Professional Documents
Culture Documents
by
ABHINAW KUMAR RAI
ELECTRICAL ENGINEERING
BANKURA UNNAYANI INSTITUTE OF ENGINEERING
ACKNOWLEDGEMENT
The dissertation has been prepared based on the
vocational training undergone in a highly
esteemed organization of Eastern region, a
pioneer in Generation Transmission & Distribution
of power, one of the most technically advanced &
largest thermal power stations in West Bengal,
the Mejia Thermal Power Station (M.T.P.S), under
DVC. I would like to express my heartfelt
gratitude to the authorities of Mejia Thermal
Power Station and BANKURA UNNAYANI INSTITUTE OF
ENGINEERING for providing me such an opportunity to
undergo training in the thermal power plant of
DVC, MTPS. I would also like to thank the
Engineers, highly experienced without whom
such type of concept building in respect of
thermal power plant would not have been
possible. Some of them are:
1) Mr. Parimal Kumar Dubey
2) Mr.
3) Mr.
4) Mr.
INTRODUCTION
Damodar Valley Corporation was established on 7th July
1948.It is the most reputed company in the eastern
zone of India. DVC in established on the Damodar River.
It also consists of the Durgapur Thermal Power Plant in
Durgapur. The MTPS under the DVC is the second
largest thermal plant in West Bengal. It has the
capacity of 2340MW with 4 units of 210MW each, 2
units of 250MW each & 2 units of 500 MW each. With
the introduction of another two units of 500MW that is
in construction it will be the largest in West Bengal.
Mejia Thermal Power Station also known as MTPS is
located in the outskirts of Raniganj in Bankura District.
It is one of the 5 Thermal Power Stations of Damodar
Valley Corporation in the state of West Bengal. The total
power plant campus area is surrounded by boundary
walls and is basically divided into two major parts, first
the Power Plant area itself and the second is the Colony
area for the residence and other facilities for MTPS
employees.
TECHNICAL SPECIFICATION OF
MTPS
INSTALLED CAPACITY: 1) Total number of Units : - 4 X 210 MW(unit 1 to 4) with Brush
Type Generators, 2 X 250 MW(unit 5 and 6) with Brush less Type
Generators, 2*500 MW(unit 7 and 8) Generators.
2) Total Energy Generation: - 2340 MW
3) Source of Water: - Damodar River
4) Sources of Coal: - B.C.C.L and E.C.L, also imported from
Indonesia
Station
Unit no.
MEJIA TPS
1,2,3&4
5&6
1&2
MEJIA TPS
Capacity(MW
)
210
250
500
Boiler
Make
BHEL
BHEL
BHEL
Turbine
Make
BHEL
BHEL
BHEL
COAL HANDLING
PLANT
Coal
transported
from mines by
railway wagons
Unloaded to a
moving
underground
conveyor belt
Crusher
house
(20mm)
Dead
storage
(40 days)
Combustion
Live storage (
hrs)
(BOILER HOUSE)
Boiler (hot
air+coal
dust)
Pulverized
coal (200
mesh)
COAL
MILL
Chlorination:
Neutral organic matter is very heterogeneous i.e. it contains
many classes of highmolecular weight organic compounds.
Humic substances constitute a major portion ofthe dissolved
organic carbon from surface waters. They are complex mixtures
of organic compounds with relatively unknown structures and
chemical composition.
BOILER
Boiler is an enclosed vessel in which water is heated and
circulated until the water is turned in to steam at the required
pressure. Coal is burned inside the combustion chamber of
boiler. The products of combustion are nothing but gases.
These gases which are at high temperature vaporize the water
inside the boiler to steam.
Types of Boiler:
1.Fire tube
2.Water tube
Super heater: Super heaters (SH) are meant for elevating the
steam temperature above the saturation temperature in
phases; so that maximum work can be extracted from high
energy (enthalpy) steam and after expansion in Turbine, the
dryness fraction does not reach below 80%, for avoiding
Turbine blade erosion/damage and attaining maximum Turbine
internal efficiency. Steam from Boiler Drum passes through
primary super heater placed in the convective zone of the
furnace, then through platen super heater placed in the radiant
zone of furnace and thereafter, through final super heater
placed in the convective zone. The superheated steam at
requisite pressure and temperature is taken out of boiler to
rotate turbo-generator.
TURBINE
A steam turbine is a prime mover which continuously converts
the energy of highpressure, high temperature steam supplied
by the boiler into shaft work with lowpressure, low temperature
steam exhausted to a condenser.
Cooling tower
Cooling towers cool the warm water discharged from the
condenser and feed the cooled water backto the condenser.
They thus reduce the cooling water demand in the power
plants. Wet coolingtowers could be mechanically draught or
natural draught. In M.T.P.S the cooling towers are I.D.type for
units 1-6 and natural draught for units 7&8.
CHIMNEY
A chimney may be considered as a cylindrical hollow tower
made of bricks or steel. In MTPS the chimneys of eight units are
made of bricks. Chimneys are used to release the exhaust
gases (coming from the furnace of the boiler)high up in the
atmosphere. So, the height of the chimneys are made high.
ELECTROSTAIC PRECIPITATOR
The principal components of an ESP are 2 sets of electrodes
insulated from each other. First set of rows are electrically
grounded vertical plates called collecting electrodes while the
second set consists of wires called discharge electrodes. the
negatively charged fly ash particles are driven towards the
collecting plate and the positive ions travel to the negatively
charged wire electrodes. Collected particulate matter is
removed from the collecting plates by a mechanical hammer
scrapping system.
ELECTRIC GENERATOR
In M.T.P.S. there are 6 electric generators for units 1 to 6. These
are 3 phase turbo generators, 2 pole cylindrical rotor type
synchronous machines which are directly coupled to the steam
turbine. The generator consist of 2 parts mainly the stator and
the rotor. Stator: The stator body is designed to withstand
internal pressure of hydrogen-air mixture without any residual
deformation. The stator core is built up of segmental punching
TRANSFORMERS
4. Lightning arrestors
5. Transformer bushings
6. Breather and silica gel
Generating transformer 1, 2, 3, 4
MVA: 150/200/250 (H.V.)
AUXILIARY TRANSFORMRERS
Station Service Transformers Normal source to the station
auxiliaries and standby source to the unit auxiliaries during
start up and after tripping of the unit is station auxiliary
transformer. Quantity of station service transformers and
their capacity depends upon the unit sizes and nos. Each
station supply transformer shall be one hundred percent
standby of the other. Station service transformers shall cater
to the simultaneous load demand due to start up power
requirements for the largest unit, power requirement for the
station auxiliaries required for running the station and
power requirement for the unit auxiliaries of a running unit
in the event of outage of the unit source of supply. The
no. and approximate capacity of the SST depending upon the
no. and MW rating of the TG sets are indicated below.
Specification
MVA: 12.5/16
The above figure shows the power line diagram in the control
room. It clearly shows how the electric power generated by the
generator is transmitted through the generating transformers
into the bus and the distribution of power by the unit auxiliary
transformers.
EXCITATION SYSTEM
The purpose of excitation system is to continuously provide the
appropriate amount of D.C. field current to the generator field
winding. The excitation system is required to function reliably
under the following conditions of the generator and the
system to which it is connected.
Functional components of an excitation system :
A good excitation system consists of properly co-ordinated
functional components which are
a) Excitation Power source
b) Semiconductor Rectifier
c) Voltage controller
SWITCHYARD SECTION
A switchyard is essentially a hub for electrical power
sources. For instance, a switchyard will exist at a generating
station to coordinate the exchange of power between the
generators and the transmission lines in the area. A switchyard
will also exist when high voltage lines need to be converted to
lower voltage for distribution to consumers. Here in MTPS there
is a big switch yard section for the units one to six, and also for
seven & eight there also a switch yard. Some of the operation
of the components of the switch yard is sometimes done from
the control rooms of respective units. That is the switch yard
under each unit is sometimes control from the control rooms of
each unit respectively
Transformer :
respectively.
In
electrical
system
it
is
necessary
to
4.Potential transformers :
In any electrical power system it is necessary to
a) Monitor voltage and power factor,
b) Meter power consumption,
c) Feed power to control and indication circuit and
d) Detect abnormalities
(i.e. under/over voltage, direction of power flow etc) and
feed impulse to protective device/alarm circuit. Standard relay
and metering equipments does not permit them to be
connected directly to the high voltage system.Potential
transformers therefore play a key role by performing the
following functions.
POWER TRANSFORMER:
The use of power transformer in a switchyard is to change the
voltage level. At the sending
and usually
step
up
transformers are used to evacuate power at transmission
voltage level. On the other hand at the receiving end step down
transformers are installed to match
the voltage to
sub
transmission or distribution level. In many switchyards
autotransformers are used widely for interconnecting two
switchyards with different voltage level (such as 132 and 220
KV)
1-Main tank
2-Radiator
3-Reservoir tank
4-Bushing
5-WTI & OTI Index
6-Breather
7-Buccholz relay
Insulator
The live equipments are mounted over the steel
structures or suspended from gantries with sufficient
insulation in between them. In outdoor use electrical
porcelain insulators are most widely used. Following two
types of insulators are used in switchyard.
a. Pedestal type
Instantaneous relay
Bus bar trip relay
Lock out relay
Numerical LBB protection relay
Transformer differential protection relay
Circulating differential protection relay
Contact multi-relay
Auxiliary relay
Trip circuit R-Phase relay
EUS section relay
DC fail accept relay
Trip circuit R-phase super relay Y-phase B-phase
LBB protection relay.
SWITCHGEAR
HV SWITCHGEARS
Indoor metal clad draw out type switchgears with associated
protective and control equipments are employed (fig. 2). Air
break, Air Blast circuit breakers and Minimum Oil circuit
breakers could still be found in some very old stations.
Present trend is to use SF6or vacuum circuit breakers. SF6 and
vacuum circuit breakers requires smaller size panels and
thereby reasonable amount of space is saved. Fig. 2: General
arrangement of 6.6 KV switchgear panels The main bus bars
of the switchgears are most commonly made up of high
conductivity aluminium or aluminium alloy with rectangular
cross section mounted in side the switchgear cubicle
supported by moulded epoxy, fibre glass or porcelain
insulators. For higher current rating copper bus bars are
sometimes used in switchgears.
LV SWITCHGEARS
LV switchgears feed power supply to motors above 110 KW and
upto160 KW rating and to Motor Control Centers (M.C.C). LV
system is also a grounded system where the neutral of
transformers are solidly connected to ground. The duty
involves momentary loading, total load throw off, direct on
line starting of motors and under certain emergency
condition automatic transfer of loads from one source of supply
to the other. The switchgear consists of metal clad continuous
line up of multi tier draw out type cubicles of simple and robust
construction. Each feeder is provided with an individual front
access door. The main bus bars and connections shall be of
high grade aluminium or aluminium alloy sized for the
specified current rating. The circuit breakers used in the LV
switchgear shall be air break 3 pole with stored energy, trip
free shunt trip mechanism. These are draw out type with
three distinct position namely, Service, Test and Isolated. Each
position shall have mechanical as well as electrical
indication. Provision shall be there for local and remote
electrical operation of the breakers. Mechanical trip push
button shall be provided to trip manually in the event of failure
of electrical trip circuit. Safety interlocks shall be provided to
prevent insertion and removal of closed breaker from
Service position to Test position and vice versa.
SWITCHING SCHEMES
One Main Bus and Transfer Bus scheme
This scheme is used in switchyards up to 132 KV. Under normal
condition all feeders arefed through their respective circuit
breakers from the main bus bar. During shutdown or outage of
any feeder breaker, that feeder can be transferred to transfer
bus and diverted through bus coupler breaker. In that case the
protection shall be transferred to the bus coupler circuit breaker
by changing the position of the trip transfer switch located at
the switchyard control panel. This diversion of the feeder from
its own circuit breaker to bus coupler circuit breaker and the
vice versa is possible even in live condition without any
interruption of supply to that feeder. In case of any main bus
fault the entire switchyard will collapse. To avoid such total
collapse of the switchyard a bus section circuit breaker is
provided in the middle position of the main bus.
GENERATOR PROTECTION
The purpose of generator protection is to provide
protection against abnormal operating condition and during
fault condition. In the first case the machine and the associated
circuit may be in order but the operating parameters (load,
frequency, temperature) and beyond the specified limits.
Such abnormal running condition would result in gradual
deterioration and ultimately lead to failure of the generator.
Over
current
protection:
d)
Unbalance
loading
protection:
Unbalance
loading is caused by single phase short circuit outside the
generator, opening of oneof the contacts of the generator
circuit breaker, snapping of conductors in the switchyard or
excessive single phase load. Unbalance load produces ve
phase sequence current which cause overheating of the
rotor surface and mechanical vibration. Normally 10% of
unbalance is permitted provided phase currents do not
exceed the rated values. For ve phase sequence currents
above 5-10% of rated value dangerous over heating of rotor
is caused and protection against this is an essential
requirement.
In the event
of loss of prime mover the generator operates as a motor
and drives the prime mover itself. In some cases this condition
could be very harmful as in the case of steam turbine sets
where steam acts as coolant, maintaining the turbine blades at
a constant temperature and the failure of steam results in
overheating due to friction and windage loss with subsequent
distortion of the turbine blade. This can be sensed by a power
relay with a directional characteristic and the machine can be
taken out of bar under this condition. Because of the same
reason a continuousvery low level of output from thermal sets
are not permissible.
This protection is
basically designed as back up protection for the part of the
installation situated between the generator and the
associated generator and unit auxiliary transformers. A back up
protection in the form of minimum impedance measurement is
used, in which the current windings are connected to the CTs in
the neutral connection of the generator and its voltage
windings through a P.T to the phase to phase terminal
voltage. The pick up impedance is set to such a value that it
is only energized by short circuits in the zone specified above
and does not respond to faults beyond the transformers.
c)
Inverse time
voltage relay connected across the secondary of the high
impedance neutral grounding transformer relay is used for
protection of around 95% of the stator winding against earth
fault.
Earth fault in
the entire stator circuits are detected by a selective earth
fault protection covering 100% of the stator windings. This
100% E/f relay monitors the whole stator winding by means of a
coded signal current continuously injected in the generator
winding through a coupling.
Under normal running
condition the signal current flows only in the stray
capacitances of the directly connected system circuit.
f) Rotor earth fault protection:
Normally a single rotor
earth fault is not so dangerous as the rotor circuit is
unearthed and current at fault point is zero. So only alarm is
provided on occurrence of 1st rotor earth fault. On occurrence
of the 2nd rotor earth fault between the points of fault the
field winding gets short circuited. The current in field circuit
increases, resulting in heating of the field circuit and the
exciter. But the more dangerous is disturbed symmetry of
magnetic circuit due to partial short circuited coils leading
to mechanical unbalance.
Battery Bank
Normally D.C. power is supplied by the float charger and the
batteries are kept in float condition at 2.15 V per cell to avoid
discharging. The charger consists of silicon diode or thyristor
rectifiers preferably working on 3 ph. 415 V supply in
conjunction with an automatic voltage regulator. When there
is a failure in the A.C. supply the batteries will come into
operation and in this process the batteries run down
within few hours.
After normalization of A.C. power the
batteries are charged quickly by using the boost charger at
2.75 V per cell. During this time the float chargeris isolated and
load is connected through the tap off point. After normalization
of battery voltage these are again put back into the float
charging mode. The output from the battery as well as the
charger is connected to the D.C. distribution board. From
D.C. distribution board power supply is distributed to different
circuits. D.C. system being at the core of the protection and
control mechanism very often two 100% capacity boards
with individual chargers and battery sets are used from
the consideration of the reliability and maintenance facility.
These two boards are interconnected by suitable tie lines.
CONCLUSION
The practical experience that I have gathered
during the overview training of large thermal
power plant having a large capacity of 2340 MW
for Unit# I to VIII in three weeks will be very
useful as a stepping stone in building bright
professional career in future life. It gave me large
spectrum to utilize the theoretical knowledge and
to put it into practice. The trouble shooting
activities in operation and decision making in
case of crisis made me more confident to work in
the industrial atmosphere. Moreover, this
overview training has also given a self realization
& hands-on experience in developing the
personality, interpersonal relationship with the
professional executives, staffs and to develop the
leadership ability in industry dealing with workers
of all categories. I would like to thank everybody
who has been a part of this project, without
whom this project would never be completed
with such ease.