Presented by:

Akbar Ahmad 2011PE09

MNNIT 9/28/2013

Bhupesh Kumar Pal 2011PE05

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INTRODUCTION TO ESSAR-MAHAN POWER PLANT

1200-MW (2x600 MW) coal-fired pit-head power plant Located in Singrauli district, Madhya Pradesh CONSULTANTS
ESSAR ENGINEERING SERVICES LTD. TCE CONSULTING ENGINEERS LTD.

SUPPLIER
ESSAR CONSTRUCTION (I) LTD.

EBOP (Electrical Balancing of Plant)

ALSTOM T&D INDIA LTD

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No. of Lines:

4
Line 1 & 2: Line 3 & 4: VINDHYACHAL- KORBA LINE MAHAN- SIPAT LINE

Coal Source
Mahan Coal Block located at 4 Km distance from site allotted to Joint venture Company Mahan Coal Ltd formed between Essar Power & Hindalco.

Water Source
Rihand water Reservoir

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Operations In Thermal Power Station

Step wise operations in a thermal power plant are as follows:

Coal is used as a fuel to boil the water. Water is boiled to form pressurized steam. Pressurized steam is the force that cause the turbine to rotate at a very high speed. Low pressure steam after pushing through the turbine goes into the condenser. Condenser the place where the steam is condensed back it its liquid form .Then the process is repeated.

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BASIC OPERATION : A thermal power plant basically works on Rankine cycle.

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Definition Of Thermal Power Station

A thermal power station is a power plant in which the prime mover is steam driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator . After it passes through the turbine, the steam is condensed in a condenser and recycled to where it was heated; this is known as a Rankine cycle. The greatest variation in the design of thermal power stations is due to the different fuel sources. Some prefer to use the term energy center because such facilities convert forms of heat energy into electrical energy.

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1. Cooling tower 2. Cooling water pump 3. Transmission line (3-phase) 4. Unit transformer (3-phase) 5. Electric generator (3-phase) 6. Low pressure turbine 7. Boiler feed pump 8. Condenser 9. Intermediate pressure turbine 10. Steam governor valve 11. High pressure turbine 12. Deaerator 13. Feed heater 14. Coal conveyor 15. Coal hopper 16. Pulverised fuel mill 17. Boiler drum 18. Ash hopper 19. Superheater 20. Forced draught fan 21. Reheater 22. Air intake 23. Economiser 24. Air preheater 25. Precipitator 26. Induced draught fan 27. Chimney 7 Stack

COAL FEEDING SYSTEM

Wagon Tippler

Conveyor

Coal Hopper

Coal is conveyed through rail wagon from out side of plant and through conveyor system collected in hopper and grinded to a very fine powder by large metal spheres in the pulverized fuel mill.

Pulverized Mill

Pulverized coal is put in boiler furnace in which water is heated and circulated until the water is turned in to steam at the required pressure The steam then rises up and gets collected inside the boiler drum. The boiler is made up of carbon steel. Boiler drum is cylindrical drum like structure contains mixture of water and steam. The steam that comes out of the boiler with increased temperature and pressure. Types of boilers are natural circulation, dry bottom, and tangential fired, radiant heat type Boiler in this plant is four corners tangential-firing type

SUPERHEATER: Super heater is a component of a steam-generating unit in which steam, after it has left the boiler drum, is heated above its saturation temperature

REHEATER : Reheater is also steam boiler component in which heat is added to this intermediate-pressure steam, which has given up some of its energy in expansion through the high-pressure turbine.
DEARATOR: A deaerator is a device that is widely used for the removal of oxygen and other dissolved gases from the feedwater to steam-generating boiler.

Manufacturer

Harbin Boiler Group Co. Ltd (HBC)

Operational Parameters

BMCR Steam Flow rate Tph Superheater Outlet Steam Pressure Mpa (g) Steam Temp
oC

TMCR 1875.12 17.34 541 1579.6 3.662 325.3 3.477 541 275.1

2060 17.5 541 1725.78 4.006 335.1 3.816 541 281.2

Steam Flow rate Tph Reheater Inlet Steam Pressure Mpa (g) Steam Temp Reheater Outlet Feed Water Flue Gas at Air Preheater Outlet Efficiency Heating Surface Area % m2
oC

Steam Pressure Mpa (g) Steam Temp Temp

oC oC

87.25 66970

A steam turbine is a device that extracts thermal energy from pressurized steam and uses it to do mechanical work on a rotating output shaft The turbine is used to drive an electrical generator

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CONDENSER :

Steam after rotating steam turbine comes to condenser. These condensers are heat exchangers which convert steam from its gaseous to its liquid state. In so doing, the latent heat of steam is given out inside the condenser. COOLING TOWERS :
The condensate water after condensation is initially at high temperature. This hot water is passed to cooling towers. It is a tower in which atmospheric air circulates in direct or indirect contact with warm water and the water is thereby cooled. Water, acting as the heat-transfer fluid, gives up heat to atmospheric air, and thus cooled.

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ECONOMISER :
Flue gases coming out of the boiler carry lot of heat. Function of economiser is to recover some of the heat from the heat carried away in the flue gases up the chimney and utilize for heating the feed water to the boiler. It is placed in the passage of flue gases in between the exit from the boiler and the entry to the chimney. AIR PREHEATER : The remaining heat of flue gases is utilised by air preheater. It is a device used in steam boilers to transfer heat from the flue gases to the combustion air before the air enters the furnace

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ELECTROSTATIC PRECIPITATOR : It is a device which removes dust or other finely divided particles from flue gases by charging the particles inductively with an electric field, then attracting them to highly charged collector plates. SMOKE STACK (CHIMNEY) : A chimney is a system for venting hot flue gases or smoke from a boiler, stove, furnace or fireplace to the outside atmosphere. They are typically almost vertical to ensure that the hot gases flow smoothly, drawing air into the combustion through the chimney effect

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The transformation of mechanical energy into electrical energy is carried out by the generator. When the rotor is energised the flux lines emitted by it are cut by the stator windings which induces an emf in them given by E = 4.44 f N

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Manufacturer

Harbin Generator Co. Ltd.

Rated Output
Phase Frequency Speed

600 MW
Hz rpm A KV

705.88 MVA
3 50 3000

Stator Winding Type

Stator Current Stator Voltage Power Factor

YY
20377 20 0.85 (lag)

Stator winding
Cooling mode Generator Frame Rotor winding volume m t t t
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Water
Hydrogen 110 66.5 300 465

(including rotor)
Generator Rotor Weight Generator Stator Weight Generator Total Weight

Excitation type

static excitation 17

The transformer is a device that transfers electrical energy from one electrical circuit to another through the medium of magnetic field and without the change of frequency. The two windings are not connected electrically but coupled magnetically. Its efficiency is in the range of 97 to 98 %. Main Transformers

Generator Transformer (GT):-This is a step up transformer. - This supply gets its primary supply from generator and its secondary supplies the switchyard from where it is transmitted to grid. - primary is in STAR and secondary is in DELTA - GT 1 & GT 2 - 3x1PH, 250MVA & there are two GT in this plant

GENERATOR TRANSFORMER Make AREVA Type Double Wound Service Outdoor No. of Windings Per Phase 02 No. of Phases 01

Rated Power (HV)

Rated Power (LV) Rated Voltage at No Load (HV) Rated Voltage at No Load (LV) Rated Line Current (HV) Rated Line Current (LV) StationRated Transformer (ST):Frequency

250 MVA 250 MVA

420/ 3 Kv
20 Kv 1029.8 A 12500 A 50 Hz

- It is a step down transformer -same rating as the generator transformer - primary is connected in delta and secondary in star -These are 2 in number each of 70 MVA.

STATION TRANSFORMER Make AREVA Type Double Wound Service Outdoor No. of Windings Per Phase 02 No. of Phases 03 Rated Power (PRI) 70 MVA Rated Power (SEC 1) 25 MVA Rated Power (SEC 2) 45 MVA Rated Voltage at No Load (HV) 20 kV Rated Voltage at No Load (SEC 1) 34.5 kV Rated Voltage at No Load (SEC 2) 11.5 kV Rated Line Current (PRI) 2023.12 A Rated Line Current (SEC 1) 418.87 A Rated Line Current (SEC 2) 2261.87 A Rated Frequency 50 Hz

Unit Auxiliary Transformer (UT): -This is a step down transformer. -The primary receives from generator and secondary supplies a 6.6 KV bus -This is oil cooled -These are 4 in number

UNIT TRANSFORMER
Make Type No. of Windings Per Phase No. of Phases Rating Rated Power (HV) Rated Power (LV) Rated Voltage at No Load (HV) Rated Voltage at No Load (LV) Rated Line Current (HV) Rated Line Current (LV) Rated Frequency AREVA Double Wound 02 03

36/ 45 MVA 36/ 45 MVA 20 kV 11.5 kV 1040.46/ 1300.58 A 1809.49/ 2261.87 A 50 Hz

Overview of Under construction BOP- Raw Water System Raw Water Reservoir Raw Water Pump House

Chemical House

Cascade Aerator

Sludge Pit HRSCC -1B Back Wash Pit

Pipe Rack PR32

HRSCC 1A Rapid Gravity Sand Filter

Filter Water Tank & Pump House

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Overview of Under construction BOP- De-mineralization System

DM Plant

DM Tanks

DM Regeneration Area

Neutralization Pit

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Overview of Under construction BOP- Coal Feeding System Wagon Tippler 1 & 2 Wagon Tippler 3 & 4 Sloping Conveyor Tunnel

CHP Retaining Wall

Conveyor 3A/3B

TP-3

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Overview of Under construction BOP- Coal Feeding System

Crusher House

Coal Stock Yard

Stacker Reclaimer

TP-4

Conveyor 4A/4B

Conveyor 5A/5B

TP-5

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Overview of Under construction Boiler System

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Three breakers for two buses. High reliability and operational flexibility Capability of isolating any circuit breaker or either main bus for maintenance without service interruption. A bus fault does not interrupt service. Double feed to each circuit.

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Bus Ducts Circuit Breaker Capacitive Voltage Transformer (CVT) Electro Magnetic Voltage Transformer(EMVT) Isolators/Disconnectors Earth Switches Current Transformers Wave trap Surge/Lightning Arrestors

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Originally developed in the 1960s, Isolated phase bus duct (IPB or IPBD), is a method of construction for circuits carrying very large currents, typically between a generator and Generator Step-Up Transformer Conductors are rolled hollow aluminum tubes, supported within the enclosure on porcelain or polymer insulators

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Also of two types(a) segregated phase bus duct (b) non-segregated phase bus duct

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These are the automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. These fault current levels can be 20 or 30 times larger than the current under normal operating conditions. They are used to immediately discontinue electrical flow in case any fault is detected. When a fault condition is detected by the pilot devices/relays, some mechanically stored energy (using something such as springs or compressed air) contained within the breaker is used to separate the contacts. When a current is interrupted, an electric arc is generated Since we are operating on a very high voltage of transmission, this arc can be extremely dangerous and hence, it must be contained, cooled and extinguished in a controlled way, so that the gap between the contacts can again withstand the voltage in the circuit. Circuit breakers normally interrupt all three phases simultaneously.
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The insulating fluids commonly used in circuit breakers are: Compressed air Oil which produces hydrogen for arc excitation. Vacuum Sulphur hexafluorides (SF6 ) Circuit Breaker used at ESSAR-MAHAN switchyard : SF6 Circuit Breaker manufactured by ALSTOM SPECIFICATION

Rated Voltage: 420 kV Rated Normal Current: 3000 A Frequency: 50 Hz Short Time Withstand Current: 40 kA Short Circuit Breaking Current: 40 kA Short Circuit Making Current: 100 kAp SF6 Gas Pressure at 20oC: 0.85 MPa (abs) Total Mass of SF6 Gas: 70.8 kg Rated Opening Time: 30 ms (max) Rated Closing Time: 110 ms Quantity: 8 (with pre insertion resistor), 2 (without PIR)
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The capacitor voltage transformer is used as a means of delivering a filtered, low-voltage signal to the protected relay portions of the attached electrical circuitry These transformers are mostly used within the high-voltage circuitry as measurement devices and as a means of protecting specific parts of the circuitry. It systematically step the amount of signal it receives upon input, within the parameters set by the smaller components of the circuit. These components are usually meters or other measurement devices that are used to record the amount of signal received by and output through the circuit in its entirety. The CVT is a capacitor divider with top connected to the line (400kV) and bottom earthed.
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A tap of the capacitor at 22 kV is connected to a transformer inside the tank. The transformer will have 3 secondary windings to give 110 V each. 2 cores are for protection, 1 for metering.

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In this type of vts the voltage step down takes place by means of electro magnetic circuit. It is specially dedicated for line metering purposes.

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These are the electrical switches to completely de-energized an electrical circuit for service or maintenance Isolators are disconnecting switches it is used for open the circuit under no load condition Opened or closed only when circuit breaker is open. Accompanied with Earth Switches to earth the residual/ magnetizing currents when isolator opens. Two types Horizontal Upright Pantograph Isolator Center break

Isolator Specifications Rated Voltage: 420 kV Rated Current: 2500 A

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Earth Switch is connected between the line conductor and Earth. Normally it is open when the line is disconnected, the earth switch is closed so as to discharge the voltage trapped on the line capacitance to the earth. When isolator is in open condition, earth switch is closed and vice versa. Normally the Earth switch is mounted on the frame of the isolator

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It is used for measurement of current as well as protection purposes. Much higher values of line currents will be stepped down to some standard low values, thus can be measured easily. CT is always connected in series with the power line with the primary being the line itself. The secondary winding is having taps to have different CT ratios such as 2000/1, 1000/1, 500/1. There are 5 secondary windings. Core I - Metering or measurement Core II Open Circuit, Earth fault, Back Up Protection Core III - Main Protection (Differential Protection for Transformer, Distance Protection for lines) Core IV & V Bus Bar protection
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CT Type 2 CORE 4 CORE 5 CORE Core I,II,IV,V Core III

Purpose Metering Metering Protection Metering

Accuracy 0.2 S 0.2 S PS 0.2 S

Burden 5 VA 5 VA 20 VA 20 VA

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key component in PLC (Power Line Carrier) systems Used for remote control signals, voice communication, remote metering and control between substations in the electrical T&D network. High voltage transmission lines are also used for transmitting carrier signals between 30 kHz and 500 kHz Line traps prevent transmission of these high frequency signals to unwanted directions without loss of energy at power frequency. Line traps are series-connected to the transmission lines. Continuous Current Rating: 2400 A

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Main coil

carries the rated current of the transmission line and is designed to withstand the maximum short-circuit current. Its low self-capacitance provides a high self-resonance frequency

Extremely reliable tuning devices

inside the main coil on the central tie rod.

This key sub-component of a line trap is mounted

Protective Device

The protective device is connected across the main coil and the tuning device to prevent the line trap from being damaged by transient overvoltages
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It is a protective device which diverts the transient over voltage surges to earth & protect the substation equipment from lightning & switching over voltage surges. Acts as open circuit during normal conditions and provides a short circuit path during lightning surges and over voltages. The connection made in LA is, one terminal is plugged in to high voltage terminal & other terminal is earthed. They are generally connected in parallel with the equipment to be protected and function to divert the surge current safely to ground. They present high impedance at power frequency but low impedance to surge currents. SPECIFICATIONS Zinc Oxide, Gapless Type Rated Voltage: 360 kV Nominal Discharge Current: 10 kA
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 One

and a half breaker scheme makes it reliable. Zero Emission Plant.

Almost

Full

Utilization of Steam is ensured.

Coal

Waste is proposed to be managed to make Bricks.

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 We

have come to know what all processes are needed to generate and run the plant on a 24x7 basis.

This

plant is an example in terms of working efficiency and management of resources to all other thermal plants in our country.
training gave us an opportunity to clear our concepts from practical point of view with the availability of machinery.

The

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