the performance and lifetime of the generator. To reduce the effect, two types of cooling
system are used in OPEX AND SINHA.
a. Water Cooling System

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In OPEX AND SINHA, De-mineralized Water is used for cooling the stator of generator because
of its increased resistivity greater than the mineral water. Water carrying hollow pipes are passed
through the stator windings and water is supplied through these tubes by a pump. When the water
is circulating, then the hot part of the stator comes in contract with water and water absorbs heat
and finally sent to the cooling chamber. This heat exchanging process is continuously doing by a
motor.

Figure 2.19: Water Cooling System

3.6 Fuel supplying system

In a gas power plant, the main fuel is gas. Here at OPEX AND SINHA, the natural gas is supplied by
Titas Gas Transmission and Distribution Company Limited. The engines are run by gas. Gas is supplied
in the pre-combustion chamber at 8 bar pressure. So gas is stored in a big tank for regular flow.

Figure 2.2: Gas Reservoir Tank

2.7 Lube Oil System
Lube Oil and Control Oil systems are designed to provide pressurized lubricating oil to various
types of industrial rotating equipment. Typically, these lube oil systems include pumps, heat

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exchangers, filters, controls and instrumentation.The pumps, pressure regulation valves and safety
valves are integrated into one module fitted at the free end of the engine. Filter, cooler and thermostatic
valves make up another module. The lube oil filtration is based on an automatic back-flushing filter. The
filter elements are made of a seamless sleeve fabric with hightemperature resistance. A centrifugal filter
is mounted in the back-flushing line, acting as an indicator of excessive dirt in the lube oil. The engine
uses a pre-lubricating system before starting to avoid the wear of engine parts. At OPEX AND SINHA,
they are using shell lubricating oil.

Figure 2.7: Lube Oil Drum

3.8 Exhaust Module
Exhaust gas comes out from the turbocharger normally. At OPEX AND SINHA, the exhaust gas
temperature is around 550⁰C which is used in the boiler to produce steam for other factories. After this,
the extra gas is released to the atmosphere by the exhaust module.

Figure 2.9: Exhaust Module Outside of the OPEX AND SINHA Plant
3.9 Main Control Module
The core of the engine control system is the main control module. This is responsible for ensuring the
engine’s reliable operation and for keeping the engine at optimum performance in all operating
conditions such as varying ambient temperature and gas quality. The main control module reads the
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information sent by all the other modules. Using this information, it adjusts the engine’s speed and load
control by determining reference values for the main gas admission, air-fuel ratio, and ignition timing.
The main control module automatically controls the start and stop sequences of the engine and the safety
system. The module also communicates with the plant control system (PLC).

3.10 Monitoring Modules

Monitoring modules are located close to groups of sensors, which reduces cabling on the engine. The
monitored signals are transmitted to the main control module and used for the engine control and safety
system. The monitored values are also transferred to the operator interface on the external control system.

Chapter 4: Boiler and Compressor

4.1Boiler
The heat of combustion of gas in the boiler is utilised to convert water into steam at high temperature and
pressure. Water is contained in the boiler drum and the heat released during combustion of gas converts
water into the steam at the desired temperature and pressure. Then the steam is used todyeing clothe,
washing clothe and do laundry clothe of Different Garments factory. In Opex and Sinha power station has
six boilers for 3 units. The boilers are stack drum type, means there are drums within the boiler and flue
gas passes through the stack to atmosphere. Here upper drum is called a boiler drum from where saturated
steam leaves the boiler. The lower drum is called the mud drum, where liquid feed water enters. Tubes are
used to connect the two drums. Rating of the boilers in Opex and Sinha power station is given below.

Figure 3.1: Boiler of Opex and Sinha

Table 4.1: Boiler specification.

1. Boiler capacity 12ton/hour

2. Boiler using Fuel Natural gas

2. Maximum working pressure 10 bar

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4. Water content 17.3m3

5. Maximum thermal heat 7.8MW

6. Maximum thermal capacity 1800C.

7. Maximum Gas consumption 8243/hrs.

8. Gas Volume 14.6m3

9. Burner motor 21W

10. RPM 2900

11. Working temperature of Economizer 1840C

12. Exhaust Gas temperature inlet of Economizer 2600C

13. Exhaust Gas temperature outlet of Economizer 1600C

14. Thermal capacity of Economizer 390KW

15. Working inlet temperature of Economizer 700C

16. Water content 88Ltr.

The primary requirements of the boiler

 Water must be safelycontained.
 Steam must be delivered at rated pressure,temperature.
 Maximum heat from external combustion source should beutilized
4.2 Main Components of Boiler
The components of boiler are used for producing and delivering steam safely to the desired location.
These components also maintain the desired pressure, temperature and quality. The main components of
boiler are given below.
Boiler Drum
Water is reserved in the boiler drum. Water comes to the boiler drum from economizer. A level is
maintained for water pressure by a level transmitter. If the water level crossed the boiler the system will
tripped. This system is controlled by an automatic safety valve. From the boiler drum the saturated steam
is supplied to the super heater. Boiler drum is one of the most important components of boiler. It is a
horizontal drum and the water comes from water treatment plant.

Furnace.
Furnace is the chamber inside the boiler where natural gas is burned with the presence of air for
producing heated gas or flue gas. In a furnace chamber, heat is necessary to generate steam and the heat is

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generated by a combustion. At OPEX AND SINHA, every boiler has its own furnace chamber. Draft fan
is used to supply the air into the furnace.

Burner
Burner is the chamber in the boiler where natural gas or coal is burnt in the presence of air for producing
heated gas or flue gas. In power plant of OPEX AND SINHA each furnace has 8 burners. The
temperature inside the furnace chamber is 600°C.

Figure 2.5: The Burner of OPEX AND SINHA

Super Heater
Super heater is a subcritical component of the boiler that heat up the saturated vapor, at constant
pressure, so it becomes superheated steam.There are three types of super heaters radiant,
convection and separately fired. Radiant super heater is used in OPEX AND SINHA. There are
four stages in super heater. The steam will pass consecutively the primary super heater, secondary
super heater platform, intermediate secondary super heater and the final secondary super heater.
This steam produced by final secondary super heater is called superheated steam or dry vapor. It
contains no moisture at all, and stores very high heat energy, much higher than the saturated vapor.

Economizer
An economizer is a mechanical device which is used as a heat exchanger by preheating a fluid to reduce
energy consumption. Function of economizer is to recover some of the heat which is carried away by the
exhaust flue gas. The recovered heat is utilized to raise the temperature of feed water. Then the feed water
at raised temperature is supplied to the boiler. If the feed water at raised temperature is supplied to the
boiler, it needs to provide less heat to convert the water into steam. Recovery heat from flue gas raises
feed water temperature up to 345°C. Economizer is used to save the consumption of fuel.

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Figure 2.6: Economizer

Regenerative Air Heater
Regenerative air heater captures the heat of boiler exhaust gas as it is made of heat-absorbing metallic
elements. Air from the Forced Draught (FD) fan is passed through the RAH and inside the RAH, there are
pipes containing flue gas. So air becomes hot and flue gas releases heat when air comes in contact with
the pipes of flue gas. The captured heat is released into the cooler air and this air is entered to the furnace.
Chimney
A chimney is a structure that provides ventilation for hot flue gases or smoke from a boiler, stove,
furnace or fireplace to the outside atmosphere. Furnace produces flue gas. This flue gas is used to
create the steam for rotating the turbine. The flue gas passes through several numbers of equipment
and finally goes into the nature through chimney. Figure 3.3 shows the flue gas stack of GPS.

Pressure Gauge

The pressure gauge is mounted on the top of the shell. It indicates the amount of pressure observed inside
the boiler. It is a dial-type instrument that indicates pressure in different units such as kgf/cm 2 or K.pa or
PSI. Now a day’s digital type instruments are also used where it senses the pressure by some transducers
and sends the signal to the display unit.

Water Level Indicator

During the operation of the boiler, the operator must know the level of water. If not knowing the boiler
cannot withstand the pressure and may lead to an explosion. So, a water level indicator is mounted to the
shell of the water tube boiler.

Safety Valve

Water at higher pressures has a lot of energy so, safety precautions should be taken to prevent any loss.
For this purpose, we install a safety valve to the boiler. Whenever the pressure is above the prescribed
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limit I,e withstand capability then safety valve will be opened. At-least two safety valves are to be
provided.

Feed Check Valve

It is used for the entry of feed water into the boiler and also used as a non-return valve to prevent the feed
water from returning.

Forced Draught Fan (FD fan)

The main function of FD fan is to create positive pressure. It is installed near or at the base of the boiler to
supply air to the boiler furnace chamber and force the flue gas to pass through the super heaters, re-heater
and economizer. It also sucks the air and delivers it to the combustion chamber. The fan motor rotates at
600 rpm up to 750 rpm.

Condenser
Condenser is a mechanical device which converts the steam into water. A condenser is a part of steam
generator where exhaust steam is condensed and converted into water. Condenser creates a very low
pressure at the exhaust of turbine, which permits expansion of the steam in the prime mover to a very low
pressure.

4.3 Boiler Protection System

Boilers need some protection to keep the system running. The protection system is given below.

a. Temperature Control
In OPEX AND SINHA, platinum material is used as resistance. It is used for accuracy and long-term
stability. Normally temperature of the super-heated steam inside the super heater is about 550°C. If main
steam temperature is above 565°C or below 450°C, the resistance temperature detector sensor passes a
signal to the control room.

b. Lube Oil Flow Control

Lube oil pump is a one kind of pump which controls the flow of lube oil. The lube oil pump needs to
operate over a wide range of temperature and liquid viscose conditions. The regulation system does not
work if the lube oil temperature is below 17°C.

c. Air Pressure Control

At OPEX AND SINHA, furnace pressure is controlled by force draught (FD) and induced draught (ID)
fans. FD fan is a fan or blower that is installed near boiler to supply air to the boiler furnace and maintain
1.6 kgf-cm2 positive pressures. ID fan is a fan which is located near the base of chimney. In OPEX AND
SINHA, it is used to suck hot gases from the boiler side and maintain 0.9 kgf-cm 2 negative pressure from
the furnace to the outlet of the ID fan.

d. Drum Level Feed Water Control

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Drum contains both water and steam. From drum, water goes to furnace through water tube and absorbs
heat and turns into steam. The steam goes to drum as saturated steam. The minimum level of drum is -160
mm and the maximum level of drum is +200mm.
4.4 Compressor
Air Compressor Working Principle

The reciprocating piston air compressor is available in a one-stage and two-stage design with the main
difference being a second compression in a two-stage to compress the air to a higher psi in garages,
shops, and for portable .The process of compressing air is similar to the operation of an internal
combustion engine and is powered with electricity. Air compressor parts are also similar to a small gas
engine. They consist of a piston, connecting rod, crankshaft, cylinder, and valve head.

The air is compressed in the following manner:

 The valve head at the top of the compressor tank draws air in by the downward movement of the
piston in the cylinder.
 As the piston moves up, the air is compressed.
 The increased pressure forces the discharge valve to open, so then the air moves into the tank.
 With every stroke, more pressure is built up in the tank until it reaches capacity and the pressure
switch shuts off the motor.
 Two-stage compressors have the same operation with the addition of a second cylinder, which air
is pumped into to create greater pressure.

The main component of Air Compressor

This alphabetized air compressor parts list consists of parts from our reciprocating piston models and
rotary screw models to help you become more familiar with the functions of your air compressor:

Actuators: 
The actuator creates rotary or linear movement and is what outputs the compressed air to the tools or
processes that use pressurized air for power. Any leaks or other deficiencies in the air movement
coming into the actuator will result in a decrease of the air force coming out. Small particles that have
found their way into the air will cause blockages in the actuator, as well as many other parts of your
air compressor.

Belts: 
Belt tension should be checked every 40 hours for wear and operation. Working to drive the operation
of your compressor, the belts need to be of the highest quality and fit properly.

Bumpers:

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 Valve bumpers surround the valves for added protection from accidental contact. Replace this small
shielding part when needed to prevent the more expensive replacement of valves.

Bushings:
 Bushings create some space between moving parts. Used in the internal components of the air
compressor, your bushings offer protection from serious breakdowns, minimizing side-to-side play.

Couplings: 
Used on internal components to prevent leaking from the high-pressure system.

Dryers:
 Our Air dryers purify your compressed air by absorbing water vapor. A flow of ‘wet’ compressed air
is passed through two pressurized tanks that contain our highly absorbent desiccant. Q-Sorb is an
advanced formula of activated alumina that significantly reduces operating costs. Keep your air dryer
operating efficiently with regular checks of desiccant and filters.

Gauges: 
The gauge on your air compressor measures the pressure of the air in your tank. Your gauge is
informative in a number of ways, specifically for daily checks to ensure your pressure is at the
intended level, so you can attend to any deficiencies as soon as possible.

Motors: 
In general, your air compressor has an electric motor to run the operation of compressing air.
Different compressors require different sizes of motors (hp). If you’re replacing a worn-out motor, be
sure to have the recommended replacement motor installed.

Piston Rings:
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 Our reciprocating piston models create air pressure with the movement of the piston and connecting
rods. These parts are under great pressure when in motion and require a lubricant free of contaminates
and of the highest quality. Fluid analysis of your QuinSyn fluid in a rotary screw compressor is
important for the overall function of your air compressor and to detect possible issues early. It’s also
especially important to use Quincy oil to prevent premature wearing of your piston rings that prevent
excessive oil carryover.

Rotors:
 In our rotary screw air compressors, assembly consists of two interlocking helical rotors that
compress the air coming in through the inlet valve. With proper operation, these rotors have an
extremely long life.
Shims: Adding supporting spacers in the installation of your air compressor may be necessary. These
metal shims will provide you with the needed support for a reliable system.

Springs:
Various components of your compressor use springs for the mechanics of the system. Determine
when to replace springs with regular service checks.

Valves: 
Allowing air in and out, draining water, and regulating air flow, valves are an essential component
that require regular inspection during your interval checks and regular servicing. Our quality
engineered valves are designed for resilience and a long life. They operate with the highest efficiency,
using Buna-N or Viton seats and seals.

Chapter 5: Sub-station of OPEX AND SINHA

5.1Introduction
The assembly of apparatus are used to change some characteristic (e.g. voltage, ac to dc, frequency,
power factor etc.) of electric supply is called a Sub-Station. Sub-station is an important part of power
system which is used for transmission and distribution of electricity. Various kinds of safety equipment
are installed here for security purposes. Transformer is connected with generator which supplies power to
the generator for excitation. The auxiliary transformer is directly connected with generator to supply the
auxiliary equipment. The substation supplies the voltage of 400V.

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Figure 4.1: Single line diagram of unit-5 at OPEX AND SINHA sub-station [12]
5.2 Transformer
A transformer is a static device that converts ac electric power at a particular voltage level to the same ac
electric power at another voltage level at constant frequency. It is the major equipment in a sub-station.
Varies types of transformers like power transformer, auxiliary transformer, coupling transformer and
instrument transformer such as current transformer and potential transformer were observed in OPEX
AND SINHA power station. Different types of transformers at OPEX AND SINHA are discussed in this
section.

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Figure 4.2: Transformer at OPEX AND SINHA

Instrument Transformer
Instrument transformer is a transformer mostly used for measuring electrical quantities i.e. voltage,
current and also for protection purposes. This transformer steps down either the ac system voltage or
current. All the instrument transformers of OPEX AND SINHA are single phase transformer. Instrument
transformer is classified into two groups.
a. Current Transformer (CT)
b. Potential or Voltage Transformer (PT)
a. Current Transformer (CT)
Current transformer (CT) is used for stepping down AC current from higher value to lower value for
measurement and protection. At OPEX AND SINHA, current transformers are used at 132 kV and 230
kV bus bar systems. Ratio of these transformers is 1500-750/1 that means at primary side current is 1500-
750 A and at secondary side current is 1 A with rated frequency 50 Hz.

Figure 4.3: Current Transformer at OPEX AND SINHA

b. Potential or Voltage Transformer (PT)

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Potential transformer is used for stepping down voltage from higher value to lower value for
measurement and protection. It is also known as voltage transformer. At OPEX AND SINHA, potential
transformers are used at 132 kV and 230 kV bus bar systems. At 230 kV bus bar, the PT ratio is 230
kV/100 V and at 132 kV bus bar, PT ratio is 132 kV/100 V.

Figure 4.4: Potential Transformer at OPEX AND SINHA

Auxiliary Transformer
Auxiliary transformer is used to provide power to the auxiliary equipment of a power station. At OPEX
AND SINHA, auxiliary transformer is directly connected to the generator output and supplies power to
the auxiliary equipment such as motors, lights, other plant loads etc. If the self-auxiliary part of the
generator fails to operate, then the auxiliary transformer will be connected to the bus bar and system will
keep in running condition. For unit 2 and 3 auxiliary transformer is connected with 33 kV bus-bar and for
unit 3, 4, 5, 6 auxiliary transformers are connected with 33 kV, 132 kV bus bar.

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Figure 4.5: Auxiliary Transformer at OPEX AND SINHA

Coupling Transformer
Coupling transformer is used in sub-station to step up or step down the voltage level while keeping the
power same. In OPEX AND SINHA, coupling transformer is connected between132 kV bus and 230 kV
bus. If any fault occurs for an example, voltage level falls down and 132 kV bus bar becomes de-
energized, then coupling transformer will energize 132 kV bus bar by taking voltage from 230 kV bus bar
in step down condition. Similarly, for 230 kV bus bar coupling transformer will take voltage from 132 kV
in step up condition.
Cooling System of Transformer
At OPEX AND SINHA, there are two types of cooling system used for transformer cooling.
a. Oil Natural Air Forced (ONAF) cooling system
b. Oil Forced Air Forced (OFAF) cooling system
a. ONAF Cooling System
In Oil Natural Air Forced (ONAF) cooling system, the heated oil transfers its heat to the transformer tank
and the surface of transformer tank dissipates. If dissipating surface of transformer is increased,
transformer heat dissipation will increase. Instead of increasing the dissipation surface, air flow is
increased in this system. Fans blowing air on cooling surface is employed. Forced air flow is better than
natural air flow because here fans are mounted near the radiator and the forced air takes away the heat
from the surface of radiator.

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Bushing

Oil Tank

Fan
Winding

Figure 4.7: Oil Natural Air Forced (ONAF) cooling system [13]
b. OFAF Cooling System
In Oil Forced Air Forced (OFAF) cooling system, oil is forced by a pump which circulates within the
closed loop transformer tank and forced air exchange heats from the dissipating surface. Here, cooling
fans are used to give forced air. This will increase the capacity of power transformer by 66% of the base
capacity.
Bushing

Oil Pump
Oil Tank

Fan
Winding

Figure 4.8: Oil Forced Air Forced (OFAF) cooling system [13]
Silica Gel Breather
When load on transformer increases, then the insulating oil of the transformer gets heated up and the
volume of the insulating oil is increased. So, the air above the oil level in conservator will come out.
Again at low temperature, the volume of the oil is decreased and then natural air enters into the
conservator. In natural air, there is more or less moisture and this moisture is very harmful for transformer
insulation. The silica gel is a very good absorber of moisture. In that case, silica gel breather is used for
filtering air from moisture. Silica gel breather for transformer is connected with the conservator tank by
means of breathing pipe. It is nothing but a pot of silica gel through which air passes during the breathing
of transformer.

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Figure 4.9: Silica gel breather at OPEX AND SINHA

Transformer Tap Changer
A tap changer is a selecting mechanism of connection point, which is used in distribution transformers to
regulate the output voltage to the required levels. To keep the supply voltage within the limits, it deals
with variable control by allowing a variable number of turns to be selective in discrete steps.

Figure 4.10: A tap changer of distribution transformer at OPEX AND SINHA

Megger Test
Megger test is used to determine the insulation resistance of winding of the transformer. To perform this
test, the primary and secondary terminals are connected with the megger and the voltage is applied from
an external dc source.
Bay
A bay is the interconnection among potential transformer (PT), lightning arrester, isolator, current
transformer (CT) and circuit breaker. There are three kinds of bay.
a. Incoming feeder bay
b. Outgoing feeder bay
c. Transformer bay
5.3 Protection System of Sub-station
To save electrical equipment, protection system plays an important role by dealing with the protection of
electric power system from faults and isolates the faulty elements. At OPEX AND SINHA, many
protecting devices like circuit breaker, isolator, insulator, lightning arrester, relay etc. are used to operate
and maintain the power system. Protection system of OPEX AND SINHA are discussed in this section.
Relay

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Relay is a sensing device which senses an abnormal condition of electrical circuit and operates its contact
automatically by sending information to the circuit breaker for tripping. There are different types of relays
used at OPEX AND SINHA for different purposes, which are discussed below.
a. Differential Relay Protection
b. Buchholz Relay Protection
c. Distance Relay Protection
a. Differential Relay Protection
The differential relay measures the primary and secondary winding current and compares between them.
If any unbalance is found, then the relay will be active and it will trip both the primary and secondary
sides the circuit breaker. Differential relay is a very commonly used relay for protecting transformers,
generators, bus-bar and transmission line.
b. Buchholz Relay Protection
Buchholz relay is the gas actuated relay. It is placed between the main tank and the conservator. When the
fault occurs inside the transformer, the temperature of the oil increases. The oil evaporates in the form of
the gas. The generation of the gas depends on the magnitude of the fault occurs inside the transformer.
The internal faults occur in the transformer such as impulse breakdown of the insulating oil, insulation
failure of turns and buchholz relay protects the transformer from these faults.

c. Distance Relay Protection

Distance relay protection is specially used in transmission lines to identify the faulty distance by
measuring impedance. So, it is also known as impedance relay. If any fault occurs in the transmission line
then this relay begins to work. The operation of this relay depends on the ratio of voltage and current.

Circuit Breaker
Circuit breaker is a piece of equipment which works as a switch and operates manually or automatically
for control and protection of electrical power system. Under normal condition, the circuit breaker operates
manually. Under fault condition like overload, short circuit etc. The circuit breaker automatically
disconnects the circuit from the system and saves equipment on the system.
At the OPEX AND SINHA, there are different types of circuit breakers. These are discussed below.
a. Oil Circuit Breaker
b. Air Circuit Breaker
c. Vacuum circuit breaker
d. MCCB
e. MCB

a. Oil Circuit Breaker

Oil circuit breaker is such type of circuit breaker which used oil as a dielectric or insulating medium for
arc extinction. In oil circuit breaker the contacts of the breaker are made to separate within an insulating
oil. When the fault occurs in the system the contacts of the circuit breaker are open under the insulating
oil, and an arc is developed between them and the heat of the arc is evaporated in the surrounding oil.
OPEX AND SINHA has some oil circuit breakers.

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b. Air Circuit Breaker

Air Circuit Breaker (ACB) is an electrical device used to provide Overcurrent and short-circuit
protection for electric circuits over 800 Amps to 10K Amps. These are usually used in low voltage
applications below 450V. We can find these systems in Distribution Panels (below 450V). Here in
this article, we will discuss the working of Air Circuit Breaker. Air circuit breaker is circuit
operation breaker that operates in the air as an arc extinguishing medium, at a given atmospheric
pressure. There are several types of Air circuit breakers and switching gears available in the market
today that is durable, high-performing, easy to install and maintain. The air circuit breakers have
completely replaced oil circuit breakers.

Figure 4.12: Air circuit breaker at OPEX AND SINHA

Vacuum circuit breaker

A breaker which used vacuum as an arc extinction medium is called a vacuum circuit breaker. In
this circuit breaker, the fixed and moving contact is enclosed in a permanently sealed vacuum
interrupter. The arc is extinct as the contacts are separated in high vacuum. It is mainly used for
medium voltage ranging from 11 KV to 33 KV.

Molded Case Circuit Breaker

A molded case circuit breaker, abbreviated MCCB, is a type of electrical protection device that
can be used for a wide range of voltages, and frequencies of both 50 Hz and 60 Hz. The main
distinctions between molded-case and miniature circuit breaker are that the MCCB can have
current ratings of up to 2,500 amperes, and its trip settings are normally adjustable. An additional
difference is that MCCBs tend to be much larger than MCBs

miniature circuit breaker (MCB)

A miniature circuit breaker (MCB) automatically switches off electrical circuit during an
abnormal condition of the network means in overload condition as well as faulty condition.

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Nowadays we use an MCB in low voltage electrical network instead of a fuse. The fuse may not
sense it but the miniature circuit breaker does it in a more reliable way. MCB is much more
sensitive to overcurrent than fuse. Handling an MCB is electrically safer than a fuse. Quick
restoration of supply is possible in case of a fuse as because fuses must be re-warble or replaced
for restoring the supply. Restoration is easily possible by just switching it ON. Let’s look at the
working of the miniature circuit breaker.

Isolator
Insulator operates manually like a mechanical switch which is used on both ends of the breaker to isolate
a section from any energized conductor for maintenance and repairs under no load condition. If isolator
opens under on-load condition, then arc creates and it could be harmful for the system and the things near
the isolator.

Figure 4.14: Isolator at OPEX AND SINHA

Lightning Arrester
Lightning arrester is used in sub-station to protect the electrical equipment from high voltage due to
lighting strikes by grounding the current caused for over voltage of lighting. Lightning arrester has a high
voltage terminal and a ground terminal. When a direct lighting strikes on a transmission line, it produces
high voltage on the transmission line. Then arc is formed for providing a low resistance path for the surge
of extra voltage to the ground. As a result, the extra charges are grounded by the lightning arrester. It does
not work under normal condition. There are various types of lightning arrester. In Opex and Sinha,
polymer metal oxide and zinc oxide arresters are mainly used.

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Figure 4.15: Lightning arrester at OPEX AND SINHA

Feeder
Feeders are the power lines through which electricity is transmitted in power systems. Feeder transmits
power from generating station or substation to the distribution points. They are similar to distributors
except the fact that there is no intermediate tapping done and hence the current flow remains same at the
sending as well as the receiving end.
Earthing Switch
Earthing switch is a safety device which stands for ensuring the safety of a substation. Earthing switches
are integral parts of circuit breakers. When a circuit breaker is removed and racked out, the sections of the
bus bar adjacent to the circuit breaker are automatically earthed by means of these switches. It is very
important for sub-station as it is a switch between the line conductor and earth. This switch is normally
open. Earthing switch is used to earth the live parts during maintenance and during testing.
During maintenance although circuit is open still there are some voltages on line, due to
which capacitance between line and earth is charged. Before maintenance of that equipment the charge
need to be neutralized. The trapped charge of various equipment because of various capacitance is
discharged by earthing switch make the system safe for human during maintenance.
Transmission Equipment
At OPEX AND SINHA, there are different types of transmission equipment that are described below.
Bus Bar
Bus Bar is an electrical conductor that makes a common connection between several circuits. It is used
when a number of lines operating at the same voltage have to be electrically connected. There are two
types of bus bars used in OPEX AND SINHA. At OPEX AND SINHA, all incoming feeders are
connected to single bus bar system and double bus bar system is used between 132 kV and 230 kV bus
bar system. There are two types of bus bar system in OPEX AND SINHA. Single bus bar arrangement is
the simplest form of arrangement of bus-bar as each generator and feeder is controlled by a circuit
breaker. Here all the incoming and outgoing lines are connected to it. The advantages of single bus bar
system include low initial cost, less maintenance and simple operation. However, the disadvantage is
when repairing has to be done on the bus bar or a fault occurs at the bus bar, the supply will be
completely interrupted. The arrangement of 11 kV is single bus bar arrangement. Another form of bus bar
system is double bus bar. A double bus bar arrangement consists of two bus bars which are controlled by
two circuit breaker. One is a main bus bar and another is a spare bus bar. Each bus bar has capacity to
carry the entire sub-station load. The incoming and outgoing lines are connected to either of the bus bars
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by a bus bar coupler. At the OPEX AND SINHA, the incoming and outgoing lines are connected to main
bus bar.

Figure 4.16: Bus Bar at OPEX AND SINHA

Wave Trapper
Wave trappers are parallel tuned inductor-capacitor tank circuit which are used at sub-stations using
Power Line Carrier Communication (PLCC). It operates at high frequency and the frequency acts as
harmonics towards the electrical equipment. The wave trapper allows the power signal to flow and traps
the communication signal to protect electrical equipment. It reduces corona losses in power system.

Figure 4.17: Wave Trapper at OPEX AND SINHA

Transmission System
Electrical transmission system is the means of transmitting the power from generating station to different
load center. For transmitting the power, transmission lines are used which are generally three types. These
are given below. [18]
a. Short transmission line which is less than 80 km
b. Medium transmission line which is greater than 80 km and less than 160 km
c. Long transmission line which is greater than 160 km

Switchgear of OPEX AND SINHA:

At OPEX AND SINHA, there are three engines that are generating 11KV each and they deliver this
amount of current to the main bus-bar after proper synchronization. In this plant, switchgear panels are
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operating at Low Voltage (LV) and Medium Voltage (MV). Plant medium voltage is 11KV and low
voltage is 415 kV. There are two types of transmission panels; one is Low Transmission (LT) panel and
the other one is High Transmission (HT) panel. At HT panel, VCB and SF6 circuit breaker are used and
at LT panel, ACB circuit breaker is used.2000KVA or 1000KVA auxiliary step-down transformer is used
for generating 415V for the LT section. This 415V is used for auxiliary modules of a generator. There are
three Power and Motor Control Center (PMCC) sections and two outgoing feeders where 11KV is
supplied directly through the bus-bar. A generator (250KVA) is supplying 415V at LT side bus bar when
transformer 1 and transformer 2 are deactivated. It is also used at the starting condition of the engine
when there is no current at 415V line for auxiliary equipment. At 415V bus-bar line generator and
station, auxiliaries are connected through two couplers where Air Circuit Breaker (ACB) is used. There is
also an Automatic Transfer switch (ATS) connection between Power Development Board (PDB) and
plant generator that is used as back up when the plant engine is in the tripped condition.

Figure 3.2: Switch Gear panel of OPEX AND SINHA

Protection System of Sub-station
Most of the sub-station equipment are expensive. To protect electrical equipment from damage, the
protection system plays an important role. The protection system of substation isolates the faulty parts
from the working system and minimizes the losses. Circuit breaker, isolator, insulator, relay lightning
arrester, etc. are used to protect the power system. The protection system of a sub-station should be
strong to supply power safely and continuously.
Busbar Trunking system

Busbar trucking is a prefabricated, modular system, designed to carry and distribute electricity. General
contruction is of, insulated aluminium or copper conductors which complies with standards, covered by
metal housing.

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Relay

Relay is a sensing device that senses an abnormal condition of the electrical circuit and operates its
contact automatically by sending information to the circuit breaker for tripping. There are different types
of relays used at OPEX AND SINHA POWER LTD. for different purposes, which are discussed below.
a. Differential Relay Protection
b. Buchholz Relay Protection
c. Distance Relay Protection

a.Differential Relay Protection

A differential relay is a device that senses and operates when the phase difference is found between the
current entering into the electrical system and the current leaving the system. If any imbalance is found,
then the relay will operate and it will trip both the primary and secondary sides of the circuit breaker.
Differential relay is a very commonly used relay for protecting transformers, generators, and
transmission lines.

b. Distance Relay Protection

It is also known as impedance relay. If any fault occurs in the transmission line, then this relay operates.
The operation of this relay depends on the ratio of voltage and current. When some faults like earth fault
occur in transmission lines then the distance relay identifies the location of the fault by measuring
impedance.

c. Buchholz Relay Protection

Buchholz relay is a safety device. It is a type of oil and gas actuated protection relay. It is placed between
the main tank and the conservator. Whenever a minor fault occurs inside the transformer, heat is
produced by the fault currents. The produced heat causes the decomposition of transformer oil and gas
bubbles are produced. These gas bubbles flow in an upward direction and get collected in the Buchholz
relay. The collected gas diOpex and Sinhaaces the oil in Buchholz relay and the diOpex and
Sinhaacement is equivalent to the volume of gas collected. The diOpex and Sinhaacement of oil causes
the upper float to close the upper mercury switch which is connected to an alarm circuit. Hence, when a
minor fault occurs, the connected alarm gets activated. The collected amount of gas indicates the severity
of the fault that occurred. During minor faults, the production of gas is not enough to move the lower
float. Hence, during minor faults, the lower float is unaffected. During major faults, like phase to earth
short circuit, the heat generated is high and a large amount of gas is produced. This large amount of gas
will similarly flow upwards, but its motion is high enough to tilt the lower float in the Buchholz relay. In
this case, the lower float will make the mercury switch to lower which will trip the transformer from the
supply, i.e. transformer is isolated from the supply.

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Chapter 5
WTP and ETP
Introduction
Water treatment plant is very important for the production of steam and cooling of used steam.
Water is used to generate steam in all thermal power plants, where steam is used in turbine as
prime mover. Another application of water is to condensate the steam into water. The
condensation is used to increase the efficiency of the thermal power plant. The source of the raw
water is Shitalakhya river. This raw water is purified and softened by mechanical and chemical
processes. Then it is supplied to the system. In this chapter we will discuss about the process of
water treatment. The block diagram of water treatment process is shown in figure 2.1.The main
objective of water treatment plant is to produce mineral free water which is called demi water.
Demi water is needed to get rid of the problems of scaling, erosion and corrosion.

Figure 2.1: Flow diagram of water treatment process at OPEX AND SINHA

Water TreatmentProcedure
River water has two types of substances:
 Dissolved solidand
 Un-dissolvedsolid.
Dissolved solids are different types of ions and minerals. Un-dissolved solids are clay, mud etc.
By following several steps, these solids can be removed. OPEX AND SINHA mainly follows
the following steps.

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Clarification
Water is collected from the river Shitalakhya. Here, raw water is mixed with Aluminum
Sulphate (Al2SO4). The sludge is deposited in a tank. The chemical reaction is
Al2SO4+6H2O (clay) →2Al(OH)3 (sludge)+3H2SO4
This sludge is removed from the tank and the clarified water is stored in coagulated tank. By
using clarification, 70% of un-dissolved solid from water is removed. Clarifier system of OPEX
AND SINHA is shown in figure 2.2.

Figure 2.2: The clarifier system in OPEX AND

SINHA.

Filtration
After clarification, the water contains a lot of small or big particles which are harmful and
destructive to the plant. So this clarified water is used for filtering. The filter removes any solid
particle like sand, siltetc.

Demineralization
Demineralization is the process of removing mineral salts from water by using ion exchange
process. Demineralized water or demi water is water of which the minerals or salts are removed.
It is used in applications where water with low salt content or low conductivity is required, for
example as boiler feed water. Demineralized water is also known as deionized water with
removed mineral ions. Mineral ions such as cations of sodium, calcium, iron, copper, etcand
anions such as chloride, sulphate, nitrate, etcare common ions present inwater. When it is passed
through cation exchanger resin, these cations are caught by the following reactions.
R-H2+CaCl2→ R-
Ca+2HCl
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R-H+NaCl→ R-Na+HCl
This water also contains negative ion like Cl -, SO 2-,4 NO3-. During the passing of this water
through anion exchanger resin, these anions are caught by the following reactions.
R-(OH)2+H2SO4 → R-SO4+2H2O
R-OH+HCl →R-Cl+H2O
This demi water is stored in demi tank which is used for producing steam.

Effluent Treatment Plant

ETP is stand for Effluent Treatment Plant. It is used in sewerage and wastewater system. ETPS is very
important for Garments and Textile Industry. ETP purify waste water comes from different industry like
textile, garments, ternary, pharmaceuticals etc. The industrial effluent treatment plants involve different
stages of treatment including physio chemical treatment and biological treatment flowed by tertiary
treatment. ETP reduce the cost of environmental control, the principal activities undertaken by Ministry
of Environment and Forest consist of protection of environment, in the framework of egislations directed
by the United Nations Environment program (UNEP)

Flow Chart of ETPS: 

Textile/Chemical/Ternary Industry etc

Bar Screen

Collection Tank

Process House

Equalization Tank

Neutralization

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Chemical coagulation

Biological Oxidation Tank

Flash Mixer with Polymer

Settling and Separation of Sludge with pressure

Filtration

Treated water to discharge

Bar Screen:
Bar screen are very well matched for removing suspended and floating coarse from wastewater such as
weed, reed and rags. Bar screen is first step of etps – effluent water treatment process.
Bar Screen

Collection Tank:

It is primary tank where wastewater stored from different section like dyeing, washing, knitting, finishing
etc. Wastewater treatment plant is same meaning of effluent water treatment process.

Equalization Tank
After primary mixing, the liquor passes to equalization tank by mixing of effluent from various process
takes place

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Polymer Mixing Systems:

In flash mixer alum works upon sludge so that postponed solids settle down in etps. A polymeric material
having a large number ion exchange sites. Generally, polymer mixer is general system which is used in
ETPs as flocculants and on some occasions as coagulants. Polymer mixing systems can be classified in 3
types e.g. cationic, anionic and nonionic polymer mixer.

Biological Oxidation Tank:

Echo system installed here. It is the last process of biological oxidation. ETP system use biological
oxidation system, physical and chemical treatment process. Industrial water treatment and water recovery
is the process for good environment.

Chapter 7: Conclusion

7.1Discussion
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In Bangladesh, electricity plays a major role in the growth of economy. Government is trying to provide a
stable supply of electricity. OPEX AND SINHA is one of the largest power station in Bangladesh for
generating electricity. At OPEX AND SINHA, the main fuel is natural gas. OPEX AND SINHA has two
kinds of power plant. One is steam power plant which has the capacity of 28MW. During our internship,
we have gathered practical experience about power generation and distribution. As a result we are able to
relate the theoretical knowledge with the practical one. The overall experience helps us understand the
working procedure of power station and thereby, provide us confidence to build our future carrier in
power sector.
7.2 Limitations
During our internship at OPEX AND SINHA, we faced some problem.
a. Our internship duration was only 15 days at OPEX AND SINHA which was not sufficient to the
whole process of OPEX AND SINHA.
b. We have just observed the system and working procedure at OPEX AND SINHA, we could not
participate in any practical work
c. All the machines and equipments were in operational mode, so it was risky to learn about all the
equipment.
d. The safety equipments were not available at OPEX AND SINHA such as earplug, headphone and
helmet for the internship students.
7.3Recommendations

After completing internship, we have some recommendations which are given below.

a. Students who are willing to go for internship should do power sector related courses like power
station, switch gear and protective relays before internship for better understanding.
b. If the duration of the internship can be increased then student will learn more.
c. The safety equipment should be provided by the authority and students should use this.
d. Everybody should know the precautions of a power station.

Reference

1. http://www.Opex and Sinha.com/profile.php.

2. V. P. Vasandani and D,S Kumar, “Heat Engineering”, 4th edition, Netaji Subash Marg, New
Delhi, Metropolitan Book Co. Pvt. Ltd, 1996
3. Stephen J. Chapman, “Electrical Machinery Fundamentals”, 5th edition, New York:
McGraw Hill,1985.
4. V.K. Mehta and Rohit Mehta, “Principle of Power System”, 4th edition, New delhi, S.
Chand and company limited, 2014
5. Sunil S. Rao, “Switchgear protection and power Systems”, 12th edition, Naisarak, Delhi,
Khanna publishers, 2007
6. “Transformer equipments”, Wikipedia [Online]
7. http://www.electrical4u.com/what-is-transformer-definition-working-principle-oftransformer
8. https://Opex and Sinhapowerstation.wordpress.com/category/technology/
9. https://www.genewsroom.com/press-releases/ge-repower-bpdb%E2%80%99s-Opex and Sinha-
station-bangladesh-283107
10. http://www.xinhuanet.com/english/2017-09/13/c_136607232.htm
11. https://www.electrical4u.com/differential-protection-of-generator-or-alternator/
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12. http://www.razibsaha.com/Opex and Sinha-power-plant-internship-report-bangladesh/

13. http://top10electrical.blogspot.com/2014/02/cooling-methods.html
14. https://Opex and Sinhapowerstation.wordpress.com/category/technology/
15. https://www.genewsroom.com/press-releases/ge-repower-bpdb%E2%80%99s-Opex and Sinha-
station-bangladesh-283107
16. http://www.xinhuanet.com/english/2017-09/13/c_136607232.htm
17. https://www.dhakatribune.com/business/2018/09/18/record-11-534mw-power-generation-in-
bangladesh
18. Intern lecture at OPEX AND SINHA

Md. Abdul Gaffar Md. Rasel Nahian Maisha

SID: 2015-3-80-003 SID: 2016-1-80-015 SID: 2015-2-80-012