Harsimran Jot

PROJECT REPORT
(Project Semester January-June)
TATA POWER PROJECT ANALYSIS

Submitted by
SWAPNIL VERMA Roll No - 100804071
Under the Guidance of
Mr. SHAKTI SINGH A!!"!#$%# Pro&'!!or(
Mr. BIRBAL SINGH TANWAR HEA)-ELECTRICAL* CONTROL + INSTR,MENTATION ENGG.(
)'-$r#.'%# o& El'/#r"/$l $%0 I%!#r1.'%#$#"o% E%2"%''r"%2 THAPAR ,NIVERSITY-PATIALA J1%' 3013
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)ECLARATION
I hereby declare that the project wor entitled !"#"# P$%&' P'$J&(" #)#*+SIS, is an authentic record of my own wor carried out at #*S"$- P'$J&("S I).I# *I-I"&. as re/uirement of fi0e months project semester for the award of de1ree of 23& (&lectrical 4 Instrumentation &n1ineerin1) at "hapar Uni0ersity-Patiala5 under the Guidance of -r3 2irbal Sin1h "anwar and -r3 Sha ti Sin1h5 durin1 January to June 67113
S%#P)I* 8&'-# 'oll )o -17797:7;1
.ate<
(ertified that the abo0e statement made by the student is correct to the best of our nowled1e and belief3
Mr. SHAKTI SINGH ASSISTANT PRO4ESSOR(
Mr. BIRBAL SINGH TANWAR HEA)-ELECTRICAL* CONTROL + INSTR,MENTATION ENGG.(
ACKNOWLE)GEMENT
"rainin1 in an or1ani=ation li e !#*S"$- P'$J&("S I).I# *I-I"&., which is fuelled by the indi0iduals with so much =est 4 ener1y5 teamin1 up to form a formidable force5 was in itself a true learnin1 e>perience which is 1oin1 to help me immensely in my career3
I hereby con0ey my than s to all those who ha0e rendered their 0aluable help5 support and 1uidance durin1 my trainin1 period3 ?irst of all I wish to e>press my sincere than s to all the employees at #lstom Projects India *imited5 )oida5 who were of 1reat help durin1 the course of my trainin1 period3 I specially want to than -r 23)3Samanta who too personal interest in my trainin1 4 also lend me a helpin1 hand in understandin1 the 0ery basics of this project3
*ast but not the least I would li e to than plannin1 and optimi=ation team for their support and for bein1 source of learnin1 for me3
%ith best re1ards< S%#P)I* 8&'-#
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S,MMARY
%e as &n1ineerin1 students are studyin1 theory subjects as well as some practical too so that we may not feel short of practical trainin1 which will be useful in our job later3 "han s to T5$-$r ,%"6'r!"#7 that it has pro0ided us fi0e months trainin1 slot to help us learn better3 "heory alon1 with practical is always beneficial as it ma es us learn /uic ly3 It further 1i0es us confidence to wor in a company and brin1 laurels to our country by our 1ood and admirable job3 Under1oin1 industrial trainin1 in a well established and one of the best professionally mana1ed company li e ALSTOM PROJECTS IN)IA LT)5 was indeed a 1reat help to me and also to my career3 "he initial phase of my trainin1 included my familiari=ation with APIL and its employees3 "his was followed by my in0ol0ement in the project allotted to me ! TATA POWER PROJECT ANALYSIS, as described3 I 1ot the opportunity to wor in the en1ineerin1 department related to boilers3 -y project was basically re1ardin1 the electrical scope in boilers3 I had the pri0ile1e of wor in1 with hi1hly e>perienced en1ineers and the ad0anced technolo1y used in boilers business3 #s a complementary to trainin1 e0ery trainee has to prepare a report on the project wor s they ha0e done durin1 their trainin13 "his report is the continuation of that tradition3 It is an attempt to present an account of practical nowled1e and obser0ation 1athered durin1 the trainin1 period3
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TABLE O4 CONTENTS
C5$-#'r No. T"#l'
"itle Pa1e .eclaration of the Student #c nowled1ement Summary (onclusion 'eferences #ppendi>
P$2' No.
1 6 @ : A A6 A@
1.
Co.-$%7 Pro&"l'
131 #lstom Power 136 #lstom "ransport 13@ #lstom Grid 13: #lstom In India
8
9 9 A 17
3.
I%#ro01/#"o% To T5'r.$l Po8'r Pl$%# A%0 Bo"l'r!

631 &lectricity (ost
19
1:
9. 4.
T5'r.$l Po8'r Pl$%# Bo"l'r

:31 %ater #nd Beat System :3131 Sensible Beat #ddition :3136 *atent Beat #ddition :313@ SuperheatC'eheat :36 (ombustion System :3631 (oal System :3636 #ir System :363@ ?lue Gas System :363: #sh System
1: 17
1; 19 1A 67 61 61 61 66 6@
:.
T7-'! O& Bo"l'r!

D31 $n "he 2asis $f ?irin1 D36 $n "he 2asis $f Steam Parameters D3@ $n "he 2asis $f #rran1ement
34
6D 69 @7
;.
Br"'& A<o1# T$#$ Po8'r Pro='/#

E31 2oiler "ype $f "ata Power Project E36 Site (onditions E3@ &lectric Power
91
@1 @1 @@
7.
S/o-' O& El'/#r"/$l Wor> I% T$#$ Po8'r Pro='/#
99
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8. ?.
El'/#r"/$l S7!#'. )'!"2% Cr"#'r"$ 4or T$#$ Po8'r Pro='/# E%2"%''r"%2 A%0 )'!"2%"%2 T5' Pro='/#
A31 Pipin1 4 Instrumentation .ia1ram A36 &lectrical *oad *ist
94 97
@; :7
10. 11.
P$/>$2' )'!/r"-#"o%! Bo"l'r MCC

1131 S*. $f -(( 1136 Specifications $f *" -(( 113@ 2us 2ar (alculations $f -(( 113: "ests Performed ?or -(( :D
41 41
:D D6 D6
13. 19.
Lo/$l P1!5 B1##o% S#$#"o%! Mo#or!

1631 *" -otor %ith .ol Startin1 1636 *" -otor %ith 8?. Startin1
:9 :?
DA E;
14. 1:. 1; .
Tr$%!&or.'r! ,!'0 4or V4) S7!#'. A/#1$#or! C$<l' + C$<l' C$l/1l$#"o%!

1E31 Sample (alculation $f Selection $f (able 1E36 (able Si=ed 2ased $n -a>imum (ontinuous *oad (urrent
73 7: 7?
91 91
17. 18. 1? . 30 .
A6"$#"o% W$r%"%2 L$.-! 4or C5".%'7

1;31 "ypes $f #0iation %arnin1 *amps
83
9@
E$r#5"%2 L"25#%"%2 Ill1."%$#"o%

6731 Intent $f Specification
89 8; 87
9;
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LIST O4 4IG,RES 4"21r' N1.<'r 1 3 9 4 : ; 7 8 ?*10 11 13 19 14*1: 1;*17 18 1? 30 31 33 39 34 3: 3; P$2' N1.<'r 13 14 1; 17 18 1? 33 3; 3? 98 9? 41 43 49 :3 :9 71 74 77 7? 81 8: 87
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1. COMPANY PRO4ILE
#lstom5 a world leader in transport infrastructure5 power 1eneration and transmission3 Present in around 177 countries5 Sales 6711C6716< 1A3A billion euros3 A65E77 employees uptil @1st -arch 67163 (haired by Patric Fron3
1.1 ALSTOM POWER

(lose to 6DG of the worldHs power production capacity depends on #lstom technolo1y and ser0ices3 $ur clean technolo1ies 1enerate electricity e/ui0alent to the needs of around 136 billion homes3 ?rom 1as to wind5 customers can choose from a portfolio of products co0erin1 all fuel types5 the broadest in the industry3 In desi1n5 manufacture5 procurement5 construction and ser0icin15 they ha0e been settin1 the benchmar in clean5 efficient5 fle>ible and inte1rated power 1eneration solutions for o0er a century3 "he company desi1ns5 manufactures and supplies a comprehensi0e ran1e of state-of-the-art products and systems for the power 1eneration and industrial mar ets3 "his includes 1as5 1eothermal5 coal5 nuclear5 wind5 solar and hydropower3 #lstom Power Bead/uarters is at 2rown 2o0eri Strasse ; S%I"I&'*#).3
1.3 ALSTOM TRANSPORT

# promoter of sustainable mobility5 #lstom "ransport de0elops and mar ets the most complete ran1e of systems5 e/uipment and ser0ices in the railway sector3 #lstom "ransport mana1es entire transport systems5 ta in1 in rollin1 stoc 5 si1nallin1 and infrastructure5 and offers !turn ey, solutions3 "he company is no3 1 in the hi1h and 0ery hi1h speed train sector and eeps in0estin1 in hi1h end se1ments5 while de0elopin1 products suited to the specific needs of the emer1in1 mar ets3 #lstom "ransport is present in o0er E7 countries and employs some 6;5777 people3 "he "ransport Sector has successfully established its 1lobal presence throu1h a strate1y of or1anic5 profitable 1rowth in e>istin1 and new mar ets5 complemented by tar1eted ac/uisitions and alliances3 #*S"$- is a world leader for railway e/uipment and ser0ices3 In particular5 the "ransport Sector is number 1 in 0ery hi1h-speed trains5 number 6 in tramways
and metros5 and is amon1 the leaders for electrical and diesel multiple units5 information systems5 traction systems5 power supply systems and trac wor 3 $ne of the SectorHs ey competiti0e stren1ths is its industry-leadin1 product and ser0ice offerin13 "his allows #*S"$- to offer the optimal solution to its customersH specific needs5 as well as to optimi=e the inte1ration of the 0arious parts in full system projects3
1.9 ALSTOM GRI)

Pro0idin1 the most ad0anced electrical 1rid solutions to meet world electricity demand %ith an increased demand for ener1y worldwide5 and consumption forecasts predictin1 ener1y production increases of around 97G between 677E and 67@7J5 #lstom GridHs dedicated teams combine their s ills to deli0er customer-0alued solutions to build smarter5 more stable5 more efficient and en0ironmentally friendly electricity 1rids worldwide3 #nd with o0er 16D years of e>perience5 we are well positioned to meet the ener1y challen1es of today and tomorrow3 #lstom Grid5 as one of the three 1lobal players in electrical transmission5 boasts technolo1ies and e>pertise5 which ha0e always ensured hi1her safety5 reliability and capacity of power 1rids around the world3 Bere are some customers across the 1lobe who ha0e relied on #lstom Grid products and solutions3 &.? (?rance) .u e &ner1y (United States) '%& and &3$) (Germany) 8attenfall (Sweden) .ewa (.ubai) &lectrobras (2ra=il) &s om (South #frica)
THAPAR UNIVERSITY, PATIALA Page A
1.4 ALSTOM IN IN)IA

#lstom has been associated with IndiaHs pro1ress for a century and has a lon1-standin1 reputation for pro0idin1 hi1hly inno0ati0e and sustainable solutions for meetin1 the countryHs ener1y and transport re/uirements3 "he company has full capabilities in en1ineerin15 manufacturin15 project mana1ement and supply of power 1eneration5 transmission and transport sector re/uirements3 Since its inception in the year 1A115 the company has been at the forefront of leadin1-ed1e technolo1y at e0ery le0el5 ser0in1 these three infrastructure mar ets essential to economic5 social and en0ironmental de0elopment of India3 "he company wor s with a number of strate1ic partners in India to offer a wide ran1e of solutions for e0ery sector K Power5 "ransport 4 Grid3 %ith power transmission now included in the business portfolio5 #lstom in India loo s forward to new syner1ies amon1st its three core sectors and is well poised to offer end-to-end solutions to its customers3 #lstom has been present in India for almost 177 years3 It has been instrumental in chartin1 the 1rowth trajectory5 throu1h its presence in major states of India3 )'l5"@NCR (orporate $ffice #lstom India5 Bead $ffice #*S"$- Projects India *imited M1.<$" 'e1istered office V$0o0$r$ Bydro -anufacturin1 and #ssembly unit5 Ser0ices< hi1h speed balancin1 of all rotatin1 e/uipments5 Global "echnolo1y (entre Co".<$#or' "ransport -anufacturin1 ?acility )1r2$-1r Power boilersC(oal-fired boilersCIndustrial and B'SGs S5$5$<$0 (oal Pul0erisers 4 -illin1 System5 Bi1h Pressure Pipin15 Beat &>chan1ers5 (ondensers 4 Iron (astin1s
Kol>$#$ &(S and "hermal Ser0ice5 Sales $ffice5 &n1ineerin1 (entre B'%2$l1r1 "ransport Software .e0elopment (entre5 #lstom 4 Infosys '4. (entre M1%0r$ #lstom - 2?* Power *td - -anufacturin1 ?acility Under (onstruction( Al!#o.Gr"0 Lo/$#"o%! $ffices and (ity addresses #*S"$- "4. India *imited3
#lstom in India has made strate1ic partnerships with local stron1 players to brin1 in frontline technolo1ies5 to enhance the /uality and the efficiency of the power sector3
Al!#o. $%0 B5$r$# 4or2' L"."#'0 JV "% 300? "he J8 will manufacture steam turbines and au>iliary e/uipments with an annual capacity of D777 -%3
Al!#o. $%0 BHEL "% 300: #lstom and 2B&* entered into a 1D year license a1reement for manufacture5 supply and technolo1y transfer for supercritical boilers3
Al!#o. $%0 I%&o!7! "% 300: Strate1ic partnership in areas of 1lobal '4.5 &n1ineerin1 and &n1ineerin1 I" ser0ices to de0elop ne>t 1eneration solutions for the power sector3
Al!#o. $%0 NTPC "% 1??? "his D7<D7 joint 0enture underta es reno0ation5 moderni=ation5 retrofit and refurbishment of old and a1ein1 power plants3
3. INTRO),CTION TO THERMAL POWER PLANT AN) BOILERS

# thermal power station is a power plant in which the prime mo0er is steam dri0en3 %ater is heated5 turns into steam and spins a steam turbine5 which dri0es an electrical 1enerator3 #fter it passes throu1h the turbine5 the steam is condensed in a condenser and recycled to where it was heatedL this is nown as a 'an ine cycle3 "he 1reatest 0ariation in the desi1n of thermal power stations is due to the different fuel sources3 #lmost all coal5 nuclear5 1eothermal5 solar thermal electric5 and many natural 1as power plants are thermal3 )atural 1as is fre/uently combusted in 1as turbines as well as boilers3 Power plants burnin1 coal5 fuel oil5 or natural 1as are often called fossil fuel power plants3
4"21r' 1 THERMAL POWER PLANT
# fossil-fuel power station is a type of power station that burns fossil fuels such as coal5 natural or petroleum (oil) to produce electricity3 In a fossil fuel power plant the chemical ener1y stored in fossil fuels such as coal5 fuel oil5 natural 1as or oil shale and o>y1en of the air is con0erted successi0ely into thermal ener1y5 mechanical ener1y and5 finally5 electrical ener1y3 (entral station fossil-fuel power plants are desi1ned on a lar1e scale for continuous operation3 In many countries5 such plants pro0ide most of the electrical ener1y used3 ?ossil fuel power stations ha0e rotatin1 machinery to con0ert the heat ener1y of combustion into mechanical ener1y5 which then operates an electrical 1enerator3 "he prime mo0er may be
THAPAR UNIVERSITY, PATIALA Page 1@
a steam turbine or a 1as turbine3 #ll plants use the ener1y e>tracted from e>pandin1 1as steam or combustion 1ases3 2yproducts of thermal power plant operation must be considered in their desi1n and operation3 %aste heat ener1y5 which remains due to the finite efficiency of the (arnot5 'an ine or .iesel power cycle5 is released directly to the atmosphere5 directly to ri0er or la e water5 or indirectly to the atmosphere usin1 a coolin1 tower with ri0er or la e water used as a coolin1 medium3 "he flue 1as from combustion of the fossil fuels is dischar1ed to the air3 "his 1as contains carbon dio>ide5 water 0apour5 as well as substances such as elemental nitro1en5 nitro1en o>ides5 sulfur o>ides5 mercury5 traces of other metals5 and5 for coal-fired plants5 fly ash3 Solid waste ash from coal-fired boilers must also be remo0ed3 Some coal ash can be recycled for buildin1 materials3 ?ossil fueled power stations are major emitters of ($ 65 a 1reenhouse 1as (GBG) which accordin1 to a consensus opinion of scientific or1ani=ations is a contributor to 1lobal warmin1 as it has been obser0ed o0er the last 177 years3 "he ener1y efficiency of a con0entional thermal power station5 considered as salable ener1y as a percent of the heatin1 0alue of the fuel consumed5 is typically @@G to :9G3 "his efficiency is limited as all heat en1ines are 1o0erned by the laws of thermodynamics3 "he rest of the ener1y must lea0e the plant in the form of heat3 "his waste heat can 1o throu1h a condenser and be disposed of with coolin1 water or in coolin1 towers3
631 ELECTRICITY COST

"he direct cost of electric ener1y produced by a thermal power station is the result of cost of fuel5 capital cost for the plant5 operator labour5 maintenance5 and such factors as ash handlin1 and disposal3 Indirect5 social or en0ironmental costs such as the economic 0alue of en0ironmental impacts5 or en0ironmental and health effects of the complete fuel cycle and plant decommissionin15 are not usually assi1ned to 1eneration costs for thermal stations in utility practice5 but may form part of an en0ironmental impact assessment3
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@3 THERMAL POWER PLANT LAYO,T
4"21r' 3
13 (oolin1 tower3 63 (oolin1 water pump3 @3 "ransmission line (@-phase)3 :3 Unit transformer (@-phase)3 D3 &lectric 1enerator (@-phase)3 E3 *ow pressure turbine3 ;3 (ondensate e>traction pump3 93 (ondensor3 A3 Intermediate pressure turbine3 173 Steam 1o0ernor 0al0e3 113 Bi1h pressure turbine3 163 .eaerator3 1@3 ?eed heater3 1:3 (oal con0eyor3 1D3 (oal hopper3 1E3 Pul0erised fuel mill3 1;3 2oiler drum3 193 #sh hopper3 1A3 Superheater3 673 ?orced drau1ht fan3 613 'eheater3 663 #ir inta e3 6@3 &conomiser3 6:3 #ir preheater3 6D3 Precipitator3 6E3 Induced drau1ht fan3 6;3 (himney Stac 3 (oal is con0eyed (1:) from an e>ternal stac and 1round to a 0ery fine powder by lar1e metal spheres in the pul0erised fuel mill (1E)3 "here it is mi>ed with preheated air (6:) dri0en by the forced drau1ht fan (67)3 "he hot air-fuel mi>ture is forced at hi1h pressure into the boiler where it rapidly i1nites3 %ater of a hi1h purity flows 0ertically up the tube-lined walls of the boiler5 where it turns into steam5 and is passed to the boiler drum5 where steam is separated from any remainin1 water3 "he steam passes throu1h a manifold in the roof of the drum into the pendant superheater (1A) where its temperature and pressure increase rapidly to around 677 bar and D;7M(5 sufficient to ma e the tube walls 1low a dull red3 "he steam is piped to
THAPAR UNIVERSITY, PATIALA Page 1D
the hi1h pressure turbine (11)5 the first of a three-sta1e turbine process3 # steam 1o0ernor 0al0e (17) allows for both manual control of the turbine and automatic set-point followin13 "he steam is e>hausted from the hi1h pressure turbine5 and reduced in both pressure and temperature5 is returned to the boiler reheater (61)3 "he reheated steam is then passed to the intermediate pressure turbine (A)5 and from there passed directly to the low pressure turbine set (E)3 "he e>itin1 steam5 now a little abo0e its boilin1 point5 is brou1ht into thermal contact with cold water (pumped in from the coolin1 tower) in the condensor (9)5 where it condenses rapidly bac into water5 creatin1 near 0acuum-li e conditions inside the condensor chest3 "he condensed water is then passed by a feed pump (;) throu1h a deaerator (16)5 and pre-warmed5 first in a feed heater (1@) powered by steam drawn from the hi1h pressure set5 and then in the economiser (6@)5 before bein1 returned to the boiler drum3 "he coolin1 water from the condensor is sprayed inside a coolin1 tower (1)5 creatin1 a hi1hly 0isible plume of water 0apor5 before bein1 pumped bac to the condensor (9) in coolin1 water cycle3 "he three turbine sets are sometimes coupled on the same shaft as the three-phase electrical 1enerator (D) which 1enerates an intermediate le0el 0olta1e (typically 67-6D 8)3 "his is stepped up by the unit transformer (:) to a 0olta1e more suitable for transmission (typically 6D7-D77 8) and is sent out onto the three-phase transmission system (@)3 &>haust 1as from the boiler is drawn by the induced draft fan (6E) throu1h an electrostatic precipitator (6D) and is then 0ented throu1h the chimney stac (6;)3 #lstom is basically concerned with the manufacturin1 of boilers of steam power plant for different clients3.ependin1 upon the re/uirements it has manufactured no of boilers for its customers3 ALSTOM !1--l"'0 #8o 1%"#! o& 3 A 390 To%! P'r Ho1r TPH( <l$!# &1r%$/' 2$! &"r'0 <o"l'r! &or TATA S#''l $# J$.!5'0-1r. T5'!' $r' #5' l$r2'!# <l$!# &1r%$/' 2$! &"r'0 <o"l'r! <1"l# "% #5' /o1%#r7 <7 ALSTOM I%0"$. M7 -ro='/# 8$! r'2$r0"%2 #5' $%$l7!"! o& #5"! TATA POWER LIMITE) PROJECT.
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:3 BOILER
"he boiler 1enerates hi1h pressure steam by transferrin1 the heat of (ombustion in 0arious heat transfer sections3 # boiler incorporates a firebo> or furnace in order to burn the fuel and 1enerate heat3 "he 1enerated heat is transferred to water to ma e steam5 the process of boilin13 "his produces saturated steam at a rate5 which can 0ary accordin1 to the pressure abo0e the boilin1 water3 "he hi1her the furnace temperature5 the faster the steam production3 "he saturated steam thus produced can then either be used immediately to produce power 0ia a turbine and alternator5 or else may be further superheated to a hi1her temperatureL this notably reduces suspended water content ma in1 a 1i0en 0olume of steam produce more wor 3 #ny remainin1 heat in the combustion can then either be e0acuated or made to pass throu1h an economi=er5 the role of which is to warm the feed water before it reaches the boiler3
4"21r' 9 BOILER SYSTEM
4.1 WATER AN) STEAM SYSTEM

8olume of one unit mass of steam is thousand times that of water5 when water is con0erted to steam in a closed 0essel the pressure will increase3 2oiler uses this principle to produce hi1h pressure steam3
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(on0ersion of %ater to Steam e0ol0es in three sta1es3 Beatin1 the water from cold condition to boilin1 point or saturation temperature K sensible heat addition3 %ater boils at saturation temperature to produce steam - *atent heat3 addition3 Beatin1 steam from saturation temperature to hi1her temperature called Superheatin1 to increase the power plant output and efficiency3 4.1.1 S'%!"<l' H'$# A00"#"o% 1. 4''0 W$#'r P1.-. "he first step is to 1et a constant supply of water at hi1h pressure into the boiler3 Since the boiler is always at a hi1h pressure3 N2oiler feed water pumpH pumps the water at hi1h pressure into the boiler from the Nfeed water tan H3 "he pump is a in to the heart in the human body3 3. Pr'-H'$#"%2 O?eed water heatersH5 usin1 e>tracted steam from the turbine5 adds a part of the sensible heat e0en before the water enters the boiler3 9. E/o%o."B'r. -ost of the sensible heat is absorbed in the &conomi=er3 "hese are a set of coils made from steel tubes located in the tail end of a boiler3 "he hot 1ases lea0in1 the boiler furnace heat the water in the coils3 "he water temperature is sli1htly less than the saturation temperature3?rom the economi=er the water is fed to the OdrumO3
4"21r' 4 ECONOMICER
4.1.3 L$#'%# H'$# A00"#"o% 1( )r1.. "he drum itself a lar1e cylindrical 0essel that functions as the stora1e and feedin1 point for water and the collection point for water and steam mi>ture3 "his is the lar1est and most important pressure part in the boiler and wei1hs in the ran1e 6D7 "ons for E77 -% power plants3 3( W$#'r W$ll! 2oilin1 ta es place in the N%ater %allsH5 which are water filled tubes that form the walls of the furnace3 %ater %alls 1et the water from the Ndown comersH5 which are lar1e pipes5 connected to the drum3 "he down comers and the water wall tubes form the two le1s of a water column3 #s the water heats up in the furnace a part of the water in the water-wall tubes becomes steam3 "his water steam mi>ture has a lower density than the water in the down comers3 "his density difference creates a circulation of water from the drum5 throu1h the down comers5 water walls and bac to the drum3 Steam collects at the upper half of the drum3 "he steam is then sent to the ne>t sections3 "he temperature in the drum5 down comers and water wall is at the saturation temperature3
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4"21r' : STEAM )R,M AN) WATER WALL
4.1.9 S1-'r5'$# @ R'5'$# 1. S1-'r5'$#'r Steam from the drum passes to the Superheater coils placed in the ?lue 1as path33 "he steam temperature increases from the saturation temperature till the ma>imum re/uired for operation3 "he superheated steam then finally 1oes to the turbine3 ?inal Superheater temperatures are in the 'an1e of D:7 to D;7 M( for lar1e power plants and Superheated steam pressures are around 1;D bar3 3. R'5'$#'r Steam from the e>haust of the first sta1e turbine 1oes bac to the boiler for reheatin1 and is returned to the second sta1e3 'eheater coils in the flue 1as path does the reheatin1 of the returned steam3 "he reheat steam is at a much lower pressure than the super heated steam but the final reheater temperature is the same as the superheated steam temperature3 'eheatin1 to hi1h temperatures impro0es the output and efficiency of the Power Plant3 ?inal 'eheater temperatures are normally in the ran1e of DE7 to E77 M(3 'eheat steam pressures are normally arou nd :D bar3
4"21r' ; S,PERHEATER AN) REHEATER
4.3 COMB,STION SYSTEM

2oilers burn coal to produce steam3 2urnin1 coal in0ol0es fuel preparation5 pro0idin1 the necessary combustion air and remo0al of the flue 1ases and ash3 4.3.1 Co$l S7!#'. (oal recei0ed from the mines is stored in the coal yard adjacent to the power plant3 It is then con0eyed on a daily basis3 N(oal feedersH continuously feed the re/uired amount of coal to the N(oal Pul0eri=ersH3 1. Co$l P1l6'r"B'r! Grinds the coal to a 0ery fine powder to ma e it burn easily3 Pul0eri=ers ha0e steel rollers or steel balls5 which crush the coal between them into a fine powder3 "his powder is easy to burn3 Since coal contains moisture3 Bot air form the Primary #ir ?ans dries the coal in the pul0eri=ers3 "his ma es the burnin1 easy and efficient3 "his air also carries the dry coal powder from the pul0eri=ers to the burners in the boiler furnace3 In the burners the coal powder is mi>ed with the re/uired amount of (ombustion air and burned in the furnace3 4.3.3 A"r !7!#'.
(orrect amount of air is the most essential in1redient for (ombustion3 -ore air or less air both ma es the combustion process inefficient3 1. 4or/'0 )r$&# 4$% Supplies most of the (ombustion air3 "his fan ta es air from the atmosphere and blows it into the furnace throu1h air ducts3 "he #ir Beater heats the air before it enters the ?urnace3 3. A"r Pr'5'$#'r Utili=es the heat of the hot flue 1ases that lea0e the boiler to heat the combustion air3 Bot air impro0es the efficiency of combustion3 "he #ir Beater wor s on the re1enerati0e principle3 Steel plates alternati0ely placed in the hot flue 1as path and then in the air path heats the cold air enterin1 the #ir Beater3
9. Pr".$r7 A"r 4$% Supplies the air to the pul0eri=ers for dryin1 and transportin1 coal3 "his air called the Primary air also is heated in the #ir Beater3 4.3.9 4l1' 2$! !7!#'.. (oal burns in the furnace 1i0in1 out heat and formin1 flue 1ases3 1. I%01/'0 )r$&# 4$% "he Induced draft fan draws out the hot flue 1ases from the furnace3 "he 1as passes throu1h the 0arious heatin1 surfaces of the boiler5 the &lectrostatic Precipitator and dischar1es to the atmosphere at the top of the stac 3 Induced .raft ?an pro0ides the ener1y for this flow of flue 1ases3 "he Induced .raft ?an is normally located adjacent to the Stac 3 3. El'/#ro!#$#"/ Pr'/"-"#$#or! (aptures the fly ash in the flue 1ases without lettin1 them out into the atmosphere3 Bi1h 0olta1e electrodes placed in the 1as path ioni=e the ash particles which collects on collectin1 electrodes and falls into ash hoppers3
9. S#$/> or #5' C5".%'7 .isperses the hot 1ases and any other particles at a 1reat hei1ht3 "he hei1ht enables a 0ery lar1e dispersion area and re1ulates emission concentrations at 1round le0els to the le0el acceptable to humans and 0e1etation3 Stac hei1hts for lar1e power plants are around 6D7 to 697 meters3 4. B$l$%/'0 )r$&# "he ?orced .raft fan and the Induced .raft fan operate in such a way that the air pressure in the furnace is at =ero pressure ie< at atmospheric pressure3 "his is called the N2alanced .raft systemH3
4.3.4 A!5 S7!#'.. #sh is the inert matter in coal and is the residue after combustion3 "his has to be collected and disposed off without lettin1 it out into the atmosphere3 # part of the ash5 around 1D G collects as N2ottom ashH at the bottom of the furnace3 "he other part collects as N?ly ashH in the &lectrostatic Precipitators3 "he collected ash is then transported to disposal yards or stora1e silo
4"21r' 7 BOILER COMB,STION SYSTEM
:. TYPES O4 BOILERS
2oiler classification can be based on many factors li e usa1e5 fuel fired5 fuel firin1 system5 type of arran1ement etc3 (ommonly nown types are pul0eri=ed coal fired boilers5 fluidi=ed bed boilers5 super critical boilers5 oil and 1as fired boilers3 "he main purpose of steam boilers is to 1enerate steam5 and so the way in which the steam is 1enerated and consumed forms the major cate1ory3 "he major two 1roups of boiler
application are Industrial steam 1enerators and power 1eneration boilers3 2oilers are also classified as fire tube and water tube boilers3 ?ire tube boilers ha0e almost become e>tinctL howe0er this can be classified as

*ocomoti0e boilers Industrial boilers .omestic use boilers o0er when si=e and capacity increased3 "his can be classified
%ater tube boilers too
dependin1 on type of circulation used to 1enerate steam as

)atural circulation boiler ?orced circulation boilers Super critical pressure boilers
.ependin1 on type of firin1 adopted in boilers they can be classified as

Sto er fired Pul0eri=ed coal fired ?luidi=ed bed boilers
$f these the sto ers which were predominantly used in early days of hi1h pressure hi1h capacity boilers are bein1 replaced by pul0eri=ed coal fired boilers and fluidi=ed bed boilers3 ?luidi=ed boilers are also 1oin1 throu1h fast de0elopment and can be now sub classified as

2ubblin1 fluidi=ed bed boilers Pressuri=ed fluidi=ed bed boilers (irculatin1 fluidi=ed bed boilers3
"he hi1her capacity boilers are mainly circulatin1 fluidi=ed bed boilers due inherent limitations in bubblin1 bed boilers3 2oilers can be classified based on the type of fuel used as
(oal fired boilers $il fired boilers Gas fired boilers -ulti-fuel fired
8arious types of arran1ement are used by desi1ners in desi1nin1 the boiler for meetin1 the end re/uirement3 Bence boilers are classified based on the arran1ement as

Pac a1e boilers ?ield erected boilers .rum type boilers "ower type or sin1le pass "wo pass boilers
:.1 ON THE BASIS O4 4IRING

1. C"r/1l$#"%2 4l1"0"B'0 B'0 Bo"l'r (irculatin1 ?luidi=ed 2ed combustion has 1i0en boiler and power plant operators a 1reater fle>ibility in burnin1 a wide ran1e of coal and other fuels3 #ll this without compromisin1 efficiency and with reduced pollution3 #t the bottom of the boiler furnace there is a bed of inert material3 2ed is where the coal or fuel spreads3 #ir supply is from under the bed at hi1h pressure3 "his lifts the bed material and the coal particles and eeps it in suspension3 "he coal combustion ta es place in this suspended condition3 "his is the ?luidi=ed bed3 ?ine particles of partly burned coal5 ash and bed material are carried alon1 with the flue 1ases to the upper areas of the furnace and then into a cyclone3 In the cyclone the hea0ier particles separate from the 1as and falls to the hopper of the cyclone3 "his returns to the furnace for recirculation3 Bence the name (irculatin1 ?luidi=ed 2ed combustion3 "he hot 1ases from the cyclone pass to the heat transfer surfaces and 1o out of the boiler3 "o start with the bed material is sand3 Some portion is lost in the ash durin1 the operation and this has to be made-up3 In coal fired boilers the ash from the coal itself will be the ma eup material3 ?or hi1h sulphur coals
*imestone addition to the bed material reduces S$ 6 emissions3 (?2( uses crushed coal of @ to E mm si=e3 "his re/uires only a crusher not a pul0eri=er3 3. P1l6'r"B'0 Co$l Bo"l'r -ost of the coal fired power plants use the Pul0eri=ed (oal (P() firin1 technolo1y3 "he technolo1y is pro0en and is in use for nearly a century3 #d0ances o0er the years ha0e impro0ed the efficiency of combustion5 reliability and reduced emissions3 P( firin1 utilises coal 1round to a 0ery fine powder sprayed into the furnace for combustion3 P( firin1 uses around @7 G of the combustion air as hi1h pressure primary air for dryin1 and transportin1 fuel3 "hey do not ha0e refractory co0erin1 on the furnace tubes or other heat transfer areas3# ?lue Gas .esulphuri=ation unit is re/uired for the reduction of Sulphur .io>ide3 #round 1D G of ash collects at the bottom of the furnace and the balance in the electrostatic precipitators3
4"21r' 8 TYPES O4 BOILERS
:.3 ON THE BASIS O4 STEAM PARAMETERS

#s the pressure increases the boilin1 temperature increases and the latent heat of 0apori=ation decreases3 # further increase in pressure and temperature leads us to a point at which the latent heat of 0apori=ation is =ero5 or there is no boilin13 %ater directly becomes steam3 "his is the (ritical Pressure and the (ritical "emperature3 ?or steam this occurs at @;: de1 ( and 6673E bar3 (on0entional steam power plants operate at a steam pressures in the ran1e of 1;7 bar3 "hese are S1</r"#"/$l -o8'r -l$%#!3 "he new 1eneration of power plants operates at pressures hi1her than the critical pressure3 "hese are S1-'r/r"#"/$l -o8'r -l$%#!. "he operatin1 pressures are in the ran1e of 6@7 to 6ED bar3 "he efficiency of the 'an ine cycle depends on the pressure at which it operates3 Bi1her pressure and temperature increase the efficiency of the thermal cycle and power plant3 "his is the reason for operatin1 at hi1her steam pressures3 *ar1e Subcritical thermal power plants with 1;7 bar and D:7 C D:7 M ( (SB C 'B) operate at an efficiency of @9 G3 Supercritical units operatin1 at 6D7 bar and E77CE1D M ( can ha0e efficiencies in the ran1e of :6 G3 In supercritical units the water enterin1 the boiler has to be of e>tremely hi1h le0els of purity3 Supercritical boilers do not ha0e a steam drum that separates the steam and the water3 If the enterin1 water /uality is not 1ood5 carryo0er of impurities can result in turbine blade deposits3 Supercritical power plants use special hi1h 1rade materials for the boiler tubes3 "he turbine blades are also of impro0ed desi1n and materials3 In fact5 the 0ery increase in hi1her pressure and temperature desi1ns are dependent on the de0elopment of newer and newer alloys and tube materials3
:.9 ON THE BASIS O4 ARRANGEMENT

1. To8'r T7-' Bo"l'r "ower-type sin1le pass desi1ns find application in cases where the fuel used is hi1hly erosi0e in nature3 "he supercritical units normally 1o with tower type construction due to the fact that tower type can adapt to the spiral wall construction easily3 "he heat transfer tube bundles of superheater5 reheater and economi=er in the top pass all han1 in one support system throu1h 0ertical supportin1 tubes3 "his enables the boiler structure to respond to all transient phenomena arisin1 from load chan1es or other dynamic processes3 #s the flue 1ases tra0el throu1h the superheater5 reheater5 and economi=er pressure parts section without any chan1e in direction5 the erosion rate in these types of boilers is lower3 "he 0ery tall structure of the tower type desi1n re/uires e>tra care and chec in1 to be done if the unit is to be put in a hi1h wind load or cyclone-prone area3 "hese types of boilers ha0e hi1her amount of settlement of ash on the heat transfer surface and so they need a hi1her fre/uency of soot blowin13 3. T8o P$!! Bo"l'r In the case of the two pass desi1n5 the 1as flow ta es a turn from the furnace outlet throu1h a small hori=ontal pass to the second pass where a part of the superheater surface5 sometimes e0en a portion of reheater surface and economi=er surface5 is accommodated3 .ue to the chan1e in direction of flue 1as the ash particles se1re1ate and lead to hi1her erosion rate in locali=ed areas3 "his desi1n has the ad0anta1e that they ha0e about :7 G fewer erection pressure parts welds and also parallel erection of first and second pass is possible5 thus reducin1 the total erection time3 &0en thou1h this type of desi1n has an inherent disad0anta1e for hi1h ash coals5 there are desi1ns for protectin1 the pressure parts from erosion5 and the a0ailability losses in these units ha0e been contained due to pressure part failures by erosion3 Some boiler desi1ners e0en today prefer a two pass desi1n for sub-critical and supercritical units and feel they are more economical than the tower type3
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4"21r' ? TOWER TYPE BOILER
4"21r' 10 TWO PASS BOILER
E3 BRIE4 ABO,T TATA POWER PROJECT

"ata Power Proposes to set up a capti0e power plant at Jamshedpur5 &ast Sin1bhum district in the state of Jhar hand3 "his specification co0er the desi1n5 manufacture5 assembly5 testin15 pac in15 supply stora1e at site5 start up5 commissionin1 and 1uarantee test for two (6) )os3 1as fired boiler for power 1eneration 3"he boiler shall ha0e a ma>imum continuous 'atin1 (-(') of 6@7 tons per hour at a steam pressure of A136 bar and temperature of D:7 PD 7( at super heater out let3 "he desi1n5 manufacture and installation of 2oiler shall be strictly in accordance with Indian 2oiler re1ulation (I2') and accordin1 to the list of standards 1enerally applicable3
;.1 BOILER TYPE O4 TATA POWER PROJECT

OIL@GAS 4IRE) BOILERD - "he main fuel used in this boiler is (o e-$0en C 2last ?urnace Gas and *. Gas3 ($ 1as will be used durin1 start up3 %hen ($ 1as will not be a0ailable in sufficient /uantity then *.$ can be used alternati0ely and shall be desi1ned to meet D7G SG-('3 "he system shall be desi1ned for burnin1 a combination of *.5 (o e $0en 1as and 2last ?urnace 1as3 "he firin1 system also shall be suitable for 177G -(' with 2?G firin1 without ($ 1as and *.$ support3
;.3 SITE CON)ITIONS

1. LOCATION
"he site is located at Jamshedpur5 &ast Sin1hbhum .istrict5 in the state of Jhar hand5 India3 3. SITE CLIMATIC CON)ITIONS 333:;367( 333@3A7( 3339:G 3336:G 333A7mm
-a>imum air temperature -inimum air "emperature -a>imum 'elati0e Bumidity -inimum 'elati0e Bumidity Bea0iest 'ainfall in 1hour
Prominent wind direction
333?rom west in winter and ?rom east in summer
9.
)ESIGN CON)ITIONS
#ll e/uipment in 1eneral5 shall be desi1ned for smooth5 efficient and troubleKfree operation in tropical humid climate for a ma>imum temp of D77c3
AIRPORT
"he nearest airport is at Jamshedpur3
RAILWAY STATION
"he nearest railway station is at "atana1ar5 D m from plant site3
ROA)
#t "atana1ar5 about E Fms from the plant site3
COMM,NICATION
Postal tele1raph5 telephone5 tele> and &-mail facilities are a0ailable at Jamshedpur3
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;.9 ELECTRIC POWER

:1D P17G5 @phase :wire5 D7 B=PDG effecti0ely earthed electrical power supply will be made a0ailable at -(( incomin1 terminal inside turbine buildin1 and from -(( to electrical e/uipment power supply 5cables are in otherHs scope3 Incomer cable for boiler -(( will be terminated by the other a1ency3 Bowe0er5 motorHs load abo0e 1;D F%5 E3E F8 supply will be pro0ided which would be fed from purchasers E3E F8 switchboard3 2ut for I. 4 ?. fan motors5 for speed controllin1 purpose5 *" 8?. system shall be pro0ided which will compromise step down transformer from E3E F8 to ;1D 0olts5 EA7 0olts 8?.s and motors3
7. SCOPE O4 ELECTRICAL WORK IN TATA POWER PROJECT

"he followin1s are the main electrical scope of "ata Power Project I. 4 ?. fan *" motors shall be pro0ided with 8?. for speed control3 "he I. fan system shall consist of E3EF8 to EA78 step down transformers5 EA78 8?. and EA78 motors3 ?. fan system consists of :1D8 8?. and :1D8 motors3 *" dri0e motors complete with all fittin1s and accessories shall be operated with :1D 8 #( D7 B= @ phase supply3 "hey should be pro0ided with 8?. for speed control with soft startin1 facilities and by pass .$* start3.( starter shall be pro0ided for all .( motors &n1ineerin1 4 .esi1n of 6 nos3 :1D8 -(( for all the consumers and all the *" dri0es of boiler with spare feeder as re/uired3 -otors up to @; % ratin1 will ha0e microprocessor-based relay ha0in1 $C( 4 phase fault with fault current indication3 2eyond @; % ratin15 microprocessor based composite motor protection relay with $C*5 stallin15 phase unbalance5 phase fault 4 earth fault protection3 #ll modules of -(( shall be draw out type3 &n1ineerin1 4 .esi1n of *ocal Push 2uttons station for both B" and *" dri0es3 #ll motor operated 0al0eCdamper actuators shall ha0e inte1ral starters3
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&n1ineerin1 4 .esi1n of all 131 F8 1rade (*") power5 control and instrumentation cables includin1 termination on both sides complete with accessories for all interconnection between the field e/uipmentCinstruments to junction bo>es and control panels and special cables shall be included in scope3
&n1ineerin1 4 .esi1n of GI cable trays5 supports5 GI pipes5 GI conduits5 adapter bo>es5 terminal bo>5 junction bo> etc and all other cablin1 accessories from boiler main column to boiler au>iliary e/uipment C instruments3
&n1ineerin1 4 .esi1n of e/uipment such as motors5 8?.s5 0al0es5 *P2S5 J2s5 cable trays earthin13
.esi1n and Preparation of S*. and control schematic for boiler -((5 cable routin1 dia1rams5 cable schedule5 cable interconnection dia1rams and 2$Q for all cables
8. ELECTRICAL SYSTEM )ESIGN CRITERIA 4OR TATA POWER PROJECT

"he desi1n5 manufacture5 performance5 testin1 and installation (includin1 safety and other essential pro0isions) of e/uipment and accessories would5 in 1eneral5 comply with the latest issue of the followin1
R#pplicable standards and codes of practices published by 2ureau of Indian Standards R (entral 2oard of irri1ation and power R Indian &lectricity #ct R(entral &lectricity #uthority RIndian &lectricity 'ules R&/uipment specific statutory re1ulation RIndian ?actory #ct
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&/uipment and accessories5 for which Indian standards are not a0ailable5 shall be desi1ned5 manufactured and test in accordance with the latest issue of reco1ni=ed standard such as I&(5 IS etc3
Vol#$2' L'6'l 13 Power supply E3E F8 (SC-17G) @ phase5 @ wire5 D7 B= non effecti0ely earthed3 :1D 8 (SC-17G)5 @ Phase5 : %ire5 D7B= effecti0ely earthed3 63 (ontrol supply 11785 1 Phase5 6wire5 D7B= deri0ed from :1D 8 C 117 8 1-phase transformer @ :3 ?or instrument 4 control supply ?or space heater and lamp supply 6:8 .(5 S17G 4 -67G 6 wire Supply3 6:785 1 Phase5 6 %ire5 and D7 B= supply3
D3 E3
Supply of normal -(2-.2
:1D85 @Phase5 : %ire5 D7 B= supply
Supply of .( motors5 control and 66785 S17G 4 -1DG .3( supply protecti0e system3 de0ices of electrical
;3 93 A3 173
Uninterruptible Power Supply -eterin1 Plant illumination &mer1ency illumination
6:785 1Phase5 6 %ire 11785 #(5 P" Supply 6:785 1phase5 *ine 4)eutral 66785 6 %ire5 unearthed .3(3
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P'r."!!"<l' V$r"$#"o%! "he system C unit CPlantCe/uipment will be desi1ned suitable for followin1 0ariation in 0olta1e and fre/uency3 8olta1e Power supply (ontrol supply P17G P17G ?re/uency SDG to -DG SDG to -DG
Cr"#'r"$ &or !'l'/#"o% o& 6ol#$2' l'6'l &or 0r"6' .o#or! General-purpose :1D8 -otor5 1enerally rated up to 1;D F% with robust industrial desi1n and it is for *" -otor and abo0e 1;D F% this is for B" motor3 S7!#'. E$r#5"%2D :1D 8 systems will be solidly earthed3
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?. ENGINEERING AN) )ESIGNING THE PROJECT
?.1 PIPING AN) INSTR,MENTATION )IAGRAMS

#lso nown5 as en1ineerin1 flow drawin1s are a type of process en1ineerin1 drawin1s that describes all the process desi1n aspects of a plant3 Process desi1n means all that stuff that ma es up a plant3 Includin1< -ajor and -inor e/uipments 8al0es Instrumentation Stand alone (ontrollers 2uttons -otor and .ri0es *imit and Point .e0ices Pipin1 8irtual .e0ices
P+I) !1--or# 0o/1.'%#!< Process ?low .rawin1s Pipin1 and -aterial specifications &/uipment and Instrumentation specifications ?unctional control document
P+I) $r' 1!'0 &orD #ct as definition of process from which all en1ineerin15 fabrication5 construction and operation is based3 Ser0e as reference for process safety information in process safety mana1ement3
L"."#$#"o%!D )ot to Scale )ot 1eometrically accurate )ot definite )ot drawn consistently
?.3 P+I) 4OR )I4ERRENT STAGES O4 A BOILER SYSTEM

*ow press boiler startup system Bi1h press boiler startup and warmup system 2oiler circulation pump system &conomi=er system &0aporator system %ater separator system Superheater system 'eheater system *i1ht oil supply and burner detail
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Bea0y oil supply and burner detail (ombustion air and flue 1as system (oal feeder and pul0eri=er system Soot blower system
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4"21r' 11 P+I) )IAGRAM
?.9 ELECTRICAL LOA) LIST

Prepared from P4I. Used to prepare S*. for manufacturin1 -((5 control schematic drawin1 and -(( specifications also re/uired for -(( manufacturin1 Used to manufacture power distribution panels S*. ?or determination of power supply to 0arious loads
4"21r' 13 ELECTRICAL LOA) LIST
10. PACKAGE )ESCRIPTIONS

R -(( (-otor (ontrol (entre)3 R *P2S (*ocal Push 2utton Station)3 R -otors3 R #ctuator3 R Power5 (ontrol 4 Instrument (able3 R &arthin13
11. ENGINEERING* )ESIGN AN) COMMISSIONG O4 BOILER MCC

)&-# defines a motor control center in I(S-19-6771 as bein1 a floor-mounted assembly of one or more enclosed 0ertical sections ha0in1 a hori=ontal common power bus and principally containin1 combination motor control units3 "hese units are mounted one abo0e the other in the 0ertical sections3 "he sections normally incorporate 0ertical buses connected to the common power bus5 thus e>tendin1 the common power supply to the indi0idual units3 Power may also be supplied to the indi0idual units by bus bar connections5 by stab connection5 or by suitable wirin13 #ccordin1 to the )&-# definition5 motor control centers< R #re floor-mounted assemblies R Ba0e one or more enclosed 0ertical sections R Ba0e a common hori=ontal power bus R -ay incorporate 0ertical buses connected to the common bus R Principally contain combination motor control units
:1D8 -(( is used for *" motors5 0al0es and other consumers3
TYPES O4 MCC< -(( are 1enerally of followin1 types< .raw out type -(( or fi>ed type -(( .ouble front -(( or Sin1le front -((
)r$8 o1# #7-' 0o1<l' &ro%# Bo"l'r MCC! $r' 1!'0 "% #5"! -ro='/#. 1 %o. MCC -'r <o"l'r.
E%2"%''r"%2 A/#"6"#"'! R'2$r0"%2 Bo"l'r MCC -(( specifications alon1 with data sheet are prepared3 "he documents include General notes5 General arran1ement dia1ram5 Sin1le line dia1ram5 2ill of -aterial5 Schematic dia1ram5 2us 2ar calculations3 "hese documents are forwarded to supply chain mana1ement department for brin1in1 offer from 0arious manufacturers3 &n1ineerin1 department is e0aluatin1 these offers and 1i0e their appro0al for manufacturin1 clientCconsultant3 %hen the -(( is ready then that is bein1 inspected at manufacturerHs shop floor3 -(( is dispatched to site after ownerHs clearance3 -(( is installed and commissioned at site3 clearance5 parallely these documents are forwarded to
4"21r' 19 MOTOR CONTRL CENTRE
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4"21r' 14 GENERAL ARRANGEMENT )IAGRAM
4"21r' 1: MCC SPECI4ICATIONS
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4"21r' 1; SINGLE LINE )IAGRAM
4"21r' 17 BILL O4 MATERIAL
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11.1 SINGLE LINE )IAGRAM O4 MCC

Incomer no315 Incomer no36 and bus coupler should be interloc ed in such a way so that only two of them can be closed at a time3 .raw out type electrically operated #(2 shall be used for Incomer-1 4 Incomer-6 4 2us coupler #(2 shall ha0e short circuit5 o0er current and earth fault protection3 F%B meter shall be di1ital type 'S port 4 class-73D3 -(( shall be double front and fi>ed type3 #ll motor feeders shall ha0e $)5 $??5 "'IP5 &S5 I).I(#"I$) *#-P (Start5 Stop5 and "est &mer1ency Stop) Push 2utton and Selector Switch (?or *ocal and .(S Selection) .$* Starter shall be pro0ed with mechanical interloc 3 Beater ?eeder shall be connected with suitable copper bus up to terminal bloc s3 &ach of the selection 1and 6 shall be pro0ided with separate measurin1 cubical in which all the control wire for inter connection to *ocal Push 2utton Station5 .(S etc3 shall be terminated o0er suitable rated terminal bloc 3
11.3 SPECI4ICATION O4 LT MCC

1. SERVICE CON)ITION -(( shall be suitable for operation in hot5 humid area3 &lectrical e/uipment and system desi1n shall be based on ser0ice condition and au>iliary power supply condition 1i0en in the specification3 .esi1n ambient temperature is D7 7(5 relati0e humidity shall be ma>imum 9EGand minimum 6;Gand an altitude not e>ceedin1 D7 meter abo0e sea le0el3 Importance factor is 63D (for &lectrical e/uipment)5 13D for other3
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3. )ESIGN CRITERIA &/uipment type System 8olta1e < *" -(( < :1D85 @ ph5:wire5D7 B=
8ariation in 0olta1e and fre/uency
< P17G 4 PDG
System &arthin1 'ated short time withstand for 1 sec .esi1n ambient temperature Isolatin1 switch 4 contactor
< solidly 1rounded < D7 F# < D7 7( < #t least 67G more than (onnected load
9. 4EE)ER )ETAILS Incomer-6 and 2us (oupler shall be mechanically interloc ed in such way that only one of them could be closed at any one time under normal operatin1 condition and with defeat pro0ision for &mer1ency condition3
&ach Incomer module shall be pro0ided with *ine P"5 :1DCroot@C117Croot@5++5 fuse in primary and secondary50oltmeter selectin1 switch and 0oltmeter5 measurin1 ("s for 'C+C2 phase5 ammeter selector switch5 ammeter and '+2 indication lamp3 &ach incomer shall be pro0ided with di1ital class type 73D accuracy ener1y meters and fuse with isolatin1 switch3
"he bus section module shall be pro0ided with bus P" same as described abo0e in P" with 8oltmeter and selector switch for each of the bus section 1 and 63 #lso
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measurement ("s shall be pro0ided in 'C+C2 phase alon1 with ammeter and selector switch to indicate current flowin1 throu1h the bus section brea erC isolator3
In out1oin1 module all feeder modules shall be pro0ided with re/uired S?U units and indication lamp for 'C+C2 phase o0er suitable B'( fuse protection3 $ne measurement (" and one ammeter shall be pro0ided in all feeders rated at E@# and abo0e3 #ll motor feeder modules shall be pro0ided with re/uired S?U unit with B'( fuses5 motor contactors5 o0erload relay etc3 #ll components shall be carefully chosen to adhere to "ype -6coordination preferably from sin1le 0endor3 -otor $)C$??C"'IPP&. indication lamp shall be pro0ided3 2imetal reset shall be possible from door mounted reset button3
-echanically and electrically interloc ed contactors shall be pro0ided in '.$* feeders3 "hree Position selector switch ma e before brea type (*$(#* C -((C .(S) shall be pro0ided for each motor feeder3 -otor Start (?orward C'e0erse) C Stop C"est Push 2uttons shall be pro0ided in all motor feeders3 #u>iliary contactor recei0in1 i1nition command from .(S command from .(S shall be pro0ided with '( suppression coils3
It shall be possible to operate and chec the circuit of the motor starter after switchin1 of the incomin1 isolatin1 switch5 start and stop command from .(S and from *P2S shall be recei0ed at the motor starter module 3"he followin1 si1nals shall be send to .(S for which re/uired no3 $f au>iliary switches in the incomin1 isolator5 contact multiplication relays as needed shall be pro0ided in the -((3
.(S mode is selected throu1h additional contact in the selector switch3 $0er load relay is operate throu1h suitable contact multiplication3
4. SHORT CIRC,IT C,RRENTS "he short circuit current of :1D8 bus is D7F# for 1sec3 "he momentary current ratin1 shall be 631 times this 0alue3 :. C,RRENT TRANS4ORMER "he thermal and dynamic stability current for ("s shall be same as for the S?U3 (" ratio shall be cast resin type 4 shall be as per re/uirement3 -easurin1 ("s shall be conformin1 to accuracy class 137 and burden of ("s shall be as re/uired by the associated measurin1 e/uipment3 "he (" ratio shall be as re/uired by the associated measurin1 instrument3 "he ("s shall ha0e saturation factor of not more than 13D and hi1her limit shall be compatible with o0erload capacity of the instrument connected on the secondary side3 Protection ("s shall ha0e their accuracy and burden as re/uired by the protection circuit in which they are used and shall of accuracy class DP673 (" shall be of cast resin type3 ;. POTENTIAL TRANS4ORMER PT!( P"s pro0ided on each incomer Cbus coupler feeder shall be of draw out type 3"he P"s shall be dry epo>y resin molded type with 0olta1e ratin1 of :1DC'oot@C117C'oot@3 (urrent limitin1 B'( fuse shall protect hi1h 0olta1e windin1 of 0olta1e transformer3 "he 0olta1e transformer and fuses shall be completely disconnected and 0isibly 1rounded in fully draw out position3 *ow 0olta1e fuses5 si=ed to pre0ent o0erload5 shall be installed in all un1rounded secondary leads3 ?uses shall be suitably located to permit easy replacement while the switch is ener1i=ed3 "he technical particulars and accuracy class of the P" shall be as per re/uirement3
THAPAR UNIVERSITY, PATIALA Page :A
7. INTERNAL CONTROL S,PPLY ?or control of all other out1oin1 feeders5 dual control transformers in each section with suitable autoCmanual chan1eo0er switch are pro0ided3 (ontrol transformers shall be si=ed such that no de0ices malfunction due to in rush current of the lar1est rated contactors coil3 (ontrol transformer shall be housed in separate modules3 PlusC-inus 63DG5 DG taps shall be pro0ided on the primary to1ether with nonma1netic shieldin1 bCw primary and secondary windin1s3 (ontrol transformers shall be rated for :1D8 C6:785 D7B=5 minimum @ F8# ratin1 double wound with copper windin13 .P -(2s shall be pro0ided on incomin1 sides of supplies3 (ontrol buses of two sections shall be connected throu1h auto chan1eo0er scheme3 *&.s shall be pro0ided for the indication purpose3 Incomer to indi0idual control transformer shall be protected by a suitable rated "P) isolator and out1oin1 from control transformer to the chan1eo0er selector switches shall be pro0ided with -(2 protection3 8. PROTECTIVE EARTHING (ontinuous earth bus of minimum si=e ED>9 mm aluminum at bottom of panel desi1ned to carry the pea short circuit and short time fault current as specified3 #ll metallic enclosures Cmodule doors shall be connected positi0ely to earth by suitable earth connectors C fle>ible copper connectors respecti0ely to ensure electrical safety3 %ithdraw able units pro0ided with self-ali1nin15 sprin1 loaded5 sil0er plated copper scrappin1 earth contact of ma e before Cbrea after type ensurin1 earth continuity from ser0ice to the test position3 ?. MAGNETIC CONTACTORS @ Pole type contactors shall be capable of interruptin1 ten times the rated current for rated si=e up to 177# and ei1ht times the rated for lar1er si=es3
THAPAR UNIVERSITY, PATIALA Page D7
Suitable to carry the prospecti0e short circuit current without dama1e or injurious heatin1 till the prospecti0e de0ice operates3 Insulation for coils shall be class & or better3 Shall pic up positi0ely at 0olta1e between 9DG to 117G of rated 0alue3 .rop out shall be not more than ;7G of rated 0alue3 ?or fre/uently re0ersin1 dri0es5 #( @ ratin1 selected shall be D7G hi1her than full load current of the motor at the specified duty cycle3 'e0ersin1 contactor shall be electrically and mechanically interloc ed3 .erated #(: ratin1 shall be selected for inchin1 and plu11in1 operation of the dri0es3 -inimum 6 )$S6 )( au>iliary contacts with minimum ratin1 of 17#5 :1D8 for rated duty #(-6@ duty class3 Isolators shall be of #(-6@ duty class3 10. THERMAL OVERLOA) RELAY "ype< "hree elements positi0e actin1 ambient temperature compensated with
adjustable settin1s3 'elay< (ontact< Sin1le phase pre0ented relay shall be inbuilt3 -anual reset type with one chan1e o0er contact3 'esettin1 of the relay
shall be possible with compartment doors only after openin1 the door3 "he entire switch5 fuse5 contactor 4 o0erload selection shall be as per coordination type 6 IS< 1@A:;3 ?or A7F% and abo0e comprehensi0e microprocessor based motor protection relay shall be pro0ided3 ?or motors startin1 hi1h inertia loads saturable type protection class ("s shall be used for bimetallic circuit3 11. P,SH B,TTON + LAMPS "ype< Push buttons shall be hea0y duty5 push to actuate type with inte1ral plate mar ed with its function3
(ontacts< &ach push buttons shall ha0e two normally open and two normally closed contacts3 .uty class shall be @77 switchin1 cycles per hour3
*amps< Panel lamp with door switch shall be pro0ided in the cable alley of each 0ertical panel of -(( with a 6:8 1phase5 D# Soc et outlet for use durin1 maintenance3
13. METERS "ype< #ll indicatin1 instrument (AE>AEmm) shall ha0e A77 scale5 anti1lare 1lass and accuracy class of the full scale3 &ach meter shall ha0e =ero adjuster on the front3 -otor ammeter shall ha0e an e>tended suppressed end scale ran1e to indicate startin1 current (E to 9 times to full load current)3 #mmeter5 (" 4 (urrent transducer for all feeders DBP 4 abo0e to be pro0ided3 19. RELAYS )ecessary protection relays as per S*. 4 au>iliaryHs relays as re/uired for interloc s5 alarms etc3 shall be pro0ided3 14. MOTOR HEATERS Inte1ral circuit with re/uired interloc in1 with main contactor for power supply to space heaters for motors shall be pro0ided in modules as re/uired and terminated suitably3 1:. SWITCHES "ype< "riple pole5 air brea 3 .uty< #( 6@ -echanism< Quic brea and /uic ma e mechanism with an e>ternal handle3 "he handle should be in stay put condition in $) and $?? position3 (apability< Switches shall be capable of withstandin1 the fault current of bac up fuses3
General< #ll modules shall ha0e defeat interloc on door5 which allows door openin1 in switch on condition3
1;. 4,SES "ype< B'( fuse lin types with a minimum interrupturin1 capacity e/ual to listed short circuit current3 (haracteristics< -otor fuse characteristics and ratin1 shall be chosen to ride o0er startin1 period without blowin1 off3 ?ittin1< ?uses shall be furnished complete with bases and other fittin1 so as to permit easy replacement3 17. SELECTOR SWITCH "ype< 'otary type clearly showin1 the operatin1 position3 (ontact< Selector switch shall ha0e stay put contact with o0al handles3 )umber of contact shall be as per re/uirement of the control circuit with spare3 18. PAINTING #ll metal surfaces shall be cleaned5 and 1i0en two coats of rust resistance primer followed by two coats of finish paints3 "he internal color of the panel will be 1lossy white and e>ternal per shade E@1 of IS D3 1?. MARSHALLING PANEL &ach of the section 1 and 6 shall be pro0ided with a separate marshallin1 cubicle in which all the control wires for inter connection to local pushbutton stations5 .(S etc shall be terminated o0er suitably rated terminal bloc 3
11.9 B,S BAR CALC,LATIONS 4OR MCC

(alculation for minimum cross section area of conductors with re1ard to thermal stresses due to short circuit currents3
THAPAR UNIVERSITY, PATIALA Page D@
(alculation for temperature rise of (u bus bars E77#50ertical bus bar (alculation for temperature rise of (u bus bar 1777#5hori=ontal bus bar
11.4 TESTS PER4ORME) 4OR MCC

Short circuit withstand test(D7 # for 1 sec rms with an initial pea of 17D #) 8erification of temperature rise limits .e1ree of protection a1ainst solid bodies .e1ree of protection a1ainst li/uid bodies
13. LPBS LOCAL P,SH B,TTON STATION(

*P2S5 (*ocal push button station) is used for start and stop the motor and it is used for all *" motors3 &mer1ency push button in local push button station3 2y use we can directly stop the motor3
4"21r' 18 P,SH B,TTON
LPBS TYPED ?ollowin1 three types of *P2S 1i0en below1. S#$r#* S#o- LPBSD Start5 stop *P2S is used in small motor of ratin1 up to 17F%3 2y
usin1 this we can start and stop small motor directly when we select the selector switch on the *P2S mode3 2ut only when we select the *P2S on the selector switch3
3.
S#$r#* S#o-* A..'#'r LPBS< Start5 Stop5 #mmeter *P2S is used in lar1e motor of
ratin1 abo0e 17F%3"his is possible only when we select selector switch on *P2S mode3 %e can start and stop *P2S in that case3 #mmeter is used in this case for meterin1 purpose3
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9.
E.'r2'%/7 S#o- LPBS< - &mer1ency5 Stop5 *P2S is used in &mer1ency case3 It is
loc able mushroom type5 used when fault occurs in lar1e ratin1 de0ice3 2y use this we can directly stop the motor3
4"21r' 1? M,SHROOM HEA) P,SH B,TTON
13.1 SPECI4ICATION 4OR LOCAL P,SH B,TTON STATIOND

General Industrial type *ocal Push 2utton Station
APPLICABLE STAN)AR)S
)'!/r"-#"o% *ow 0olta1e switch1ear 4 (ontrol 1ear assemblies 'e/uirements R'E1"r'.'%# as per IS3
*8 switch1ear and control
as per IS
.e1ree of protection
as per IS
Safety
I3& 'ules and 1uidelines of Statutory authorities of the %est 2en1al 1o0ernment3
1. E%6"ro%.'%#
THAPAR UNIVERSITY, PATIALA Page DD
8olta1e Csystem
:1D8 P17G5 ?re/uency D7 B= PDG5@phase5 : wire system with solidly 1rounded neutral 3
#ltitudeCtempC'B
*ess than 1777 m abo0e -S* :D .e1ree ( 177G 'B
3. EA'/1#"o%
(onstruction
2olted assembly suitable for wall or structure mountin13
IP D: for indoor and IP DD for $utdoor3
*e1end for pushbuttons K
#nodi=ed aluminum le1end plates shall be pro0ided for all Pushbuttons3 -ar in1 shall be as 'e/uired< S"#'"5 $)5 UP5 ?$'%#'. S*$%5 (*$S&5 S"$P5 $??5 .$%)5 '&8&'S&5 ?#S"5 $P&) &tc3
(olor code for push buttons
'&.< for S"$PC $??5 G'&&)< for S"#'"C$) 2*#(F< for S*$%C?#S"C(*$S&C$P&)3
.uty
(ontinuous duty S1 Cother Intermittent duties li e S6CS@CS: or any other duty suit dri0en
THAPAR UNIVERSITY, PATIALA Page DE
e/uipment re/uirementC process re/uirement3
@3 Co%!#r1/#"o% 0'#$"l! General %here motors are installed in isolated location away from the associated controls5 either a main circuit isolatin1 switch or loc able type stop push button unit pro0ided near the motor for disconnection of the motor supply in case of an emer1ency
-aterial
.ie cast aluminum enclosure3
Gas ets
)eoprene rubber pro0ided to ma e the push button station dust and oil ti1ht3
Push button
663D dia5 dustCoil li1ht5 shrouded type for Start-UpCStop functions 4 loc able mushroom
&- stop function for .$*C Star -delta dri0es5 ?'%C'&8C S"$P functions 4 loc able -ushroom type -&- stop function for control 0al0es3 "he loc in1 of the $??CS"$P push button shall be by means of pressin1 the push
THAPAR UNIVERSITY, PATIALA Page D;
button and unloc in1 shall be by the operation of a ey3 "he off push button shall be pro0ided with two (ontacts K on for switchin1 off the main contactor at the -(( and the other for announcin1 to the .(S that the off P2 is operated
Indicatin1 *amp
-otor $) indicatin1 lamp shall be pro0ided in all the push button stations that shall be of cluster *&. type suitable for the adapted control 0olta1e3
$utdoor type push-button Stations
Suitable canopy pro0ision shall be ensured besides pro0ision of rubber seal for push buttons
(ontrol %irin1 and terminal bloc s
131F8 1rade5 P8( insulated (u wires of cross section 13D s/ mm for all control connections3#ll control wirin1 shall be ferruled terminal bloc s )o &>ternal connection shall be terminated directly on the control de0ices in side pushbutton stations3
Paintin1 Ccolor
'#*< ;7@65 siemens 1rey5 ShadeE@6 for
outdoors as per IS
4. S$&'#7 &'$#1r'! &arthin1 two nos3 earthin1 bolts for interconnection to the earthin1 mat
19. MOTORS
Mo#or! Ar' 4ollo8"%2 T8o T7-'! G"6'% B'lo8 W5"/5 W' ,!' "% TPL Pro='/# *" -otor with .$* startin1 *" -otor with 8?. startin1
THAPAR UNIVERSITY, PATIALA Page DA
19.1 LT Mo#or 8"#5 )OL !#$r#"%2D General purpose :1D8 #( motors5 1enerally rated up to 19D F% is called *" motor with robust industrial desi1n5 ener1y efficient5 fully derated for the ambient and duty condition specified and fully conformin1 to IS @6D for desi1n5 construction and testin1 features3
A--l"/$<l' S#$%0$r0! "hree-phase induction motors (includin1 losses and test) IS @6D
'otatin1 &lectrical machines
as per IS
.imensions of @-phase footCflan1e mounted induction motorsC 0ertical shaft motors
as per IS
-ethod of determination of efficiency of rotatin1 &lectrical machines
as per IS
.e1ree of protection pro0ided by enclosure for rotatin1 electrical machinery3
as per IS
?lame proof enclosure for electrical

THAPAR UNIVERSITY, PATIALA Page E7
as per IS
apparatus
.esi1nation of methods of coolin1 of rotatin1 electrical machines
as per IS
Permissible limit of noise le0el by rotatin1 electrical machine
as per IS
-echanical 8ibration of rotatin1 electrical machines
as per IS
&ner1y efficient @ Phase S/uirrel (a1e induction motors
as per IS
"emperature rise measurement of rotatin1 electrical machines
as per IS
Safety
I3& rules and 1uidelines of statutory authorities of the state 1o0ernment
E%6"ro%.'%# 8olta1eCsystem
:1D8 P17G5D7B=PDG @ phase :-wire system
solidly 1round neutral3
System Short (ircuit *e0el
@E -8#
#ltitudeC"emperature
less than 1777 m abo0e :D .e1( for indoor 4D7 .e1( for outdoor
Special re/uirements
based on actual site re/uirement
Startin1 'e/uirement for .irect on line (.$*) startin1
#ll .$* start motors shall be capable of startin1 and acceleratin1 the coupled loads with ;DG of the rated 0olta1e at the motor terminal without injurious heatin1
.eratin1
"he motor and its 0arious components shall be suitably derated to operate satisfactorily at specified altitude altitude5 ambient temp5 relati0e humidity temp5 relati0e humidity
EA'/1#"o% O-#"o%! #doption of type of -otor

S/uirrel (a1e Induction -otors
for continuous duty applications5 for centrifu1al fansCpumps and compressor dri0es
In0erter Grade -otor
for satisfactorily wor in1 with IG2" in0erter based transistor supplies3
*ocation
IndoorC $utdoor
Speed (no of poles)
"o suit mechanical e/uipment supplier3
-ethod of (oolin1
totally enclosed fan cooled type("&?()
.uty
continuous duty S1
"ype of Startin1 C(ontrols
.$* startin1Csoft startersC IG2" based in0erter circuit for 0ariable speed dri0es3
"ype of brea in1
type to suit the dri0en e/uipment re/uirement3
)o of starts for (ontinuous duty -otors

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Up to and includin1 ;D % ratin1L : cold starts5 @ hot starts on an hourly basis5for ratin1 hi1her
than ;D % 5@ cold starts or 6 hot starts on an hourly basis3
$0erload re/uirement
to suit dri0en e/uipments re/uirement
$0er speed re/uirement
to suit dri0en e/uipment re/uirement3
IP D: for indoor5 IP DD for for outdoor with additional remo0able canopy protection o0er the motor3
Co%!#r1/#"o% 0'#$"l
?rame si=es
to confirm to IS C I&( standard frame si=e3
&ner1y efficient motors for (ontinuous .uty application Startin1 current re/uirements
conform to IS up to D7 BP ratin1L abo0e D7 BP ratin15 hi1her efficiency motor are preferred3 limited to E times the full load current of full load current of s/uirrel ca1e motors when started directly online3
Startin1 tor/ue re/uirement

THAPAR UNIVERSITY, PATIALA Page E:
to suit dri0en e/uipments re/uirement and in
conjunction with the selection of the speed tor/ue characteristics 3 -oment of Inertia motor inertia shall be ta en into account alon1 with that of the dri0en e/uipment to arri0e at the startin1 time which shall be within the limit 0alue
Pull out "or/ue
minimum 677G at rated 0olta1e and fre/uency for s/uirrel ca1e motor shall be considered3
Co%!#r1/#"o% $!-'/# "% <r"'&
Bousin1
cast ironCfabricated steel
Stator
low loss5 insulated ('G$ silicon steel3
'otors
die cast aluminumCcopper bars
Shaft
carbon steel &)95 open ey ways as re/uired
&nd shield and bearin1 co0er
cast iron
THAPAR UNIVERSITY, PATIALA Page ED
2earin1 and lubrication
ballCroller bearin1 with lithium comple> based lubrication ion 3
$il seal
synthetic rubber
%indin1
AA3AG pure5 electrolytic 1rade copper windin1
Insulation
class ? with ad0anced materials5 complete Impre1nation and "ropicalisation3
"emperature rise
limited to that of class 2 (;7de13( o0erD7de1( ambient temperature)
#nti-condensation Beaters
pro0ided throu1h separate terminal bo>es Indoor duty @;F% 4 abo0e $utdoor duty @7F% 4 abo0e
*imit of 0ibration
dynamically balanced and shall satisfy the re/uirement specified as per IS3
S$&'#7 &'$#1r'!
THAPAR UNIVERSITY, PATIALA Page EE
&arthin1
the motor body pro0ided with 6 separate earthin1 terminals for earthin1 in compliance with I3& rules
19.3 LT .o#or 8"#5 V4) !#$r#"%2D
-otor shall be 1eneral purpose5 constantC0ariable speed5 s/uirrel ca1e induction type5 suitable for :1D8 for ?. fan motor 4 EA78 for I. fan motor @ phase5D7 B= power supply 4 suitable for IG2" based 8?. as well as .$* startin1 with robust industrial desi1n5 ener1y efficient5
THAPAR UNIVERSITY, PATIALA Page E;
full derated for ambient 4 duty condition specified 4 fully conformin1 to IS @6D for desi1n5 construction and testin1 features3
A--l"/$<l' !#$%0$r0! "hree phase induction motors (Includin1 losses and tests) IS @6D
'otatin1 electrical machines
as per IS
.imensions of @-phase footCflan1e -ounted induction motors
as per IS
-ethod of determination of efficiency $f rotatin1 electrical machines
as per IS
"erminal mar in1 and direction of rotation ?or electrical machines
as per IS
.e1ree of protection pro0ided by enclosure $f rotatin1 electrical machine
as per IS
?lame proof enclosure for electrical apparatus

as per IS
.esi1nation of methods coolin1 of electrical -achines
as per IS
Permissible limit of noise le0el by rotatin1 &lectrical machines
as per IS
-echanical 0ibration of rotatin1 electrical -achines
as per IS
E%6"ro%.'%# 8olta1eCsystem E3E 0 P17G5 D7B= P@G5@ phase5 @ wire system resistanceCreactance 1rounded neutral
System short circuit le0el
:@3;F# for 36D sec3
#ltitude Ctemperature
less than 1777m abo0e -S*C:Dde1 (
Special re/uirements
based on actual site re/uirement3
Startin1 re/uirements for direct

THAPAR UNIVERSITY, PATIALA Page EA
.$* start motors shall be capable of
$nline startin1(.$*)
startin1 and acceleratin1 the coupled load with 97G of the rated 0olta1e at the motor terminals without heatin1
.eratin1
suitably derated for suitable operation satisfactory operation for ambient temperature5 relati0e humidity5 0olta1e and fre/ 0ariations
EA'/1#"o% o-#"o% S/uirrel ca1e induction motor for continuous duty applications for (entrifu1al fanCpumps5 compressor or dri0es
*ocation
IndoorCoutdoor
Speed ()o of Poles)
to suit dri0en e/uipments re/uirement3
-ethod of coolin1
totally enclosed fan cooled type ("&?()
.uty
THAPAR UNIVERSITY, PATIALA Page ;7
continuous duty s1
"ype of startin1 C control
.$* startin1
)o of starts
minimum 6 consecuti0e hot startsChr3
IP D: for indoor3 IP% DD for outdoor5 with remo0able canopy protection o0er the motor
Co%!#r1/#"o% 0'#$"l ?rame si=es to conform to ISCI&( Standard frame si=es
Startin1 tor/ue re/uirements
to suit dri0en e/uipment re/uirement and conjunction with the selection of speed tor/ue characteristic3
%indin1
AA3AG pure5 electrolytic copper windin1
Insulation
class ? with ad0anced material5 complete impre1nation and tropical insulation3
"emperature rise
limited to class 2(;7de1( o0er D7de1( ambient temperature)
*imit of 0ibration
.ynamically balanced #nd satisfy the re/uirement as per IS
Pre0ention of shaft current
suitable earthin1 of one of the bearin1 or earthin1 of shaft throu1h suitable brush mana1ement3
&mbedded "emperature .etector(&".)
E for windin1 and 1 each for the bearin1 suitable for connection for di1ital temp scanner with alarm and trip contacts
S$&'#7 4'$#1r'!
motor body pro0ided with separate earthin1 terminals
14. SL) O4 V4) SYSTEM 4OR I) AN) 4) 4AN MOTORS
4"21r' 30 SL) O4 V4) SYSTEM 4OR I) AN) 4) 4AN MOTORS
14.1 TRANS4ORMERS ,SE) 4OR V4) SYSTEM

"ransformer applications (on0erter duty transformer
"ype and -a e
Indoors5 two windin15 @ phase5 dry type cast resin insulated step down
?ull load ratin1
1;D7 8#
)o load 0olta1e ratio
E3EC73;1D F8
?ull load 0olta1e ratio
E3EC73EA7 F8
THAPAR UNIVERSITY, PATIALA Page ;@
'ated current
1D@379A# for B8 1:1@31@# for *8
'ated ?re/uency
D7 B=
System &arthin1
B8--edium resistance *8-Solidly 1rounded
"ap (han1er
$ff circuit (SC-DG in steps of 63DG)
$0er flu>in1 capacity
117G continuous
Impulse withstand 0olta1e
E7 F8 pea
Power fre/uency withstand 0olta1e $f windin1 B8C*8 Parallel operation of transformers
67C@ F8 rms
not applicable
System fault le0el Pro0ision of stand by earth fault
6D # sym at EE7785D7 # sym at E778 throu1h neutral ("
"emperature rise abo0e D7 de13( ambient

THAPAR UNIVERSITY, PATIALA Page ;:
;7 de13(-correspondin1 to class 2 for windin15 for core same as windin1
*osses
)o load loss at rated 0olta1e and fre/uency @3E F% *oad loss at rated current and at ;D .e13( 1@3D F%
&fficiency at ;D de13( and at 739 p3f la1
#t 177G load A93;AG #t ;DG load A93ADG #t D7G load AA371G
'e1ulation at full load and at ;D de13(
#t u3p3f 39;G #t 739 p3f la1 @3@@G
%indin1s
6 windin1s per phase
Quantity of transformers
6 nos3per 2oiler ("otal : for 6 boilers)
4"21r' 31 CAST RESIN )RY TYPE TRANS4ORMERS
1:. ACT,ATOR
#ctuator is a de0ice5 which con0erts ener1y in motion3 It is used for control purpose3 It acts as a transducer accepts a si1nal and con0erts it into physical action3
1:.1 SPECI4ICATION O4 MOTORISE) VALVE ACT,ATOR

1. SCOPE
THAPAR UNIVERSITY, PATIALA Page ;D
"his Specification co0ers the desi1n5 material and performance testin1 of all electric motor actuator for 0al0es5 damper and 1ates3 #ll electric motor actuator shall be furnished in accordance with this specification and the accompanyin1 dri0en e/uipment specification3 3. STAN)AR)
&lectrical e/uipments confirmin1 to the latest applicable I3S "he motors shall be installed in hot5 humid (ma>3 9EG5 min36;G)and tropical temperature and relati0e humidity of 177G3 "he reference ma>imum ambient temperature for desi1nin1 the indoor motors shall be ta en as D7 de13 (enti1rade and DD.e13(enti1rade for outdoor motors and an altitude less than 1777meter abo0e mean sea le0el5 minimum ambient temp3is D7.e13(enti1rade3Unless otherwise stated5 electrical e/uipment Csystem desi1n shall be based on ser0ice condition5 au>iliary power supply and other detail of the dri0en e/uipment specification3 ?or motor installed outdoor and e>posed to direct sunli1ht5 the effect of solar heat shall be considered in the determination of the desi1n ambient temperature and shall not be less than DD .e13centi1rade3Under seismic condition importance factor is 63D for electrical e/uipment and 13D for other3 9. SERVICE CON)ITIONS
"he actuator shall be suitable for operation in hot5 humid and tropical atmosphere in a hi1hly polluted dusty area3 Unless otherwise stated5 electrical e/uipment and system desi1n shall be based on the ser0ice conditions and au>iliary power supply 4. PER4ORMANCE
#ctuator shall meet the followin1 re/uirements $pen and close the 0al0e C damper completely and ma e lea ti1ht 0al0e without jammin13 #ttain full speed operation before 0al0e load is encountered and import an unseatin1 blow to start the 0al0e in motion (Bammer blow effect)3 $perate the 0al0e stem at standard speed and shall function a1ainst desi1n differential pressure across the 0al0e seat3
THAPAR UNIVERSITY, PATIALA Page ;E
closure
"he motor reduction 1ear shall be sufficient to loc the shaft when motor is deener1i=ed and pre0ent drift from tor/ue switch sprin1 pressure3
"he entire mechanism shall withstand shoc resultin1 from closin1 with improper settin1 of limit switches or from lod1in1 of forei1n material under 0al0e seat3
:.
MOTOR "he dri0e motor shall be @ phase5 s/uirrel ca1e induction motor suitable for class ? insulation and IP DD enclosure5 desi1ned for hi1h tor/ue with low inertia and with linear characteristic and also for reser0in1 ser0ices3 "he motor shall be desi1ned for full 0olta1e direct on line start with startin1 current limited to E times full load current includin1 IS tolerances3 "he motor shall be capable of startin1 at ;DG of rated 0olta1e and runnin1 at 97G of rated 0olta1e at rated tor/ue for a period of D minutes3 &arthin1 terminal shall be pro0ided on either side of the motor Supply 0olta1e will be :1D 8oltP17G5 @ phase5 : wire5 and D7B= PDG3 (ombined 0olta1e and fre/uency 0ariation will be absolute 17G3 Protection shall be pro0ided so that motor shall be de-ener1i=ed in the e0ent of a stall when attemptin1 to unseat a jammed 0al0e3 "he motor construction shall be suitable for easy dis-assembly and re-assembly 3the enclosure shall permit easy remo0al of any part of motor for inspection and repairs3
;.
HAN) WHEEL
&ach actuator shall be pro0ided with a hand wheel for emer1ency manual operation3 "he hand wheel shall de- clutch automatically when the motor is ener1i=ed3 7. SPACE HEATER
THAPAR UNIVERSITY, PATIALA Page ;;
# Space heater shall be included in the limit switch compartment suitable for 6:78 #(5 sin1le phase5 D7 B= supply3 8. WIRING AN) TERMINAL BOF
#ll electrical de0ices shall be wired up to and terminated in a terminal bo>3 "he internal wirin1 shall be of 131F0 1rade P8( insulatedL stranded cable of appropriate si=e5 but in case shall be less than 63Dmm6 cu cable3 #ll wirin1 shall be identified at both ends with ferrules Cnumbers3 "he terminal bo> shall be whether proof with remo0able front co0er3 "he terminal bo> shall be suitable for connection of 63D mm6 cu conductors3 "he terminal shall be of stud type (screw dri0er operated) embedded in a terminal bloc of hi1h trac -resistance compound3 Power terminal shall be shrouded from the control terminal by means of an insulatin1 co0er 3the terminal component shall be separated from the inner electrical components3"he terminal bo> of the electrical actuator shall be pro0ided with four cable entry pro0isions for isolatin1 dri0e and fi0e entry pro0isions for re1ulation dri0es3
4"21r' 33 ACT,ATOR
1;. CABLE + CABLE CALC,TATION

&lectrical cable may contain one or more metal conductor5 which may be indi0idually insulated or co0ered3 %e use here two type of cable LT Po8'r C$<l'! LT Co%#rol C$<l'!
POWER CABLE S"B' Co%01/#or

(63D-E@7)s/3mm Stranded al or cu3 #l is preferred3 P8( or T*P& &>truded P8( 'ound wire GIC?lat wire GI
CONTROL CABLE
(13D-63D)s/3mm Stranded cu is preferred P8( &>truded P8( 'ound wire GIC?lat wire GI
I%!1l$#"o% I%%'r S5'$#5 Ar.o1r
O1#'r S5'$#5
P8(CB'P8((e>truded) ?'*S properties
P8((e>truded) ?'*S Properties
THAPAR UNIVERSITY, PATIALA Page ;A
"he scope of wor
includes desi1nL en1ineerin15 supply and installation of all inter
connectin1 131 F8 power and control cable as re/uired between 0arious e/uipment of boiler5 -(( and purchaser B" switchboard3 "he re/uired B" power supply cables between purchasers B" switch board to the tendered B" .ri0e motor only would be 1i0en as free issue item to the successful tendered3 "he boiler -(( as well as purchaser B" switchboard would be located at the switch1ear room at the "G buildin13 131 0 1rade power and control cables for interconnectin1 purchaserHs feeders at B8
distribution board and B" dri0e motors and local pushbutton station (*P2S)5 field mounted safety etc3 131 0 1rade power and control cables re/uired for interconnectin1 the :1D0 -((s to
0arious loads li e 0arious dri0e motor Cactuators5 local push button stations5 field mounted safety switch5 88?. (0ector control 0ariable fre/uency dri0es)5 .(S (di1ital control system) system etc3 F8 1rade control cables re/uired for interconnectin1 the :1D8 -(( and boiler
control panels and purchase B" switchboard and local push button stations3 F8 1rade power cables re/uired in li1htin1 circuits with annealed and stranded
copper conductors of cross section minimum of 63D s/3mm #ll cablin1 accessories li e cable 1lands5 lu1s5 cable trays5 clamp5 B" termination it
and accessories etc3
4"21r' 39 CABLE SCHE),LE
1;.1 SAMPLE CALC,LATION O4 SELECTION O4 CABLE

C$<l' 0'!"2% /r"#'r"$D cable si=e are arri0ed at by the calculation based on the followin1 consideration Short circuit current and its duration (ontinuous current ratin1 capacity of cable Permissible 0olta1e drop durin1 startin1 and runnin1 condition of motor .eratin1 factor due to ambient temperature5 1roupin1 and layin1 criteria of cable
1;.3 CABLE SICES BASE) ON MAFIM,M CONTIN,O,S LOA) C,RRENTD

M$A".1. Lo$0 C1rr'%#
-a>imum *oad (urrent $f a -otor is 1i0en as I?* UPC (root@JpfJVJ0) I?* Ufull load current5 PU power in VUefficiency50Uphase 0olta1e )'r$#"%24$/#or ,%"6'r!$l C$<l'! C$#$lo21' T$>'% $! R'&'r'%/'( %5 Pf Upower factor5
.eratin1 factor for D7de1( #mbient temperature ( 1)U7391(#s per table) Group deratin1 factor ( 6)U73EE for multi core cable (#s per table) $0er all deratin1 factor U
1
J 6U 7391J73EEU73D@:
.erated currentUI?*C .eratin1 factor I.U1E37;C73D@: I.U@737A#mps $n the basis of this current we use catalo1ue chec si=e
R$#'0 C1rr'%# C$rr7"%2 C$-$/"#7
'ated current carryin1 capacity of @3DJ63D s/3mm (u cable U@7 in air3 Bence @3D>63D mm s/ cable is suitable for D3D % motor3 N1.<'r O& R1%! R'E1"r'0
'Unearest inte1er 1reater than I*C I.5 'U1E37EC@737A5 'U73D1A;3
17. AVIATION WARNING LAMPS 4OR CHIMNEY
4"21r' 34 AVIATION WARNING LAMPS
Supply and installation re/uired set of a0iation obstruction warnin1 lamp for the chimney as per rele0ant standard should be include in scope3 It is used for protection of chimney3 It installs at the top of the boiler chimney5 transmission line5 airport5 telephone tower etc3 It 1i0es warnin1 lamp si1nal to the plane3
17.1 TYPES O4 AVIATION WARNING LAMPD

#0iation warnin1 lamps are of three types 1i0en bellow 1. Lo8 I%#'%!"#7 A6"$#"o% 8$r%"%2 l"25#! < "hese li1ht should be used where the object
and its hei1ht abo0e the surroundin1 1round are less than :Dm3-a in1 use of most ad0anced technolo1ies5 we created new a1e low intensity *&. li1hts3 3. M'0"1. I%#'%!"#7 A6"$#"o% 8$r%"%2 l"25#D -edium Intensity $bstacle li1hts should
be used e>tensi0ely when the hei1ht abo0e the le0el of the surroundin1 1round is 1reater then
:Dm3-edium intensity obstruction li1hts are re/uired to be installed at hi1h rise buildin15 which are more than 177 meter abo0e the 1round le0el3 9. H"25 I%#'%!"#7 A6"$#"o% 8$r%"%2 l"25#< "hese li1hts should be used to indicate the
presence hei1ht abo0e the le0el of the surroundin1 1round e>ceeds 1D7 meters3
18. EARTHING
"he process of connectin1 the metallic frame (i3e3 )on current carryin1 part) of electrical e/uipment or electrical system to earth is called 1roundin1 or &arthin13 T7-'! o& E$r#5"%2D &arthin1 are of followin1 four types 1i0en below< 13 63 @3 :3 Solid or effecti0e 1roundin1 'esistance 1roundin1 'eactance 1roundin1 Peterson coil 1roundin1
"he choice of method of 1roundin1 depends upon many factors includin1 the si=e of the system5 system 0olta1e and the scheme of protection to be used3 I% #5"! TPL -ro='/# 8' 1!' !ol"0 or '&&'/#"6' E$r#5"%23 1. Sol"0 or E&&'/#"6' Gro1%0"%2< %hen the neutral point of @- phase system (&313@-phase
1enerator5 @-phase transformer etc3)is directly connected to the earth throu1h a wire of ne1li1ible resistance and reactance5 it is called solid 1roundin1 or effecti0e 1roundin13 "enderer shall include supply and installation of one lot of earthin1 stations5 earthin1 conductor 4accessories re/uired for earthin1 of e/uipment C accessories co0ered under this scope3 #ll non current carryin1 metallic parts of 0arious electrical e/uipment as well as metallic conduit C GI Pipe5 cable trac 5 trays cable 1lands and brac ets5 supportin1 structure5 etc shall be effecti0ely earthed3 "he method establishment of sub earth mat and e/uipment earthin1 shall be as per the re/uirement of IS3 Solid 1roundin1 is usually employed where the circuit impedance is sufficiently hi1h so as eep the earth faults current with in safe limits3 "his
system of 1roundin1 is used for 0olta1e up to @@ 0 with total power capacity not e>ceedin1 D777 F8#3 3. R'!"!#$%/' Gro1%0"%2< %hen the neutral point of a @-phase system (e313@-phase
1enerator5@-phase transformer etc3)is connected to the earth throu1h a resistor5 it is called 'esistance 1roundin13 It is used on a system operatin1 at 0olta1e between 636 8 and @@ 0 with power source capacity more than D777 F8#3
9.
R'$/#$%/' Gro1%0"%2< %hen neutral point of the three phase system is connected to
the earth throu1h reactance it is called reactance 1roundin13 In this case fault current is more than resistance 1roundin1 for same fault condition3 Bi1h transient 0olta1e appears under fault conditions3
4.
P'#'r!o% Co"l Gro1%0"%2< %hen the 0alue of * of arc suppression coil is such that the
fault current I? e>actly balances the capaciti0e current I(5 it is called resonant 1roundin1 or Peterson coil 1roundin13
S'l'/#"o% $%0 I%!#$ll$#"o% o& EE1"-.'%# E$r#5"%2D "he method adopted for e/uipment earthin1 shall be in accordance with the rele0ant clauses of I& rules 3#ll earthin1 shall be subject to the appro0al of the chief electrical inspector5 1o0ernment of west 2en1al3
"he minimum si=e of 1al0ani=ed -S flatCstranded wire for earthin1 0arious e/uipments shall be as follow< -ain earth mat Sub earth mat 333;Dmm>17 mm 333D7 mm>Emm 333D7mm>Emm
*" #( motors from 1D7 % up to 19D %
*" #( motors from 117 % up to 1@6 % *" #( motors from DD % up to A7 % *" #( motors from 1D % up to :D % *" #( motors from @3;D % up to 11 % *" #( motors from 73;D % up to 636 % *ocal control post Cpanels *ocal push-button station5limit switches Switch bo>es5 isolator and soc et outlet up to 1E#3
333:7mm>Emm 3336Dmm>Emm 3336Dmm>Emm 3331E s/mm stranded 333 E s/mm stranded W1E s/mm stranded WE s/mm stranded
Isolator and soc et outlet abo0e 1E# up to and includin1 177#
333D7 s/mm stranded3
1?. LIGHTNING
#n electric dischar1e between clouds an earth5 between the clouds or between the char1e centres of same clouds is nown as li1htnin13 L"25#%"%2 Pro#'/#"o% S7!#'.D Supply and installation of li1htnin1 protection system for the boiler and chimney shall be tendered scope of wor includin1 spi es5 down comers5
interconnection and dedicated earth station3 #ll buildin1 and plant structures are to be protected a1ainst atmospheric flash o0er and li1htnin1 stro es in such a manner as to eliminate any dan1er to the personnel employed therein3 Stipulation of IS as to shall be followed3 # Nfaraday ca1eH made of hot 1al0ani=ed strip steel connected to all buried pipes and steel structure crossin1 this ca1e rin1 are laid around each main buildin1 or plant unit as &arthin1 de0ice3 "his is separate from the electrical e/uipment earthin1 rin1 main3 ?ollowin1 buildin1sCstructure shall be pro0ided with li1htnin1 protection3 -ain plant buildin1 2oiler area
.esi1n shall be as per the standard li e IS and Indian electricity rules3 #ll li1htnin1 arrestor earth leads of the buildin1 and plant unit shall be connected to this ca1e rin13 &arthin1 electrode and 1rid for li1htnin1 protection are distinct and separate from the earthin1 system for the earthin1 of electrical e/uipment and at no place will be connected to the other earthin1 system3
4"21r' 3: LIGHTNING PROTECTION
30. ILL,MINATION LIGHTING(
4"21r' 3; BOILER ILL,MINATION
30.1 INTENT O4 SPECI4ICATION

"his specification co0ers the desi1n5 material5 construction features5 manufacture5 inspection 4 testin1 at the 0endors Csub-0enderHs wor and deli0ery at site3
STAN)AR)S
*atest applicable IS standards Cpublication e>cept when other stated3
EG,IPMENT PER4ORMANCE AN) SPECI4IC TECHNICAL REG,IREMENT
"he scope includes boiler illumination system to achie0e re/uired illumination le0els as per IS 1uidelines3 "he scope shall co0er the followin1 system< )ormal #( li1htin1 of the boiler system &mer1ency .( li1htin1 of the boiler system
Illumination shall be pro0ided in 0arious le0els of platforms5 access platforms5 near dri0e or actuator and inspection openin1 and in landin1s staircase5 chimney 1allery etc3 "he illumination system shall include the followin1 in re/uired /uantities *i1htin1 .2s *i1htin1 fittin1 with lamps *i1htin1 fi>tures and accessories (ables and wirin1 (lamps switches conduits brac ets han1ers J2s
#ll li1htin1 in outdoor area and peripheral li1htin1 shall ha0e auto $)C$?? facility with suitable timer3 Illumination le0el en0isa1ed for different areas will be as indicated below<
S3)o3 13
#rea 2oiler #rea
*u> 177
"ypes of li1ht fittin1s BPS8 Incandescent lamp
'emar s #( normal li1htin1 .( &mer1ency li1htin1 #( normal li1htin1 .( &mer1ency li1ht
63
Staircase 4landin1 D7 area
BPS8 Incandescent lamp
-ain li1htin1 supply for normal 4 emer1ency li1htin1 will be from purchaserHs normal 4 emer1ency -(2-.2s3
Sufficient number of area wise sub li1htin1 distribution boards (S*.2s) will be distributed all o0er the plant3 #ll the S*.2s will be fed from -(2-.2s3 Separate circuit and .2 shall be considered for normal li1htin1 as well as for ser0ice switch soc ets3 #ll S*.2s will ha0e one incomer only3 S*.2s will ha0e -((2 as incomer feeder and -(2 as out1oin1 feeder3 Separate circuit will be used for .( emer1ency li1htin1 system will be fed from purchaserHs -(2-.2 at 1178 .(3 'e/uired /uantity of outdoor type distribution boards incorporatin1 miniature circuit brea er (-(2-.2) shall be supplied and installed for feedin1 the li1htin1 circuit3 2oth normal li1htin1 as well as emer1ency li1htin1 shall be considered throu1h separate circuit and distribution boards3 Separate -(2-.2s shall be pro0ided for .( emer1ency li1htin1 as well as for ser0ice switch soc ets3 &>plosion ha=ardous areas will ha0e flameproof fittin1s Cjunction bo>es3 .ust proofCti1ht li1ht fittin1 will be used for e>ceptionally dusty en0ironment areas3 "he 0olta1e of maintenance li1htin1 networ and cable premises li1htin1 networ will be 6: 0olts and lamps suitable for 6:78 C6:83 ?ollowin1 types of li1ht fittin1 shall be considered< Industrial BPS8 (Bi1h pressure sodium 0apour) li1ht fittin1 ((hi1h Cmedium Clow)bay) Industrial BPS8 li1ht fittin1s (bul headCwell 1lass) Incandescent lamp for .( emer1ency li1ht (bul head type)
:1D85 @ pin5 E@# and @6# %eldin1 switch outlets shall be pro0ided in the 0arious premises as per re/uirement5 items such as brac ets han1ers clamps5 junction bo>es etc which are re/uired to ma e the li1htin1 installations completes in all respect shall also be supplied3 "he bidder shall include all cables5 wirin1 and other accessories re/uired for abo0e ar1umentation3
THAPAR UNIVERSITY, PATIALA Page A7
"he li1htin1 installation shall be carried out throu1h 131 0 1rade armored Power cable specified as under and shall be of copper conductor of minimum cross section 63D s/3mm annealed and stranded copper conductor3 -iscellaneous items li e 6:78 sin1le pole switch5 6:78 Soc et outlets5 6:8 maintenance (with 6:7C6:8dry type transformer)5 lamp5 cables and wirin15 etc shall be pro0ided by the bidder as per re/uirement of the plant3 Purchaser shall pro0ide necessary power supply at each of the normal -(2-.2 at :1D85 @ phases5 D7 B= 4 at each of the emer1ency -(2-.2 at 1178 .(3 (omplete earthin1 of the illumination networ shall be under scope of the bidder3 ?ollowin1 type of lamp shall be 1enerally used BPS8 .( &mer1ency (G*S) < ;7%5 16D%5 6D7%5 :77% <E7%
&). $? .$(U-&)"
CONCL,SION AN) 4,T,RE SCOPE O4 WORK

.urin1 my term at Al!#o. Pro='/#! I%0"$ L#0* it was the first time I was e>posed to the industry for such a lon1 period of time3It helped me to 1ain a familiari=ation with the department5 helped me to 1ather a flow of information3 "his project semester has really helped me to understand the meanin1 of team wor and wor culture within and outside the department3 "he company officials and wor ers were more than helpful and I too a leap of faith in them3 Bence5 it was a 1reat learnin1 e>perience for me3 I 1ot to now about how thin1s wor in as co0eted enterprise as Al!#o. Pro='/#! I%0"$ L#0. which has spread its roots all o0er the 1lobe3 2y accomplishin1 the project I was e>posed to *atest 2oiler "echnolo1y used by the company to manufacture boilers for its clients &n1ineerin1 and the desi1n operations carried out by the department to help manufacture the boiler Scope of electrical wor used in boilers
"his trainin1 really helped me to brid1e the 0ast 1ap between the theoretical and practical aspects of loo in1 a problem3 I am sure that after this trainin1 and practical nowled1e I will be able to 0isuali=e wor situation better3 "his trainin1 definitely will enhance my rate of pro1ress in future3 "his will ob0iously help me in brid1in1 up my professional career3 Bence to summari=e5 this trainin1 has put me one step ahead towards bein1 a 1ood &lectrical &n1ineer3 "his trainin1 was one of the most e>citin15 enrichin15 challen1in1 nowled1eable part of my life3 "his report bears a li0e testimony to this3
RE4ERENCES
www31oo1le3co3in www3howstuffwor s3com www3bri1hthub3com (ompany manuals and datasheet )otes pro0ided by #lstom India Projects *td -entor Su11estions www3alstom3com
THAPAR UNIVERSITY, PATIALA Page A@
APPEN)IF
ABBREVIATIONS ,SE)
SLD MCC MCCB Brea"ers ACB S#U LPBS LD& S'MCR Ma(im!m Contin!o!s Rating Single Line Diagram Motor Control Centre Molded Case Cir !it Air Cir !it Brea"ers S$it % #!se Unit Lo al P!s% B!tton Station Lig%t Diesel &il Steam 'enerated
MLDB Distri)!tion Board SLDB Distri)!tion Board *B #RLS

Smo"e
Main Lig%ting S!) Lig%ting *!n tion Bo(

#lame Retardant Lo$ Cross Lin"ed Pol,et%,lene Hig% Press!re Sodi!m 'eneral Lig%ting Ser.i e
+LPE HPSV 'LS
Va-o!r
THAPAR UNIVERSITY, PATIALA Page A:

Harsimran Jot

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PROJECT REPORT

(Project Semester January-June)

TATA POWER PROJECT ANALYSIS

SWAPNIL VERMA Roll No - 100804071

Under the Guidance of

Mr. SHAKTI SINGH A!!"!#$%# Pro&'!!or(

Mr. BIRBAL SINGH TANWAR HEA)-ELECTRICAL* CONTROL + INSTR,MENTATION ENGG.(

THAPAR UNIVERSITY, PATIALA Page 1

S%#P)I* 8&'-# 'oll )o -17797:7;1

Mr. SHAKTI SINGH ASSISTANT PRO4ESSOR(

Mr. BIRBAL SINGH TANWAR HEA)-ELECTRICAL* CONTROL + INSTR,MENTATION ENGG.(

THAPAR UNIVERSITY, PATIALA Page 6

%ith best re1ards< S%#P)I* 8&'-#

THAPAR UNIVERSITY, PATIALA Page @

THAPAR UNIVERSITY, PATIALA Page :

I%#ro01/#"o% To T5'r.$l Po8'r Pl$%# A%0 Bo"l'r!

T5'r.$l Po8'r Pl$%# Bo"l'r

T7-'! O& Bo"l'r!

Br"'& A<o1# T$#$ Po8'r Pro='/#

S/o-' O& El'/#r"/$l Wor> I% T$#$ Po8'r Pro='/#

THAPAR UNIVERSITY, PATIALA Page D

P$/>$2' )'!/r"-#"o%! Bo"l'r MCC

Lo/$l P1!5 B1##o% S#$#"o%! Mo#or!

Tr$%!&or.'r! ,!'0 4or V4) S7!#'. A/#1$#or! C$<l' + C$<l' C$l/1l$#"o%!

A6"$#"o% W$r%"%2 L$.-! 4or C5".%'7

E$r#5"%2 L"25#%"%2 Ill1."%$#"o%

THAPAR UNIVERSITY, PATIALA Page E

LIST O4 4IG,RES 4"21r' N1.<'r 1 3 9 4 : ; 7 8 ?*10 11 13 19 14*1: 1;*17 18 1? 30 31 33 39 34 3: 3; P$2' N1.<'r 13 14 1; 17 18 1? 33 3; 3? 98 9? 41 43 49 :3 :9 71 74 77 7? 81 8: 87

THAPAR UNIVERSITY, PATIALA Page ;

1.1 ALSTOM POWER

1.3 ALSTOM TRANSPORT

1.9 ALSTOM GRI)

THAPAR UNIVERSITY, PATIALA Page A

1.4 ALSTOM IN IN)IA

THAPAR UNIVERSITY, PATIALA Page 17

THAPAR UNIVERSITY, PATIALA Page 11

THAPAR UNIVERSITY, PATIALA Page 16

3. INTRO),CTION TO THERMAL POWER PLANT AN) BOILERS

4"21r' 1 THERMAL POWER PLANT

631 ELECTRICITY COST

THAPAR UNIVERSITY, PATIALA Page 1:

@3 THERMAL POWER PLANT LAYO,T

THAPAR UNIVERSITY, PATIALA Page 1D

THAPAR UNIVERSITY, PATIALA Page 1E

4"21r' 9 BOILER SYSTEM

4.1 WATER AN) STEAM SYSTEM

THAPAR UNIVERSITY, PATIALA Page 19

THAPAR UNIVERSITY, PATIALA Page 1A

4"21r' : STEAM )R,M AN) WATER WALL

THAPAR UNIVERSITY, PATIALA Page 67

4"21r' ; S,PERHEATER AN) REHEATER

4.3 COMB,STION SYSTEM

THAPAR UNIVERSITY, PATIALA Page 61

THAPAR UNIVERSITY, PATIALA Page 66

THAPAR UNIVERSITY, PATIALA Page 6@

4"21r' 7 BOILER COMB,STION SYSTEM

%ater tube boilers too

dependin1 on type of circulation used to 1enerate steam as

.ependin1 on type of firin1 adopted in boilers they can be classified as

Sto er fired Pul0eri=ed coal fired ?luidi=ed bed boilers

THAPAR UNIVERSITY, PATIALA Page 6D

:.1 ON THE BASIS O4 4IRING

THAPAR UNIVERSITY, PATIALA Page 6E

LIST O4 4IG,RES 4"21r' N1.<'r 1 3 9 4 : ; 7 8 ?10 11 13 19 141: 1;*17 18 1? 30 31 33 39 34 3: 3; P$2' N1.<'r 13 14 1; 17 18 1? 33 3; 3? 98 9? 41 43 49 :3 :9 71 74 77 7? 81 8: 87

ess than 1777 m abo0e -S :D .e1ree ( 177G 'B