“Heavens Light is Our Guide”

Rajshahi University of engineering and technology

Department of Electrical and Electronic Engineering
“ATTACHMENT REPORT”

Course No: EEE 4100

Course name: Industrial Training

Industrial Training Report on Bheramara 410 MW

Combined Cycle Power Plant

Submitted by: Submitted to:

Md. Sajeed -ur- Rahman
Roll: 1801072 Tasnim Sarkar Joyeeta
Section: B Lecturer
Department: Electrical and Department of Electrical and
Electronic Engineering Electronic Engineering

Date of Submission: 12/ 06 /2023

 ACKNOWLEDGEMENT

Industrial training provides students the opportunity to test their interest in a particular zone
and also provides students a moderate level of practical knowledge. It was a great privilege for
the graduating students, us, to attend the Industrial Training course introduced by the
Department of EEE, Rajshahi University of Engineering & Technology (RUET) at Bheramara
410 MW Combined Cycle Power Plant to have a clear view of the operation of power plants
as well as professional life in power sector of Bangladesh. The Industrial Training course
which included theoretical and practical visit classes. We, a team of 11 members attended the
training program. We gained practical knowledge about power plants and observed the
operating system of power plants. There we also got the knowledge of power distribution and
maintenance of that plant. We got a chance to visit steam power plant, gas engine power plant,
substation, water management plant and other auxiliary components of power station. We
gathered practical experience about different major components of power station such as gas
turbine, steam turbine, operation and control unit, cooling system and maintenance procedures
of the plants. We gathered practical knowledge about different types of equipment used in the
substation of the plant such as power transformers, instrument transformers, circuit breakers,
relays, lightning arresters, bus bar, and transmission and distribution system. We learnt about
the water management system. Inside the report I have described about my experiences at
Bheramara 410 MW Combined Cycle Power Plant.

I am deeply grateful and humble to my respected supervisor, Tasnim Sarkar Joyeeta

, Lecturer, Department of Electrical and Electronic Engineering, Rajshahi University of
Engineering & Technology for her guidance, encouragement and kind consideration in many
ways regarding this industrial attachment.

1
 OBJECTIVES
The prime purpose of the training was to merge our academic knowledge with the practical
knowledge of power station. This program was taken to fulfill our academic requirement. We
chose a power plant for this industrial training for a close observation of a power plant and
application of our academic knowledge in practical field. In this training, the main focus was on
generation system, transmission process and maintenance of Bheramara 410 MW Combined Cycle
Power Plant to get a complete overview. The objectives were:

❖ To gather practical knowledge of a real power plant.

❖ To become familiar with the various equipment and devices that are used in power plant.
❖ To know about generation system of electricity.
❖ To get familiar with corporate life.
❖ To become introduced with practical generation and transmission system.
❖ To compare the theoretical knowledge gained with the practical one.
❖ To get an overview of a real electrical power generating plant.

Contents

Acknowledgement 1
Objectives 2
Contents 2-5

Chapter 1 Introduction 6
1.1 Introduction 6
1.2 Introduction to Bheramara 410 MW CCPP 6-7
1.3 Plant Overview 7-8

Chapter 2 Schematic Arrangement of CCPP 8

2.1 Different Section of CCPP 8-9
2.2 Short Description 9

2
 2.3 Schematic Arrangement of CCPP 10

Chapter 3 Gas Turbine Plant 10

3.1 Gas Booster Compressor 10-11
3.2 Turbine Cooling Air Optimization 11-12
3.3 Gas Turbine 12
3.4 Compressor 12
3.5 Combustor 13
3.6 Turbine 13

Chapter 4 Water Treatment Plant 14

4.1 Water Treatment Plant 14
4.2 Makeup Water Intake 15
4.3 Coagulation and Clarification 15-16
4.4 Filtration and Ultra-filtration 16-17
4.5 Ion Exchange Softening 17
4.6 De-alkalization 17-18
4.7 Demineralization 18
4.8 Remove Osmosis and Nano-filtration 19
4.9 Demineralization Water Tank 19-20

Chapter 5 Steam Turbine Plant 20

5.1 Introduction to Boiler 20-21
5.2 Parts of Boiler 21
5.2.1 Furnace 21-22
5.2.2 Feed Water Pump 22
5.2.3 Steam Separator 22-23
5.2.4 Steam Drum 23-25

3
 5.2.5 Super Heater 25-26
5.2.6 Economizer 26
5.2.7 De-aerator 26
5.2.8 Chimney 26-27
5.3 Heat Recovery Steam Generator 27-28
5.4 Steam Turbine 28
5.4.1 High Pressure Cylinder 29
5.4.2 Intermediate Pressure Cylinder 29
5.4.3 Low Pressure Cylinder 29

Chapter 6 Generator 29
6.1 Introduction to Generator 29-30
6.2 Gas and Steam Turbine Generator 30-31
6.3 Main Components of Generator 31-32
6.3.1 Stator 32
6.3.2 Rotor 32
6.3.3 Armature Winding 32
6.3.4 Carbon Brush 32
6.3.5 Slip Ring 32
6.4 Excitation System of the Generator 33
6.5 Generator Protection System 33
6.5.1 Over Current and Under Voltage Protection System 33
6.5.2 Over Speed Protection System 34
6.5.3 Temperature Protection System 34
6.5.4 Over Voltage Protection System 34
6.6 Generator Cooling System 34
6.6.1 Water Cooling 34
6.6.2 Hydrogen Cooling 35

4
 6.7 Control Room 35-36

Chapter 7 Cooling Unit 36

7.1 The Cooling Tower 36-37

Chapter 8 Sub Station 37

8.1 Introduction to Sub-Station 37-38
8.2 Objectives of Sub-Station 38-39
8.3 Familiarization with the Apparatus of Sub-Station 39
8.4 Power Transformer 39-40
8.5 Bushing 40-41
8.6 Cooling System of Power Transformer 41-42
8.7 Tap Changer 42
8.8 Conservator 42-43
8.9 De-hydrating Breather 43-44
8.10 Auxiliary Transformer 44-45
8.11 Instrument Transformer 45-46
8.12 Bus Bar 47
8.13 Protection Devices of the Plant 47-56

Chapter 9 Switchgear and Protection 57

9.1 Introduction to Switch Gear 57
9.2 Protection Relays 58
9.3 Fire Protection 58
9.4 Control Panel 59
9.5 UPS Panel 59-60
9.6 Safety Rules 61
Chapter 10 Conclusion 62

5
 Chapter 1
Introduction

1.1 Introduction
Power stations are the stations where bulk electric power is generated. Alternators are used to
produce electrical power where a prime mover (e.g., diesel engine, steam turbine, water turbine
etc.) is coupled with each alternator to produce mechanical energy for the rotation of the rotor of
the alternator.

Figure 1.1: Simple block diagram of power generation

While designing a power station two important factors should be considered. The first one is the
necessary power generating equipment should be selected and placed in such a way that maximum
of return will result from minimum expenditure over the working life of the station or plant. The
second one is the plant operation will be such so as to provide cheap, reliable and continuous
service.

1.2 Introduction to Bheramara 410 MW CCPP

Bheramara 410 MW Combined Cycle Power Plant which is a 410 MW dual fuel fired power
project. It is located in Bahirchar, Bheramara, Kushtia Bangladesh. Post completion of
construction in March 2017. The project is developed and owned by North West Power
Generation Company Limited. It is a Combined Cycle Gas Turbine (CCGT) power plant that is
used for Baseload. The power plant run on dual fuel. The primary fuel being used to power plant
is natural gas. In case of shortage of natural gas the plant can also run on High Speed Diesel Oil.
The fuel is procured from Sundarbans Gas Company Limited.
The plant is located at Bahirchar union of Bheramara upazila under the Kushtia district in the
western sector of Bangladesh. The Pabna-Kushtia highway has gone aside the power plant.
Moreover the plant is situated on the bank of river Padma. There is also good railway connection.
The Bheramara Railway Station is connection with both Khulna and Rajshahi Divisional city
through railway.

Fig.1.1. Location of Bheramara 410 MW CCPP

1.3 Plant Overview
The following table shows an over view about Bheramara 410 MW CCPP:
Power Plant location Bahirchar, Bheramara, Kushtia
Executive Agency North West Power Generation Company
Limited (An Enterprise of Bangladesh Power
Development Board)
EPC Contractor M/s. Marubeni Corporation Japan
Financer GOB & JICA
EPC Contract Signing Date 16/03/2014
Manufacture of GT & ST Mitsubishi Hitachi Power System (MHPS)
Fuel Type Duel Fuel (Natural Gas + HSD)
Generation Capacity 410 MW
Commercial operation Date 09/05/2017 (Simple Cycle)
14/12/2017 (Combined Cycle)
ISO Certification ISO 9001: 2015, ISO 14001:2015 & ISO
45001:2018 Certified
Number of units Single Unit

Speed of Engine 3000 rpm

Power Factor 0.8 lagging

Operating Frequency 50 Hz

Service Voltage 230 KV, 132KV (Transmission)

Number of Substation 2
 Fig.1.2. Plant Overview

Chapter 2
Schematic Arrangement of CCPP

2.1 Different Section of CCPP

Combined Cycle Power Plant consists of different sections which are listed below:
❖ Gas Turbine Plant
❖ Fuel supply system
❖ Hear Recovery Steam Generation (HRSG)
 ❖ Steam turbine plant
❖ Water Treatment Plant
❖ Cooling Unit
❖ Control Room
❖ Protection System

2.2 Short Description

The whole power generation process starts when natural gas enters into the Gas Booster
Compressor and meanwhile air from atmosphere is sucked into the Air Filter. At the Gas Booster
Compressor, pressure of the natural gas increases from 3-7 bar to 33-40 bar and at the filter, the
air is filtrated. Then the fuel enters into TCA Cooler where its temperature increases before
entering Combustor and the air enters into Gas Turbine after getting compressed in the
Compressor. The fuel is burned and a large amount of heat is produced which is used by the air to
rotate turbine blades. As the gas turbine works as the prime mover of the alternator, so there
produces voltage in the alternator which is in amount of 18 kV. Then at the switchyard, the
generated voltage is stepped up at 138 kV with the help of transformer and supplied to the PGCB
substation.
The flue gases are passed through the HRSG to recover the heat energy and using the heat energy
steam is produced. This steam rotates the steam turbine and the alternator coupled with it produces
voltage of 14.5 kV. Then at the switchyard, the generated voltage is stepped up at 138 kV with
the help of transformer and supplied to the PGCB Substation. The water is needed for producing
steam is supplied from DM Plant or water treatment plant and cooling tower. Water treatment
plant purifies the water and cooling tower cools down the wet steam from the turbine. The total
plant is monitored and operated from Central Control Room and the electrical equipment are
protected by the switchgear.
The whole station needs 17 MW power each day which is taken from the generated power of the
station using Unit Auxiliary Transformer. If somehow the station is tripped, the station takes
power from national grid using Stationery Auxiliary Transformer.
2.3 Schematic Arrangement of CCPP

Air Air Filter Chimney

Gas Booster TCA Gas Turbine Alternator Switchyard

Compressor
Flue
gases
Chimney

HGRS Steam Alternator

Turbine

Switchyard
DM Plant Cooling
Tower

Fig.2.1. Schematic Arrangement of CCPP

 Chapter 3
Gas Turbine Plant

Introduction:

Gas turbine works on the principle of Brayton cycle. The Brayton cycle is a thermodynamic
cycle that describes the operation of certain heat engines that have air or some other gas as
their working fluid.

• 1-2 Isentropic compression (in a compressor)

• 2-3 Constant pressure heat addition
• 3-4 Isentropic expansion (in a turbine)
• 4-1 Constant pressure heat rejection

Fig 3.1 : Brayton cycle

3.1 Gas Booster Compressor
A gas compressor is a mechanical device that increases the pressure of a gas by reducing its
volume. Compressors are similar to pumps. A fuel gas boosting compressor supplies gas for gas
turbine power plants. If the gas compressor fails, the gas turbine power plant stops entirely.

Compressors are critically important for reliable gas turbine power plant operation. At the same
time, the demands on compressors have been increasing because gas turbines require higher fuel
gas pressures to achieve increased performance efficiency and because pipeline pressures fluctuate
due to increased overall and peak demand requirements. Therefore, selecting the correct type of
fuel gas compressor is one of the most important factors in achieving successful plant operation.
 Fig.3.2. Gas Booster Plant

Gas turbines require a certain pressure of fuel gas to combine the fuel gas and pressurized air before
combustion. At Bheramara 410 MW CCPP, gas booster compressor increases the pressure of fuel
gas from 3-7 bar to 37-40 bar. If the fuel pressure falls below 33 bar, the station will trip. So, gas
booster compressor is an important factor in a generating station.
There have three gas booster compressor denoted by GBC-1, GBC-2,GBC-3. The fuel gas
compression is done using two units of the gas booster compressor and one unit is instandby.

3.1 Turbine Cooling Air Optimization

Turbine Cooling Air Optimization improves the performance of gas turbines in power plants. It
improves the power generation efficiency of air-cooled gas turbines through control of the turbine
cooling air fans to optimize the rotor cooling air temperature. It can lower the temperature of
discharge air from the compressor outlet using a fan and heat exchanger. This cooled air lowers
the temperature of the turbine blades and rotor. In most cases, the fuel gas temperature is controlled
to reach a set temperature, unlike the RCA temperature.
 Fig.3.3. Turbine Cooling Air Optimizer

This means that the excessive cooling could adversely affect gas turbine performance during low
ambient temperatures in winter months or partial load operation times. Switching the turbine
cooling air optimizer fan to inverter control and optimizing the RCA temperature is a shortcut to
improving power generation efficiency.

3.2 Gas Turbine

A gas turbine is a combustion engine at the heart of a power plant that can convert natural gas or
other liquid fuels to mechanical energy. This energy then drives a alternator that produces the
electrical energy that moves along power lines to homes and businesses. It consists of three main
parts which are-

• Compressor
• Combustor
• Turbine

3.3 Compressor

The compressor used in the plant is generally of rotatory type. The air at atmospheric pressure is
drawn by the compressor via the filter which removes the dust from air. The rotatory blades of the
compressor push the air between stationary blades to raise its pressure. Thus, air at high pressure
is available at the output of the compressor.
3.4 Combustor

The air at high pressure from the compressor is led to the combustion chamber via the regenerator.
In the combustion chamber, heat is added to the air by burning oil. The oil is injected through the
burner into the chamber at high pressure to ensure atomization of oil and its thorough mixing with
air. The result is that the chamber attains a very high temperature (about 3000°F). The combustion
gases are suitably cooled to 1300˚F to 1500˚F and then delivered to the gas turbine.

3.1 Turbine

The products of combustion consisting of a mixture of gases at high temperature and pressure are
passed to the gas turbine. These gases in passing over the turbine blades expand and thus do the
mechanical work. The temperature of the exhaust gases from the turbine is about 900˚F. In an ideal
gas turbine, gases undergo four thermodynamic process: an isentropic compression, an isobaric
combustion, an isentropic expansion and heat rejection.

Fig.3.3. A photograph of Gas Turbine

Heat is added in the combustion chamber and specific volume of the gas increases, accompanied
by a slight loss in pressure. During expansion through the stator and rotor passages in the turbine,
irreversible energy transformation once again occurs. Fresh air is taken in, in place of the heat
rejection.
 Chapter 4
Water Treatment Plant

4.1 Water Treatment Plant

Water treatment plant processes the water to be used in the proper form to ensure longevity and
safety of the equipment. Water treatment is very important for power plants. Chemical composition
of underground raw water or river water is very harmful for metals. To increase the durability of
pipe and boiler, water needs to be dematerialized in water treatment unit.
In a power plant water is used as steam. Boiler generates steam. If water is used in boiler without
any treatment then boiling temperature of water will increase because of impurities present in it.
This will increase the cost of burning process. Untreated water contains different minerals which
can create sludge or scale inside boiler and steam pipe. This can damage boiler and create an
obstacle to flow of steam. Treated water is also used for engine cooling. Dematerialized water
cools engines without making corrosion.
A boiler feed water treatment system might be made up of the technologies necessary to remove
problematic dissolved solids, suspended solids, and organic material, including any number of the
following:
Iron: either soluble or insoluble, iron can deposit on boiler parts and tubes, damage downstream
equipment, and affect the quality of certain manufacturing processes.
Copper: can cause deposits to settle in high-pressure turbines, decreasing their efficiency and
requiring costly cleaning or equipment change-outs.
Silica: if not removed to low levels, especially in high-pressure boilers, silica can cause extremely
hard scaling.
Calcium: can cause scaling in several forms depending on the chemistry of the boiler feed water
(e.g. calcium silicate, calcium phosphate, etc.).
Magnesium: if combined with phosphate, magnesium can stick to the interior of the boiler and
coat tubes, attracting more solids and contributing to scale.
Aluminum: deposits as scale on the boiler interior and can react with silica to increase the
likelihood of scaling
Hardness: also causes deposits and scale on boiler parts and piping.
Dissolved gasses: chemical reactions due to the presence of dissolved gases such as oxygen and
carbon dioxide can cause severe corrosion on boiler pipes and parts.
4.2 Makeup Water Intake
Makeup water, or water replacing evaporated or leaked water from the boiler, is first drawn from
its source, whether raw water, city water, city treated effluent, in plant wastewater recycle (cooling
tower blowdown recycle) well water, or any other surface water source. Here in Bheramara 410
MW CCPP most of the time, water is collected from ground. The condensed water of cooling
tower is recycled for further use. In monsoon season, the Padma river water level rises. At that
time, water is collected from the river.

Fig.4.1. A Photograph of Water Intake

4.3 Coagulation and Clarification

After all the large objects are removed from the original water source, various chemicals are added
to a reaction tank to remove the bulk suspended solids and other various contaminants. This
process starts off with an assortment of mixing reactors, typically one or two reactors that add
specific chemicals to take out all the finer particles in the water by combining them into heavier
particles that settle out.
 Fig.4.2. A Clarifier Tank
The most widely used coagulates are aluminum based such as alum and poly-aluminum chloride.
Here the raw water is mixed with 𝐴𝑙2S𝑂4. The sludge deposited in a tank and the clarified water
is stored in a coagulated tank. By using clarification 70% of un-dissolved solid from water is
removed. The chemical reaction is
𝐴𝑙2S𝑂4+ Clay(𝐻2O)→Al(𝑂𝐻)2.
Sometimes a slight pH adjustment will help coagulate the particles as well.

4.4 Filtration and Ultrafiltration

The next step is generally running through some type of filtration to remove any suspended
particles such as sediment, turbidity and certain types of organic matter.
It is often useful to do this early on this process, as the removal of suspended solid upstream can
help protect membranes and iron exchange resins from fouling later on the pretreatment process.
Depending on the type of filtration used, suspended particles can be removed down to under one
micron.
 Fig.4.3. A Photograph of Ultra Filtration

4.5 Ion exchange softening

When pretreating boiler feed water, if there’s high hardness complexed with bicarbonates, sulfates,
chlorides or nitrates, a softening resin can be used. This procedure uses a strong acid cation
exchange process, whereby resin is charged with a sodium ion and as the hardness comes through,
it has a higher affinity for calcium, magnesium and iron so it will grab that molecule and release
the sodium molecule into the water.

4.6 De-alkalization
After the softness process, some boiler feed water treatment systems will utilize de-alkalization to
reduce alkalinity/ph, an impunity in boiler feed water that can cause foaming, corrosion and
embrittlement. Sodium chloride de-alkalization uses a strong anion exchange resign to replace
bicarbonate, sulfate and nitrate for chloride anions. Although it doesn’t remove alkalinity 100
percent, it does remove majority of it with what can be an easy to implement and economic process.
Weak acid de-alkalization only removes cations bound to bicarbonate, converting it to carbon
dioxide. It is a partial softening process that is also economical for adjusting the boiler feed water
pH.
 Fig.4.4. Ion exchanging and De-alkalization

4.7 Demineralization
Demineralization is the process of removing mineral salts from water by using ion exchange
process. Demineralized water is also known as deionized water with removed mineral ions.
Mineral ions such as cat-ions of sodium, calcium, iron, copper etc. and anions such as chloride,
sulfate, nitrate etc. are common ions present in water. This deionized exchanger resin, these cat-
ions are caught by following reactions
R-𝐻2 + Ca(𝐻𝐶𝑂3)2 → R-Ca + 2𝐻2C𝑂3
R-𝐻2 + MgS𝑂4 → R-Mg + 𝐻2𝑆𝑂4
R-H + NaCl → 𝑅-Na + HCl
This water also contains negative ions like 𝐶𝑙−, 𝑆𝑂2−, 𝑁𝑂2−. When passing this water through
4 3
anion exchanger resin, these anions are caught by following reactions.
R-(𝑂𝐻)2+ 𝐻2𝑆𝑂4 → R-𝑆𝑂4 + 2𝐻2O
R-OH + HCl → R-Cl + 𝐻2O
This demi water is stored in demi tank. Then this water is used for producing steam.
4.8 Remove Osmosis and Nano-filtration
Reverse osmosis and nano-filtration are often used down the line in the boiler feed water treatment
system process so most of the harmful impunities that can foul and clog the RO/NF membranes
have been removed.

Fig.4.5. A Photograph of HCl Acid Plant

Similar processes of separation, they both force pressurize water through semipermeable
membrane, tapping contaminants such as bacteria, salts, organics, silica and hardness while
allowing concentrated purified water through. Not always required in boiler feed water treatment,
these filtration units are used mostly with high pressure boilers where concentration of suspended
and dissolved solid needs to be extremely low.

4.9 Demineralized water tank

After all the treatments performed, demineralized water is reserved in the plant for supplying to
boiler in future.
 Fig.4.6. A photograph of Demi water tank

Chapter 5
Steam Turbine Plant

5.1 Introduction to Boiler

A boiler is a closed vessel in which water or other fluid is heated to produce steam in high
temperature and pressure. The boilers make sure that the turbine is receiving the steam in such a
condition required by the turbine itself to meet its rated capacity.
The boiler system was adopted to raise the steam and make it suitable to drive the turbine which
in turn drives an alternator to generate electricity. The whole system is operated with a number of
parts. The direction of flow of the water and steam through these various parts is maintained
through different valves.
Boilers are engaged in producing steam by recovering the heat from the exhaust gas. The boilers
make sure that the turbine is receiving the steam in such a condition required by the turbine itself
to meet its rated capacity. There is only one kind of boiler in Bheramara 410 MW CCPP and it is
exhaust gas boilers. Exhaust gas boilers are always in operation. At emergency situation when
there is gas crisis, oil is burned instead of gas. The flue gas of the burning oil is used at the
emergency situation.
 Fig.5.1. A Photograph of Steam Generator

5.2 Operation principle

The Rankine cycle, also called the Rankine vapor cycle, is a thermodynamic cycle that converts heat into
mechanical energy.

Fig 5.2. Rankine Cycle

• Pump: Compression of the fluid to high pressure using a pump (this takes work)
• Boiler: The compressed fluid is heated to the final temperature (which is at boiling point), therefore,
a phase change occurs—from liquid to vapor
• Turbine: Expansion of the vapor in the turbine.
• Condenser: Condensation of the vapor in the condenser (where the waste heat goes to the final heat
sink (the atmosphere or a large body of water (ex. lake or river).
1. The high pressurized gas was fed into the boiler where the gas was burnt into the furnace
2. Due to heat from the furnace, the water present in the boiler drum was changed to the high-
pressure steam.
3. From the boiler this high-pressure steam was passed to the super heater where this was again
heated up to its dryness.
4. After that this superheated steam struck the turbine blades with a high speed and the turbine
blades started rotating to at high speed. Here the stored potential energy of the steam was gets
converted into mechanical energy.
5. A generator was coupled with the turbine rotor. As the turbine was being rotated with the help
of highly pressurized steam, the generator also rotated with same speed and mechanical energy of
the turbinewas converted into electrical energy.
6. After the hitting of the turbines blades most of the energy was lost which was used to rotate the
turbineand the steam was left the turbine with low pressure.
7. Then this low-pressure steam was being entered into the condenser. Where Cold water was
necessaryto be circulated in the condenser from the cooling tower and the low-pressure wet steam
was being converted into water during the process.
8. On the other hand, condensed water with the feed water was passed to the economizer where it
was heated up by the economizer. And finally, the feed water had been entered into the boiler by a
feed waterpump and the cycle was repeated.
9. The burnt flue gases from the furnace was being passed through the superheater, economizer
and air pre-heater. This heat of the flue gases was used again to heat the steam in the super heater
to its dryness, to heat feed water in the economier before entering into the boiler and to heat air
form the atmosphere inthe air pre-heater before it enters into the furnace.
10. These processes was being continued to produce required power from the stream turbine.

5.2 Parts of Boiler

➢ Furnace
➢ Feed water pump
➢ Steam drum
➢ Super Heater
➢ Economizer
➢ De-aerator
➢ Chimney

In Bheramara, there are three water tube boilers to generate steam for the power plant. The water
is treated in the water treatment plant and the treated water is passed to the boiler and converts into
steam. The steam is collected into the steam drum which is a part of the boiler.

5.2.1 Furnace
The purpose of furnace is to attain a higher processing temperature in comparison to open-air
systems, as well as the efficiency gains of a closed system. Here, with the presence of air the
natural gas is burned to produce heated gas or flue gas. The ratio of gas and air is 1:14. . Draft fan
is used to supply the air into the furnace. Finally the saturated steam from the furnace goes to the
boiler drum.

In Bheramara 410 MW CCPP, every furnace chamber has twelve burners. Inside the chamber the
temperature is 15000˚C to 18000˚C. The treated water from the feed water tank enters into the
furnace through tube stand flue gas produced inside the furnace. The flue gas releases heat to the
water as a result water becomes saturated steam. Saturated steam temperature is about 350°C.

5.2.2 Feed Water Pump

To control the flow of water from feed water tank to steam drums or economizer, there are two
feed water pumps. Water flows in two directions from feed water tank. One is from feed water
tank to low pressure drum and another is from feed water tank to the economizer of the boiler.
Pumping is required for each flow. Feed pumps are used to draw water from deaerator and supply
them to high pressure heater. They are-
❖ Motor driven
❖ Multi-stage centrifugal pumps
 Fig.5.2. A Photograph of Water Pump

5.2.3 Steam Separator

In boiler drum cyclone separators are used to separate steam particles from water. Cyclones are
mostly used for removing industrials dust from air or process gases. They are the principal type of
gas-solid separator. Most common form of particulate removal gas is spun rapidly-heavier
particulate matter to collect on outside of separator by centrifugal force, where it is collected and
removed.
As with centrifugation, the driving force behind cyclone separation is centrifugal force and the
difference in specific gravity between the particle (water particle) and the carrier gas (steam). In a
Cyclone, the air or vapor containing particulate material is forced into along the tangential axis. A
helical flow pattern is set up within the chamber. The centrifugal force causes the particles to
migrate to the outside of the chamber. Here they fall down to the bottom of the cyclone by gravity.
The air moves up the center of the cyclone and reaches the top.
5.2.4 Steam Drum
Steam drum is a reservoir of water or steam at the top end of the water tubes. The drum stores the
steam generated in the water tubes and acts as a phase-separator for the steam/water mixture. There
are three types of steam drum:
1. Low Pressure Drum
2. Intermediate Pressure Drum
3. High Pressure Drum

Low Pressure Drum

There is a low pressure drum where the water of low pressure is stored coming from feed water
tank. The pressure is around 7 bar at LP Drum. The water is then transferred to the low pressure
evaporator of Boiler through some valves. The steam produced in LP Evaporator is then transferred
to the LP Drum. The low pressured steam of 190 degree Celsius is transferred to places where low
pressure steam consumption is necessary.

Fig.5.3. Low Pressure Drum

Intermediate Pressure Drum
There is a intermediate pressure drum where the water of moderate pressure is stored coming from
the low pressure drum. The water is then transferred to moderate pressure evaporator of boiler
through some valves. The steam produced in IP evaporator is then transferred to IP drum. The
moderate pressure steam of around 250 degree Celsius is transferred to places where moderate
pressure steam consumption is necessary.

Fig. 5.4. Intermediate Pressure Drum

High Pressure Drum

This is a type of steam drum where steam of high pressure is stored and supplied. The steam from
economizer is stored at HP Drum firstly and then it is transferred to the high pressure evaporator
of boiler through valves. Then the steam of increased temperature is again stored into HP Drum
and then again transferred into super heater in the Boiler. The extremely heated steam from super
heater is again stored in HP drum and then transferred to the header to be supplied to the turbine.
x

Fig.5.5. High Pressure Drum

5.2.5 Super Heater

This section increases the temperature of steam to 265 degree Celsius to remove any remaining
water and feed to the High pressure drum through the highest positioned way. A line is available
below to take back some of the steam back to super heater for perfect heating. When steam has no
water it is called saturated heated steam. The super heated steam’s main purpose is to increase the
temperature of saturated steam without raising its pressure.
At Bheramara 410 MW CCPP, temperature of the super-heated steam inside the super heater is
about 540°C. There are three super heaters inside the boiler section of every steam power plant of
Bheramara. There are bundles of tubes inside the super heater which carries the saturated steam
and the flue gas passes around these tubes. The flue gas releases heat when it passes around the
tubes and the saturated steam receive the heat and becomes dry.

Types of super heater in Bheramara:

➢ Ceiling super heater
➢ Radiant super heater
➢ Platen super heater
➢ High pressure convective super heater 1st stage.
➢ High pressure convective super heater 2nd stage.
➢ Low pressure convective super heater 1st stage.
➢ Low pressure convective super heater 2nd stage.
5.2.6 Economizer
Function of economizer is to recover some of the heat which is carried away by the flue gas. The
recovered heat is utilized to raise the temperature of feed water. Then the feed water at raised
temperature is supplied to the boiler. If the feed water at raised temperature is supplied to the boiler,
it needs less heat to convert the water into steam. Recovery heat from flue gas raise feed water
temperature up to 345°C. Economizer is used to save the consumption of fuel. Flue gas
temperature before economizer 545-5500 degree Celsius.

➢ Feed water temperature at inlet of economizer 235-245 degree Celsius (With HPH)
➢ Feed water temperature at outlet of economizer 345 degree Celsius (With HPH)

5.2.7 De-aerator
De-aerator is a device which is used to remove air and other dissolved gases from the feed water
to steam generating boilers. The metal piping and other metallic equipment is damaging because
of dissolved oxygen in boiler. It increases the efficiency and optimum thermodynamic utilization.
So de-aerator is used in Bheramara to keep safe of the equipment.

5.2.8 Chimney
A chimney is a structure which provides ventilation for hot flue gases or smoke from a boiler to
outside atmosphere. Furnace produces flue gas. This flue gas is used to create the steam for rotating
the turbine. The flue gas passes through several numbers of equipment and finally goes into the
nature through chimney. In Bheramara, there are two chimney. One is for gas turbine and the
another is for steam turbine.

Fig.5.6. A Photograph of Chimney

5.3 Heat Recovery Steam Generator (HRSG)
The HRSG is basically a heat exchanger, or rather a series of heat exchangers. It is also called a
boiler, as it creates steam for the steam turbine by passing the hot exhaust gas flow from a gas
turbine or combustion engine through banks of heat exchanger tubes. After burning of gas fuel in
combuster and heat is used in gas turbine. This gas has high temperature. This high temperature
gas is used to produce steam and this steam is then used in steam turbine. Modular HRSG can be
categorized by a number of ways such as direction of exhaust gases flow or number of pressure
levels. Based on the flow of exhaust gases, HRSGs are categorized into vertical and horizontal
types. In horizontal type HRSGs, exhaust gas flows horizontally over vertical tubes whereas in
vertical type HRSGs, exhaust gas flow vertically over horizontal tubes.

Based on pressure levels, HRSGs can be categorized into single pressure and multi pressure. Single
pressure HRSGs have only one steam drum and steam is generated at single pressure level whereas
multi pressure HRSGs employ two (double pressure) or three (triple pressure) steam drum. Each
section has a steam drum and an evaporator section where water is converted to steam. This steam
then passes through super heaters to raise the temperature beyond the saturation point. The HRSG
can rely on natural circulation or utilize forced circulation using pumps. As the hot exhaust gases
flow past the heat exchanger tubes in which hot water circulates, heat is absorbed causing the
creation of steam in the tubes. The tubes are arranged in sections, or modules, each serving a
different function in the production of dry superheated steam. These modules are referred to as
economizers, evaporators, super heaters/re-heaters and preheaters.
 Fig.5.7 A photograph of HRSG

The superheated steam produced by the HRSG is supply to the steam turbine where it expands
through the turbine blades, imparting rotation to the turbine shaft. The energy delivered to the
generator drive shaft is converted into electricity. After exiting the steam turbine, the steam is sent
to a condenser which routes the condensed water back to the HRSG.

5.4 Steam Turbine

Steam turbine power plant uses steam to move the turbine. In Bheramara 410 MW CCPP, steam
is used to move turbine so it is a steam turbine power plant. Steam turbine is the device which is
used to convert thermal energy to mechanical energy. The turbine mainly consists of rotor and
stator blades. The steam expands from high pressure to lower pressure in blades and this steam
applies force across these blades, as a result turbine rotor begins to rotate. So the thermal energy
transforms into mechanical energy.

The steam turbines used in Bheramara 410 MW CCPP have three different sections. The size and
characteristics of the blades of the turbines in these sections are different from each other. These
are:
➢ High pressure cylinder (HPC)
➢ Intermediate pressure cylinder (IPC)
➢ Low pressure cylinder (LPC)
5.4.1 High Pressure Cylinder

High Pressure Cylinder from the super heater, steam with 130 kg/cm2 pressure and 540ºC
temperature first enters the high pressure turbine and then hits the high pressure turbine blades.
The high pressure turbine has 12 stages with moving and fixed blades. After completing twelve
stages, the temperature of steam falls to 332ºC and pressure 28 kg/cm2. Steam again goes to super
heater to gain heat.

5.4.2 Intermediate Pressure Cylinder

From the re-heater steam goes to the intermediate pressure cylinder. This cylinder has eleven
stages. Here, steam pressure is 25 kg/cm2 and the temperature is 540ºC. If the temperature falls
below 440ºC or raise above 540ºC then the intermediate pressure cylinder (IPC) valve will trip and
the steam will go to the boiler for gaining more heat. After completing eleven stages, the
temperature of steam falls to 171ºC and pressure 1.34 kg/cm2.

5.4.3 Low Pressure Cylinder

From the intermediate pressure cylinder, steam enters the low pressure cylinder and continues its
expansion. Here, the pressure is about 1.34 kg/cm2 and the temperature is about 171ºC. In low
pressure cylinder blades are larger than the previous two sections but the energy of steam is less
than the previous two sections. In LPC, steam temperature at 171ºC and pressure 1.34 kg/cm2
flows from the turbine. The low pressure turbine is coupled with the generator at Bheramara. In
low pressure cylinder, the steam losses their all energy and goes to the condenser.

Chapter 6
Generator

6.1 Introduction to Generator

Generator converts mechanical energy to electrical energy. AC generator is also known as
alternator. Depending on power generating capacity, there are two types of generator in
Bheramara. These are 180 MW gas turbine generators and 140.5 MW steam turbine generators.
The ratings of gas turbine generator and steam turbine generators are shown in the following table.

6.2 Gas Turbine Generator

Fig.6.1. Gas Turbine Generator

Rating Table of Gas Turbine Generator

Type MBH Phase connection Y(star)
KV 18 Rotor voltage 18000 V
Power factor 0.80 Rotor current 13311 A
Frequency 50 HZ Excitation voltage 450 V
RPM 3000 Field current 3170 A
Number of Phase 3 Direction of rotation Counter clockwise
Steam Turbine Generator

Fig.6.2. Steam Turbine Generator

Rating Table of Steam Turbine Generator

Type MB Phase connection Y(star)
KV 14.5 Rotor voltage 14500 V
Power factor 0.80 Rotor current 7486 A
Frequency 50 HZ Excitation voltage 295 V
RPM 3000 Field current 1280 A
Number of Phase 3 Direction of rotation Counter clockwise

6.3 Main Components of Generator

The generator consists of different components. The major components are discussed below:
➢ Stator
➢ Rotor
➢ Carbon Brush
➢ Slip ring
➢ Armature Winding
 ➢ Excitation System of the Generator
➢ AC or DC Excitation

6.3.1 Stator
The stator is the stationary part of a generator. It contains either an electromagnet or a permanent
magnet. In Bheramara Power Station, we saw electromagnet type stator. This electromagnet stator
contains wire winding. A moving magnetic field which is generated by the rotor around the stator
induced a voltage difference between the windings of the stator and it produces alternating current
as output of the generator.

6.3.2 Rotor
The rotor is the rotating part of a generator. In this generator, rotor is an electromagnet. Coil
energizes the rotor and makes it an electromagnet. The coil that energies the rotor is known as the
field coil. At Bheramara, the rotor is used as the field exciter and the rotor is driven by the generator
prime mover.

6.3.3 Armature Winding

The armature winding is a part of a stator. It is the main current-carrying winding in which the
electromotive force or counter electromotive force of rotation is induced. The current in the
armature winding is known as the armature current.

6.3.4 Carbon Brush

Carbon brush supplies power to the slip ring. Carbon brush always remains in contract with the
slip ring and provide power to the rotor. For two slip rings in the generator, there are two carbon
brushes in the generator. The combination of slip rings and carbon brush provide power to the
rotor and make the rotor an electromagnet. Graphite or carbon powder is commonly used for
manufacturing of carbon brush.

6.3.5 Slip Ring

A slip ring is used in any electromechanical system that requires rotation while transmitting power.
Slip ring allows the transmission of electrical power from a stationary part to a rotating structure.
The Slip ring is connected to the rotor to allow the supply of the power to the rotor.
6.4 Excitation System of the Generator
Exciter or Excitation is very important for the generator. Excitation is the process by which
magnetic field is created. DC or direct current magnetic field is the excitation system for
generators. DC power supply is needed to create this magnetic field.

Fig.6.3. Turning Gear Motor

6.5 Generator Protection System

Different electrical and mechanical faults can affect the performance of the generator. To protect
the generators from those faults different electrical and mechanical protections are required.
Immediate shutdown or alarming occurs if any fault is found.

6.5.1 Over Current and Under Voltage Protection

In grid system more than one generators supply the load and if for any reason one or more
generators suddenly trip, other generators try to supply the load and each of these generators will
experience a sudden increase in current and thus decrease in voltage. In Bheramara, automatic
voltage regulator is connected to the system which tries to restore the voltage. Under voltage relay
is also used for the under voltage protection. In Bheramara, over current relay is used for over
current protection. To construct this relay only current coil is needed, there is no need of voltage
coil.
6.5.2 Over Speed Protection
Over speed protection is generally provided for prime mover driven generators. Prime mover is
the part that rotates the rotor of the generator. In Bheramara, a steam turbine works as a prime
mover. If the prime mover speed increases then the generator frequency increases. The speed
governor normally controls the speed of the rotor. If any abnormality exists, it trips the circuit
breaker of the generator.

6.5.3 Temperature Protection

Temperature protection is needed to protect the generator from overheating. Overheating is caused
due to overload in grid system or failure in cooling system. It could cause serious damage to the
generator. To protect the stator against overheating, embedded resistance temperature detector or
thermocouples are used. In Bheramara, thermocouple is used to detect the temperature. When it
starts to overheat, the temperature change is detected and the relay operates an alarm.

6.5.4 Over Voltage Protection

Over voltage occurs due to sudden loss in the load on the generator. If suddenly load decreases
then the voltage start to rise and causes over voltage. Here, prime mover speed does not change
with the load change. The over voltage protection is provided by two over voltage relays.
Instantaneous relay operates for 130 to 150% of the rated voltage and IDMT relay operates for
110% of rated voltage

6.6 Generator Cooling System

Generator deals with very high power. So the temperature of generator rises while running. Too
much heat affects the performance and lifetime of the generator. In Bheramara, there are cooling
systems installed for the generator which absorb the temperature of the generator while it is
running.

6.6.1 Water Cooling

Water flow is used in generator for cooling purpose in steam turbine generator. This type of
cooling system is used for stator cooling. Stator is surrounded by the water. The water absorbs
heat and then carries the heat away.Water flows continuously by a motor to dissipate the heat.
 6.6.2 Hydrogen Cooling
Hydrogen cooling system is used for rotor cooling in gas turbine generator. In this system
hydrogen gas is used to dissipatethe heat from the rotor. As hydrogen gas is lighter than air, it does
less interruption with the rotatingspeed of the rotor than air. For this cooling system hydrogen gas
is supplied by a hydrogen plant. In this hydrogen plant, water is electrolyzed into hydrogen and
oxygen. Hydrogen cooling system is used in gas turbine generator because of getting high
efficiency. Hydrogen is highly combustible that’s why it is sealed by nitrogen gas.

Fig.6.4. Hydrogen Generating Plant

6.6.3 Sealing system
6.6.3.1 Nitrogen Sealing
In Gas turbine generator, H2 is used as coolant. Hydrogen is highly combustible. That’s why Nitrogen
gas is used for sealing.
6.6.3.2 Oil sealing
Some devices are oil sealed. Which also used for transferring heat
6.7 Control Room
Control room or operation center is a room serving as a central space where a large physical facility
or physically dispersed service can be monitored and controlled. In Bheramara there is only one
control room. The control room has both analog and digital controlling system. The analog system
are controlled using various switch and meters. The digital system is software based. Both systems
are shown below.
 Fig.6.7 Control Room of Bheramara 410 MW CCPP

Chapter 7
Cooling Unit

7. 1 The Cooling Tower

The cooling tower rejects waste heat to the atmosphere with the cooling water stream of a lower
temperature. When the water and air meet, a small amount of water is evaporated, creating a
cooling action. The cooled water is then pumped back to the condenser or process equipment where
it absorbs heat. It will then be pumped back to the cooling tower to be cooled once again. Cooling
tower is a very important part of the plant. It is used to keep the temperature of different equipment
low. Otherwise hazard can occur. Here in the cooling unit the water used is used repeatedly. The
water is not wasted in the unit. The water that cools down the machinery gets hot. This heat is then
transferred to the air making the water to cool down again. Then this water is used again. The
cooling tower of Bheramara 410 MW CCPP is placed just outside the engine room.
 Fig.7.1. A photograph of cooling tower

Chapter 8
Sub-Station

8.1 Introduction to Sub-station

The electrical substation is the part of a power system in which the voltage is transformed from
high voltage to low voltage or low voltage to high voltage for electrical power transmission and
distribution, frequency and power factor are controlled, ac to dc or dc to ac conversion etc. are
performed. The electricity is transmitted at very high voltages and low currents to reduce the
copper loss, eddy currents loss, and other transmission losses. At power plants the power is
generated and is transmitted to the national grid. As this transmission is long transmission so
without increasing the voltage level it will result in a huge amount of loss and also huge amount
of copper will be required to transmit the power. The generated voltage at Bheramara CCPP is for
Gas Turbine generator 18 kV and Steam Turbine generator 14.5 KV. This voltage is steeped up to
138 kV for transmission and distribution purpose. The sub-stations of our country is transformer
based and here mainly the voltage levels are changed. Here at Bheramara 410 MW CCPP, the sub-
station is also transformer based. Mainly here the voltage level is changed and besides this the
protection of the different electrical instruments are also provided here. So for any power plant
sub-station is the most needed part of the system.
 Fig.8.1. Sub-Station Of Bheramara 410 MW CCPP
There are two sub-stations in Bheramara 410 MW CCPP. One is for Gas Turbine generation, where
the voltage is being stepped up to 132 KV from 18 KV. The another is for Steam Turbine
generation, where the voltage is being stepped up to 138 KV from 14.5 KV.

8.2 Objectives of Sub-station

The main task of a sub-station is to change the voltage level. The voltage may be steeped up for
transmission system and in the same manner the voltage may be steeped down for distribution
purpose. Besides changing the voltage level, sub-station performs a lot of functions which are
listed below:
❖ Protection of transmission system.
❖ Controlling the exchange of energy.
❖ Ensure steady state & transient stability.
❖ Load shedding and prevention of loss of synchronism.
❖ Maintaining the system frequency within targeted limits.
❖ Voltage control, reducing the reactive power flow by compensation reactive power and
tap-changing.
❖ Securing the supply by proving adequate line capacity.
❖ Data transmission via power line carrier for the purpose of network monitoring, control
and protection.
❖ Fault analysis and pin-pointing the cause and subsequent improvement in that area of field.
❖ Determining the energy transfer through transmission lines. Reliable supply by feeding the
network at various points.
 ❖ Establishment of economic load distribution and several associated functions.

8.3 Familiarization with the Apparatus of the Sub-Station

The two sub-stations of Bheramara 410 MW CCPP are situated beside the power generation
section of the power plant. Both of them are outdoor type sub-station. The sub-stations of
Bheramara contain the following apparatus:
❖ Power Transformers
❖ Auxiliary Transformers
❖ Instrument Transformers
❖ Bus Bars
❖ Lightning Arresters
❖ Relays
❖ Circuit Breakers
So from the list of apparatus it is clear that the sub-station not only changes the voltage level but
also it provides security to the transformer used in the sub-station and the transmission and
distribution system. Lightning arresters, relays and circuit breaker are protective device of the sub-
station. Now we will discuss about each type of apparatus of Bheramara 410 MW CCPP sub-
station with its necessary photograph on the following segments.

8.4 Power Transformer

Power transformers are the transformers which are used for changing the voltage levels starting
from kV to MV. Power transformer is the main apparatus of any sub-station of Bangladesh. That’s
why these sub-stations are known as transformer sub-station. In Bheramara 410 MW CCPP the
sub-station is also transformer sub-station. The power transformers operating principle is same as
the normal transformer, only difference is in the power rating level. Voltage is supplied to the
primary winding of the power transformer and magnetic fluxes are produced due to the application
of voltage. These fluxes cut the coils of the secondary winding of the power transformer and thus
a voltage is induced there. In this way we get voltage on the secondary side of the transformer
without any electrical interconnection between the two windings. Voltage is induced in
electromagnetic induction process. If the turns of primary winding is more than the turns of
secondary winding then the transformer will act as step down transformer and vice-versa.
As said earlier that the rating of power transformer is very high, here from the photograph of rating
plate we see that the power rating of power transformer on Bheramara 410 MW CCPP sub-station
Gas Turbine Generator generates 18 KV and Steam Turbine Generator generates 14.5 KV which
are transformed by step-up power transformer to 132 KV and goes to the national grid. Again the
transformer handle voltage which lies in kV range.
The power transformer is made up of several parts. Main parts of the transformer are:
❖ Tank and Tank Cover
❖ Primary & Secondary Windings
❖ Bushings
❖ Tap Changers
❖ Cooling System
❖ Conservator
❖ Breather

Fig.8.2. A Photograph of Power Transformer

The primary and secondary windings of the transformer is inside the metallic cover of the
transformer so it is not possible to find out which side is low and which side is high voltage side
seeing the windings because the windings are not visible from outside.

8.5 Bushing
Bushing is a hollow insulator through which the conductors carrying power from the alternator or
from the grid are connected to the transformer. Bushing is a very important part of a transformer.
As said earlier it is not possible to see the windings of power transformer, so to find out the high
and low voltage side we must follow the bushing of the transformer. The sides which has more
bushing are high voltage side and the side which has less number of bushing are low voltage side.
 Fig.8.3 Bushing of Transformer

8.6 Cooling System of Power Transformer

As the power transformer functions at high voltage so huge amount of heat will be produced in the
transformer. Transformers have to overcome the heat produced so proper cooling system should
be provided to the transformer. For primary cooling purpose a cooling fan at the bottom of the
power transformer is connected. This cooling fan exhausts the heat produced inside the transformer
and inhale cool air from the surrounding.

Fig.8.4 A Photograph of Cooling Fan

Actually the transformer tank is filled with transformer oil. This transformer oil serves two
purposes. One is that this oil works as insulating medium between the windings of the transformer
and the second one is that this oil works to cool down the transformer.
The cooling equipment collects hot oil at the top of the tank and returns cooled oil lower down on
the side. Two circuits- the inner circuit transfers the loss energy from the heat producing surface
to the oil. In the outer circuit, the oil transfers the heat to a secondary cooling medium (air).

8.7 Auxiliary Transformer

The power plant itself requires electrical power to operate loads and different devices used to
control the system of the power plant. So there must be a mechanism to satisfy this need. Auxiliary
transformers serve this purpose. This transformer is directly connected to the generator output. It
is a three-winding transformer. It has one primary and two separate secondary windings. Primary
winding takes voltage according to the generator voltage rating. The voltage of the secondary
windings is generally 18 KV or 14.5 KV.
One auxiliary transformer is used to step down the 18 kV to 400 V for internal consumption of the
plant. So an auxiliary transformer is used to provide supply to the auxiliary equipment and gives
supply substations own needed power.

Fig.8.8 A Photograph of Unit Auxiliary Transformer

8.8 Instrument Transformer

Power transformer of the sub-station operates on high voltages and current. Measuring of the
voltages and current of the transformers are very important to know whether desired output voltage
or current is obtained or not. But we cannot measure high voltages and current using the voltmeter
or ammeter usually used in our practical life. So to measure this high voltages and current,
measuring instruments, known as instrument transformers are used. There are two types of
instrument transformers.
1. Current Transformer (CT)
2. Potential Transformer (PT)

A metering arrangement must be included with the transformer for the measurement purpose of
CT and PT.

Current Transformer

A current transformer (CT) is used in sub-station to measure the high currents available in the
windings of the power transformer. Normal ammeter cannot measure this high current. CT is
actually a step up transformer where the voltage in the secondary of CT is stepped up i.e. the
current in the secondary winding of CT is stepped down and taken to a measurable range. If the
current in the power transformer winding is 1000 A (say) then CT will be able to take this current
to a very low level (say) 5 A. This amount of current can easily be measured. A current transformer
also isolates the measuring instruments from what may be very high voltage in the monitored
circuit. Current transformers are commonly used in metering and protective relays in the electrical
power industry.
In sub-station current transformers are basically used to take the readings of the currents entering
the substation and going out from the sub-station. Three current transformers are used for three
phases each side of the common bus.

Potential Transformer

Potential transformers are used to measure the potential of the windings of the power transformers.
The available voltmeter in practice cannot measure voltage of kV range. PT is a stepped down
transformer where the voltages of secondary windings of the PT are very low comparing to the
primary winding. For example, we let the primary winding voltage of PT is 11 kV. Now PT will
stepped this voltage to a range of 250 V which is easily measurable. So using PT we can measure
the voltage of high or low voltage sides of power transformers. Here in Bheramara 410 MW
CCPP there is a PT for each phase of the power transformer in each side. PT is also used to serve
protection against over voltage.
 Fig.8.9. A Photograph of Transformer including CT and PT

8.9 Bus Bar

The bus is the line in which the incoming feeders come into and get into the instruments for further
step up or step down. In Bheramara 410 MW CCPP, there are two lines in the bus of each phase
so that if any fault occurs in the one the other can still have the current and the supply will not
stop. The size of the bus bar is designed such a way that the maximum amount of current that can
be safely carried. The bus bars here are supported by insulators, without completely surrounding
it. Earth bus bars are bolted directly onto the metal chassis of their enclosure.

Fig.8.10. A Photograph of Bus Bar

8.10 Protective Devices of the Plant

For any electrical equipment, before using it, proper protection should be taken to avoid any
hazardous condition of the equipment as well as its effect to human being. In a power plant,
equipment of very high costs are used. So protection must be taken before going to the operation
of the power plant.

The protective devices which are used in Bheramara 410 MW CCPP are listed below:

❖ Lightning arrester
❖ Relay
❖ Earth switches
❖ Insulator
❖ Isolator
❖ Circuit breakers

Lightning arrester

Lightning arrester is a device that protects electrical equipment from an excessive voltage resulting
from a lightning discharge or other accidental electrical surge by discharging it to earth. Lightning
is a natural calamity, so if lightning arresters are connected to the system then in case of lightning,
the insulation of any equipment, the windings of a transformer, the transmission lines, insulator
etc. may be damaged.

Fig.8.11. A Photograph of Lightning arrester

Lightning arresters are connected with the power circuit. There is a air gap in the lightning arrester.
Under normal operating conditions, this gap remains open and no current flows through the
arrester. When a lightning strikes, the air gap in the lightning arrester is broken down and the
current flows to the ground through a non-linear resistance. So the huge voltage due to lightning
will not affect the system at all.

Fig.8.12. A Photograph of Surge Monitor

Lightning arresters are connected with all the equipment of the sub-station because any harm to
any equipment will discontinue the power supply from the power plant. To measure the severity
of the lightning stroke, a surge monitor is connected with the system which will measure the
amplitude level of the surge voltage caused by lightning.

Protective Relay

A protective relay is a device that detects the fault and initiates the operation of the circuit breaker
to isolate the defective element from the rest of the system. The relays detect the abnormal
conditions in the electrical circuit by constantly measuring electrical quantities which are different
under normal and fault conditions. Relay is mainly used in the circuit breaker to detect the fault.
 Fig. 8.13. Basic Block Diagram of a Protective Relay

Circuit breaker (CB) is connected in series with the bus bar to be protected. Primary of a CT is
connected with the CB. Under normal operating condition, current flows through the CB and
primary of CT to the feeder. If any fault occurs in the feeder, it will consume more current thus
the secondary of CT will be energized enough to operate the relay coil and the trip contact will be
closed. Thus current will flow through the trip coil and it will be energized and the trip coil will
trip the circuit breaker. So the circuit will be opened and no harm will appear in the system. Again
a PT is also connected which will operate the relay to detect over voltage fault and protect the
system from any kind of harm. So we see that the relay plays an important role to for the protection
purpose of the system.

Insulator

Insulator is a material or a substances that do not conduct heat or electricity because they have no
free moving electrons. Conductors are said to be insulated when they are covered with an insulating
material such as rubber sheath, PVC etc. Insulation of the conductor taking electricity from the
alternator to sub-station or from sub-station to grid is of very importance. If those conductors are
not insulated then it will be very much hazardous to human being working in the power plant.
Again the very high voltage will also form corona.
 Fig.8.14. A Photograph of Insulator

Not only for conductors but also each and every equipment of the sub-station requires insulation.
The lightning arrester needs solid insulator. The body transformer tank is supported with proper
insulation. The circuit breaker also needs insulation because touching live conductors may cause
death of the personnel associated with the instruments.

Circuit Breaker

Electrical circuit breaker is a switching device which can be operated manually and automatically
for controlling and protection of electrical power system respectively. As the modern power
system deals with huge currents, the special attention should be given during designing of circuit
breaker for safe interruption of arc produced during the operation of circuit breaker. During short
circuit fault or any other types of electrical fault these equipment as well as the power network
suffer a high stress of fault current in them which may damage the equipment and networks
permanently. For saving these equipment and the power networks the fault current should be
cleared from the system as quickly as possible. Again, after the fault is cleared, the system must
come to its normal working condition as soon as possible for supplying reliable quality power to
the receiving ends. The circuit breakers cannot detect fault, they can remove the fault if detected
properly. Protective relay is used in association with circuit breaker to detect the fault.

There is a fixed contact and a moving contact which is normally closed. Here oil has been used as
arc quenching medium. Whenever CB operates the two contacts are separated.
 Fig.8.15. Basic construction diagram of a Circuit Breaker

During interruption of huge current, when the two contacts are separated there would be large
arcing in between switching contacts, so care should be taken to quench these arcs in circuit
breaker in safe manner.

Depending on the arc quenching medium, circuit breaker is classified into the following types:

1. Oil circuit breaker (OCB)

2. Air circuit breaker (ACB)
3. SF6 circuit breaker
4. Vacuum circuit breaker (VCB)

At Bheramara 410 MW CCPP, Air Circuit Breaker and Vacuum Circuit Breaker is used for
protection purpose..

Vacuum Circuit Breaker

A vacuum circuit breaker is such kind of circuit breaker where the arc quenching takes place in
vacuum. The technology is suitable for mainly medium voltage application. The salient feature of
vacuum as an arc quenching medium is that as soon as the arc is produced in vacuum, it is quickly
extinguished due to the fast rate of recovery of dielectric strength in vacuum.
With rated current up to 3000 A, these breakers interrupt the current by creating and extinguishing
the arc in a vacuum container. These are generally applied for voltages up to about 35,000 V,
which corresponds roughly to the medium-voltage range of power systems. Vacuum circuit
breakers tend to have longer life expectancies between overhaul than do air circuit breakers.

Fig.8.16. A Photograph of Vacuum Circuit Breaker

Air Circuit Breaker

The circuit breakers where air is used as arch quenching medium is known as air circuit breaker.
Though most of the circuit breaker of Bheramara 410 MW CCPP is vacuum circuit breaker, there
are also some air circuit breaker. The break down strength of air is 30 kV/cm. So it should not be
used in the power transformer where the high voltage sides operate on 33 kV. So Air Circuit
Breaker can be used in auxiliary transformer and in the alternator. Here in Bheramara 410 MW
CCPP, air circuit breaker has been used in protection of alternators and the auxiliary transformer.
 Fig.8.17. A Photograph of Air Circuit Breaker

Isolator

Isolators are used for isolating the circuit when the current has already been interrupted. They
allow currents into the circuit until circuit is repair again. Isolators re used for connecting and
disconnecting parts of electrical installation after de-energizing.
The use of this isolator is to protect the transformer and the other instrument in the line. The isolator
isolates the extra voltage to the ground and thus any extra voltage cannot enter the line. Thus an
isolator is used both before and after the bus for protection. They are manually operated only unlike
circuit breaker.
Circuit breaker always trip the circuit but open contacts of breaker cannot be visible physically
from outside of the breaker and that is why it is recommended not to touch any electrical circuit
just by switching off the circuit breaker. So for better safety there must be some arrangement so
that one can see open condition of the section of the circuit before touching it. Isolator is a
mechanical switch which isolates a part of circuit from system as when required. Electrical
isolators separate a part of the system from rest for safe maintenance works. So definition of
isolator can be rewritten as Isolator is a manually operated mechanical switch which separates
a part of the electrical power system normally at off load condition. Isolator is situated in both
sides of circuit breaker.
Earth Switches

As per the name, earth switch refers to the switches which will be connected to earth and the
charges associated with the system will be discharges to the earth. Whenever any fault occurs, the
circuit breaker trips the circuit but this is not enough to repair the fault, the faulty portion is isolated
to go for further fault remove operation. But as all the parts like circuit breaker, isolators internally
are made of conducting material so some charges may be stored in those material. So it is not wise
enough to go for maintenance work after just isolating the system. Earth switch is used with
isolator which takes the stored charge back to the ground so no harmful effect may arises later.

Chapter 9

Switchgear and Protection

9.1 Introduction to Switch Gear

Protection of power system is must because of the normal operation schemes to be continued. It
also makes sure of prevention of electrical failure and mitigates the effects of electrical failure.
Protection scheme in substation and grid can be divided into four parts.

❖ Transformer Protection Schemes

❖ Feeders Protection Schemes
❖ Bus bar Protection Schemes
❖ Alternator Protection Schemes.

In Bheramara 410 MW CCPP, different protective systems were used. In switchgear room,
different protective systems for the alternators were situated.

Fig.9.1. A photograph of Switch Gear

9.2 Protection Relays

The protection relays are equipped for fault protection of system operation. Protection relays are
designed and applied to provide maximum discrimination between faulty and healthy circuits.
System equipment will remain inoperative during transient phenomena which may arise during
switching or other disturbance to the system. Types of protection relays which are normally used
for system protection include:

❖ Over current and earth fault protection.

❖ Differential protection.
❖ REF protection.
❖ Standby unrestricted earth fault.
❖ Tripping relay.
❖ Pilot wire protection.
❖ Trip circuit supervision.

The following relays are employed to protect the transformer against internal faults:
❖ Buchholz relays.
❖ Differential relays.
❖ Pressure relief relays.
❖ Over current and earth fault relays.
❖ Thermal over heating protection:
a. Winding temperature
b. Oil temperature

Primarily The alternator is protected by alternator neutral earthing switch and alternator earthing
switch in state of on load state and off load state during maintenance respectively. In relay
protection, there is buchholz trip, earth fault trip, pressure relief valve trip, surge relay trip, over
current trip etc. in the control unit.

9.3 Fire Protection

Power plant is a very sensitive place. Any little source of fire can result in huge devastation. So
the following initiatives are taken to prevent fire incident.

❖ The whole place is kept very clean.

❖ Leaked Lube oil is cleaned and swept off the engine and the floor regularly.
❖ All places are monitored.
❖ Overheated instruments give alarm and thus they are manually and automatically shut
down or cooled.
9.4 Control Panel

Control panel room is the main commanding room for all the electrical and some of mechanical
equipment used in the plant i.e. engines, turbine, alternators, transformers, feeder lines and
everything. For the generated and consumed power control rooms defines the bus bars as high
voltage (HV), medium voltage (MV) and low voltage (LV) bus for 138 kV, 18 kV or 14.5 KV and
400 V respectively. The MV bus is sectionalized in two section consisted by two engines engine
end and other engine and the turbine on the other end. Synchronization is one of the most important
control unit of control panel where voltage and frequency of the generation end is strictly
synchronized with the voltage and frequency of the national grid. Talking about turbine control
panel, there are alarm over main oil tank level fluctuation, turbine speed fluctuation, exhaust steam
pressure fluctuation, lube oil pressure fluctuation etc.

Fig.9.2. A Photograph of Control Panel

9.5 UPS Panel

In control room there is a UPS panel. If there is a blackout, AC power will not be available in the
electrical protection devices will not operate. To avoid any such situation, UPS panel is used. UPS
is an uninterruptable power supply which uses converter inverter set. AC input is first converted
to DC and again converted to AC. The battery bank installed for UPS is connected in between
converter inverter set so that if AC supply to converter fails, battery comes on load and supplies
DC to inverter for maintaining the AC power supply at output end.
 Fig.9.3. A Photograph of Battery House

Fig.9.4. A Photograph of Battery Fuse Panel

9.6 Safety Rules

Power plants are much safer than they once were; however, plant employees still encounter
hazards. Training, along with proper operation and maintenance procedures, are key to reducing
accidents and mitigating their effects.

Among the most common hazards to power plant workers are electrical shocks and burns, boiler
fires and explosions, and contact with hazardous chemicals. While these are most certainly not the
only hazards encountered by power plant workers, they are definitely worth review. While not
exhaustive, the items listed here are based on actual operating experience and point out some
typical personnel safety precautions.

❖ Do not use open-ended pipes for rodding observation ports or slag on furnace walls. Hot
gases can be discharged through the open-ended pipe directly onto its handler. The pipe
can also become excessively hot.

❖ Be prepared for hot water in drums and headers when removing manhole plates and hand
hole covers.

❖ Never use toxic or volatile fluids in confined spaces.

❖ Never open or enter rotating equipment until it has come to a complete stop and its circuit
breaker is locked open and any other drive devices are immobilized. Some types of rotating
equipment can be set into motion with very little force. These types should be locked with
a brake or other suitable device to prevent rotation.

❖ Always secure the drive mechanism of dampers, gates and doors before passing through
them.

❖ Never enter a vessel, especially a boiler drum, until all steam and water valves, including
drain and blowdown valves, have been closed and locked or tagged. It is possible for steam
and hot water to back up through drain and blowdown piping, especially when more than
one boiler or vessel is connected to the same drain or blowdown tank.

❖ Do not inspect for tube leak locations until metal and refractory surfaces are cool. Read the
single line diagram and wiring schemes

❖ Avoid contact with energized electrical equipment. Always disconnect the power fast.

❖ Always be aware. Don’t store highly inflammable liquids near electrical equipment.
 Chapter 10
Conclusion

The industrial training at Bheramara 410 MW Combined Cycle Power Plant was a great
opportunity for me to gain practical knowledge about the overall operation of a power plant and
checking all the procedures of power generation which we studied in different courses of our
academic session. The training was highly successful. We received insight of the whole plant right
from the fuel procurement, processing, combustion, generation and transmission of electricity. The
whole process of power generation was explained in detail by the engineers working in Bheramara
410 MW CCPP with detailed description about each equipment with their specifications. The
authorities of Bheramara 410 MW CCPP are very considerate about all kinds of safety and security
of the plant. During the training we experienced a lot of things about power plant and power system
practically. This training program helped me absorbing the theoretical aspects of power system
more efficiently. I hope this training will play an important role in my future life to apply my
knowledge and experience in the related field efficiently and I would really appreciate more such
visits in the future.

REFERENCES

[1] V.K. Mehta and R. Mehta; ‘Principles of power system’, S. Chand & Company LTD.,
Revised Edition, 2021-2022.

[2] http://nwpgcl.gov.bd/site/page/9463e14e-c29e-4755-9257-b6f0760bd7dd/-

[3] https://en.wikipedia.org/wiki/Bangladesh_Power_Development_Board

[4] http://power-systems-protection.blogspot.com/2011/01/buchholz-relays.html

[5]
https://en.htc.cn/?gclid=CjwKCAjwtIaVBhBkEiwAsr7c620OZYpiK_3P4Z8deJY5IO0t57dEypjj
TJytcWmSCImxY9fIERHgBoC6VYQAvD_BwE

[6] http://nwpgcl.gov.bd/

[7] https://en.wikipedia.org/wiki/Turbine
[8] https://en.wikipedia.org/wiki/Boiler
[9] https://www.google.com/search?q=buchholz+relay&source=lnms&tbm=isch&sa=X&ved=0a
hUKEwi768fckJvYAhVEqo8KHQGrCykQ_AUICigB&biw=1280&bih=615#imgrc=j9MYz
39v3JI14M
[10] https://www.wilsonplumbingandheating.com/blog/2017/september/helpful-hints-tomaintain
your-steam-boiler/

[11] https://en.wikipedia.org/wiki/Soot_blower

[12] Information are also collected from the members of Bheramara 410 MW CCPP trainee
provided with slides and pdfs.