PROJECT REPORT

VOCATIONAL TRAINING AT
Kanti Bijlee Utpadan Nigam Limited .
(A Joint Venture Of NTPC Ltd. & BSEB)
Kanti , Muzaffarpur.
FROM 20/05/2015 TO 06/06/2015

SUBMITTED BYROHAN KUMAR

ROLL NO-BETN1EE12020
B.TECH(ELECTRICAL ENGG.)
VI SEM
ITM UNIVERSITY GWALIOR(M.P)

ACKNOWLEDGMENT
I am highly indebted to HOD of C& I Department, all faculty members
of department for providing me an opportunity to have practical
exposure at KBUNL/MTPS Kanti (Joint venture of NTPC Ltd & BSEB)
I express my sincere thanks to A.CHARKBORTY for giving me an
opportunity to take such valuable vacational training in his department.
I also pay my sincere gratitude to Sh.J P Kushwaha (Dy. MGR,C&I) ,
Sh. Anjani Kr Verma (Asst. MGR,C&I), Sh. R N Verma (Asst.
MGR,C&I), Vikas Kumravat(Asst. MGR,C&I) & Vikas Koshta(Asst.
MGR,C&I) for their continuous assistance, guidence and valuable
suggestions .
Last but not the least I am also thankful to Sh. Arun Kr Singh for his
contribution.
My special thanks to HR deptt for faciliating me to impart training at
this project.

Submitted byROHAN KUMAR

B.TECH(ELECTRICAL ENGG.)
ITM UNIVERSITY GWALIOR(M.P)
ROLL NO-BETN1EE12020

ABSTRACT
Any thermal power plant is converting the chemical energy of fossil fuel (coal)
into electrical energy. The process involved for this conversion is based upon the
Modified Rankine Cycle.
The major components that are used to accomplish the modified rankine cycle are
Boiler feed pump,
The steam generator water walls (evaporator),
Steam generator super heaters,
Steam turbine,
Reheater,
Condenser,
Regenerative feed heaters etc.
All components of a power generating cycle are vital and critical in operation. In
Modified Rankin Cycle, the two most important aspects that is added are reheating
& regenerative heating. By reheating we used to send the steam coming from
exhaust of the turbines back to the reheater of the boiler so that its enthalpy
increases and more work can be done by this steam the other purpose is to make
steam dry so that no harm will be done to the blades of the turbine.
In MTPS Kanti, we have three turbines in Tandem coupling namely one H.P
Turbine, one I.P Turbine & one L.P Turbine coupled with the generator to which is
synchronized with the grid to produce electricity at 50Hz.
In all my modesty, I wish to record here that a sincere attempt has been made for
the presentation of this project report. I also trust that this study will not only prove
to be of academic interest but also will be able to provide an insight into the area of
technical management.

INDEX
CONTENT
PAGE NO.
ABOUT NTPC LTD.-------------------------------------------ABOUT KBNUL , KANTI-------------------------------------OPERATION OF POWER PLANT-------------------------PARTS OF POWER PLANT----------------------------------VARIOU CYCLE OCCUR IN POWER PLANT----------ELECTRICAL MAINTENANCE-----------------------------1 MOTOR---------------------------------------------------------------------2.HIGH TENSION/LOW TENSION SWITCHGEAR---------------3. COAL HANDLING PLANT----------------------------------------------4. TRANSFORMER------------------------------------------------------------5. GENERATOR------------------------------------------------------------------6. SWITCH YARD-----------------------------------------------------------------

CONTROL SYSTEM OF POWER PLANT----------------------

ABOUT NTPC
India largest power company, NTPC was set up in 1975 to accelerate power
development in India. NTPC is emerging as a diversified power major with
presence in the entire value chain of the power generation business. Apart from
power generation, which is the mainstay of the company, NTPC has already
ventured into consultancy, power trading, ash utilization and coal mining. NTPC
ranked 341st in the 2010, Forbes Global 2000 ranking of the Worlds biggest
companies. NTPC became a Maharatna company in May, 2010, one of the only
four companies to be awarded this status.
The total installed capacity of the company is 39,174 MW (including JVs) with 16
coal based and 7 gas based stations, located across the country. In addition under
JVs, 7 stations are coal based & another station uses naptha/LNG as fuel. The
company has set a target to have an installed power generating capacity of
1,28,000 MW by the year 2032. The capacity will have a diversified fuel mix
comprising 56% coal, 16% Gas, 11% Nuclear and 17% Renewable Energy
Sources(RES) including hydro. By 2032, non-fossil fuel based generation capacity
shall make up nearly 28% of NTPC portfolio.
NTPC has been operating its plants at high efficiency levels. Although the
company has 17.75% of the total national capacity, it contributes 27.40% of total
power generation due to its focus on high efficiency.
In October 2004, NTPC launched its Initial Public Offering (IPO) consisting of
5.25% as fresh issue and 5.25% as offer for sale by Government of India. NTPC
thus became a listed company in November 2004 with the Government holding
89.5% of the equity share capital. In February 2010, the Shareholding of
Government of India was reduced from 89.5% to 84.5% through Further Public
Offer. The rest is held by Institutional Investors and the Public.

Strategies of NTPC

Vision
To be the worlds largest and best power producer,
powering Indias growth.

Mission
Develop and provide reliable power, related products and
services at competitive prices, integrating multiple energy
sources with innovative and eco-friendly technologies and
contribute to society.

Core value-BE COMMITTED

B
Business Ethics
--------------------E------------------- Environmentally
--& Economically
Sustainable
Customer Focus
C-------------------Organizational
O------------------- & Professional
Pride
Mutual Respect
M------------------ & Trust
-Motivating Self
M------------------ & others
-I
Innovation &
------------------ Speed
Total Quality
T---------------- for Excellence
-Transparent &
T---------------- Respected
-Organization
E
Enterprising
---------------Devoted

D---------------NTPC is the second largest owner of trees in the country after the
Forest department

Kanti Thermal Power Station

Kanti Thermal Power Station is located
in Kanti, Muzaffarpur,90 km away from Patna, the capital of
the Indian state of Bihar.It is managed by the Kanti Bijlee Utpadan
Nigam Ltd (KBUN),-a joint venture
between NTPC and BSEB Patna.The majority shares of the Joint
Venture Company is hold by NTPC,with NTPC 64.57% and BSEB
35.43%.The plant has not been functional since 2003, however
three successful trial runs have paved way for commercial
production of Electricity by the end of 2013. In November
2013,Nitish Kumar said that another new 500MW power plant will
be set up at Kanti. The first 195 MW unit was commissioned by
BHEL at the 2x195 MW plant in May 2015.

History
First started in 1985, Kanti Power Plant has an installed capacity of 1102 MW. An
additional capacity of 1952 MW is being erected and is due to be completed by
December 2014.Bihar is the most power stricken state of India; and in the issue of
uplifting our current nation, an excellent and clean 'Thermal Power station' is a
necessity. Kanti thermal Power Plant came into existence in 1985 with the efforts
of then MP of Muzaffarpur,

Operations
To take over Muzaffarpur Thermal Power Station (2*110MW), a subsidiary
company named Vaishali Power Generating Company Limited (VPGCL) with
NTPC on 06/09/2006,-contributing 51% of equity; and the balance equity was
contributed by Bihar State Electricity Board. The company was rechristened as

Kanti Bijlee Utpadan Nigam Limited on April 10, 2008. Present equity holding is
64.57% by NTPC & 35.43% by BSEB. The company is renovating and
modernising the existing unit.The total cost of its renovation and modernization
has been over Rs. 500 Crores.The station has an installed capacity of 2 X 110 MW.
Both the units are under renovation and modernization.An additional capacity of
220MWx2 is being erected and is due to be completed by December 2014.In
March 2013, the renovation work of two old units was completed.MTPS started
commercial production from November 1, 2013 by sypplying 94 MW.This is first
generation in 11 years since 2002.

Sta
ge

Unit
Numb
er

Stage
1
-1

Stage 2
-1

Install
ed
Capac
ity
(MW)

Date of
Commissio
ning

Status

110

1985 March

This unit went down in

2003 and then its
renovation started
by Bharat Heavy
Electricals in April
2008 and is now
running at full
capacity since
November 2013 .

110

1986 March

This unit too is non

functional since 2003
and is also undergoing
renovation by Bharat
Heavy Electricals. But,
since 14 November
2014 this unit has
been functional after

Sta
ge

Unit
Numb
er

Install
ed
Capac
ity
(MW)

Date of
Commissio
ning

Status

the renovation and

modernisation work.
Till now KBUNL has an
installed capacity of
220 MW.

Stage
3
-2

195

5th May,
2015

The original planned

capacity of the unit
was 250 MW but was
reduced to 195 MW
Scheduled
after Airport Authority
of India raised concern
over its chimney
height.
Bhel commissioned the first
195MW unit at Muzaffarpur
Thermal Power Station in
India on 5th May, 2015. The
commissioning is the first of
the two units at 390MW
Muzaffarpur Thermal Power
Station (TPS).

Stage 4
-2

195

Under
Construction

Original planned
capacity was 250 MW

Sta
ge

Unit
Numb
er

Install
ed
Capac
ity
(MW)

Date of
Commissio
ning

Status

but reduced to 195

MW.
Total 610

OPERATION OF A POWER PLANT

Basic Principle: As per FARADAYs Law-Whenever the amount of

magnetic flux linked with a circuit changes, an EMF is produced in
the circuit. Generator works on the principle of producing
electricity. To change the flux in the generator turbine is moved in

a great speed with steam. To produce steam, water is heated in

the boilers by burning the coal.
In kanti bijlee utpadan nigam limited(A Subsidiary ofNTPC Ltd. Kanti
Muzaffarpur) steam is produced and used to spin a turbine that operates a
generator. Water is heated, turns into steam and spins a steam turbine which drives
an electrical generator. After it passes through the turbine, the steam is condensed
in a condenser; this is known as a Rankine cycle.
The electricity generated at the plant is sent to consumers through high-voltage
power lines The In kanti bijlee utpadan nigam limited has Steam Turbine-Driven
Generators which has a collective capacity of 220Mw(2*110Mw).

Basic Steps of Electricity Generation

The basic steps in the generation of electricity from coal involves following steps:
# Coal to steam

# Steam to mechanical power

# Mechanical power to electrical power

Coal to Electricity : Basics

Mechnical power to Electrical power

As blade of turbine rotate, the shaft of generator, which is coupled to the
turbine also rotate.it result rotation of coil of the generator, which cause
induced electricity to produce.

PARTS OF A POWER PLANT

The various parts are listed below:1.Cooling tower
3. Transmission line (3-phase)
phase)

2. Cooling water pump

4. Unit transformer (3-

5. Electric generator (3-phase)

6. Low pressure turbine

7. Condensate extraction pump

8. Condenser

9. Intermediate pressure turbine

11. High pressure turbine

10. Steam governor valve

12. Deaerator

13. Feed heater

15. Coal hopper
17. Boiler drum
19. Super heater
21. Reheater
23. Economiser
25. Precipitator

14. Coal conveyor

16. Pulverised fuel mill
18. Ash hopper
20. Forced draught fan
22. Air intake
24. Air preheater
26. Induced

27. Flue Gas

1. Cooling Tower
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove
process heat and cool the working fluid to near the wet-bulb air temperature or in
the case of closed circuit dry cooling towers rely solely on air to cool the working
fluid to near the dry-bulb air temperature. Common applications include cooling
the circulating water used in oil refineries, chemical plants, power stations and
building cooling. The towers vary in size from small roof-top units to very large
hyperboloid structures that can be up to 200 meters tall and 100 meters in diameter,

or rectangular structures that can be over 40 meters tall and 80 meters long.
Smaller towers are normally factory-built, while larger ones are constructed on
site. The absorbed heat is rejected to the atmosphere by the evaporation of some of
the cooling water in mechanical forced-draft or inducedDraft towers or in natural
draft hyperbolic shaped cooling towers as seen at most nuclear power plants.

2. Cooling Water Pump

it pumps the water from the cooling tower which goes to the condenser.

3. Three phase transmission line Three phase electric power is a common

method of electric power transmission. It is a type of polyphase system mainly
used to power motors and many other devices. A three phase system uses less
conductive material to transmit electric power than equivalent single phase, two
phase, or direct current system at the same voltage. In a three phase system, three
circuits reach their instantaneous peak values at different times. Taking current in
one conductor as the reference, the currents in the other two are delayed in time by
one-third and two-third of one cycle .This delay between phases has the effect of
giving constant power transfer over each cycle of the current and also makes it
possible to produce a rotating magnetic field in an electric motor. At the power
station, an electric generator converts mechanical power into a set of electric
currents, one from each electromagnetic coil or winding of the generator. The
current are sinusoidal functions of time, all at the same frequency but offset in time
to give different phases. In a three phase system the phases are spaced equally,
giving a phase separation of one-third of one cycle. Generators output at a voltage
that ranges from hundreds of volts to 30,000 volts.

4. Unit transformer (3-phase) At the power station, transformers step-up this

voltage to one more suitable for transmission. After numerous further conversions
in the transmission and distribution network the power is finally transformed to the
standard mains voltage (i.e. the household voltage). The power may already have
been split into single phase at this point or it may still be three phase. Where the
step-down is 3 phase, the output of this transformer is usually star connected with
the standard mains voltage being the phase-23 neutral voltage. Another system
commonly seen in North America is to have a delta connected secondary with a
center tap on one of the windings supplying the ground and neutral. This allows for

240 V three phase as well as three different single phase voltages( 120 V between
two of the phases and neutral , 208 V between the third phase ( or wild leg) and
neutral and 240 V between any two phase) to be available from the same supply.

5. Electrical generator An Electrical generator is a device that converts

kinetic energy to electrical energy, generally using electromagnetic induction. The
task of converting the electrical energy into mechanical energy is accomplished by
using a motor. The source of mechanical energy maybe water falling through the
turbine or steam turning a turbine (as is the case with thermal power plants). There
are several classifications for modern steam turbines. Steam turbines are used in
our entire major coal fired power stations to drive the generators or alternators,
which produce electricity. The turbines themselves are driven by steam generated
in "boilers or "steam generators" as they are sometimes called. Electrical power
stations use large steam turbines driving electric generators to produce most (about
86%) of the worlds electricity. These centralized stations are of two types: fossil
fuel power plants and nuclear power plants. The turbines used for electric power
generation are most often directly coupled to their-generators .As the generators
must rotate at constant synchronous speeds according to the frequency of the
electric power system, the most common speeds are 3000 r/min for 50 Hz systems,
and 3600 r/min for 60 Hz systems. Most large nuclear sets rotate at half those
speeds, and have a 4-pole generator rather than the more common 2-pole one.

6. Low Pressure Turbine Energy in the steam after it leaves the boiler is
converted into rotational energy as it passes through the turbine. The turbine
normally consists of several stages with each stages consisting of a stationary blade
(or nozzle) and a rotating blade. Stationary blades convert the potential energy of
the steam into kinetic energy and direct the flow onto the 24 rotating blades. The
rotating blades convert the kinetic energy into impulse and reaction forces, caused
by pressure drop, which results in the rotation of the turbine shaft. The turbine
shaft is connected to a generator, which produces the electrical energy. Low
Pressure Turbine (LPT) consists of 4x2 stages. After passing through Intermediate
Pressure Turbine steam is passed through LPT which is made up of two parts- LPC
REAR & LPC FRONT. As water gets cooler here it gathers into a HOTWELL
placed in lower parts of turbine.

7. Condensation Extraction Pump A Boiler feed water pump is a specific

type of pump used to pump water into a steam boiler. The water may be freshly
supplied or returning condensation of the steam produced by the boiler. These
pumps are normally high pressure units that use suction from a condensate return
system and can be of the centrifugal pump type or positive displacement type.
Construction and operation: Feed water pumps range in size up to many
horsepower and the electric motor is usually separated from the pump body by
some form of mechanical coupling. Large industrial condensate pumps may also
serve as the feed water pump. In either case, to force the water into the boiler, the
pump must generate sufficient pressure to overcome the steam pressure developed
by the boiler. This is usually accomplished through the use of a centrifugal pump.
Feed water pumps usually run intermittently and are controlled by a float switch or
other similar level-sensing device energizing the pump when it detects a lowered
liquid level in the boiler. Some pumps contain a two-stage switch. As liquid lowers
to the trigger point of the first stage, the pump is activated. If the liquid continues
to drop, (perhaps because the pump has failed, its supply has been cut off or
exhausted, or its discharge is blocked) the second stage will be triggered. This
stage may switch off the boiler equipment (preventing the boiler from running dry
and overheating), trigger an alarm, or both. 25

8. Condenser The steam coming out from the Low Pressure Turbine (a little
above its boiling pump) is brought into thermal contact with cold water (pumped in
from the cooling tower) in the condenser, where it condenses rapidly back into
water, creating near Vacuum-like conditions inside the condenser chest.

9. Intermediate Pressure Turbine Intermediate Pressure Turbine (IPT)

consists of 11 stages. When the steam has been passed through HPT it enters into
IPT. IPT has two ends named as FRONT & REAR. Steam enters through front end
and leaves from Rear end.

10. Steam Governor Valve Steam locomotives and the steam engines used on
ships and stationary applications such as power plants also required feed water
pumps. In this situation, though, the pump was often powered using a small steam
engine that ran using the steam produced by the boiler a means had to be provided,
of course, to put the initial charge of water into the boiler (before steam power was
available to operate the steam-powered feed water pump).The pump was often a
positive displacement pump that had steam valves and cylinders at one end and
feed water cylinders at the other end; no crankshaft was required. In thermal plants,
the primary purpose of surface condenser is to condense the exhaust steam from a
steam turbine to obtain maximum efficiency and also to convert the turbine exhaust

steam into pure water so that it may be reused in the steam generator or boiler as
boiler feed water. By condensing the exhaust steam of a turbine at a pressure below
atmospheric pressure, the steam pressure drop between the inlet and exhaust of the
turbine is increased, which increases the amount heat available for conversion to
mechanical power. Most of the heat liberated due to condensation of the exhaust
steam is carried away by the cooling medium (water or air) used by the surface
condenser. Control valves are valves used within industrial plants and elsewhere to
control operating conditions such as temperature, pressure, flow and liquid level by
fully or partially opening or closing in response to signals received from
controllers that compares a set point to a 26 process variable whose value is
provided by sensors that monitor changes in such conditions. The opening or
closing of control valves is done by means of electrical, hydraulic or pneumatic
systems.

11.High Pressure Turbine Steam coming from Boiler directly feeds into HPT
at a temperature of 540C and at a pressure of 136 kg/cm2. Here it passes through
12 different stages due to which its temperature goes down to 329C and pressure
as 27 kg/cm2. This line is also called as CRH COLD REHEAT LINE. It is now
passed to a REHEATER where its temperature rises to 540C and called as HRHHOT REHEATED LINE.

12. Deaerator A Deaerator is a device for air removal and used to remove
dissolved gases (an alternate would be the use of water treatment chemicals) from
boiler feed water to make it noncorrosive. A dearator typically includes a vertical
domed deaeration section as the deaeration boiler feed water tank. A Steam
generating boiler requires that the circulating steam, condensate, and feed water
should be devoid of dissolved gases, particularly corrosive ones and dissolved or
suspended solids. The gases will give rise to corrosion of the metal. The solids will
deposit on the heating surfaces giving rise to localized heating and tube ruptures
due to overheating. Under some conditions it may give rise to stress corrosion
cracking. Deaerator level and pressure must be controlled by adjusting control
valves the level by regulating condensate flow and the pressure by regulating
steam flow. If operated properly, most deaerator vendors will guarantee that
oxygen in the deaerated water will not exceed 7 ppb by weight (0.005 cm3/L)

13. Feed water heater A Feed water heater is a power plant component used to
pre-heat water delivered to a steam generating boiler. Preheating the feed water
reduces the irreversibility involved in steam generation and therefore improves the
thermodynamic efficiency of the system. This reduces plant operating costs and
also helps to avoid thermal shock to the boiler 27 metal when the feed water is
introduced back into the steam cycle. In a steam power (usually modelled as a
modified Rankine cycle), feed water heaters allow the feed water to be brought up
to the saturation temperature very gradually. This minimizes the inevitable
irreversibility associated with heat transfer to the working fluid (water).

14. Coal conveyor Coal conveyors are belts which are used to transfer coal
from its storage place to Coal Hopper. A belt conveyor consists of two pulleys,
with a continuous loop of material- the conveyor Belt that rotates about them.
The pulleys are powered, moving the belt and the material on the belt forward.
Conveyor belts are extensively used to transport industrial and agricultural
material, such as grain, coal, ores etc.

15. Coal Hopper Coal Hoppers are the places which are used to feed coal to
Fuel Mill. It also has the arrangement of entering Hot Air at 200C inside it which
solves our two purposes:- 1. If our Coal has moisture content then it dries it so that
a proper combustion takes place. 2. It raises the temperature of coal so that its
temperature is more near to its Ignite Temperature so that combustion is easy.
16. Pulverized Fuel Mill A pulveriser is a device for grinding coal for combustion
in a furnace in a fossil fuel power plant.
17. Boiler drum Steam Drums are a regular feature of water tube boilers. It is
reservoir of water/steam at the top end of the water tubes in the water-tube boiler.
They store the steam generated in the water tubes and act as a phase separator for
the steam/water mixture. The difference in densities between hot and cold water
helps in the accumulation of the hotter- water/and saturated steam into steam
drum. Made from high-grade steel (probably 28 stainless) and its working involve
temperature of 390C and pressure well above 350psi (2.4MPa). The separated
steam is drawn out from the top section of the drum. Saturated steam is drawn off
the top of the drum. The steam will re-enter the furnace in through a super heater,
while the saturated water at the bottom of steam drum flows down to the mud-

drum /feed water drum by down comer tubes accessories include a safety valve,
water level indicator and fuse plug.
18. Ash Hopper A steam drum is used in the company of a mud-drum/feed water
drum which is located at a lower level. So that it acts as a sump for the sludge or
sediments which have a tendency to accumulate at the bottom.
19. Super Heater A Super heater is a device in a steam engine that heats the
steam generated by the boiler again increasing its thermal energy. Super heaters
increase the efficiency of the steam engine, and were widely adopted. Steam which
has been superheated is logically known as superheated steam; non- superheated
steam is called saturated steam or wet steam. Super heaters were applied to steam
locomotives in quantity from the early 20th century, to most steam vehicles, and
also stationary steam engines including power stations.
20. Force Draught Fan External fans are provided to give sufficient air for
combustion. The forced draught fan takes air from the atmosphere and, warms it in
the air preheater for better combustion, injects it via the air nozzles on the furnace
wall.
21. Reheater Reheater is a heater which is used to raise the temperature of steam
which has fallen from the intermediate pressure turbine. 29
22. Air Intake Air is taken from the environment by an air intake tower which is
fed to the fuel.
23. Economizers Economizer, or in the UK economizer, are mechanical devices
intended to reduce energy consumption, or to perform another useful function like
preheating a fluid. The term economizer is used for other purposes as well-Boiler,
power plant, heating, ventilating and air-conditioning. In boilers, economizer are
heat exchange devices that heat fluids , usually water, up to but not normally
beyond the boiling point of the fluid. Economizers are so named because they can
make use of the enthalpy and improving the boilers efficiency. They are devices
fitted to a boiler which save energy by using the exhaust gases from the boiler to
preheat the cold water used to fill it (the feed water). Modern day boilers, such as
those in cold fired power stations, are still fitted with economizer which is
decedents of Greens original design. In this context there are turbines before it is

pumped to the boilers. A common application of economizer in steam power plants

is to capture the waste heat from boiler stack gases (flue gas) and transfer thus it to
the boiler feed water thus lowering the needed energy input , in turn reducing the
firing rates to accomplish the rated boiler output . Economizer lower stack
temperatures which may cause condensation of acidic combustion gases and
serious equipment corrosion damage if care is not taken in their design and
material selection.
24. Air Preheater Air preheater is a general term to describe any device designed
to heat air before another process (for example, combustion in a boiler). The
purpose of the air preheater is to recover the heat from the boiler flue gas which
increases the thermal efficiency of the boiler by reducing the useful heat lost in the
flue gas. As a consequence, the flue gases are also sent to the flue gas stack (or
chimney) at a lower temperature allowing simplified design of the ducting and the
flue gas stack. It also allows control over the temperature of gases leaving the
stack. 30
25. Precipitator An Electrostatic precipitator (ESP) or electrostatic air cleaner is a
particulate device that removes particles from a flowing gas (such as air) using the
force of an induced electrostatic charge. Electrostatic precipitators are highly
efficient filtration devices, and can easily remove fine particulate matter such as
dust and smoke from the air steam. ESPs continue to be excellent devices for
control of many industrial particulate emissions, including smoke from electricitygenerating utilities (coal and oil fired), salt cake collection from black liquor
boilers in pump mills, and catalyst collection from fluidized bed catalytic crackers
from several hundred thousand ACFM in the largest coal-fired boiler applications.
The original parallel plate-Weighted wire design (described above) has evolved as
more efficient (and robust) discharge electrode designs, today focus is on rigid
discharge electrodes to which many sharpened spikes are attached , maximizing
corona production. Transformer rectifier systems apply voltages of 50-100
Kilovolts at relatively high current densities. Modern controls minimize sparking
and prevent arcing, avoiding damage to the components. Automatic rapping
systems and hopper evacuation systems remove the collected particulate matter
while on line allowing ESPs to stay in operation for years at a time.

26. Induced Draught Fan The induced draft fan assists the FD fan by drawing out
combustible gases from the furnace, maintaining a slightly negative pressure in the
furnace to avoid backfiring through any opening. At the furnace outlet and before
the furnace gases are handled by the ID fan, fine dust carried by the outlet gases is
removed to avoid atmospheric pollution. This is an environmental limitation
prescribed by law, which additionally minimizes erosion of the ID fan.
27. Flue gas stack A Flue gas stack is a type of chimney, a vertical pipe, channel
or similar structure through which combustion product gases called flue gases are
exhausted to the outside air. Flue gases are produced when coal, oil, natural gas,
wood or any other large combustion 31 device. Flue gas is usually composed of
carbon dioxide (CO2) and water vapour as well as nitrogen and excess oxygen
remaining from the intake combustion air. It also contains a small percentage of
pollutants such as particulates matter, carbon mono oxide, nitrogen oxides and
sulphur oxides. The flue gas stacks are often quite tall, up to 400 meters (1300 feet)
or more, so as to disperse the exhaust pollutants over a greater area and thereby
reduce the concentration of the pollutants to the levels required by government's
environmental policies and regulations. The flue gases are exhausted from stoves,
ovens, fireplaces or other small sources within residential abodes, restaurants,
hotels through other stacks which are referred to as chimneys.

VARIOUS CYCLES AT POWER STATION

# PRIMARY AIR CYCLE
# SECONDARY AIR CYCLE
# COAL CYLCE
# ELECTRICITY CYCLE
# FLUE GAS CYCLE
# CONDENSATE CYCLE
# FEED WATER CYCLE
# STEAM CYCLE

ELECTRICAL MAINTENANCE DEPARTMENT

Electrical maintenance include:
Motors
High Tension/Low Tension Switchgear
Coal handling plant
Generators
Transformers
Switch yard

MOTORS
Motors can be classified as AC and DC.

AC MOTORS

1. Squirrel cage motor

2. Wound motor
3. Slip ring induction motor
In modern thermal power plant three phase squirrel cage induction motors are used
but sometime double wound motor is used when we need high starting torque e.g.
in ball mill.
THREE PHASE INDUCTION MOTOR
Ns (speed) =120f/p
Stator can handle concentrated single layer winding, with each coil occupying one
stator slot The most common type of winding are:
1. DISTRIBUTED WINDING : This type of winding is distributed over a number
of slots.
2. DOUBLE LAYER WINDING : Each stator slot contains sides of two different
coils

SQUIRREL CAGE INDUCTION MOTOR

Squirrel cage and wound cage have same mode of operation. Rotor conductors cut
the rotating stator magnetic field. an emf is induced across the rotor winding,
current flows, a rotor magnetic field is produced which interacts with the stator
field causing a turning 43 motion. The rotor does not rotate at synchronous speed,
its speed varies with applied load. The slip speed being just enough to enable
sufficient induced rotor current to produce the power dissipated by the motor load
and motor losses.
BEARINGS AND LUBRICATIONS
A good bearing is needed for trouble free operation of motor. Since it is very
costly part of the motor, due care has to be taken by checking it at regular intervals.
So lubricating plays an important role. Two types of lubricating are widely used
1. Oil lubrication
2. Grease lubrication
3. Insulation
INSULATION
Winding is an essential part so it should be insulated. Following types of insulation
are widely used
TYPES OF INSULATION
CLASS TEMP

UPTO WHICH THEY ARE EFFECTIVE

(DEGREE CENTIGRADE)
Y

90

105

120

130

155

180

more than 180

# F class insulation is generally preferred.

MAIN MOTOR USED IN BOILER AND OFF SIDE AREA
1. ID FAN
It is located between EP and chimney used for creating induced draft in the
furnace.
2. PA FAN
It is used for handling atmospheric air up to temperature 50 degree centigrade
3.FD FAN
It is used for handling secondary air for the boiler.
4. SCANNER FAN
It is required for requisite air for scanner cooling.
5. IGNITOR FAN
It supplies air for cooling of igniters.

INSTRUMENTS
1. MICROMETER
This instrument is used for measuring inside as well as outside diameter of
bearing.
2. MEGGAR
This instrument is used for measuring insulation resistance.
3. VIBRATION TESTER -- It measures the vibration of the motor. It is
measured in three dimensions-axial, vertical and horizontal.

SWITCH GEAR
INTRODUCTION
Switchgear is one that makes or breaks the electrical circuit. It is a switching
device that opens& closes a circuit that defined as apparatus used for switching,
Lon rolling & protecting the electrical circuit & equipments. The switchgear
equipment is essentially concerned with switching & interrupting currents either
under normal or abnormal operating conditions. The tubular switch with
ordinary fuse is simplest form of switchgear & is used to control & protect&
other equipments in homes, offices etc. For circuits of higher ratings, a High
Rupturing Capacity (H.R.C) fuse in condition with a switch may serve the
purpose of controlling &protecting the circuit. However such switchgear cannot
be used profitably on high voltage system (3.3 KV) for 2 reasons. Firstly, when
a fuse blows, it takes some time to replace it &consequently there is
interruption of service to customer. Secondly, the fuse cannot successfully
interrupt large currents that result from the High Voltage System. In order to
interrupt heavy fault currents, automatic circuit breakers are used. There are
very few types of circuit breakers in B.P.T.S they are VCB, OCB, and SF6 gas
circuit breaker. The most expensive circuit breaker is the SF6 type due to gas.
There are various companies which manufacture these circuit breakers:
VOLTAS, JYOTI, and KIRLOSKAR. Switchgear includes switches, fuses,
circuit breakers, relays & other equipments.
THE EQUIPMENTS THAT NORMALLY FALL IN THIS CATEGORY
ARE:1. ISOLATOR
An isolator is one that can break the electrical circuit when the circuit is to be
switched on no load. These are used in various circuits for isolating the certain
portion when required for maintenance etc. An operating mechanism box
normally installed at ground level drives the isolator. The box has an operating
mechanism in addition to its contactor circuit and auxiliary contacts may be
solenoid operated pneumatic three phase motor or DC motor transmitting

through a spur gear to the torsion shaft of the isolator. Certain interlocks are
also provided with the isolator
These are--1. Isolator cannot operate unless breaker is open
2. Bus 1 and bus 2 isolators cannot be closed simultaneously
3. The interlock can be bypass in the event of closing of bus coupler breaker.
4. No isolator can operate when the corresponding earth switch is on
2. SWITCHING ISOLATOR
Switching isolator is capable of:
1. Interrupting charging current
2. Interrupting transformer magnetizing current
3. Load transformer switching.
Its main application is in connection with the transformer feeder as the unit
makes it possible to switch gear one transformer while the other is still on load.
3.CIRCUIT BREAKER
One which can make or break the circuit on load and even on faults is referred
to as circuit breakers. This equipment is the most important and is heavy duty
equipment mainly utilized for protection of various circuits and operations on
load. Normally circuit breakers installed are accompanied by isolators
4. LOAD BREAK SWITCHES
These are those interrupting devices which can make or break circuits. These
are normally on same circuit, which are backed by circuit breakers
5. EARTH SWITCHES
Devices which are used normally to earth a particular system, to avoid any
accident happening due to induction on account of live adjoining circuits. These

equipments do not handle any appreciable current at all. Apart from this
equipment there are a number of relays etc. which are used in switchgear.

LT SWITCHGEAR
In LT switchgear there is no interlocking. It is classified in following ways:1. MAIN SWITCH
Main switch is control equipment which controls or disconnects the main
supply. The main switch for 3 phase supply is available for the range 32A, 63A,
100A, 200Q, 300A at 500V grade.
2. FUSES
With Avery high generating capacity of the modern power stations extremely
heavy carnets would flow in the fault and the fuse clearing the fault would be
required to withstand extremely heavy stress in process. It is used for supplying
power to auxiliaries with backup fuse protection. With fuses, quick break, quick
make and double break switch fuses for 63A and 100A, switch fuses for
200A,400A, 600A, 800A and 1000A are used.
3. CONTACTORS
AC Contractors are 3 poles suitable for D.O.L Starting of motors and
protecting the connected motors.
4. OVERLOAD RELAY
For overload protection, thermal overload relay are best suited for this purpose.
They operate due to the action of heat generated by passage of current through
relay element.
5. AIR CIRCUIT BREAKERS
It is seen that use of oil in circuit breaker may cause a fire. So in all circuits
breakers at large capacity air at high pressure is used which is maximum at the
time of quick tripping of contacts. This reduces the possibility of sparking. The
pressure may vary from 50-60kg/cm^2 for high and medium capacity circuit
breakers.

CONTACTORS

HT SWITCHGEAR
1. MINIMUM OIL CIRCUIT BREAKER
These use oil as quenching medium. It comprises of simple dead tank row
pursuing projection from it. The moving contracts are carried on an iron arm
lifted by a long insulating tension rod and are closed simultaneously pneumatic
operating mechanism by means of tensions but throw off spring to be provided
at mouth of the control the main current within the controlled device.
Type-HKH 12/1000c
Rated Voltage-66 KV
Normal Current-1250A
Frequency-5Hz
Breaking Capacity-3.4+KA Symmetrical
3.4+KA Asymmetrical
360 MVA Symmetrical

 Motor Voltage-220 V/DC

2. AIR CIRCUIT BREAKER
In this the compressed air pressure around 15 kg per cm^2 is used for extinction of
arc caused by flow of air around the moving circuit . The breaker is closed by
applying pressure at lower opening and opened by applying pressure at upper
opening. When contacts operate, the cold air rushes around the movable contacts
and blown the arc:
It has the following advantages over OCB:i.
ii.
iii.
iv.
v.
vi.
vii.

Fire hazard due to oil are eliminated.

Operation takes place quickly.
There is less burning of contacts since the duration is short and consistent.
Facility for frequent operation since the cooling medium is replaced
constantly.
Rated Voltage-6.6 KV
Current-630 A
Auxiliary current-220 V/DC 51

3. SF6 CIRCUIT BREAKER

This type of circuit breaker is of construction to dead tank bulk oil to circuit
breaker but the principle of current interruption is similar to that of air blast circuit
breaker. It simply employs the arc extinguishing medium namely SF6. When it is
broken down under an electrical stress, it will quickly reconstitute itself.
Circuit Breakers-HPA
Standard-1 EC 56
Rated Voltage-12 KV
Insulation Level-28/75 KV
Rated Frequency-50 Hz
Breaking Current-40 KA
Rated Current-1600 A

 Making Capacity-110 KA
4.VACUUM CIRCUIT BREAKER
It works on the principle that vacuum is used to save the purpose of insulation
and. In regards of insulation and strength, vacuum is superior dielectric medium
and is better that all other medium except air and sulphur which are generally
used at high pressure.
Rated frequency-50 Hz
Rated making Current-10 Peak KA
Rated Voltage-12 KV
Supply Voltage Closing-220 V/DC

GENERATORS
The generator works on the principle of electromagnetic induction. There are
two components stator and rotor. The rotor is the moving part and the stator is
the stationary part. The rotor, which has a field winding, is given a excitation
through a set of 3000rpm to give the required frequency of HZ. The rotor is
cooled by Hydrogen gas, which is locally manufactured by the plant and has
high heat carrying capacity of low density. If oxygen and hydrogen get mixed
then they will form very high explosive and to prevent their combining in any
way there is seal oil system. The stator cooling is done by de-mineralized (DM)
water through hollow conductors. Water is fed by one end by Teflon tube. A
boiler and a turbine are coupled to electric generators. Steam from the boiler is
fed to the turbine through the connecting pipe. Steam drives the turbine rotor.
The turbine rotor drives the generator rotor which turns the electromagnet
within the coil of wire conductors.
Carbon dioxide is provided from the top and oil is provided from bottom to the
generator. With the help of carbon dioxide the oil is drained out to the oil tank.
Hydrogen gas is used to cool down the rotor.
Lube oil is used to cool the bearings.

 DM water is used to cool the stator

Seal oil is used to prevent hydrogen leakage
Seal oil coolers are present to cool the seal oil
Hydrogen dryer are used which removes the moisture from hydrogen gas
and
then is supplied to the generator.
Clarified water in cooling tower is used to cool down the hydrogen gas
RATINGS OF THE GENERATORS USED
Turbo generator 110MW
The 110 MW generator generates 11.00 KV. The voltage is stepped up to 220
KV with the help of generator transformer and is connected to the grid
The voltage is stepped down to 6.6 KV with the help of UNIT AUXILLARY
TRANSFORMER (UAT) and this voltage is used to drive the HT motors. The
voltage is further stepped down to 415 V and then to 220 V and this voltage is
used to drive Lt Motors.

TRANSFORMERS
INTRODUCTION
It is a static machine which increases or decreases the AC voltage without
changing the frequency of the supply. It is a device that:
Transfer electric power from one circuit to another.
It accomplishes this by electromagnetic induction.
In this the two electric circuits are in mutual inductive influence of each
other

WORKING PRINCIPLE:
It works on FARADAYS LAW OF ELECTROMAGNETIC INDUCTION
(self or mutual induction depending on the type of transformer)
MAIN PARTS:
1.CONSERVATOR
It is used generally to conserve the insulating property of the oil from
deterioration& protect the transformer against failure on account of bad quality of
oil.

2.SILICAGEL DEHYDRATING BREATHER

It is used to prevent entry of moisture inside the transformer tank. The breather
consists of silica gel

3.GAS OPERATED RELAY (BUCHHOLZ RELAY) It is a gas actuated relay

used for protecting oil immersed transformer against all types of faults. It indicates
presence of gases in case of some minor fault & take out the transformer out of
circuit in case of serious fault.
4. BUSHINGS It is made from highly insulating material to insulate & to bring out
the terminals of the transformer from the container. The bushings are of 3 types:
a. Porcelain bushings used for low voltage transformer
b. Oil filled bushings used for voltage up to 33KV.
c. Condensed type bushings used for voltage above 33KV
5.OIL GUAGE
Every transformer with an oil guage to indicate the oil level. The oil guage may be
provided with the alarm contacts which gave an alarm the oil level has dropped
beyond permissible height due to oil leak etc.
6.TAPPINGS
The transformer are usually provided with few tappings on secondary side so that
output voltage can be varied for constant input voltage.
7.RADIATORS
It increases the surface area of the tank & more heat is thus radiated in less time.
8.WINDINGS TEMPERATURE INDICATOR (OIL GUAGE)
Device which indicates the temperature of winding of transformer & possible
damage to the transformer due too overload can be prevented.

COOLING OF TRANSFORMERS OF LARGE MVA

As size of transformer becomes large, the rate of the oil circulating becomes
insufficient to dissipate all the heat produced & artificial means of increasing the

circulation by electric pumps. In very large transformers, special coolers with

water circulation may have to be employed.
TYPES OF COOLING
Air cooling
1. Air Natural (AN)
2. Air Forced (AF)
Oil immersed cooling
1. Oil Natural Air Natural (ONAN)
2. Oil Natural Air Forced (ONAF)
3. Oil Forced Air Natural (OFAN)
4. Oil Forced Air Forced (OFAF)
Oil immersed Water cooling
1. Oil Natural Water Forced (ONWF)
2. Oil Forced Water Forced (OFWF)
UNIT AUXILIARY TRANSFORMER (UAT)
The UAT draws its input from the main bus-ducts. The total KVA capacity of UAT
required can be determined by assuming 0.85 power factor & 90% efficiency for
total auxiliary motor load. It is safe & desirable to provide about 20% excess
capacity then circulated to provide for miscellaneous auxiliaries & possible
increase in auxiliary.

STATION TRANSFORMER
It is required to feed power to the auxiliaries during startups. This transformer is
normally rated for initial auxiliary load requirements of the unit in typical cases;
this load is of the order of 60% of the load at full generating capacity. It is provided
with on load tap change to cater to the fluctuating voltage of the grid.

NEUTRAL GROUNDED TRANSFORMER

This transformer is connected with supply coming out of UAT in stage-2. This is
used to ground the excess voltage if occurs in the secondary of UAT in spite of
rated voltage.

SWITCH YARD
As we know that electrical energy cant be stored like cells, so what we generate
should be consumed instantaneously. But as the load is not constants therefore we
generate electricity according to need i.e. the generation depends upon load. The

yard is the places from where the electricity is send outside. It has both outdoor
and indoor equipments.
OUTDOOR EQUIPMENTS
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.

BUS BAR.
LIGHTENING ARRESTER
WAVE TRAP
BREAKER
CAPACITATIVE VOLTAGE TRANSFORMER
EARTHING ROD
CURRENT TRANSFORMER.
POTENTIAL TRANSFORMER
LIGHTENING MASK

INDOOR EQUIPMENTS
i.
ii.
iii.

RELAYS.
CONTROL PANELS
CIRCUIT BREAKERS

BUS BAR
Bus bars generally are of high conductive aluminum conforming to IS-5082 or
copper of adequate cross section .Bus bar located in air insulated enclosures &
segregated from all other components .Bus bar is preferably cover with
polyurethane.
BY PASS BUS
This bus is a backup bus which comes handy when any of the buses become faulty.
When any operation bus has fault, this bus is brought into circuit and then faulty
line is removed there by restoring healthy power line.
LIGHTENING ARRESTOR
It saves the transformer and reactor from over voltage and over currents. It
grounds the overload if there is fault on the line and it prevents the generator
transformer. The practice is to install lightening arrestor at the incoming terminal
of the line. We have to use the lightning arrester both in primary and secondary of

transformer and in reactors. A meter is provided which indicates the surface

leakage and internal grading current of arrester.
WAVE TRAP
Power line carrier communication (PLCC) is mainly used for telecommunication,
tele-protection and tele-monitoring between electrical substations through power
lines at high voltages, such as 110 kV, 220 kV, and 400 kV. PLCC integrates the
transmission of communication signal and 50/60 Hz power signal through the same
electric power cable. The major benefit is the union of two important applications
in a single system. WAVETRAP is connected in series with the power
(transmission) line. It blocks the high frequency carrier waves (24 KHz to 500
KHz) and let power waves (50 Hz - 60 Hz) to pass-through.
BREAKER
Circuit breaker is an arrangement by which we can break the circuit or flow of
current. A circuit breaker in station serves the same purpose as switch but it has
many added and complex features. The basic construction of any circuit breaker
requires the separation of contact in an insulating fluid that servers two functions:
i. extinguishes the arc drawn between the contacts when circuit breaker opens.
ii. It provides adequate insulation between the contacts and from each contact to
earth.
CAPACITATIVE VOLTAGE TRANSFORMER
A capacitor voltage transformer (CVT) is a transformer used in power systems to
step-down extra high voltage signals and provide low voltage signals either for
measurement or to operate a protective relay. It is located in the last in the
switchyard as it increases the ground resistance. Finally the voltage from CVT in
the switchyard is sent out from the station through transmission lines.
EARTHING ROD
Normally un-galvanized mild steel flats are used for earthling. Separate earthing
electrodes are provided to earth the lightening arrestor whereas the other
equipments are earthed by connecting their earth leads to the rid/ser of the ground
mar.

CURRENT TRANSFORMER
It is essentially a step up transformer which step down the current to a known ratio.
It is a type of instrument transformer designed to provide a current in its secondary
winding proportional to the alternating current flowing in its primary.
POTENTIAL TRANSFORMER
It is essentially a step down transformer and it step downs the voltage to a known
ratio.
RELAYS
Relay is a sensing device that makes your circuit ON or OFF. They detect the
abnormal conditions in the electrical circuits by continuously measuring the
electrical quantities, which are different under normal and faulty conditions, like
current, voltage frequency. Having detected the fault the relay operates to complete
the trip circuit, which results in the opening of the circuit breakers and disconnect
the faulty circuit. There are different types of relays:
i.
ii.
iii.
iv.

Current relay
Potential relay
Electromagnetic relay
Numerical relay etc.

AIR BREAK EARTHING SWITCH

The work of this equipment comes into picture when we want to shut down the
supply for maintenance purpose. This help to neutralize the system from induced
voltage from extra high voltage. This induced power is up to 2KV in case of 400
KV lines.
ELECTROSTATIC PRECIPITATOR
An electrostatic precipitator ( ESP) or electrostatic air cleaner is a particulate
collection device that removes particles from a flowing gas (such as air) using the
force of an induced electrostatic charge. Electrostatic precipitators are highly
efficient filtration devices that minimally impede the flow of gases through the
device, and can easily remove fine particulate matter such as dust and smoke from
the air stream.

In contrast to wet scrubbers which apply energy directly to the flowing fluid
medium, an ESP applies energy only to the particulate matter being collected and
therefore is very efficient in its consumption of energy (in the form of
electricity).The most basic precipitator contains a row of thin vertical wires, and
followed by a stack of large flat metal plates oriented vertically, with the plates
typically spaced about 1 cm to18 cm apart, depending on the application. The air or
gas stream flows horizontally through the spaces between the wires, and then
passes through the stack of plates. A negative voltage of several thousand volts is
applied between wire and plate. If the applied voltage is high enough an electric
(corona) discharge ionizes the gas around the electrodes. Negative ions flow to the
plates and charge the gas-flow particles. The ionized particles, following the
negative electric field created by the power supply, move to the grounded plates.
Particles build up on the collection plates and form a layer. The layer does not
collapse, thanks to electrostatic pressure (given from layer resistivity, electric field,
and current flowing in the collected layer).

CONTROL & INSTRUMENTATION

INTRODUCTION

This division basically calibrates various instruments and takes care of any faults
occur in any of the auxiliaries in the plant. Instrumentation can be well defined
as a technology of using instruments to measure and control the physical and
chemical properties of a material.

C&I LABS
Manometry Lab.
Protection and Interlocks Lab.
Automation Lab.
Electronics Lab.
Water Treatment Plant.
Furnaces Safety Supervisory System Lab

OPERATION AND MAINTAINANCE

Control and Instrumentation Department has following Control Units:
1. Unit Control Board.
2. Main Control Board
3. Analog & Digital Signal Control
4. Current Signal Control
This department is the brain of the plant because from the relays to transmitters
followed by the electronic computation chipsets and recorders and lastly the
controlling circuitry, all fall under this.

MANOMETRY LAB
TRANSMITTERS

It is used for pressure measurements of gases and liquids, its working principle is
that the input pressure is converted into electrostatic capacitance and from there it
is conditioned and amplified. It gives an output of 4-20 ma DC. It can be mounted
on a pipe or a wall. For liquid or steam measurement transmitters is mounted
below main process piping and for gas measurement transmitter is placed above
pipe.
MANOMETER
Its a tube which is bent, in U shape. It is filled with a liquid. This device
corresponds to a difference in pressure across the two limbs.
BOURDEN PRESSURE GAUGE
Its an oval section tube. Its one end is fixed. It is provided with a pointer to
indicate the pressure on a calibrated scale. It is of 2 types :
(a) Spiral type: for Low pressure measurement.
(b) Helical Type: for High pressure measurement. While selecting Pressure Gauge
these parameters should keep in mind1. Accuracy
2. Safety
3. Utility
4. Price
ACCURACY
Higher Accuracy implies Larger Dial Size for accuracy of small and readable
pressure scale increments.

SAFETY

While selecting Pressure Gauge it should consider that Gauge Construction

Material should be chemically compatible with the environment either inside or
outside it.
UTILITY
It should keep it mind that range of the Gauge should be according to our need else
Overpressure Failure may occur resulting in damage of Gauge.
PRICE
Lager the Gauges Dial size larger would be our price. Better Gauges
Construction material also increases the cost. So they must be chosen according to
our need.
2. PROTECTION AND INTERLOCKING
INTERLOCKING
It is basically interconnecting two or more equipments so that if one equipment
fails other one can perform the tasks. This type of interdependence is also created
so that equipments connected together are started and shut down in the specific
sequence to avoid damage. For protection of equipments tripping are provided for
all the equipments. Tripping can be considered as the series of instructions
connected through OR GATE, which trips the circuit. The main equipments of this
lab are relay and circuit breakers. Some of the instrument uses for protection are:
RELAY
It is a protective device. It can detect wrong condition in electrical circuits by
constantly measuring the electrical quantities flowing under normal and faulty
conditions. Some of the electrical quantities are voltage, current, phase angle and
velocity. 2. FUSES it is a short piece of metal inserted in the circuit, which melts
when heavy current flows through it and thus breaks the circuit. Usually silver is
used as a fuse material because:
a. The coefficient of expansion of silver is very small. As a result no critical
fatigue occurs and thus the continuous full capacity normal current ratings are
assured for the long time.

b. The conductivity of the silver is unimpaired by the surges of the current that
produces temperatures just near the melting point c. Silver fusible elements can be
raised from normal operating temperature to vaporization quicker than any other
material because of its comparatively low specific heat.
Miniature Circuit Breaker
They are used with combination of the control circuits to.
a) Enable the staring of plant and distributors.
b) Protect the circuit in case of a fault. In consists of current carrying contacts, one
movable and other fixed. When a fault occurs the contacts separate and are is stuck
between them. There are three types of trips
. I. MANUAL TRIP
II. THERMAL TRIP
III. SHORT CIRCUIT TRIP
Protection and Interlock System1) HIGH TENSION CONTROL CIRCUIT
for high tension system the control system is excited by separate D.C supply. For
starting the circuit conditions should be in series with the starting coil of the
equipment to energize it. Because if even a single condition is not true then system
will not start.
2) LOW TENSION CONTROL CIRCUIT
For low tension system the control circuits are directly excited from the 0.415 KV
A.C supply.
The same circuit achieves both excitation and tripping. Hence the tripping coil is
provided for emergency tripping if the interconnection fails.
3. AUTOMATION LAB
This lab deals in automating the existing equipment and feeding routes. Earlier,
the old technology dealt with only (DAS) Data Acquisition System and came to be

known as primary systems. The modern technology or the secondary systems are
coupled with (MIS) Management Information System. But this lab universally
applies the pressure measuring instruments as the controlling force. However, the
relays are also provided but they are used only for protection and interlocks.
4. PYROMETRY LAB
LIQUID IN GLASS THERMOMETER
Mercury in the glass thermometer boils at 340 C which limits the range of
temperature that can be measured. It is L shaped thermometer which is designed to
reach all inaccessible places.
ULTRA VIOLET SENSOR-This device is used in furnace and it measures the
intensity of ultra violet rays there and according to the wave generated which
directly indicates the temperature in the furnace.
THERMOCOUPLES- This device is based on SEEBACK and PELTIER effect. It
comprises of two junctions at different temperature. Then the emf is induced in the
circuit due to the flow of electrons. This is an important part in the plant.
RTD (RESISTANCE TEMPERATURE DETECTOR)- It performs the function of
thermocouple basically but the difference is of a resistance. In this due to the
change in the resistance the temperature difference is measured. In this lab, also
the measuring devices can be calibrated in the oil bath or just boiling water (for
low range devices) and in small furnace (for high range devices) .
5. FURNACE SAFETY AND SUPERVISORY SYSTEM LAB
This lab has the responsibility of starting fire in the furnace to enable the burning
of coal. For first stage coal burners are in the front and rear of the furnace and for
the second and third stage corner firing is employed. Unburnt coal is removed
using forced draft or induced draft fan. The temperature inside the boiler is
1100C and its heights 18 to 40 m. It is made up of mild steel. An ultra violet
sensor is employed in furnace to measure the intensity of ultra violet rays inside
the furnace and according to it a signal in the same order of same mV is generated
which directly indicates the temperature of the furnace. For firing the furnace a 10
KV spark plug is operated for ten seconds over a spray of diesel fuel and pre-

heater air along each of the feeder-mills. The furnace has six feeder mills each
separated by warm air pipes fed from forced draft fans. In first stage indirect firing
is employed that is feeder mills are not fed directly from coal but are fed from
three feeders but are fed from pulverized coalbunkers. The furnace can operate on
the minimum feed from three feeders but under no circumstances should anyone
be left out under operation, to Prevent creation of pressure different with in the
furnace, which threatens to blast it.
6. ELECTRONICS LAB
This lab undertakes the calibration and testing of various cards. It houses various
types of analytical instruments like oscilloscopes, integrated circuits, cards auto
analyzers etc. Various processes undertaken in this lab are:
1. Transmitter converts mV to mA.
2. Auto analyzer purifies the sample before it is sent to electrodes. It extracts the
magnetic portion.
ANNUNCIATIN CARDS They are used to keep any parameter like temperature
etc. within limits. It gets a signal if parameter goes beyond limit. It has a switching
transistor connected to relay that helps in alerting the UCB.
CONTROL & MONITORING MECHANISMS
There are basically two types of Problems faced in a Power Plant
1. Metallurgical
2. Mechanical
Mechanical -Problem can be related to Turbines that is the max speed permissible
for a turbine is3000 rpm so speed should be monitored and maintained at that
level. Metallurgical Problem can be view as the max Inlet Temperature for Turbine
is 1060 C so temperature should be below the limit. Monitoring of all the
parameters is necessary for the safety of both:
1. Employees
2. Machines

So the Parameters to be monitored are:

1. Speed
2. Temperature
3. Current
4. Voltage
5. Pressure
6. Eccentricity
7. Flow of Gases
8. Vacuum Pressure
9. Valves
10. Level
11. Vibration

PRESSURE MONITORING
Pressure can be monitored by three types of basic mechanisms
1. Switches
2. Gauges
3. Transmitter type
For gauges we use Bourdon tubes. The Bourdon Tube is a non-liquid pressure
measurement device. It is widely used in applications where inexpensive static
pressure measurements are needed. A typical Bourdon tube contains a curved tube
that is open to external pressure input on one end and is coupled mechanically to
an indicating needle on the other end, as shows schematically below.

For Switches pressure switches are used and they can be used for digital means of
monitoring as switch being ON is referred as high and being OFF is as low. All the
monitored data is converted to either Current or Voltage parameter.
The Plant standard for current and voltage are as under
Voltage : 0 10 Volts range
Current : 4 20 milli-Amperes
We use 4mA as the lower value so as to check for disturbances and wire breaks.
Accuracy of such systems is very high.
ACCURACY: 0.1 % Programmable Logic Circuits (PLCs) are used in the
process as they are the heart of Instrumentation

TEMPERATURE MONITORING
We can use Thermocouples or RTDs for temperature monitoring. Normally RTDs
are used for low temperatures. Thermocouple selection depends upon two factors:
1. Temperature Range
2. Accuracy Required
Normally used Thermocouple is K Type Thermocouple:

In this we use Chromel (Nickel-Chromium Alloy) / Alumel (Nickel-Aluminium

Alloy) as two metals. This is the most commonly used general purpose
thermocouple. It is inexpensive and, owing to its popularity, available in a wide
variety of probes. They are available in the200C to +1200C range. Sensitivity is
approximately 41 V/C.
RTDs are also used but not in protection systems due to vibrational errors.
We pass a constant current through the RTD. So that if R changes then the Voltage
also changes
RTDs used in Industries are Pt100 And Pt1000
Pt100: 0C 100 ( 1 = 2.5 0C )
Pt1000: 0C - 1000
Pt1000 is used for higher accuracy.
The gauges used for Temperature measurements are mercury filled Temperature
gauges.
For Analog medium thermocouples are used and for Digital medium Switches are
used which are basically mercury switches.

FLOW MEASUREMENT
Flow measurement does not signify much and is measured just for metering
purposes and for monitoring the processes
ROTAMETERS:
A Rotameter is a device that measures the flow rate of liquid or gas in a closed
tube. It is occasionally misspelled as 'Rotometer'. It belongs to a class of meters
called variable area meters, which measure flow rate by allowing the cross
sectional area the fluid travels through to vary, causing some measurable effect. A
rotameter consists of a tapered tube, typically made of glass, with a float inside that
is pushed up by flow and pulled down by gravity. At a higher flow rate more area
(between the float and the tube) is needed to accommodate the flow, so the float
rises. Floats are made in many different shapes, with spheres and spherical ellipses

being the most common. The float is shaped so that it rotates axially as the fluid
passes. This allows you to tell if the float is stuck since it will only rotate if it is
not.
For Digital measurements Flap system is used.
For Analog measurements we can use the following methods
1. Flow meters
2. Venturimeters / Orifice meters
3. Turbines
4. Mass flow meters (oil level)
5. Ultrasonic Flow meters
6. Magnetic Flow meter (water level )
Selection of flow meter depends upon the purpose, accuracy and liquid to be
measured so different types of meters used.
TURBINE TYPE:
They are simplest of all. They work on the principle that on each rotation of the
turbine a pulse is generated and that pulse is counted to get the flow rate.

VENTURIMETERS :
Referring to the diagram, using Bernoulli's equation in the special case of
incompressible fluids (such as the approximation of a water jet), and the theoretical
pressure drop at the constriction would be given by (/2)(v2 2- v1 2). And we
know that rate of flow is given by: Flow = k (D.P) Where DP is Differential
Pressure or the Pressure Drop.

CONTROL VALVES
A valve is a device that regulates the flow of substances (either gases, fluidized
solids, slurries, or liquids) by opening, closing, or partially obstructing various
passageways. Valves are technically pipe fittings, but usually are discussed
separately. Valves are used in a variety of applications including industrial,
military, commercial, residential, transportation. Plumbing valves are the most
obvious in everyday life, but many more are used.
Some valves are driven by pressure only, they are mainly used for safety purposes
in steam engines and domestic heating or cooking appliances. Others are used in a
controlled way, like in Otto cycle engines driven by a camshaft, where they play a
major role in engine cycle control.
Many valves are controlled manually with a handle attached to the valve stem. If
the handle is turned a quarter of a full turn (90) between operating positions, the
valve is called a quarter-turn valve. Butterfly valves, ball valves, and plug valves
are often quarter-turn valves. Valves can also be controlled by devices called
actuators attached to the stem. They can be electromechanical actuators such as an
electric motor or solenoid, pneumatic actuators which are controlled by air
pressure, or hydraulic actuators which are controlled by the pressure of a liquid
such as oil or water. So there are basically three types of valves that are used in
power industries besides the handle valves.
They are

: PNEUMATIC VALVES They are air or gas controlled which is compressed to

turn or move them
HYDRAULIC VALVES They utilize oil in place of Air as oil has better
compression
MOTORISED VALVES These valves are controlled by electric motors

FURNACE SAFEGUARD SUPERVISORY SYSTEM

FSSS is also called as Burner Management System (BMS). It is a microprocessor
Based programmable logic controller of proven design incorporating all protection
facilities required for such system. Main objective of FSSS is to ensure safety of
the boiler.
The 95 MW boilers are indirect type boilers. Fire takes place in front and in rear
side. Thats why its called front and rear type boiler.
The 210 MW boilers are direct type boilers (which means that HSD is in direct
contact with coal) firing takes place from the corner. Thus it is also known as
corner type boiler.
IGNITER SYSTEM
Igniter system is an automatic system, it takes the charge from 110kv and this
spark is brought in front of the oil guns, which spray aerated HSD on the coal for
coal combustion. There is a 5 minute delay cycle before igniting, this is to evacuate
or burn the HSD. This method is known as PURGING.
PRESSURE SWITCH
Pressure switches are the devices that make or break a circuit. When pressure is
applied, the switch under the switch gets pressed which is attached to a relaythat
makes or break the circuit.
Time delay can also be included in sensing the pressure with the help of pressure
valves.

Examples of pressure valves:

1. Manual valves (tap)
2. Motorized valves (actuator) works on motor action
3. Pneumatic valve (actuator) - works due to pressure of compressed air
4. Hydraulic valve