CHAPTE R 8

Auxiliary systems 8.1 Fly Ash Collection

Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag filters located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators or bag filters. Generally, the fly ash is pneumatically transported to storage soils for subsequent transport by trucks or rail road cars.

8.2 Bottom Ash Collection And Disposal

At the bottom of the furnace, there is a hopper for the collection bottom ash. This hopper is always filled with water to quench the ash and clinkers falling down from the furnace. Some arrangement i s included to crush the clickers and for conveying the crushed clickers and bottom ash to a storage site .

8.3 Boiler Make-Up Water Treatment Plant And Storage

Since there is continuous withdrawal of steam and continuous return on condensate to the boiler, losses due to blow down and leakages have to be made up to maintain a desired water level in the boiler steam drum. For this, continuous water-make up water is added to the boiler water system. Impurities in the raw water input to the plant generally consist of calcium and magnesium salts which impart hardness to the water. Hardness in the make-up water to the boiler will form deposits on the tube water surface which will lead to overheating and failure of the tubes. Thus, the salts have to be removed from sing the water, and that is done

by water demineralising treatment plant (DM). A DM plant generally consists of cat ion, an ion, and mixed bed exchangers. Any ions in the final water from this process consist essentially of hydrogen ions and hydroxide ions, which recombine to form pure water. Very pure DM water becomes highly corrosive once it absorbs oxygen from the atmosphere because of its very high affinit y for oxygen. The capacity of the DM plant is dictated by the type and quality of salt in the raw water input. However some storage is essential as the DM plant may be down for maintenance. For this purpose, a storage tank is installed from which DM water is continuously withdrawn from boiler make-up. The storage tank for DM water is made from materials not affected by corrosive water, such as PVC. The piping and valves stainless steel doughnut float is provided on top of the water in the tank to avoid contact with air. DM water make-up is generally added at the steam space of the sur e face condenser. This arrangement not only sprays the water but also DM water gets deaerated, with the dissolved gases being removed by an air ejector attached to the condenser .

8.4 Oil System

An auxiliary oil system pump is used to supply oil at the start-up of the steam turbine generator. It supply the hydraulic oil system required for system turbines main inlet steam stop valve, the governing control valves, the bearing and seal oil systems, the relevant hydraulic relays and other mechanisms. At a present speed of the turbine during start-up, a pump driven by the turbine main shaft takes over the functions of the auxiliary system.

8.5 Generator Heat Dissipation

The electricity generator requires cooling to dissipate the heat that it generates. While small units may be cooled by air drawn through filter at the inlet, larger units generally requires special cooling arrangements. Hydrogen gas cooling, in an oil sealed casing, is used because it has the highest known heat transfer coefficient of any gas and for its low viscosity which reduce windage losses. This system requires special handling during start-up, with air in the chamber first displace by carbon dioxide before filling with hydrogen. These ensure that the highly flammable hydrogen does not mix with oxygen in the air . The hydrogen pressure inside the casing is maintained slightly higher than atmospheric pressure to avoid air ingress. The hydrogen must be sealed against outward leakage where the shaft emerges from the casing. Mechanical seals around the shaft are installed with a very annul ar gap to avoid rubbing between the shaft and the seals. Seal oil is used to prevent the hydrogen gas leakage to atmosphere. The generator also uses water cooling. Since the generator coils are at a potential of about 22kv and water is conductive, an insul ating barrier such as Teflon is used to interconnect the water line and the generator high voltage windings. De mineralized water of low conductivity is used.

8.6 Generator High Voltage System

The generator voltage ranges from 11kv in smaller units 22kv in larger unit the generator high voltage leads are normally large aluminum channels because of their high current as compared to the cables used in smaller machines. They are enclosed in well -grounded aluminum bus ducts and are supported on suitable insul ators. The generator high voltage channels are connected to step -up transformer for connecting to a high

voltage electrical substation for further transmission by the local power grid. The necessary protection and metering devices are included for the high voltage leads. Thus, the steam turbine generator and the transformer form one unit. In smaller units, generating at 11kv, a breaker is provided to connect it to a common 11kv bus system. The crushed coal is conveyed from the storage pile to soils or hoppe rs at the boilers by another belt other systems.

8.7 Monitoring And Alarm System

Most of the power plant operational controls are automatic. However, at times, manual interventation may be required. Thus, the plant is provided with monitors and alarm systems that alert the plant operates when certain operating parameters are seriously deviating from their normal range.

8.8Battery Supplied Emergency Lighting And Communication

A central battery system consisting of lead acid cell units is provided to supply emergency electric power, when need, to essential items such as the power plants control systems, communication systems, turbine lube oil pumps, and emergency lightning. This is essential for a safe, damage free shutdown of the units in an emergency s ituation.

8.9 Transport Of Coal Fuel To Site And To Storage

Most thermal stations use coal as the main fuel. Raw coal is transported from coal mines to a power station site by trucks, barges, bulk cargo ships or railway cars. Generally, when shipped by railways, the coal cars are

sent as a full train of cars. The coal received at site may be of different sizes. The railway cars are unloaded at site by rotary dumpers or side tilt dumpers to tip over belts below. The coal is generally conveyed to crushers which crush the coal to 6mm size. The crushed coal is then sent by belt conveyors to a storage pile. Normally, the crushed coal is compacted by bulldozers, as compacting of highly volatile coal avoids spontaneous ignition conveyer system.

8.10 Advantages And Disadvantages Of Thermal Power Plant Advantages

y The fuel cost is low. y Less initial cost as compared to other generating stations. y It can be installed at any place irrespective of the existence of coal. y The coal can be transported to the site of the plant by rail or road. y It requires less space as compared to hydro electric power station. y The cost of generation is lesser then that of the diesel power

station.

Disadvantages
y It pollutes the atmosphere due to the production of large amount of

smoke and fumes.

y The Efficiency of coal plant is very low (approx 30% to 35%). y It is costlier in running cost as compared to the hydro electric plant.

CHAPTER 9
CONTROL SYSTEM 9.1 Auto Control System
Auto control system forms the following operations:
y Generator voltage control. y Undelayed limiting control for the output current of the thyristor

set.
y Limiting control for the under exited range. y Delayed limiting control function over exited range. y Automatic field separation during shutdown of the generator. y Delayed limiting control for the stator over current. y V/Hz limiter to prevent over fluxing of the limit transformer and of

generator. Auto control system performs the following components:

y Actual voltage feedback signal forming unit. y Reactive/ Active current detection unit. y LI meters. y Voltage regulator unit. y Universal amplifier. y Gate control.

Set generator terminal voltage feedback is taken from generator PT. output of PT (11GV) given to actual voltage feedback sign forming unit, which produce DC signal proportional to generator voltage.

Output of the reactive/ active detection unit, which is proportional reactive current, added vectorically to actual voltage signal to

compensate for reactive drip of unit transformer/ when generator is connected to the net through unit transformer. The rectified, filtered compound voltage given as an actual value to regulator is compared to actual value, reference value and limiters output (10V) is directly depends on the:
y Differences between actual value and reference value. y Setting of its proportional and inte gral feature.

9.2 Limiters Intervene

Output of AVR is given to the gate control circuit, which produces firing pulses displaced by 60, this firing pulse is given to the gate control circuit of Thyristor Bridge, firing angle, which devices conduction per iod of thyristor depends on the firing pulse. Thus according to input signature to gate control circuit, thyristor bridge output varies and control the excitation .

9.3 Manual Control System

In case when any part of auto control system fails, to continue the operation, manual channel is provided. It consist s of following units.
y Universal amplifier. y Reference value generator. y Current regulator.

y Gate control set for manual system .

The thyristor set input AC current which proportional to main exciter current i.e. output DC current of thyristor set, in sensed by using CTs having buren resistors in AC voltage developed across the resistor is given to the universal amplifier. Where it is rectifier and filtered. Output of that universal amplifier is used as an actual value to current regulator; the reference value (10V) is derived from highly reliable and stabilized power supply by higher and lower commands. This voltage signal given as a reference value to current regulator. It compares actual values with set point and its output directly depends on
y Difference between set point and actual value. y Setting of its proportional integral factors. y Limitations of generator voltage given to the current regulator.

This output of current regulator after being six firing pulse displaced by 60.1 his firing pulse given to the gate circuit of thyristor bridge and it controls the firing angle of thyristor bridge output current to set point value.

9.4 Limitation Of Manual Channel

It does not ensure synchronism during transie nt condition.
y It controls the excitation irrespective of generator terminal voltage

within limitations given to the excitation current regulator.

y It also does not ensure safe operation of machine near operating

limits. Because of the above limitations manual channel is used only in emergencies.

CHAPTER 10
BATTERY CHARGER 10.1 DC Supply
DC supply is the heart of power station. Battery and battery charger should be kept in service continuously to ensure reliable supply. The failure of DC supply cannot be tolerated. Battery should be always in charger condition and ready to take load in cas e of AC power supply failure. On resuming AC supply the battery is recharged by putting charger on boost. After charging of battery cells charger should be put on float charging to supply station demand and keeping battery in float charging condition. DC supply is used to run the DC motors as DC seat & DC flushing motors and DC emergency lighting in case of total power supply failure. Also DC supply is used for various control circuit such as 22kv, 6.6kv and 415 volt breakers closing, tripping and indicatio n, relay control circuits, MMF circuit, MARP circuits and annunciations circuits. DC system can be divided mainly into three parts.

10.2 Station Battery

Two battery sets are installing having 110 cells in each set two supply 220V DC two battery sets are installed having 25 cells in each set two supply 50V DC which is for boiler control desk annunciation.

10.3 Battery Charger For 220 Volts DC System

The general purpose of this battery charger unit is two DC power to power station in conjunction with 110 lead acid cells to ensure an interrupter supply irrespective of AC main supply AC input 415 volts 3-

phase supply to given two battery charger from 415 volts emergency MCC. Float charger is capable for floating 110 lead acids cells from 1085 volts per cells 2.65 volts/cell at a maximum charging current of 80 amp. During the normal time battery is floated by means float charger, which also supplies the constant load. In case of emergency the constant load is being taken care of the battery which is conne cted to the bus by means of switch SW-10. When the mains resume there is a need for the battery to be recharged since the same would have discharged being emergency. For this purpose the float/boost change over switch is kept in the boost position. During the boost charging the load is taken care of by the float rectifier in the unlikely event mains failure during boost charging, the float boost change over switch SW-10 must be put position. During changeover of the switch from the boost to float position the continuity of supply is maintain through the silicon diode MP -3 the output supply of DC bus is kept appreciable constant.

10.4 In Brief Battery Charger

Purpose of battery in power station:
y To run DC emergency flushing oil pump and seal oil pump of

turbine generator set in case of total supply failure of the station.

y For DC emergency lighting of the station in case of total power

supply failure.
y For trip free operation of circuit breaker a nd reliable protection and

controls in emergency. For safety of the station, it is important to maintain the battery vigilantly, for emergency services.

Points for the battery charger to be observed:

y Check the indication for the following are ok. y AC three phase main supplies input to charger. y AC three phase control supply. y DC output. y Check that the charger DC output voltage and current are normal. y The charge/discharge meter indicates whether the battery to getting

charged or discharged. See that the meter indicated the charging condition of the battery.
y See that no alarm is persisting. No abnormal indication to

appearing.
y See that the battery charger is clean.

CONCLUSION
This training helped me to realize the importance of each and every subject. I realized that even though practical knowledge is very necessary, one cannot do without the theory part which forms the base. I came to know that no matter in which department yo u are, you need to have knowledge of each and every field & everything should be in a balanced manner. This has led me to give importance to everything in life as everything has its own importance. This training enables me to supplement my study with a pra ctical bias has vital orientation with industry. For an electrical engineering student the working at the power plant is major importance. It was my pleasure that I got chance to be trained at
Thermal Power Station .

We get introduced to the whole generatio n process of electric power. We got the knowledge of the whole equipment used for the protection system. We got knowledge from the switch yard. We understand about the latest technologies used for the controlling. We also introduced to the latest equipment in the power plant.

REFERANCE

Sr. No.
1. 2. 3. 4.

Name Of The Book

Switchgear and Protection Electrical Power System Electrical Machine Power System

Author
R.P.Ajwalia J.B.Gupta B.L.Theraja V.K.Mehta

Table 1.8 References