KSTPS Traning Report

Kota Super Thermal Power Station (K.S.T.P.
S), Kota
CHAPTER -1
INTRODUCTION
For the power generation with 2x110 MW and
3x210 MW of K.S.T.P.S. authorities are required to be operative to active
full operation. The auxiliaries are basically operation either on L.T. System
i.e. 415 V 3-Ø power supply is made available to the system after providing
the station transformer of 3x50 MVA capacity with voltage 220 KV/ 7.2/7.2
KV & different service transformers of capacity 1.0 MVA, 1.5 MVA, 2.0
MVA, which are located near the load centre as the transformer having the
voltage of 6.6 KV /415 V. The 6.6 KV power is distributed through 6.6 KV
interconnected Bus System for all the five units with a control through DC of
220 V.
The 415 V power supply is done through a L.T.
SWGR (Switchgear) which are located nearby the distribution transformer as
well as the load centers. The all incomers, which are breaker controlled , are
having the control the L.T. SWGR are having the control system on 110/ 220
V AC. The 6.6 KV power supply which are either MOCB (Minimum Oil
Circuit Breaker) of JYOTI MAKE or Air Circuit Breakers.
The 6.6 KV power supply to various draining equipment’s
i.e. more is made through breakers which are either MOCB of Jyoti make air
circuit breaker which are either of voltage makers as well as SF 6 of NGEF
make. The LT supply is also controlled through air break circuit breaker
which are either L&T make or English Electric Company of India. The
M.B.M ENGINEERING COLLEGE, JODHPUR 1

Kota Super Thermal Power Station (K.S.T.P.S), Kota
various H.T. motors are switched on started through on direct ON line
(DOL) in order to inverse the availability of equipment at full efficiency
without time gap.
Further , the 6.6 KV system which is normally in delta
configuration and terms as an unearthed system so also to keep the running
motor complete in operating condition in case of any one .phase of motor
winding is earthed due to any one reason. Earthling is detected by an
protection system with alarm facility to take remedial measures immediately
and at the same time to maintain the generation level in the same condition,
prior to occurring the earth fault the single phase earth fault is detected in due
course till the motor is not earthed to other or another phase. “PUBLIC
ADDRESS SYSTEM” is available through in area of each unit which helps
in fast communication for prompt remedial measure.
Soot Blowers are there in the boiler area on the furnace side or
Zone which helps in blowing the soot / ash deposition regularly of the
furnace wall / economizer tubes to keep heat transfer at the required
parameter.
In April 1973, Central Electricity Authority prepared a
Project Report for power station comprising of the two units of each of
capacity 110 MW for RSEB subsequently in September. 1975 this was
revised by the Consultant Thermal Design Organization , Central Electricity
Authority for invention of 2x110 MW units being manufactured by BHEL,
Hyderabad in 1st Stage. The planning commission cleared the project report

in Sept., 1976 for installation of two units each of 110 MW in first estimated
cost of Rs. 143 Crores.
The KSTPS has four stage & six unit power station. In first
stage there is 2 unit of 110 MW, in second stage 2 unit of 210 MW. In third
& fourth stage, there each having 210MW &195 MW units respectively. The
construction of fifth stage Of 195 MW is under construction and may be
possibly completed up to sept. 2008. The total power generated in KSTPS is
1045 MW.
K.S.T.P.S. IS DESISIGNED IN FOLLOWING STAGES:-
 STAGE I - 2x110 MW
 STAGE II - 2X210 MW
 STAGE III - 1X210 MW
 STAGE IV - 1X195 MW
 STAGE V - 1X195MW *
* Stage V is to be commissioned shortly in Sept. 2008.

LOCATION:-
The Kota Thermal Power Station is ideally on the left
bank of Chambal River at Up Stream of Kota Barrage. The large expanse of
water reached by the barrage provides an efficient direct circulation of
cooling system for the power station. The 220 KV GSS is within ½ Kms.
from the power station.
LAND:-
Land measuring approx. 250 hectares was required for the
project in 1976, For disposal of ash tank very near to power station is
acquired which the ash in slurry form is disposed off through ash and slurry
disposal plants.
COAL:-
Coal India limited owns and operates all the major coal fields
in India through its coal producing subsidiary companies viz. Eastern Coal
Fields Limited, Western Coal Fields Limited/Coal India limited is supply
coal from its coal mines of coal producing subsidiaries BCCL, SECL & ECL
to Kota Thermal Power Station through railway wagons. The average
distances of SECL, ECL & BCCL are 800, 950 and 1350 Kms. respectively.
WATER:-
The source of water for power station is reservoir formed by
Kota Barrage on the Chambal River. In case of large capacity plants huge
quantities of coal and water is required. The cost of transporting coal and
water is particularly high. Therefore, as far as possible, the plant must be
located near the pit rather than at load centre for load above 200 MW and
375 MW. The transportation of electrical energy is more economical as
compared to the transportation of coal.
DESIGN FEATURES:-
The satisfactory design consists of the flowing steps.
• Estimation of cost.
• Selection of site.
• Capacity of Power Station.
• Selection of Boiler & Turbine.
• Selection of Condensing Unit.
• Selection of Electrical Generator.
• Selection of Cooling System.
• Design of Control and instrumentation system.
The design of steam power station requires wide
experience as the subsequent operation and maintenance are greatly affected
by its design. The most efficient design consist of properly sized component
designed to operate safely and conveniently along with its auxiliaries and
installation.

CHAPTER -2
General Layout & Basic Idea
A control system of station basically works on
Rankin Cycle. Steam is produced in Boiler is exported in prime mover and
is condensed in condenser to be fed into the boiler again. In practice of good
number of modifications are affected so as to have heat economy and to
increase the thermal efficiency of plant.
The Kota Thermal Power Station is divided into four main circuits :
 Fuel and Ash Circuit.
 Air and Gas Circuit.

 Feed water and Steam Circuit.
 Cooling Water Circuit.
Fuel & Ash Circuit:-
Fuel from the storage is fed to the boiler through
fuel handling device. The fuel used in KSTPS is coal, which on combustion
in the boiler produced the ash. The quantity of ash produced is
approximately 35-40% of coal used. This ash is collected at the back of the
boiler and removed to ash storage tank through ash disposal equipment.
Air and Gas Circuit:-
Air from the atmosphere is supplied to the combustion
chamber of Boiler through the action of forced draft fan and induced draft
fan. The flue gas gases are first pass around the boiler tubes and super
heated tubes in the furnace, next through dust collector (ESP) & then
economizer. Finally, they are exhausted to the atmosphere through fans.
Feed Water and Steam Circuit:-
The condensate leaving the condenser is
first heated in low pressure (LP) heaters through extracted steam from the
lower pressure extraction of the turbine. Then its goes to dearator where
extra air and non-condensable gases are removed from the hot water to avoid
pitting / oxidation. From deaerator it goes to boiler feed pump which
increases the pressure of the water. From the BFP it passes through the high
pressure heaters. A small part of water and steam is lost while passing
through different components therefore water is added in hot well. This water
is called the make up water. Thereafter, feed water enters into the boiler
drum through economizer. In boiler tubes water circulates because of density
difference in lower and higher temperature section of the boiler. The wet
steam passes through superheated. From superheated it goes into the HP
turbine after expanding in the HP turbine. The low pressure steam called the
cold reheat steam (CRH) goes to the reheater (boiler). From reheater it goes
to IP turbine and then to the LP turbine and then exhausted through the
condenser into hot well.
Cooling Water Circuit:-
A large quantity of cooling water is required to
condense the steam in condenser and marinating low pressure in it. The
water is drawn from reservoir and after use it is drained into the river.

COAL HANDLING PLANT
INTRODUCTION:-
It can be called the heart of thermal power plant because
it provided the fuel for combustion in boiler. The coal is brought to the
KSTPS through rails there are fourteen tracks in all for transportation of coal
through rails. The main coal sources for KSTPS are SECL (South Eastern
Coalfields Limited), ECL (Eastern Coalfield Limited) and BCCL (Bharat
Coking Coal Limited). Everyday 3 to 4 trains of coal are unloaded at KSTPS.
Each train consists of 58 wagons and each wagons consists of 50 tonnes of
coal. The approximate per day consumption at KSTPS is about 1400 metric
tones. It costs approximate 2 crores of rupees per day including
transportation expenses. The coal is firstly unloaded from wagon by wagon
triplers then crushed by crushers and magnetic pulley and pulverized to be
transformed to the boiler. The whole transportation of coal is through
conveyor belt operated by 3-Ø Induction motor.
The coal handling plant can broadly be divided into three sections :-
1) Wagon Unloading System.
2) Crushing System.
3) Conveying System.

WAGON UNLOADING SYSTEM:-
Wagon Tripler:-
It unloads the coal from wagon to hopper. The hopper,
which is made of Iron , is in the form of net so that coal pieces of only equal
to and less than 200 mm. size pass through it. The bigger ones are broken by
the workers with the help of hammers. From the hopper coal pieces fall on
the vibrator. It is a mechanical system having two rollers each at its ends.
The rollers roll with the help of a rope moving on
pulley operated by a slip ring induction motor with specification:
Rated Output. : 71 KW.
Rated Voltage. : 415 V.

Rated Current. : 14.22 Amp.
Rated Speed. : 975 rpm.
No. of phases. : 3
Frequency. : 50 Hz.
The four rollers place themselves respectively behind
the first and the last pair of wheels of the wagon. When the motor operates
the rollers roll in forward direction moving the wagon towards the “Wagon
Table”. On the Wagon table a limit is specified in which wagon has to be
kept otherwise the triple would not be achieved.
CRUSHING SYSTEM:-
Crusher House:-
It consists of crushers which are used to crush the coal
to 20 mm. size. There are mainly two type of crushers working in KSTPS:-
Primary Crushers i.e. i) Rail crushers or ii) Rotary breaker.
Secondary Crushers. i.e. Ring granulators.
Primary Crushers:-
Primary crushers are provided in only CHP stage 3
system, which breaking of coal in CHO Stage 1 & Stage 2 system is done
at wagon tripler hopper jail up to the size (-) 250 mm.

Roll Crusher:-
Type : 80” 5 A breakers.
Capacity : 1350 TPH Rates/ 1500 TPH Design.
Feed material : Rom Coal.
Feed size. : (-) 1200 mm. (approx.)
End Product size : (-) 500 mm.
Motor rating. : 2 Nos. 125 KW, 100 rpm.
Crushers. : 225.
Rotary Breaker:-
Type : 12’ x 21o Rotary Breaker.
Capacity : 800 TPH Rated/ 1000 TPH Design.
Feed Material. : Coal with rejects.
Feed size. : (-) 0-500 mm.
End product size : (-) 0-200 mm.
Motor rating. : 125 HP, 1500 rpm.
Secondary Crusher:-
Basically there are four ways to reduce material size : impact attrition ,
Shearing and Compression. Most of the crushers employ a combination of
three crushing methods. Ring granulators crush by compressing
accompanied by impact and shearing.The unique feature of this granulator is

the minimum power required for tone for this type of material to be crushed
compared to that of other type of crushers.
Construction & Operation:-
Secondary crushers are ring type granulators crushing at the rate
of 550 TPH / 750 TPH for input size of 250 mm. and output size of 20 mm.
The crusher is coupled with motor and gearbox by fluid coupling.
Main parts of granulator like break plates, cages , crushing rings and other
internal parts are made of tough manganese (Mn) steel.
The rotor consists of four rows of crushing rings each set having 20
Nos. of toothed rings and 18 Nos. of plain rings. In CHP Stage 1 & 2 having
64 Nos. of ring hammers. These rows are hung on a pair of suspension shaft
mounted on rotor discs.
Crushers of this type employ the centrifugal
force of swinging rings stroking the coal to produce the crushing action. The
coal is admitted at the top and the rings strokes the coal downward. The coal
discharges through grating at the bottom.
CONVEYING SYSTEM:-
Stacker Reclaimer:-
The stacker re-claimer unit can stack the material on to the pipe or
reclaim the stack filed material and fed on to the main line conveyor. While
stacking material is being fed from the main line conveyor via tripler unit
and vibrating feeder on the intermediate conveyor which feds the boom

conveyor of the stacker cum reclaimer. During reclaiming the material dis
discharged on to the boom conveyor by the bucket fitted to the bucket wheel
body and boom conveyor feeds the material on the main line conveyor
running in the reverse direction.
Conveyor belt Specification of Stacker / Reclaimer:-
Belt width. : 1400 mm.
Speed. : 2.2 m/second.
Schedule of motor : All 3-Ø induction motors.
Bucket wheel motor : 90 KW.
Boom Conveyor motor : 70 KW.
Intermediate Conveyor Motor : 90 KW.
Boom Housing Motor : 22 KW.
Slewing assembly. : 10 KW.
Travel Motor : 7.5 KW.
Vibrating Feeder. : 2x6 KW.
Total installed power. : 360 KW.
Conveyor Specification:-
Capacity. 1) 1350 tonne per hour.
2) 750 tonne per hour.
No. of conveyor. : 38

Horizontal length .: 28 meters.
Lift(M) (approx.) : Variable to suit the system.
Belt width. : 1400 mm.specification of conveyor motor
FEEDERS:-
This structure is erected to serve the purpose of storage. Under ground
machines are installed known as plow feeder machines.
These machines collect the coal from conveyor and drop it
to the other from one conveyor with the help of jaws and this coal is taken to
huge erected structure from where the coal falls to the ground. Jali chutes
are used to prevent dust.

ASH HANDLING PLANT
This plant can be divided into 3 sub plants as follows:-
1) Fuel and Ash Plant.
2) Air and Gas Plant.
3) Ash Disposal and & Dust Collection Plant.
Fuel and ash plant:-
Coal is used as combustion material in KTPS, In order to get an
efficient utilization of coal mills. The Pulverization also increases the overall
efficiency and flexibility of boilers. However for light up and with stand
static load , oil burners are also used. Ash produced as the result of
combustion of coal is connected and removed by ash handling plant. Ash
Handling Plant at KTPS consists of specially designed bottom ash and fly
ash in electro static precipitator economizer and air pre-heaters hoppers.
Air & Gas Plant:-
Air from atmosphere is supplied to combustion chamber of
boiler through the action of forced draft fan. In KTPS there are two FD fans
and three ID fans available for draft system per unit. The air before being
supplied to the boiler passes through pre-heater where the flue gases heat it.
The pre heating of primary air causes improved and intensified combustion
of coal.
The flue gases formed due to combustion of coal first passes
round the boiler tubes and then it passes through the super heater and then
through economizer . In re-heater the temperature of the steam (CRH)
coming from the HP turbines heated with increasing the number of steps of
re-heater the efficiency of cycle also increases. In economizer the heat of
flue gases raises the temperature of feed water. Finally the flue gases after
passing through the Electro-Static Precipitator is exhausted through chimney.
Ash Disposal & Dust Collection Plant:-
KSTPS has dry bottom furnace. Ash Handling Plant
consists of especially designed bottom and fly ash system for two path boiler.
The system for both units is identical and following description is applied to
both the units the water compounded bottom ash hopper receives the bottom
ash from the furnace from where it is stores and discharged through the
clinker grinder. Two slurry pumps are provided which is common to both
units & used to make slurry and further transportation to ash dyke through
pipe line.
Dry free fly ash is collected in two number of 31 fly ash
hoppers which are handled by two independent fly ash system. The ash is
removed from fly ash hoppers in dry state is carried to the collecting
equipment where it is mixed with water and resulting slurry sump is
discharged

Utilisation:-
Utilisation of coal-ash is always practise than its disposal. There are various
methods of utilisation of coal-ash along with established engineering
technologies some of them are mentioned below:
1. Manufacturing of building materials.
2. Making of concrete.
3. Manufacturing of pozzuolana cement.
4. Road construction etc.
In all the above cases financial constraint discourages the
entrepreneurs to take up the work. In view of the environmental impact of
disposal, Government may give attractive subsidy and create marketing
facility so that entrepreneurs may come forward to use as their raw material.

ELECTRO-STATIC
PRECIPITATOR
Scope & Principle of Operation:-
For general mankind , today an Eco
friendly industry is must. As far as air pollution is concerned now a days
various flue gases filter are there in service. The choice depends on the size
of suspended particle matter. These filters are E.S.P. Fabric filter high
efficiency cyclone separations and sitelling room. Fop fly ash , where the
particle size vary from 0.75 microns to 100 micron use gradually use E.S.P.
to purify the flue gases due to its higher efficiency & low running cost etc.
In an ESP the dust lidder gas is passed through an intense electric field,
which causes ionization of the gases & they changed into ion while traveling
towards opposite charged electrode get deposited as particles and thus dust is
electric deposited an electrode creating the field. It is continuous process.
CONTROLLER:-
Now a day micro-processor based intelligent
controllers are used to regulate the power fed to the HVR. The controls the
firing / ignition angle of the thyristor connected in parallel mode. Input out
waves of the controller and HVR are also shown above, which clearly
indicates that average power fed to ESP field can be controlled by variation
of the firing angle of thyristor.

The output of controller with respect to time is also controlled
by microprocessor, so that ESP operation is smooth and efficient . The chars
is as shown :
As can be seen in the event of spark between
electrode the output of controller is reduced to zero for few millisecond for
quenching the spark. Controller also takes place care of fault in KVR and
gives a trapping and non-trapping alarm as per the nature of fault.

HIGH VOLTAGE RECTIFIER TRANSFORMER:-
HVR receives the regulated supply from
controller. It steps upto high voltage rectifier. The D.C. supply is fed to
E.S.P. field through its negative bushing. The positive bushing so connected
to earth through small resistance which forms a current feed back circuit. A
very high resistance column is also connected with negative bushing . It
forms the voltage feed back circuit. These two feedback are used in the
controller for indication and control purpose.
E.S.P. FIELD:-
The field consists of emitting and collecting electrodes
structure which are totally isolated from each other and hanging with the top
roof of field. The emitting is also isolated from the roof through the support
insulators which are supporting the emitting electrode frame works and also
the supply to these electrodes is fed through support insulators. The
collecting electrodes are of the shape of flat plates. By several similar plates
which the emitting electrodes are of the shape of spring. Strong on the
emitting frame work with the help of hooks in both the ends.
The ash depositing on these electrode is rapped down by
separate wrapping mechanism happens at the bottom of the field. From these
hoppers ash is evacuated by ash handling system and dispose to the disposal
area. The wrapping system is automatically controlled with the help of the
programmable metal controller, located in the ESP auxiliaries control panels.

CHAPTER -3
BOILER
A boiler (or steam generator) is a closed vessel in which water,
under pressure is converted into steam. It is one of the major components of
a thermal power plant. A boiler is always designed to absorb maximum
amount of heat released in process of combustion. This is transferred to the
boiler by all the three modes of heat transfer i.e. conduction, convection and
radiation.
Boilers are classified as:-
Fire tube boiler:-
In this type the products of combustion pass
through the tubes which are surrounded by water. These are economical for
low pressure only.
Water tube boiler:-
In this type of boiler water flows inside the tubes and hot
gases flow outside the tubes. These tubes are interconnected to common
water channels and to steam outlet.
• The water tube boilers have many advantages over the fire tube boilers
• High evaporation capacity due to availability of large heating surface.

• Better heat transfer to the mass of water.
• Better efficiency of plant owing to rapid and uniform circulation of
water in tubes.
• Better overall control.
• Easy removal of scale from inside the tubes.
In KSTPS, Natural circulation, tangentially
fired, over hanged type, Water tube boilers are used. Oil burners are provided
between coal burners for initial start up and flame stabilization. Firstly, light
oil (diesel oil) is sprayed for initialization then heavy oil (high speed diesel
oil) is used for stabilization of flame. Pulverized coal is directly fed from the
coal mills to the burners at the four corners of the furnace through coal pipes
with the help of heated air coming from PA fan. Four nos. of ball mills of
34MT/hr. capacity each have been installed for each boiler. The pressure
inside boiler is -ive so as to minimized the pollution and looses & to prevent
the accidents outside the boiler.
For ensuring safe operation of boilers,
furnace safe guard supervisory system (FSSS) of combustion engineering
USA designed has been installed. This equipment systematically feed fuel to
furnace as per load requireme. The UV flame scanners installed in each of
the four corners of the furnace, scan the flame conditions and in case of
unsafe working conditions trip the boiler and consequently the turbine.

Turbine - boiler interlocks safe guarding the boiler against possibility furnace
explosion owing to flame failure.
Furnace:-
Furnace is primary part of the boiler where the chemical
energy available in the fuel is converted into thermal energy by combustion.
Furnace is designed for efficient and complete combustion. Major factors
that assist for efficient combustion are the temperature inside the furnace and
turbulance, which causes rapid mixing of fuel and air. In modern boilers,
water-cooled furnaces are used.

PULVERISED FUEL SYSTEM:-

The boiler fuel firing system is tangentially firing system in which the fuel is
introduced from wind nozzle located in the four corners
inside the boiler.
The crushed coal from the coal crusher is transferred
into the unit coalbunkers where the coal is stored for
feeding into pulverizing mill through rotary feeder The
rotary feeders feed the coal to pulverize mill at a definite
rate. Then coal burners are employed to fire the pulverized coal along with
primary air into furnace. These burners are placed in the corners of the
furnace and they send horizontal streams of air and fuel tangent to an
imaginary circle in the center of the furnace.
Fuel Oil System:-
The functional requirement of the fuel burning system is to
supply a controllable and uninterrupted flammable furnace input of fuel and
air and to continuously ignite and burn the fuel as rapidly as it is introduced
into the furnace. This system provides efficient conversion of chemical
energy of fuel into heat energy. The fuel burning system should function
such that fuel and air input is ignited continuously and immediately upon its
entry into furnace.
The Fuel air (secondary air) provided FD fan, surrounds the fuel
nozzles. Since this air provides covering for the fuel nozzles so it is called as

mantle air. Dampers are provided so that quantity of air can be modulated.
Coal burners distribute the fuel and air evenly in the furnace.
Ignition takes place when the flammable furnace input is heated above
the ignition temperature. No flammable mixture should be allowed to
accumulate in the furnace. Ignition energy is usually supplied in the form of
heat. This ignition
energy is provided by oil guns and by igniters.
Boiler Drum:-
The drum is a pressure vessel. Its function is to separate water and steam
from tmixture (of steam & water) generated in the furnace walls. It provides
water storage for preventing the saturation of tubes. It also houses the
equipment needed for purification of steam. The steam purification primarily
depends on the extent of moisture removal, since solids in steam are carried
by the moisture associated with it. The drum internals reduce the dissolved
solids content of the steam to below the acceptable limit. drum is made up of
two halves of carbon steel plates having thickness of 133 mm.

The top half and bottom half are heated in a plate heating
furnace at a very high temperature and are pressured to form a semi
cylindrical shape. The top and bottom semi cylinders with hemispherical
dished ends are fusion welded to form the boiler drum. The drum is provided
with stubs for welding all the connecting tubes i.e. downcomer stubs,
risertubes stubs and superheater outlet tube stubs.
Boiler drum is located at a height of 53m from ground. The drum is
provided with manholes and manhole covers. Manhole is used for facilitating
the maintenance person to go inside the drum for maintenance.
The drum form the part of boiler circulating system i.e. movement of
fluid from the drum to the combustion zone and back to boiler drum. Feed
water is supplied to the drum from the economizer through feed nozzles.
Water from the drum goes to water walls through six downcomers.
Main parts of boiler drum are:-

• Feed pipe
• Riser tube
• Down comer
• Baffle plate
• Chemical dosing pipe
• Turbo separation
• Screen dryer
• Drum level gauge
Draft System:-
The combustion process in a furnace can take place only
when it receives a steady flow of air and has the combustion gases
continuously removed. Theoretically balanced draft means keeping furnace
pressure equal to atmospheric pressure, but in practice the furnace is kept
slightly below atmospheric pressure. It ensures that there is no egress of air
or hot gas and ash into boiler house.
Draught Fans:-
A fan can be defined as volumetric machine which like pumps moves
quantities of air or gas from one place to another. In doing this it overcomes

resistance to flow by supplying the fluid with the energy necessary for
contained motion. The following fans are used in boiler house.
Primary air fan (P.A. fan) or Exhauster fan-
Pulverized coal is directly fed from coal mills to the burners at the four
corners of the furnace through coal pipes with the help of heated air coming
from PA fan. Secondly, this fan also dries the coal. Usually sized for 1500
RPM due to high pressure.
Forced draught fan (F.D. fan):-
The combustion process in the furnace can take place only when it
receives a steady flow of air. This air is supplied by FD fan. Thus FD fan
takes air from atmosphere at ambient temperature & so provides additional
draught. Its speed varies from 600-1500 RPM.
Specification of Force Draft fan:
3φ ,6.6KV,700KW
Rated.current-74A
RPM-1500
Discharge- 408 T/Hr

Induced draught fan (I.D. fan):-
The flue gases coming out of the boiler are passed to the
ESP & then dust free gases are discharged up by the chimney to the
atmosphere through the ID fan.
• Specification of ID fan: -
3φ ,6.6KV,1750KW
Rated.current-192.1A
RPM-745
Discharge- 720 T/Hr
Igniter air fan:-
It is used to provide necessary combustion air to ign iter. Two fans are
usually provided. One will run and 2nd will remain as stand by. A control
damper is provided on the discharge which modulates to maintain a constant
differential pressure across igniter when any igniter is in service. Typical
speed is 1460 RPM.
Scanner Air Fan:-
Used to provide necessary cooling air to the flame scanners.
Two air fans are usually provided. One will run and other will remain as
stand by. When F.D. fans trip the scanner air fan will draw air from
atmosphere through emergency damper. Typical speed 3000 RPM.

Economizer:-
he
flue gases coming out of the boiler carry lot of heat. An economiser extracts
a part of this heat from the flue gases and uses it for heating the feed water
before it enters into the steam drum. The use of economiser results in saving
fuel consumption and higher boiler efficiency but needs extra investment. In
an economizer, a large number of small diameter thin walled tubes are placed
between two headers. Feed water enters the tubes through the other. The flue
gases flow outside the tubes.
Air preheaters:-
Air preheaters are employed to recover the heat from the
flue gases leaving the economiser and are used to heat the incoming air for
combustion. This raises the temperature of the furnace gases, improves
combustion rates and efficiency and lowers the stack (chimney) temperature,
thus improving the overall efficiency of the boiler. Cooling of flue gases by
20% raises the plant efficiency by 1%.

In KSTPS regenerative type of preheater is used. They use a
cylindrical rotor made of corrugated steel plate. The rotor is placed in a drum
which is divided into two compartments, i.e. air compartment (primary air
coming from primary air fan and secondary air for air coming from FD fan
with +ive pressure) and flue gases (from economizer with –ive pressure)
compartments. To avoid leakage from one compartment to other seals are
provided.
The rotor is fixed on an electrical shaft rotating at a speed of 2 to 4
rpm. As the rotor rotates the flue gases, are pass through alternatively gas
and air zone. The rotor elements are heated by flue gases in their zone and
transfer the heat to air when they are in air zone. The air temperature
required for drying in the case of coal-fired boiler decided the size of the air
heaters
Superheater:-
Superheated steam is that steam, which contains more heat than the
saturated steam at the same pressure i.e. it, has been heated above the
temperature corresponding to its pressure. This additional heat provides more
energy to the turbine and thus the electrical power output is more.
A superheater is a device which removes the last traces of moisture
from the saturated steam leaving the boiler tubes and also increases its
temperature above the saturation temperature.

The steam is superheated to the highest economical temperature not only to
increase the efficiency but also to have following advantages –
• Reduction in requirement of steam quantity for a given output of
energy owing to its high internal energy reduces the turbine size.
• Superheated steam being dry, turbine blades remain dry so the
mechanical resistance to the flow of steam over them is small resulting
in high efficiency.
• No corrosion and pitting at the turbine blades occur owing to dryness
of steam.
Reheater:-
Reheaters are provided to raise the temperature of the steam from
which part of energy has already been extracted by HP turbine. This is done
so that the steam remains dry as far as possible through the last stage of the
turbine. A reheater can also be convection, radiation or combination of both.
Circulation System:-
In natural circulation system, water delivered to steam generator from
header, which are at a temperature well below the saturation value
corresponding to that pressure. After header, it is delivered to economizer,
which heated to above the saturation temperature.
From economizer the water enters the drum and thus joins the circulation
system through down covering water wall tubes. In water wall tubes a part
of the water is converted to steam due to boiler and the mixture flows back to
the drum. In the drum, the steam is separated out through the steam
separators and passed to the super heater. After the super heater when the
steam temperature becomes high and pressure upto 150 Kg./cm3 steam is
allowed to enter the turbine to convert potential energy to kinetic energy.
Soot Blower:-
The boiler tubes are cleaned with the help of steam by the process
called soot blowing. We are well known that a greater no. of tubes are
presented inside the boiler. Slowly and slowly the fine ash particles are
collected on the tube surface and from a layer this is called soot. Soot is a
thermal insulating material.
There are mainly three types of soot blower are used in KSTPS: -
• Water wall soot blower
• Super heater soot blower
• Air pre heater soot blower

TECHNICAL SPECIFICATION OF BOILER
1.Type : Direct fired, natural circulation
balance draft water tube boiler.
2. No. of Units. : Two.
3.Make : BHEL.
4.Capacity. : 375 tonnes per hour.
5.Steam Pressure. : 139 Kg./Cm2
6.Efficiency : 86.6 %.
7.No. of fans in service.
a) ID fans. : 2 Nos.
b) FD fans. : 2 Nos.
c) PA fans. : 2 Nos.
d) Seal Air fan. : 1 No.
e) Scanner Air fan. : 1 No.
f) Igniter fan. : 1 No.
8. Steam Temperature : 540oC.
9. No. of coal mills in : 3 Nos.service.
10.No. of soot blowers : 70 Nos.

FUEL :-
a) COAL:-
Type : Slack Coal.
Quantity consumed : 3074 tones per day.
Type of handing. : Conveyor.
Ash disposal : Wet system.
B) OIL:-
Type. : HSD and fuel oil.
Quantity. : a) HSD – 5520 KL per year. *
b) Furnace Oil : 28800 KL per year.
No. of chimney / stack. : 1 / 2.
Height of Chimney. : 180 Meters.
Volume of flue Gas/ : 198 M3/ Sec.Air emitted.
Temp. of flue gas. : 140oC.
ESP : One for each unit.

GENERAL DESCRIPTION:-
Boilers are tangentially fired,
balance draft, natural circulation , radiant type, dry bottom with direct fired
pulverized coal from bowl mills. They are designed for burning low grade
coal with high ash content. Oil burners are located between coal burners for
flame stabilization. Pulverized coal is directly fed from the coal mills to the
burners at the four corners of the furnace through coal pipes. The pulverized
fuel pipes from the mills to the bunkers are provided with basalt lined bends
to reduce erosion and to improve the life of these pipes owing to poor grade
of coal there is a high percentage of mill rejects. The mill rejects are
conveyed in a sluice way to an under-ground tank. From this tank the
mixture is taken to an overhead hydro-bin where water is decanted and the
mill reject are disposed off by trucking. ESP with collection efficiency of
99.8% have been provided to reduce environmental pollution and to
minimize induce draft fan wear. A multi-flue reinforced concrete stack with
two internal flues has been provided.
Two boiler feed pumps each of 100 % capacity
are driven by AC motor through hyd. coupling with scoop tube arrangement
for regulating feed water pressure for each unit.
The air required for combustion is supplied bytwoforced draft fans.

Due to anticipated high abrasion of ID fans impellers. Three ID fans each of
60% capacity have been provided one ID fan to serve as standby.
For ensuring safe operation of boilers,
furnace safe guard supervisory system (FSSS) of combustion engineering
USA designed has been installed. This equipment systematically feed fuel to
furnace as per load requirement.
The UV flame scanners installed at two elevation in each of the four
corners of the furnace, scan the flame conditions and in case of unsafe
working conditions but out fuel and trip the boiler and consequently the
turbine. Turbine – boiler interlocks safe guarding the boiler against
possibility furnace explosion owing to flame failure.
Facilities have been provided to simultaneously unload
and transfer 10 light oil and 40 heavy oil tankers to the designated tanks. Oil
preheating arrangement is provided on the tanks floors for the heavy oil
tanks.Superheated steam temperature is controlled by attemperation.
Re-heater steam temperature is primarily by tilting fuel burners through + 30 o
and further control if necessary is done by attemperation.

CHAPTER - 4
STEAM TURBINE
INTRODUCTION:-
Turbine is a machine in which a shaft is rotated steadily by
impact or reaction of current or stream of working substance ( steam , air ,
water, gases etc) upon blades of a wheel. It converts the potential or kinetic
energy of the working substance into mechanical power by virtue of dynamic
action of working substance. When the working substance is steam it is
called the steam turbine.
PRINCIPAL OF OPERATION OF STEAM TURBINE:-

(1.) Working of the steam turbine depends wholly upon the dynamic
action of Steam. The steam is caused to fall in pressure in a passage of
nozzle: doe to this fall in pressure a certain amount of heat energy is
converted into mechanical kinetic energy and the steam is set moving with a
greater velocity. The rapidly moving particles of steam, enter the moving
part of the turbine and here suffer a change in direction of motion which
gives rose to change of momentum and therefore to a force. This constitutes
the driving force of the machine. The processor of expansion and direction
changing may occur once or a number of times in succession and may be
carried out with difference of detail. The passage of steam through moving
part of the commonly called the blade, may take place in such a manner that
the pressure at the outlet side of the blade is equal to that at the inlet inside.
Such a turbine is broadly termed as impulse turbine. On the other hand the
pressure of the steam at outlet from the moving
(2.) blade may be less than that at the inlet side of the blades; the drop
in pressure suffered by the steam during its flow through the
moving causes a further generation of kinetic energy within the
blades and adds to the propelling force which is applied to the
turbine rotor. Such a turbine is broadly termed as impulse
reaction turbine.
The majority of the steam turbine have, therefore
two important elements, or Sets of such elements . These are (1) the nozzle in

which the system expands from high pressure end a state of comparative rest
to a lower pressure end a status of comparatively rapid motion.
(2.) The blade or deflector , in which the steam particles changes its
directions and hence its momentum changes . The blades are attach to the
rotating elements are attached to the stationary part of the turbine which is
usually termed the stator, casing or cylinder.
Although the fundamental principles on which all steam
turbine operate the same , yet the methods where by these principles carried
into effect very end as a result, certain types of turbine have come into
existence.
1. Simple impulse steam turbine.
2. The pressure compounded impulse turbine.
3. Simple velocity compounded impulse turbine.
4. Pressure-velocity compounded turbine.
5. Pure reaction turbine.
6. Impulse reaction turbine.
7.
TECHNICAL DATA OF TURBINES :-
The main technical data of 110 MW turbine is given below:-
Rated output. 110 MW.
Economic output 95 MW.
Rated speed. 3000 rpm

Direction of rotation viewing from Clockwise
the front bearing pedestal.
Rated steam pressure before 130 ata
stop valve.
Maximum steam pressure before 146 ata
stop valve.
Rated temperature of steam before 535oC
the stop valve.
Maximum temperature of steam before 545oC
the stop valve.
Rated pressure of steam 31.6 ata
MP Casing.
Rated pressure of steam before 35 ata
MP Casing:-
Rated Temp. of steam before 535oC.
MP Casing.
Maximum Temp. of steam before 545oC.
MP Casing.
Informative heat flow at the economic output 2135 K cal/Kwh
Informative heat rate at the rated output 2152.5 K Cal/Kwh.

HP Cylinder 2 row carts wheel
+ 8 moving wheels.
MP Cylinder 12 moving wheels.
LP cylinder 4 moving wheels of
Double row design.
Quantity of oil for first filling. 1800 liters.
for the turbine.
• Single flow HP turbine with 25 reaction stages.
• Double flow IP turbine with 20 reaction stages per flow.
• Double flow LP turbine with 8 reaction stages per flow.
2 main stop & control valves. & 2 steam check valve in CRH.
2 reheat stop & control valves. & 2 bypass stop & control
valve.
At KSTPS there are 2x110 MW
turbines installed for unit 1 & 2 and 210 MW turbines installed for units 3, 4
& 5 & one 195 MW turbine installed for unit 6 & 7 (which one is under
final stage of construction & generation of power is expected in Sept,
2008).
Description of Steam Turbines:-
1) Steam flow:-
210 MW steam turbine is a tandem compound machine with HP, IP &
LP parts. The HP part is single flow cylinder and HP & LP parts are double
flow cylinders. The individual turbine rotors and generator rotor are rigidly
coupled. The HP cylinder has a throttle control. Main steam is admitted
before blending by two combined main stop and control valves. The HP
turbine exhaust (CRH) leading to reheated have tow swing check valves that
prevent back flow of hot steam from reheated, into HP turbine. The steam
coming from reheated called HRH is passed to turbine via two combined
stop and control valves. The IP turbine exhausts directly goes to LP turbine
by cross ground pipes.
2) HP Turbine:-
The HP casing is a barrel type casing without axial joint. Because of
its rotation symmetry the barrel type casing remain constant in shape and
leak proof during quick change in temperature. The inner casing too is
cylinder in shape as horizontal joint flange are relieved by higher pressure
arising outside and this can kept small. Due to this reason barrel type casing
are especially suitable for quick start up and loading.The HP turbine consists
of 25 reaction stages. The moving and stationary blades are inserted into
appropriately shapes into inner casing and the shaft to reduce leakage losses
at blade tips.
3) IP Turbine:-
The IP part of turbine is of double flow construction. The casing of IP
turbine is split horizontally and is of double shell construction. The double

flow inner casing is supported kinematically in the outer casing. The steam
from HP turbine after reheating enters the inner casing from above and below
through two inlet nozzles. The centre flows compensates the axial thrust and
prevent steam inlet temperature affecting brackets, bearing etc. The
arrangements of inner casing confines high steam inlet condition to
admission branch of casing, while the joints of outer casing is subjected only
to lower pressure and temperature at the exhaust of inner casing. The
pressure in outer casing relieves the joint of inner casing so that this joint is
to be sealed only against resulting differential pressure.
The IP turbine consists of 20 reaction stages per flow. The moving and
stationary blades are inserted in appropriately shaped grooves in shaft and
inner casing.
4) LP Turbine:-
The casing of double flow type LP turbine is of three shell design. The
shells are axially split and have rigidly welded construction. The outer casing
consist of the front and rear walls , the lateral longitudinal support bearing
and upper part.
The outer casing is supported by the ends of longitudinal beams on the
base plates of foundation. The double flow inner casing consist of outer shell
and inner shell. The inner shell is attached to outer shell with provision of
free thermal movement.
Steam admitted to LP turbine from IP turbine flows into the inner
casing from both sides through steam inlet nozzles.

ELECTRICITY GENERATOR
Thermal power station burns the fuel and use the
resultant heat to raise the steam which drives the turbo-generator. The fuel
may be “Fossil” (Coal, Oil and Natural Gas) whichever fuel is used the
object is same to convert the heat into mechanical energy to electrical energy
by rotating a magnet inside the set of winding. In a coal fired thermal power
station other raw materials are air and water. The coal is brought to station
by train or other means travels from the coal handling system.
i) By conveyer belts to coal bunkers from where it is fed to pulverizing
mills.
ii) Mills grind it fine as face powder.
iii) Then this powdered coal mixed with preheated air is blow into boiler
by a Fan known as primary air fan (PA fan).
iv) When it burns more like a gas as solid in conventional domestic or
industrial grate with additional amount of air called secondary air
supplied by “Forced Draft Fan”. As the coal has been grinded so
resultant ash is also as fine as powder. Some of its fine particles blinds
together to form a lump which falls into the ash pit at the bottom of
furnace.

v) The water quenched ash from the bottom of furnace is carried out
boiler to pit for subsequent disposal.
vi) Most of ash still in fine particles form is carried out to electrostatic
precipitators where it is trapped by electrode charged with high
voltage electricity. The dust is then conveyed to the disposal area or
to bunkers for sale.
vii) Now after passing through ESP few gases are discharged up to
chimney
Meanwhile the heat reloaded from the coal has been absorbed by
kilometers a long tube which lies in boiler walls inside the tubes “Boiler
Feed Water” which is transferred into turbine blades and makes them
rotate. To the end of the turbine rotor of
generator is coupled, so that when turbine rotates the rotor turns with it.
The rotor is housed inside the stator having coil of copper bars in which
electric is produced through the movement of magnetic field created by
rotor The electricity passes from the stator winding to the transformer
which steps up the voltage so that it can be transmitted effectively over
the power line of grid
The steam which has given up its heat
energy in changed back into a condenser so that it is ready for reuse. The
cold water continuously pumped in condenser. The steam passings
around the tubes loose heat and rapidly change into water. But these two
types of water (boiler feed water and cooling water ) must never mix
together. The cooling water is drawn from the river but the Boiler Feed
Water must be pure than potable water (DM Water).
TURBO GENERATOR
THEORY :-
TURBO GENERATOR manufactured by B.H.E.L. and
incorporated with most modern design concepts and constructional features,
which ensures reliability, with constructional & operational economy. The
generator stator is a tight construction, supporting & enclosing the stator
windings, core and hydrogen coolers. Cooling medium hydrogen is
contained within frame & circulated by fans mounted at either ends of rotor.
The generator is driven by directly coupled steam turbine at a speed of 3000
r.p.m. the Generator is designed for continuous operation at the rated output.
Temperature detectors and other devices installed or connected within then
machine, permit the windings, teeth core & hydrogen temperature, pressure
& purity in machine under the conditions. The source of excitation of rotor
windings is thyristor controlled D.C. supply. The auxiliary equipment’s
supplied with the machine suppresses and enables the control of hydrogen
pressure and purity, shaft sealing lubricating oils. There is a provision for
cooling water in order to maintain a constant temperature of coolant
(hydrogen) which controls the temperature of windings

Main parts of generator:-
(A) STATOR:-
i. STATOR FRAME:-
The stator frame of welded steel frame construction, which gives
sufficient & necessary rigidity to minimize the vibrations and to withstand
the thermal gas pressure. Heavy end shields enclose the ends of frame and
form mounting of generator bearings and radial shaft seals. Ribs subdivide
the frame and axial members to form duct from which the cooling gas to &
fro radial ducts in the core and is re-circulated through internally mounted
coolers. All the gas ducts are designed so as to secure the balanced flow of
hydrogen to all parts of the core.
The stator constructed in a single piece houses the
core and windin gs. The horizontally mounted water cooled gas coolers
being so arranged that it may be cleaned on the water side without opening
the machine to atmosphere. All welded joints exposed to hydrogen are
specially made to prevent leakage. The complete frame is subjected to
hydraulic test at a pressure of 7 ATA.

ii. STATOR CORE:-
It is built up of special sheet laminations and whose assembly is
supported by a special guide bass. The method of construction ensures that
the core is firmly supported at a large number of points on its periphery. The
laminations of high quality silicon steel which combines high permeability
with low hysterias and eddy current losses. After stamping each lamination
is varnished on both sides with two coats. The segment of insulating
material is inserted at frequent intervals to provide additional insulation. The
laminations are stamped out with accurately fine combination of ties.
Laminations are assembled on guide bass of group separated by radial ducts
to provide ventilation passage. The ventilation ducts are disposed so as to
distribute the gas evenly over the core & in particularly to give adequate
supports to the teeth. At frequent intervals during stacking the assembled
laminations are passed together in powerful hydraulic press to ensure tight
core which is finally kept between heavy clamping plates which are non-
magnetic steel. Use of non-magnetic steel reduces considerably by heating
of end iron clamping. The footed region of the core is provided by pressing
figures of non-magnetic steel, which are welded to the inner periphery of the
clamping plates. In order to reduce the losses in the ends packets special

dampers are provided at either ends of core. Mostly dampers are provided to
prevent hunting in ac machines.
iii. STATOR BARS:-Stator bars are manufactured as half bars.
Each stator half coil is composed of double glass cover and bars
of copper transposed in straight portion of “Robill Method” so
that each strip occupies every radial portion in the bar. For an
equal length along the bar. They are made in strips to reduce
skin effect. The winding overhead is in volute shape. The
overhung portion of the bar is divided into four quadrants &
insulated. The arrangement reduces additional losses due to
damping currents which otherwise be present due to self-
induced non-uniform flux distribution in the coil slots. The
main distribution for the bar consists of resin rich mica loosed
thermosetting epoxy. This has excellent mechanical and
electrical properties & does not require any impregnation. Its
moisture absorbing tendency is very low and behavior of mica
is for superior than any other conventional tape insulation
system. Semi-conductor coating is also applied to a part of
overhung with a straight overlap of conductive coil in the sides
to reduce eddy currents to minimum. Conductor material is
electrolytic copper connections brazed with free coating silver
alloy to obtain joints , which are both electrically &
mechanically sound.

iv. STATOR WINDINGS:-
Stator windings are double star layers , lap wound, three phase, short
pitch type. The top & bottom are brazed and insulated at either end to form
turns. Several such turns form a phase . Phases are connected to form a
double star winding. The arrangement of complete stator winding electrical
circuit is viewed from turbine end of generator & rotor windings. Slot
numbering is clockwise from turbine end. A thick line identifies the top bar
in slot No.1 . End windings will be sealed against movement of short circuit
by both axial & peripheral bracing. The later consists of hardened glass
laminated blocks inserted between adjacent coil sides in coil overhangs, so
that with the coils , they form a continuous rigid ring. Glass cord or top is
used lashing the packing of blocks. The complete assembly is secured by
high tensile brass blots. The winding is designed to withstand short circuit
stresses. The exposed portion of windings are finally coated. Insulation of
individual bars & stator windings at various stress is tested with applied high
voltages of AC of Hz.
v. TERMINAL BUSHINGS:-
Six output leads (3 long,3 short) have been brought out
of the coming on the exciter side. External connections are to be made to the
three shorter terminals, which are phase terminals. The large terminals are of
neutral & current transformer is inserted. The conductor of Generator
terminal bushing having hollow copper tubes with Copper brazed at the ends
to avoid leakage of hydrogen. Hollow portions enables bushings to be

hydrogen cooled. Ends of bushings are Silver-plated : middle portion of the
bushing is adequately insulated & has a circular flange for bolting the stator
casing. Gaskets are provided between the Flange of terminal bushings and
castings to make it absolutely gas tight.
iv. BEARINGS:-
Generator bearings have electrical seats of consists of
steel bodies with removable steel pads. The bearings are formed for forced
lubrication of oil at a pressure of 2-3 ATM/ From the same pump that
supplies oils to the turbine , bearings & governing gears. There is a
provision to ensure & measure the rotor bearing temperature by inserting a
resistance thermometer in the oil pockets.
vii. VENTILATION SYSTEM:-
The machine is designed with ventilation system having 2
atm rated hydrogen pressure. Two axial fans mounted on either side of the
rotor to ensure circulation of hydrogen. The stator is designed for radial
ventilation by stem. The end stator core packets & core clamping & plates
are intensively cooled by Hydrogen through special ventilation system.
Design of special ventilation is so as to ensure almost uniform temperature of
rotor windings and stator core. Rated load operating temperature is well
within the limits corresponding to the Class B operation. Embedded
Resistance Temperature Detectors do continuous monitoring of Hydrogen
temperature at active parts of Generator.
HYDROGEN COOLERS:-
Three Hydrogen Coolers each comprising of two individual units
are mounted inside the stator frame. The inlet and outlet of cooling water
from both of machine i.e. from non-driving side as well as turbine side. The
Clearing of the individual cooler element can be carried out from both ends
of the Generator even during operation. The assembly of individual cooler
elements in stator frame is however carried out only from the non-driving
side.
(B) ROTOR :-
Rotor shaft consists of single piece alloy steel forging
of high mechanical and magnetic properties performance test includes :-
1. Tensile test on specimen piece.
2. Surface examination.
3. Sulfur prist tests.
4. Magnetic crack detection .
5. Visual examination of bore.
6. Ultrasonic examination.
Slots are milled on the rotor gorging to receive
the rotor winding. Transverse slots machined in the pole faces of the rotor to
equalize the moment of inertia in direct and quadrilateral axis of rotor with a
view minimizing the double frequency.

VIBRATION OF ROTOR:-
The fully brazed rotor is dynamically
balanced and subject to 120 % over speed test at the work balancing tunnel
so as to ensure reliable operation.
ROTOR WINDINGS:-
Rotor winding is of direct coil type and consists of parallel strips of
very high conductivity Silver Bearing Copper, bent on edge to form coil.
The coils are placed in impregnated glass, laminated short shells; using glass
strips inter turn insulation and will be brazed at the end to form continuous
winding. The complete winging will be packed at high temperature and
pressed to size by heavy steel damping rings. When the windings have
cooled, heavy dove tail wedges of non-magnetic materials will seal the
insulation at the top of slot portion. The cooling medium hydrogen gas will
be brought in direct contact with copper by means of radial slots in
embedded portion. Treated glass spacers inserted between the coils and solid
ring prevent lateral movement of coil overhang. The formation and
description of glass spacer is such as to leave ample space for ventilation.

BEARINGS:-
The bearings are self-aligned & consist of slip steel
shells linked with special bearing metal having very low coefficient of
friction. The bore is machined on an elliptical shape so as to increase the
mechanical stability of the rotor. The bearing are pressure lubricated from
the turbine oil supply. Special precautions are taken to prevent oil & oil
vapor from shaft seals and bearing along the shaft. The circulation of shaft
current is liable to damage. The bearing surface is protected by insulation so
placed that the bearings, seals & necessary pipes are inclined from the frame.
SLIP RINGS:-
The slip rings are made of forged steel. They are located at either
side of Generator Shaft. The slip ring towards the exciter side is given +ve
polarity initially. They have helical grooves and skewed holes in the body
for cooling purpose by air. Calibrated mica is first built up to required
thickness on the shaft where slip rings are located. The slip rings are
insulated from the rotor shaft. Excitation current is supplied to the rotor
winding. Through the slip rings, which are connected to the winding. On
one end and to the slip ring on the other end with insulated ( terminal) studs
passing ‘though’ the radial holes in the rotor shaft. The terminal studs at
both the ends of excitation leads are fitted gas cat seals to prevent leakage.
BUSH GEAR ASSEMBLY:-
Generator bushes are made from the various compositions of
natural graphite and binding material. They have a low coefficient of friction
and are self lubricating. The brushes are provided with a double flexible
copper or pigtails. A helical spring is mounted rapidly over each bush so that
pressure is applied on the centerline of bush. A metal cap is riveted to the
brass bead and is provided with a hole to maintain the position of the spring
plug. Several brush holder, each carrying on brush in radial position are
fixed to a silver plated copper studs mounted on the collecting arm
concentric with each slip rings. The collecting arm is made out of a copper
strip.
DRYING OF WINDING:-
Generator stator bars are insulated with mica insulation , which is
homogeneous in nature and practically impervious to moisture, and reduce
time required to draught. The insulation resistance of the stator phase
winging against earth and with reference to other phases under hot condition
shall not be less than the value obtained automatically.
Rin = µ/(s/100+1000) m 52
U = rated winding Voltage under test.
Rin = insulation resistance under hot conditions Rated o/p of turbo
generator.
The insulation resistance of entire excitation system circuit.
In hot condition must not fall below 0.5 m 52. The insulation resistance in
calculated as per the formula
Rin = Rv (U1 +U2) / (U-1)

Rin = Insulation resistance of exciter
Rv = Internal resistance of voltmeter
U1 = Voltage measured btw. Slip ring & shaft/ earth (volts).
TECHNICAL DATA:-
(A) Generator (110 MW):-
Type : t.g.p. 2,34,602
Continuous apparent power : 1,37,500 KVA.
Active power : 7,10,000 KW.
Power factor : 0.8 (lagging).
Rated voltage : 1000 + 5% rated.
Current : 7,220 A
Critical speed : 3000 r.p.m. at
frequency : 50 Hz.
Phase connection : double star.
No. of terminals : 6.
Main diameter of slip rings : 420 mm.
Voltage regulation : 39%.
Reactance : Informative.
HYDROGEN COOLER:-

Nos. of elements : 6
Cooling medium : Water, H 2 at 2
ATM.
Discharge losses : 1500 KW.
Quantity of H2 : 30 M3/ sec.
Quantity of water Temp : 34oC,
Cooling cold H2 Temp. : 400C
How resistance(H2 side) : 12 mm. of peak.
Inherent voltage regulation : 39%
Short circuit ratio : 0.5%.
Type : HC-WLL-BS/C46.

COOLING SYSTEM
a) GENERAL:-
In KSTPS hydrogen cooling system is employed for
generator cooling. Hydrogen is used for cooling medium primarily because
of its superior cooling properties & low density. Thermal conductivity of
hydrogen 7.3 times of air. It also has higher transfer co-efficient . Its ability
to transfer heat through forced convection is about 75% better than air.
Density of hydrogen is approx. 7/14 of the air at a given temperature and
pressure. This reduces the wind age losses in high speed machine like turbo-
generator. Increasing the hydrogen pressure the machine improve its
capacity to absorb & remote heat. Relative cooling properties of air and
hydrogen are given below :-
1) Elimination of fire risk because hydrogen will not support combustion.
2) Corona discharge is not harmful to insula. since oxidation is not
possible.

3) Smooth operation of machine in view of vertical elimination of wind
age noise & the use of heavy gas light enclosure and dirty probe
casing.
At pressure 0.035 atm. of hydrogen heat carrying capacity
is 1. But at 2.0atm. of hydrogen heat carrying capacity is 1.95 to overcome
the serious possibility of hydrogen explosion with in the machine and to
ensure the safety of operation purity of hydrogen on the generator. Casing
must be maintained as high as possible. The purity of hydrogen should be
98% above but should not be less than 98% . In case of hydrogen purity
drops below 98% an alarm is provided.
b) HYDROGEN DRYERS:-
Two nos. of dryers are provided to absorb the
hydrogen in the Generator. Moisture in this gas is absorbed by silica gel in
the dryer as the absorbed gas passes through it. The satural of silica gel is
indicated by change in its color from blue to pink. The silica gel is
reactivated by heating. By suitable change over from drier to the other on un-

interrupteddryingisachieve
HYDROGEN COOLED ALTERNATOR
CHAPTER - 5

EXCITATION SYSTEM
The electric power Generators requires direct current excited magnets
for its field system. The excitation system must be reliable, stable in
operation and must response quickly to excitation current requirements.
When excitation system response is controlled by fast acting regulators, it is
chiefly dependent on exciter. Exciter supply is given from transformer and
then rectified.
(A) Function of excitation system:-
The main function of excitation system is to supply
required excitation current at rated load condition of turbo Generator. It
should be able to adjust the field current of the Generator, either by normal
controller automatic control so that for all operation & between no load and
rated load. The terminal voltage of the system machine is maintained at its
value. The excitation system makes contribution improving power system
stability steady state condition. The excitation system that are commonly
termed quick response system and have following principal feature :- Exciter
of quick response & high voltage of not less than 1.4 times the rated filed
voltage and nominal exciter response of minimum 0.5.
(B)Type of Excitation System:-
There have been many developments in excitation system design. There has
been continuing reach among the design and the use alike from improving
the excitation system performance. The ultimate is to achieve stability;

accuracy etc. the modern excitation system adopted presently on BHEL
makes turbo-generator I. Conventional DC excitation system. Brushes
excitation system.
STATIC EXCITATION SYSTEM :-
In KSTPS static excitation system is provided it mainly consists of
the following:-
1) Rectifier transformer.
2) Nos. of thyristor converters.
3) An automatic voltage regulator (AVR).
4) Field suppression equipment.
5) Field flashing equipment.
GENERAL ARRANGEMENT:-
In the excitation system the power required for
excitation of Generation are tapped from 11 KV bus ducts through a step
down rectifier transformer. After rectification in thermistor, converter, the
DC power is fed to the Generator field winding through a field breaker. The
AVR control the o/p from thyristor converter by adjusting the firing angle
depending upon Generator voltages. The field flashing system facilitates
initial built up of the Generator voltage from the static AC or DC supply.

(I) RECTIFIER TRANSFORMER :-
This transformer steps down the bus voltage 11 KV to 640 V
and has a rating of 1360 KVA. It is dry type, it is however provided with
current relays and two temperature sensors.
(II) A THYRISTOR CONVERTOR :-
The thyristor panel and are intended for
controlled rectification of AC Input power. 6. Thyristor converter are
connected in parallel each rates for continuous current o/p of 20 % of the
rated capacity i.e. 20 % reserve. Each thyristor converter consists of 6
thyristor connected in 3-3 , full wave, 6-pulse bridge from and they are
cooled by fans provided with a fuse for protection against short circuit.
(III) AUTOMATIC VOLTAGE CONTROLS :-
The AVR is transistorized thyristor controlled
equipment with very fast response. The AVR is also having provision of
stator and rotor currents limits and load angle limits for optimum utilization
of lagging and leading reactive capacities of generator.
(IV) FIELD SUPRESSION EQUIPMENT:-
The field equipment consists of a field breaker with discharge resistors. The
field breakers have 4 main breaking contacts and two discharge contacts,
which close before main contact break.
(a) A very fast response.
(b) Extremely reliable in view of static components.

(c) Low maintenance cost.
(d) High efficiency.
(e) Fast field suppression through field and discharge resistance as well as
through Thyristor Bridge, feeding the Generator field.
OPERATION:-
After bringing the speed to operation speed say 3000 r.p.m.
, the voltage is slowly built up with the help of excitation system. This
action is taken for synchronizing the Generator.
(A) SYNCHRONIZING:-
For synchronizing the Generator to the grid system 5
condition of equality have to be satisfied. These are (I)_Voltage (II)
Frequency (III) Phase displacement (IV) Phase sequence (V) Wave form.
Wave form and phase sequence of the Generator are determined at the design
of each connection SYNCHRONIZING of the generator.

WATER TREATMENT PLANT
The principle problem in high pressure boiler is to
control corrosion and steam quality. Internal corrosion costs power station
crores of rupees in repair without strict control impurities in steam also form
deposit over turbine blades and nozzles. The impurities present in water are
as follows :-
1) Un-dissolved and suspended solid materials.
2) Dissolved slats and minerals.
3) Dissolved gases
4) Other minerals ( oil, acid etc.).
5). a) Turbidity & Sediment.
b) Silica.
c) Micro Biological.
d) Sodium & Potassium Salt.
e) Dissolved Sales Minerals.
6). a) O2gas.
b) CO2 gas.
D.M. PLANT:-
In this plant process water is fed from all these
dissolved salts. Equipment for demineralization cum softening plant is
supplied and erected by M/s. Wanson (India) Ld., Pune. This plant consists
of two streams each stream with activated carbon filter, weak acid , cation
exchanger and mixed bed exchanger. The filter water to DM plant through
250 dia. header from where a heater top off has been taken to softening plant.
Two filtered water booster pumps are provided on filtered water line for
meeting the pressure requirement in DM Plant.
Sodium Sulphate solution of required strength is
dosed into different filtered water by mean of dosing pump to neutralize
chlorine prior to activated carbon filter. When water passed an activated
carbon filter will remove residual chlorine from water. Provision is made for
back washing the activated carbon filter. When pressure drop across filter
exceeds a prescribed limit from the activated carbon filter the works acid
cation unit. The deception water the weak base anion exchanger unit water
then enters de-gasified unit where free CO2 is scrubbed out of water by
upward counter flow of low pr. air flow through degasified lower and
degassed water is pumped to strong base exchanger ( anion exchanger).
Arrangement for dosing ammonia solution into de-mineralized water
after mixed bed unit has been provided p+1 correction before water is taken in
de-condensate transfer pump the DM water to unit condensor as make up.
C.W. PLANT:-
Circulating water pump house has pumps for
condensing the steam for condensor. Five pumps are used for condensing
Unit No.1 & 2 and after condensing this water is discharged back into the
river.Each pump has capacity of 8275 M3/Hr, and develop pressure about

1.94 Kg./Cm2.Three seal water pump are used for sealing circulating water
pump shaft at pr. 4.5 kg./cm2.
Two pump for unit 1 & 2 with one stand by is used for supplying
raw water to chlrofied chemical dosing is tone between and chlorified water
is taken through main line. From main line water passes through filter bed to
filter the water. Chlorified water is pumped to 42 m elevation by two pumps
of capacity 270 M3/Inch at discharge pressure of 6.9 Kg./Cm2. At 42 M
elevation the water is stored in tank and used for cooling the oil coolers and
returned back to river. Oil coolers are situated on ground and there are no. of
tress for each unit.
B.C.W. PUMP HOUSE:-
Filter water after demineralization is used for
bearing cooling from BCW pump house after passing through strainer and
heat exchanger it enters at 30-32oC and leave exchanger at 38oC. The raw
water used in ash handling plant and remaining quantity is stored in sumps of
BCW Pump House. From here the water is pumped to CW Pump by TWS
(Traveling water screens) pumps are run by motors of 90 KW and has a
capacity of 240 Cum/hr/pump at pressure of 5 kg/cm2.
BCW here stand for water used for cooling oil used for
cooling the bearing. In CW pump house water is discharged from nozzle and
impinged for traveling water screens for cleaning it.

CHAPTER-6
TRANSFORMER
Transformer is a static device which is used

to change the voltage level keeping the power and frequency same. In the
plant transformer is one of the most important equipment. In the whole plant,
there are about 83 transformer installed at various places to operate the
auxiliaries.
Main transformers, which are necessary:
1. To step up the generated voltage.
2. To supply power to the auxiliaries from the generator.
3. To start the plant by taking the supply from the grid.
Are installed in a transformer yard. It is located in between the
main plant and the switchyard. The main transformers installed in the
transformer yard are:
1. GENERATOR TRANSFORMER (GT – A):-
It steps up the voltage from 16.5 KV to 220 KV. It connects the
plant with the 220 KV switchyard.
2. GENERATOR TRANSFORMER (GT – B):-
It steps up the voltage from 16.5 KV to 400 KV. It connects the
plant with the 400 KV switchyard.
3. STATION TRANSFORMER (ST):-
It is a step down transformer with 50 MVA capacities. It is used
to step down 220 KV from the grid to 6.9 KV.
4. UNIT AUXILIARY TRANSFORMER (UAT):-
It is a step down transformer with 20 MVA capacities. It steps
down the voltage from 16.5 KV to 6.9 KV.
5. STATION SERVICE TRANSFORMER (SST):-

It is a step down transformer with 2MVA capacity. It is used to
step down from 6.6 KV to 0.4333 KV.

6. UNIT SERVICE TRANSFORMER (UST):-
It is a step down transformer with 2 MVA capacity. It is used to
step down from 6.6 kV to 0.4333 KV.
GENERATOR TRANSFORMER :-
Type of cooling ONAN ONAF OFAF

Rating HV (in MVA) 160 240 315
Rating LV (in MVA) 160 240 315
Line Current HV 219.9 329.9 433.0
Line Current LV 5598.5 8397.8 11022
Temperature rise in oil (°C) 45 45 45
Temperature rise in wdg (°C) 50 50 50
No load voltage HV (KV) - 420KV

No Load voltage LV (KV)- 16.5 KV
Connection symbol – Ynd11
Oil - 65300 Liters
There are 5 generator transformers in the plant, one for each unit. The output
from the generator is fed to the generator transformer, which step up the
voltage from 16.5 KV to 400 KV and supplies power to grid. Generator
transformer winding connected in star\delta with a phase displacement of 30
degrees. Three – phase supply from the generator is connected to the low
voltage side bushings and the output is taken from the opposite side. Neutral
point on the H.V. side is provided at the side of the tank. Neutral is solidly
grounded.
In case neutral is solidly connected to the earth a very small current flowing
through the neutral causes the tripling of the transformer. So in this case
more care is to be taken.
STATION TRANSFORMER:-
When the unit is to be started, power supplied to the auxiliaries is

taken from the station transformer. The rating of the station transformer is 50

MVA. It takes power from the grid at 220 kV and steps it down to 6.6 kV. At
the time of starting all the auxiliaries are supplied from the station
transformer. When the generator is synchronized and starts producing power,
about 80% of the load is shifted on to the unit auxiliary transformer. The load
that requires uninterrupted supply is left connected on the station
transformer.
There are 5 S.T’s in the plant, one for each stage.
Type of cooling ONAN ONAF
MVA rating
H.V. 40 50
L.V. 26 31.05
Current (line)
H.V. 105 131
L.V. 3351 4189
Voltage (line):-
H.V. L.V.
220 Kv 6.9 Kv
UNIT AUXILIARY TRANSFORMER:-
Each unit has two unit auxiliary transformers. When the unit starts
generating electricity these transformers are energized and then supplies
power to the auxiliaries. Before starting of the unit, UAT bus is connected to
the station bus. Auxiliaries of one unit take about 20MW of power. UAT is
connected between the generator and the GT. A tapping is taken from the
power coming from the generator to the GT. UAT relieves GT from extra
load of about 20 MW which is to be supplied to the auxiliaries via GT and
ST thus increasing the efficiency. It is a step down transformer, which steps
down the voltage from 16.5 kV to 6.9kV. The rating of UAT is 20 MVA.
UAT bus supplies only those auxiliaries, which are not necessary to be
energized in case of sudden tripping of generator.

UNIT STATION TRANSFORMER:-
It is a step down transformer, which is connected to the station bus. It

steps down the voltage from 6.6 kV to 0.433 kV it is used to supply the low
voltage auxiliaries.
UNIT SERVICE TRANSFORMER:-
It is also a 66-kV/ 415 V transformers which is used to supply the

auxiliaries connected to the unit secondary switchgear bus.
SWITCH YARD
220 KV SYSTEM :-

Two 220 KV bus bars have been provided in
switch yard and are inter-connected through a bus coupler. Each of the two
110 MW generator is connected to this system through a step up of 125
MVA 240/ 11 KV yard generator transformer. There are two step down
transformer each feeding 6.6 KV system ( Station Switchyard ) viz. BS-IS &
SB-IB. Each station transformer has two windings one secondary side and is
rated for 50/25/25 mva, 270/7/7.2 kva four feeder take off from 220 switch
yard, two to SKATPURA GSS and other to HEERAPURA , Jaipur GSS.
Each of four feeder are provided with bypass isolators which is connected
across line breaker and breaker isolator. By closing bus coupler between 220
KV buses and putting line feeders whose breaker required maintenance of
any one bus through by pass isolators and all other line feeders whose
breaker is by passed is then transformed to bus coupler breaker. A brief
description of equipments of 220 KV system is as follows.
CIRCUIT BREAKERS :-
Each of generator transformer, station transformer, line feeder
and bus coupler is provided with minimum oil circuit breaker of BHEL
make. It is rated for 245 KW, 2500 A and 13400 MVA circuit breaker is
used to break the circuit either in load condition or in no load condition.
ISOLATOR:-
All the isolators are provided in 220KV switchyard and are
motor operated. Triple pole double breaker type and power switch yard L&T

make these and are rates for 245 KV and 1250 A. The four isolators are
provided with earth switch.
CIRCUIT TRANSFORMER:-
All the 220 KV current transformers are provided for measuring
and protection. They are BHEL make, single phase, oil filled nitrogen sealed
outdoor type. All the E.T.S. are multi-cored with each core having
specification upon duty it is to perform. Feeder circuit have 5 cores.
1) Bus bar protection core I 1250/250/IA.
2) Distance protection core II 600-300/IA.
3) O/C and E/F protection core 600-300 /IA.
4) For metering and measuring 600-300/ IA.
POTENTIAL TRANSFORMER:-
Each of 220 KV buses is provided with three P.T.’S
are core for each phase of BHEL make. There are single phase , oil filled
outdoor. N2 sealed , elicitor magnetic type P.T. has two secondary windings
on secondary side and selected for 220/53 KV, 10/53 KV.
LIGHTENING ARRESTOR:-
For protection against lightening each of line feeder,
generator transformer , station transformer has been provided with three L.A.
(one for each phase). All the L.A. are 2 Ø outdoor type and are rated for 198

KV these are manufactured by W.S. insulator. The L.A. of generator
transformer and station transformer are located near them.
It has larger value of capacitance and will
change upto line voltage. If we have to do some work on line, first earth line
through earthing isolator for discharging the line capacitance and then work.
220 KV MOCB:-
Manufacturer : BHEL, Hyderabad.
Total Nos. : 9
Type : HLR 245/2503 B-I.
Rated Frequency. : 50 Hz.
Nominal Current. : 2240 Amp.
Type of operating mechanism. : Motor charging Spring Closed.
220 KV ISOLATORS:-
Manufacturer : A&S Power SWGR LTD
Number : 36
Type : Double break operated.
Rated Current. : 1250 Amp.
No. of Phase. : 3Ø
Rated Voltage. : 245 KV.
220 KV Current Transformer:-

Manufacturer. : BHEL, Trichy.
Type : Outdoor, Oil filled.
Nominal : 220 KV.
Max. : 245 KV.
Rated Frequency. : 50 Hz.
No. of Phase. : 1-Ø
Class of Insulation : A.
Rated Primary Voltage. : 2220/ 53 V.
Secondary Voltage Wdg.I: 110/53 V.
Wdg.II. : 110/53 V.
CIRCUIT BREAKER:-
Make : L&T Circuit Breaker Ltd.
Type : Air Circuit Breaker.
Maximum Continuous Voltage : 500 V.for circuit breaker operation.
No. of Phase. : 3-Ø
Rated Voltage. : 415 V.
POWER CAPACITOR:-
Make : L&T Limited.
Type. : ML1,ML2,ML3,ML4, ML8, ML12,.

No. of Poles. : 3.
Rated Voltage for main Contacts. : 500 V.
220 KV LIGNTENING ARRESTOR:-
Manufacturer. : W-S Isolators India Ltd. Chennai.
Type : Heavy Duty CPL II.
No. of Phases. : 3-Ø
Nominal Discharge Current. : 10 KA.
High Current Impulse. : 100 KA.
Long Duration Rating. : 500 KA.

CHAPTER -7
PROTECTION
1. Field Protection.
2. Pole Slipping.
3. Plane Overload Protection.
4. Inter-turn Fault
5. Negative Phase Sequence Protection.
6. Reverse Power Protection.
7. Forward Power Protection.
8. Under Frequency & Over Frequency Protection.
9. Generator Voltage Protection.
10. Rotor Earth Fault Protection.
General Protection:
It is most important electrical equipment of many generating station.
Tripping of even a generating unit may cause overloading of associated
machines and even to system un-stability . The basis function of protection
applied to generator is to reduce voltage to minimum by rapid discrimination
clearance of faults. Unlike other apparatus the opening of C.B. to isolate
faulty generator is not sufficient to prevent future damage.

SALIENT FEATURE OF K.S.T.P.S.
1. LOCATION Sakatpura, Kota.
2. CAPACITY
A) 1ST Stage. 2x110 MW.
B) 2nd Stage. 2x210 MW.
C) 3rd Stage. 1x210 MW.
D) 4th Stage. 1x195 MW.
E) 5th Stage 1x195 MW (to be commissioned in
September 2008).
3. SOURCE OF WATER. Chambal River.
4. BOILER
a) type. tangentially fired natural
circulation, balance draft ,
direct fired radiant reheat,
water tube boiler.
b) No. of units. 6
c) Max. efficiency. BHEL (86.6 + 1) %
d) Capacity. 375 tonnes 1 Hr.
e) Steam Pressure 139 Kg./cm2
f) Steam Temp. 540oC,

g) No. of draft fans in i) FD fans 2 Unit ( Each boiler)
Service. ii) ID fan 2 Unit ( Each boiler ).
h) No. of Air fans in Service.
i) Primary 2 Unit.
ii)Seal Air fan. 1 Unit.
iii) Scanner. 1 Unit.
i) No. of coal mills in service. 3 Unit.
j) No. of Soot blower in service. 68
k) No. of oil burners. 8
5. Fuels:-
A) COAL:-
i)Type. Stack Coal.
ii) Calorific Value. 4450 K.Cal./Kg.
iii) Qty. Used. 3074 tonnes per day.
iv) Ash contents. 40%
v) Sulphur contents. 0.5%.
vi)Type of Handling. Belt Conveyor.

CONCLUSION
The first phase of practical training has
proved to be quiet fruitful. It provided an opportunity for encounter with
such huge machines like wagon tippler .110 MW & 210 MW turbines and
generators.
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 also provides an opportunities to lean low technology used at
proper place and time can cave a lot of labour e.g. wagon Tripler (CHP).But
there are few factors that require special mention. Training is not carried out
into its tree sprit. It is recommended that there should be some project
specially meant for students where presence of authorities should be ensured.
There should be strict monitoring of the performance of students and system
of grading be improved on the basis of work done.
However training has proved to be quite
fruitful. It has allowed an opportunity to get an exposure of the practical
implementation to theoretical fundamentals.

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Kota Super Thermal Power Station (K.S.T.P.

For the power generation with 2x110 MW and

3x210 MW of K.S.T.P.S. authorities are required to be operative to active

voltage of 6.6 KV /415 V. The 6.6 KV power is distributed through 6.6 KV

The 415 V power supply is done through a L.T.

SWGR (Switchgear) which are located nearby the distribution transformer as

Circuit Breaker) of JYOTI MAKE or Air Circuit Breakers.

The 6.6 KV power supply to various draining equipment’s

circuit breaker which are either of voltage makers as well as SF 6 of NGEF

M.B.M ENGINEERING COLLEGE, JODHPUR 1

(DOL) in order to inverse the availability of equipment at full efficiency

without time gap.

Further , the 6.6 KV system which is normally in delta

configuration and terms as an unearthed system so also to keep the running

motor complete in operating condition in case of any one .phase of motor

winding is earthed due to any one reason. Earthling is detected by an

protection system with alarm facility to take remedial measures immediately

ADDRESS SYSTEM” is available through in area of each unit which helps

in fast communication for prompt remedial measure.

furnace wall / economizer tubes to keep heat transfer at the required

In April 1973, Central Electricity Authority prepared a

capacity 110 MW for RSEB subsequently in September. 1975 this was

revised by the Consultant Thermal Design Organization , Central Electricity

Authority for invention of 2x110 MW units being manufactured by BHEL,

M.B.M ENGINEERING COLLEGE, JODHPUR 2

cost of Rs. 143 Crores.

construction of fifth stage Of 195 MW is under construction and may be

possibly completed up to sept. 2008. The total power generated in KSTPS is

K.S.T.P.S. IS DESISIGNED IN FOLLOWING STAGES:-

 STAGE III - 1X210 MW

* Stage V is to be commissioned shortly in Sept. 2008.

M.B.M ENGINEERING COLLEGE, JODHPUR 3

The Kota Thermal Power Station is ideally on the left

bank of Chambal River at Up Stream of Kota Barrage. The large expanse of

water reached by the barrage provides an efficient direct circulation of

from the power station.

Land measuring approx. 250 hectares was required for the

Fields Limited, Western Coal Fields Limited/Coal India limited is supply

to Kota Thermal Power Station through railway wagons. The average

The source of water for power station is reservoir formed by

water is particularly high. Therefore, as far as possible, the plant must be

compared to the transportation of coal.

The satisfactory design consists of the flowing steps.

• Capacity of Power Station.

• Selection of Boiler & Turbine.

• Selection of Condensing Unit.

• Selection of Electrical Generator.

• Selection of Cooling System.

• Design of Control and instrumentation system.

The design of steam power station requires wide

experience as the subsequent operation and maintenance are greatly affected

M.B.M ENGINEERING COLLEGE, JODHPUR 5

General Layout & Basic Idea

A control system of station basically works on

Rankin Cycle. Steam is produced in Boiler is exported in prime mover and

is condensed in condenser to be fed into the boiler again. In practice of good

number of modifications are affected so as to have heat economy and to

increase the thermal efficiency of plant.

 Fuel and Ash Circuit.

 Air and Gas Circuit.