A PROJECT REPORT

BY

SAPTADEEP SARKAR
ROLL NO- 13031616045

AT

Chandrapura Thermal Power Station

(C.T.P.S)
VOCATIONAL TRAINING
Station: Chandrapura Thermal Power
Station (CTPS), DVC
Centre: Chandrapura, Jharkhand
Duration: 26th Dec 2018 to 25th Jan 2019
Name: Saptadeep Sarkar
Roll no- 13031616045
College- Techno India Salt Lake, Kolkata
Discipline: B.tech ( Electrical Engg.)

A PROJECT REPORT ON- Operation

and Maintenance of Thermal Power
Plant.

2
 Contents
1. Acknowledgement
2. Introduction to DVC & DVC-CTPS
3. Complete description of Power plant
4. Coal Handling Plant
5. Boiler
6. Turbine
7. Condenser
8. Cooling Tower
9. Turbo generator
10. Transformer
11. Switchyard
12. Switchgear
13. Communication
14. Ash Handling plant (AHP)
15. ESP
16. Motors
17. Safety
18. Conclusion
19. Reference

3
 Acknowledgement
The dissertation has been prepared based on the vocational
training undergone in a highly esteemed organisation of Eastern
region, a pioneer in Generation Transmission & Distribution of
power, one of the most technically advanced power stations in
India , the Chandrapura Thermal Power Station (C.T.P.S), under
DVC.
I would like to express my heartfelt gratitude to the
authorities of Chandrapura Thermal Power Station for providing
me such an opportunity to undergo training.
I would also like to thank the highly experienced Engineers,
without whom such type of concept building in respect of thermal
power plant would not have been possible. At last but not the least,
I would like to convey my thanks to all the members of the staff
of DVC-CTPS who have helped me at every stage of training.

( Training Period: 26th December 2018 to 25th January 2019 )

Mr. G P Raut Mr. Ramesh Kumar

(SE (M), FQA,DVC,CTPS) (EE (M))

4
 INTRODUCTION
Damodar Valley Corporation (DVC) is a public sector company
which operates several power stations in the Damodar River
area of West Bengal & Jharkhand, India.
The company operates both thermal power station and hydel
power dams under the Indian Ministry of Power. The present
capacity of DVC is 6357.2 MW . The Damodar Valley
Corporation has been generating and transmitting power since
1953.

Hydel Power Plants

Sl. No. Name State Installed

Capacity

1 Tilaiya Jharkhand 4MW

Dam

2 Maithon Jharkhand 63.2MW

Dam

3 Panchet Jharkhand 80MW

Dam

5
Thermal Power Plants

Sl. Name State Installed

No. Capacity

1 Bokaro Jharkhand 630MW

Thermal
Power Station
B

2 Chandrapura Jharkhand 890MW

Thermal
Power Station

3 Durgapur West 350MW

Thermal Bengal
Power Station

4 Durgapur West 1000MW

Thermal Bengal
Power Station

6
5 Mejia Thermal West 2340MW
Power Station Bengal

6 Koderma Jharkhand 500+500MW

Thermal
Power Station

7 Raghunathpur West 200MW

Thermal Bengal
Power Station

8 Bokaro Jharkhand 1200MW

Thermal
Power
Station- A

DVC-CTPS -
CHANDRAPURA
Chandrapura Thermal Power Station (CTPS) is
located at Bokaro district in the State of Jharkhand.
It has five working unit with a total installed capacity
of 890 MW. All of the units are coal-based. CTPS had the
pride of being largest pulverized fuel fire power
station of Asia and unit number one was the first
reheat unit installed in India with highest steam
parameters. Electrical switchyard of CTPS is a pride
of DVC, being India’s 2nd biggest network.
7
 Technical Aspects

• INSTALLED CAPACITY: - Total Units - 5 Nos.

➢ 3 X 130 MW (U#1,2&3)
➢ 2 X 250 MW (U#7&8)

• Total Energy Generation: - 890 MW

• Source of Water: - Damodar River
• Types of Fuel used: - Coal, LDO & HFO
• Sources of Coal: - B.C.C.L and C.C.L
• Sources of Oil: - Indian Oil

8
Capacity

The individual units has the generating capacity as follows:

Unit Generating Commissioned Current

No. Capacity on status

U#1 130 MW 1964 October Shutdown

(GE)
U#2 130 MW 1965 May Shutdown
(GE)
U#3 130 MW 1968 July Shutdown
(GE)
U#7 250 MW 2011 Running
(BHEL) November
U#8 250 MW 2011 July Running
(BHEL)

Project Cost.

The approved cost of Unit 7 & 8 (2 X250 MW) is Rs. 2500 Crore.
(The current production cost is approx
Rs. 3.50/KW)

9
 OVERVIEW OF A
THERMAL POWER
PLANT

Simplified Diagram

PA fan – Primary Air fan

FD fan- Forced Draft fan
ID fan- Induced Draft fan
ESP- Electrostatic Precipitator
CEP- Condensate Extraction Pump
BFP- Boiler Feed Pump
GSC- Gland Steam Cooler

10
LPH – Low Pressure Heater
DA- Deaerator
HPH- High Pressure Heater
OAC- Open Approach Channel
RAH- Regenerative Air Heater
DM water- De-Mineralized water
The coal from mines is received at track hopper in
CHP through Wagons. The unloaded coal (max. size
250 mm2) is scooped into conveyor by Rotary Plough
Feeders & is passed through suspended magnet,
magnetic separators, and metal detectors, to ensure
that sized coal, free of foreign material is supplied.
Then it is sent to Crusher House for further crushing
to 25- mm2 size. After crushing, the coal again
screened for elimination of extraneous materials,
weighed and sent to boiler bunkers. Excess coal, if
any, is sent to coal yard for stacking. It then falls
through a weigher into the Bowl Mill where it is
pulverized. The mill usually consists of a round metal
table on which large steel rollers or balls are
positioned. The table revolves, forcing the coal
under the rollers or balls which crush it. Air is drawn
from the top of the boiler house by the FD Fan and
passed through the RAH, and then send to boiler for
burning of coal. PA Fan takes air from atmosphere
and distributes them into 4 parts and fed directly to
Mill blowing coal along pipes to boiler furnace.
The boiler consists of a large number of tubes
extending the full height of the structure and the
heat produced raises the temperature of the water
circulating in them to form superheated steam which
passes to the Boiler drum. The steam is fed through
the outlet valve to the HP Turbine(High Pressure
turbine) at around 540°C and 147kg/cm^2.After
11
this, it is returned to the boiler and reheated before
being passed through the IP & LP
Turbine(Intermediate and Low Pressure
Turbine).The water fed into boiler is DM water.
From the turbine the steam passes into Condenser
to be turned back into water. This is pumped
through CEP which sends water through LPH, and
HPH for further heating and BFP then sends it to the
Economizer where the temperature is raised
sufficiently for the condensate to be returned to the
lower half of the steam drum of the boiler.
The flue gases produced in boiler are used to
reheat the condensate in the Economizer and then
passes through the ESP where ash is collected.
Finally, they are drawn by the ID Fan into the main
flue and to the chimney.
From the boiler, a steam pipe conveys steam to
the turbine through a stop valve (which can be used
to shut off steam in an emergency) and through
control valves that automatically regulate the supply
of the steam to the turbine. The turbine shaft usually
rotates at 3000 RPM. This speed is determined by
the frequency of the electricity system and the
number of poles of machine (2- pole machine here).
Cold water from feed pool is circulated through
the condenser tubes and as the steam from the
turbine passes round them it is rapidly condensed
into water. Water which gets heated up in condenser
by cooling steam is sent to Cooling tower and then
left into feed pool from where it can be further used.
The electricity is produced in turbo generators
and is fed through terminal connections to Generator
Transformer, those steps up the voltage to

12
 220kv(U#7&8). From here conductors carry it to
Switchyard from where it is sent for use.

Coal Handling Plant

Objectives of Coal Handling Plant are
• Transportation and Handling of Coal.

• Arrangement for transferring of coal from coal- wagons to

coal-bunker or coal stock yard.

• Supply of Crushed coal to bunker

13
 CHP: Overview
Track Paddle Magnetic
Coal Mine
Hopper Feeder Separator

Crusher House
Coal
Bunker
Stack Yard

Fig: The coal Conveyor Belt & CHP of Unit # 7 & 8

At power plant, coal is unloaded in track hoppers of length

200-250m normally.

Paddle Feeder is used to feed coal to conveyor belt from

track hopper.

After separation of magnetic particles from coal, it is

carried to the Crusher House through conveyor belts and

14
after that it is either stored at Stack Yard to be carried to
coal bunker for burning.

WATER TREATMENT
PLANT

Raw water supply

Raw water received at the thermal power plant is passed through

Water Treatment Plant to separate suspended impurities and
dissolved gases including organic substance and then through
Demineralised Plant to separate soluble impurities.

15
Deaeration

In this process, the raw water is sprayed over cascade aerator in

which water flows downwards over many steps in the form of thin
waterfalls. Cascading increases surface area water to facilitate
easy separation of dissolved undesirable gases (like hydrogen
sulphide, ammonia, volatile organic compound etc.) or to help in
oxygenation of mainly ferrous ions in presence of atmospheric
oxygen to ferric ions.

Coagulation

Coagulation takes place in clariflocculator. Coagulant destabilises

suspended solids and agglomerates them into heavier floc, which
is separated out through sedimentation. Prime chemical used for
coagulation is alum.

Filteration

Filters remove coarse suspended matter and remaining floc or

sludge after coagulation and also reduce the chlorine demand of
the water.
Chlorination

Neutral organic matter is very heterogeneous i.e. it contains many

classes of high molecular weight organic compounds. Humic
substances constitute a major portion of the dissolved organic
carbon from surface waters. They are complex mixtures of

16
organic compounds with relatively unknown structures and
chemical composition

DM (Demineralised
Water) Plant
In De-mineralised Plant, the filter water of Water Treatment Plant
is passed through the pressure sand filter (PSF) to reduce turbidity

and then through activated charcoal filter (ACF) to adsorb the

residual chlorine and iron in filter water

17
 BOILER
Boiler is device for generating steam for power processing or
heating purposes. Boiler is designed to transmit heat from an
external combustion source contained within the boiler itself.
Boilers may be classified on the basis of any of the following
characteristics:

1. Use: The characteristics of the boiler vary according to the

nature of service performed. Customarily Boilers are called
either stationary or mobile.

2. Pressure: To provide safety control over construction

features, all boilers must be constructed in accordance with
the Boiler Codes which differentiates boilers as per their
characteristics.

3. Materials: Selection of construction materials is controlled

by boiler code material specifications.

4. Size: Rating core for boilers standardize the size and ratings
of boilers based on heating surfaces. The same is verified by
performance tests.

5. Tube Contents: In addition shell type of boiler, there are 2

general steel boiler classifications, the fire tube and water tube
boilers.

6. Firing: The boiler may be a fired or unfired pressure vessel.

18
7. Heat Source: The heat may be derived from
a) The combustion of fuel
b) The hot gases of other chemical reactions
c) The utilization of nuclear energy

8. Fuel: Boilers are often designated with respect to the fuel

burned.

9. Fluid: The general concept of a boiler is that of a vessel that

is to generate a steam.

19
10. Circulation: The majority operate with natural
circulation. Some utilize positive circulation in which the
operative fluid may be forced ‘once through’ or controlled with
partial circulation.

11. Furnace position: The boiler is an external

combustion device in that the combustion takes place outside
the region of boiling water. The relative location of the furnace

20
to the boiler is indicated by the description of the furnace as
being internally or externally fired. The furnace is internally
fired if the furnace region is completely surrounded by water
cooled surfaces. The furnace is externally fired if the furnace is
auxiliary to the boiler.

Boiler Accessories

Boiler furnace: A boiler furnace is that space under or

adjacent to a boiler in which fuel is burned and from which the
combustion products pass into the boiler proper. It provides a
chamber in which the combustion reaction can be isolated and
confined so that the reaction can be isolated and confined so
that the reaction remains a controlled force. It provides
support or enclosure for the firing equipments.
Boiler Drum: The function of steam drum is to separate the
water from the steam generated in the furnace walls and to
reduce the resultant solid contents of the steam to below the
prescribed limit of 1ppm. The drum is located on the upper
front of the boiler.

Economizer: The purpose of the economizer is to preheat

the boiler feed water before it is introduced into the steel drum
by recovering the heat from the fuel gases leaving the boiler.
The economizer in the boiler rear gas passes below the rear
horizontal super heater.

Super Heater: There are 3 stages of super heater besides the

side walls and extended side walls. The first stage consists of
horizontal super heater of convection mixed flow type with
upper and lower banks located above economizer assembly in
the rear pass. The 2nd stage super heater consists of pendant
platen which is of radiant parallel flow type. The 3rd stage
21
 super heater pendant spaced is of convection parallel flow type
the outlet temperature and pressure of the steam coming out
form the super heater is 540 ºC and 147 kg/cm2.

Preheater: The function of preheater is to reheat the steam

coming out from high pressure turbine to a temperature of
540 ºC. Burners: there are total 24 pulverized coal burners for
corner fired C.E. type boilers and 12 oil burners provided each
in between 2 pulverized fuel burners.

Igniters: There are 12 side Eddy plate oil/ H.E.A igniters per
boiler. The atomizing air for igniters is taken from plant air
compressor at 7 kg/cm2. There are 2 igniter air fans supply air
for combustion of igniter oil. Mainly 2 types of igniters are
used:-

1. eddy plate igniter

2. high energy arc type igniter.

Boiler Feed Pump

BFP is multistage centrifugal pump meant to supply boiler
with required feed water at high pressure.

It comprises of impeller and diffuser arrangement to

simultaneously increase velocity and pressure.

22
 TECHNICAL SPECIFICATION OF BFP
Unit 7 & 8
• No. of BFP - 3 (2 running + 1 Standby)
• CAPACITY (M3/HR) - 380
• DELIVERY HEAD - 2320 M
• PERMISSIBLE +VE SUC. HEAD - 10kg/cm2
• FEED WATER TEMP.(0C) - 165
• NO. OF PUMP STAGES - 11
• PUMP I/L TEMP.(0C) MAX. - 165
• NOMINAL SPEED (RPM) - 2890
• Power - 6.6 MW
• FLOW RATE THROUGH R/C( M3/HR) - 130

STEAM TURBINE
A steam turbine is a mechanical device that extracts thermal
energy from pressurized steam, and converts it into useful
mechanical work.

Three turbines, HP turbine, IP turbine and LP turbine, are

synchronized together with a common shaft connected to the
generator. HP and IP turbines have single flow unit while LP

23
turbine has double flow unit so as to accommodate the
increase in volume of steam due to the drop in pressure.

High pressure steam enters the HP turbine at 147 Kg/cm2 and

540o C temperature. The steam leaves the HP turbine at a
pressure of 30 Kg/cm2 and is carried to re-heaters which heats
it up to a temperature of 540o C while maintaining its pressure
at 30 Kg/cm2. This steam is carried to IP turbine after which
it is directly send to LP turbine. The steam reaches to LP
turbine at a pressure of 1.5 Kg/cm2.

The steam is also carried from turbines to LP heaters and HP

heaters to heat the water entering the boiler. After loosing its
pressure and temperature steam is taken to the condenser.

Power output is proportional to the steam pressure drop in the

turbine

24
 Impulse and
reaction
Turbine

16 May 2013 PMI Revision 00 31

25
 Turbine Auxiliaries
Regenerative Heaters

• The regenerative heaters are used to heat the Condensate from

the condenser to the boiler inlet.
• This makes the mean temperature of heat addition in boiler
high resulting in high efficiency.
• The heating is done by steam bled from different stages of HP,
IP and LP turbines.
• The heaters are non mixing type.
• The drip formed is cascaded to lower heaters in the line and
finally to deaerator( for HP heaters) and condenser ( for LP
heaters)
• The heaters before BFP are called Low Pressure Heaters (LPH)
and those after BFP are called High pressure heaters (HPH).
• The Deaerator is the only mixing type heater in the power
plant.
• In some design drip pumps are used to pump the drip from
LPHs to the main condensate line.

Ejector

• The ejector is used to remove air from the condenser steam

space so that proper cooling and thus vacuum can be
maintained.
• The ejector uses steam and expands it in the nozzles of the
ejector to create vacuum which sucks the air steam mixture.
This is then expanded in the diffuser and pressure is increased.
• A 3 stage ejector is used to eject the air from the condenser to
the atmosphere.
26
 COOLING WATER CYCLE:
Condenser:

Condenser is basically a heat exchanger which condenses a

steam and converted into water. After expansion of steam in
LP turbine it enters in the condenser. In condenser there are
many water tubes are provided to condensate the steam.

• It is provided to expand the working steam below the

atmospheric pressure.
• It also converts the steam water mixture to water by
condensation.
This water can be easily transported (than the steam) to the
boiler.
• There are tubes which carry the clarified water.
• On the shell side the steam condenses.
• These tubes can be made of alloys of Cu & Ni, SS.
• During overhauling the tubes are cleaned by special bullets
which are triggered by pressurized water. This cleaning
removes deposits from the tube inner surface.

27
 Cooling Tower

The hot water from condenser outlet reaches to

cooling tower. Cooling towers are evaporative coolers to
remove the heat of water so that water can be recirculating &
can be reused. This heat of water is ejected to the atmosphere
by evaporation. There are two types of cooling towers,
Natural Cooling & Forced cooling .In DVC-CTPS modern
type Forced cooling towers are used in which cooling fan
(suction) is required to remove the heat of water.

28
 Turbo-GENERATOR

This Turbo generator is basically a Synchronous Alternator. The

stator houses the armature windings and the rotor houses the field
windings. D.C. voltage is applied to the field windings through the
slip rings or brushless excitation system. When the rotor is rotated
the lines of magnetic flux cut through the stator windings. This
induces an e.m.f. in the stator windings.
The rotor is rotated at 3000 rpm by the turbines and a frequency
of 50 Hz is required, by the formula f=NP/2, we see that it is a 2 pole
machine. The generator used in DVC has YY configuration in the
stator. This is done to distribute the amount of generated current

29
 among the two circuits in order to increase the amount of output
current by reducing the branch impedance since voltage induced
remains constant.

Generator Components

1. Rotor: The rotor is a cast steel ingot and it is further forged

and machined. The rotor is to be designed very accurately as it
has to work on speeds such as 3000 rpm. Also a fairly high
current is to be carried by the rotor windings to generate the
necessary magnetic field.

2. Rotor winding: Silver bearing copper is used for the winding

with mica as the insulation between conductors. A
30
 mechanically strong insulator such as micanite is used for
lining the slots. When rotating at high speeds centrifugal force
tries to lift the windings out of the slots, so they are screwed to
the rotor body. The two ends of the windings are connected to
slip rings, usually made of forged steel.

3. Stator core: The stator is the heaviest load to be transported.

The major part of this load is stator core. This comprises of an
inner frame and outer frame. The outer frame is a rigid
fabricated structure of welded steel plates, within this shell is
a fixed cage of girder built circular and axial ribs. The ribs
divide the yoke into compartments. The inner cage is usually
fixed to the yoke by an arrangement of springs to dampen the
double frequency vibrations.
The stator core is built from a large number of punchings
or sections on thin steel plates.

4. Stator windings: Each stator conductor must be capable of

carrying the rated current without overheating. The insulation
must be sufficient to prevent leakage currents flowing between
the phases to earth. Windings for the stator are made up from
copper strips wound with insulated tape which is impregnated
with varnish, dried under vacuum and hot pressed to form a
solid insulation bar. These bars are then placed in stator slots
and held in with wedges to form the complete winding. The
end turns are rigidly braced and packed with blocks to
withstand the heavy forces.

31
 Generator Cooling

Rotor Cooling System: The rotor is cooled by means of

gap pick up cooling, wherein the hydrogen gas in the air gap is
sucked through the scoops on the rotor wedges and is directed
to flow along the ventilating canals milled on the sides of the
rotor coil, to the bottom of the slot where it takes a turn and
comes out on the similar canal milled on the other side of the
rotor coil to the hot zone of the rotor. Due to rotation of the
rotor, a positive suction as well as discharge is created due to
which a certain quantity of gas flows and cools the rotor. The
conductors used in the rotor windings are hollow which is
done to have internal cooling of the rotor.

Hydrogen Cooling System: Hydrogen is used as a

cooling medium due to its high heat carrying capacity and low
density. But it can also form an explosive, or escape out of the
generator casing which may result into many catastrophic
results. So the pressure of H2 should be maintained properly.
The filling in and purging of H2 is to be done safely without
bringing in contact with air. To fill H2 inside generator first
CO2 is filled through generator and then H2 is passed since H2
has no reaction with CO2 and while taking H2 out of generator
first H2 is taken out then CO2 is passed through generator and
then air is allowed to enter.
To stop the hydrogen from escaping the generator casing oil
sealing is done. The shaft of the rotor has many blades
connected at the end of the shaft. Each of the blades rotates in
32
the slot engraved in the generator casing. Now these slots are
filled with oil up to a certain level, so that the ends of the blades
rotate in an oil medium which is separated among them. So
when the H2 tries to escape and comes near the end of the shaft
it passes through the blade that is through the oil in the slot,
due to which a major part of it gets obstructed and the left out
gas proceeds to the next slot. Now at the end there is almost
no or negligible amount of gas leakage.

Stator Cooling System: The stator is cooled by distillate which

is fed from one end of the machine by Teflon tube and flows
through the upper bar and returns back through the lower bar
of another slot. The stator winding is cooled in this system by
circulating DM water through hollow conductors. The DM
water should be at 40°C. As it is a closed loop the water that
comes out of the generator is again cooled and demineralized.
Water passes through lower bars along the length to the other
end returns through the upper bars of another slot and drain
into drain header.

33
 Ratings of Turbo
Generator
For Unit # 7 & 8
Rated Voltage: 16.5 kV
Rated Power: 250 MW
Rated KVA : 250 MVA
Stator Current: 10219 A
Rotor Current: 2395 A
Frequency: 50 Hz
Connection: YY
Power Factor: 0.85 LAG
Coolant Used: Hydrogen
Rated H2 Pressure: 3KgF/cm2
Operational Duty: S1
Class of Insulation: F
Manufacturer: BHEL

34
 TRANSFORMER
The transformers used in a power station have its sides abbreviated
as Low Voltage (LV) and High Voltage (HV) rather than primary
and secondary.

35
 Fig: Generator Transformer Unit # 7
Major transformers in a power station:

1. Generator transformer:
The generator is connected to this
transformer by means of isolated bus duct. This transformer is used to
step up the generating voltage of 15.75 KV or 21 KV (depending on
the generator) to grid voltage normally 220 kV. This transformer is
generally provided with OFAF cooling.

36
2. Unit Auxiliary Transformer (UAT):
The UAT draws its input from the main
bus duct connecting generator to the generator transformer. It is used
for the working of large devices such as boilers, heavy motors etc.
The total kVA capacity of UAT required can be determined by
assuming 0.85 power factor and 0.9 efficiency for total auxiliary
motor load. For large units, it has become necessary to use more than
one auxiliary transformer. It uses the generated 16.5kV to c overt
into 6.6 kV.The maximum short circuit currents on auxiliary bus
should be limited with in the maximum switch gear rating available.
The maximum permissible voltage dip while starting the largest
single auxiliary motor, usually boiler feed pump, shall remain within
acceptable limits.

3. Station Transformer:
The station transformer is used to feed the
power to the auxiliaries during the start up. This transformer
normally rated for the initial auxiliary load requirements of unit. In
physical cases this load is of order of 60% of the load at full
generating capacity. It is also provided with on load tap changer to
cater to the fluctuating voltage of the grid.

4. Auto Transformer(AT):
It connects 220KV substation to 132 KV
substation & Vice-Versa.

Cooling of Transformer

37
 Heat is produced in the winding due to the current flowing in
the conductors (I2R) and in the core on account of eddy
currents and hysteresis losses. In small dry type transformer
heat is dissipated directly to the atmosphere. In oil immersed
transformer heat is dissipated by Thermo Siphon Action.

The purpose of using oil is:-

a. Cooling: Provides a better cooling and helps in exchanging
heat
b. Insulation: A non conductor of electricity so good insulator.
The oil used is such that its flash point is pretty high so that it
doesn’t have any possibility to catch fire.
There various types of cooling:-
i. AN – Air Natural
ii. ON – Oil Natural
iii. AF – Air forced
iv. OF – Oil forced
v. ONAF – Oil natural Air forced
vi. OFAN - Oil forced Air natural
vii. OFAF – Oil forced Air forced

The oil serves as the medium for transferring the heat

produced inside the transformer to the outside transformer.
Thermo siphon action refers to the circulating currents set up
in a liquid because of temperature difference between one part
of the container and other.
When oil gets heated up the oil with greater temp, goes to the
upper side of the transformer. Now if it is Oil natural it is
cooled in it as it is whereas in Oil Forced a radiator is being
constructed and a pump is being attached to it to pull the oil
from the upper part of the transformer.
Now this oil in the chamber gets cooled either by direct
heat exchanging through the atmosphere which is called Air
38
Natural or by forced air draft cooling by a radiator with many
electric fans which are automatically switched on and off
depending upon the loading of transformer which is known as
Air Forced cooling. As the oil gets cooled it becomes heavier
and sinks to the bottom.

UNIT # 7 & 8
GENERATOR TRANSFORMERS 2 Nos. (one for each unit)

Rating: 250MVA
No load voltage : 220/sqrt(3)/16.5kV
Current : 10291/656.08
Cooling : OFAF
Vector group: Ynd11*
Phase : 3
Freq.: 50HZ Manufacturer

: BHEL
*after 3 phase bank formation.

UNIT AUXILIARY 4 Nos. (Two for each unit)

TRANSFORMERS (UAT)

Rating : 32 MVA
Transformation ratio: 16.5v 12% / 6.9-0-6.9 Vector
group: d/ d-d 11-11

39
STATION SERVICE 2 Nos. (One for each unit)

TRANSFORMER (SST)

Rating : 66 MVA
Transformation ratio: 220kV 12% / 6.9-0-6.9 kV Vector
group: Yo/ d-d 11-11
Make: BHEL

40
 SWITCHYARD
It is a switching station which has the following credits:
(i) Main link between Generating plant and Transmission
system, which has a large influence on the security of the
supply.
(ii) Step-up and/or Step-down the voltage levels depending
upon the Network Node.
(iii) Switching ON/OFF Reactive Power Control devices,
which has effect on Quality of power.

Fig: Switchyard Unit # 7 & 8

Switchyard Equipments

41
Transformers:
Transformer transforms the voltage levels from higher to
lower level or vice versa, keeping the power constant.
Auto transformer (AT) are used to connect 400KV switchyard
to 132KV switchyard.

Circuit breakers:
Circuit breakers makes or automatically breaks the electrical
circuits under loaded condition.

Isolators:
Opens or closes the electrical circuits under No-load
conditions.

Instrument transformers :
Instrument transformers are used for stepping-down the
electrical parameter (Voltage or Current) to a lower and safe
value for Metering and Protection logics.
CTs are single phase oil immersed type.secondary current is
generally 1A, but also 5A in certain cases.
The CVTS are used at 220KV & above. For lower voltages
electromagnetic type transformers are mostly used. The
secondary voltage is 110/sqrt(3).

Earth switch:
Earth switches are device which are normally used to earth a
particular system to avoid accident, which may happen due
to induction on account of live adjoining circuits. These don’t
handle any appreciable current at all.

42
 Lightning arrestors: station type “lightening arresters”
are provided at the terminals of the transformers for
protection against lightening or any surges developing in the
system, the practice is also to install lightening arresters at
the incoming terminals of the line. Shielding of substation
from direct lightening stroke is provided through earth wires
located at structures
‘peaks’. Recently masts are also used for the purpose of
shielding substation.

Overhead earth wire:

It protects the O/H transmission line from Lightning strokes.
Now a days OPGW are used for communication purpose also.

Switchgear

Switchgear is one which makes or breaks an electric circuit.

The equipments which normally fall in this category are:-

• Isolators
• Switching Isolators
• Circuit Breakers
• Load Break Switches
• Earth Switches

Isolators can break an electric circuit when the circuit is to

be switched on no-load only. These are normally used in
various circuits for the purpose of isolating a certain portion
when required for maintenance etc.
43
 Switching isolators are capable of
1. Interrupting transformer magnetized currents
2. Interrupting line charging current and
3. Load transfer switching
Its main application is in connection with transformer
feeders as the unit makes it possible to switch out one
transformer while the other is still on load.

Circuit Breakers can break or make the circuit on load and

even on faults. The equipment is most important and is heavy
duty equipment mainly utilized for protection of the various
circuits and operation at load. Normally circuit breakers are
installed accompanied by isolators.

Load break switches are those interrupting devices which

can make or break circuits at 8 times the rated current. These
are normally installed on the same circuit or on the circuits
which are backed up by circuit breakers.

44
 Earth switches are devices which are normally used to earth
a particular system to avoid accident, which may happen due
to induction on account of live adjoin circuits. These do not
handle any appreciable current at all.

45
 Communication
Types of communication in TPP

1. VSAT
2. PLCC
3. VHF
4. VLDC & Operational Communication
5. Inter Communication

Modes of Communication

1. Simplex – Only Transmit and Receive

2. Half-Duplex – Either Transmit or Receive at a time

3. Fully-Duplex – Transmit and Receive at the same time

PLCC

(Power line Carrier Communication)

❖ Conventionally B-Phase wire of the transmission line

is used for communication purpose DVC-CTPS

46
Wave Trap:
It is the device used to separate out the high frequency
communication signal from the low frequency power signal.
Wave traps are installed at the exit point of the switchyard.
It consists of an inductor in series with the transmission line
and a capacitor after the inductor in parallel. The series
inductor bypasses the low frequency power signal and blocks
the high frequency communication signal to enter the
switchyard, whereas the parallel capacitor bypasses the high
frequency communication signal and blocks the low frequency
power signal.
This kind of arrangement ensures the
safety of both the communication as well as power
generation syste

Now a days OPGW (Optical Ground Wire) are used in place of

wave trap system and is more efficient and reliable.

47
 ASH HANDLING PLANT
A large quantity of ash is, produced in steam power plants
using coal.
Ash produced in about 10 to 20% of the total coal burnt in the
furnace. Handling of ash is a problem because ash coming out
of the furnace is too hot, it is dusty and irritating to handle and
is accompanied by some poisonous gases. It is desirable to
quench the ash before handling due to following reasons:
1. Quenching reduces the temperature of ash.
2. It reduces the corrosive action of ash.
3. Ash forms clinkers by fusing in large lumps and
by quenching clinkers willdisintegrate.
4. Quenching reduces the dust accompanying the ash.
Fly ash is collected with an electrostatic precipitator (ESP)

48
 ELECTROSTATIC
PRECIPATATOR
It is a device which captures the dust particles from the
flue gas thereby reducing the chimney emission. Precipitators
function by electrostatically charging the dust particles in the
gas stream. The charged particles are then attracted to and
deposited on plates or other collection devices. When enough
dust has accumulated, the collectors are shaken to dislodge the
dust, causing it to fall with the force of gravity to hoppers
below. The dust is then removed by a conveyor system for
disposal or recycling.

Collector plate Emitter coil

Flue gas

Gas distribution
ELECTROSTATIC PRECIPATATOR

49
 Electrostatic precipitation removes particles from the
exhaust gas stream of Boiler combustion process. Six
activities typically take place:
➢ Ionization - Charging of particles
➢ Migration - Transporting the charged particles to the
collecting surfaces

➢ Collection - Precipitation of the charged particles onto the

collecting surfaces
➢ Charge Dissipation - Neutralizing the charged particles on
the collecting surfaces
➢ Particle Dislodging - Removing the particles from the
collecting surface to the hopper

50
➢ Particle Removal - Conveying the particles from the hopper
to a disposal point

MOTOR
A 3-φ induction motor, stator connected 2 or 3φ supply
produces a rotating magnetic field. Speed of rotation is
proportional to the main frequency and inversely proportional
to the no. of pair of poles. Stator can have single layer windings
with each coil side occupying one stator slot. Many type of
stator windings are encountered. 2 most common types are:-

1. Single Layer winding – Each winding is distributed

over a number of stator slots.
2. Double Layer winding – Each stator slot contains
sides of two separate coils.

Definition: Motor form the single largest prime mover found

in power stations and are used for multipurpose.

Induction Motor

There are various types and sizes of motors used in the power
stations. These are used for various purposes as prime movers.
Apart from the simple motor used in different areas, these HT
motors used in the various heavy duty equipments. These are
51
 FD, ID, PA fans, boiler feed pumps, CW pumps, etc. These
motors have certain special features like cooling, auto starting,
inter locks and control. These are generally squirrel cage
motors. The rotor never rotates at the synchronous speed. Off
load, the induction motor has poor efficiency and power
factor. On load we get an efficiency of 85% and 0.8 power
factor.
Synchronous Motor

These are motors which always run at synchronous speed and

speed of rotation depends upon the pair of poles. Synchronous
motors do not start on their own they need an external exciting
system which gives it an initial rotation. Generally an
induction motor is used for this purpose. As the load increases,
load angle increases and power drawn from the supply
increases. With an excessive load, the rotor pulls out of
synchronism. When operating at synchronous speed the
power factor can be changed by varying the degree of
excitation.
The motors are generally started using DOL (Direct Online
Starters)

Rating of Various motors attached to pumps and

fans:

1) BFP-4000 kW, 6.6kV, 405A, p.f.-0.89, 2979 RPM. This is the

biggest motor of power plant consuming a huge power and
rotating at speed greater than that of turbine.

2) CEP-250 kW, 6.6kV,26A,1480 RPM

3) Mill motors-340 kW,6.6kV,41 A,991 RPM

52
4) CWP-2000 kW, 6.6 kV, 250 A, p.f.-0.74, 300RPM.This is also
a big motor which needs to pump large quantity of water
thereby reducing its speed.

5) ID fan-1250 kW, 6.6 kV, 147 A, 597 RPM

6) PA fan-420 kW, 6.6 kV, 45.9 A, 1490 RPM
7) FD fan-1st speed - 550 kW, 6.6 kV, 73 A, 597 RPM
2nd speed -1000kW, 6.6 kV, 114 A, 746 RPM

SAFETY
➢ Control and elimination of Hazard to attain an acceptable level
of Risk is termed as Safety

Safety = Hazard Elimination + Risk Management

Common Hazards

➢ Direct contact with electricity (Electric Shocks)

➢ Boiler fires and explosions

53
➢ Outcomes Of Accidents
Contact with hazardous chemicals

Negative Positive

▪ Injuries ▪ Reoccurrence can be

▪ Losses prevented
▪ Death ▪ Improvement in design of
equipments

Accident prevention Strategies

❖ Engineering Methods
❖ Administrative controls
❖ Personal Protective Equipments ( A Second Line of Defence )
❖ Training & Education ( Imparting Morale & Knowledge )

54
 Prevention systems for Fire hazards
( At DVC – CTPS )
➢ Fire extinguishers
➢ Co2 flooding system
➢ Water spray system
➢ Nitrogen flooding
➢ Gas flooding system

Steps of Risk Assessment

1. Identify the Hazard

2. Decide who might be harmed and how
3. Evaluate the risks & decide on precautions
4. Record risk ratings & identify the existing risk controls
5. Review your assessment & update if necessary

55
 CONCLUSION

Industrial training being an integral part of engineering

curriculum provides not only easier understanding but also
helps acquaint an individual with technologies. It exposes an
individual to practical aspect of all things which differ
considerably from theoretical models. During my training, I
gained a lot of practical knowledge which otherwise could have
been exclusive to me. The practical exposure here will pay rich

The training at DVC-CTPS was

dividends to me, when I will set my foot as an Engineer.

altogether an exotic experience, since work, culture and

mutual cooperation was excellent here. Moreover fruitful
result of adherence to quality control awareness of safety and
employees were fare which is much evident here.

56
 BIBLIOGRAPHY

➢ IN HOUSE MAGAZINES AND MANUALS OF DVC

➢ PICTURES TAKEN FROM

• DVC-CTPS UNIT#7 &8

• GOOGLE.CO.IN/DVC-CTPS

➢ WEBSITES VISITED :

• WWW.GOOGLE.COM/DVC-CTPS

• WWW.DVC.ORG

• WWW.WIKIPEDIA.COM/DVC-CTPS

57