QUESTION AND ANSWERS ON POWER PLANT BASICS

1. What are typical modules of a power plant?

a. Tg package
i Turbine
ii Generator
iii Condenser
iv Feed water heaters
v Cooling oil system
vi Ejectors
B. Boiler package
i. Boiler
ii. Steam drum
iii. Furnace
iv. Water wall
v. Air box
vi. Draught fans
vii. Feed pumps
viii. Deaerator
ix. Economizer
x. Pre air heater
xi. Blow down system
xii. Fuel feeding system
xiii. Bunker

2. What is auxiliary power consumption / %?

Power required (for running the various modules such as boiler, cooling tower, fuel
handling system, water treatment plant etc in a power plant)to generate rated
capacity at the generator terminal. Auxiliary consumption is normally 10-12 % of
rated capacity of generated power.

3. What is heat rate and how it is calculated?

Heat rate is the amount of heat required to generate the desired power. It is a
ratio of enthalpy difference to the generated power. (steam flow x difference in
enthalpy / generated power; unit kcal/kw-hr)

4. What is the typical mass/energy balance diagram of a power plant?

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 QUESTION AND ANSWERS ON POWER PLANT BASICS

Mass / energy balance diagram is nothing but the diagram which shows the
pressure, temperature, enthalpy & flow of steam /water in various stages of power
plant heat cycle; a model hmbd is enclosed.

5. What are typical modules of a power plant?

b. Tg package
i Turbine
ii Generator
iii Condenser
iv Feed water heaters
v Cooling oil system
vi Ejectors
B. Boiler package
i. Boiler
xiv. Steam drum
xv. Furnace
xvi. Water wall
xvii. Air box
xviii. Draught fans
xix. Feed pumps
xx. Deaerator
xxi. Economizer
xxii. Pre air heater
xxiii. Blow down system
xxiv. Fuel feeding system
xxv. Bunker

C. Esp
d. Chimney
E. Ash handling system package
- ash silo
- ash transmitters
- ash conveying compressors
- ash conveying pipes
- ash conditioners
F. Cooling tower / air cooled condenser
(i) Cooling tower
(ii) Cooling water pumps
(iii) Cooling water chemical treating system
g. Water treatment plant package
- clarifier
- sand filters

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 QUESTION AND ANSWERS ON POWER PLANT BASICS

- ultra filter
- carbon filters
- cartridge filters
- reverse osmosis filters
- degasser
- strong acid cation
- strong base anion
- mixed bed
h. Fuel handling system package
- fuel receivers (wagon / truck trippler)
- bull dozers / handling vehicles etc.
- stocker and reclaimer
- fuel hoppers
- fuel feeders
- crushers
- screeners
- conveyers
- metal separators
- metal detectors
- on line weigher
i. Compressed air system
j. Electricals
k. Instrumentation and control system

6. Turbine: what are the efficiencies relevant to turbine?

A) stage efficiency
B) cylinder efficiency
C) turbine efficiency
D) gear box efficiency
E) generator efficiency.

7. What are the losses associated with turbine?

a) Exhaust steam heat loss
b) Friction loss
c) Leakage loss
d) Radiation losses

8. What is happening in boiler?

Heat energy is liberated in the furnace by burning the fuel with the support of air
which is utilized to heat the saturated water and converted into steam. This steam
is further superheated through various superheater and finally used to rotate the
turbine.

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 QUESTION AND ANSWERS ON POWER PLANT BASICS

9. What are parameters of a boiler?

A) flow in kg/hr (or) t/hr
B) pressure in kg/cm^2
C) temperature of steam(deg c)

10. How the boiler efficiency is arrived at?

Boiler efficiency is arrived from the losses listed in the answer of question 12.0 as
per asme ptc 4.1

11. What are the losses associated with boiler?

A) sensible heat loss
B) dry flue gas loss
C) air moisture loss
D) h2 combustion loss, fuel moisture
E) unburnt carbon loss
F) radiation loss

12. What are the limiting velocities of steam, water, air and flue gas in fbc, cfbc,
travelling grate and gas fired boilers?
Water suction side – up to 1m/s
Water delivery side - up to 3.0 m/s
Saturated steam - up to 40 m/s (depends on pipe size &
Pressure)

Super heated steam - up to 60 m/s (depends on pipe size &

Pressure)
Air - upto 12 m/s
Flue gas - 8 to 10 m/s

13. What do you mean by turn down ratio?

Ratio between maximum and minimum steam generated in the boiler.

14. What are typical calorific values of various fuels?

Indian coal - 3800 kcal / kg
Imported coal - 6000 kcal / kg
Pet coke - 8000 kcal / kg
Lignite - 3800 kcal / kg
Biomass /agro waste - up to 4000 kcal / kg
Char - 2200 kcal / kg
Husk - 3150 kcal/kg

15. What are possible failures of boiler and its causes?

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 QUESTION AND ANSWERS ON POWER PLANT BASICS

Tube failure
1) Due to erosion
2) Due to corrosion
3) Due to scale formation

16. What is the water quality required for using it in boiler?

Conductivity - 0.2 ms/cm
Silica - 0.02 ppm
Ph level - 8.8 – 9.2
Hydrazine(residual) - 0.02 ppm
O2 - < 0.007 ppm
Hardness - nil

17. What are different sources of water?

a) Deep bore well water
b) River water
c) Sea water
d) Mines water
e) Rain water
f) Lake water
g) Pond
h) Well, deep-well.

18. What is scheme of water treatment?

A. Raw water - scr – mgf –dm – boiler water.
B. Raw water – scr – mgf – uf – ro – dg – mb – boiler water
C. Raw water - mgf - ro – dg – mb - boiler water.
D. Raw water - mgf- softner – cooling tower make-up water
Where,
Scr – solid contact reactor clarifier
Mgf – multi grade filter
Uf – ultra filter
Ro – reverse osmosis
Dg – degasser
Mb – mixed bed
Dm – demineralization plant

19. What are typical fuel handling systems for various fuels?
Grizzle hopper  raw coal conveyor  crusher  vibrating screen 
 finished conveyor  bunker
 reject conveyor  crusher

20. What are different types of mills/equipments required for fuel preparation?
A) impact crusher
B) reversible swing hammer crusher

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 QUESTION AND ANSWERS ON POWER PLANT BASICS

C) ball mills

21. What type of generator is used in power plants?

Cylindrical rotor generator

22. What are different types of cooling tower used in power plants?
- natural draught cooling tower
- forced draught cooling tower
- induced draught counter flow type
- induced draught cross flow type
- jet type cooling tower
- mist type cooling tower

23. What are different types of air cooled condensers †by flows?

Air cooled condenser is available with different type of fin configuration,
A) l fins
A) knurling l fins
B) double l fins
C) extended fins
D) extended hot dip galvanized fins

24. What are selection criteria for air cooled condenser / cooling tower?
Air cooled condenser
- turbine exhaust enthalpy
- turbine exhaust pressure
- flow
- ambient temperature
Cooling tower
- availability of water
- wet bulb temperature
- range delta t
- approach

25. Boiler: what are factors influencing the pressure drop in a system?
- area
- inner surface of the material
- velocity
- span / length of the system
- bends & elbows
- vertical lift

26. What is heat transfer co-efficient?

The heat transfer co-efficient is the average rate of heat transfer from steam to feed
water or from condensate to feed water and is expressed in kcal/hr.-m2-°c.

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27. What do you mean by log mean temperature difference?

Lmtd is the ratio of the difference between the initial temperature difference and the
terminal temperature difference to the nepierian logarithm of the ratio of the initial
temperature difference to the terminal temperature difference

Logarithmic mean tempertature difference “lmtd”

A-b
Lmtd = ------------------
Ln (a / b)
Where,
A = (t1 – t2)
B = (t2 – t1)
T1 = inlet temperature of hot fluid
T2 = outlet temperature of hot fluid
T1 = inlet temperature of cold fluid
T2 = outlet temperature of hot fluid

28. What are different components in various types of boilers?

a) Steam drum
b) Mud drum
c) Air box
d) Water wall panels
e) Riser and downcomer pipes
f) Convection superheater
g) Radiant super heater
h) De – super heater
i) Bed coils
j) Bed super heater
k) Economiser
l) Air pre heater
m) Fans – id, fd, pa
n) Bunker
o) Fuel handling system
p) Esp
q) Chimney

29. What is longitudinal and transverse pitch?

Longitudinal pitch is the pitch along the flow path
Transverse pitch is the pitch perpendicular to the flow path

30. What is the fluidising velocity in atmospheric fluidised bed boiler?

2.5 – 2.8 m / s

31. What is the velocity used in cfbc boilers?

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 QUESTION AND ANSWERS ON POWER PLANT BASICS

5m/s

32. When a pc firing is used?

When the boiler capacity is above 200 tonnes, pc firing is used.

33. What are the criteria for gas cooling in a boiler (exit flue gas temperature)?
The exit flue gas temperature is limited to 140oc to 150oc. If it is further allowed to cool,
the gas tend to condensate and form an acid. (the temperature at which the so2 will react
with the moisture and form as sulphuric acid is called dew point temperature).

34. What is the different air heaters used and what are the selection criteria?

1. Regenerative type.
The regenerative type heat exchangers conducting member which is exposed
alternatively to the hot exhaust gases and the cooler compressed air. It absorbs
heat from hot gases and gives it up when exposed to air.the heat capacity member
is made of a metallic mesh or matrix which is rotated slowly (40-60 r.p.m) and
continuously exposed to the hot and cold air.

2. Recuperative type.
The recuperative heaters continuously transfer the heat from hot gases to cold air.
It alternatively gets heated and cooled by hot gases. The flue gases flow through
the tubes and air is passed over the outer surface of the tubes

The recuperative type heaters requires more heat transfer area hence which occupies more
space. This type is normally not recommended above 60mw.

35. What is the equipment used for separation of ash in flue gas of boiler?
(i) Mechanical dust collector
(ii) Trema cyclone
(iii) Bag filter
(iv) Electro static precipitator - electrical type
(v) Wet scrubber.

36. How the collected ash is transported to ash silo?

The collected ash is transported by
(i) Dry type ash handling system
- lean phase ash handling
– dense phase ash handling
(ii) Wet type ash handling system – (low pressure, high pressure) water is mixes to the
ash then submergible ash conveyors is used to transport to the ash silo.
(iii) Mechanical ash handling system
- enmass chain conveyor
- screw conveyor

37. What are selection criteria for mdc, esp, and gas scrubber?

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 QUESTION AND ANSWERS ON POWER PLANT BASICS

A) type of boiler combustion

B) type of fuel firing
C) ash sieve analysis
D) flue gas
E) ash in temperature
F) nature of ash
G) ash chemical composition
H) inlet dust level control
I) outlet dust level control

38. Why is valve required and what are different kinds of valves used in a boiler, water
and steam pipelines?
Valve is required for control & regulating the flow of water and steam in boiler and also to
isolating the equipment
Valve types:
1. Gate valve
2. Globe valve.
3. Non return valve
4. Foot valve.
5. Butterfly valve.
6. Ball valve
7. Needle valve
8. Rack & pinion valve
9. Safety valve
10. Pressure safety valve.
11. Control valve
A) flow control valve
B) pressure control valve
C) temperature control valve
12. Motorized valves
A) inching type (globe valve)
B) non inching type (gate valve)

39. What are different kind of feeders used in boilers and its selection criteria?
A) coal, indian coal, imported coal, rice husk - pocket feeder or rotary air lock feeder
(small capacity boiler) use to feed a single fuel
B) (coal +pet coke, coal + lignite, imported coal + kutch lignite, etc) - drag chain feeder
(high capacity boiler) use to feed a combination
C) bio mass fuels (i.e bagasse ,wood chips ,etc ) - drum feeder use to feed over bed &
(traveling grate boiler)
D) bio mass fuels (i.e bagasse ,wood chips ,etc ) - screw feeder use to feed
(traveling grate boiler)

40. Why is thermal insulation and refractory required in boiler and pipelines?
All exposed portions of the plant which operate at temperatures of 60°c and above during
normal operation shall be thermally insulated to minimize the temperature loss to

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 QUESTION AND ANSWERS ON POWER PLANT BASICS

atmosphere hence the outer surface of the cladding is limited not to exceed more than 20°c
above ambient.

41. What are the software’s used in determining the flexibility analysis of a piping
circuit?
A) cae pipe
B) ceaser

42. What happens to allowable stress of a material if the temperature increases?

The allowable working stress of any material is inversely proposed to increase in
temperature.

43. What is called creep strength?

Creep (of concrete/element):
The increase of strain in the concrete /element with respect to time under sustained load
is termed creep.

44. What is the pipe and tube?

Tube – exposed to the surface (less than 3” dia)
Pipe – not exposed to surface (greater than 3” dia)

45. What are the different sections used in boiler industry?

‘i’ section, ‘l’ section, ‘c’ channel section, ., i.e., angle, channel, beam, fabricated beams,
plates, rods.

45. What is the plant efficiency of power plant?

The Plant Efficiency of the Power plant is calculated as follows

Plant Efficiency = Electrical Output in Kcal/hr / Heat input in Kcal/hr

Where,

Inlet Steam (TPH) x (Inlet Turbine Steam Enthalpy –

Feed Water Enthalpy)
a) Heat Input (Kcal/hr) = -------------------------------------------------------
Boiler Efficiency

b) Conversion factor - “1 MW = 860 x 103 Kcal/hr”

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 QUESTION AND ANSWERS ON POWER PLANT BASICS

Hence, the Plant Efficiency

= MW (1 MW = 860 x 103 Kcal/hr) / Heat Input (Kvcal/hr)

46. What are the different kinds of turbine and when each of them is selected?
a) Impulse turbine
b) Reaction turbine
Nowadays all TG Suppliers adopt Reaction Turbine only. However the First stage
alone could be of Impulse Blades. Hence we can say that the Turbines offered are
Impulse cum Reaction Turbine.

47. What are the different kinds of boilers?

Boilers are mainly classified as Industrial boiler and Utility boilers. The utility
boilers are large capacity steam generators used purely for the electrical power
generation. The industrial boilers are mainly for use in the process industries.

The boilers are further classified based on the configuration and type of firing tc.,
as follows,
a) Based on configuration,
Fire tube boiler – Flue gas passes in side the Tubes
Water tube boiler – Flue gas passes outside the Tubes.
b) Based on the Fuel firing
Solid fuel Fired Boiler
Liquid Fuel Fired Boiler
Gas Fuel Fired Boiler

c) Based on source of heat

Waste Heat recovery boilers – Utilising Heat energy from Waste
gas in Steel industries.
Chemical recovery boilers – Firing Black liquor from Pulp and
Paper mills.

d) Based on the type of Combustion

FBC boiler – Fluidised Bed Combustion Boiler
CFBC boiler – Circulating Fluidised Bed
Combustion Boiler
Dumping grate boiler – Fixed Grate are placed in the
Furnace
Travelling Grate Boiler - Moving Grates are places in the
Furnace

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Pulverised fuel fired boiler – Fules are Pulverised using Mills and
burned through burners.

c) Based on supports
Top supported boiler – Total Boiler is hanged from the
Top Structure
Bottom supported boiler – Total Boiler is rested on the
Bottom Structure

d) Based on circulation
Natural Circulation
Sub
Forced Circulation
– Water flows due to Density
difference. The use of Natural
circulation is limited to the
Critical Boilers due to its limitation.
– Water flows through external
forces like Pump

48. What is pressure and temperature profile in different kinds of boiler?

The Pressure and Temperature profile for various kinds of Boiler are as follows

PRESSURE, ata TEMPERATURE,oC

45 440
65 485
85 485-510
105 530

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49. What are the safety devices incorporated in a boiler?

A. SAFETY VALVE:
In order to avoid the explosion of boiler due to over pressure, 2 or 3
numbers of Safety Valves are provided in a boiler which will relieve
theexcess pressure and safeguard the boiler from explosion.

B. DRUM VERY LOW LEVEL TRIP:

In order to prevent the boiler from water starvation, drum very low level
trip is made through an independent level switch or level transmitter inspite
of supplying water continuously. If the water level trips below this very low
level, this level switch will trip the ID fan which will trip all the fans and fuel
feeders and the boiler will be terminated from firing and pressure
parts damage due to overheating can be avoided.

C. FURNACE DRAUGHT SWITCH:

In order to avoid back firing through manual door for the operating staff,
furnace draught switches are provided in the side point of + 10 mWc
whenever furnace become positive due to failure of dampers, actuators etc.
This switch senses the positive pressure and trip the FD fan so that back
firing and fire accident will be avoided.

D. General:
Wherever the controls are vital, there redundant gauges, valves are
provided. Example: Water level gauge, safety valve, level transmitter,
pressure transmitter etc.(2 Nos) are provided. In case of failure of 1
number other will help to manage the situation. This is mandatory as per
IBR also.

E. In Oil fired and Gas fired boilers, apart from the above safety features, an
explosion door is also provided at the roof panel and the furnace. This will
avoid fire side explosion in oil and gas fired boilers. Moreover, burner
management system has some in-built safety interlock like purging of oil,
evacuation of unburnt gas inside furnace by running ID fan alone before
starting burner etc. to take care of oil fired boiler safety.

50. What is the cost of water treatment in each of this scheme per litre?

For Scheme refer question no 22.

Scheme Cost / m3
Scheme a Rs.18 – Rs.20
Scheme b Rs.15 – Rs.18
Scheme c Rs.12 – Rs.15
Scheme d Rs.7 – Rs.10

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 QUESTION AND ANSWERS ON POWER PLANT BASICS

51. What is function of cooling tower or air cooled condenser in a power plant?
a) Cooling tower is a semi enclosed device used for Cooling of Hot water from the
Water Cooled Condenser by Evaporative Cooling i.e.,contact with Atmospheric air.
The Back pressure of Turbine can be achieved to 0.1 ata and below with Water
Cooled Condenser and Cooling Tower combination.

b) The Air Cooled Condenser is an Alternative of Water Cooled Condenser. This is

selected where there is a Water Scarcity. The function of Air Cooled Condenser is
to condense the Exhaust Steam from the Turbine and to maintain Vacuum in
theTurbine. The back pressure of 0.18 to 0.2 ata is only possible with Air
Cooled Condenser. This back pressure has a direct impact in the Power
generation i.e. if Back pressure increases, power generation decreases for a same
quantity of steam.

52. What is bed height in fluidised bed combustion boiler?

In FBC boiler, the bed material is used as a heat transfer media which takes heat
from the fuel combustion and transfer the same to bed coil immersed inside the
bed material. Normally bed coil steam generation is around 35 to 40% of the total
steam generated in FBC boiler. In order to immerse the bed coil heat transfer
area arrived as per thermal design, the bubbling fluidized bed has to expand to
certain height. The height to which the fluidized bed expand and immerse the bed
coil is called Expanded Bed Height. This varies between fuel to fuel, the bed
temperature also varies between fuel to fuel. Though the expanded bed height
covers approximately 900 to 1200 mmWc from air nozzle tube, the real bed height
is calculated as follows

Theoretical calculation:
Expanded bed height – Air nozzle height
-------------------------------------------------------
2

Arrived bed height from operating parameter:

Bed height = Air box pressure – Distributed plate drop

53. How NOX, SOX is controlled in various type of boilers?

Sox is controlled by adding Limestone. In Conventional Boiler, the emission of SOx is

controlled by 15% only by adding Lime, whereas in FBC boiler the Sulphur Retension is
possible upto 80 to 85%,. In case of CFBC Boiler the Sulphur Retension is possible upto
95%. . The reaction of limestone (CaCo3) with Sulphur is as follows
CaCO3 = CaO + CO2
CaO + SO + ½ O2 = CaSO4

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Low NOX can be achieved by following methods:

By delaying the mixing of secondary air into the fuel which produces low
temperature diffusion flame which inhibits NOx formation
- Directing the fuel and the excess air into the centre of the furnace, with
remaining secondary air directed parallel to the furnace wall

54. What are boiler quality materials used?

PIPE(Headers)
a. SA 106 Gr. B
b. SA 335 P11
c. SA 335 P22
PLATE:
a. SA 515 Gr.60
b. SA 516 Gr.70
c. IS 2062
d. IS 2062 (Structural)
e. SS 304
TUBE:
a. SA 210 Gr.A1
b. SA 213 T11
c. SA 213 T22
d. SA 213 T91
e. SA 312 TP 347H
ERW:
BS 3059

55. How flexibility is provided in a pipeline circuit?

In order to take care the Thermal Expansion of Piping during Operating Condition,
Expansion loops are provided approximately for every 25 to 35 meters.

The Expansion loop is nothing but a “C” type of piping loop constructions made up of Elbows.

The Expansion loop shall be of Horizontal loop or Vertical loop.

Type - I

Type - II

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56. What is Tensile strength, shear strength and elongation %?

a) Tensile Strength
When the resistance offered by a section of a member is against an increase
in length, the section is said to the offer a tensile strength.
Tensile load
Tensile strength = --------------------
Area of the material

b) The intensity of the shear resistance along the shear area

Shear resistance
Shear strength = ---------------------
Shear area of the material

c) % of elongation is the ratio of the change in length to the original length

Change in length
% of elongation = ----------------------
Original length

57. What are alloying elements in boiler steel?

The Alloys used in Boiler Matériel are

i. Chromium, Cr
ii. Molybedenum, Mo
iii. Vanadium, V

Few examples are given below

Material SA210 Gr.A1 SA 213 T91 SA 213 T22

Carbon 0.27 0.08 - 0.12% 0.05 min - 0.15 max
Manganese 0.93 (Max) 0.3 - 0.6% 0.3 to 0.6%
Phosphorus 0.035 0.020% 0.025%
Sulphur 0.035 0.010% 0.025%
Silicon 0.10 0.2 - 0.5% 0.5%
Chromium 8 - 9.5% 1.9 - 2.6%
Molybdenum 0.85 – 1.05% 0.87-1.13%
Vanadium 0.18 – 0.25 ---

58. What are different manufacturing processes used in manufacturing and building of
a boiler, coal and ash handling plants, fuel preparation plants, cooling towers,
condensers, turbines, fans, ESP, control panel, DCS etc?

Shop To Answer

59. What are different types of welding used in the manufacture of boiler and the
equipment used limitation of each process?

Shop To Answer

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60. What are codes used in the manufacture of boilers?

a. Indian Boiler Regulations (IBR)

b. ASME
c. British Standard

61. What are standards relevant to materials in boiler/power plant materials? –

a. ASME Section –II Part – D

b. INDIAN STANDARD
c. BRISTISH STANDARD

62. Why soil bearing capacity is important in foundations?

– To distribute the Dead loads, Live load, External load and Wind Load to the soil and to
design the footing size and shape of the foundation, the Soil Bearing Capacity is required.

63. What are loads considered in designing boiler, chimney and for dispatch in a
power plant?

Dead load, Live load, Wind load, Seismic load are to be considered for designing Boiler,
Chimney or for any other equipments.

64. What are different kinds of ladder used in power plant?

There is only one type of ladder available is called monkey ladder. If it is provided with safe
guard ring, it is called Cage ladder.

65. What are emission levels in a boiler permitted?

Boiler size Old New (after 1979) Protected Area

Less than 200 Mw 600 mg/Nm³ 350 mg/Nm³ 100 mg/Nm³
200 Mw & above ––– 150 mg/Nm³ 100 mg/Nm³

66. What are the effluents in a power plant and what is the treatment scheme
used for these effluents?
- Sewages, Boiler blow down, WTP reject.
- For 1.Sewages – Aerobic treatment + filter, 2.Boiler blow down,
- WTP reject – Primary + Secondary clarification + Aerobic treatment + filter + UF+ RO.

67. What is the approach temperature considered for cooling tower?

The difference between the Wet Bulb Temperature and the Cold Water temperature
(i.e.,Cooling Tower Outlet Temperature) is called Approach.

The Optimum Approach varies from 4oC to 5oC.

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If the Approach decreases, the size of the Cooling Tower will increase and ultimately
increase the initial cost of Cooling Tower.

68. What is the loss of water in cooling water circulation system?

In Cooling Water recirculation system, there are Three losses
a. Drift Loss
b. Evaporation Loss
c. Blow down Loss

a. The Drift Loss (D) may vary from 0.1 to 0.2 % in Cooling Water Supply.
T1 - T2
b. Evaporation Loss,E = -------------
6.11
E
c. Blow Down Loss, B = ------------- - D
COC – 1
Where, COC – Cycles of Concentration

Total Losses = D + E + B = 1.8 – 2% of Total Circulating water flow for a COC of 4.

69. TURBINE: What are the failures one can face in turbine blades, bearings?
a. Turbine blades:
1. Silica deposits
2. Vibration due to imbalance
3. Overloading
b. Bearings : Temperature shootup due to improper oil cooling.

70. What is the power demand of the country currently and anticipated demand by
2012, 2020?
Marketing can only furnish the information.

71. What are the power consumption levels across the globe?
Marketing can only furnish the information

72. What are investment levels required (project cost) for various capacities range in
the case of thermal, hydel, wind nuclear power plants.
Marketing can only furnish the information

73. What is present level of power generation in each of the above catagories in India
and the world?
Marketing can only furnish the information

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74. What are the features of Fire fighting system of a Power Plant?

It is mandatory that the Power Plant equipments shall be protected from Fire
Accidents with proper Fire Detection and Fire Protection system as per TAC (or)
NFPA norms
TAC – Tariff Advisory Committee
NFPA – National Fire Protection Association of India

01. FIRE DETECTION SYSTEM

Fire Detection system is an Automatic system which senses the fire / smoke
and gives the alarm as well as activate the Fire protection system to fight
against the fire. The systems involved in the Fire Detection system is given
below

a) Non Addressable Fire Alarm system

In this system, the premises will be covered with the Sensing elements such
as Photo Electric and Ionisation smoke detectors which is fixed in the roof
and form as a grid all around the Buildings (or) premises. In case of fire, the
detectors will sense and give the signal to the Fire Alarm Panel. In this, only
the zone will be identified and the exact location of the fire can not be
identified.
(Ex.: Fire in the Ist floor / IInd floor / IIIrd floor can only be identified)

b) Addressable Fire Alarm System

In this system, the premises will be covered with the Sensing elements such
as Photo Electric and Ionisation smoke detectors which are fixed in the roof
and forms as a grid all around the Buildings as a groups. The no of channels
for alarm will be grouped room vise. The sensing cable cost & Alarm Panel
cost are higher. In case of fire, the detectors will sense and give the signal
to the Fire Alarm Panel. In this, the specific zone and the exact location of
the fire can be identified. (Ex.: Fire in the Control room of III rd floor can
be exactly identified)

75. FIRE FIGHTING SYSTEM

Fire Fighting is the system used to quench the fire by use of various Fire Fighting
devices. The systems involved in the Fire Fighting system are given below

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a) Fire Hydrant system

Fire Hydrant system is a Manual system in which the Fire Hydrants are laid
all around the hazard zones at the regular intervals of 45 m between each
hydrants. Whenever there is a fire, the Pressurized water i.e., 7 or 8.8
Kg/cm2 maintained in the Hydrant main line shall be used for quenching the
fire by connecting the Hose pipes. Also, there is an another equipment called
Water Monitor, which is capable of delivering the water at high pressure
with out connecting hose from the delivery point will cover the maximum
coverage length & height of 45 m approximately.

b) High Velocity Water Spray system

High Velocity Water Spray system is an Automatic system in which the

Quartzoid bulb detectors & High Velocity Spray nozzle forms a single
component, which is kept all around the Transformer at three levels. In case
of fire, Quartzoid Bulb Detector which is held infront of the High Velocity
Spray nozzle will burst due to high temperature i.e., 65 oC & above and the
High Velocity Spray nozzle gets open. The High Pressure water will spray
through the High Velocity Spray nozzles and the fire will be quenched. This
is applicable only for the Transformer area since the Transformer contains
Oil.

c) Medium velocity Water Spray system

Medium Velocity Water Spray system is an Automatic system in which the

Quartzoid bulb detectors & Medium Velocity Spray nozzle forms a single
component, which is kept all around the premises. In case of fire, Quartzoid
Bulb Detector which is held In front of the Medium Velocity Spray nozzle
will burst due to high temperature i.e., 65 oC & above and the Medium
Velocity Spray nozzle gets open. The Pressurized water will spray through
the Medium Velocity Spray nozzle and the fire will be quenched. This is
applicable for Main Oil Tank, Cable Galleries, Coal Conveyors etc.

d) Foam Spray system

Foam Spray system is a Manual Foam type Fire Extinguisher which is

generally installed nearer to the Oil tanks. In case of Fire, the Foam will be
sprayed over the Fire manually such that the contact between the fire with
Atmosphere will be cut down and leads to lack of Oxygen within the covered
area. Due to lack of Oxygen , the fire will be quenched.

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e) CO2 Flooding system

CO2 Flooding system is an Automatic system in which the CO 2 Spray nozzles

are laid all around the Control room in connection with common CO 2 discharge
header line which is always kept closed by the Solenoid valve. In case of
Fire, the Heat detectors/Smoke Detectors will sense the fire and gives the
indication to the Solenoid valve and the valve will be opened. If the Valve
Opened, the CO2 will be sprayed all over the room which makes insufficient
O2, so that spreading of fire will be avoided and finally the fire will be
quenched. This system is a very active system but hazardous to the Human
being.

ELECTRICAL

76. What is Megawatt (M.W)?

Mega Watt is the unit of Power, 1000kW is equal to One MW and 0.746 kW is equal
to One HP (horse Power)

77. What is DCS and why it is required?

DCS is a Distributed control system. It is a system used to monitor and control the
total power plant including Boiler, Turbine & Other Auxiliaries.

78. What is synchronizing and what precaution is required for synchronizing?

Paralleling of any two different sources of power can be done only through
Synchronizing. Synchronizing is nothing but matching of voltage, frequency & phase
sequence between two sources of power.

79. How is the turbine coupled with generator?

Turbine and generator will be coupled through spacer coupling. Low rpm TGs
(3000rpm) are directly coupled with generator, whereas higher rpm TGs (8000rpm)
are coupled through gear box which reduces the generator rpm from 8000 to 3000.

80. What is the voltage at which power is generated?

11 / 6.6 / 0.433 KV.

81. Why is station transformer required?

Normally EB grid is used for taking start-up power. The supply available will be
mostly HV (High Voltage), whereas the power required for us will be MV (Medium
voltage) or LV (Low Voltage). Hence a Station transformer (ST) is required in-
between to utilize the EB power for start-up of power plant.

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82. What is the difference between AC and DC current?

AC means Alternating current and DC means Direct current. DC cannot be
generated directly. Even in DC generator power is generated in AC and converted
internally into DC. Only AC current can be generated. AC cannot be stored, whereas
DC can be stored.

83. How is the generator connected to station transformer through cable or bus bar?
Station transformer will not be connected to generator. Normally generator will be
connected to GT (Generator Transformer) or GT & UAT (Unit Auxiliary
Transformer) or MV switchgear depending on scheme selected. Busbar / cable is
selected based on current rating (i.e. capacity of generator). Station Transformer
requirement is explained for Question no. 75.

84. What are the protection devices in this circuit?

Electrical Protections devices are Circuit breakers (SF6, VCB, ACB, MCCB, MCB),
Fuses, Relays, Earthing flats, Lightning arrestors. However the relays are the major
protection device in power plant. The various relays are Over-current relay, Earth
fault relay, Under voltage relay, Over frequency relay, Reverse power relay etc.

85. What is typical single line diagram of power plant modules?

Single line diagram (SLD) is a diagram used to show the various Electrical
Equipments Connected in a Power plant and the scheme for Power Distribution of
the power plant. Atypical SLD is enclosed.

86. What are the components used in an electrical power distribution?

How can the above components be classified in short?
a) Transformers (GT / UAT / ST / SAT / Lighting).
b) Circuit Breakers (HV/MV/LV).
c) Switchgears (Switches, Fuses, Contactors).
d) Relays.
e) Cables & Cable trays.
Circuit breakers, Switchgears & Relays are part of Panels (HV/MV/LV). Panels are
classified as PCC (Power Control Center) and MCC (Motor Control Center).

87. What is all about instrumentation in a power plant?

Instrumentation is a department which will do the engineering of all analog /digital
instruments involved in a power plant used for controlling / monitoring the power
plant. Analog instruments shall involve Transmitters, Transducers, RTDs, and
Thermocouples like 4-20mA & 0-40mV. Digital Instruments shall involve Solenoid
Valves, Switches and Contactors like ON / OFF & High / Low.

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88. What are different types of cables used in a power plant?

Depending on conductor - Copper / Aluminium (Normally copper conductors will
be used for Control, Instrumentation and power cables of less than 4sq.mm.
Aluminium conductors will be used for Power cables of 4sq.mm and above)

Depending on Insulation - PVC / XLPE / FR / FRLS (All HT cables will be XLPE

Insulated, LT cables shall be PVC or XLPE based on customer requirement. FR/FRLS
cables shall be provided for critical application where fire may cause)
XLPE – Cross Linked Poly Ethylene
FR – Fire retardant
FR – Fire retardant Low Smoke
Other Categories - Screened / Unscreened (all HT cables and Instrument cables
(for analog signals) will be screened)
Armored / Unarmored (normally all cables in power plant will be Armored)

89. Why is earthing done in electrical circuits?

a) To create Low resistance path in the plant to discharge the
leakage current caused in an electrical circuit.
b) To protect human being from current shock causing due to
leakage current.
Leakage current may occur due to insulation failure, presence of foreign materials
in the electrical equipments, voltage spikes, etc.

90. What is the relationship between line and phase current, voltage in a three phase
a.c.circuit?
The relationship differs based on the Connection. In Delta connection, Phase and
line voltage are same and line current is root three times the phase. In star
connection, Phase and line current are same and Line Voltage root three times Phase
voltage

91. What is the formula to compute power in an a.c circuit?

Power (in KW) = Sq root (3) X Voltage X Current X Power factor
Power (in KVA) = Sq root (3) X Voltage X Current

92. What is series and parallel circuit?

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Phase / +ve
M M

Neutral / -ve Series Circuit

Phase / +ve

Parallel Circuit M M
Neutral / -ve

93. What are the measuring instruments in an electrical circuit?

a) Ammeter – Current
b) Voltmeter – Voltage
c) Tri vector Meters – Current, Voltage, KW, KVA, KVAr, KWH, KVAH,
KVArH, freq
d) Frequency Meter
e) Power Factor Meter
f) Energy Meters – KWH

94. What is the transmission voltages used?

220, 132/110, 66, 33, 11, 6.6, 0.433 kV
Power Evacuation can be done in any voltage levels depending on requirement.
Normally Power plant of less than 30MW will be evacuated through cables in 11 or
6.6kV voltages. In case of Power export of more than 40 MW, the same shall be
though Transmission lines of 33kV & above only in india.

95. What are different power transmission systems?

The Power can be transmitted either through cable or Bus duct (Aluminium or
copper) or Transmission lines.

96. What are the classifications of insulation used in industry and what is relevant
voltage for each of this category?
The Materials used for Insulation are Epoxy, Porcelain, PVC, etc. In case of
Switchboards Insulation will be done through PVC sleeves and FRP/Epoxy boards. In
case of Cables the insulation will be done either with PVC or XLPE. In case of
Support insulators or bushings the material shall be Epoxy or Porcelain. Like wise
insulation will differ from equipment to equipment. Insulation material is basically
selected based on temperature class (i.e the temperature that the insulation can
withstand). In case of higher insulation (ie higher voltage levels) the Thickness or
Quantity of material used for insulation shall vary and not the Material. Material
depends on application and not on voltage class.

97. What are testing equipments used in electrical circuit?

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Multimeters, Meggar, HV generators are the widely used testing equipments.

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