Report on Industrial Training at B.E.C.L.

Training Duration : 8th June 2016- 22

June 2016

BHAVNAGAR ENERGY COMPANY LIMITED

Village Padva ,Taluko- Ghogha

Dist.- Bhavangar
SHANTILAL SHAH ENGINEERING COLLEGE
BHAVNAGAR
  Prepared By :-

(1) BEENA TUVAR

(B.E.-VI, Electrical)

(2) SHIIVANI PAREKH

(B.E.-VI, Electrical)

 Acknowledgement :

By achieving Approvel from the management of Bhavanagar

Energy Compony Limited (BECL) for the industial training, we
commenced our training at BECL plant. I really thanks to the Chief
General Manager Mr. Sudhir Bhargvaof BECL Thermal Power
Station, for permitting us to take vocational training of 15 days. I
convey my sincere gratitude to the Training head and also to the
HOD of Electrical Department and engineers of electrical
department. During my Training, I obtain the precious guidance
from,
 Mr. Ravirajsinh Zala (Engineer Electrical)
Thank you for your anticipation…..

HOD (Electrical Dept.)

Mr. Sanjay Rudakia

  Flow of Report :

Sr. No. Name of Topic

1. Constitutional view of plant

2. Simple Block Diagram of Thermal power plant

3. Different units of plant

4. Detailed information about Switch-yard

5. Protection Strategies

6. Basic Analysis of Components Employed in plant

7. Enclosure
  Why did we choose this plant?
-This plant is located quite near to the Bhavnagar. So, it can be
easilyaccessible &they also have transportation facility throughout
the city area. It is the best one plant which has been established in
this area. It has the plenty number of equipments to run the plant
continuously.

-By case out this thermal base power plant we would achieve
precious information regarded with it. Also get overall view and
practical knowledge about power system. And how to generate
power in the power station and their different auxiliary equipments
of the thermal power plant.

-It is the biggest one plant in India in the category of C.F.B.C.

Boiler is used to generate the power.

 Purpose of Training :-

-My main purpose of training is to gain overall information

regarding thermal power plant and its necessary accessories.
Also to get overall view and practical knowledge about power
system. And how to generate power in the power station and their
different auxiliary equipments of the thermal power plant.
  Constitutional view of plant:

-BhavnagarEnergy Company (B.E.C.L.), a government of

Gujarat’s Public Sector Undertaking (PSU) was incorporated on
26th July, 2007 under Companies act, 1956.
-B.E.C.L. has been promoted to exploit the lignite resources
available in the Bhavnagar district in the saurashtra Region for
power generation purpose.
-Thus, it was proposed to install 2*250 MW lignite based thermal
power plant at village padva, taluka-Ghogha of Bhavnagar district
in Gujarat.
-This is means that the two unit of power plant and each unit
produce the 250 MW power. Now unit-1 is completed and unit-2 is
in process. This power plant has estimated investment is about the
four thousand cores. This power plant is the basically used the
boiler& coal is combustion fuel. Which is converted into steam in
boiler and this steam is utilized in the turbine and finally convert
into electrical energy by the generator and then fed to the grid.
-250MW full load achieved on 16th, May, 2016 leading to COD.
And unit -2 synchronized is done on the date of 9 June 2016.
Now the both of units are to ready for the generation.
 Simple Layout of T.P.P :-
-The Thermal Power Plant in which the prime mover is steam
driven. Waterheated, turns into steam and spins a steam turbine
which either drives an electric generator or does some other work,
like ship propulsion.
-After it passes through the turbine, the steam is condensed in
condenser and recycled to where it was heated; this is known as a
Rankin cycle.
-The greatest variation in design of thermal power plant is due to
the different fuel sources.

 Different Units of Plant ;

  Switch yard
 T.G. unit( turbine & generator unit)
 Boiler
 ESP( electro static precipitator)
 Conveyer belt
 Cooling tower & cw unit
 Pump house
 Chimney
 DM Plant
 Silo Ash handling
 Compressor unit
 Control unit
 Screen house
 Staker reclaimer &bucket wheel(BWSR)
 Coal crusher(pulverized coal)
 Lime stone & lignite crusher

-Detailed information about the switch yard is given here, in

language as easy as possible.
- it contain many parts like,Isolators,circuit breakers,Earth
Swiches,Arc Horm,Insulator String,C.T.,P.T.,Wave trap, lightning
arrestor,conductors,etc.
  Switch yard :-

-Switch yard is basically consist of C.T. ,P.T., isolator , PLCC

(Power line carrier communication) ,transformer , hollow
insulator ,bay, circuit breaker ,transfer bus, earth switch, lightning
arrestor.
-This switch yard also has a control through the PLC-
programmable logic control and also used SCADA-(super
visionary control & monitoring data acquisition) software. Control
room contain metering &protection panel, PLCC Room.
 Outer view of Switch-yard

-The power generated by the plant is fed to grid by the Switch

yard. T.G. unit is 16.5 kW by generator and then it step-up to the
convert in 220kv by the transformer. This voltage is passed
through the CT and then isolator is connect than finally connect to
the circuit breaker. And also used to lightning arrestor to protect
the over current. the Control room also used the Master realy-86.
This is used for tripping signals. PLCC is used for the
communication between two substations. Modern substations may
be implemented using international standards such as IEC Standard
61850
Model of PLCC SCADA of switch yard is given below,

 Generator ;-
-The working principle of generator is based on faraday’s law of
electromagnetic induction, which states that the E.M.F. is always
produced in the conductor which is placed in the magnetic field
when there is a relative motion between conductor and the
magnetic field.
-If the output electrical energy is AC, it is called AC Generator
orAlternator. If output electric energy is DC then it is called DC
Generator.
-In small generator, the magnetic field is being produced in the
stator and the emf is produced in the rotor through faraday’s law.

Parameters Rating
Output power 250 MW
Power factor 0.86 lag
KVA 294100 KVA
Stator voltage 16500 V
Stator current 10281 A
Rotor voltage 299 V
Rotor current 2497 A
R.P.M 3000
Frequency 50
Phase 3
Connection Y- Y
Coolant Hydrogen
-Whereas, in large generator, the magnetic field is produced by the
electromagnetic in the rotor and the emf is produced in the stator.
Output is taken out from the stator.

 Transformer :-
-It is a static device used for transforming power from one circuit
to another without changing frequency. Generation of electric
power in low voltage level is very much cost effective. Hence,
electric power is generated in low voltage level. Usually, voltage is
transmitted at high level. If voltage level of power is increased, the
electric current of the power is reduced which causes reduction in
ohmic loss or I²R losses.

 Current Transformer :-

-When current in a circuit is too high to directly apply to

measuring instruments, a current transformer produces a reduce
current accurate proportional to the current in the circuit, which
can be conveniently connected to measuring and recording
instruments. The secondary current of CT is generally 1 to 5 A.

-The rating of CT is 400/800:1

  Potential Transformer :-

- A voltage transformer or potential transformer is like general

purpose step down transformer. Primary of this transformer is
connected across the phase or and ground depending upon the
requirement. The system voltage is applied across the terminals of
a primary winding of the transformer and then proportionate
secondary voltage appears across secondary terminals of the PT.
The secondary voltage of PT is generally 110 V.
 Generator Transformer :-

-TYPE OF COOLING: - ONAN/ONAF/OFAF

-RATING (HV):- 190/250/315 MVA
-RATING (LV):- 190/250/315 MVA
-NO LOAD VOLTAGE (HV):- 230 KV
-NO LOAD VOLTAGE (LV):- 16.5 KV
-LINE CURRENT (HV):- 790.72 AMP.
-LINE CURRENT (LV):- 11022.14 AMP.
-MAKE: - BHEL
-WEIGHT OF CORE & WINDING:-155000 KG
-WEIGHT OF OIL: - 53070 KG
-TOTAL WAIGHT: - 263250 KG
  Unit auxiliary Transformer :-

-TYPE OF COOLING:- ONAF/ONAN

-RATING (HV):- 50 MVA/40 MVA
-RATING (LV1&LV2):- 25 MVA/20MVA
-NO LOAD VOLTAGE (HV):- 16.5 KV
-NO LOAD VOLTAGE (LV1&LV2):-6.9 KV
-LINE CURRENT (HV):-1749.55 AMP.
-LINE CURRENT (LV1&LV2):- 2091.94 AMP.
-MAKE: - BHEL
  Station Auxiliary Transformer :-

TYPE OF COOLING: - ONAF/ONAN

RATING (HV):- 50 MVA/40 MVA
RATING (LV1&LV2):- 25 MVA/20MVA
NO LOAD VOLTAGE (HV):- 16.5 KV
NO LOAD VOLTAGE (LV1&LV2):-6.9 KV
LINE CURRENT (HV):-1749.55 AMP.
LINE CURRENT (LV1&LV2):- 2091.94 AMP.
MAKE: - BHEL
YEAR OF MFD:-2012
 Station Transformer :-

TYPE OF COOLING:-ONAN/ONAF
RATING (HV):-20 MVA/25 MVA
RATING (LV1):- 10 MVA/12.5 MVA
RATING (LV2):- 10 MVA/ 12.5 MVA
NO LOAD VOLTAGE (HV):- 220 KV
NO LOAD VOLTAGE (LV1):- 36 KV
NO LOAD VOLTAGE (LV2):-6.9 KV
LINE CURRENT (HV):-52.49 /65.61 AMP
LINE CURRENT (LV1):- 160.38/ 200.47 AMP
LINE CURRENT (LV2):-836.74/1045.99 AMP
MAKE: - EMCO
VECTOR GROUP:-YNyn0yn0
 Buchholz relay :-

- In the field of electric power distribution and transmission,

a Buchholz relay is a safety device mounted on some oil-
filled power transformers and reactors, equipped with an
external overhead oil reservoir called a "conservator". The
Buchholz relay is used as a protective device sensitive to the
effects of dielectric failure inside the equipment.

-It isconnected between the conservator and oil tank of a

transformer.
  Operation:-

- A circuit breaker can be reset to resume a normal operation.

Depending on the model, the relay has multiple methods to detect a
failing transformer. On a slow accumulation of gas, due perhaps to
slight overload, gas produced by decomposition of insulating oil
accumulates in the top of the relay and forces the oil level down. A
float switch in the relay is used to initiate an alarm signal.
Depending on design, a second float may also serve to detect slow
oil leaks. If an electrical arc forms, gas accumulation is rapid, and
oil flows rapidly into the conservator. This flow of oil operates a
switch attached to a vane located in the path of the moving oil.
This switch normally will operate a circuit breaker to isolate the
apparatus before the fault causes additional damage. Buchholz
relays have a test port to allow the accumulated gas to be
withdrawn for testing. Flammable gas found in the relay indicates
some internal fault such as overheating or arcing, whereas air
found in the relay may only indicate low oil level or a leak.

 Circuit Breaker :-
-The general way of classification is on the basic of medium use
for arc extinction.

1) Oil circuit breaker:-

-In such circuit breaker, some insulating oil is used as an arc
quenching medium. The contacts are opened under oil and an arc is
struck between them.

2) Air blast circuit breaker:-

-These breakers employ a high pressure air – blast as an arc
quenching medium.
 3) Sulphur hexafluoride (SF6) circuit breaker:-

-SF6 is used as the arc quenching medium. The SF6 is an electro-

negative gas and has a strong tendency to absorb free electrons.
The contacts of the breaker are open in a high pressure flow of SF6
gas and an arc is struck between them. It is used to220kv voltage
range. This type of circuit breaker are used in the switch yard.

4) Vacuum circuit breaker:-

-In such breakers, vacuum (degree of vaccum being in the range

from 10-7 to 10-5 torr) is used as the arc quenching medium. Since
vacuum offers the highest insulating strength. It has far superior
arc quenching properties than any other medium. When any fault
occurs in the transmission line, relay senses that fault and gives the
signal to the circuit breaker. Hence, the circuit breaker trips. It is
an automatically operated electric switch designed to protect an
electrical circuit from damage caused by overload or short-circuit.
Its basic function is to detect a fault condition and by Interrupting
continuity, to immediately discontinue electrical flow. It is used to
above 6.6kv voltage range. It is used in distribution panels.
  Isolator:-
- Circuit breaker always trip the circuit but open contacts can’t 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 and when required.
Electrical isolators are used to isolate the transmission lines for
activities like maintenance.
-So definition of isolator can be rewritten as it is manually
operated mechanical switch which separate a part of the electrical
power system normally at off load conditions.
  Earth switch:-

-The use of earth switch is to send any trapped charge in the line
into ground after the line is switched off. Mainly what happens,
when the line is switched off, some charges remain trapped in line
due to their own capacity and also due to influence of side by line.
This trapped charge is dangerous if someone goes for maintenance
of that line. So it is very much require to neutralize that much
charge and here comes the use of earth switch.

-Whenever the isolator is in opened condition, the earth switch

used to be in closed condition. In this way this ensures the
grounding of any charges present in the line.Also,whenever the
isolator is in closed position, the earth switch used to be opened.
  LightningArrestor:
-These are equipment’s designed to protect insulators of power
lines and electrical installations from lighting surges by diverting
the surge to earth and instantly restoring the circuit insulation to its
normal strength with respect to earth.
  BUS:-
-In the field, there are three type of bus which are,

 Bus-1:
This Bus is charged when the generator send the
power.
 Bus-2:
This Bus is also charged but usage is as per require.
 Transfer bus:
This Bus is used only when the emergency occurs or
when any of available bus under fault or under
maintenance. It provides the redundancy in
availability of bus.

 Relay :-

-A relay is automatic device which senses an abnormal condition

of electrical circuit and closes its contacts. These contacts in turns
close and complete the circuit breaker trip coil circuit hence make
the circuit breaker tripped for disconnecting the faulty portion of
the electrical circuit from rest of the healthy circuit.

-Types of protection relays are mainly based on their characteristic,

logic, on actuating parameter and operation mechanism.
 Protection Strategies :-
  Causes of Failure :-
ENVIRONMENTAL
SYSTEM
OPERATION
DESIGN
MANUFACTURE
MATERIALS
MAINTENANCE

 Protection Used in Transformer :-

-TRANSFORMER DIFF PROTECTION

-OVER FLUXING PROTECTION
-LINE DIFF PROTECTION
-REF PROTECTION
-BUCHHHOLZ TRIP
-OTI PROTN TRIP
-WTI TRIP
-OSR TRIP

(1) Differential Protection:

-In Transformer diff. protection we use 2 Group of current

transformer in both LV& HV side of transformer.

-Whenever any type of internal fault occur current entering and

current leaving in both CT are different and this current flow
through trip coil.

-Works on current comparison principle.

-Relays with bias characteristic should only be used.

(2)Restricted Earth Fault Protection:

-Restricted earth fault protection is provided in power transformer

for sensing internal earth fault of transformer.

-Uses high impedance principle.

(3)Buchcholz Relay Protection:
-Oil Leakage
-Severe winding fault
-Accumulation of Gas
  T.G. Unit :-

-This unit is consist of the turbine and generator and also it

auxiliary equipment. The steam from the boiler is fed to the turbine
and then rotate the turbine. The turbine shaft is connect to the
generator. And generator is convert the mechanical energy to the
electrical energy. Turbine is rotate through the exciter. The
generator bus-duct is connect to the SAT (station auxiliary
transformer) and UAT (utilization auxiliary transformer).
  Turbo generator ratings:-
Gas pressure 4 bar

Insul. class F

R.P.M. 3000

Hz 50

Phase 3

CONN. YY

Coolant Hydrogen

Division Hardwar

 Cooling system :-

-If we want to flow more current in a conductor than its current

carrying capacity than we have to cool down the conductor, that’s
why we need cooling system in generator, We use hollow
conductor to circulate water to keep its temperature low which has
pressure of 2.5 kg/cm2.One end of each conductor is connected to
the inlet header and the other one with outlet header with the help
of Teflon tube. The other part of generator is filled with H2 which
has pressure of 3.5 kg/cm2 so because of this pressure difference if
due to any reason some damage occurs in stator conductors even
then water will not get out from it and prevent any casualties.
Although there is a chance that H2 may enter in the stator
conductor in water so there is an equipment called Gas trap which
detects H2 leakage in water.
  Boiler:-

-The main function of boiler is to convert or generate the steam

from the coal combustion. The steam is produce in the boiler is
utilized by the turbine. In this thermal power plant the type of
boiler is the CFBC boiler. CFBC boiler - circulating fluidized bed
combustion. CFBC is this boiler is the feed to the lignite coal.
Boilers are pressure vessels designed to heat water or produce
steam, which can then be used to provide space heating and service
water heating to a building. In most commercial buildings heating
application, the heating source in the boiler is a natural gas.
Combustion is take place by LDO (light diesel oil) and FO
(furnace oil). The burner mixes the fuel and oxygen together and
with the assistance of an ignition device provides a platform for
combustion. This combustion takes place in the combustion
chamber and the heat that it generates is transferred to the water
through the heat exchanger. Controls regulate the ignition, burner
firing rate, fuel supply, exhaust draft, water temperature, steam
pressure, and boiler pressure. Plate type un-cooled (hot) cyclones
with Loop Seal assembly are adopted in CFBC boilers. Hot
cyclones separate the circulating bed material from the flue gas
stream leaving the furnace at around 880◦C.

 CST:
Condensed storage tank is used to store fresh water from DM
plant.
  Hot well:
A tank or reservoir in which hot water is collected before
being recirculated, especially condensed steam about to be
returned to a boiler
 CEP:
Used To remove condensate under vacuum

 BFP (Boiler feed pump):

Transport water from feed storage tank to boiler drum
through HP heater and economizer Capacity: 4 MW

 Condenser:
-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.
-The surface condenser is a shell and tube heat exchanger in which
cooling water is circulated through the tubes. The exhaust steam
from the low pressure turbine enters the shell where it is cooled
and converted to condensate (water) by flowing over the tubes. Is
the condenser can be made cooler, the pressure of the exhaust
steam is reduced and efficiency of the cycle increases. Functions
of condenser: To provide lowest economic heat rejection
temperature for steam.
-To convert exhaust steam to water for reserved thus saving on
feed water requirement. In direct contact type exhaust steam is
mixed directly with DM water.
  Working cycle of boiler:
-BFP> economizer> increase the temperature > drum> furnace
>combustor> flue gas > cycloash (60um) >super heater> HP
(high pressure)>turbine low temperature low pressure >IP (low
pressure)> reheater > LP (low pressure) >condenser >cooling
tower >Dearator > BFP.

 DEMINERALISATION WATER TREATMENT

PLANT (DM PLANT) :-
-This plant produces demineralized water by means of ion
exchange technology and this water is completely free from the
mineral salts. This plant is used following acids NAOH & HCL. It
performs following processes:
1. Distillation
2. Deionization
3. Membrane Filtration
4. Electrodyalisis

 Cycles Included in Thermal power station :

1. Coal and Ash Cycle
2. Water and steam Cycle
3. Air and Flue Gas Cycle
4. Cooling Water Cycle
  ESP ( electrostatic precipitator unit):-
-This ESP unit is basically used to remove the carbon, sulphur and
other impurities from the gas than finally it is passed through the
atmosphere. ESP is basically consist of the electrode. The
electrode is the negatively charged and then positive and negative
electrode are separated out provided with the liberating on the
hammer and then finally passed through the atmosphere.
-ESP field is the consist of the 24 transformer with conv. Of ac to
dc by using the rectifier. It is also consists of the PA& SA fan.
Each rating is the 4900kw. The control of this ESP unit is the
through the ESP control building which is consist of the panels for
controlling the ESP field and ash inlet valve.
-ESP consists of emitting and collecting plates. Plates of ESP are
charged. So ash particles will be collected on the plates. Due to
continuous hammering collecting plates, ash will collects in
hopper.
-An ESP is a filtration device that removes fine particles, like dust
and smoke, from a flowing gas using the force of an induced
electrostatic charge mainly minimally through the unit.

Requirement
After combustion of coal, ash and fuel gases are produced. In
mixture, 95% ash is there. If we don’t remove the ash from fuel
gases, it will go in the atmosphere, then pollution level of air will
be increased. It is harmful for nature and livings. So, we have to
collect ash from mixture.
Components
Discharged electrodes
Collecting plates
Rectifier transformer
Hoppers and dust handling& Heaters and purge air system

 Coal Unloading:
-To unload the coal wagon WTPS has wagon tippler house. There
are total five wagon tipplers in WTPS.

Operation:
Primary Crusher:
-Coal size – Up to 10mm x10 mm Primary Crusher contains a
vibrating screen. Coal particles less than 10mm x10mm will
directly bypass the crusher through vibrating screen.
Coal Stack:
- If output of secondary crusher is more than bunker’s requirement
then it is stacked with the help of conveyor belt and stacker. It is
reclaimed when necessary through conveyor belts. Currently coal
stored in stack is 5,00,000 MT.
Bunker:
-Coal is stored in bunkers over the top of unit. Capacity of each
bunker is about 800 Ton. Each unit has 4 bunkers.
RCF (Raw coal feeder):
-Coal enters in the bowl mill through RCF. It consists of chain
drive. Quantity of coal through RCF is regulated by clutch motor.
By regulating speed of motor feed rate of coal to the bowl mill is
regulated. Here, the weight of the coal is measured by Load Cell
which works on the piezo-resistive principle.

 PA fan, SA fan, ID fan :-

Primary Air Fan:-
PA fan is used to collect or transfer the pulverized coal from bowl
mill to the furnace. PA fan suck the air from atmosphere and it
passes through the air-pre-heater to the hot primary air header.
Cold air is coming from PA fan is taken into cold primary air
header. Then mixture of both cold and hot air coming from header
is passed to bowl mill which lift coal to the furnace. The
temperature of the air is maintained by using hot and cold air
mixture. When the coal contains humidity the hot air thrown is
higher.
Secondary Fan:-
FD fan provides secondary air, which is used in the furnace for
coal firing. The forced draft fan takes the air from atmosphere and,
first warming it in the air pre heater for batter combustion, injects
it via the air nozzles on the furnace wall.
Induced Drought Fan:-
Suck the gases out of the furnace and throw them into the stack by
creating sufficient negative pressure in the furnace in balanced
draft units. It is located between ESP and Chimney.
  Ash handling system:
-At the bottom of the furnace ash is collected which is called
bottom ash. It makes slurry when mixed with water. Slurry is
pumped into ash pond through pumps. Fly ash is considered to be
collected in EPS hoppers. Fly ash from ESP hoppers extracted by
vacuum pumps up and then it is collected in sack or in silo.

 Conveyer belt:-
-Conveyer belt is used to the transfer the coal from the coal storage
to the boiler. The conveyer belt is the driven by the motor. The
coal is not directly feed to the boiler.
-Firstly the boiler is start with the LDO & HFO fire oil is used than
the coal is feed to the boiler. This procedure is carried by the metal
tank. Stacker reclaimer is used to storage of the coal.
-The bucket wheel is used to storage of coal when requirement of
the coal passed through the belt. This unit commonly named as the
BWSR unit. The conveyer belt is fed to the screen house first and
then it is fed to the boiler.
  Crusher house:-
-Crusher house is provided to the crush the coal and coal crush is
done by the crusher. This crusher house is increase the coal surface
area.

 Screen house:-
-Screen house is used to screen the coal. Suppose the coal 20mm
size of coal is select then this size of coal is passed through the
boiler remaining other size of coal is the re feedback to the crusher
house.

 Enclosure:-
-Practical training has proved to be quite precious for us. It
provided an opportunity for encounter with such huge machines
like wagon tippler, stacker machine, generators & turbines.

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

-It has allowed an opportunity to get an exposure of the practical

implementation to theoretical fundamentals.