INDUSTRIAL TRAINING

For final year diploma students

(C-21 curriculum)

REPORT

NAME OF THE ORGANIZATION

SRRS GOVT POLYTECHNIC

NAME & PIN OF THE STUDENT

G.SAIKRISHNA

&

21024-EE-078

Department of Electrical and Electronics Engineering

SRRS GOVERNMENT POLYTECHNIC

SIRCILLA
 2X600 MW SINGARENI THERMAL POWER PLANT
Jaipur (v&m), Mancherial, (Dist), Telangana- 504216
INDUSTRIAL TRAINING REPORT

SUBMITTED BY
G.SAIKRISHNA
(Industrial Trainee, DEEE)
Training Duration
(21.12.2023 to 15.06.2024)
Under The Guidance
Of
Sri K.SANTHOSH KUMAR
DGM (Operations-Electrical)
STPP, SCCL
 ACKNOWLEDGEMENT
Training has an important role in exposing the real life situation in an industry.
It was a great experience for me to work on training at (2×600 MW) SINGARENI
THERMAL POWER PLANT, JAIPUR Through which I learn how to work in a
professional environment.

Now, I would like to thank industrial training Incharge Sri K.SANTHOSH KUMAR
(DGM(O/M) of SINGARENI THERMAL POWER PLANT for his guidance during the
industrial training

And I also like to thank the people who guided me and have been a constant
source of inspiration throughout the tenure of my training and other faculty
members whose guidance and encouragement made my training successful.
ABSTRACT

Thermal power plants play a crucial role in global energy production,

utilizing fossil fuels or renewable sources to generate electricity. This
abstract provides an overview of the key components and operations
of thermal power plants, focusing on their efficiency and
environmental impact. It discusses the combustion process, steam
generation, turbine operation, and electricity generation.
Additionally, it highlights measures for improving efficiency and
reducing emissions, such as advanced technologies and renewable
energy integration. Understanding the principles and challenges of
thermal power plants is essential for addressing energy demands
while mitigating environmental impacts. As the part of case study we
are going to visit (2×600MW) SINGARENI THERMAL POWER PLANT,
JAIPUR.
SINGARENI THERMAL POWER PLANT
2×600MW
JAIPUR
M/S STPP HAS SET UP STAGE-1(2×600) MW COAL BASED THERMAL
POWER PLANT AT PEGADAPALLI VILLAGE, MANCHERIAL, TELANGANA
STATE .

COMMERCIAL OPERATION (COD) DATES:

UNIT 1 - 25.09.2016

UNIT 2 - 02.12.2016

• 10 MW Ground mounted solar plant -10.02.2020

• 5 MW –floating solar project -22.01.2023
• 10 MW – Floating solar power plant is under
Execution.

FGD (Flue Gas Desulphurization) system for stage-1

(2×600 MW) is under Execution.

Proposed to set up stage -2 (1×800 MW)

 PROJECT DETAILS : 2×600 MW

• Location : Near Pegadapally village, jaipur mandal,

Mancherial Dist , Telangana

• Distance from nearest town : Mancherial 14.6 KM

• Site elevation : 144 meter above MSL

• Land : stage-1 -300 Ha Stage-2- 127 Ha

• S Source of water -2 TMC : Pranahita River near Devulawada

Village

1 TMC : Godavari River at shetpalli village

 PROJECT DETAILS: 2×600 MW

• Cooling System : Closed cycle with IDCT

• Primary Fuel : Coal

• Fuel requirement : 4.784 MMTPA of G10 grade

coal at 85% PLF
• Project cost : Stage -1 (2×600 MW) Rs. 8584
Cr.

• BTG Package by : M/S BHEL

• BOP Package by : M/S MBE

• Technical Consultancy : M/S NTPC

❖ Why power is required?

Power is required to do work in a particular amount of

time.

❖ Why Electrical power is required?

Electrical power can be delivered over long distances

by transmission lines and used for various applications by
converting it to other forms of energy like light, heat, sound ,
wave , mechanical energy with high efficiency.
 CLASSIFICATION OF POWER PLANTS

▪ Conventional (non-renewable)
▪ sources of energy

❖ Thermal power plant

❖ Nuclear(Atomic) power plant

❖ Hydro electric power plant

 Non-conventional(renewable)
 Sources of energy

 Solar power plant

 Wind power Plant

 Wave power plant

 Tidal power plant

 Geothermal power plant

 Bio-mass power plant

Selection of Site for Thermal Power Plants (Coal)

➢ Availability of Coal

➢ Availability of land and its nature

➢ Ash Disposal Facility

➢ Transport Facilities

➢ Availability of a Labour

➢ Public problems
 TOPICS PAGE NO

Introduction 1

Working principle 2

Process of thermal power 3-5

plant
Boiler 6-15

Turbine 16-23

Switch gear 24-29

Switch yard (400 kv) 30-50

Fuel oil pump house 51-60

Raw water pump house 61-65

CW Pump & Induced draft 66-74

cooling tower (IDCT)
DM Plant 75-92

Coal handling plant 93-97

Ash handling plant 98-115

Electrical Maintenance 116-118

Department
 INTRODUCTION

• Singareni thermal power plant existing 1200 MW coal-Fired power

station owned by Singareni collieries company

• The power station is located village in mancherial district of Telangana,

India

❖ Singareni thermal power plant in Telangana came into existing in the year
2016.

• Coal is supplied from SRP, indaram, coal mines, srirampur, Telangana.

• Cool is used primary main fuel for generation of electricity. However

light diesel oil ( LDO) Heavy fuel oil(HFO) is used in power as
supplementary fuel under emergency conditions.

• The equipments are supplied by BHEL, Bhopal.

• They are total two units in STPP, capacity of 600 MW each.

• The ultimate aim to convert chemical energy of coal or oil to "electrical

energy"

• In India thermal power plant generates 75.43% of total power generation.

 WORKING PRINCIPLE

✓ Firstly the water is taken into the boiler from a water source. the boiler
is heated with the help of coal.

✓ The increase in temperature helps in the transformation of water into

steam. The steam generated in the boiler is sent through a steam
turbine.

✓ The turbine has blades the rotate when high velocity steam flows across
them. This rotation of turbine blades is used to generate electricity.

✓ Generator is connected to the steam turbine when the turbine turns,

electricity generated and given as output by the generator which is then
supplied to the consumers through High- voltage power lines
 BOILER

In a thermal power plant, a boiler is a crucial component that

converts water into steam by utilizing the heat generated from
burning fossil fuels such as coal, natural gas, or oil. The steam
produced in the boiler is then used to drive turbines, which in turn
generate electricity. Boilers typically consist of a furnace where the
fuel is burned, tubes or pipes where water is heated to produce steam,
and various controls and safety mechanisms to regulate the process.
The efficiency and performance of the boiler greatly impact the overall
efficiency and output of the power plant.
Boiler or the steam generator is the main part in the power generation
process. At STPP the type of boiler is “TOP SUPPORTED FUSSION
WELDED WATER WALL PANELS CONTROLLED CIRCULATION
TANGENTIONAL FIRING BOILER “. The water is converted into steam
by using the heat released in the process of combustion of coal in the
presence of oxygen.

Auxillaries:
The various parts of the boiler are as follows:

1) Economizer

2) Boiler drumb

3) Water tubes.

4) Headers

5) Super heaters

6) Reheaters

7) Air-Preheater

8) Draught system
FURNACE:
The furnace takes coal from the coal mills, oil from oil guns,
and air from FD Fans respectively for the process of the
combustion. The furnace has four walls. The wind boxes which
allow oil into the furnace, coal inlets, oil guns are all arranged
at the four corners of the wall of the furnace. There are igniters
which are at the corner ignite oil and air mixer by producing
high voltage spark. Fire from four corners is tangential to the
fire walls.

BOILER DRUM:-
It is the main part of the boiler, in which steam and water
separates.
In the Boiler water circulates from the drum into un-heated
down comer pipes, then from the down comer pipes into
heated furnace water wall tubes and then back into the drum
with the use of steam generating water circulating pumps
(SGWCP)
Boiler Drumb
REHEATER:-
The function of the re-heater is to increase the temperature
of the steam leaving HPT again to 540 ⁰C then the pressure
up to 42 kg/ sq cm. The re-heater steam temperature is
achieved by gaining the heat from the waste flue gases
leaving the boiler. The flue gas flow is split into two paths
respectively for heat in the super heater and the re-heater.
Then the steam goes to the Intermediate Pressure Turbine
(IPT).

ECONOMISER:-
The economizer consists of the feed water through which
the heat recovery takes place in the furnace. The steam and
water produced in the economizer are feed into the boiler
drum. It is located below the LPSH in the boiler and above
pre heater. It is there to improve the efficiency of boiler by
extracting heat from flue gases to heat water and send it to
boiler drum.
AIR PRE-HEATER:
Each 600 MW boiler is provided with Tri-sector re-
generative air pre-heater which heats the air by using the heat
of the exit flue gases. Each Air pre-heater can meet maximum
continuous rating (MCR) of the steam generator.
The heating elements (Baskets) are of specially made metal
plates and arranged compactly in three layers. The housing
surrounding the rotor is provided with duct connection both
ends for air and gas. It adequately sealed by radial, axial,
circumferential sealing members which form passages for air
and flue gas. The rotor supported by Thrust bearings at the
top. Separate oil reservoir and level indicator are provided for
each bearing. As the rotor slowly rotates, the heating
elements (baskets) alternatively pass through the gas and air
passages. Heat from the hot flue gases absorbed by the basket
while passing through the gas passage and carried over to the
air passage, thus transferring the heat to the air steam.
BUNKERS
✓ In a thermal power plant, bunkers are storage facilities
used to store coal before it is fed into the pulverizers for
grinding. They serve as reservoirs to ensure a steady
supply of coal to the boiler furnace, helping to maintain a
consistent and reliable operation of the power plant.
Bunkers also act as a buffer, allowing the power plant to
handle fluctuations in coal supply and demand more
effectively.
MILLS
✓ The mills in a thermal power plant are responsible for
grinding coal into a fine powder, which is then blown into
the boiler furnace for combustion. These mills crush the
coal into small particles, increasing its surface area and
facilitating efficient combustion. Properly ground coal
ensures a more uniform and controlled combustion
process, leading to higher efficiency and lower emissions
in the power plant.
• Primary air fan:- To supplying air to the pulverizers, where
coal is crushed into a fine powder before being blown into
the furnace. It helps in maintaining the proper air-fuel ratio
for efficient combustion in the boiler.
• Induced draft fan:- It helps to create a negative pressure or
suction inside the furnace, which draws the combustion
gases (flue gases) from the furnace through the boiler and
out of the chimney. This fan plays a crucial role in
maintaining proper combustion and ensuring efficient heat
transfer within the boiler system.
• Forced draft fan:- To supplying air to the boiler furnace
under pressure. It helps to ensure proper combustion by
delivering a controlled amount of air to the furnace, which
is essential for efficient burning of the fuel (typically coal)
and maintaining optimal operating conditions within the
boiler system.

• Seal fan:- To maintain a positive pressure inside the boiler

furnace. It helps prevent the ingress of air from the
atmosphere into the furnace, which could disrupt
combustion and decrease efficiency. The seal fan also helps
to maintain a proper seal around various openings and joints
in the boiler system, ensuring safe and efficient operation
 TURBINE
Turbine: The high-pressure steam produced is directed into a
turbine. Turbines are typically large, rotating machines with
blades attached to a shaft. The high-pressure steam enters the
turbine and causes the blades to rotate.
Mechanical Energy Conversion: As the steam flows over the
blades, its high pressure and temperature cause the blades to
spin. This spinning motion is converted into mechanical
energy.
Generator: The shaft connected to the turbine is also
connected to a generator. As the turbine spins, it rotates
magnets inside the generator, producing electricity through
electromagnetic induction.
Electricity Generation: The electricity generated by the
generator is then sent to power distribution systems, where it
can be transmitted over long distances and distributed to
homes, businesses, and industries.
Steam Expansion: After passing through the turbine, the
steam loses pressure and temperature. It is then condensed
back into water using cooling water in a condenser, and
the cycle repeats.
Construction&Auxillaries
High pressure turbine:- High-pressure (HP) turbine in a thermal
power plant, particularly one rated at 180 megawatts, is to convert
the high-pressure steam energy generated in the boiler into
mechanical energy. This mechanical energy drives the turbine
rotor, which is connected to the generator, thereby producing
electrical power. The HP turbine extracts energy from the steam at
higher pressures and temperatures, contributing to the overall
efficiency and power output of the plant.

Intermediate-pressure (IP) turbine:- An intermediate-pressure

(IP) turbine, particularly one rated at 206 megawatts, in a thermal
power plant is to extract energy from the intermediate-pressure
steam produced in the boiler. This turbine is positioned between
the high-pressure (HP) turbine and the low-pressure (LP) turbine in
the turbine cycle. Its function is to further expand the steam to
extract additional energy before it enters the low-pressure turbine.
This allows for efficient utilization of the available energy in the
steam and contributes to the overall power generation capacity of
the plant.
Low-pressure(LP)turbine(1) :- It particularly one rated at 112
megawatts (MW), in a thermal power plant is to extract energy from
the low-pressure steam produced in the boiler. LP turbine 1 further
expands the steam and converts its energy into mechanical energy,
which is then used to drive the generator and produce electricity. This
turbine is part of the overall turbine cycle and contributes to the
efficient generation of power in the plant by utilizing the remaining
energy in the steam after it has passed through the high-pressure and
intermediate-pressure turbines.

Low-pressure(LP)turbine(2):- The second low-pressure (LP) turbine,

also rated at 112 megawatts (MW), in a thermal power plant is similar
to that of LP turbine 1. LP turbine 2 further extracts energy from the
low-pressure steam that has already passed through LP turbine 1. By
expanding the steam further, LP turbine 2 converts more of its energy
into mechanical energy, which drives the generator to produce
additional electricity. This turbine helps maximize the overall
efficiency of the power plant by fully utilizing the energy content of
the steam before it is condensed and returned to the boiler for
reheating.
Generator:- Generator rated at 600 megawatts (MW) in a thermal
power plant is to convert mechanical energy into electrical energy. In
the context of a thermal power plant, the generator is driven by the
turbine, which is typically powered by steam produced in the boiler.
As the turbine rotates, it turns the generator rotor, which is
surrounded by a magnetic field. This interaction between the rotating
rotor and the stationary magnetic field induces an electrical current in
the generator windings, producing electricity. The 600 MW generator
in this case signifies its capacity to produce electrical power, making it
a significant component in the power generation process of the plant.

Exciter:- The purpose of an exciter in a thermal power plant is to

provide the initial magnetic field necessary for the generator to start
producing electricity. The exciter is a small generator connected to the
main generator shaft, and it generates a small amount of electrical
power to energize the magnetic field coils in the stator of the main
generator. Once the main generator reaches a sufficient speed and
voltage, it becomes self-sustaining and can continue generating
electricity without the need for the exciter. Essentially, the exciter
jump-starts the generation process in the main generator, ensuring a
smooth and reliable startup of the power plant.
Condenser:- The condenser plays a crucial role in the Rankine cycle
by condensing the steam exiting the turbine into water. This
condensation allows the steam to release its latent heat,
converting it back into high-pressure liquid water, which can then
be pumped back into the boiler to be reheated, completing the
cycle.

Hot well:- The hot well in a condenser of a thermal power plant

collects hot condensed water for reuse in the boiler, optimizing
water usage and plant efficiency.
Condensate extraction pump:- The condensate extraction pump in a
thermal power plant is responsible for pumping the condensed water
from the condenser's hot well back into the boiler for reheating,
ensuring continuous operation of the steam cycle and maximizing
energy efficiency.

Gland steam cooler:- The gland steam cooler in a thermal power plant
is designed to cool the steam that is used to seal the turbine shaft
glands. By cooling the gland steam, it condenses any remaining
moisture and prevents it from entering the turbine, ensuring efficient
turbine operation and minimizing wear on turbine components.

Drain cooler:- The drain cooler in a thermal power plant serves to cool
the condensate drains from various components, such as the
condenser and turbine gland seals. By cooling the condensate, it helps
maintain optimal temperature levels and prevents thermal shock
when the condensate is returned to the boiler for reheating, ensuring
efficient and stable operation of the power plant.

Low pressure heater:- Low-pressure heaters in a thermal power plant

serve to preheat the feedwater using the extracted steam from
various stages of the turbine. This preheating helps improve the
efficiency of the power plant by utilizing the heat energy from the
steam that would otherwise be wasted. Additionally, preheating the
feedwater reduces the amount of fuel needed to reach the desired
steam conditions in the boiler, thus lowering operating costs and
improving overall plant performance.
Deareator:- To remove dissolved gases, such as oxygen and carbon dioxide, from
the feedwater before it enters the boiler. This is crucial because dissolved gases
can cause corrosion and damage to boiler components. By removing these
gases, the deaerator helps prevent corrosion, prolongs the life of the boiler, and
ensures the efficient operation of the power plant. Additionally, the deaerator
also helps in heating the feedwater to the required temperature before it enters
the boiler, which further enhances boiler efficiency.

Boiler feed pump:-The boiler feed pump in a thermal power plant is responsible
for pumping feedwater from the condensate system into the boiler at high
pressure. This pump ensures a steady and reliable supply of water to the boiler,
maintaining the required water level and pressure for efficient steam
generation. By delivering water to the boiler at high pressure, the boiler feed
pump helps maximize the efficiency of the boiler and overall power plant
operation

High-pressure (HP) heaters:- In a thermal power plant are strategically placed

components designed to preheat the feedwater using steam extracted from the
turbine at high pressure. Their primary function is to improve the overall
efficiency of the power plant by recovering heat energy from the turbine
exhaust steam and transferring it to the feedwater before it enters the boiler.
This preheating process helps reduce the amount of fuel required to heat the
water to boiler operating temperature,

Drumb:-The drumb in a thermal power plant refers to the steam drum, which is
a crucial component of a boiler. Its purpose is to separate steam from water. It
receives water from the economizer and feeds it into the boiler tubes. As the
water is heated, it boils and produces steam. The steam separates from the
water in the steam drum, and the dry steam is then sent to the superheater for
further heating, while the water is returned to the boiler tubes to continue the
cycle.
 SWITCH GEAR

Introduction:
Introducing switchgear into a thermal power plant involves
installing electrical equipment that controls, protects, and
isolates electrical circuits and equipment. This helps manage
the flow of electricity within the plant, ensuring safe operation
and efficient power distribution. Switchgear typically includes
circuit breakers, disconnect switches, fuses, and relays,
providing essential functions like switching, protection, and
metering. Integrating switchgear enhances the reliability and
safety of the power plant's electrical system, enabling efficient
generation and distribution of electricity.
Single line diagram
Types of switchgear:
❖ HT switchgear:- High-tension (HT) switchgear in a
thermal power plant is crucial for managing high-voltage
electricity distribution. It controls and protects electrical
equipment, ensuring safe operation and reliable power
supply throughout the plant. It includes components like
circuit breakers, disconnect switches, and protection relays
to safeguard against overloads, short circuits, and other
electrical faults.

❖ LT switchgear:- LT switchgear in a thermal power plant

refers to low voltage switchgear, typically operating at
voltages below 1000 volts. It's crucial for controlling,
protecting, and distributing electrical power within the
plant's low voltage network. This switchgear ensures the
safe and efficient operation of various electrical equipment,
such as motors, pumps, fans, and lighting systems. It plays a
vital role in maintaining the overall reliability and stability of
the power plant's electrical distribution system.
400KV SWITCH YARD
 What is Switchyard and difference with
substation?
❖ A Enclosed area of switching facilities of power station called as
switchyard

❖ A switching station is a substation without transformers and operating

only at a single voltage level.

❖ Substations transform voltage from high to low, or the reverse, or

perform any of several other important functions

➢ What is Bus bar and Models?

An electrical bus bar is defined as a conductor or a group of
conductor used for collecting electrical energy from the incoming
feeders and distributes them to the outgoing feeders

➢ Types of Busbar Arrangements:

1. Single Bus bar Arrangement

2. Single Bus-Bar Arrangement with Bus Sectionalized

3. Main and Transfer Bus Arrangement

4. Double Bus Double Breaker Arrangement

5. Sectionalized Double Bus Bar Arrangement.

6. One and a Half Breaker Arrangement

7. Ring Main Arrangement

8. Mesh Arrangement
 What is one and half

❖ In T4his Two Buses Are Provided.

❖ These Two Buses Are Inter-connected By Three Circuit Breakers.

❖ Line - 1 Is Connected In Between 1-52 Cb & 2-52 Cb.

❖ They Are Designated As 1-52 Cb, 2-52 Cb, 3-52 Cb

❖ Line - 2 Is Connected In Between 3-52 Cb & 2-52 Cb.

❖ Line-1 Having Two Feeding Paths I.E Via Bus-1 & 1-52 Cb Via Bus-2, 3-52
Cb & 2-52 Cb

❖ Line-2 Having Two Feeding Paths I.E Via Bus-2 & 3-52 C Via Bus-1, 1-52
Cb & 2-52 Cb

❖ For Interrupting Line-2 The 3-52cb And 2-52cb Is To Be Tripped.

❖ Normally In All Types Of Busbar Configurations One Breaker Is Sufficient

For One Feeder.

❖ Here Two Feeders Are Controlled By Three Breakers. So It Is Called One

& Half Breaker System.

❖ In This System Full Dia Means 2 Feeders Controlled By 3 Cbs.

❖ Half Dia Means 1 Feeder Controlled By 2 Cbs. (Nothing But Double Cb

System)
PROS & CONS OF ONE & HALF BREAKER SYSTEM
Advantages:
➢ If Main Cb Problem / For Periodical Maintenance, During That Period
The Feeder Is Feeding From Tie Cb & Other Bus. Need Not Require
Transfer The Feeder

➢ If Tie Cb Problem / For Periodical Maintenance,

➢ If Busbar-1/2 Operated /For Periodical Maintenance, Only

The Main Breakers Connected To Busbar-1 Will Trip. During
That Period The Feeders Connected To Bus-1 Are Feeding Via Tie Cb
From Bus-2/1.

➢ In This Busbar Protection Is Simple And Need Not Require Selection

Of Isolator.

➢ It Is More Reliable System For Operation & Maintenance Point Of

View.

Disadvantages:
➢ Ct Connections & Protection Trip Logics Are Some What Complicated.
Complex Control & Protection Philosophy

➢ Cost Towards Cts, Circuit Breakers & Panels Are To Be Increased Due To
Extra Bay.

➢ The Operations For Operator Point Of View Is Little Bit Complicated When
Compared To Conventional System.

➢ Space Occupation For Bay Is More I.E Cost Of Land Is Increase

 WHAT IS DIA AND BAY

➢ Two Feeders and Three Bays consists One Dia

➢ Bay consists of mainly three equipment, which are 1) Isolator

2) Breaker 3) Current transformer

One and Half Scheme bus bar arrangement generally two types,

1.H Type Configuration

2.I Type Configuration
 DIAs and Bays in STPP

• Here in STPP , we have 5 Dias and Two Auxiliary Bays

• Dia-1 : 401 (Bus Reactor) , 402 (Line-Reactor Tie) , 403 (Line-1)

• Dia-2 : 404 (GT-1), 405( GT-1&ST-1Tie), 406 (ST-1)

• Dia-3 : 407 (Line-2), 408 (Line-ICT Tie) , 409 (ICT)

• Dia-4 : 410 (ST-2) , 411 (GT-2 & ST-2 Tie) , 412 (GT-2)

• Dia-5 : 413 (Line-3) , 414 (Line3&4 Tie) , 415 (Line-4)

• Two Aux Bays : 416 (Bus-1&3 section) , 417 (Bus-2&4 Section)

• There are four main buses in 400kV Switchyard

• Main bus-1&2

• Main bus-3&4
 Primary Equipment in Switchyard

1. Current transformer
2. Capacitor Voltage Transformer
3. SF6 Circuit Breaker
4. Isolator with Earth switch
5. Lightening Arrestor
6. Transformers
7. Control and Relay Panels
8. Bus Reactor
9. Wave Trap
 CURRENT TRANSFORMER

❖ A current transformer (CT) is a type of instrument transformer used to

measure AC Current. It produces an alternating current (AC) in its
secondary
Which is proportional to its primary

❖ Hair Pin type , Live Tank type of CT using in

STPP Switchyard

❖ Based on secondary core we have two types

Protection CT (5 Secondary Cores)
Metering CT (2 Secondary Cores)
 CAPACITIVE VOLTAGE TRANSFORMER

➢ A capacitor voltage transformer (CVT or CCVT), is a

transformer used in power systems to step down
extra high voltage signals and provide a low voltage
signal, for metering or operating a protective

➢ CVT’s offer the advantage that the voltage divider

capacitor, being itself relatively smaller and lighter,
configuration makes the transformer’s iron core
much smaller in size

➢ CVT’s are also used to tune to PLCC,

Power Line Carrier Communication
 SF6 CIRCUIT BREAKER
▪ A circuit breaker is an automatically operated electrical
device designed to protect an electrical circuit from
damage caused by excess current, typically resulting from
an overload/ short- circuit.

❖ Advantages of SF6 gas breakers for using in EHV

Substations

• Very short arcing period due to superior arc

• quenching property of SF6.
• Can interrupt much larger currents as compared to
other breakers.
• No risk of fire.
• Low maintenance, light foundation.
• No over voltage problem.
• There are no carbon deposits.
 ISOLATOR AND EARTH SWITCH

➢ Isolator is a mechanical switch which isolates a part

of circuit from system as when required. Electrical
isolators separate a part of the system from rest for
safe maintenance works.

➢ Three types of isolators are generally used

in switchyard/ Substation,

1. Horizontal double break

2. Horizontal central break
3. Pantograph type
 LIGHTENING ARRESTORS

A lightning arrester is a device used on electrical

power systems and telecommunications systems to
protect the insulation and conductors of the system
from the damaging effects of lightning

The typical lightning arrester having two terminal

which are high-voltage terminal and a ground
terminal

It is placed very near to the equipment and when the

lightning occurs the arrester diverts the high voltage
wave of lightning to the ground
 BUS REACTOR

❖ Shunt reactors are used in high voltage systems to

compensate for the capacitive generation of long
overhead lines

❖ The reasons for to limit the over voltages. Whenever

there is a increase in system voltage due to capacitance
formation it injects inductive power to the system and
thus neutralizes it
❖ The second reason is to limit the transfer of reactive
power. If the reactive power transfer is minimized i. e.
the reactive power is balanced in the different parts of
the networks, a higher level of active power can be
transferred in the network.
 WAVE TRAP

A line trap/ Wave Trap (high-frequency stopper) is a

maintenance-free parallel resonant circuit, mounted
inline on high- voltage (HV) AC transmission power
lines to prevent the transmission of high frequency
(40 kHz to 1000 kHz) carrier signals of power line
communication to unwanted destinations.

The lines trap acts as a barrier or filter to prevent

signal losses.

The inductive reactance of the line trap presents a

high reactance to high-frequency signals but a low
reactance to mains frequency
 WORKING PRINCIPLE OF SURGE COUNTER

➢ Surge counter has mainly two functions,

1.Surge Counter will automatically record the number of lightning

and switching surge discharges of Station class surge arresters on a
cyclometer dial.

2.The surge counter also has a continuous A.C Leakage

Current indicator. The indicating ammeter has a 0-5 mA crest scale

visible through the glass housing.

EARTHING PROTECTION IN SWITCH YARD

Earthing is to be provided in substations due to
following reasons:-
➢ The earthing is to maintain a low potential on any object.

➢ The purpose of a earthing system in a substation area is to limit the

potential gradient within and immediately outside the area to a value,
safe for the working personnel. Safety is to be ensured under normal as
well as under abnormal conditions

➢ The earth resistance for the switchyard area should be lower than 0.5Ω

➢ The grounding conductor material should be capable of carrying the

maximum earth fault current without over-heating and mechanical
damage. The maximum fault level in the 400KV has been estimated to be
40kA.
 PROTECTIONS IN SWITCH YARD

o Bus bar Differential Protection

o Line Protection
o TEED Differential Protection
o Bus Sectionalize Breaker Protection
o Breaker failure Protection
o Carrier Tripping Scheme

6CT METHOD IN 1 & ½SCHEME

CT CORES IN TRANSFORMER DIA

CT CORES IN LINE DIA

 LINE DISTANCE PROTECTION

The distance relay compares the currents and voltages at the

relaying point with current providing the operating torque and
the voltage provides the restraining torque. In other words an
impedance relay is a voltage restrained over current relay.

The distance relays are fed from the secondary of line CTs and line
CVTs
Z secy = Z pri/Impedance ratio (where Impedance ratio = PT
Ratio/CT Ratio)
 AUTO RECLOSING

➢ About 80-90% of the faults occurring are transient in nature. Hence

the Automatic Re
➢ closure of breaker (after tripping on Fault) will result in the line
being successfully re-
➢ energized.

ADVANTAGES:

➢ A. Decreasing outage time.

➢ B. Improving Reliability.
➢ C. Improving system stability.
➢ D. Reduce fault damage and Maintenance Time.
➢ DEAD TIME: The time between the Auto-reclosing Scheme being
energized and the
➢ operation of the contacts which energize the Circuit Breaker closing
circuit.

➢ RECLAIM TIME: The Time Following a successful closing operation

measured from the instant the Auto-Reclosing relay closing
contacts make which must elapse before the Auto-Reclosing
relay initiates another reclosing attempt. In other words, it may be
said to be the time between 1st and 2nd Auto-Re closure.
AUTO RE CLOURE IN ONE & HALF SCHEME

o The Auto-Reclosure Functions used for the Bus Breakers Main-1,

Main-2 are set as Masters and one for the Center Breaker (TIE)
as Follower. Co- ordination is required between the Auto-Reclosure
Functions..

o Each Line Protection relays starts both MAIN & TIE Circuit Breakers
to trip for the Concerned line. After a Successful reclosure of the
Main Breaker, The Tie Breaker will be reclosed after a
supplementary time delay. Should the Main CB Auto-Reclosure
relay not be successful in its reclosing attempts, the Tie CB
Auto-Reclosure is blocked.

o If the Main CB is Open or its Auto-Reclosure Relay is not ready

or Out of service, The TIE CB Auto-Reclosure will reclose The TIE
Breaker after its own dead time without any supplementary time
delay.
FUEL OIL PUMP HOUSE
• INTRODUCTION:
➢ Fuel oil is a type of organic fuels. i.e it can generate substantial
quantity of heat by reacting with oxygen.

➢ Crude petroleum is the source fuel oil.

• Fuel oil used in power plant as:

1. Light Diesel oil (LDO) storage tanks -2 each -500KL

Unloading pumps -2

2. Heavy Fuel oil (HFO) storage tanks -2 each -2000KL

Unloading pumps -6

• Why we use fuel oils in power plant:

➢ To provide ignition energy to light off coal burns .

➢ For controlled heat input during light up period.

➢ To stabilize the coal flame at low boiler load.

• Properties of Fuel oil:

Light Diesel oil (LDO)

1. Sulphur (%) – 0.5-1.8
2. Ash content (%)-0.02
3. Relative Density- 0.85-0.87 at 15°C
4. Power point (°C Max)-12
5. Kinematic viscosity – 2.5 to 15.7 (cst)
6. Water content (%) – 0.25
7. Gross calorific value – 10700 (kcal/kg)
8. Flash point (°C min) – 66
9. Fire point (°C) -8

Heavy fuel oil (HFO)

10. Sulphur (%) – 2-4
11. Ash content (%)-0.1
1. Relative Density- 0.85-0.89 at 95 at 15°C
2. Power point (°C Max)-24
3. Kinematic viscosity – 180 to 500 (cst)
4. Water content (%) – 1.0
5. Gross calorific value – 10500 (kcal/kg)
6. Flash point (°C min) – 66
7. Fire point (°C) -128
 LDO PUMP SET SYSTEM:

Components:
1.Storage Tanks
2.Sucssion MIV (motorized inlet valve)
3.Stranners
4.Screw pumps
5.NRV (Non-return-valve) 7. MOV(motorized orerated valve
6.Discharge valve 8.CV ( Control valve)
PROCESS:

✓ Oil from the tankers via receiving header is pumped into the
both LDO Storage tanks by LDO unloading pumps.

✓ LDO Storage tanks capacity each 500 KL.

✓ There is a connection through MIV to stranners from the

storage tanks.

✓ Any dust particles are filtered or cleared in the stranners.

✓ Oil is flowing into the screw pumps forwarded oil to the

boiler through the proper line-up with 20 kg/ cm2 pressure.
• In a thermal power plant, the LDO (Light Diesel Oil) system is a
backup fuel system used when the primary fuel, such as coal or
natural gas, is unavailable or during startup. Here's how the LDO
system typically works:

1. *Storage and Handling*: LDO is stored in tanks on-site, similar to

other fuels. It's generally kept in a separate storage area from
other fuels to prevent contamination.

2. *Pumping and Injection*: When needed, LDO is pumped from the

storage tanks to the boiler system. It's injected into the boiler
furnace in a controlled manner.

3. *Combustion*: In the boiler furnace, LDO mixes with air and ignites
to produce heat. This heat then generates steam by heating water,
which is used to drive turbines for electricity generation, similar to
other fuel systems.

4. *Control and Monitoring*: The LDO system is monitored closely to

ensure proper fuel flow and combustion. Control systems regulate
the injection of LDO into the furnace to maintain stable and
efficient operation.

5. *Emergency Use*: LDO is often used as an emergency backup fuel.

If the primary fuel supply is disrupted, the LDO system can be
quickly activated to maintain power generation, ensuring
continuity of electricity supply.
6. *Startup*: During startup of the power plant or after maintenance
shutdowns, LDO is sometimes used initially before switching over
to the primary fuel once the system is fully operational.

Overall, the LDO system provides a reliable backup option for thermal
power plants, ensuring uninterrupted power supply during
emergencies or when transitioning between different fuel sources.
However, it's typically more expensive than primary fuels and is
used sparingly, primarily for backup purposes.

LDO UNLOADING PUMP SYSTEM:

 HFO PUMP SET SYSTEM

COMPONENTS:
1.Suction MIV

2.Stranners

3.Forwarding pumps-3

4. Non-return valve-3

5.Discharging MIV-3

6.MOV (Motorized Operated valve)

7.CV(Control valve)
8.Recirculation valve
 PROCESS:

✓ OIL from the tankers via receiving header is pumped into both
HFO Storage by unloading pumps.

✓ Storage tanks capacity each 2,000 KL.

✓ There is a connection to MIV through the stranners from the

storage tanks.

✓ Any dust particles are filtered or cleared in the stranners.

✓ Oil is flowing into the screw pumps to the heaters through the
NRV, with proper lin-up

✓ There is a connection from the steam line to the heaters from

the boiler.

✓ In the process ,The oil melts at a heat of steam, it is flowing into

stranners to the boiler.

• HFO stands for Heavy Fuel Oil. In thermal power plants, the HFO
system is used for power generation by burning heavy fuel oil in
boilers to produce steam, which then drives turbines to generate
electricity. Here's how the HFO system typically works:
HFO HEATER SET
HFO UNLOADING PUMP SYSTEM
RAW WATER PUMP HOUSE
INTRODUCTION:

RAW WATER PUMP HOUSE in a thermal power plant is

crucial for sourcing water needed for various processes like
cooling and boiler feed. It's responsible for pumping
untreated water from a natural source, such as a river or
lake, into the plant's water treatment facilities. This
untreated water, known as raw water, undergoes
treatment to remove impurities before being used in
different plant operations. The pump house typically
includes pumps, pipelines, and monitoring systems to
ensure a steady and reliable water supply to the plant.
SINGLE LINE DIAGRAM
EQUIPMENT

➢PLC (Programmable logic controller)

➢Battery room
➢Raw water pumps -3
➢Ash water make up pumps -2
➢Seal water pumps -2
➢Sump (storage tank)
➢Over head tank
➢Reservoir -2

PROCEDURE

❖ Water is flowing from reservoir to sump.

❖ There is a connection from sump to the raw water

pump.

❖ Discharge water flow of raw water pump 1.1 kg/cm2

pressure to the CW pump.
RAW WATER PUMP

BATTERY ROOM

RESERVIOR
INTRODUCTION:

The CW (Cooling Water) pump house in a thermal power plant is

a crucial component responsible for circulating water to cool
down various equipment, such as condensers, turbines, and heat
exchangers. It ensures optimal operating temperatures,
preventing overheating and maintaining efficiency in power
generation processes. Typically, the CW pump house contains
high-capacity pumps, piping systems, and monitoring equipment
to manage the flow and temperature of cooling water
throughout the plant.
 CW/SACW PUMP SYSTEM

EQUIPMENT:
➢ CW Fore bay
➢ CW pumps -5
➢ Discharge valves
➢ Recirculation line
➢ SACW pumps -3
➢ Condenser -2
PROCEDURE:

❖ Water supply to the forebay of CW pump house from the

DM plant.

❖ There is a connection of forebay to the cw pumps and SACW

Pumps .

❖ The flow of water is make-up in the CW pumps to the

condenser through the proper line.

❖ The water is circulating through the IDCT ( Induced draft

cooling tower ) to the forebay and through SACW pump to
the compressors of AHP,BTG.
CW PUMPS
 INDUCED DRAFT COLING
TOWER
(IDCT)

INTRODUCTION:
Induced draft cooling towers are crucial components in
thermal power plants for heat dissipation. Unlike natural
draft towers, induced draft towers use fans to pull air
through the tower, enhancing cooling efficiency by creating
a draft that draws heat away from the water circulating
within the tower. This process helps maintain optimal
operating temperatures for the power plant's equipment,
improving overall efficiency and performance

Details:
➢ There are 4 cooling towers ,each unit has 2 towers.
➢ A tower has 11 fans
PROCESS:

1. *Heat Exchange*: Hot water from the plant's

condenser enters the cooling tower.
2. *Distribution*: The hot water is distributed over the fill
material inside the tower. The fill material increases the
surface area for better heat exchange.
3. *Airflow*: Fans at the top of the tower induce air to
flow upwards through the tower. As air rises, it comes into
contact with the water, causing evaporation.
4. *Heat Dissipation*: Evaporation removes heat from the
water, cooling it down.
5. *Exhaust*: The warm, moist air exits the top of the
tower, carrying away the heat.
6. *Collection*: Cooled water collects at the bottom of
the tower and returns to the condenser, ready to absorb
more heat.

This continuous process helps dissipate heat from the

power plant's operations, ensuring efficient and safe
functioning.
INDUCED DRAFT FAN
 DM PLANT

A DM (Demineralization) plant in a thermal power plant is a water

treatment system used to remove dissolved salts and minerals
from the feed water, ensuring high-purity water for the boiler. It
typically consists of ion exchange resins that exchange ions in the
water with ions of similar charge in the resin, effectively removing
impurities. This process helps prevent scaling and corrosion in the
boiler, improving efficiency and prolonging equipment lifespan.
❖ Labs :
• Coal lab
• Water lab
• Oil lab

❖ Chemicals:
✓ Poly electrolyte
✓ Alum or poly Aluminum chloride
✓ Chlorine

❖ Water treatment :
➢ Suspended impurities particles ( pre-treatment)
➢ Dissolved solid gases (post-treatment) (cat ions,
Anions)

❖ Pre-treatment (CW)
➢ Oxidation
➢ Cascade Areator (5600 m3)
➢ Stilling chamber
➢ Inlet valves -3
➢ Clarifiers -3
➢ Storage tank- CW fore bay & HVAC System

DM Water storage tanks-2, (2000m3),H-10m.

 COAL LAB

Equipment :
➢ Thermo gravimetric Analyzer TGA-2000A
Types of analyzes :
❖ Proximetric Analyzes

✓ Proximate analysis is a method used to determine the

basic composition of a material, typically coal, by
measuring its moisture, volatile matter, fixed carbon, and
ash content.
✓ Inherent moisture
✓ Volatile matter
✓ Ash
➢ Fixed Carbon

➢ BOM Calorimeter
✓ It analyzes Gross colorific value of burned coal (212
microns)

Types of crushers in coal lab:

➢Jaw crusher -50 mm
➢Double roll crusher -12.55 mm
➢Double roll crusher -3.35 mm
➢ Pulverizer -212 µm size
 JAW CRUSHER

DOUBLE ROLL CRUSHER-12.55 MM

DOUBLE ROLL CRUSHER-3.35 MM

PULVARIZER-212 µm
Thermo gravimetric Analyzer TGA-2000A

BOM Calorimeter
 WATER LAB
Types of testing:
❖ Raw water :- PH value, Conductivity , Turbidity , Total
hardness, chloride , calcium hardness, magnesium
hardness, p-Alkanity, m-Alkanity, silica, free residual
chlorine.
❖ DM water: - PH value, Conductivity, Silica.
❖ Boiler water: - PH value, Conductivity, Silica.
Adding chemicals: - Ammonia, phosphorus ( for booster
and starting of boiler.
Equipment:
➢ PH meter:-To measure PH value.
➢ Conductivity meter:- to measure the conductivity in the
concentration of water.
➢ Turbidity meter:- To measure Turbidity of water (dust
particles).
➢ Spectrophoto meter:- To measure silica, phosphate,
Ammonia, cloride, iron, sulphate.
➢ Auto balance:- To measure weight of water samples.
➢ OR set:- It analyses of gases in the water
Adding chemicals:- pairagolal, KOH (potassium
hydroxide).
➢ Hot plate:- heating of water samples.
➢ Sodium flame photometer:- To measure sodium.
WATER LAB

AUTO BALANCE
PH METER & CONDUCTIVITY METER

TURBIDITY METER
SPECTROPHOTO METER

OR SET
 OIL LAB
The oil lab monitors and analyzes the quality of oils used in the
process to ensure they meet standards, prevent
contamination, and maintain efficient operation.
EQUIPMENT:
❖ KF Titration instrument:- To measure moisture content in
the oil (ppm).
❖ Metal index:- To appear iron particles in oil.
❖ Oil testing centrifuge:- To observe sedimentation in oil.
❖ Bacteriological incubator:- It is used for oil heating in lab
❖ Viscosity bath:- Viscosity baths are constant temperature
baths that are used for precise control of temperature
during viscosity measurements in silicone oil or mineral
oil.
❖ Pall instrument:- To measure moisture content in the oil .
OIL LAB

KF TITRATION
OIL TESTING CENTRIFUGE

BACTERIOLOGICAL INCUBATOR
VISCOSITY BATHS

PALL INSTRUMENT
AUTO BALANCE

SAMPLES
 Process
❖ Cascade aerators:-in demineralization plants oxygenate water,
remove carbon dioxide and volatile compounds, control
temperature, and promote mixing for efficient treatment.
❖ Stilling chamber :-in a demineralization plant serves to calm
incoming water flow, allowing suspended solids to settle out
before further treatment.
❖ Clarifiers:- in a demineralization plant serve to separate
suspended solids from water through sedimentation, producing
clearer water for subsequent treatment processes.
❖ Forebay:- The forebay in a DM plant acts as a reservoir,
regulating the flow of raw water and settling out debris before
demineralization.
❖ Rapid gravity sand filter:- rapid gravity sand filter in a DM plant
removes impurities from water using gravity and sand filtration,
producing high-quality demineralized water.
❖ Filter water reservoir:- The filter water reservoir in a DM
(Demineralization) plant serves to store filtered water before it
undergoes demineralization processes, ensuring a steady supply
of clean water for treatment.
❖ Filter water supply pumps:- water supply pumps are crucial for
maintaining water flow. Installing filters on these pumps helps
prevent debris and contaminants from entering the system,
ensuring clean water production and prolonging the life of the
pumps.
➢ Activated carbon filter:- To remove organic contaminants,
chlorine, and other impurities from water, improving its taste
and odor. It's a crucial step in the purification process, ensuring
high-quality water output.
➢ Weak acid cation exchanger:- To remove positively charged
ions, such as calcium, magnesium, and sodium, from water. It
replaces these ions with hydrogen ions, effectively softening the
water and reducing its mineral content.
➢ Strong acid cation exchanger:- to remove positively charged
ions, such as calcium, magnesium, and sodium, from water. It
exchanges these ions with hydrogen ions, effectively softening
the water and reducing its mineral content. This process helps
prepare the water for further purification steps in the DM plant.
➢ De-Gassified tower:- To removes dissolved gases like carbon
dioxide from water, preventing interference with the
demineralization process and ensuring high-quality output.
➢ De-Gassified water storage tank:- The de-gassified water
storage tank in a DM plant stores water stripped of dissolved
gases, like oxygen and carbon dioxide, preventing corrosion and
ensuring quality for downstream processes.
Weak acid anion exchanger:- To removes negatively charged
ions, such as bicarbonates, sulfates, and silicates, from water,
helping to further purify it by exchanging them with other anions
like chloride ions. This process aids in achieving the desired level
of demineralization and purity in the water.
Strong acid anion exchanger:-To removes negatively charged
ions, such as chloride, nitrate, and sulfate, from water by
exchanging them with other anions like hydroxide ions,
contributing to the process of demineralization and ensuring
water purity.
Mixed bed :- The mixed bed in a DM (Demineralization) plant
acts as a final polishing step, removing any remaining traces of
ions from the water to achieve ultra-pure quality. It consists of a
mixture of strong acid cation and strong base anion exchange
resins, effectively removing both cations and anions to produce
high-quality demineralized water.
DM water storage tank:- To store the demineralized water
produced by the plant. These tanks ensure a constant and
reliable supply of high-quality water for various industrial
processes, laboratories, or other applications that require ultra-
pure water.
 COAL
HANDLING PLANT

Introduction:
 A coal handling plant in a thermal power plant is responsible
for handling and processing coal from arrival at the plant to its
utilization in power generation. It involves activities such as
unloading coal from trains or trucks, storing it in stockpiles,
preparing it for combustion through processes like crushing
and pulverizing, and finally delivering it to the boiler for
burning to produce steam

Coal crushing: - 200mm to 20mm

Belt speed:- 3.1 m/s
Load of belt:-1400 TPH MAX
SINGLE LINE DIAGRAM
1. Coal Unloading: Coal arrives at the power plant either by rail or by
trucks. It is unloaded from the transportation vehicles using
equipment such as cranes, conveyors, or dumpers and transferred to
the coal storage area.

2. Coal Storage: The unloaded coal is stored in coal bunkers or

stockpiles, where it awaits further processing. The size and capacity of
the storage area depend on the plant's requirements and operational
needs.

3. Coal Crushing: Large chunks of coal are crushed into smaller

particles using coal crushers. This process reduces the size of coal to a
more manageable level for transportation and combustion.

4. Coal Conveying: Conveyors are used to transport the crushed coal

from the crushers to other areas within the plant, such as the coal
bunkers, coal handling plant, or directly to the boiler for combustion.

5. Coal Screening: In some cases, coal may need to be screened to

remove impurities or to ensure uniform particle size before it is fed
into the boiler. Screening equipment such as vibrating screens or
trommel screens are used for this purpose.
6. Coal Washing (Optional): Depending on the quality of coal and the
specific requirements of the power plant, coal may undergo a washing
process to remove impurities such as sulfur, ash, and moisture. This
helps improve the efficiency of combustion and reduces
environmental emissions.

7. Coal Reclaiming: If coal is stored in stockpiles, a reclaiming process

is used to retrieve coal from the stockpiles and transfer it to the coal
handling system for further processing or combustion.

8. Coal Feeding to Boiler: Finally, the processed coal is fed into the
boiler for combustion to generate steam, which drives the turbine
connected to the generator to produce electricity.

Throughout the entire process, various auxiliary systems such as dust

suppression, ash handling, and environmental control systems may be
employed to ensure efficient and environmentally responsible coal
handling operations. Regular maintenance and monitoring of
equipment are also essential to ensure smooth and reliable operation
of the coal handling plant.
 CRUSHER HOUSE

Head pulley:- The head pulley motor in the crusher house of a coal
handling plant drives the conveyor belt to transport crushed coal,
ensuring smooth operation, proper tension, and directional control
for efficient coal handling (520 KW).

Rack & pinion gate

Crushers:- The crusher in the crusher house of a coal handling plant

reduces large chunks of coal into smaller particles, facilitating
transportation, storage, and combustion, ultimately contributing to
efficient coal handling and power generation (550KW,1,2,3,4).

Vibrating screen feeder (VFD):- The vibrating screen feeder in the

crusher house of a coal handling plant separates and screens coal
particles, ensuring uniform size distribution and efficient feeding to
the crusher for further processing, enhancing the overall coal handling process
(45 KW,1,2,3,4).
Belt feeder:- The belt feeder in the crusher house of a coal handling
plant regulates the flow of coal onto the conveyor belt, ensuring a
consistent and controlled feed rate to the crusher for efficient coal
processing and handling (22 KW,1,2,3).

Reversible belt feeder:- The reversible belt feeder in the crusher

house of a coal handling plant can change the direction of coal flow
on the conveyor belt, allowing for flexible operation and efficient
feeding of coal to the crusher, enhancing overall coal handling
versatility and productivity (37 KW 1,2).

Flow chart:-

HEAD PULLEY

RACK & PINION GATE (RPG)

VIBRATING SCREEN FEEDER (VSF)

CRUSHER

BELT FEEDER

REVERSE BELT FEEDER

CONVEYER BELT
 TRACK HOPPER
In a coal handling plant within a thermal power plant, a track hopper
is a key component used to unload coal from incoming trains or trucks
onto a conveyor belt system. It serves as a storage and distribution
point for the coal before it is further processed. The track hopper
typically has multiple compartments or bins to accommodate
different grades or types of coal, allowing for efficient management of
the coal supply. It plays a vital role in ensuring a steady and
uninterrupted flow of coal to the power generation process.
 ASH
HANDLING
PLANT
Introduction:-

An Ash Handling Plant in a thermal power plant is designed to handle

the ash generated from combustion processes in boilers. It involves
collecting, transporting, and disposing of ash to prevent
environmental pollution and ensure efficient operation of the plant.
Typically, it includes equipment like ash hoppers, conveyors, ash
handling systems, and ash storage facilities. The main types of ash
produced are bottom ash and fly ash, each requiring different
handling methods.

o Over view
o Types of Ash produced
DIFFERENT AREA’S IN AHP:
➢ BOTTOM ASH HOPPER
➢ ASH SLURRY PUMP HOUSE (ASPH)
➢ ASH WATER PUMP HOUSE (AWPH)
➢ HYDROBIN’S
➢ ASH WATER RECOVER PUMP HOUSE
➢ ESP(ELECTRO STATIC PRICIPTATOR)
➢ COMPRESSOR HOUSE
➢ SILO’S AREA
➢ FA SILO
➢ HCSD SILO
➢ DYKE AREA
➢ BA DYKE
➢ FA DYKE
➢ SEEPAGE PUMP HOUSE (SWPH)
BOTTOM ASH HANDLING SYSTEM:
• Each V-shape compartment has two outlet opening at bottom.

• One opening of each compartment will be normally used for

removing ash and other will be standby.

• At each opening one feed gate along with single roll clinker grinder
& jet pump will be provided.

• Other auxiliary facility like flushing headers, refractory cooling

water system provided satisfactory operation system

• One set of feed gate, clinker grinder, ejector feed sump and jet
pump will be operated to remove bottom ash and coarse ash to
ash slurry sump.

• Clinker grinder will crush all ash clinkers to (-) 25 mm size.

• Crushed ash & water slurry conveyed to ash slurry sump by 2 sets
jet pumps Through BA disposal lines.

• HP water for jet pump supplied by HPWP located in ash water

pump house.
ASH SLURRY PUMP HOUSE (ASPH)

▪ Bottom ash discharge slurry is conveying to Ash dyke or

Hydrobin using Slurry series pumps.

▪ Slurry pump house having three no. Slurry sumps having

capacity 64m3 each.

▪ Each Slurry sump having two series stage pumps(namely

A1+A2,B1+B2,C1+C2).

▪ Each slurry series stage pump having discharge pressure

35MWC,Flow 760M3/Hr.

▪ Stage-1 pump is variable speed Gearbox(Fluid coupling)

driven motor.

▪ Stage-2 pump is V-belt driven motor.

▪ Five stage seal water pump having 8kg/cm2 disc. pressure

(1W+1S) is used for slurry series pump gland
sealing.(Present service water used for sealing purpose).

▪ Service water cooling system provided for fluid coupling

which is used for variable RPM.
 ▪ A1,B1&C1 Slurry pump fluid coupling cooling return water
send to slurry sump.

SLURRY WATER SUMP SOURCE FOR:-

✓ UNIT 1 and 2 clinker grinder outlet slurry

✓ Neutral pit water from demineralization plant
✓ Slurry pumps A1,B1&C1 cooler return cooling water
✓ ESP drain sump discharge water
✓ ASPH Low pressure water for sump make up
✓ Both unit APH wet ash collection discharge

SEALING WATER:
✓ Sealing water used for the seal the slurry water from slurry
pumps glands.
✓ Seal the sludge from sludge from sludge pump glands.
✓ Clinker grinder mechanical seal cooling & sealing purpose.
✓ For effective utilization of service water and reduction of aux.
power consumption. Instead of seal water service water used
for above equipment.
✓ For redundancy and emergency purpose fire water can be
used sealing purpose.
✓
ASH WATER PUMP HOUSE:
o Ash water sump capacity 1054 m3
o Ash water sump make up

o SURGE TANK

over flow from hydro bins

o RECOVERY PUMP

water collected from ash dyke recovery

o RAW WATER PUMP

water from raw water lake
o CT BLOW DOWN
return cooling water from turbine condenser

header

AWPH PUMP DETAILS:

❖ Bottom ash high pressure pump(1W+1S)

❖ Bottom ash Low pressure pump(2W+1S)

❖ Economizer water pump(1W+1S)

❖ Fly Ash Water Pump(2W+1S)

❖ Flushing water pump

❖ Bottom ash high pressure pump(1W+1S/B)
✓ Used for transport the boiler bottom ash to slurry sump
through jet pump.
✓ Used for Bottom ash seal trough flushing hopper flushing &
refectory cooling.
✓ Used for Slurry sump flushing.
✓ Used for Hydro bins flushing purpose (side & centre).
✓ Used for Settling tank and sludge tank flushing.
❖ Bottom ash Low pressure pump(2W+1S/B)
✓ Used for Bottom ash hopper make up.
✓ Used for Bottom ash seal trough make up.
✓ Used for Bottom ash refectory cooling.
✓ Used for Slurry sump level make up.
❖ Economizer water pump(1W+1S/B)
✓ Used for Economiser ash hopper continuous de-ash through
flushing apparatus
❖ Fly Ash Water Pump(2W+1S/B)
✓ Used for Fly ash de-ash to dyke through Abel pump
❖ Flushing water pump
✓ Used for Slurry pump flushing before stopping the slurry series
❖ APH wash water pump (1W+1S/B) (Located at CW pump area)
✓ Boiler air pre heater washing
✓ Convert the APH dry ash to ash slurry
 HYDROBIN AREA:
➢ For safe Environment to avoid water and soil pollution in
power plants ,Bottom Ash slurry recycle process will be held in
Hydro bin.
➢ Total 6 no. Hydro bin are available for both units.
➢ Bottom ash discharge slurry was collected in hydro bin
➢ From Slurry, Water was removed by decanting procedure and
collected wet ash loaded in open trucks and dumped in mines.
➢ Each Hydro bin having ash holding capacity of 600ton.
➢ The Water in the slurry was collected and reused for Ash
handling plant.

From slurry, water removed in two stage.

o First Stage:

➢ Slurry heavy ash settled in hydro bin, from over flow water
fine ash collected in settling tank ,and the sludge collected in
surge tank.
➢ The over flow water from surge tank was used for Ash water
sump make up.
➢ The fine ash and sludge collected in tanks was removed using
Sludge pump(1W+1S) and discharge to selected hydro bin.
Second Stage:
❖ To remove the remaining water in Hydro bin
❖ After 1hr completion of filling the heavy material was settled,
centre decanting valve to be open, after half an hour side
decanting valve to be open and the drain valve.
❖ These decanting discharge lines go to settling tank.
❖ The total decanting takes almost 8 hours.
❖ Ready for bottom ash unloading decided by the operator after
visual inspection of hydro bin from top.
❖ Each bin having two discharge chute
❖ 35 to 40 trucks required for empty the hydro bin.

SETTLING & SURGE TANK

▪ In Settling tank and Surge tank the fine ash(sludge) which is
collected at bottom area was removed by Sludge pump and
discharge goes to seleted Hydro bin.
▪ Sludge pump(1W+1S) runs almost continuously
▪ Sludge pump Operation:

✓ Pump sealing provided by service water pump (pressure

>4kg/cm2)
✓ Pump can be started from PLC
✓ Line up v/vs with selected tank(settling, surge) with
selected pump
✓ H.P water provided at the suction area for pump flushing
before stopping the pump
✓ In Every Shift at least 1 hour surge tank to be taken in
service.
ASH WATER RECOVERY PUMP HOUSE
Recovery pump (1W+1S)

o Flow: 700m3/hr, Head: 28MWL, 90KW motor.

o It is used to pump water from dyke to ash water pump house
for sump make up
o Pumps can be started from PLC, Manual suction v/v can be
operate in local.
o Recovery sump make up can be taken from Over flow Lagoon
by opening make up butter fly valves.

Dust suppression pump(2W+1S)

o Flow: 50m3/hr, Head: 40MWL, 15KW motor.

o It is used to suppress the ash dust in fly & bottom ash dyke.
o Pumps take suction from Recovery sump.
ELECTRO STATIC RECIPITATOR

INTRODUCTION:

Electrostatic precipitator is a pollution controlling equipment

ESP helps in removing impurities (here Ash particles from flue

gas) from air and gases.

An ESP can be called an electrical equipment as separation of

impurities from gas stream and their holding on to collecting
plates till the same are dislodged by application of rapping force
for collection into the hoppers are made possible by electrostatic
forces.
 THE OPERATION OF ESP CAN BE DEVIDED
INTO FOLLOWING STEPS
❖ Generation of charge carriers

❖ Charging of dust particles

❖ Deflection and separation of particles

❖ Dust deposition

❖ Dust removal

WORKING PRINCIPLE
When a DC high voltage is applied between emitting and collecting
electrodes ,it induces ionization of gas molecules adjacent to the
emitting electrode and creates –ve charges. These charges charge the
dust particles. Thus the dust particles experience a force, which causes
the particles to move towards the collecting electrodes and deposited
on them.
 DUST REMOVAL (RAPPING MECHANISM)

Rapping Mechanism is provided for both Emitting and collecting

electrodes.

The rapping system employs tumbling hammers mounted on

horizontal shaft which is driven by geared motor. As the shaft rotates
slowly the hammer tumble on the shock bar which transmits blow to
the collecting electrodes. One complete revolution of rapping shaft
will clear the entire field.

ELECTRICAL CIRCUIT DIAGRAM

ESP FLY ASH SYSTEM
▪ VACCUM CONVEYING SYSTEM
▪ PRESSURE CONVEYING SYSTEM

COMPRESSOR HOUSE
➢ NTRUMENT AIR COMPRESSOR
✓ NO. OF COMPRESSORS: 04
✓ CAPACITY : 900M3/HR
✓ DISCHARGE PR. : 8.0 KSC
✓ WORKING : 2 NO.
✓ STANBY : 2 NO.

➢ TRANSPORT AIR COMPRESSOR

✓ NO. OF COMPRESSORS: 06
✓ CAPACITY : 5900M3/HR
✓ DISCHARGE PR. : 1.5 KSC
✓ WORKING : 4 NO.
✓ STANBY : 2 NO.

SILO’S AREA
❖ FLY ASH SILO
✓ NO. OF FLY ASH SILO : 04 NO.
✓ EACH SILO CAPACITY : 900TONS
❖ HCSD SILO
✓ NO. OF FLY ASH SILO : 03 NO.
✓ EACH SILO CAPACITY : 500TONS
FLY ASH SILO’S

HCSD SILO’S
FLY ASH UTILIZATION
❖ Cement Factories
❖ Brick Production
❖ Land Development
❖ Concrete Products
❖ Roads/Embankments
❖ Manufacture of Asbestos Products
❖ Mine Filling
 ELECTRICAL MAITANENCE DEPARTMENT

Transformer working and maintenance:

Transformers are devices that transfer electrical energy from one
circuit to another through mutual electromagnetic induction. They
consist of two or more coils of insulated wire wound around a core,
typically made of iron or ferrite. When an alternating current flows
through the primary coil, it generates a changing magnetic field in the
core, which induces a voltage in the secondary coil. This process allows
transformers to step up or step down voltage levels, making them
essential in electricity distribution, power transmission, and various
electronic devices.

Maintenance:
1. Monitor oil levels and quality regularly.
2. Clean bushings and connections.
3. Check for overheating signs.
4. Tighten loose connections.
5. Schedule periodic professional inspections.
 3-PHASE INDUCTION MOTOR
A 3-phase induction motor works on the principle of electromagnetic
induction, when three phase AC power is supplied to the stator
winding, Electromagnetic field is created, Assuming, the
electromagnetic field linked as rotating magnetic field, It induces
current in the rotor conductors, rotating magnetic field is created in
the stator, cuts across the conductive bars of the rotor and
Electromagnetic force EMF

The EMF induced in the router causes current to flow in a direction

opposite to that of the rotating magnetic field in the state and leads
to a twisting motion after q in the motor while the routeroted slightly
slower than the synchronous speed due to sleep different shall over
the motor to develop dark and perform mechanical work.

Maintenance
1. Regular Inspections:* Check for wear, damage, and overheating
regularly.

2. *Lubrication:* Keep motor bearings properly lubricated.

3. *Cleaning:* Keep the motor clean from dust and debris to prevent
damage.

4. *Tighten Connections:* Ensure electrical connections are tight to

prevent overheating.

5. *Temperature Monitoring:* Use thermal sensors to monitor

motor temperature.

6. *Testing:* Conduct insulation resistance and load tests

periodically.
Switch gear Maintenance
1. *Regular Inspections:* Conduct routine visual inspections to
check for signs of wear, corrosion, or loose connections.

2. *Cleaning:* Keep switchgear cabinets clean from dust and debris

to prevent insulation breakdown and ensure proper operation.

3. *Tightening Connections:* Check and tighten electrical

connections to prevent overheating and ensure efficient power
transmission.

4. *Functional Testing:* Perform regular functional tests to ensure

all components, such as circuit breakers and relays, operate
correctly.

5. *Thermographic Inspections:* Use Thermo graphic imaging to

detect any hot spots or abnormal temperature rises, which could
indicate potential faults.

6. *Oil Analysis:* If applicable, regularly analyze the condition of oil-

filled equipment like transformers to detect any signs of degradation
or contamination.