Power Station Report

Undergraduate Internship
INTERNSHIP REPORT ON
GHORASHAL POWER STATION
Submitted by
Abdul Aziz (2014-1-80-055)

Din Mahmud Arafat (2014-2-80-011)
Turja Krishna Bhowmick (2014-2-80-025)
Submitted to the
Department of Electrical & Electronic Engineering
East West University
In partial fulfilment of the requirements for the degree of Bachelor Science in

Electrical & Electronic Engineering
(B.Sc in EEE)
Summer, 2018
Approved by
………………………. …...………………………
Academic Advisor Department Chairperson
Dr. Halima Begum Dr. Mohammad Mojammel Al Hakim
Department of Electrical and Electronic Engineering, East West University Page 1

TRAINING CERTIFICATE
Department of Electrical and Electronic Engineering, East West University Page i

Department of Electrical and Electronic Engineering, East West University Page ii

Department of Electrical and Electronic Engineering, East West University Page iii
AUTHORIZATION LETTER
We declare that we are the sole authors of this internship report. We authorize East West University
to allow other institution or persons to use this internship report for industrial attachment and
similar purposes. We further authorize East West University to reproduce this internship report by
photocopy or other means, in total or in part, at the request of other institution or individuals for
the purpose of industrial attachment.
---------------------------- -------------------------- --------------------------

Abdul Aziz Din Mahmud Arafat Tujra Krishno Bhowmick
Department of Electrical and Electronic Engineering, East West University Page iv

APPROVAL LETTER
This is to certified that Abdul Aziz, Student ID:2014-1-80-055, Din Mahmud Arafat, Student ID:
2014-2-80-011 and Turja Krishno Bhowmick, Student ID: 2014-2-80-025 are student of B.Sc in
Electrical and Electronics Engineering from East West University have successfully completed
the industrial training under Ghorashal Power Station, BPDB held from 18.04.2018 to 05.05.2018.
------------------------
Dr. Halima Begum
Assistant Professor
Department of Electrical and Electronics Engineering
Department of Electrical and Electronic Engineering, East West University Page v

ACKNOWLEDGEMENT
Firstly we would like to thank almighty Allah for giving us the opportunity to complete our
internship and prepare the internship report. We declare that we are the sole authors of this
internship report. We authorize East West University to allow other institution or persons to use
this internship report for industrial attachment and similar purposes. We further authorize East
West University to reproduce this internship report by photocopy or other means, in total or in
part, at the request of other institution or individuals for the purpose of industrial attachment.
In the arrangement of this intern report, we recognize the consolation and help given by various
individuals from BPDB (Bangladesh Power Development Board).We are thankful to the
management of BPDB (Bangladesh Power Development Board) for providing us with the
opportunity to accomplish our industrial training in Ghorashal Power Station. We would like to
thank Course Co-ordinator, Engr. Mohammad Ali Firoz, Deputy Director and Associate Course
Co-ordinator, Mr. Nitai Chandra Shaha, Sub-Assistant Engineer in Ghorashal Training Centre. We
also thank all the engineers and members of Ghorashal Power Station for their guidance and
suggestions during internship.
We would also like to thank our supervisor Dr. Halima Begum, Assistant Professor, Department
of Electrical and Electronic Engineering, East West University, Bangladesh, for giving us the
opportunity to do this internship report under her supervision and guiding us through her
assistance. We would like to mention the name of Dr. Mohammad Mojammel Al Hakim
respectable Chairperson and Professor of the Department of Electrical & Electronic Engineering,
East West University, Bangladesh.
Finally we want to thank all of our teachers, friends and family for their inspiration and co-
operation throughout our whole academic life in EWU including complete our internship.
Department of Electrical and Electronic Engineering, East West University Page vi

EXECUTIVE SUMMARY
Accessibility of energy is one of the vital elements for modern development. Expanding
industrialization has made higher need of energy in Bangladesh. The administration of Bangladesh is
trying to give the required energy to the entire country by 2020. Power sector is very important to
boost up the industrial as well as economic development of a country. In modern world we cannot
think a day without electricity. Day by day the demand of electricity is increasing but the
generation of power is not increasing so much in Bangladesh. To fulfil the large demand of electric
power in Bangladesh, the Ghorashal Power Station (GPS) plays a vital role in power generation
being the largest power generation station in Bangladesh. The installed capacity is 1315 MW
which is separated by Thermal Power Plant and Combined Cycle Power Plant which installed
capacity are respectively 950MW and 365 MW.
We did our internship at GPS. It is situated in Palash, Narsingdi on the bank of the river
Shitalakhya. Our training duration was of 15 days. In GPS, we visited the entire power plant and
achieved a clear idea about generation, control and maintenance processes. This report consists of
a brief description of these processes, visits to different sites and the knowledge that we acquired
at GPS. A lot of steps are needed to complete the supply of the power to the grid. We observed the
generator, transformer and steam turbine. Substation is an important part of a power station to
transmit power and for protection purpose. We acquired knowledge about various types of
transformers, bus-bars, circuit breakers (SF6 and oil), lightning arresters and other equipments of
the substation which were taught and shown by the engineers of the substation of GPS.
Department of Electrical and Electronic Engineering, East West University Page vii
TRAINING SCHEDULE
The table of our training schedule in Ghorashal Power Station (GPS) is given below:
Date Subjects Time Mentor
Engr. Abdullah Bin Aziz

Generation, Transmission &
Distribution.
18.04.2018 09am to 05pm
Engr. Md. Niaz Morshed
(Wednesday) Thermal Diagram of 210MW
Unit.
Engr. Md. Asraful Islam
Start up procedure of 210MW
steam turbine power plant.
Shut down procedure of 210MW Engr. Kartick Chandra
19.04.2018 09am to 05pm
steam turbine power plant.
(Thursday)
Chemical plant and its control, Mr. Md. Abdul Mannan
demi water and its different stage.
20.04.2018 Gas turbine operation & 09am to 05pm Engr. Md. Istiak Hossain
(Friday) maintenance.
Practical visit at 4th unit Re- Engr. Jasim Uddin Khadem
21.04.2018 powering project.
(Saturday) Practical visit at 365MW CCPP. 09am to 05pm Engr. Md. Rukanuzzaman
CCPP, Their flow diagram and Engr. Md. Sultan Salahuddin

22.04.2018 working principle.
(Sunday) Transformer failure, their causes 09am to 05pm Engr. Md. Masud Rana
remedies.
Synchronization system,
Department of Electrical and Electronic Engineering, East West University Page viii
condition, generation, grid Engr. Md. Delower Hossain

voltage relation, problem and Khalifa
solution of 210MW unit. 09am to 05pm
23.04.2018 Turbine rolling, synchronization,
(Monday) load shearing, load reduction, Engr. Md. Aminul Haque
emergency shutdown of turbine.
Relays, their functions and Engr. Md. Sariful Islam
24.04.2018 characteristics.
(Tuesday) Generator, Exciter & Motors. 09am to 05pm Engr. Md. Amirul Momenin
Transmitter, controller, control Engr. Dilip Kumer Biswas

loop, control valve.
25.04.2018 Circuit breaker, Isolator, Bus bar 09am to 05pm
(Wednesday) and Lightning arrestor, Engr. Md. Abul Basher
Grounding. Feeder and their
functions.
Substation, Switchgear & Engr. Md. Abu Baker
protection of high voltage system. Siddique
26.04.2018
(Thursday) Construction and working 09am to 05pm
Engr. Khirod Mohan Bose
principle of Boiler and its
Auxiliaries.
HFO plant and impact of IPP.

27.04.2018
Sustainable development goals 09am to 05pm Engr. Md. Azzizul Haque
(Friday)
and its impact in power sector.
Basic principle of DCS and Engr. Kh. Mokammel Hossain

28.04.2018 09am to 05pm
Networking.
(Saturday)
Thermometer, Monometer. Engr. Md. Towhidur Rahman
Department of Electrical and Electronic Engineering, East West University Page ix

Discussion on power plant

Engr. Md. Enamul Haque
Simulator at Simulator lab.
30.04.2018
Demonstration of gas turbine
(Monday) 09am to 05pm Engr. Md. Jewel Hossain
power plant using power plant
Serazi
Simulator at Simulator lab.
03.05.2018 Different test procedure of
(Thursday) transformer and practical 09am to 05pm Engr. Abu Baker
demonstration at electrical lab.
04.05.2018 Different types of protection Engr. Md. Mahabubur
(Friday) system used in Boiler, Turbine 09am to 05pm Rahman
and Generator.
05.05.2018 Examination, Round Table
09am to 05pm Engr. Mohammad Ali Firoz
(Saturday) conference & Evaluation.
Department of Electrical and Electronic Engineering, East West University Page x

Table of Contents
TRAINING CERTIFICATE ........................................................................................................ i
AUTHORIZATION LETTER ................................................................................................... iv
APPROVAL LETTER ................................................................................................................ v
ACKNOWLEDGEMENT ........................................................................................................... vi
EXECUTIVE SUMMARY ........................................................................................................ vii
TRAINING SCHEDULE .......................................................................................................... viii
Table of Contents ......................................................................................................................... xi
List of Figures ........................................................................................................................... xviii
List of Tables ............................................................................................................................... xx
Chapter 1: Introduction ............................................................................................................... 1
1.1 Introduction ............................................................................................................................. 1
1.1.1. Objective of the Internship .............................................................................................. 1
1.1.2. Company Profile ............................................................................................................. 1
1.1.3. Vision & Mission of GPS ................................................................................................ 3
1.1.4. Production Capacity ........................................................................................................ 4
1.1.5. Future Plan ...................................................................................................................... 5
1.1.6.Scope and Methodology................................................................................................... 5
Chapter 2: Water Treatment Plant & Cooling System ............................................................. 6
2.1. Introduction ............................................................................................................................ 6
2.2. Water Treatment Procedure ................................................................................................. 7
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2.2.1. Clarification ..................................................................................................................... 7
2.2.2. Filtration........................................................................................................................... 8
2.2.3. Demineralization.............................................................................................................. 8
2.3. Cooling System........................................................................................................................ 8
2.3.1. Hydrogen Cooling .......................................................................................................... 9
2.3.2. Water Cooling .................................................................................................................. 9
2.3.3. Lube Oil Cooling ............................................................................................................. 9
Chapter 3: Steam Generating Plant .......................................................................................... 10
3.1. Boiler ............................................................................................................................................ 10
3.1.1. Boiler Specification ....................................................................................................... 11
3.2. Different Types of Boiler Equipment ................................................................................. 11
3.2.1. Boiler Drum ................................................................................................................... 11
3.2.2. Furnace ........................................................................................................................... 12
3.2.3. Burner .................................................................................................................................. 12
3.2.4. Super Heater ....................................................................................................................... 13
3.2.5. Economizer ................................................................................................................... 13
3.2.6. Deaerator ....................................................................................................................... 13
3.2.7. Chimney ........................................................................................................................ 13
3.2.8. Condenser ..................................................................................................................... 14
3.2.9. Safety Valve .................................................................................................................. 15
3.2.10.Water Level Indicator .................................................................................................. 15
3.2.11.Forced Draft Fan .......................................................................................................... 16
3.2.12.Induced Draft Fan ........................................................................................................ 16
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3.3. Boiler Protection ................................................................................................................... 17
3.3.1.Gas Control System ....................................................................................................... 17
3.3.2.Temperature Control ..................................................................................................... 17
3.3.3.Lube Oil Flow Control .................................................................................................. 17
3.3.4.Air Pressure Control ...................................................................................................... 18
3.3.5.Drum Level Feed Water Control ................................................................................... 18
3.3.6.Trouble Shooting of boiler ............................................................................................ 18
Chapter 4: Steam Turbine ......................................................................................................... 20
4.1. Introduction .......................................................................................................................... 20
4.2. Sections of a Steam Turbine ................................................................................................ 20
4.2.1. High Pressure Cylinder ................................................................................................... 20
4.2.2. Intermediate Pressure Cylinder ...................................................................................... 21
4.2.3. Low Pressure Cylinder ................................................................................................... 21
4.3. Oil Pumps Associated with Turbine ................................................................................... 22
4.3.1. Main Oil Pump ............................................................................................................... 22
4.3.2. Starting Oil Pump ................................................................................................................ 22
4.3.3. Stand by Oil Pump ......................................................................................................... 22
4.3.4. Emergency Oil Pump ..................................................................................................... 22
4.3.5. Lubricating Oil Pump ..................................................................................................... 22
4.4. Auxiliary Equipment of Turbine ........................................................................................ 22
4.4.1. Governor .......................................................................................................................... 22
4.4.2. Turbine Bearings .............................................................................................................. 23
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4.4.3. Condenser ........................................................................................................................ 23
4.4.4. Nozzle .............................................................................................................................. 23
4.5. Turbine Protection ............................................................................................................... 24
4.5.1.Turbine Pressure and Temperature Control .................................................................. 24
4.5.2.Lube Oil Temperature Control ..................................................................................... 24
4.5.3.Speed Regulation ........................................................................................................... 25
4.5.4.Vibration Protection ...................................................................................................... 25
Chapter 5: Generator ................................................................................................................. 26
5.1. Introduction .......................................................................................................................... 26
5.2. Main Components of the Generator ................................................................................... 28
5.2.1. Stator .............................................................................................................................. 28
5.2.2. Rotor ............................................................................................................................... 28
5.2.3. Carbon Brush .................................................................................................................. 29
5.2.4. Slip Rings ....................................................................................................................... 29
5.2.5. Armature Winding .......................................................................................................... 29
5.3. Excitation System of the Generator .................................................................................... 30
5.4. Synchronization System of Generator ................................................................................ 30
5.4.1. Voltage Synchronization ................................................................................................ 30
5.4.2. Frequency Synchronization ............................................................................................ 30
5.4.3. Phase Synchronization ................................................................................................... 30
5.5. Generator Protection System .............................................................................................. 30
5.5.1. Over Current / Under Voltage Protection ....................................................................... 30
5.5.2. Over Speed Protection .................................................................................................... 31
Department of Electrical and Electronic Engineering, East West University Page xiv
5.5.3. Stator Earth Fault Protection .......................................................................................... 31
5.5.4. Rotor Earth Fault Protection .......................................................................................... 31
5.5.5. Frequency Protection ...................................................................................................... 31
5.5.6. Temperature Protection .................................................................................................. 32
5.5.7. Over Voltage Protection ................................................................................................. 32
5.6. Generator Cooling System ................................................................................................... 32
5.6.1. Water Cooling ................................................................................................................ 32
5.6.2. Hydrogen Cooling .......................................................................................................... 32
Chapter 6: Combined Cycle Power Plant ................................................................................. 34
6.1. Introduction .......................................................................................................................... 34
6.2. Section of Combined Cycle Power Plant .............................................................................. 34
6.2.1. Gas Turbine................................................................................................................... 34
6.2.1.a. Air Inlet ............................................................................................................ 34
6.2.1.b. Compressor ...................................................................................................... 34
6.2.1.c. Combustion Chamber ....................................................................................... 35
6.2.1.d. Exhaust Module ............................................................................................... 35
6.2.2. Heat Recovery Steam Generator................................................................................... 35
6.2.3. Steam Turbine ............................................................................................................... 36
6.2.4. Fuel for CCPP ............................................................................................................... 36
6.2.5. Efficiency of CCPP ....................................................................................................... 36
Chapter 7: Substation and Control Room ................................................................................ 37
7.1.Introduction ........................................................................................................................... 37
Department of Electrical and Electronic Engineering, East West University Page xv

7.2. Major Components of Substation in GPS ........................................................................... 38
7.2.1. Bus Bar ....................................................................................................................... 38
7.2.2. Circuit Breaker ........................................................................................................... 39
7.2.2.a. Oil Circuit Breaker ........................................................................................... 39
7.2.2.b. Air Blast Circuit Breaker ................................................................................. 39
7.2.2.c. SF6 Circuit Breaker .......................................................................................... 40
7.2.3. Isolator ....................................................................................................................... 41
7.2.4. Bus Coupler................................................................................................................ 41
7.2.5. Lightning Arrester ...................................................................................................... 42
7.2.6. Earthing Switch .......................................................................................................... 43
7.2.7. Transformer ................................................................................................................ 43
7.2.8.a. Power Transformer ........................................................................................ 44
7.2.8.b. Auxiliary Transformer .................................................................................. 44
7.2.8.c. Coupling Transformer ................................................................................... 45
7.2.8.d. Instrument Transformer ................................................................................ 46
7.2.8.e. Current Transformer ...................................................................................... 47
7.2.8.f. Potential Transformer ................................................................................... 48
7.3.Transformer Protection ....................................................................................................... 49
7.3.1. Earth Fault Protection ................................................................................................ 49
7.3.2. Differential Relay Protection ..................................................................................... 50
7.3.3. Buchholz Relay Protection ......................................................................................... 50
7.3.4. Distance Relay Protection .......................................................................................... 50
7.4.Cooling System ...................................................................................................................... 50
7.5. Silica Gel Breather ................................................................................................................ 51
Department of Electrical and Electronic Engineering, East West University Page xvi
7.6. Control Room of Steam Power Plant .................................................................................. 51
7.6.1. Unit-1 and Unit-2 Control Room .................................................................................. 52
7.6.2. Unit-3,4,5 and 6 Control Room .................................................................................... 52
7.7. Control Room of Combined Cycle Power Plant .................................................................. 52
Chapter 8: Conclusion ................................................................................................................ 54
8.1. Introduction .......................................................................................................................... 54
8.2. Problems ................................................................................................................................ 54
8.3. Recommendations................................................................................................................. 54
References .................................................................................................................................... 55
Daily Activity Report .................................................................................................................. 56
Department of Electrical and Electronic Engineering, East West University Page xvii
List of Figures
Figure 1.1: Ghorashal Power Station (inside) ............................................................................ 2
Figure 1.2: Ghorashal Power Station (outside) .......................................................................... 2
Figure 2.1: Flow diagram of water treatment process in GPS .................................................... 6
Figure 2.2: The clarifier system in GPS ..................................................................................... 7
Figure 3.1: Boiler ...................................................................................................................... 10
Figure 3.2: Boiler drum of unit 4 of GPS ................................................................................... 12
Figure 3.3: Chimney of unit 4 of GPS ...................................................................................... 14
Figure 3.4: Condenser of unit-6 in GPS ..................................................................................... 14
Figure 3.5: Safety Valve ............................................................................................................. 15
Figure 3.6: Water Level Indicator .............................................................................................. 15
Figure 3.7: Forced Draft Fan ...................................................................................................... 16
Figure 3.8: Induced Draft Fan .................................................................................................... 16
Figure 4.1: High pressure cylinder rotor of unit-4 in GPS ........................................................ 20
Figure 4.2: Intermediate pressure cylinder rotor of unit-4 in GPS ............................................. 21
Figure 4.3: Low pressure cylinder of unit-4 in GPS................................................................... 21
Figure 4.4: Steam turbine condenser of unit-4 in GPS ............................................................... 23
Figure 4.5: Lube oil pipe of unit-4 at GPS ................................................................................. 24
Figure 5.1: Generator of unit-4 in GPS ...................................................................................... 27
Figure 5.2: Stator of unit-4 generator in GPS ............................................................................. 28
Figure 5.3: Rotor of unit-4 generator in GPS ............................................................................. 29
Figure 5.4: Hydrogen Cooling System ....................................................................................... 33
Figure 6.1: Heat Recovery Steam Generator ............................................................................. 36
Department of Electrical and Electronic Engineering, East West University Page xviii
Figure 7.1: 230KV and 132 KV single line diagram of GPS substation ................................... 37
Figure 7.2: Substation of GPS .................................................................................................... 38
Figure 7.3: Air blast circuit breaker............................................................................................ 40
Figure 7.4: SF6 circuit breaker ................................................................................................... 41
Figure 7.5: Lightning Arrester ................................................................................................... 42
Figure 7.6: Transformer ............................................................................................................. 43
Figure 7.7: Power Transformer .................................................................................................. 44
Figure 7.8: Current Transformer ................................................................................................ 47
Figure 7.9: Potential Transformer .............................................................................................. 48
Figure 7.10: Silica gel breather of GPS ...................................................................................... 51
Figure 7.11: Control Room of Steam Power Plant ..................................................................... 52
Department of Electrical and Electronic Engineering, East West University Page xix
List of Tables
Table 1.1: The profile of GPS ................................................................................................ 3
Table 1.2: Capacities of different units of GPS ...................................................................... 4
Table 3.1: Boiler specification ............................................................................................... 11
Table 5.1: Ratings of 55 MW Generator ................................................................................ 26
Table 5.2: Ratings of 210 MW Generator .............................................................................. 27
Table 7.1: Ratings of 230 KV Auxiliary Transformers. ......................................................... 45
Table 7.2: Ratings of 230 KV Coupling Transformers. ......................................................... 46
Table 7.3: Ratings of 230 KV Current Transformers. ............................................................ 48
Table 7.4: Ratings of 230 KV Potential Transformers. .......................................................... 49
Department of Electrical and Electronic Engineering, East West University Page xx

Chapter 1: Introduction
1.1 Introduction
Ghorashal Power Station (GPS) is the largest power station in Bangladesh. It has started its
operation in 1974. The Ghorashal power station is a thermal power plant situated beside the bank
of Sitalakha River at Palash, Narshingdi. It has the generation capacity of 1315 MW which is
generated by seven units of gas fired steam turbines for unit one to six and gas fired gas turbines
and steam turbines for unit seven which is known as Combined Cycle Power Plant. The installed
capacity of steam turbine units and combined cycle unit are respectively 950MW and 365 MW.
The type of power plant of GPS is thermal power plant. It is a great opportunity to do internship
at GPS. During the time of internship we have achieved practical knowledge on generation,
operation, instrumentation, transmission and control section of GPS. Here we relate the theoretical
knowledge with the practical activities in GPS. In this report we will discuss what we have
observed and learnt at GPS.
1.1.1. Objective of the Internship

The main objective of this internship is to achieve practical knowledge and gather experience about
power station. In this internship report, we focused on the power generation process, various
protection systems, control system, transmission of generated electricity, identification of different
types of problems and maintenance of the equipment such as generator, transformer at GPS.
1.1.2. Company Profile

GPS is the largest power station in Bangladesh. It is situated on the Eastern bank of river
Shitalakhya at North East of Dhaka under Palash, Narsingdi district. In this power station, natural
gas (CH4) is used as fuel from Titas Gas Transmission and Distribution Company [1].

Figure 1.1: Ghorashal Power station (inside view)
Figure 1.2: Ghorashal Power station (outside view)
The profile of GPS is given below:

Table 1.1: The profile of GPS.
Name Ghorashal Power Station
Year of establishment 1974
Corporate office Bangladesh Power Development Board

(BPDB)
Technopromexport, Russia(steam turbines)

Company Name
Dongfang, China(combined cycle power plant)
Main Work Power generation
Steam Turbines (1-6 units)

Number of Generation Units 7
Combined Cycle 7th unit
Installed Capacity 1315 MW
De-rated Capacity 910 MW
Area 0.43 km2
Regular employee 1500
Above information are collected from the mentors of GPS.
1.1.3. Vision and Mission of GPS

The vision of GPS is to provide quality and reliable electricity to the people of Bangladesh for
desired economic, social and human development of the country undertaking institutional and
structure reforms leading to the creation of an organization of international standard.
The mission of GPS are:
• Generate more power than it is generating at present.

• Make electricity available to all citizens on demand by the year 2021.

• Follow international standard and adopt modern technology and practices in power
generation and distribution activities.
• Ensure improved and satisfactory services to the consumers.
• Increase power generation capacity to more than 1500 MW.
1.1.4. Production Capacity
GPS has a total of 7 units; 2 units with 55 MW capacity each, 4 units with 210 MW capacity each
are steam turbine power plants and 1 unit with 365MW capacity is combined cycle power plant.
All the units which are steam turbine power plants have been installed by a company named
Technopromexport, Russia and the unit of combined cycle power plant has been installed by a
company Dongfang, China. The description of the power generating units of GPS is shown in table
1.2.
Table 1.2: Capacities of different units of GPS.
Unit no Installed De-rated Present Status

Capacity(MW) Capacity(MW)
Unit-1 55 40 Running
Unit-2 55 - Overhauling
Unit-6 210 - Under tendering process

for repair since 2010
Total = 1315 MW Total = 910 MW

1.1.5. Future Plan

Installed generation capacity of Ghorashal Power Station (GPS) is 1315 MW. A plan has been
taken to increase the total established generation capacity. In order to achieve this target, GPS has
decided to set up a new power plant project named ‘Bangladesh Ghorashal unit 4 Re-powering
Project’. This will be the first repowering project of the country and will provide a much-needed
increase in power generation capacity for Bangladesh by adding more than 200 megawatts (MW)
of cleaner power to the national grid. The project’s objective is to increase generation capacity and
efficiency of the targeted power plant. The key activity of the proposed project is to convert unit
4, one of the four 210 MW gas-fired steam units at Ghorashal Power Station (GPS), into a
combined cycle unit for an upgraded total capacity of about more than 409 MW. The steam unit is
currently generating 170MW and the overall efficiency of the unit is around 31%. The proposed
project would increase the overall efficiency of the unit to 54% and the generation output will also
be more than doubled with only 18% increase in gas requirement. Fuel consumption (per GWh)
would be reduced by 44%, which would also lead to lower greenhouse gas emissions. Board of
Executive Directors of The World Bank approved the project and contract was signed on 21st
December, 2015. The Power Development Board (PDB), the Ministry of power, Energy and
Mineral Resources declared that the construction of Bangladesh Ghorashal unit 4 Re-powering
Project will be completed by March, 2022.
1.1.6. Scope and Methodology

In this internship report we have highlighted generation, transmission and distribution process of
electrical power by GPS. We have also included the description of electrical equipment which are
needed for the generation, transmission and distribution process. We have also added meter testing
and risk management of GPS in this report. The data we used here were collected during the
internship period.

Chapter 2: Water Treatment Plant & Cooling System
2.1. Introduction
Water treatment plant is very important for the production of steam and cooling of used steam.
Water is used to generate steam in all thermal power plants, where steam is used in turbine as
prime mover. Another application of water is to condensate the steam into water. The condensation
is used to increase the efficiency of the thermal power plant. The source of the raw water is
Shitalakhya river. This raw water is purified and softened by mechanical and chemical processes.
Then it is supplied to the system. In this chapter we will discuss about the process of water
treatment. The block diagram of water treatment process is shown in figure 2.1.The main objective
of water treatment plant is to produce mineral free water which is called demi water. Demi water
is needed to get rid of the problems of scaling, erosion and corrosion.
Figure 2.1: Flow diagram of water treatment process at GPS

2.2. Water Treatment Procedure

River water has two types of substances:
• Dissolved solid and
• Un-dissolved solid.
Dissolved solids are different types of ions and minerals. Un-dissolved solids are clay, mud etc.
By following several steps, these solids can be removed. GPS mainly follows the following
steps.
2.2.1. Clarification
Water is collected from the river Shitalakhya. Here, raw water is mixed with Aluminum Sulphate
(Al2SO4). The sludge is deposited in a tank. The chemical reaction is
Al2SO4+6H2O (clay) →2Al(OH)3 (sludge)+3H2SO4
This sludge is removed from the tank and the clarified water is stored in coagulated tank. By using
clarification, 70% of un-dissolved solid from water is removed. Clarifier system of GPS is shown
in figure 2.2.
Figure 2.2: The clarifier system in GPS.

2.2.2. Filtration
After clarification, the water contains a lot of small or big particles which are harmful and
destructive to the plant. So this clarified water is used for filtering. The filter removes any solid
particle like sand, silt etc.
2.2.3. Demineralization
Demineralization is the process of removing mineral salts from water by using ion exchange
process. Demineralized water or demi water is water of which the minerals or salts are removed.
It is used in applications where water with low salt content or low conductivity is required, for
example as boiler feed water. Demineralized water is also known as deionized water with removed
mineral ions. Mineral ions such as cations of sodium, calcium, iron, copper, etc and anions such as
chloride, sulphate, nitrate, etc are common ions present in water. When it is passed through cation
exchanger resin, these cations are caught by the following reactions.
R-H2+CaCl2→ R-Ca+2HCl
R-H+NaCl→ R-Na+HCl
This water also contains negative ion like Cl-, SO42-, NO3-. During the passing of this water
through anion exchanger resin, these anions are caught by the following reactions.
R-(OH)2+H2SO4 → R-SO4+2H2O
R-OH+HCl →R-Cl+H2O
This demi water is stored in demi tank which is used for producing steam.
2.3. Cooling System

Steam power plants boil water to create steam, which then spins turbines to generate electricity.
The heat coming from burning fuel boils the water. Once steam has passed through a turbine, it
must be cooled back into the water before it can be reused to produce more electricity. Cold water
cools the steam more effectively and allows more efficient electricity generation. The heat build-
up can lead to acceleration of wear and tear of the turbines. It can also compromise the efficiency
of the power plant productivity. Therefore, cooling system is important.

2.3.1. Hydrogen Cooling

Hydrogen cooling is mainly used for cooling the rotating part and also for the generator.
In GPS, the electrolyzer plant is used for the production of hydrogen. A closed loop
process is used for this cooling process and a small fan is used to circulate the hydrogen
gas.
2.3.2. Water Cooling

Water carrying tubes passes through the stator coils to cool the stator winding. Demi water
is supplied through the tubes to cool the stator coil. The water is supplied by the pump
through hollow structured slots of the stator. The water in the tubes absorbs the heat of the
stator and goes to the cooling chamber. The water is again re-circulated to the tubes for
cooling. Water is also used to cool the hydrogen which is used to cool down the rotating
part.
2.3.3. Lube Oil Cooling

Lube oil is required to cool down the turbines. Turbines are kept to rotate at a very low
speed after the plant is shut down. Then the lube oil is supplied to the turbines for the
cooling process. The process continues until the whole heat of the turbine is not absorbed
by the lube oil. If the turbine is stopped without cooling, the turbine blades may bend.
Lube oil is also used for cooling purposes of different shafts, valves, etc. and also to rotate
the shaft smoothly so that the friction is less.

Chapter 3: Steam generating plant
3.1.Boiler
A boiler or steam generator is usually a closed vessel made of steel. Its function is to
transfer the heat produced by the combustion of fuel (solid, liquid or gaseous) to water,
and ultimately to generate steam to be used in steam engine or turbine [2]. At GPS, the
main purpose of boiler section is to produce steam to run the turbine. Boiler is designed
to transmit heat produced by burning of fuel to water and thus generate steam. To produce
steam, the boiler has some requirements. The primary requirements of the boiler are:
i. Water must be safely contained.
ii. Steam must be delivered at rated pressure, temperature.
iii. Maximum heat from external combustion source should be utilized.
Figure 3.1 shows the boiler of GPS.
Figure 3.1: Boiler

3.1.1. Boiler Specification

In GPS, there are six water tube boilers to generate steam for the power plant. The water
is treated in the water treatment plant and the treated water is passed to the boiler to be
converted into steam. The steam is collected into the steam drum which is a part of the
boiler. Table 3.1 shows the different specification of boiler.
Table 3.1: Boiler specification.
1. Boiler capacity (reheat steam) 670 ton/hour
2. Steam flow rate through intermediate super 590 ton/hour

heater.
3. Pressure in boiler drum 158kgf/cm2
4. Superheated steam pressure at the outlet of 140kgf/cm2

boiler
5. Superheated steam temperature 5450C
6. Steam pressure at the inlet of reheater 28.5kgf/cm2
7. Steam temperature at the inlet of reheater 3430C
8. Steam pressure at the outlet of intermediate S-H 26.3kgf/cm2
9. Steam temperature at the outlet of intermediate 5450C

super heater
10. Feed water temperature 2500C
11. Boiler efficiency 93%
12. Steam volume of H.P Super heater 89 m3
3.2. Different Types of Boiler Equipment
3.2.1. Boiler Drum

A boiler drum is a pressured vessel where saturated steam and feed water gets separated.
It is a pressure vessel because high pressure feed water is pumped to the boiler drum. The

water keeps circulating with the help natural and forced circulation until it becomes
saturated steam. Figure 3.2 shows the boiler drum of unit 4.
Figure 3.2: Boiler drum of unit 4 of GPS.

3.2.2. Furnace
Furnace is a chamber which is situated inside the boiler. A furnace is a device used for
high-temperature heating. Here, with the presence of air the natural gas is burnt to produce
heated gas or flue gas. The ratio of gas and air is 1:14. At GPS, every furnace chamber
has nine furnaces. Inside the chamber the temperature is about 15000C to 18000C. The
treated water from the feed water tank enters into the furnace through tubes. The flue gas
produced in the furnace releases heat to the water. As a result water becomes saturated
steam. Saturated steam temperature is about 350°C. Draft fan is used to supply the air into
the furnace. Finally, the saturated steam from the furnace goes to the boiler drum.
3.2.3. Burner
Burner is the chamber in the boiler where natural gas or coal is burnt in the presence of
air for producing heated gas or flue gas. At Ghorashal Power Station natural gas is burnt
in the presence of air for generating heat for making steam. In steam turbine power plant
of GPS each furnace chamber has twelve burners. The temperature inside the furnace
chamber is 1200-1500°C. The treated water from the feed water tank from the economizer
enters into the boiler through tubes and the flue gas produced inside the furnace passes
over the tubes.

3.2.4. Super Heater

Super heater is a subcritical component of the boiler that heat up the saturated vapor, at
constant pressure, so it becomes superheated steam. There are three types of super heaters
radiant, convection and separately fired. Radiant super heater is used in GPS. There are
four stages in super heater. The steam will pass consecutively the primary super heater,
secondary super heater platform, intermediate secondary super heater and the final
secondary super heater. This steam produced by final secondary super heater is called
superheated steam or dry vapor. It contains no moisture at all, and stores very high heat
energy, much higher than the saturated vapor.
3.2.5. Economizer
An economizer is a mechanical device which is used as a heat exchanger by preheating a
fluid to reduce energy consumption. Function of economizer is to recover some of the
heat which is carried away by the exhaust flue gas. The recovered heat is utilized to raise
the temperature of feed water. Then the feed water at raised temperature is supplied to the
boiler. If the feed water at raised temperature is supplied to the boiler, it needs to provide
less heat to convert the water into steam. Recovery heat from flue gas raises feed water
temperature up to 345°C. Economizer is used to save the consumption of fuel.
3.2.6. Deaerator
Deaerator is a device which is used to remove air and other dissolved gases from the feed
water. The metal piping and other metallic equipment get damaged because of the
dissolved oxygen in the boiler feed water. Deaerator increases the efficiency and optimum
thermodynamic utilization. So it is used at GPS to keep the equipment safe.
3.2.7. Chimney
A chimney is a structure that provides ventilation for hot flue gases or smoke from a boiler,
stove, furnace or fireplace to the outside atmosphere. Furnace produces flue gas. This flue
gas is used to create the steam for rotating the turbine. The flue gas passes through several
numbers of equipment and finally goes into the nature through chimney. Figure 3.3 shows
the flue gas stack of GPS.

Figure 3.3: Chimney of unit 4 of GPS.
3.2.8. Condenser
Condenser is a mechanical device which converts the steam into water. A condenser is a
part of steam generator where exhaust steam is condensed and converted into water.
Condenser creates a very low pressure at the exhaust of turbine, which permits expansion
of the steam in the prime mover to a very low pressure. The condenser of GPS of unit-6
is shown in figure 3.4.
Figure 3.4: The condenser of unit-6 in GPS.

3.2.9. Safety Valve

A valve opening to relieve excessive pressure automatically is called safety valve and it
prevents the building up of excessive pressure in the boiler. The safety valve is shown in
figure 3.5.
Figure 3.5: Safety valve
3.2.10. Water Level Indicator

It indicates the water level inside the boiler vessel. It shows the level of water in the boiler
drum. It warns the operator if the water level goes below a fixed mark, so that corrective
action may be taken in time to avoid any accident. When the boiler is not working, the
water level indicator can be taken out from the boiler for cleaning purposes by removing
the bolts. Figure 3.6 shows the water level indicator.
Figure 3.6: Water Level Indicator

3.2.11. Forced Draft Fan

Forced draught fan (FD fan), is used basically for providing the required quantity of hot
air to the furnace for smooth and uniform combustion of fuel. FD fan produces the positive
pressure inside the system i.e. furnace. Figure 3.7 shows the FD fan of GPS.
Figure 3.7: Forced Draft Fan

3.2.12. Induced Draft Fan
Inducted draft fan (ID fan) is located between dust collector and chimney. ID fan will take
the hot flue gases from furnace via dust collector and will deliver to chimney. ID fan
handles the flue gases i.e. hot air. Figure 3.8 shows the ID fan of GPS.
Figure 3.8: Induced Draft Fan

3.3. Boiler Protection System

Several protection schemes are employed, to protect the boiler from any damage.
3.3.1. Gas Control
To produce heat in GPS, natural gas is used as a fuel for ignition and combustion in the
boiler. The source of gas is Titas Gas Transmission and Distribution Company Limited
Bangladesh. Normal pressure of gas is 6 kgf-cm-2. But the pressure of natural gas can be
reduced from 6 kgf-cm-2 to 0.9 kgf-cm-2 before entering into the burner. The mixture of
gas and air are burned into the boiler to produce heat. If the gas pressure decreases to 0.01
kgf-cm-2, power station may be tripped. So gas control system is very important in power
station.
3.3.2. Temperature Control

The temperature is controlled in GPS by using a sensor which is called resistance
temperature detector. It is a temperature sensor called resistance thermometer that detects
any change in electrical resistance of some materials for changing temperature. In GPS,
platinum material is used as resistance. It is used for accuracy and long-term stability.
Normally temperature of the super-heated steam inside the super heater is about 550°C. If
main steam temperature is above 565°C or below 450°C the resistance temperature
detector sensor passes a signal to the control room. Resistance is measured by applying a
constant current and measuring the voltage drop across the resistor.
3.3.3. Lube Oil Flow Control
Lube oil pump is a one kind of pump which controls the flow of lube oil. It is mainly used
for pumping lube oil. It pumps more lube oil into the system if the pressure of the lube oil
falls. The lube oil pump needs to operate over a wide range of temperature and liquid
viscose conditions. The regulation system does not work if the lube oil temperature is
below 17°C. Every machine is operated by a rated temperature, pressure etc. which are
fixed by the manufacturer. Normally operator follows this rating to operate the machine.
This is called regulation system. To increase efficiency and life time operators follow the
ratings.

3.3.4. Air Pressure Control

At GPS, air pressure in the furnace is controlled by FD and ID fans. FD fan is a fan or
blower that is installed near boiler to supply air to the boiler furnace and maintain 1.6 kgf-
cm2 positive pressures. ID fan is a fan which is located near the base of chimney. In GPS,
it is used to suck hot gases from the boiler side and maintain 0.9 kgf-cm2 negative pressure
from the furnace to the outlet of the ID fan.
3.3.5. Drum Level Feed Water Control

The boiler of GPS uses differential pressure transmitter which represents the level control
measurement and probe type sensor which gives level alarms and low and high shutdown.
The drum level must be controlled within specific limits and it is specified by the boiler
controller. Drum contains both water and steam. From drum, water goes to furnace
through water tube and absorbs heat and turns into steam. The steam goes to drum as
saturated steam. The minimum level of drum is -160 mm and the maximum level of drum
is +200 mm.
3.3.6. Trouble shooting of Boiler

1. Super heater/ water wall tube leakage.
Symptom:
• Abnormal sound in the furnace.
• Increase of feed water consumption.
• Decrease of waste gas temperature.
• Emission of white smoke at the outlet of chimney.
• Decrease of live steam temperature.
Solution: Quick shutdown of unit for maintenance.
2. Boiler condenser tube leakage.

Symptom:
• Drop of temperature of live steam.
• Drop of live steam temperature although injection line is fully closed.
Solution: Quick shutdown of unit for maintenance.

3. Feed water regulating valve doesn’t work.

Symptom: Drum water level gradually become high.
Solution:
• Close gate valve and regulating valve.
• Close the hydro coupling of feed pump.
• Open the drum emergency drain valve.
• Increase the load.

Chapter 4: Steam Turbine
4.1. Introduction
Steam turbine power plant uses steam to move the turbine. Steam turbine is a mechanical
device that converts thermal energy to mechanical energy. The turbine mainly consists of
rotor and stator blades. Steam applies force on the blades, for that turbine rotor start
rotating. So, the thermal energy transforms into mechanical energy. At GPS, steam is used
to move the turbine therefore it is known as steam turbine power plant.
4.2. Sections of a Steam Turbine

There are three sections of a steam turbine. These are
i. High pressure cylinder (HPC)
ii. Intermediate pressure cylinder (IPC)
iii. Low pressure cylinder (LPC)
4.2.1. High Pressure Cylinder

From super heater steam with 130 kg/cm2 pressure and 540oC temperature enters into the
high-pressure turbine. High-pressure turbine has twelve stages with moving and fixed
blades. After completion of steam flow throughout the twelve stages of HPC, the steam
temperature falls to 336oC and pressure falls to 28.4 kg/cm2. This steam enters into re-
heater to gain heat once again and leave re-heater with 540oC. But the pressure remains
almost same (25 kg/cm2). High pressure cylinder rotor of unit-4 at GPS is shown in figure
4.1.
Figure 4.1: High pressure cylinder rotor of unit-4 in GPS.

4.2.2. Intermediate Pressure Cylinder

From the re-heater steam goes to the intermediate pressure cylinder which has eleven stages. Now
steam pressure is 25 kg/cm2 and the temperature is 540ºC. If temperature falls below 440o C or
rises above 565o C then the intermediate pressure cylinder (IPC) valve trips. After completion of
steam flow throughout the eleven stages of IPC, the stream temperature falls to 171o C and pressure
becomes 1.34 kg/cm2. Intermediate pressure cylinder rotor of unit-4 at GPS is shown in figure 4.2
Figure 4.2: Intermediate pressure cylinder rotor of unit-4 in GPS.
4.2.3. Low Pressure Cylinder

From the intermediate pressure cylinder, steam goes to low-pressure cylinder. Here, the
pressure is about 1.34 kg/cm2 and the temperature is about 171oC. LPC blades are larger
than the previous two sections but the energy of steam is less here compared to other two
sections. LPC is divided into two sections and each section contains 3 or 4 stages. In LPC,
steam losses all its energy and moves to the condenser. Low pressure cylinder of unit-4 at
GPS is shown in figure 4.3.
Figure 4.3: Low pressure cylinder of unit-4 in GPS.

4.3. Oil Pumps Associated with Turbine
4.3.1. Main Oil Pump

During the running condition, main oil pump is coupled with turbine rotor for turbine
regulation and lubrication system. Main oil pump rotates at the speed of 3 rpm and oil
pressure is 20 kg/cm2.
4.3.2. Starting Oil Pump
Starting oil pump is used for supplying oil when the unit starts. The power of electric
motor is 200 KW and voltage is 6.6 KV. At the time of starting turbine, starting oil pump
supplies oil for turbine regulation and lubrication system.
4.3.3. Standby Oil Pump

During turbine shut down condition stand by oil pump supplies oil to the turbine
lubrication system. Stand by oil pump rotates at the speed of 1450 rpm. The power of
electric motor is 22 KW and voltage is 6.6 KV.
4.3.4. Emergency Oil Pump
When AC supply is not available and oil pressure falls below the required pressure
emergency oil pump handles the situation. This is a centrifugal pump, driven by a DC
electric motor. The power of electric motor is 13 KW and voltage is 6.6 KV and the
rotation rate is 1500 rpm.
4.3.5. Lubricating Oil Pump

Lubricating oil pump is used for the protection of turbine bearing. Lubricating and cooling
the bearings is the main purpose of using the lubricating oil pump. When the main oil
pump and standby oil pump cannot supply oil, lube oil pump is used for supplying lube
oil. The emergency oil pump operates when the AC supply is unavailable and lubrication
pump works only when DC supply is available. Lubrication oil pump works in AC supply
if the oil pressure of main oil pump and standby oil pump oil is below the required pressure
level.
4.4. Auxiliary Equipment of Turbine
4.4.1. Governor
Turbine operation is to be maintained at a constant speed. By controlling the flow of the

steam into the turbine, governor helps to control the rotating speed of turbine. When steam
turbine speed is increased on low load condition steam turbine governor decreases the
quantity of the steam going inside the turbine.
4.4.2. Turbine Bearings
There are two types of bearings: journal bearing and thrust bearing. Journal bearing is
used to support the weight of turbine rotor. The bearing metal is divided into six pads
which are self-aligned. Journal bearing is the main bearing of steam turbine. The thrust
bearing is located on the main shaft of the turbine. Axial thrust of the turbine is absorbed
by the thrust bearing.
4.4.3. Condenser
Condenser is a device in which the exhaust steam from steam turbine is condensed. Main
purpose of a steam condenser is to maintain a low back pressure on the exhaust side of
the steam turbine. In every unit of GPS, two condensers are used. One is left condenser
and the other is right condenser. Working procedure of both condensers is same. Turbine
condenser is shown in figure 4.4.
Figure 4.4: Steam turbine condenser of unit-4 in GPS.
4.4.4. Nozzle
Nozzle is a device which is used to rotate the turbine at a low speed at the starting and
after tripping [3]. Nozzle receives steam though governing valve and converts the pressure
and heat energy of steam to kinetic energy and guides the steam into the first stage of
moving blades. Nozzle reduces the possibility of damage of turbine at the sudden change
of during starting time.

4.5. Turbine Protection

To protect the turbine from being damaged several protection schemes are used.
4.5.1. Turbine Pressure and Temperature Control

Turbine operates at a certain pressure. At GPS, two types of pressure are monitored in the
turbine. These are above atmospheric pressure and below atmospheric pressure.
Temperature sensors are located at the main steam path, re-heat line, turbine extraction
lines and on low-pressure turbine exhaust. To determine the steam temperature in the
turbine, thermocouples are used in a steam line. Thermocouples generate electrical signals
and pass it to the control room.
4.5.2. Lube Oil Temperature Control

Lube oil is used for the purpose of cooling and lubrication of turbine and generator
bearing. It acts as a cleaning agent. If lube oil temperature is over 60ºC or under 40ºC, the
sensor passes a signal and the alarm alerts the operator about the situation and allows time
to take proper action. The regulation system does not work if the lube oil temperature is
below 17ºC. So, lube oil temperature is very important to get good performance of the
turbine. Lube oil pipe is shown in figure 4.5.
Figure 4.5: Lube oil pipe of unit-4 at GPS.

4.5.3. Speed Regulation

Before switching off the turbine, it is very important to move the turbine blade slowly for
72 hours to prevent rotor damage. Turbine needs to run slowly to save it from any kind of
massive damage.
4.5.4. Vibration Protection

For machinery equipment, vibration is very harmful. The action of equipment moving
back and forth or from side to side or from up and down per unit time is called the vibration
rate. At GPS, the allowable vibration rate is 1.2 mm/s. Vibration recorders are set to drive
an alarm in the control room when excess vibration high occurred in the turbine. This
alarm alerts the control operator to take proper action during vibration condition. There
are several vibration protection systems that are provided with contacts. During excessive
vibration condition, a solenoid trip is activated by these contacts.

Chapter 5: Generator
5.1. Introduction
Generator converts mechanical energy into electrical energy. There are two types of
generator at GPS. These are 55 MW generators and 210 MW generators. Unit 1 and 2
have 55 MW generators and unit 3,4,5,6 have 210 MW generators. The ratings of 55 MW
and 210 MW unit-4 generators are shown in table 5.1 and table 5.2 respectively.
Table 5.1: Ratings of 55 MW Generator.

Type TB-60-2
Apparent power 68750 KVA
Rated power 55000 KW
Power factor 0.80
Frequency 50 Hz
RPM 3000
Number of Phase 3
Phase connection Y (star)
Rotor voltage 400 V
Rotor current 1445 A
Stator voltage 11.5 KV
Stator current 2761 A

Table 5.2: Ratings of 210 MW Generator.

Type TΓB-200 MT3
Apparent power 247000 KVA
Rated power 210000 KW
Power factor 0.85
Frequency 50 Hz
RPM 3000
Number of phase 3
Phase connection Y (star)
Rotor voltage 430 V
Rotor current 1950 A
Stator voltage 15.75 KV
Stator current 7698 A
Figure 5.1: Generator of unit-4 in GPS.

5.2. Main Components of the Generator

The generator consists of different components. The major components are discussed
below:
5.2.1. Stator
Stator is the stationary part of a generator. The stator converts the rotating magnetic field
to electric current. It has a double layer chain type bar winding (Cu winding) with inner
cooling by water (distillate) circulating through the hollow conductors. A moving
magnetic field which is generated by the rotor induces a voltage difference between the
windings of the stator and it produces alternating current as output of the generator. The
stator of unit-4 generator is shown in figure 5.2.
Figure 5.2: Stator of unit-4 generator in GPS.
5.2.2. Rotor
Rotor is the rotating part of a generator. In GPS generators, rotor is an electromagnet. Coil
energizes the rotor and it becomes electromagnet. The coil that energizes the rotor is
known as field coil. At GPS, the rotor is used as the field exciter. Here the rotor is driven
by the generator prime mover. The rotor of unit-4 generator is shown in figure 5.3.

Figure 5.3: Rotor of unit-4 generator in GPS.
5.2.3. Carbon Brush

Carbon brush remains in contact with the slip ring and provide power to the rotor. For two
slip rings there are two carbon brushes. The combination of slip rings and carbon brush
provide power to the rotor and make the rotor an electromagnet. Graphite or carbon
powder is used for the manufacturing of carbon brush.
5.2.4. Slip Rings

Slip ring allows the transmission of electrical power from a stationary part to a rotating
structure. It is fitted on to rotor shaft. The brush holder gear is fitted on slip-rings. The
rated diameter of the slip rings is 440 mm and the minimum diameter is 425 mm. Slip
rings improve mechanical performance and simplify system operation.
5.2.5. Armature Winding

Armature winding is a part of a stator. It is the main current-carrying winding in which
the electromotive force is induced. Current in the armature winding is called armature
current.

5.3. Excitation System of the Generator

Excitation is the process by which magnetic field is created. All the six units of GPS use
DC excitation system and DC power is used for that. For large generators, high amount
of DC power is needed. For this purpose GPS uses AC power, which is stepped down by
a transformer and then rectified to DC power by bridge rectifier. The DC power is then
delivered to the rotor. This DC current is transmitted to the rotor through slip rings.
5.4. Synchronization System of Generator

In an AC electric power system, synchronization is the process of matching the speed and
frequency of a generator or other source to a running network. This process includes
synchronization of voltage, frequency and phase.
5.4.1. Voltage Synchronization
The magnitude of sinusoidal voltage produced by the generator must be equal to the
magnitude of the sinusoidal voltage of the grid. To obtain this objective all the units at
GPS has constant generating voltage. For example, unit-1 always generate 10.5 KV.
5.4.2. Frequency Synchronization
Bangladesh national grid frequency is normally 50 Hz. To synchronize with the national
grid frequency, the generator rotates at a speed of 3000 rpm.
5.4.3. Phase Synchronization

Phase of the generator must be synchronized with the phase of the grid. If the grid
sequence is R-Y-B then the generator sequence must be also R-Y-B. Generator’s phase
angle and phase sequence have to be synchronized with the gird.
5.5. Generator Protection System

Various types of electrical and mechanical faults can affect the performance of the
generator. To protect the generators from those faults different electrical and mechanical
protections are required.
5.5.1. Over Current / Under Voltage Protection
In a system more than one generators supply the load and if for any reason one or more
generators suddenly trip, other generators try to supply the load. Each of these generators

will experience a sudden increase in current and thus decrease in voltage. At GPS,
automatic voltage regulator is connected to the system which tries to restore the voltage.
Under voltage relay is also used for the under-voltage protection. Over current relay is
used for over current protection [4].
5.5.2. Over Speed Protection

All generators in GPS are prime mover driven generator. Over speed protection is
generally provided for prime mover driven generators. Prime mover is the part that rotates
the rotor. At GPS, steam turbine works as the prime mover. When the prime mover speed
increases the generator’s speed, frequency of the generated voltage also increases. Speed
governor normally controls the speed of the rotor. If any abnormality happens, it trips the
circuit breaker of the generator.
5.5.3. Stator Earth Fault Protection
These types of faults occur when the stator of the generator becomes short with the
ground. Normally, the stator of a generator is close to the ground. Stator earth faults also
happen due to the degradation of insulation in the windings. If this fault occurs, the normal
low neutral voltage will rise as high as line-to-neutral voltage. This fault can be detected
by measuring secondary voltage of neutral grounding transformer.
5.5.4. Rotor Earth Fault Protection
Rotor earth fault may be caused due to insulation failure of rotor winding. Two methods
are available to detect this type of fault. First method is that one resistor is connected to
the field winding and exciter. The resistor is centrally tapped and grounded with a voltage
sensitive relay. If any earth fault occurs, the relay senses and closes the path. In the second
method, one voltage sensitive relay is connected to the field and exciter circuit. Other
terminal of the voltage sensitive relay is grounded. A capacitor and secondary of one
auxiliary transformer is installed between ground and relay. When earth fault occurs, a
secondary voltage will appear across the secondary winding of the auxiliary transformer.
Then relay will be operated by sensing the voltage. At GPS, both of the methods are used.
5.5.5. Frequency Protection

Generator operated with a frequency range. When generator operates over or under this
limit, vibration occurs in the generator which can damage the rotor. It happens because of
sudden load change in the grid. When the frequency falls below 48 Hz or goes over 52 Hz

relay operates.
5.5.6. Temperature Protection
Temperature protection is a protection that protect generator from overheating.
Overheating occurs due to overload in grid system or failure of cooling system. For the
protection of the stator against overheating, embedded resistance temperature detector or
thermocouples are used in GPS. Thermocouple is used to detect the temperature, when it
starts to overheat the temperature change is detected and the relay operates.
5.5.7. Over Voltage Protection
Over voltage fault happen when suddenly load is decreased on the generator. Prime mover
speed does not change with the load change. The over voltage protection is provided by
two over voltage relays. They are instantaneous relay and Inverse Definite Minimum Time
(IDMT) relay. Instantaneous relay operates for 130 to 150% of the rated voltage and
IDMT relay operates for 110% of rated voltage.
5.6. Generator Cooling System

Generator deals with high power so, the temperature of generator rises during running
condition. High heat affects the performance and lifetime of the generator. To reduce the
effect, at GPS there are cooling systems installed for the generator.
5.6.1. Water Cooling
Water flow is used in generator for cooling purpose and it is basically used for stator
cooling. The water circulation happens through the hollow tubes of the stator. Water
absorbs heat and then carries the heat away. Continuous water flow is controlled by a
motor.
5.6.2. Hydrogen Cooling
Hydrogen cooling system is used for rotor cooling. Hydrogen gas is used to dissipate the
heat from the rotor. Hydrogen gas is lighter than air so it does not interrupt with the
rotating speed of the rotor. Hydrogen gas is supplied from a hydrogen plant. Figure 5.4
shows the hydrogen plant of GPS.

Figure 5.4: Hydrogen Cooling System

Chapter 6: Combined Cycle Power Plant
6.1. Introduction
Ghorashal 365 MW combined cycle power plant has started its commercial operation of
supplying electricity to the national grid. The project was one of the 14 mega power
projects undertaken by the government to improve the country’s power supply
situation. The capacity of combined cycle power plant is 365 MW [5]. It is the seventh
unit of Ghorashal power station which is the combination of gas fired gas turbines and
steam turbines. Natural gas is used as fuel for this power plant.
6.2. Sections of Combined Cycle Power Plant

The sections of combined cycle plant are gas turbine, heat recovery steam generator and
steam turbine.
6.2.1. Gas Turbine

At GPS, the gas turbine has a compressor, a combustion chamber and an exhaust module.
Gas turbines require less amount of metal that must withstand the high temperatures and
pressures, and therefore lower quantities of expensive materials can be used [6]. In this
type of cycle, the input temperature of the flue gas, is relatively high (900 to 1,400 °C).
The output temperature of the flue gas is also high (450 to 650 °C).
6.2.1.a. Air Inlet
Air inlet is a device which is used to remove foreign particle from the air. Air contains
many foreign particle and this air is mixed with fuel and produced flue gas which can
damage turbine blades. For reason air is filtered in 3 stage by this device. The optimum
ratio of the air and fuel is 12:1. At GPS, they keep the ratio at 12:1 for better performance.
6.2.1.b. Compressor
A compressor is a mechanical device for increasing the pressure of a gas by mechanically
decreasing its volume. Combined cycle power plant uses natural gas as fuel. The
compressor reduces the volume of the gas. The pressure of the gas increases from 7 bar to
31.5 bar using air compressor. Air compressor is coupled with generator and turbine to

increase the efficiency of the plant. Based on the design there are two types of compressor
at GPS and those are centrifugal and axial flow type compressor.
6.2.1.c. Combustion Chamber
The combustor burns a fuel-air mixture and delivers the products of combustion to the
turbine at temperatures within design range. The filtered air enters the compressor section
which is compressed there and moved to the combustion chamber. In the combustor, fuel
is added to the compressed air and ignited continuously with high pressure. Next, the
continuous high pressure combustion gas is directed into the turbine section where the hot
gas expand through the turbine blades to create torque that provides a portion of the power
to drive the compressor section and to turn the generator to generate electricity. After the
hot gasses exit the turbine they are directed into the exhaust section and the heat recovery
steam generator (HRSG) boiler to produce steam to be used in the steam turbine generator
[7].
6.2.1.d. Exhaust Module
Exhaust gas or flue gas is emitted as a result of the combustion of fuels. From gas turbine
(hot gases) exit via the exhaust section or module. Structurally, this section supports the
power turbine and rear end of the rotor shaft. The exhaust case typically has an inner and
outer housing. It often disperses downwind in a pattern called an exhaust plume.
6.2.2. Heat Recovery Steam Generator
A heat recovery steam generator (HRSG) is an energy recovery heat exchanger that
recovers heat from the hot gas stream. Highly purified water flows inside the tubes of
HRSG and hot gas pass around the tubes. HRSG produces steam that can be used to drive
a steam turbine. The hot gases leave the HRSG at around 140oC and are discharged into
the atmosphere. HRSG at GPS is shown in figure 6.1.

Figure 6.1: Heat Recovery Steam Generator.

6.2.3. Steam Turbine
The generated steam in the HRSG is used to drive steam turbine. Turbine rotor and
generator rotor are coupled together.
6.3. Fuel for CCPP

Combined-cycle power plant uses both gas and steam turbines to produce up to 50%
more electricity from the same fuel than simple-cycle plant. Basically, natural gas is the
main fuel for combined cycle power plant and it is more versatile than coal or oil and can
be used in 90% of energy applications.
6.4. Efficiency of CCPP

Combined cycle power plant ensures the efficient use of fuel and maximum power
generation. Roughly the steam turbine cycle produces one third of the power and gas
turbine cycle produces two thirds of the power output of the CCPP. At GPS, the efficiency
of combined cycle power station was 58% when it was operating new. Simple gas turbine
of GPS have maximum 36% efficiency and steam turbine have 33% efficiency. But while
performing in combined mode the efficiency of gas turbine is increased up to 50%.

Chapter 7: Substation and Control Room
7.1. Introduction
Substations consist of high voltage electrical equipment like transformers, switchgear,
circuit breakers and associated devices. A substation includes transformers to change
voltage levels between high transmission voltages and lower distribution voltages, or at
the interconnection of two different transmission voltages. The purpose of a substation is
to ‘step down’ high voltage electricity from the transmission system to lower voltage
electricity so it can be easily supplied to homes and businesses through our distribution
lines. Between the generating station and consumer, electric power may flow through
several substations at different voltage levels. In Ghorashal Power Station, Unit -1 and
Unit-2 generates electricity at 11.5 KV. Also Unit-3, Unit-4, Unit-5 and Unit-6 generates
at 15.75 KV. The electricity of 11.5 KV is transformed to 132 KV and 15.75 KV to 230
KV by step-up transformer. Here, in Ghorashal different types of equipment in the
substation are used for the protection, transmission and distribution system. Figure 7.1
shows 230 KV and 132 KV single line diagram of GPS substation.
Figure 7.1: 230 KV and 132 KV single line diagram of GPS substation.

Here, in single line diagram we can observe that from generator 2.5 MVA transformer is connected
which supplies power to the generator for excitation. From generator two 125 MVA transformer
is connected which transforms the voltage from 15.75 KV to 230 KV and supply the power to the
1230 KV grid line. There is a 32 MVA reserve transformer which is installed in the substation. It
takes power from the grid and supplies to the auxiliary equipment of the substation at 0.4 KV
voltages when the generator is in off mode. The auto transformer is installed between 230 KV grid
line and 132 KV grid line. This transformer supplies power to one grid line from another when
there is excess power in other grid line. Figure 7.2 shows the substation of GPS.
Figure 7.2: Substation of GPS
7.2. Major Components of Substation at GPS
7.2.1. Bus Bar

A bus bar is a strip of metal used to conduct electricity within an electrical
substation, distribution board, electric switchboard or other electrical equipment. Bus
bars distribute electricity with greater ease and flexibility than some other more permanent
forms of installation and distribution. They are also used to connect high voltage

equipment at electrical switchyards, and low voltage equipment in battery banks.

Ghorashal Power Station has 132 KV and 230 KV bus bars.
Ghorashal Power Station has two types of bus bar arrangements. One is single bus bar
arrangement and another is double bus bar arrangement. Single bus bar arrangement is a
simplest form of arrangement of bus-bar as each generator and feeder is controlled by a
circuit breaker. Here all the incoming and outgoing lines are connected to it. The
arrangement of 11 KV is single bus bar arrangement. It is a simple operation. It has low
cost and low maintenance. Double bus bar arrangement requires two bus bars and two
circuit breakers. It does not require any additional equipment like bus coupler and switch.
In Ghorashal, there are two identical bus bars connected in such a way that any incoming
and outgoing line can be taken from any of these two identical bus. These lines are
connected in parallel.
7.2.2. Circuit Breaker

A circuit breaker is an electrical device which works as a switch and operates
automatically when any abnormality is found in voltage and current flow. It is a protective
device. It protects the whole electrical system from abnormal condition like overload,
short circuit etc. If any abnormality occurs, the circuit breaker automatically disconnects
the circuit from the system. There are three types of circuit breakers at GPS.
7.2.2.a. Oil Circuit Breaker

Oil circuit breaker is a kind of circuit breaker which uses oil as a dielectric or insulating
medium for arc extinction. In oil circuit breaker the contacts of the breaker are made to
separate within an insulating oil. When the fault occurs in the system the contacts of the
circuit breaker are open under the insulating oil, and an arc is developed between them
and this arc is quenched by oil vaporization [8]. GPS has some oil circuit breakers.
7.2.2.b. Air Blast Circuit Breaker

Air blast circuit breaker uses compressed air or gas as the arc interrupting medium. In the
air blast, circuit breaker compressed air is stored in a tank and released through a nozzle
to produce a high-velocity jet; this is used to extinguish the arc. When arc creates for
sudden break of circuit, high pressure air flows to the arc between fixed contacts and the

moving contacts to cool down the arc. The operation is safe and has low maintenance cost.
Figure 7.3 shows air blast circuit breaker.
Figure 7.3: Air Blast Circuit Breaker
7.2.2.c. SF6 Circuit Breaker

In Sulpher Hexafluoride or SF6 circuit breaker, Sulpher Hexafluoride (SF6) gas is used as
an insulating and arc quenching medium. SF6 gas has many superior properties which
make it perfect for arc quenching. SF6 circuit breaker is most popular and widely used
breaker because it has lower operating noise and no emission of hot gases, and relatively
low maintenance. In Ghorashal, the weight of the SF6 gas is 26 kg and the total weight of
the device is 3530 Kg. The temperature range of the SF6 circuit breaker is - 25°C to +55°C.
The SF6 circuit breakers in GPS are made by Siemens, Germany. Figure 7.4 shows SF6
circuit breaker.

Figure 7.4: SF6 Circuit Breaker
7.2.3. Isolator
Isolator is a manually operated mechanical switch which separates a part of the electrical
system. Isolators are used to open a circuit under no load. Its main purpose is to isolate
one portion of the circuit from the other and is not intended to be opened while current is
flowing in the line. Isolators are generally used on both ends of the breaker so that repair
or replacement of circuit breaker can be done without and danger. If isolator opens under
on load condition then arc creates and it could be harmful for the system and the things
near the isolator.
7.2.4. Bus Coupler

Bus coupler is a device which is used to couple one bus to the other without any
interruption in power supply and without creating hazardous arcs. Bus coupler is a breaker

used to couple two bus bars in order to perform maintenance on other circuit breakers
associated with that bus bar. The system can get electricity from other bus through bus
coupler.
7.2.5. Lightning Arrester

Lighting arrester is used for the protection of the equipment at the substations against
travelling waves. It protects the equipment of Ghorashal Sub Station from the lighting
surge. When a travelling wave reaches the arrester it sparks over at a certain prefixed
voltage. The arrester provides a conducting path to the waves of relatively low impedance
between the line and the ground. Lightning occurs when clouds are highly charged with
respect to ground. It has a high voltage terminal and a ground terminal. There are various
types of lightning arrester. In Ghorashal, polymer metal oxide and zinc oxide arresters are
mainly used. Figure 7.5 shows lightning arrester.
Figure 7.5: Lightning Arrester

7.2.6. Earthing Switch

Earthing switches are safety devices which are integral parts of circuit breakers. When a
circuit breaker is removed and racked out, the sections of the bus bar adjacent to the circuit
breaker are automatically earthed by means of these switches. It is very important for sub-
station as it is a switch between the line conductor and earth. This switch is normally
open. Earthing switch is used to earth the live parts during maintenance and during testing.
During maintenance although circuit is open still there are some voltages on line, due to
which capacitance between line and earth is charged. Before maintenance of that
equipment the charge need to be neutralized. Earthing switch discharges the trapped
charge to earth and keep the equipment safe for human.
7.2.7. Transformer
Transformer is a device that transfers electric energy from one alternating-current circuit
to one or more other circuits, either increasing (stepping up) or reducing (stepping down)
the voltage. Ghorashal has various transformers namely power transformer, auxiliary
transformer, coupling transformer and instrument transformer such as current transformer
and potential transformer. Power transformer, auxiliary transformer and coupling
transformer are used to step up or step down the voltage. Current transformer and potential
transformer are used for measuring and protection purpose. Figure 7.6 shows transformer.
Figure 7.6: Transformer of GPS

7.2.7.a. Power Transformer

The power transformer of the substation in GPS is used to step-up the voltage. Unit 1 and
2 generate 11.5 KV which is transformed by step-up power transformer to 132 KV and
supplies to the national grid. Figure 7.7 shows power transformer.
Figure 7.7: Power transformer of GPS
7.2.7.b. Auxiliary Transformer
Auxiliary transformer is used to provide power to the auxiliary equipment of a power

station. This transformer is directly connected to the generator output. It is a three-winding
transformer. It has one primary and two separate secondary windings. Primary winding
takes voltage according to the generator voltage rating. The voltage of the secondary
windings is generally 11 KV or 6.6 KV. It uniquely sends the trip current to portions of
the ground fault protection circuits. Table 7.1 shows the ratings of an auxiliary
transformer.

Table 7.1: Ratings of an Auxiliary Transformer.

Year of Manufacture 1985
Serial No. P84-6914
Type of Cooling ONAN/ONAF
Volts 33000/6900
Insulation Level – HV 170 KV
Insulation Level – LV 60 KV
Frequency 50 Hz
Winding Temperature Rise 55ᵒC
Oil Temperature Rise 50ᵒC
Ambient Temperature 45ᵒC
Total Weight 38800 Kg
Insulating Oil Weight 5000 Kg
7.2.7.c. Coupling Transformer

The coupling transformer is the power transformer that exchange power between two
different voltage level buses. GPS uses the coupling transformer between 33 KV bus and
132 KV bus. Table 7.2 shows the ratings of coupling transformer.

Table 7.2: Ratings of Coupling Transformer.

Serial No. 152810
No. of the Specification IEC 76
No. of Phase 3
Type of Cooling ONAN/ONAF
Rated Frequency 50 Hz
Rated Power 100/150 MVA
Rated Voltage – Primary 240000 V
Rated Voltage – Secondary 140000 V
Rated Current – Primary 240/360 A
Rated Current – Secondary 412/618 A
Temperature Rise of Oil 50ᵒC
Temperature Rise of Winding 55ᵒC
Ambient Temperature 45ᵒC
Conductor Material Copper
Total Mass 220000 Kg
7.2.7.d. Instrument Transformer

Basic function of instrument transformers is to step down the AC System voltage and
current. Instrument transformers are used in AC system for measurement of electrical
quantities i.e. voltage, current, power, energy, power factor, frequency. Instrument
transformers are also used with protective relays for protection of power system.
Instrument transformers are high accuracy class electrical devices used to isolate or

transform voltage or current levels. The most common usage of instrument transformers
is to operate instruments from high voltage or high current circuits, safely isolating
secondary control circuitry from the high voltages or currents. The current transformer
and potential transformer are known as instrument transformer. All the current
transformers and the potential transformers of GPS are single phase transformer.
7.2.7.e. Current Transformer

A current transformer has a primary winding, a core and a secondary winding, although
some transformers, including current transformers, use an air core. The primary winding
of the transformer is connected to the high voltage or high current circuit, and the meter
or relay is connected to the secondary circuit. Ghorashal Power Station uses current
transformer with 132 KV bus system and 230 KV bus system. Table 7.3 is showing ratings
of current transformer. Figure 7.8 shows current transformer.
Figure 7.8: Current Transformer.

Table 7.3: Ratings of 230 KV Current Transformers.

Type IMB 245
Highest System Voltage 245 KV
Rated Primary Normal Current 2000 A
Class of Insulation A
Weight of Oil 270 Kg
Total Weight 1700Kg
7.2.7.f. Potential Transformer

Potential transformer or voltage transformer is used in electrical power system for
stepping down the system voltage to a safe value which can be fed to low ratings meters
and relays. It is used to transform voltage from higher to lower value. Potential
transformer is connected in parallel with the system. There are 132 KV and 230 KV
potential transformers used in Ghorashal. Figure 7.9 shows potential transformer and table
7.4 shows the ratings of 230 KV potential transformers.
Figure 7.9: Potential Transformer.

Table 7.4: Ratings of 230 KV Potential Transformers.

Type WP 245N2
Highest System Voltage 245 KV
Rated Insulation Level 245/460/1050 KV
Rated Voltage 230/3 KV
Total Nominal 6125 mm
Rated Secondary Voltage 110/3 V
Class of Insulation A
Weight of Oil 140 Kg
Total Weight 750 Kg
7.3. Transformer Protection

Transformers are very expensive equipment. This should be used very carefully. The cost
of repair or replace is high. So it is very important to protect the transformer from any
fault that could damage it. The protective devices of a transformer are mainly of two types.
They are mechanical protection and electrical protection. Mechanical protection is used
to protect the transformer physically and electrical protection is used to protect the
transformer from any electrical fault [9].
7.3.1. Earth Fault Protection

A ground fault is an inadvertent contact between an energized conductor and ground or
equipment frame. The return path of the fault current is through the grounding system and
any personnel or equipment that becomes part of that system. Ground faults are frequently
the result of insulation breakdown. To protect the transformer from this fault, IDMT
(Inverse Define Minimum Time) relay is used. When the earth fault happens, a huge
amount of current passes through the coil and magnetic effect is created.

7.3.2. Differential Relay Protection

The differential relay is used to compare primary current and secondary current of power
transformer and if any fault is found, the relay trips both the primary and secondary circuit
breaker of the transformer.
7.3.3. Buchholz Relay Protection

Buchholz relay is a safety device which is generally used in large oil immersed
transformers. It is a type of oil and gas actuated protection relay. It is used for the
protection of a transformer from the faults occurring inside the transformer, such as
impulse breakdown of the insulating oil, insulation failure of turns etc. The Buchholz relay
is connected between the top of the transformer main tank and the conservator. It operates
in two stages. The first stage is to send an alarm and the second stage is to trip the circuit
breaker.
7.3.4. Distance Relay Protection

Distance relay protection is the most common on high voltage transmission systems.
There is one voltage element from potential transformer and a current element fed from
current transformer of the system. The deflecting torque is produced by secondary current
of CT and restoring torque is produced by secondary voltage of potential transformer.
When the ratio of voltage and current becomes less than its predetermined value then the
distance relay operates. Another name of this relay is impedance relay.
7.4. Cooling System

There are some cooling systems employed for the cooling ofthe transformer’s oil. They
are-
• Oil Natural Air Natural(ONAN)
• Oil Natural Air Forced(ONAF)
• Oil Forced Air Forced(OFAF)
• Oil Forced Water Forced (OFWF)
At GPS, oil natural air forced (ONAF) cooling system is used for transformer oil cooling.
By applying forced air, it removes the heat of the radiator’s surface and gives better
cooling than natural.

7.5. Silica Gel Breather

The natural air has moisture in it and if this air goes into the transformer then the moisture
of the air will be mixed up with oil and it is dangerous. Silica gel breather is used for
filtering air from moisture. Silica gel breather for transformer is connected with the
conservator tank by means of breathing pipe. It is nothing but a pot of silica gel through
which, air passes during the breathing of transformer. The silica gel is a very good
absorber of moisture. Freshly regenerated gel is very efficient. Figure 7.10 shows silica
gel breather of GPS.
Figure 7.10: Silica gel breather of GPS.
7.6. Control Room of Steam Turbine Power Plant

There are three control rooms of Ghorashal Power Station and each has three different
sections. The sections are Boiler desk, Turbine desk and Generator desk. Unit 1 and 2 are
operated by the control room 1. Unit 3 and 4 are operated by the control room 2 and unit
5 and 6 are operated by the control room 3. Figure 7.11 shows control room of steam
turbine power plant.

Figure 7.11: Control room of steam turbine power plant
7.6.1. Control room of Unit-1 and Unit-2

This control room is the oldest one for the Ghorashal Power Station. The control systems
of these two units are analog and the operation is manual. Always 5-6 engineers are
actively observing the control room and controlling the operations. They control all the
auxiliaries such as boiler, condenser, burner, feed water pump, low pressure and high
pressure heater, generator synchronization etc.
7.6.2. Control room of Unit 3, 4, 5 and 6

These four units are operated manually too. Ghorashal Power Station uses both analog
and digital meters for measuring data. Unit-3 and Unit-4 are controlled by a control room.
But, Unit-5 and Unit-6 are controlled by a different control room. Every control room is
divided into two parts for each of the 2 units. These two control rooms each have three
parts such as Boiler Desk, Turbine Desk and Generator Desk. The operation is as same as
control room-1.
7.7. Control Room of Combined Cycle Power Plant

There is only a single control room for the combined cycle power plant that operates 7th
Unit of Ghorashal Power station. It uses digital meters for measuring data. It is operated

manually. There are six monitors in the control room that are observing boiler desk,
turbine desk and generator desk. This control room is monitoring and controlling all the
auxiliaries of gas turbine and steam turbine like compressor, HRSG, exhaust, fuel,
efficiency etc.

Chapter 8: Conclusion
8.1. Introduction
We were taught about the theories and working principles of power system and related
equipment in the EEE courses, but from internship we acquired practical knowledge about
power system engineering and its equipment. Here, we always tried to relate academic
courses through practical participation of power generation process. Besides we also
encountered some practical problems which were not taught in my academic courses. Our
communication skill also improved through communication with different instructor. We
got familiar with industry experience, which will help us to pursue career in this field.
8.2. Problems
After completing the internship at GPS, we faced some problems.
• Our internship duration was only for 15 days in GPS which is not enough for learning
thoroughly about power plants.
• There was a huge crisis of water leakage and for that reason unit 4 was shut down
later.
• All the machines and equipment were in operational mode, so it was risky to learn
about all the equipment.
• The safety equipment were not available in GPS such as earplug headphone, helmet
for the internship students.
8.3. Recommendations
After completing internship we would like to recommend some things which may be
useful for future intern students.
• Students should complete power station, switchgear & protective relays related
courses to understand better in internship.
• If the duration of the internship can be increased then the student will learn more.
• Everyone should know the precautions of a power station.
• The safety equipment should be provided by the authority and students should use
this.

References
[1] “Company Profile” online available:
https://ghorashalpowerstation.wordpress.com/category/technology/
[Accessed: 16-June-2016].
[2] V.K. Mehta and Rohit Mehta, “Principle of Power System”, 4th edition,
New delhi, S. Chand and company limited, 2014.
[3] Nag. P . K.; “Power plant Engineering”, Tata McGraw-Hill Education Pvt.
Ltd, New Delhi, 4th Edition, 2014.
[4] “Overvoltage protection” online available:
http://www.eng.uwo.ca/people/tsidhu/Documents/Microsoft %20Word%20-
[5] “Combined cycle power plant” online available:
http://www.bpdb.gov.bd/bpdb/index.php?option=com_content&view=article&id=169&did=3
86&Itemid= 64&location=1
[6] “GAS TURBINES IN SIMPLE CYCLE” online available:
https://www.netl.doe.gov/File%20Library/Research/Coal/energy%20systems/turbines/h
andbook/1-1.pdf
[7] “Combined cycle gas and steam plants” online available:
http://opac.vimaru.edu.vn/edata/EBook/Combined%20cycle%20gas%20steam%20turbi
ne%20power%20plants.pdf
[8] Sunil S. Rao, “Oil Circuit Breaker” in Switchgear Protection and Power System,
13th ed. New Delhi, India: Khanna Publishers, 2008, pp. 89-92.
[9] https://www.electrical4u.com/transformer-protection-and-transformer-fault/

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Undergraduate Internship

Abdul Aziz (2014-1-80-055)

In partial fulfilment of the requirements for the degree of Bachelor Science in

Academic Advisor Department Chairperson

Dr. Halima Begum Dr. Mohammad Mojammel Al Hakim

Department of Electrical and Electronic Engineering, East West University Page 1

Department of Electrical and Electronic Engineering, East West University Page i

Department of Electrical and Electronic Engineering, East West University Page ii

---------------------------- -------------------------- --------------------------

Department of Electrical and Electronic Engineering, East West University Page iv

Department of Electrical and Electronic Engineering, East West University Page v

Department of Electrical and Electronic Engineering, East West University Page vi

Date Subjects Time Mentor

Engr. Abdullah Bin Aziz

CCPP, Their flow diagram and Engr. Md. Sultan Salahuddin

condition, generation, grid Engr. Md. Delower Hossain

Transmitter, controller, control Engr. Dilip Kumer Biswas

HFO plant and impact of IPP.

Basic principle of DCS and Engr. Kh. Mokammel Hossain

Department of Electrical and Electronic Engineering, East West University Page ix

Discussion on power plant

Department of Electrical and Electronic Engineering, East West University Page x

AUTHORIZATION LETTER ................................................................................................... iv

APPROVAL LETTER ................................................................................................................ v

EXECUTIVE SUMMARY ........................................................................................................ vii

TRAINING SCHEDULE .......................................................................................................... viii

Table of Contents ......................................................................................................................... xi

List of Figures ........................................................................................................................... xviii

List of Tables ............................................................................................................................... xx

Chapter 1: Introduction ............................................................................................................... 1

1.1 Introduction ............................................................................................................................. 1

1.1.1. Objective of the Internship .............................................................................................. 1

1.1.2. Company Profile ............................................................................................................. 1

1.1.3. Vision & Mission of GPS ................................................................................................ 3

1.1.4. Production Capacity ........................................................................................................ 4

1.1.5. Future Plan ...................................................................................................................... 5

1.1.6.Scope and Methodology................................................................................................... 5

Chapter 2: Water Treatment Plant & Cooling System ............................................................. 6

2.1. Introduction ............................................................................................................................ 6

2.2. Water Treatment Procedure ................................................................................................. 7

Department of Electrical and Electronic Engineering, East West University Page xi

2.2.1. Clarification ..................................................................................................................... 7

2.3. Cooling System........................................................................................................................ 8

2.3.1. Hydrogen Cooling .......................................................................................................... 9

2.3.2. Water Cooling .................................................................................................................. 9

2.3.3. Lube Oil Cooling ............................................................................................................. 9

Chapter 3: Steam Generating Plant .......................................................................................... 10

3.1. Boiler ............................................................................................................................................ 10

3.1.1. Boiler Specification ....................................................................................................... 11

3.2. Different Types of Boiler Equipment ................................................................................. 11

3.2.1. Boiler Drum ................................................................................................................... 11

3.2.2. Furnace ........................................................................................................................... 12

3.2.3. Burner .................................................................................................................................. 12

3.2.4. Super Heater ....................................................................................................................... 13

3.2.5. Economizer ................................................................................................................... 13

3.2.6. Deaerator ....................................................................................................................... 13

3.2.7. Chimney ........................................................................................................................ 13

3.2.8. Condenser ..................................................................................................................... 14

3.2.9. Safety Valve .................................................................................................................. 15