[Title]

Students learn theoretical information in the classroom and practical information

in the workplace. When academic knowledge and real-world experience are

combined, a student is completely prepared to achieve his potential. Students are

exposed to and develop knowledge of real-world workplace situations while

working on a project study in a sector. The purpose of the summer training

project is to give students the chance to experience how technology is used

practically in all types of organisations. It offers a chance to gain a sense of the

company and what it does. The fact that thermal energy is the primary source of

power generation in India, where it accounts for more than 60% of total energy

production. Indian steam power plants generate electricity. Boilers in steam

power plants use the heat produced by the combustion of fossil fuels to elevate

steam to high pressures and temperatures. The steam created in this way is

utilised to power the steam turbine connected to generators, producing

electricity as a result. The report includes information on the electricity produced

by KSTPS's seven units as well as information on the building's key components.

To better understand how KSTPS operates, adequate diagrams and layout are

provided.
We cannot achieve anything worthwhile in the field of technical education until

or unless the theoretical education acquired in classroom is effectively wedded to

its practical approach that is taking place in the modern industries and research

institutes. It gives me immense pleasure to have an opportunity to acknowledge

and to express my gratitude to those who were associated with my training at

KSTPS.

I am very thankful to Rajasthan Technical University, Kota to provide us this

opportunity of compulsorily doing practical training in any organization.

I would also like to show my sincere gratitude to Mr. Dinesh Birla, Head of

Electrical Engineering department, and Mrs. Sunita Chahar, Associate professor,

Electrical engineering department for giving me this opportunity.

I attribute heartiest thanks to all engineering departments and engineers of

KSTPS for their sample guidance during my training period.

Chapter
No.
Title Page
No.

1. Introduction to KSTPS 6
2. Plant Overview 10
3. Coal Handling Plant 12
4. Ash Handling Plant 15
5. Electrostatic Precipitator 17
6. Boiler 18
7. Steam Turbine 21
8. Turbo generator 23
9. Cooling System 28
10. Excitation System 29
11. Water Treatment Plant 30
12. Control Room 31
13. Transformer 32
14. Protection 33
15. Conclusion 34
16. References 35
Rajasthan State Electric Board (RSEB):
Rajasthan's history as a centre of power dates back to 1949, when 19 princely
states combined to establish Rajasthan. Electricity was then only available in a
relatively small number of locations and was regarded as a luxury. At that time,
not more than 42 towns and villages were electrified, and the installed generating
capacity was only 13.27 MW. However, the power sector in Rajasthan acquired
priority after the establishment of the Rajasthan State Electricity Board (RSEB) on
July 1st, 1957, and electricity plants started to proliferate all throughout the State.

RSEB Companies:
In order to make the Rajasthan State Electricity Board (RSEB) operate more
effectively, the government of Rajasthan published a gazette notification on July
19, 2000, dissolving the board into five separate corporations.
o The generation company, Rajasthan Rajya Vidyut Utpadan Nigam Ltd
(RVUNL).
o The transmission company, Rajasthan Rajya Vidyut Prasaran Nigam Ltd.
(RVPNL).
o The local distribution firm Jaipur Vidyut Vitran Nigam Ltd (RVPNL).
o The local distribution firm Ajmer Vidyut Vitran Nigam Ltd (AVVBNL).
o The regional distribution firm Jodhpur Vidyut Vitran Nigam Ltd (JDVVNL).
Rajasthan Rajya Vidyut Utpadan Nigam Ltd. (RVUNL):
By dissolving the former RSEB, Rajasthan Rajya Vidyut Utpadan Nigam Ltd. has
been given the responsibility of developing state-funded energy projects in the
state as well as running and maintaining state-owned power plants. On July 19,
2000, the Rajasthani government continued the RVUNL under the Companies Act
of 1956. Since then, the Nigam has taken the initiative to prioritise power
production and the state's massive and quick development.
The RVUNL has a 6228.35 MW installed capacity overall.
Thermal:
⮚ 1500 MW Suratgarh Super Thermal Power Plant (6x250 MW)
⮚ 1240 MW Kota Super Thermal Power Plant (2x110, 3x210, 2x195)
⮚ Chhabra Thermal Power Plant - 1000 MW (4x250 MW)
 ⮚ Kalisindh Thermal Power Station - 1200 MW (2x600 MW)
⮚ Giral Lignite Power Plant - 250 MW (2x125 MW)
Gas
⮚ Dholpur Combined Cycle Power Station (330 MW) (2x110 MW Gas Turbine,
1x110 MW Steam Turbine)
⮚ Ramgarh Gas Thermal Power Station: 273.5 MW (1x35.5 MW GT, 1x37.5
MW GT, 1x37.5 MW ST, 1x110 MW GT,1x50 MW ST)

Hydro
⮚ Rana Pratap Sagar Dam: 172 MW (4x43 MW)
⮚ Jawahar Sagar Dam: 99 MW (3x33 MW)
⮚ Dam Mahi Bajaj Sagar: 140 MW (2x25 MW, 2x45 MW)
⮚ Mini micro Hydel Systems - 23.85 MW

At the Kota Super Thermal Power Station:

Kota Rajasthan's first coal-based power plant is called the Super Thermal Power
Station. There are currently 1240 MW installed on it.

Location:

The primary industrial hub of Rajasthan is Kota, which is situated on the left bank
of the Chambal River. adequate water supply year-round in the Kota Barrage, for
example, are examples of infrastructure. Its total land area is approxpmate 250
Acres.
Sanction of Schemes (Stages I to V):

There are total 11 feeder line coming out of KSTPS. Each one is of 220
KV. They are going as follows:
 SALIENT FEATURES OF KSTPS

Design Features:
A satisfactory design consists of proper selection and design of following things:
∙ Estimation of cost
∙ Selection of site
∙ Capacity of Power Station
∙ Selection of Boiler & Turbine
∙ Selection of Condensing Unit
∙ Selection of Electrical Generator
∙ Selection of Cooling System
∙ Design of Control and instrumentation system
In design of KSTPS all these measures are considered properly.

Records of Excellence:

One of the best, most effective, most prominent power plants in the nation is
KSTPS. In 1984, 1987, 1989, 1991, and every year after that, KSTPS built a track
record of excellence and received excellent productivity awards from the Ministry
of Power, Government of India. KSTPS was given the golden shield award by the
Union Ministry of Power for consistently delivering excellent results during
2000–2001 and 2003–2004. On August 24, 2004, the Honourable President of
India, Dr. A.P.J. Abdul Kalam, presented the Golden Shield.
 Chapter 2: Plant Overview
The Closed Rankine Cycle, which is the foundation of KSTPS, entails that steam
produced in a boiler is exported in a prime mover and condensed in a condenser
before being supplied back into the boiler.

There are five major circuits in the Kota Thermal Power Station:
• Circuit for Ash and Fuel
• Electrical Circuit; Air and Gas Circuit; Feed water and Steam Circuit; Cooling
Water Circuit
Fuel and Ash Circuit: Using a fuel handling mechanism, fuel is fed from the
storage to the boiler. Coal is the fuel utilised in KSTPS, and as it burned in the
boiler, it created ash. 35 to 40 percent of the coal utilised is generated as ash. The
ash disposal machinery collects this ash at the boiler's rear and transports it to an
ash storage tank.

Air and Gas Circuit:

Forced draught and induced draught fans work together to draw air from the
atmosphere into the boiler's combustion chamber. The boiler tubes and
superheater tubes in the furnace are the first things the flue gases flow through
before going through the economizer and dust collector (ESP). Finally, they are
worn out by the environment's fans.

Feed Water and Steam Circuit:

The condensate leaving the condenser is first heated in low pressure (LP) heaters
upto 1100 c through extracted steam from the lower pressure extraction of the
turbine. Then its goes to deaerator where extra air and non-condensable gases
are removed from the hot water to avoid pitting / oxidation. From deaerator it
goes to boiler feed pump which increases the pressure of the water upto 180
Kg/Cm2 . From the BFP it passes through the high pressure heaters which
increases temperature of water upto 2400 c. A small part of water and steam is
lost while passing through different components therefore water is added in hot
well. This water is called the make-up water. Thereafter, feed water enters into
the boiler drum through economizer. In boiler tubes water circulates because of
density difference in lower and higher temperature section of the boiler. The wet
steam passes through superheater where its temperature is raised upto 5350 c -
5400 c. From superheater it goes into the HP turbine where its pressure and
temperature have been decreased to 35-37 Kg/Cm2 and 330-3350 c respectively.
After expanding in the HP turbine, the low pressure steam called again increased
to 5400 c at constant pressure. From reheater it goes to IP turbine and then to
the LP turbine and then exhausted through the condenser the cold reheat steam
(CRH) goes to the reheater (boiler) where it’s temp. is into hot well. After LP
turbine the pressure of steam is approx. 0.09 Kg/Cm2 .

Cooling Water Circuit:

A large quantity of cooling water is required to condense the steam in condenser
and marinating low pressure in it. The water is drawn from reservoir and after use
it is drained into the river.

Electrical Circuit:
The turbines rotate shaft and hence rotor of turbo generator where electricity is
generated at voltages 11/15.75/ 16 KV. Then these voltage levels are stepped up
using a step up power transformer (BHEL make) upto 220 KV voltage level. Then
the power is transmitted to other places through substations.
CHAPTER 3: Coal Handling Plant
INTRODUCTION :
It can be called the heart of thermal power plant because it provided the fuel for
combustion in boiler. The coal is brought to the KSTPS through rails there are
sixteen tracks in all for transportation of coal through rails. The main coal sources
for KSTPS are SECL (South Eastern Coalfields Limited), NCL (Northern Coalfield
Limited). Everyday 6 to 7 trains of coal are unloaded at KSTPS. Each train consists
of 58 wagons and each wagons consists of 50 tonnes of coal. The approximate per
day consumption at KSTPS is about 18000 metric tonnes. It costs approximate 4.5
crores of rupees per day including transportation expenses. The coal is firstly
unloaded from wagon by wagon triplers then crushed by crushers and magnetic
pulley and pulverized to be transformed to the boiler. The whole transportation of
coal is through conveyor belt operated by 3-Ø Induction motor.
The coal handling plant can broadly be divided into three sections:
1) Wagon Unloading System
2) Crushing System
3) Conveying System

1) Wagon Unloading System:

Wagon Trippler:
It unloads the coal from wagon to hopper. The hopper, which is made of Iron, is
in the form of net so that coal pieces of only equal to and less than 200 mm. size
pass through it. The bigger ones are broken by the workers with the help of
hammers. From the hopper coal pieces fall on the vibrator. It is a mechanical
system having two rollers each at its ends.
The rollers roll with the help of a rope moving on pulley operated by a slip ring
induction motor. The four rollers place themselves respectively behind the first
and the last pair of wheels of the wagon. When the motor operates, the rollers
roll in forward direction moving the wagon towards the “Wagon Table”. On the
Wagon table a limit is specified in which wagon to be has kept otherwise the
triple would not be achieved.
Specifications of I.M. used are:
Rated Output : 71 KW
Rated Voltage : 415 V
Rated Current : 14.22 A
Rated Speed : 975 rpm
No. of phases : 3
Frequency : 50 Hz

2) Crushing System:
Crusher House:
It consists of crushers which are used to crush the coal to 20 mm. size. There are
mainly two
type of crushers working in KSTPS:-
o Primary Crushers i.e. i) Rail crushers or ii) Rotary breaker
o Secondary Crushers. i.e. Ring granulators

3) Conveying System:
Stacker Reclaimer:
The stacker reclaimer unit can stack the material into the pipe or reclaim the
material that has been fed onto the main line conveyor and stacked. Material for
stacking is delivered onto the intermediate conveyor, which feeds the boom
conveyor of the stacker cum reclaimer, through trippler unit and vibrating feeder
from the main line conveyor. When reclaiming, material is discharged from the
bucket onto the bucket wheel body and fed by the boom conveyor onto the main
line conveyor that is moving in the opposite direction.
Conveyor belt Specification of Stacker / Reclaimer:
Belt width : 1400 mm
Speed : 2.2 m/second
Type of motor : All 3-Ø induction motors
Bucket wheel motor : 90 KW
Boom Conveyor motor : 70 KW
Intermediate Conveyor Motor : 90 KW
Boom Housing Motor : 22 KW
Slewing assembly : 10 KW
Travel Motor : 7.5 KW
Vibrating Feeder : 2x6 KW
Total installed power : 360 KW
CHAPTER 4: ASH HANDLING PLANT

This plant can be divided into 3 sub plants as follows:

1) Fuel and Ash Plant
2) Air and Gas Plant
3) Ash Disposal and & Dust Collection Plant

1) Fuel and Ash Plant:

Coal is used as combustion material in KTPS, In order to get an efficient utilization
of coal mills. The Pulverization also increases the overall efficiency and flexibility
of boilers. However for light up and with stand static load, oil burners are also
used. Ash produced as the result of combustion of coal is connected and removed
by ash handling plant. Ash Handling Plant at KTPS consists of specially designed
bottom ash and fly ash in electrostatic precipitator economizer and air
pre-heaters hoppers.

2) Air & Gas Plant:

Air from atmosphere is supplied to combustion chamber of boiler through the
action of forced draft fan. In KTPS there are two FD fans and three ID fans
available for draft system per unit. The air before being supplied to the boiler
passes through pre-heater where the flue gases heat it. The pre heating of
primary air causes improved and intensified combustion of coal.
The flue gases formed due to combustion of coal first passes round the boiler
tubes and then it passes through the super heater and then through economizer.
In re-heater the temperature of the steam (CRH) coming from the HP turbines
heated with increasing the number of steps re-heater the efficiency of cycle also
increases. In economizer the heat of flue gases raises the temperature of feed
water. Finally the flue gases after passing through the Electro-Static Precipitator is
exhausted through chimney.

3) Ash Disposal & Dust Collection Plant:

KSTPS has dry bottom furnace. Ash Handling Plant consists of especially designed
bottom and fly ash system for two path boiler. The system for both units is
identical and following description is applied to both the units the water
compounded bottom ash hopper receives the bottom ash from the furnace from
where it is stores and discharged through the clinker grinder. Two slurry pumps
are provided which is common to both units & used to make slurry and further
transportation to ash dyke through pipe line.
Dry free fly ash is collected in two number of 31 fly ash hoppers which are
handled by two independent fly ash system. The ash is removed from fly ash
hoppers in dry state is carried to the collecting equipment where it is mixed with
water and resulting slurry sump is discharged.
Utilization of Ash:

FLY ASH:
In compliance to Govt. of India Gazette Notification issued on 14th Sept. 1999 for
making available ash free of cost, KSTPS has achieved 100% Dry Fly ash utilization.
KSTPS signed agreements for dedicated generating units allocations including
Construction & Operation of complete dry fly ash evacuation system from each
unit in two phases i.e. from ESP to Intermediate Silo and Intermediate Silo to
Main Supply Silo near KSTPS boundary with following cement manufacturing
companies –
• Unit # 1&2 - M/s. Associated Cement Co. Ltd.
• Unit # 3 - M/s. Birla Cement Works Ltd.
• Unit # 4 - M/s. Grasim Industries Ltd.
• Unit # 5 - M/s. Grasim Industries Ltd
• Unit # 6 - M/s. Mangalam Cement Ltd.
• Unit # 6 - M/s. Shree Cement Ltd.
• Unit # 7 (50% each) - M/s. Grasim Industries & M/s. Shree Cement Ltd.

POND ASH:
Concerted efforts have been made towards utilization of disposed fly & bottom
ash accumulated in KSTPS ash dykes. The ash is provided free of cost and has
been utilized by various small entrepreneurs i.e. Brick-kiln industries, small fly ash
product industries, Cement manufacturing Industries and for land filling by
National Highway Authority of India in construction of NH-12 and NH-76.
FIG. 4.1 LOADING OF ASH FROM HOPPERS TO VEHICLES
 CHAPTER 5: ELECTROSTATIC PRECIPITATOR

Scope & Principle of Operation:

For general mankind, today an Eco friendly industry is must. As far as air pollution
is concerned now a days various flue gases filter are there in service. The choice
depends on the size of suspended particle matter. These filters are E.S.P. Fabric
filter high efficiency cyclone separations and settling room. For fly ash, where the
particle size vary from 0.75 microns to 100 micron use gradually use E.S.P. to
purify the flue gases due to its higher efficiency & low running cost etc. In an ESP
the dust contained gas is passed through an intense electric field, which causes
ionization of the gases & they changed into ion while traveling towards opposite
charged electrode get deposited as particles and thus dust is electric deposited an
electrode creating the field. It is continuous process.

Controller:
Now a day micro-processor based intelligent controllers are used to regulate the
power fed to the HVR. Average power fed to ESP field can be controlled by
variation of the firing angle of thyristor. The output of controller with respect to
time is also controlled by microprocessor, so that ESP operation is smooth and
efficient. As can be seen in the event of spark between electrodes the output of
controller is reduced to zero for few millisecond for quenching the spark.
Controller also takes place care of fault in HVR and gives a trapping and
non-trapping alarm as per the nature of faults.

High Voltage Rectifier Transformer:

HVR receives the regulated supply from controller. It steps up to high voltage
rectifier. The D.C. supply is fed to E.S.P. field through its negative bushing. The
positive bushing so connected to earth through small resistance which forms a
current feedback circuit. A very high resistance column is also connected with
negative bushing. It forms the voltage feedback circuit. These two feedback are
used in the controller for indication and control purpose.
E.S.P. Field:
The field consists of emitting and collecting electrodes structure which are totally
isolated from each other and hanging with the top roof of field. The emitter is
also isolated from the roof through the support insulators which are supporting
the emitter electrode frame works and also the supply to these electrodes is fed
through support insulators. The collecting electrodes are of the shape of flat
plates.
The ash depositing on these electrode is rapped down by separate wrapping
mechanism happens at the bottom of the field. Then From hoppers, ash is
evacuated by ash handling system and dispose to the disposal area. The wrapping
system is automatically controlled with the help of the programmable metal
controller, located in the ESP auxiliaries control panels.
 CHAPTER 6: BOILER
A boiler (or steam generator) is a closed vessel in which water, under pressure is converted
into steam. It is one of the major components of a thermal power plant. A boiler is always
designed to absorb maximum amount of heat released in process of combustion.

Boilers are classified as:

 Fire tube boiler:
In this type the products of combustion pass through the tubes which are
surrounded by water. These are economical for low pressure only.

 Water tube boiler:

In this type of boiler water flows inside the tubes and hot gases flow outside the tubes.
These tubes are interconnected to common water channels and to steam outlet.

In KSTPS, Natural circulation, tangentially fired, over hanged type, Water tube boilers are
used. Each unit is having its own boiler.
Oil burners are provided between coal burners for initial start-up and flame stabilization.
Firstly, light oil (diesel oil) is sprayed for Initialization then heavy oil (high speed diesel oil)
is used for stabilization of flame. Pulverized coal is directly fed from the coal mills to the
burners at the four corners of the furnace through coal pipes with the help of heated air
coming from PA fan. Four nos. of ball mills of 34MT/Hr capacity each have been installed
for each boiler. The pressure inside boiler is –ve (Approx. -5 to -1 mmWCl) so as to
minimized the pollution and loses & to prevent the accidents outside the boiler.
For ensuring safe operation of boilers, furnace safe guard supervisory system (FSSS) of
combustion engineering USA designed has been installed. This equipment systematically
feed fuel to furnace as per load requirement. The UV flame scanners installed in each of the
four corners of the furnace,
scan the flame conditions and in case of unsafe working conditions trip the boiler and
consequently the turbine. Turbine - boiler interlocks safe guarding the boiler against
possibility furnace explosion owing to flame failure.

Parts of Boiler:
● Furnace
● Pulverised fuel system
● Fuel oil system
● Boiler drum
● Draft system
● Fans (PA, FD, ID)
● Economiser
● Air preheater
● Super heater
● Reheater
● Circulation system
● Soot blowers
 Technical Specification of Boiler:
Type : Tangentially fired, natural circulation
No. of Units : 2
Make : BHEL
Capacity : 375 tonnes per hour
Steam Pressure : 139 Kg/Cm2
Efficiency : 86.6%
No. of fans in service
➢ ID fans : 2 Nos.
➢ FD fans : 2 Nos.
➢ PA fans : 2 Nos.

Steam Temperature : 540oC

No. of coal mills : 3 Nos. for each boiler
No. of soot blowers : 70

Fuel:
Coal : Bituminous coal
Type : 3074 tonnes per day
: Wet system
Quantity consumed
Ash disposal

A. Oil : HSD and fuel oil

: HSD
➢ Type
-
➢ Quantity 5520
KL
per
year
Furn
ace
Oil -
2880
0 KL
per
year

No. of chimneys : 2 (for 5 units)

Height of Chimney : 180 Meters
Volume of flue Gas : 198 M3/Sec. Air emitted
Temp. of flue gas : 140oC (when exposed to atmosphere)
FIG. 6.1 SCHEMATIC OF BOILER IN KSTPS
CHAPTER 7: STEAM TURBINE

Turbine is a machine in which a shaft is rotated steadily by impact or reaction of current or stream
of working substance (steam, air, water, gases etc.) upon blades of a wheel. It converts the potential
or kinetic energy of the working substance into mechanical power by virtue of dynamic action of
working substance. When the working substance is steam it is called the steam turbine.

FIG. 7.1 STEAM TURBINE

Principle of Operation of Steam Turbine:

Working of the steam turbine depends wholly upon the dynamic action of Steam. The steam is
caused to fall in pressure in a passage of nozzle. Due to this fall in pressure, a certain amount of heat
energy is converted into mechanical kinetic energy and the steam is set moving with a greater
velocity. The rapidly moving particles of steam, enter the moving part of the turbine and here suffer
a change in direction of motion which gives rose to change of momentum and therefore to a force.
This constitutes the driving force of the machine.
The majority of the steam turbine have, therefore two important elements, or Sets of such elements.
These are: (1) The nozzle in which the system expands from high pressure end a state of
comparative rest to a lower pressure end a status of comparatively rapid motion.(2) The blade or
deflector , in which the steam particles changes its directions and hence its momentum changes .
The blades are attach to the rotating element. The stationary part of the turbine is usually termed the
casing or cylinder.
Although the fundamental principles on which all steam turbine operate the same, yet the methods
where by these principles carried into effect very end as a result, certain types of turbine have come
into existence. They are:
✓ Simple impulse steam turbine
✓ The pressure compounded impulse turbine
✓ Simple velocity compounded impulse turbine
✓ Pressure-velocity compounded turbine
✓ Pure reaction turbine
✓ Impulse reaction turbine
Description of Steam Turbines:
Steam flow:
210 MW steam turbine is a tandem compound machine with HP, IP & LP parts. The HP part
is single flow cylinder and HP & LP parts are double flow cylinders. The individual turbine
rotors and generator rotor are rigidly coupled. The HP cylinder has a throttle control. Main
steam is admitted before blending by two combined main stop and control valves. The HP
turbine exhaust (CRH) leading to reheated have two swing check valves that prevent back
flow of hot steam from reheated, into HP turbine. The steam coming from reheated called
HRH is passed to turbine via two combined stop and control valves. The IP turbine exhausts
directly goes to LP turbine by cross ground pipes.

HP Turbine:
It is an Impulse turbine. The HP casing is a barrel type casing without axial joint. Because of
its rotation symmetry the barrel type casing remain constant in shape and leak proof during
quick change in temperature. The inner casing too is cylinder in shape as horizontal joint
flange are relieved by higher pressure arising outside and this can kept small. Due to this
reason barrel type casing are especially suitable for quick start up and loading. The HP
turbine consists of 25 reaction stages. The moving and stationary blades are inserted into
appropriately shapes into inner casing and the shaft to reduce leakage losses at blade tips.
IP Turbine:
This is a reaction turbine. The IP part of turbine is of double flow construction. The casing of
IP turbine is split horizontally and is of double shell construction. The double flow inner
casing is supported kinematically in the outer casing. The steam from HP turbine after
reheating enters the inner casing from above and below through two inlet nozzles. The centre
flows compensates the axial thrust and prevent steam inlet temperature affecting brackets,
bearing etc. The arrangements of inner casing confines high steam inlet condition to
admission branch of casing, while the joints of outer casing is subjected only to lower
pressure and temperature at the exhaust of inner casing. The pressure in outer casing relieves
the joint of inner casing so that this joint is to be sealed only against resulting differential
pressure.
The IP turbine consists of 20 reaction stages per flow. The moving and stationary blades are
inserted in appropriately shaped grooves in shaft and inner casing.

LP Turbine:
The casing of double flow type LP turbine is of three shell design. The shells are axially split
and have rigidly welded construction. The outer casing consist of the front and rear walls, the
lateral longitudinal support bearing and upper part.
The outer casing is supported by the ends of longitudinal beams on the base plates of
foundation. The double flow inner casing consist of outer shell and inner shell. The inner
shell is attached to outer shell with provision of free thermal movement.
Steam admitted to LP turbine from IP turbine flows into the inner casing from both sides
through steam inlet nozzles.
CHAPTER 8: TURBO GENERATOR

Turbo generator installed in KSTPS are manufactured by B.H.E.L. and incorporated with most
modern design concepts and constructional features, which ensures reliability, with constructional &
operational economy. There are total 7 turbo generators are installed at KSTPS out of which 2 are of
110 MW, 3 of 210 MW and 2 of 195 MW capacity. Efficiency of each unit is approx. 99%.
The generator stator is a tight construction, supporting & enclosing the stator windings, core and
hydrogen coolers. Cooling medium hydrogen is contained within frame & circulated by fans
mounted at either ends of rotor. The generator is driven by directly coupled steam turbine at a speed
of 3000
r.p.m. the Generator is designed for continuous operation at the rated output. Temperature detectors
and other devices installed or connected within then machine, permit the windings, teeth core &
hydrogen temperature, pressure & purity in machine under the conditions. The source of excitation
of rotor windings is thyristor controlled D.C. supply. The auxiliary equipment supplied with the
machine suppresses and enables the control of hydrogen pressure and purity, shaft sealing
lubricating oils. There is a provision for cooling water in order to maintain a constant temperature of
coolant (hydrogen) which controls the temperature of windings.

Stator Frame:
The stator frame of welded steel frame construction, which gives sufficient & necessary rigidity to
minimize the vibrations and to withstand the thermal gas pressure. Heavy end shields enclose the
ends of frame and form mounting of generator bearings and radial shaft seals. Ribs subdivide the
frame and axial members to form duct from which the cooling gas to & fro radial ducts in the core
and is re-circulated through internally mounted coolers. The stator constructed in a single piece
houses the core and windings. The horizontally mounted water cooled gas coolers being so arranged
that it may be cleaned on the water side without opening the machine to atmosphere. All welded
joints exposed to hydrogen are specially made to prevent leakage. The complete frame is subjected
to hydraulic test at a pressure of 7 ATA.

Stator Core:
It is built up of special sheet laminations and whose assembly is supported by a special guide bass.
The method of construction ensures that the core is firmly supported at a large number of points on
its periphery. The laminations of high quality silicon steel which combines high permeability with
low hysteresis and eddy current losses. After stamping each lamination is varnished on both sides
with two coats. The segment of insulating material is inserted at frequent intervals to provide
additional insulation.
Laminations are assembled on guide bass of group separated by radial ducts to provide ventilation
passage. The ventilation ducts are disposed so as to distribute the gas evenly over the core & in
particularly to give adequate supports to the teeth. In order to reduce the losses in the ends packets
special dampers are provided at either ends of core. Mostly dampers are provided to prevent hunting
in ac machines.

Stator Windings:
Stator windings are double star layers, lap wound, three phase, and short pitch type. The top &
bottom are brazed and insulated at either end to form turns. Several such turns form a phase. Phases
are connected to form a double star winding. The end of winding form involutes shape ends,
inclined towards machine axis by 20o, thus form a basket winding with total induced conical angle
of 40o. Due to this stray load losses in the stator ends to zero. The arrangement of complete stator
winding electrical circuit is viewed from turbine end of generator & rotor windings. Slot numbering
is clockwise from turbine end. A thick line identifies the top bar in slot No.1. The later consists of
hardened glass laminated blocks inserted between adjacent coil sides in coil overhangs, so that with
the coils, they form a continuous rigid ring. The exposed portion of windings is finally coated.
Insulation of individual bars & stator windings at various stresses is tested with applied high
voltages of AC of 50 Hz.

Terminal Bushings:
Six output leads (3 long, 3 short) have been brought out of the coming on the exciter side. External
connections are to be made to the three shorter terminals, which are phase terminals. The large
terminals are of neutral & current transformer is inserted. The conductor of Generator terminal
bushing having hollow copper tubes with Copper brazed at the ends to avoid leakage of hydrogen.
Hollow portions enable bushings to be hydrogen cooled. Ends of bushings are Silver-plated: middle
portion of the bushing is adequately insulated & has a circular flange for bolting the stator casing.
Gaskets are provided between the Flange of terminal bushings and castings to make it absolutely
gas tight.

Bearings:
Generator bearings have electrical seats of consists of steel bodies with removable steel pads. The
bearings are formed for forced lubrication of oil at a pressure of 2-3 ATM/ from the same pump that
supplies oils to the turbine, bearings & governing gears. There is a provision to ensure & measure
the rotor bearing temperature by inserting a resistance thermometer in the oil pockets.

Ventilation System:
The machine is designed with ventilation system having 2 ATM rated hydrogen pressure. Two axial
fans mounted on either side of the rotor to ensure circulation of hydrogen. The stator is designed for
radial ventilation by stem. The end stator core packets & core clamping & plates are intensively
cooled by Hydrogen through special ventilation system. Design of special ventilation is so as to
ensure almost uniform temperature of rotor windings and stator core. Rated load operating
temperature is well within the limits corresponding to the Class B operation. Embedded Resistance
Temperature Detectors do continuous monitoring of Hydrogen temperature at active parts of
Generator.

Resistance Temperature Detectors:

Leads from RTD are brought out to the terminal board by cables through conduits to protect them
from physical damage and from contact with high voltage coils. Some RTDs are in stator teeth with
7 spacers, 7 RTDs between the coil sides in stator slots with 7 spacers and 3 RTDs are there in the
stator core with spacers. The location of RTDs is in three phase’s i.e. in the centre of machine, in
each region of machine and midway between them. The detectors in the stator slots are distributed
uniformly in all three phases. Measurement of temperature of Hydrogen cooling water for Hydrogen
coolers & metals is as: Six RTDs are provided at the inlets of each of six individual Hydrogen
cooler elements for measurement of temperature of Hydrogen, similarly Six RTDs are provided at
the outlets also. One RTD along-with one spacer is provided in the lower part of stator frame for
measurement & signalization of hot Hydrogen. Six RTDs are provided at outlets of each of six
individual Hydrogen Cooler elements for measurement of temperature of cooling water at the outlet.
Two RTDs are provided in the shelves of Turbo-Generator for measurement of signalization of the
bearing metal cap. All the terminals of RTDs are brought out to a common terminal board located
on the stator frame.

Hydrogen Coolers:
Three Hydrogen Coolers each comprising of two individual units are mounted inside the stator
frame. The inlet and outlet of cooling water from both of machine i.e. from non-driving side as well
as turbine side. The Clearing of the individual cooler element can be carried out from both ends of
the Generator even during operation. The assembly of individual cooler elements in stator frame is
however carried out only from the non-driving side.
Rotor:
Slots are milled on the rotor gorging to receive the rotor winding. Transverse slots machined in the
pole faces of the rotor to equalize the moment of inertia in direct and quadrilateral axis of rotor with
a view minimizing the double frequency.

Vibration of Rotor:
The fully brazed rotor is dynamically balanced and subject to 120 % over speed test at the work
balancing tunnel so as to ensure reliable operation.

Rotor Windings:
Rotor winding is of direct coil type and consists of parallel strips of very high conductivity Silver
Bearing Copper, bent on edge to form coil. The coils are placed in impregnated glass, laminated
short shells; using glass strips inter turn insulation and will be brazed at the end to form continuous
winding. The complete winging will be packed at high temperature and pressed to size by heavy
steel damping rings. When the windings have cooled, heavy dove tail wedges of non-magnetic
materials will seal the insulation at the top of slot portion. The cooling medium hydrogen gas will
be brought in direct contact with copper by means of radial slots in embedded portion. Treated glass
spacers inserted between the coils and solid ring prevent lateral movement of coil overhang. The
formation and description of glass spacer is such as to leave ample space for ventilation.

Bearings:
The bearings are self-aligned & consist of slip steel shells linked with special bearing metal having
very low coefficient of friction. The bore is machined on an elliptical shape so as to increase the
mechanical stability of the rotor. The bearings are pressure lubricated from the turbine oil supply.
Special precautions are taken to prevent oil & oil vapour from shaft seals and bearing along the
shaft. The circulation of shaft current is liable to damage. The bearing surface is protected by
insulation so placed that the bearings, seals & necessary pipes are inclined from the frame.

Slip Rings:
The slip rings are made of forged steel. They are located at either side of Generator Shaft. The slip
ring towards the exciter side is given +ve polarity initially. They have helical grooves and skewed
holes in the body for cooling purpose by air. Calibrated mica is first built up to required thickness
on the shaft where slip rings are located. The slip rings are insulated from the rotor shaft. Excitation
current is supplied to the rotor winding. Through the slip rings, which are connected to the winding.
On one end and to the slip ring on the other end with insulated (terminal) studs passing though the
radial holes in the rotor shaft.
The terminal studs at both the ends of excitation leads are fitted gas cat seals to prevent leakage.

Bush Gear Assembly:

Generator bushes are made from the various compositions of natural graphite and binding material.
They have a low coefficient of friction and are self-lubricating. The brushes are provided with a
double flexible copper or pigtails. A helical spring is mounted rapidly over each bush so that
pressure is applied on the centre line of bush. A metal cap is riveted to the brass bead and is
provided with a hole to maintain the position of the spring plug. Several brush holder, each carrying
on brush in radial position are fixed to a silver plated copper studs mounted on the collecting arm
concentric with each slip rings. The collecting arm is made out of a copper strip.

Drying of Winding:
Generator stator bars are insulated with mica insulation, which is homogeneous in nature and
practically impervious to moisture, and reduce time required to draught. The insulation resistance of
the stator phase winging against earth and with reference to other phases under hot condition shall
not be less than the value obtained automatically.

FIG. 8.1 CROSS SECTIONAL VIEW OF A TURBO GENERATOR

Turbo Generator Specifications:

STAGE –I
Make Russian Manufacturer BHEL
Type T.G.P.
Apparent Output 137.5MVA
Active Output 110 MW
Power factor 0.8 lagging
Rated voltage 11 KV
Rated current 7200 Amp.
Rated speed 3000 rpm
Frequency 50 Hz
Phase connections Double gen. star
No. of generator terminals 6
Max. Output with air cooling 68.75MVA
Excitation voltage 230V

STAGE –II & III

Make KWVC Craftworks, Germany Manufacturer BHEL
Rated capacity 247 MVA
Rated Output 210 MW
Rated current 9050 Amp.
Rated terminal voltage 15.75 KV
Rated speed 3000 rpm
Power factor 0.8 lagging
Excitation voltage 310V
Phase sequence Double star
 Insulation class B
No. of turns per phase/pole 10
Short circuit ratio 0.49

STAGE –IV
Make KWVC Craftworks, German Manufacturer BHEL
Rated Capacity 247 MVA
Rated Output 210 MW
Rated Current 9050 Amp.
Rated Terminal Voltage 15.75 KV
Rated Speed 3000 Rpm
Power Factor 0.8 Lagging
Excitation Voltage 310 V
Phase Sequence Double Star
Insulation Class B
No. of Turns per Phase/Pole 10
Short Circuit Ratio 0.49
CHAPTER 9: COOLING SYSTEM

Cooling of Generator:
In KSTPS hydrogen cooling system is employed for generator cooling. Hydrogen is used for
cooling medium primarily because of its superior cooling properties & low density. Thermal
conductivity of hydrogen 7.3 times of air. It also has higher transfer co-efficient. Its ability to
transfer heat through forced convection is about 75% better than air. Density of hydrogen is approx.
7/14 of the air at a given temperature and pressure. This reduces the wind age losses in high speed
machine like turbo- generator. Increasing the hydrogen pressure the machine improve its capacity to
absorb & remote heat. Relative cooling properties of air and hydrogen are given below:
✓ Elimination of fire risk because hydrogen will not support combustion.
✓ Corona discharge is not harmful to insulation since oxidation is not possible.
✓ Smooth operation of machine in view of vertical elimination of wind age noise & the use of
heavy gas light enclosure and dirty probe casing.
At pressure 0.035 atm. of hydrogen heat carrying capacity is 1. But at 2.0atm. Of hydrogen heat
carrying capacity is 1.95 to overcome the serious possibility of hydrogen explosion with in the
machine and to ensure the safety of operation purity of hydrogen on the generator. Casing must be
maintained as high as possible. The purity of hydrogen should be 98% above but should not be less
than 98%. In case of hydrogen purity drops below 98% an alarm is provided.

Hydrogen Dryers:
Two nos. of dryers are provided to absorb the hydrogen in the Generator. Moisture in this gas is
absorbed by silica gel in the dryer as the absorbed gas passes through it. The saturation of silica gel
is indicated by change in its colour from blue to pink. The silica gel is reactivated by heating. By
suitable change over from drier to the other on un-interrupted drying is achieve.

Cooling of Steam:
There are two cooling tower made for cooling of steam for two last units i.e. for units 6 and 7 while
for other 5 units the cooling is done directly by passing cold water in tubes from condensate
chamber where hot steam after LPT is stored. The cold water taken for cooling of steam is directly
from Chambal River.

Dimensions of Cooling Towers:

Height : 180 m
Base Diameter: 4.9 m
Top Diameter: 4.5 m
CHAPTER 10: EXCITATION SYSTEM

The electric power Generators requires direct current excited magnets for its field system. The
excitation system must be reliable, stable in operation and must response quickly to excitation
current requirements. When excitation system response is controlled by fast acting regulators, it is
chiefly dependent on exciter. Exciter supply is given from transformer and then rectified.

In the excitation system the power required for excitation of Generation are tapped from 11 KV bus
ducts through a step down rectifier transformer. After rectification in thermistor, converter, the DC
power is fed to the Generator field winding through a field breaker. The AVR control the o/p from
thyristor converter by adjusting the firing angle depending upon Generator voltages. The field
flashing system facilitates initial built up of the Generator voltage from the static AC or DC supply.

Rectifier Transformer:
This transformer steps down the bus voltage 11 KV to 640 V and has a rating of 1360 KVA. It is dry
type, it is however provided with current relays and two temperature sensors.

Automatic Voltage Controls:

The AVR is transistorized thyristor controlled equipment with very fast response. The AVR is also
having provision of stator and rotor currents limits and load angle limits for optimum utilization of
lagging and leading reactive capacities of generator.

Field Suppression Equipment:

The field equipment consists of a field breaker with discharge resistors. The field breakers have 4
main breaking contacts and two discharge contacts, which close before main contact break.

Operation:
After bringing the speed to operation speed say 3000 r.p.m., the voltage is slowly built up with the
help of excitation system. This action is taken for synchronizing the Generator.
Synchronizing:
For synchronizing the Generator to the grid system 5 condition of equality have to be satisfied.
These are (I) Voltage (II) Frequency (III) Phase displacement (IV) Phase sequence (V) Wave form.
Wave form and phase sequence of the Generator are determined at the design of each connection
SYNCHRONIZING of the generator.
CHAPTER 11: WATER TREATMENT PLANT

The principle problem in high pressure boiler is to control corrosion and steam quality. Internal
corrosion costs power station crores of rupees in repair without strict control impurities in steam
also form deposit over turbine blades and nozzles. The impurities present in water are as follows:
✓ Un-dissolved and suspended solid materials
✓ Dissolved salts and minerals
✓ Dissolved gases (oxygen and carbon dioxide, etc.)
✓ Other minerals (oil, acid etc.)
✓ Turbidity & Sediment components (silica, Sodium and Potassium sulphates, etc.)

D.M. PLANT:
In this plant process water is fed from all these dissolved salts. Equipment for demineralization cum
softening plant is supplied and erected by M/s. Wanson (India) Ld., Pune. This plant consists of two
streams each stream with activated carbon filter, weak acid, cation exchanger and mixed bed
exchanger. The filter water to DM plant through 250 dia. header from where a heater top off has
been taken to softening plant. Two filtered water booster pumps are provided on filtered water line
for meeting the pressure requirement in DM Plant.
Sodium Sulphate solution of required strength is dosed into different filtered water by mean of
dosing pump to neutralize chlorine prior to activated carbon filter. When water passed an activated
carbon filter will remove residual chlorine from water. Provision is made for back washing the
activated carbon filter. When pressure drop across filter exceeds a prescribed limit from the
activated carbon filter the works acid cation unit. The deception water the weak base anion
exchanger unit water then enters de-gasifier unit where free CO2 is scrubbed out of water by upward
counter flow of low pr. air flow through degasified lower and degassed water is pumped to strong
base exchanger (anion exchanger).
Arrangement for dosing ammonia solution into de-mineralized water after mixed bed unit has been
provided pH +1 correction before water is taken in de-condensate transfer pump the DM water to
unit condenser as make up.

C.W. PLANT:
Circulating water pump house has pumps for condensing the steam for condenser. Five pumps are
used for condensing Unit No.1 & 2 and after condensing this water is discharged back into the river.
Each pump has capacity of 8275 M3/Hr, and develop pressure about 1.94 Kg/Cm2.Three seal water
pump are used for sealing circulating water pump shaft at pr. 4.5 Kg/Cm2.
Two pump for unit 1 & 2 with one stand by is used for supplying raw water to chloritized chemical
dosing is tone between and chloritized water is taken through main line. From main line water
passes through filter bed to filter the water. Chloritized water is pumped to 42 m elevation by two
pumps of capacity 270 M3/Inch at discharge pressure of 6.9 Kg/Cm2. At 42 M elevation the water is
stored in tank and used for cooling the oil coolers and returned back to river. Oil coolers are situated
on ground and there are no. of tress for each unit.

B.C.W. PUMP HOUSE:

Filter water after demineralization is used for bearing cooling from BCW pump house after passing
through strainer and heat exchanger it enters at 30-32oC and leave exchanger at 38oC. The raw water
used in ash handling plant and remaining quantity is stored in sumps of BCW Pump House. From
here the water is pumped to CW Pump by TWS (Traveling water screens) pumps are run by motors
of 90 KW and has a capacity of 240 Cum/hr/pump at pressure of 5 Kg/Cm2. BCW here
stand for water used for cooling oil used for cooling the bearing. In CW pump house water is
discharged from nozzle and impinged for traveling water screens for cleaning it.
CHAPTER 12: CONTROL ROOM

In control room various controls are provided simultaneously various measurement are made,
various relays are provided here. Instrumentation Limited Kota is major supplier of apparatus. All
control panels are of ABB and software used in them for controlling is of Rockwell Automation.
The whole plant is automated. All the equipments of KSTPS are controlled from control room only,
no manual checking is required.
There are total five control rooms of which one is for units 1 & 2, one is for units 3 & 4, other 3 for
three different units.
The supply voltage to measuring and protecting equipments is 110 V. There are instruments and
transducers applied at every part/ valve/ point of plant to monitor each section of plant easily and
controlling them.

Each control room has 5 different panels:

i. Control Panel I: Fan Control Desk
✓ Induced draft fan (3 Nos.) at full load and 2 Induce Draft Fans Run
✓ Forced draft fan (2 Nos.)
✓ Primary Air Fan (3 Nos.) at full load
✓ Furnace Pressure (- 5 to -10 mmwcl)
✓ Primary Air Header Pressure (750-800 level mmwcl)
✓ FO Wind box pressure or wind box differential pressure

ii. Control Panel II: Fuel Control Desk

✓ Coal, oil flow
✓ Oil pressure
✓ Temperature of mill (inlet & outlet)
✓ Flow of air
✓ Differential Pressure of mill

iii. Control Panel III: Steam & Water Desk

✓ Drum Level Control
✓ Flow of steam & water
✓ Pressure of Steam & Water
✓ Temperature of steam and water

iv. Control Panel IV: Turbine Desk

✓ Pressure Control
✓ Load Control
✓ Speed Control
✓ Effectors, Control Values, Stop Values, Deaerators

v. Control Panel V: Generator Control Panel

✓ Voltage Current MVAR
✓ Stator Rotor Temp
✓ For Stator cooling (a) H2 pressure b) H2O pressure
vi.
CHAPTER 13: TRANSFORMER

A transformer is an electrical device that transfers electrical energy between two or more circuits
through electromagnetic induction. Electromagnetic induction produces an electromotive
force within a conductor which is exposed to time varying magnetic fields. Transformers are used to
increase or decrease the alternating voltages in electric power applications.
A varying current in the transformer's primary winding creates a varying magnetic flux in the
transformer core and a varying field impinging on the transformer's secondary winding. This
varying magnetic field at the secondary winding induces a varying electromotive force (EMF) or
voltage in the secondary winding due to electromagnetic induction. Making use of Faraday's Law in
conjunction with high magnetic permeability core properties, transformers can be designed to
efficiently change AC voltages from one voltage level to another within power networks.

In KSTPS there 1 transformer for each unit. The generated voltages are 11/ 15.75/ 16 KV at KSTPS.
So accordingly 11/220 KV, 15.75/220 KV, 16/220 KV step up power transformers are installed
respectively for stepping up the voltage for further transmission.
These transformers are BHEL make having rating of 200 – 500 MVA rating. Their efficiency is
approx. 99.23%.

FIG. 13.1 TRANSFORMER

CHAPTER 14: PROTECTION

There are many types of protections are provided for each and every faulty situation that can occur
in a power station. There is a 220 KV switchyard installed in which all the protecting equipments
are installed. From this switchyard the power is transmitted to other substations and cities.

Different types of protection schemes are:

✓ Field Protection
✓ Pole Slipping
✓ Plane Overload Protection
✓ Inter-turn Fault
✓ Negative Phase Sequence Protection
✓ Reverse Power Protection
✓ Forward Power Protection
✓ Under Frequency & Over Frequency Protection
✓ Generator Voltage Protection
✓ Rotor Earth Fault Protection

Different protecting devices that are used are:

✓ Circuit breakers
✓ Current transformers
✓ Potential transformers (for measurement purpose)
✓ Isolators
✓ Lightning arresters
✓ Capacitive voltage transformers
✓ Earth switch
✓ Wave trap
✓ Vibration dampers
 CONCLUSION

The practical training has proved to be quiet fruitful. It provided an opportunity for
encounter with such huge machines like wagon tippler, 110 MW, 210 MW & 195 MW
generators and turbines.

The architecture of the power plant the way various units are linked and the way working of
whole plant is controlled make the student realize that engineering is not just learning the
structured description and working of various machines, but the greater part is of planning
proper management.

It also provides an opportunities to lean low technology used at proper place and time can
save a lot of labour e.g. wagon Tripler (CHP).But there are few factors that require special
mention. Training is not carried out into its true spirit. It is recommended that there should
be some project specially meant for students where presence of authorities should be
ensured. There should be strict monitoring of the performance of students and system of
grading be improved on the basis of work done.

This training also gives us the idea of working in a professional world. Also gives the idea
that in a power plant or any other company, branch related knowledge is not sufficient.
Person should have knowledge of all the fields so that in bad situations he/she is able to
control the situation.

However training has proved to be quite fruitful. It has allowed an opportunity to get an
exposure of the practical implementation to theoretical fundamentals.
 REFERENCES

• http://www.mapsofindia.com/kota/industries/super-thermal-power-plant.html
• http://en.wikipedia.org/wiki/Thermal_power_station
• www.geocities.com
• http://www.energymanagertraining.com/power_plants/ThermalPowerPlants.html
• www.rvunl.com

BOOKS:
• Theory of Assembly and Operation of Steam Turbine by R.K. Singhal
• Electrical Power by J.B.Gupta
• Generation of Electrical Power by B.R.Gupta
• Power System by V.K.Mehta.
• Power System Design & Analysis by B.R.Gupta
• Steam & Gas turbines and Power Plant Engineering by R.Yadav