MADHYA PRADESH POWER GENERATION

COMPANY (MPPGCL)
SATPURA THERMAL POWER STATION (2x250MW)
(STPS)
(2022-2023)
Sarni, Madhya Pradesh 460447

APPRENTICESHIP TRAINING FINAL REPORT

(2022-23)
CHECKED BY SUMMIT TO
Mr. Praveen Rai, A.E. (EMD)-IV Mr. I.H Khan (EE)
Mr. Ankit Thaware, J.E.(EMD)-IV Executive Engineer

SUMMIT TO
Mr. SUDEEP TIWARI (EE)
Executive Engineer

SUMMIT BY
SHIVAM SING
ITI (Electrician)

ACKNOWLEDGEMENTS
I take this opportunity, to acknowledge some of the people, who have
made a major contribution to the development of this project.
I am especially very grateful to Mr. Praveen Rai, (A.E.) of Satpura
Thermal Power Station,Sarni for the
guidance, inspiration, motivation and encouragement, he provided
during the course of the
Project study. He has always been nice and patient enough, to listen
to the queries and solving them, in spite of a very busy schedule.
I am also indebted to Mr. Praveen Rai Assistant Engineer &
Mr. Ankit Thaware, J.E.(EMD)-IV of Satpura Thermal Power
Station, Sarni,for the reviews, suggestions and support, he
whenever it was required. This project could not been
completed, without the assistance of all the other staff members in
the organization, who helped
me in familiarizing with the organization and assisted me through
their experiences and
Information required during the project.
I would like to express my sincere thanks to Mr. Naredra Pawar,
P.A.(STPS) Mr. Shankar Khade, my project guide, for her valuable
support. he gave me the opportunity to do this project; timely
Guidance helped me, and making this project.

SHIVAM SING
ITI (Electrician)
 DECLARATION

I hereby declare that the apprenticeship training Report entitle detailed Project report of thermal
power plant With Its Competitors” is an authentic record of my own work as requirements of one
year apprenticeship training during the period from 19th March, 2023 to 20th March, 2024 for the
award of ITI Electrician

Satpura Thermal Power Station,Sarni under the guidance of Mr. Praveen Rai, (A.E.) of Satpura
Thermal Power station in Sarni, Madhya Pradesh, India.

DATE:- 20/04/2024 SHIVAM SING

PLACE- SARNI ITI (Electrician)
THANKING
YOU

SHIVAM SING
ITI (Electrician)
 Fundamentals
1. Introduction
2. Law of Conservation of Energy
3. Temperature, Absolute Temperature
4. Pressure, Gauge Pressure and Absolute Pressure
5. Heat , Specific Heat
6. Work
7. Power
8. Energy
9. Enthalpy
10. Laws of Thermodynamics
11. Specific Heat of Gas
12. Carnot Cycle with Steam as Working Fluid
13. Rankine Cycle
14. Brayton Cycle

Heat Transfer Methods

01. Introduction
02. Heat Transfer by Conduction
03. Fourier’s Law
04. Thermal Conductivity
05. Contents v vi Contents
06. Heat Transfer by Convection
07. Newton’s Law of Cooling
08. Heat Transfer by Radiation
09. Absorption, Reflection and Transmission of Radiation
10. Emissivity
11. Stefan–Boltzmann Law
12. Geometrical Factor or Configuration Factor
13. Heat Transfer Methods in a Boiler
 Fuel and Combustion
01. Introduction
02. Solid Fuel
Wood
Coal
Coke
03. Biomass Fuel
04. Liquid Fuel
05. Gaseous Fuel
06. Blast Furnace Gas
07. Combustion
08. Chemistry of Combustion
09. Some Important Properties of Coal
10. Gradation of Coal
11. Combustion of Coal
12. Combustion of Pulverised Coal
13. Combustion of Liquid Fuel

Introduction to Boiler
01. Introduction
02. Steam Generation in a Boiler
03. Different types of Boiler
04. Fire Tube and Water Tube Boiler
05. Straight Tube, Bent Tube, Horizontal, Vertical and Inclined Boiler
06. Waste Heat Recovery Boiler (WHRB)
07. Package Boiler
08. Subcritical and Supercritical Boiler
09. Fuel-fired Boiler
10. Travelling Grate-fired Boiler
11. Spreader Stoker-fired Boiler
12. Pulverised Coal (PC)–fired Boiler
13. Air System
14. Pressure Parts (Heat Transfer Surfaces)
15. Coal Feeding System
16. Ash Handling System
17. Supercritical Boiler
18. Water and Steam Circuit
19. Air Path
20. Feedwater Path

21. Steam Path

22. Flue Gas Path
Steam Turbine
01. Introduction
02. Impulse and Reaction Turbine
03. Impulse Turbine
04. Reaction Turbine
05. Classification of Steam Turbine
06. Main Components of Steam Turbine
07. Casing
08. Rotor
09. Moving Blade
10. Fixed Blades and Diaphragm
11. Steam Sealing System
12. Bearings
13. Gland Sealing System
14. Extraction System
15. Feedwater Heater
16. Large Capacity Steam Turbine
17. Reheat Turbine
18. Multicasing Turbine
19. Multiflow Turbine
20. Feedwater Heating

Auxiliary System of Steam

01. Turbine
02. Introduction
03. Oil System
04. Oil Tank
05. Oil Pump
06. Oil Cooler
07. Oil Filter
08. Oil Centrifuge
09. Overhead Tank
10. Oil Accumulator
11. Condensate System
12. Gland Sealing System
13. Steam Ejector and Vacuum System
14. Condenser
15. Dalton’s Law of Partial Pressure
16. Condenser Efficiency
17. Cooling Water System
18. Cooling Tower
19. Cooling Water Treatment
 Generator
01. Introduction
02. Important Parts of a Generator
03. Cylindrical Rotor
04. Stator
05. Bearings
06. Enclosure
07. Cooling System of Generator
08. Closed System Air Cooling
09. Closed System Hydrogen Cooling
10. Excitation System
11. Field Supply from Excitation Transformer or Static Excitation System 406
12. Excitation Through Exciter Generator or Brushless Excitation System
13. Automatic Voltage Regulator (AVR)
14. Voltage Build-up
15. Synchronisation
16. Desynchronisation or Islanding
17. Generator Protection
18. Different Operating Conditions of Generator
19. Parallel Mode of Operation
20. Isolated Mode of Operation
EMD (Electrical Maintenance Division) at ET&I - 4 .

01. HT Motors
02. HT Switch gears
03. DG Set (Diesel Generator)
04. Transformers
05. Switch Yard
06. ESP
07. Battery Charger
08. DM Plant
09. LT Motors
10. LT Switch gears
11. Cooling tower
INTRODUCTION
The aim of this report is to share my experience at Satpura. Thermal Power Plan during my
training period of four weeks which are from 13 of Sep. 2023 to 10 Oct. 2023.
Satpura Thermal Power Plant, Sarni is the highest power generating company of
Madhya Pradesh and it is also known as M.P.P.G.C.L., Sarni. It is located in Sarni town near
Ghoradongari Railway Station, dist. Betul. It is the one of coal based plant of MPPGCL. Satpura
Thermal Power Station has an installed capacity of 500 MW. The First unit was commissioned in
October 1967. The Water for the plant has been procured from nearby Tawa Dam Lake area,
which spread in 2,893 acres (11.71 km2). The coal for the plant has been procured by
Rail/Road/Belt from Western Coal Fields. There are two units namely 10 & 11 each with of 250
MW generation capacity.
TECHNICAL SPECEFICATION
OF
SATPURA THERMAL POWER PLANT
18 K.M. FROM GHORA DONGRI
LOCATION RAILWAY - STATION DIST –BETUL

CAPACITY 1330 M.W.

SOURCE OF WATER TAWA DAM; LAKE AREA 2893 ACRE

FUEL PRIMARY FUEL -COAL

PATHAKHEDA, KANHAN, PENCH,
COAL AREA

NAGPUR, CHANDRAPUR, WANI

MODE OF TRANSPORT RAIL /ROAD/BELT
79.2 LMT (appx.) PER ANNUM (2007-

COAL LINKAGE 08)

SECONDARY FUEL –FURNACE OIL/HSD
COAL SOURCE WESTERN COAL FIELD LIMITED
STP – ITARSI/ INDORE
POWER EVACUATION 400 K.V. LINES
STP – KORADI/ BHILAI

STP – ITARSI (4)

220 K.V. LINES
STP - KALMESHWAR (1)
 OVERVEIW OF THERMAL POWER STATION

Simplified diagram of plant

The coal from mines is received at CHP (Coal Handling Plant) through Railways. The unloaded
coal (max. size 250 mm²) is scooped into conveyor and is passed through suspended magnet,
magnetic separators, and metal detectors, to ensure that sized coal, free of foreign material is
supplied. Then it is sent to Crusher House for further crushing to 25 mm² size. After crushing,
the coal again screened for elimination of extraneous materials, weighed and sent to boiler
bunkers. Excess coal, if any, is sent to coal yard for stacking. It then falls through a weigher
into the Bowl Mill where it is pulverized. The mill usually consists of a round metal table on
which large steel rollers or balls are positioned. The table revolves, forcing the coal under the
rollers or balls which crush it.
LAYOUT OF THERMAL POWER PLANT

FUEL COST

CAPITAL COST

OPERATING
COST
 ENERGY CONVERSION PROCESS IN TPS

100
80
60
40
20 ENERGY CONVERSION
0 PROCESS IN TPS

Air is drawn from the top of the boiler house by the FD Fan (Forced Draft fan) and passed
through the RAH (Regenerative Air Heater), and then send to boiler for burning of coal. PA
Fan (Primary Air fan) takes air from atmosphere and distributes them into 2 parts one send to
RAH for heating and other fed directly to Mill blowing coal along pipes to boiler furnace. The
boiler consists of a large number of tubes extending the full height of the structure and the
heat produced raises the temperature of the water circulating in them to form superheated
steam which passes to the Boiler drum. The steam is fed through the outlet valve to the HP
Turbine (High Pressure turbine) at around 540°C.After this, it is returned to the boiler and
reheated before being passed through the IP & LP Turbine (Intermediate and Low Pressure
Turbine). The water fed into boiler is DM water (De-Mineralized water).
From the turbine the steam passes into Condenser to be turned back into water. This is
pumped through CEP (Condensate Extraction Pump) which sends water through GSC (Gland
Steam Cooler), LPH (Low Pressure Heater), and HPH (High Pressure Heater) for further
heating and BFP (Boiler Feed Pump) then sends it to the Economizer where the temperature
is raised sufficiently for the condensate to be returned to the lower half of the steam drum of
the boiler.
The flue gases produced in boiler are used to reheat the condensate in the Economizer and
then passes through the RAH to the ESP

(Electrostatic Precipitator) where ash is collected. Finally, they are drawn by the ID Fan
(Induced Draft fan) into the main flue and to the chimney. From the boiler, a steam pipe
conveys steam to the turbine through a stop valve (which can be used to shut off steam in an
emergency) and through control valves that automatically regulate the supply of the steam to
the turbine. The turbine shaft usually rotates at 3000 RPM. This speed is determined by the
frequency of the electricity system and the number of poles of machine (2-pole machine
here).
Cold water from OAC (Open Approach Channel) is circulated through the condenser tubes
and as the steam from the turbine passes round them it is rapidly condensed into water.
Water which gets heated up in condenser by cooling steam is sent to Cooling tower and then
left into OAC from where it can be further used.

The electricity is produced in turbo generators and is fed through terminal

connections to Generator Transformer, those steps up the voltage to desired level (400 KV,
220 KV, 33KV). From here conductors

carry it to Switchyard from where it is sent for us

MECHANICAL OPERATIONS.

70 PAISE 30 PAISE
1 RS COAL OTHER
TOTAL
= +

Coal Handling Plant (CHP)

 FLOW CHART OF CHP S.T.P.S

In S.T.P.S. coal comes through railway and through roadways also in NBOX type
containers. NBOX containers are bigger sized container then BOBR but there is no gate
available in the bottom of those boxes. So this type of containers is rotated 160° with its
track by Wagon Tippler.
Paddle Feeder is used to feed the coal to conveyor belt from Track Hopper. Then a
network of Conveyor Belts carries the coal towards Crushers House. In each line two
conveyor belts are present (One Running, One Standby). If the amount of coal comes
through rail is excess, then some coal is stacked in uncrushed coal area.

In S.T.P.S two Crushers House are present one for every stage. In each Crushers House first
the coal is drives towards Magnetic Separator which separates metals from coal and send
the coal to Reversible Belt Feeder drops the coal into Roller Screens separates the coal
according to their size. Then bigger sized coal is sent to Crushers to convert them into
desired size (25 mm²). Then this coal is dropped into Belt Feeders which is now again
return the coal to another Conveyor Belt System (TP3A up to Tp10/TP11) which leads the
coal to the Coal Bunker on the top of the Boiler or into the stack yard using stacker
reclaimer .

This full system is full controlled and monitored from CHP

 CONTROL ROOM
B. Raw Water System
The Water for the plant is procured from nearby Satpura Dam Reservoir, which spread in 2,893
acres (11.71 km2). The Dam was built for the purpose of power generation.
The water comes from Intake Pump Houses are first stored into Raw Water Pond which is
situated near the plant. Here the dissolved solid in the water precipitate due to gravity. If the
TDS (TOTAL DISSOLVED SOLID) level is permit able then it directly sends to Ash Plant or CHP
otherwise Chlorine (CI) is added and Flux were added up and clarified the water. 65% of this
clarified water is now used in Cooling Tower Makeup Pump, Service Water Pump, Ash Makeup
Pump, etc. 35% of the clarified water is now filtrated using Gravity Sand Filter Bed. After that
this filtrated water is used in DM plant and Drinking Water for plant and colony.
C. De-mineralization Plant (DM Plant)

In De-mineralised Plant, the filter water of Water Treatment Plant is passed through the
Pressure Sand Filter (PSF) to reduce turbidity and then through Activated Charcoal Filter (ACF)
to adsorb the residual chlorine and iron in filter water. And then the water is passed through
Cation and Anion Exchange Resin Beds which removes all unwanted ions from the water.
D. Boiler & Auxiliaries
Boiler is device for generating steam for power processing or heating purposes. Boiler is
designed to transmit heat from an external combustion source contained within the boiler
itself.

A/C to IBR of boiler vessel's parameter:- 1.

Minimum Capacity of boiler 25 litres
2. Should have a min pressure of
3.5 kg/ cm2
3.Should have mounting and accessories

The Boiler used in S.T.P.S. has following characteristics:

1. The Boiler we have seen is basically a Coal Fueled Boiler. But in time of light up the Light Diesel
Fuel is used for Ignition purpose.
2. This Boiler is a Corner Fired Boiler that means the coal intake nozzles are placed to the Corner
positions of the Furnace. We have
6 no of Intake Positions in a Boiler
3. This is a Water Tube Boiler that means the water and steam mixture is flowing through the tubes
and the Fire Ball is in the open place
4. This Boiler is made to be used as a Dry Bottom Boiler which means the ash is collected in a form
of solid (from flue gas as well as from the bottom of the boiler). Due to this the temperature inside
the Furnace should be less than 1300°C otherwise the bottom ash should be converted into liquid.
5. The water steam mixture in the Boiler is Circulates Naturally due to pressure difference, NATURAL
CIRCULATION
Boiler Accessories: -
Boiler Furnace: A boiler furnace is that space under or adjacent to a boiler in which fuel is burned
and from which the combustion products pass into the boiler proper. It provides a chamber in
which the combustion reaction can be isolated and confined so that the reaction can be isolated
and confined so that the reaction remains a controlled force. It provides support or enclosure for
the firing equipment.
Boiler Drum: The function of steam drum is to separate the water from the steam generated in the
furnace walls and to reduce the resultant solid contents of the steam to below the prescribed limit
of 1ppm. The drum is located on the upper front of the boiler.

Economizer: The purpose of the economizer is to preheat the boiler feed water before it is
introduced into the steel drum by recovering the heat from the fuel gases leaving the boiler. The
economizer in the boiler rear gas passes below the rear horizontal super heater.
Super Heater: There are 3 stages of super heater besides the side walls and extended side walls.
The first stage consists of horizontal super heater of convection mixed flow type with upper and
lower banks located above economizer assembly in the rear pass. The 2nd stage super heater
consists of pendant platen which is of radiant parallel flow type. The 3rd stage super heater
pendant spaced is of convection parallel flow type the outlet temperature and pressure of the
steam coming out form the super heater is 540°C and 157 kg/cm².
Pre heater: The function of pre heater is to reheat the steam coming out from high
pressure turbine to a temperature of 540°C.

Burners: there are total 24 pulverized coal burners for corner fired C.E. type boilers and 12 oil
burners provided each in between 2 pulverized fuel burners.
Induced draft fan (ID fan): Induced draft represents the system where air or products of
combustion are driven out after combustion at boiler furnace by maintaining them at a
progressively increasing sub atmospheric pressure. This is achieved with the help of induced draft
fan and stack. Induced draft fan is forward curved centrifugal (radial) fan and sucks the fly-ash
laden gas of temperature around 125°C out of the furnace to throw it into stack (chimney). The
fan is connected with driving motor through hydro-coupling
or with variable frequency drive (VFD) motor to keep
desired fan speed.

Rating are
KW- 2250 KW

Voltage- 6.6 KV

Amps- 252 A

RPM- 746

Efficiency- 96.3

Ambient Temp.-50

Temp. Rise-70

P.F.-0.81

Forced draft fan (FD fan): Forced draft represents flow of air or products of combustion at
a pressure above atmosphere. The air for combustion is carried under forced draft conditions and
the fan used for this purpose is called Forced Draft (FD) fan. It is axial type fan and is used to take
air from atmosphere at ambient temperature to supply air for combustion, which takes entry to
boiler through wind

Rating are
KW- 750 KW

Voltage-6.6 V

Amps-81

RPM-1488

Ambient Temp.-50

Temp. Rise-70

Primary air fan (PA fan) or Exhauster fan:

The function of primary air is to transport
pulverized coal from coal mill to the furnace,
to dry coal in coal mill and also to attain
requisite pulverized coal temperature for
ready combustion at furnace. Rating are
KW- 1780KW

Voltage-6.6 KV

Amps-183 A
RPM-1492

Ambient Temp.-50

Temp. Rise-70

Coal mill or pulveriser: Most efficient way of utilizing coal for steam generation is to burn it in
pulverized form. The coal is pulverized in coal mill or pulveriser to fineness such that 70-80%
passes through a 200 mesh sieve.

Rating are
KW- 450KW

Voltage-6.6

Amps-57

RPM-987

Ambient Temp.-50

Temp. Rise-70

Fuel oil system: In a coal fired boiler, oil firing is adopted for the purpose of warming up
of the boiler or assisting initial ignition of coal during introduction of coal mill or imparting
stability to the coal flame during low boiler load condition. Efficient or complete combustion of
the fuel oil is best achieved by atomizing oil by compressed air for light oil (LDO)
ESP(ELECTROSTATIC PRECPPITATOR)

It is a device which captures the dust particles from the flue gas thereby reducing the
chimney emission. Precipitators function by electrostatic ally charging the dust particles in the
gas stream. The charged particles are then attracted to and deposited on plates or other
collection devices. When enough dust has accumulated, the collectors are shaken to dislodge
the dust, causing it to fall with the force of gravity to hoppers below. The dust is then removed
by a conveyor system for disposal or recycling.

Ratings of transformer
Rating- 83 KVA

HV voltage- 74030 V

LV voltage- 373.5 V

Cooling- ONAN

HV Current- 1.12 A LV Current- 222.2 A

There are 36 TR Sets in total

Ectrostatic precipitation removes particles from the exhaust gas stream of Boiler combustion
process. Six activities typically take place:

lonization - Charging of particles

Migration - Transporting the charged particles to the collecting urfaces

Collection - Precipitation of the charged particles onto the collecting surface

Particle Dislodging - Removing the particles from the collecting surface to the hopper

Particle Removal - Conveying the particles from the hopper to a disposal point
 GT(GENERATION TRANSFORMER)
These are step up transformers used to step up voltage levels suitable for transmission
through transmission line via switch yard.
Here we use a step up transformer which step ups 16.5kv to 400kv A.C.
We use two GT one for each unit .

Ratings are-

Rating- 315 MVA, 3 phase 50 Hz HV voltage- 420 KV

LV voltage- 16.5 KV
Cooling- OFAF HV Current-433A
LV Current- 1022.1A
Temp. Rise of oil- 35 C above ambient 50 C Temp. Rise of winding- 40 C above ambient 50C
Connection symbol-YNd1

2
 F. Ash Handling Plant
A large quantity of ash is, produced in steam power plants using coal. Ash produced in about 10 to
20% of the total coal burnt in the furnace. Handling of ash is a problem because ash coming out of
the furnace is too hot, it is dusty and irritating to handle and is accompanied by some poisonous
gases. First this ash is collected from ESP (Fly Ash, 80% of total Ash) and from the Bottom of the
Boiler (BottomAsh, 20% of total Ash).

ASP processed the ash in two different ways.

1) It mixes the Ash with water and then send this mixture is sent to Ash Pond which is situated 5Km
away from the plant. Where due to gravity the Ash Particles Precipitate due to gravity and the
clean surface water of the pond is taken back for reuse

1) In the other way it sends the dry ash to the Ash Loading Plant which loads the ash into Container
Trucks and send them to different industries like cement company, ash brick company etc.
 G. Steam Turbine & Auxiliaries
A Steam Turbine is a mechanical device that extracts thermal energy from pressurized steam, and
converts it into useful mechanical work. In

S.T.P.S. 250MW BHEL MAKE THREE CASING TANDEM COMPOUNDING REHEAT REGENERATIVE
CONDENSING
REACTION TYPE TURBINE is used in each unit as a prime mover of the alternator.

This turbine has 3 sections.

1) High Pressure Turbine (HPT) it has 23 stages.
2) Intermediate Pressure Turbine (IPT) it has 17 stages.
3) Low Pressure Turbine (LPT) it has 8 stages in each side

Three turbines, HP turbine, IP turbine and LP turbine, are synchronized together

with a common shaft connected to the generator. HP and IP turbines have single
flow unit while LP turbine has double flow unit so as to accommodate the
increase in volume of steam due to the drop in pressure.

A. HP TURBNIE B. CASING OF LP TRBINE

First the steam enters intoHP Turbine from the Boiler and after work done the pressure
and the temperature of the steam decreases. So, after HP Turbine the steam goes to Reheater
which is situated in the top of the Furnace. From Reheater the steam directly enters into IP Turbine.
After IP Turbine the steam directly went to LP Turbine.
Power output is proportional to the steam pressure drop in the turbine In
each section of Turbine some extraction points are present. The goes to
different types of Heating Section.

Turbine Accessories:-

Regenerative Heaters-
(a) The Regenerative Heaters are used to heat the Condensate water from the condenser to the
boiler inlet.
(b) This makes the mean temperature of heat addition in boiler high resulting in High Efficiency.
(c) The heating is done by steam bled from different stages of HP, IP and LP turbines.
(d) The heaters are non-mixing type.
(e) The drip formed is cascaded to lower heaters in the line and finally to Deaerator (for HP
heaters) and Condenser (for LP heaters).
(f) The heaters before BFP are called Low Pressure Heaters (LPH) and those after BFP are called
High pressure heaters (HPH).
(g) The Deaerator is the only mixing type heater in the power plant. This is used to separate the
Dissolved Oxygen (O2) from water. (h) In some design drip pumps are used to pump the drip
from LPHS to the main condensate line.
Pumps-

(a) BFP (Boiler Feed Pump) - 4MW, 400 M³/hr Rating of BFP are-
KW- 4600 KW

Voltage- 6.6 KV

Amps-468 A RPM-1493 Efficiency-97%

Ambient Temp.-50
Temp. Rise-70
(b) CEP (Condenser Extraction Pump) - 500 M³/hr
Rating are-

KW- 325 KW

Voltae-6.6KV

Amps-36 A RPM-1487 Ambient Temp.-50

Temp. Rise-70

CW & ACW Pumps

Rating are-
KW- 1800 KW
Voltage-6.6KV

Amps-200A
RPM-495
Efficiency-95
Ambient Temp.-50 Temp. Rise-70

Turbine Gland Seal- Steam is used to seal the turbines

so that the inner steam should not come out as well as the outer air should not enter
into the turbine

Condenser-Condenser is the place where the steam comes after the LP Turbine
and exchange its heat with water and itself change own phase and turn into
water. This water then stored into the Hotwell situated under the Condenser.

H. Cooling Water System

Cooling towers cool the warm water discharged from the condenser and feed the
cooled water back to the condenser. They thus reduce the cooling water demand in
the power plants.

In ST.P.S. Natural Draft Cooling Towers are used. The flue gas heat releases due to density
difference between gases. In this time the water releases its heat to the atmosphere and cool
down
 Chimney

A Chimneys may be considered as a cylindrical hollow tower made of bricks or steel. In S.T.P.S. the
chimneys of five units are made of bricks. Chimneys are used to release the exhaust gases (coming
from the furnace of the boiler) high up in the atmosphere. So, the height of the chimneys is made
high. In S.T.P.S. the height of the chimneys is approximately 175m
Formula for height of chimney
ELECTRICAL OPERATION

A. TURBO GENERATOR

This Turbo Generator is basically a Synchronous Alternator. The stator houses the Armature
Windings and the rotor houses the Field Windings. DC voltage is applied to the Field Windings
through the Brushless Excitation System. When the rotor is rotated the lines of Magnetic Flux cut
through the Stator Windings. This induces an e.m.f. in the Stator Windings.
The rotor is rotated at 3000 rpm by the Turbines to generate electricity ata frequency of 50
Hz. Because this is a 2 pole machine. Due to this huge speedthe "TURBO" term is used. Generator
Components:

1. Rotor: The rotor is a cast steel ingot and it is further forged and machined. The rotor is to be
designed very accurately as it has to work on speeds such as 3000 rpm. Also a fairly high current is
to be carried by the rotor windings to generate the necessary magnetic field.
2. Rotor winding: Silver bearing copper is used for the winding with mica as the insulation between
conductors. A mechanically strong insulator such as micanite is used for lining the slots. When
rotating at high speeds centrifugal force tries to lift the windings out of the slots, so they are
screwed to the rotor body. The two ends of the windings are connected to slip rings, usually made
of forged steel.
3. Stator core: The stator is the heaviest load to be transported. The major part of this load is stator
core. This comprises of an inner frame and outer frame. The outer frame is a rigid fabricated
structure of welded steel plates, within this shell is a fixed cage of girder built circular and axial ribs.
The ribs divide the yoke into compartments. The inner cage is usually fixed to the yoke by an
arrangement of springs to dampen the double frequency vibrations.

4. Stator windings: Each stator conductor must be capable of carrying the rated current without
overheating. The insulation must be sufficient to prevent leakage currents flowing between the
phases to earth. Windings for the stator are made up from copper strips wound with insulated tape
which is impregnated with varnish, dried under vacuum and hot pressed to form a solid insulation
bar. These bars are then placed in stator slots and held in with wedges to form the complete winding.
The end turns are rigidly braced and packed with blocks to withstand the heavy forces
Generator Cooling: -
Rotor Cooling System: The rotor is cooled by means of gap pick up cooling, wherein the hydrogen
gas in the air gap is sucked through the scoops on the rotor wedges and is directed to flow along the
ventilating canals milled on the sides of the rotor coil, to the bottom of the slot where it takes a turn
and comes out on the similar canal milled on the other side of the rotor coil to the hot zone of the
rotor. Due to rotation of the rotor, a positive suction as well as discharge is created due to which a
certain quantity of gas flows and cools the rotor.
The conductors used in the rotor windings are hollow which is done to have internal cooling of the
rotor.

Hydrogen Cooling System: Hydrogen is used as a cooling medium due to its high heat carrying
capacity and low density. But it can also form an explosive, or escape out of the generator casing
which may result into many catastrophic results. So the pressure of H₂ should be maintained
properly. The filling in and Purging of H₂ is to be done safely without bringing in contact with air. To
fill H₂ inside generator first CO₂ is filled through generator and then H₂ is passed since H₂ has no
reaction with CO₂ and while taking H₂ out of generator first H₂ is taken out then CO₂ is passed
through generator and then air is allowed to enter
. To stop the hydrogen from escaping the generator casing oil sealing is done. The shaft of the rotor
has many blades connected at the end of the shaft. Each of the blades rotates in the slot engraved in
the generator casing. Now these slots are filled with oil up to a certain level, so that the ends of the
blades rotate in an oil medium which is separated among them. So when the Hy tries to escape and
comes near the end of the shaft it passes through the blade that is through the oil in the slot, due to
which a major part of it gets obstructed and the left out gas proceeds to the next slot. Now at the
end there is almost no or negligible amount of gas leakage.

Stator Cooling System: The stator is cooled by distillate which is fed from one end of the machine by
Teflon tube and flows through the upper bar and returns back through the lower bar of another slot.
The stator winding is cooled in this system by circulating DM water through hollow conductors. The
DM water should be at 40°C. As it is a closed loop the water that comes out of the generator is again
cooled and demineralized. Water passes through lower bars along the length to the other end
returns through the upper bars of another slot and drain into drain header.

.RATINGS OF TURBO GENERATOR

Manufacturer: BHEL
R.P.M:3000 rpm
Rated Power:250 MW
Rated KVA:294100 KVA
Stator Voltage: 16.5 kvStator Current: 10291
A
Rotor Voltage: 299 v
Rotor Current:2497
Frequency:50 Hz Connection:YY
(DOUBLE-STAR)
Power Factor:0.85 LAG
Rated H₂ Pressure: 4 BAR Class of
Insulation: F
B. Excitation System
Excitation System is used to send the Field Current in the Stator Winding of an Alternator. Here we
have Brushless Excitation System for this purpose
.In Brushless Excitation System two systems namely Pilot Exciter and Main Exciter are connected to
the common shaft of the Turbo

Generator's Prime Mover

.BASIC DIA. OF BRUSHLESS EXCITATION SYSTEM

Pilot Exciter is basically a 32 pole Permanent Magnet Generator where the Permanent Magnets are
placed in the Rotor. Now as the Prime Mover rotates it generates an AC in its Stator. Using
Automatic Voltage Regulator (AVR) this AC is converted into Regulated DC which is now used to
magnetise the electro-magnets of the Main Exciter placed in its Stator Portion. Due to this an AC
voltage developed in the rotor conductors of the Main Exciter. Now Using Drum Wheel which is also
placed inside the Prime Mover Shaft this AC is converted to DC and used as Field Current of the
TURBOGENERATOR.

Ratings of Brushless Exciter -

Power-1350KW
Excitation current DC - 36.5 A
Rating DC- 420 Volts RPM- 3000
Current DC - 3200A Coolant- AIR
Excitation voltage DC -106 Volts
 C. Transformers

The transformers used in a power station have its sides abbreviated as Low Voltage (LV) and High
Voltage (HV) rather than primary and secondary.

Major transformers in a power station:

1) Generator transformer (GT): The Generator is connected to this Transformer by means of isolated
bus duct. This transformer is used to step up the generating voltage to grid voltage normally. This
transformer is generally provided with OFAF cooling

2) Unit Auxiliary Transformer (UAT): The UAT draws its input from the main bus duct connecting
generator to the Generator Transformer. It is used for the working of large devices such as BFP, CEP,
FD FAN, ID FAN, CW & ACWPUMPS etc.

3) Station Transformer (ST): The Station Transformer is used to feed the power to the auxiliaries during
the Start-ups as well as run the different parts of the plant like CHP, AHP, Raw Water Plant, DM Plant,
Fuel Oil Pump House etc.

4) Inter-Bus Transformer (IBT): IBT is a special type of

Transformer having Three Windings (Primary, Secondary, Tertiary). IBT is used to Share Power
between different Voltage BUSES. As well as they are used to manage the Power Flow of the plant
and it also helps to recover the plant in case of Power Failure
Thank You