Auxiliary Power consumption

in Power Generation
& Distribution in CPP
S.P.Patra
CPP
Dt: 13.05.11
 POWER DISTRIBUTION

SMELTER 765 MW
AUX.CONSMP CONSUMPTION

GRID
AUXILIARY 80.0 MW
POWER
T & D LOSS CONSUMPTION
EXPORT TO 40.0 MW
GRIDCO
SMELTER
T& D LOSS 5.0 MW

TOTAL 890 MW
 SP. CON. OF AUX. POWER

9.6
9.5
9.4
9.3 NORM
9.2 ACTUAL
9.1
9
2 00 3-04 2 00 4-05 20 05-06 2 006 -07 2 007-08

NORM 9 .5 9.5 9 .5 9 .5 9 .5
ACTUAL 9 .18 1 9 .49 9 9 .4 9.32 9 9.44 5
 Distribution system
 Objective
 Philosophy
 Network
 Dimensioning more
 Operation
 Energy management
 Automation
 Objective
 Uninterrupted power to all area at
required level
 Stability
 To facilitate maintenance activities
 To isolate during normal & abnormal
condition
 To meet future demands
 Philosophy
 Power transmission
 Voltage level
 Selection of equipment
 Protection of equipment
 Unit power
 Station power
 Emergency power
RAW WATER HP D/A LP HEATER GRIDCO
HEATER BFP

WATER TREATMENT
HPT IPT LPT GENERATOR
SMELTER
COOLING 10.5 KV 220 KV
TOWER

CEP
CW PUMP 6.6 KV
CONDENSER UAT
REHEATED STEAM
GT 6.6 KV
SAT

CONDENSATE CHIMNEY
STORAGE TANK

BOILER
COAL BUNKERS

ECONOMISER
ELECTRO STATIC
PRECIPITATOR
FUEL OIL TANK

MILL ID FAN
FD FANS
PA FAN

COAL CRUSHER
ASH SLURRY PUMPS
 GRID CONNECTIVITY AT
CPP
KANIHA

RENGALI

TTPS

Bus
NALCO-MERAMUNDALI-1&2 Coupler

SMELTER
CPP STATION FEEDERS
GENERATORS TRANSFORMER
 TECHNICAL DATA OF GEN.
TRANSFORMER
UNIT # 7 TO 10
 MAKE :BHEL
 CAPACITY :150MVA
 VOLTAGE PRI / SEC : 235KV / 10.5 KV
 CURRENT PRI / SEC :368.53 A / 8248.1A
 VECTOR : YN d 1
 % OF IMPEDANCE : 12.5 %
 INSULATION LEVEL :A
 COOLING : OFAF
 INSULATION LEVEL HV SIDE : 950KV PICK, 395 KV RMS
 INSULATION LEVEL HV SIDE : 75KV PICK, 28KV RMS
 OFF LOAD TAP CHANGER : + 5% TO - 5% IN 5 STEPS
 TECHNICAL DATA OF UNIT AUX.
TRANSFORMER
UNIT # 1 TO 6
 MAKE :BHEL
 CAPACITY :16MVA
 VOLTAGE PRIMARY :10.5KV
 VOLTAGE SECONDARY : 6.9KV
 CURRENT PRIMARY :879 AMPS
 CURRENT SECONDARY : 1338 AMPS
 VECTOR : D y n 11
 % OF IMPEDANCE : 7.0%
 INSULATION LEVEL :A
 COOLING : ONAN / ONAF
 OLTC : +/- 10% IN 17 STEPS
 NGR : 7.4 OHM / 600AMPS
 STATION TRANSFORMER
SAT-1, SAT-2, SAT-3

 MAKE : TELK
 RATING : 35 MVA
 PRIMARY VOLTAGE : 220KV
 SECONDARY VOLTAGE : 6.9 KV
 PHASE : 3PHASE
 FREQUENCY : 50Hz
 VECTOR : YN yn0
 IMPEDANCE : 12%
 OLTC : +/- 10% IN 17 STEPS
 NGR3.3 OHM , 7.2 KV ,1400A / 10 Sec
 Distribution Network(Area wise)
 220kv switchyard
 Power house
 Cooling water pump house
 Coal handling Plant
 DM Plant
 Ash handling Plant
 Intake Pump House
 Ash Pond
 FOPH
 Ventilation System
 Area Wise Distribution & Power Flow
IPH CHP ASH
POND

CWPH SYD WTP

ASPH PH FOPH
 Auxiliary Load
 Power House
– Compressed air
– Fuel oil
– Fuel (Coal)
– Air & Flue gas
– Condensate & Feed water
– Lub oil & control oil
– Ash collection & evacuation
– Ventilation
 Auxiliary Load
 CWPH
– Cooling water
– Auxiliary cooling water
 ASPH
– Ash disposal
– Ash removal from ESP
 CHP
– Crushed coal
– Conveying of coal
– Stacking of coal
 WTP
– DM water
– Clarifloculated water
– Smelter supply
– Service water
 220kv Bus
SF6 Bkr
UAT
6.6 kv Ring Bus GT
SAT
VCB

Generator
Reserve Board 6.6 Kv

Unit Board 6.6 Kv I/C-B

110 V AC

Reserve MCC PCC TR

ACB
UPS
230V AC 24v DCDB 220v DCDB

CHGR CHGR
CHGR
DG
 Switchyard Main Bus-1

Main Bus-2

Bkr Bus Coupler

Smelter GRIDCO
Transformer
Generator
 Ring Bus Distribution Network SB-1
9BA ASPH-1 9BA,ASPH-1
Syd-1,CWPH-3
CWPH-3
WTP-4
ST-1

SB-1 WTP-4

WTP-2
ST-2

SB2
SB3

Syd-2
CHP-2

9BB SB-2
SB-3 9CDT WTP-3,CWPH-2
CWPH-1,CHP-1 CHP-2,9CBT
9BB,Syd-2 ASPH-2
WTP-2 ST-3 9CDT
 Power House
(Reserve Switchgear)
TIE
9BA 9BB
x x x x
x x x x x x x x

9CA 1BA VENT FOPH ILU 9CB 1BB MAINT

Vent Tr- 1000kva(2 no)

Ltg Tr- 300kva(6 no) Reserve service Tr-1750kva(2 no)
Maintenance Tr
FOPH Tr-800 kva(2 no)
Power Supply through Cables
Sectional View of VCB
 Reserve PCC
Inc-A Inc-B
x Sec-A Sec-BC Sec-B x
X X
x x x x x x

I/A S/A Bunker 9PA Crane CT Pump

9CA
9CB
I/A Compressor-A,B,C,D,G&H
I/A Compressor-E,F
S/A Compressor-A,B
S/A Compressor-C,D,E,F
Bunker MCC
CT Pump
Reserve MCC
Reserve PCC
415 V ACB
 Unit Board
UAT I/C -A TIE UAT I/C-B TIE

x 1BA x x 1BB x
x x x x x x x x

PCC BFP CEP ID Fan ESP FD Fan PA Fan Mill

ESP- 1000KVA FD Fan- 400kw

PCC- 800KVA ID Fan- 900kw
BFP- 3600kw PA fan- 900kw
CEP- 300kw Mill- 320kw
Capacitive compensation in each board is 1.5 Mvar
BFP Motor -3600KW
 INC-A INC-B
Unit PCC
x B/C x
SEC-A SEC-B
x
x x x x x x
Turbine MCC
x SEC-A SEC-B x
x
x Boiler MCC SEC-B x
SEC-A
x
x SEC-A B/C-V Emergency MCC B/C-W SEC-B x
x x
x DG Inc Bkr
 Emergency Board
 Sec-A  Sec-B
 AOP-A  AOP-B
 JOP-A  JOP-B
 220v DC Charger  Seal Oil Pump (A/C)
 UPS Charger  AOP of BFP-B
 24v Charger  FD Fan LOP
 HP Bypass oil pump
Over View Of a Module
 SB-1 CWPH
SB-2 SB-3

Sec-A Sec-B Sec-C

X X

X X X X
CT MCC-A AWPH CWPH MCC
Sec-A Sec-B Sec-C
CW1,3,4,11,13 CW-2,5,6,9,14 CW-8,10,12,15
ACW-1,2 ACW-3 ACW-4,5
IDCT-1,4 IDCT-2,5 IDCT_3,6
CWPH-Tr-1 AWPH Tr-1 AWPH Tr-2
CWPH Tr-2
 Emergency Power
Total Power Failure
U-1 U-2 Tie-2 Tie-3
X X X X

Tie-1
X X X X

DG-G
DG-H

U-3
U-4 U-5 U-6
X X X X

X X X
X

Tie-2 Tie-3
DG-I DG-J
 Voltage Level
 Transmission
– 220 kv To Smelter
– 33kv to IPH & ASH Pond
 10.5 kv ( Generation)
 Distribution
– 6.6 kv HT switchgear
– 415v (PCC,MCC)
 Control
– 220v Dc (Breaker control, Protection)
– 230v Ac UPS (Recorder, Instruments & DCS)
– 110v Ac (Oil gun, Flame scanner)
– +/- 24v Dc ( Control & Instrumentation)
 Protection
 Motor (CTMM/Numerical)
– Thermal o/c, E/F, I1, I1(t), Neg. seq.
– Differential above 1 Mw (BFP)
 Feeder Protection
– Over current(51), E/F(51N)
 Transformer Protection
– Over current(51), E/F(51N)
 6.6 kv Board
– Under voltage
– O/C Current
 MCC/LT Motors
 Module  Type 2 Coordination
 Isolator  AOP Motor
 Fuse  Motor Output - 90 Kw
 Contactor  F.L.Current-157A
 Over Load Relay  Contactor-3TA28
 Aux. Contactor  O/L Range-140-170A
 Timer  Fuse-250A
 Cable-150 sq.mm
SCADA
 CHALLENGES AHEAD
 INSTALLATION OF AN EFFECTIVE PLANT-
WIDE ENERGY MANAGEMENT SYSTEM.
 REDUCTION IN AUXILIARY POWER
CONSUMPTION AND ENERGY
CONSERVATION.
 IMPROVING EQUIPMENT RELIABILITY .
 MODERNISATION AND REPLACEMENT
STRATEGIES.
 LIFE ENHANCEMENT STRATEGIES.