ACKNOWLEDGEMENT

For an Engineer it is very important to have proper matching between theoretical knowledge
gained from the books and the practical knowledge. Although an Engineer can only be
successful through sheer hard work. But the contribution of his teachers and all those who
have been helpful cannot be overlooked.
Through this acknowledgement I would like to grab the opportunity to thank all those who
have helped me right from the start of my training upto its end.
I would also like to thank the persons from GGSSTP, Ropar helping me in getting to the
depth of the working of the thermal plant.

ASE (Training Cell GGSSTP, Ropar.)

I think the knowledge gained by me during this training would greatly help me in becoming a
successful Electrical Engineer.
SUBMITTED BY,
KUNDAN KUMAR SINGH

INTRODUCTION
Electrical energy occupies top position in the energy table. It can be adopted conveniently in
the domestic, industrial and agriculture fields. The availability of electrical energy and its per
capita consumption is regarded as an index of national standard of living in the present day
civilization. The lack of electricity can hinder the economic as well as social progress of the
country.
Next to food, fuel and power are the most important items on which the standard of life
depends. Every effort is or has been made to utilize the various natural as well as artificial
sources of energy in order to increase the power potential of the nation. The energy in the
form of electricity is the most desired since it is the most economical, easy transmission, easy
control, cleanliness, greater flexibility, versatile form and can be converted into heat and
work as and when desired. The main sources of energy generation in India are solar, wind,
tidal, hydro, thermal and nuclear.
Every effort is being made to utilize full potential of energy development available. But if we
look at the data available and compare it with the developed countries, we can say that we are
still a far to go. The figures below indicate the present sources of energy and their respective
division.

TOTAL INSTALLED CAPACITY

: 89,798 MW

PEAK DEMAND

: 67,500 MW

COAL BASED THERMAL PROJECTS

: 65,000 MW

HYDRO PROJECTS

: 22,000 MW

NUCLEAR PROJECTS

: 2000 MW

WIND POWER

: 900 MW

THERMAL POWER GENERATION

In steam power plants the heat of combustion of fossil fuels (coal, oil or gas) is utilized by the
boilers to raise steam at high temperature and pressure. The steam so produced is used in
driving the steam turbines or some times steam engines coupled to the generators and thus in
generating energy.
Oil and natural gas reserves are small in our country and India has to import large quantities
of oil and increasing such imports for power generation is not desirable due to miserable
amount of foreign exchange reserves India has. This explains the dependence on coal for
generation of electricity in thermal power plants.
Large development in thermal power generation calls for proper choice of site, unit size, coal
requirements, transport facility, transmission systems etc. It is normal practice to consider
various alternative sites for locating power stations and work out cost comparison to arrive at
economically feasible sites.

COAL FOR STEAM POWER PLANTS

The main sources of coal in India are Bihar, West Bengal and the central regions. The
economic and efficient use of high ash content coal for the thermal plants calls for special
treatment. Since 50 to 60% of cost of electricity generation is due to transport cost of coal, so
it is imperative that these power plants are located near the washeries.
Main things that are to be kept in mind while selecting coal for modern steam power
stations are:
1. Size
2. Moisture
3. Ash
4. Grindability
5. Fusability of ash
6.Calorific value
7.Impurities like sulphur, phosphorous, chlorine et

SELECTION OF SITE FOR STEAM POWER PLANTS

1.SUPPLY OF WATER:
A large quantity of water is required in steam power plants. It is required:
(I)

To raise the steam in the boiler.

(II)

For cooling purposes such as in condensers.

(III)

As a carrying medium such as in disposal of ash.

(IV)

For drinking purposes.

The efficiency of direct cooled plant is about 0.5% higher than that of the plant in which
cooling towers are used. This means a saving of about Rs 7.5 lakhs per year in fuel cost for a
2000 MW station.
2.REQUIREMENT OF LAND:
The land is required not only for setting up of the plant but also for other purposes such as
staff colonies, coal storage, ash disposal etc. cost of land adds to the final cost of the plant. So
it should be available at a reasonable cost. Land should be of good bearing capacity since it
has to withstand about 7 Kg per sq. cm. Moreover, land should be reasonably level. It should
not be low lying.
3.TRANSPORTATION FACILITY:
The land and rail connections should be proper and capable of taking heavy and over
dimensioned loads of machines etc.
To carry coal, oil etc which are daily requirements, we need these transport linkages.
4.LABOUR SUPPLIES:
Skilled and unskilled labourers should be available at reasonable rates near the site of the
plant.

5.ASH DISPOSAL:
Ash is the main waste product of the steam power plant. Hence some suitable means for
disposal of ash should be applied. Ash can be purchased by building contractors, cement
manufactures or it can be used for brick making near the plant site. Otherwise wasteland
should be available near the plant site for disposal of ash.
6.DISTANCE FROM THE POPULATED AREA:
Since most of the modern generating stations employ pulverized fuel residues and fumes
from them are quite harmful. Therefore the site for the plant should be away from the
populated area.
7.CLIMATIC CONDITIONS:
Climatic conditions of a place play a significant part in economics of capital investment.

WORKING OF THE THERMAL PLANT

Thermal power station burn fuels and use the resultant steam to drive the turbo generator. The
object is to convert heat into mechanical energy in the turbine and to convert mechanical
energy into electrical energy by rotating magnets inside a set of magnets. The coal brought to
the station by means of trains travel from the coal handling plant by conveyor belts to the
coal bunkers. From where it is fed to pulverizing mills which grind it to a fine powder. Finely
powdered coal mixed with preheated air is blown into the boiler by primary air fan where it
burns more like a gas than as a solid with additional amount of air called the secondary air
supplied by the secondary draft fan. As the coal has been ground finely the resultant ash is
fine powder. Some of its contents bind together to form lumps which fall in ash pits at the
bottom of the furnace. The ash mixed with water is then taken to the pits for subsequent
disposal. The electrodes charged by high voltage electricity in the electrostatic precipitator
trap most of the ash. The dust is then conveyed by water to the disposal area or to the bunkers
while the cleaned flue gases pass on through the ID fan to discharge through the chimney.
Meanwhile the heat released from the burning of coal has been absorbed by many kms of

tubing which line the boiler. Inside these tubes is water, which takes the heat and is converted
into steam at high temperature and pressure. This steam at high temperature and pressure is
sent to the turbine where it is discharged through the nozzles on to the turbine blades. The
energy of the steam striking on the blades makes the turbine to rotate. Coupled to the turbine
is the rotor of the generator. So when the turbine rotates the rotor of the generator turns. The
rotor is housed inside a stator having heavy coils of copper bars
in which electricity is produced through the movement of magnetic field produced by the
rotor. Electricity passes from stator winding to the transformer, which increases its voltage
level so that it can be transmitted over the lines to far off places.
The steam, which has given away its energy, is changed back into water in the
condenser. Condenser contains many kms of tubing through which cold water is continuously
pumped. The steam passing over the tubes continuously loses heat and is rapidly changed
back into water. But the two waters i.e. the boiler feed water and cooling water must never
mix. Boiler water must be absolutely pure otherwise the tubing of the boiler may get
damaged due to the formation of salts inside the tubes due to the presence of different
impurities in water.
To condense large quantities of steam huge and continuous volume of water is
required. In some power stations same water has to be used again and again because there is
not enough water. So the hot water extracts are passed through the cooling towers. The
cooling towers are simply concrete shells acting as a huge chimney creating a draught of air.
The design of cooling towers is such that a draught of air is created in the upward direction.
The water is sprayed at the top of the tower. As it falls down the air flowing in the upward
direction cools it. The water is collected in a pond from where the water is recirculated by the
pumps to the condenser. Inevitably, however some of the water is taken away by the draught
of water in the form of vapours and it is this water with familiar white clouds emerging from
the cooling towers.

CONTENTS

1. INTRODUCTION
2. BRIEF HISTORY OF PLANT
3. ELECTROSTATIC PRECIPITATOR
4. DIFFERENT TRANSFORMERS INSTALLED
5. 220 KV SWITCH YARD
6. GENERATOR
7. TURBINE AND ITS AUXILIARIES
8. LT AND HT SWITCHGEAR

1.INTRODUCTION OF THE PLANT

Guru Gobind Singh Super Thermal Plant is built at a site adjacent to Nangal Hydel Channel
near Sirsa Aqueduct on a piece of land bounded by sirsa, Mansali and sutlej rivers. It is about
55 Kms from Chandigarh near village Ghanauli on Ropar-Nangal road.
Ever widening gap between power demand and its availability was one of the basic
reasons for envisaging the Guru Gobind Singh Super thermal plant for the Punjab State. The
historic town of Ropar was selected for this project for easy transportation of coal by railway,
availability of cooling water and land. The costly cooling towers have been avoided, as the
cooling water temperature is very low. Smt Indira Gandhi laid the foundation stone in
December 1980.
The total installed capacity of the power station is 1260 MW with 6 units of 210
MW each in three stages each of two units and the power plant comes in the category of
Super Thermal Plants in India.
This plant was awarded Meritorious Productivity Awards and cash rewards by
Govt. of India for its good performance during the years: 1985,1986,1987,1990 & 1992.
Special care has been taken to keep the atmosphere pollution free by providing electrostatic
precipitators with an efficiency of 99.7%, which extracts ash from the flue gases going out
from the boiler. Chimney height has been increased to 220 metros for wide spread of gases at
longer distance from the Power Plant to keep the ambient air clean.
TECHNICAL DATA:

1.COST OF THE PLANT: 1417 CRORES

2.DATE OF START: 30 DECEMBER 1980

3.DATE OF SYNCHRONIZATION:

UNIT 1

26.9.1984

UNIT 2

29.3.1985

UNIT 3

31.3.1988

UNIT 4

29.1.1989

UNIT 5

29.3.1992

UNIT 6

30.3.1993

4.DATE OF COMMERCIAL RUNNING:

UNIT 1

1.01.1985

UNIT 2

1.10.1985

UNIT 3

25.09.1988

UNIT 4

1.08.1989

UNIT 5

29.09.1992

UNIT 6

14.12.1993

5.LAND:
MAIN PLANT AREA :

210 ACRES

MARSHALLING YARD:

533 ACRES

RAILWAY SIDING :

65 ACRES

ASH DISPOSAL :

974 ACRES

RESIDENTIAL AREA:

492 ACRES
2274 ACRES

6.RAILWAY TRACK:
LENGTH OF SIDING FROM ROPAR : 8.315 KM
MARSHALLING YARD

: 38.330 KM

7.CHIMNEY HEIGHT:
UNIT 1 & 2: 110 MT
UNIT 3 & 4: 220 MT
UNIT 5 & 6: 220 MT
8. COAL:
AVERAGE DAILY REQUIREMENT: 3000 MT/UNIT

TOTAL STORAGE OF COAL : 4,00,000 MT

ASH GENERATED DAILY

: 1200 MT/UNIT

9.HEAVY FUEL DAILY REQUIREMENT:

3000 MT/UNIT
10.WATER REQUIREMENT:
A) FOR STAGE 1,2,3

: 750 CUSECS

B) CONSUMPTIVE REQUIREMENT : 21.25 CUSECS/UNIT

11.COAL HANDLING PLANT:

A) WAGON TIPPLERS

:5

B) PRIMARY CRUSHERS

:4

C) SECONDARY CRUSHER

:4

D) STACKER CUM RECLAIMER : 3

12.TOTAL ASH HANDLING:
18,00,000 MT/YEAR (VARIABLE)
13. BOILER:
TYPE

WATER TUBE SINGLE DRUM WITH

CAPACITY
MAKE
STEAM TEMPERATURE
EFFICIENCY
STEAM PRESSURE

REHEATER
680 TONS/HR
BHEL
540 C
87.16%
155 KGMS/CM2

14.SOOT BLOWERS:
RETRACTABLE SOOT BLOWERS
WALL BLOWERS
ROTATORY ARM TYPE

24 NOS
56 NOS
4 NOS

15.GENERATOR:
MAKE
TYPE
CAPACITY
KVA
VOLTAGE
AMPERES
POWER FACTOR
SPEED

BHEL
TH-210-A
210000 kW
247000 KVA
15750 VOLTS
9050 AMPS
0.85 LAGGING
3000 RPM

1.WATER TREATMENT PLANT

Water as it occurs is never Pure, and whatever may be the source, always contains
impurities either in solution or in suspension. The determination of these impurities makes
analysis of water necessary and removal/control of these impurities make water treatment
essential.
1.1 The major impurities of water can be classified in three groups:
i.

Non-ionic and Undissolved.

ii.

Ionic and Dissolved and

iii.

Gaseous.

1.1.1 NON-IONIC IMPURITIES.

These are mainly turbidity, silt, mud, dirt, and other suspended matter, microorganisms, bacteria and other organic matter, oil and corrosion products.
1.1.2 IONIC AND DISSOLVED IMPURITIES.
Any salt which dissolves in water splits into positively charge Cations
and negatively charged Anions and since these permit the water to conduct
electricity, these salts are called Electrolytes. Some of the most common Cations
in water are:Calcium, Magnesium, Sodium & Iron and rarely Ammonium and
Maganese. These Cations are associated with Anions like Bicarbonates,
Carbonates, Hydroxides (The sum of which is termed as Alkalinity) Sulphates,
Nitrates and Chlorides of all the dissolved impurities, hardness is the most trouble
some and is due to compounds of Calcium and Magnesium.
Sodium salts are highly soluble but can be corrosive if present in large
quantities as Sodium Chloride or Sodium Bicarbonate.
Dissolved Silica is another trouble some impurities especially in water fed to
Boilers of high temperature & pressure.
1.1.3 GASEOUS IMPURITIES.
Carbon Dioxide and Oxygen are the main gaseous impurities in the waters and
causes corrosion in boiler tubes.
1.2 SOURCE OF RAW WATER.
The source of raw water for GGSSTP is Nangal Hydel Channel and its quality
( designed as well as actual ) is as below:
Designed

Actual

Turbidity

100 ppm

5-60 ppm

PH

6.9 to 8.1 units

8.0 to 8.5 units

Alkalinity

60 ppm as Ca CO3

60-70 ppm

Chlorides

45.1 ppm as Ca CO3

3-10 ppm

Total Hardness

90 ppm as Ca CO3

70-90 ppm

Sulphates

44.7 ppm as Ca CO3

25-35 ppm

Calcium Hardness

60 ppm as Ca CO3

45-60 ppm

Magnesium Hardness

30 ppm as Ca CO3

30.45Pm

1.3 QUALITY OF WATER USED IN BOILERS.

It depends upon pressure. Generally, the Boiler feed water should not cause:
1.3.1 DEPOSITION OF SCALE ON METAL SURFACE.
Scale is caused by deposition of impurities (Separation of solids) from water
on heating surface. During evaporation loose precipitates are formed in Drum. It
decreases heat transfer and promotes high tube temperature (rupturing of tubes). This
decreases overall efficiency of Boiler. This is due to hardness and Silica salts, present
in water.
1.3.2 CORROSION OF BOILER TUBES.
This is caused by Acidity, Oxygen, Carbon dioxide or Chlorides. Most serious
is dissolved Oxygen in water.
1.4 EXTERNAL WATER TREATMENT.
1.4.1 REMOVAL OF TURBIDITY AND SUSPENDED SOLIDS.
1.4.1.1 CLARIFACATION.
Turbidity comprises of negatively (-vely) charged particles which remains in
colloidal form whereas suspended solids are coarse particles and hence settle rapidly.
To remove this , a coagulant is added to water to produce positively (+ vely)
charged particles which would attract the negatively (-vely) charged particles
and thus form dence flocs which settle easily. The equipment performing these
duties is called a Clarifloculator (provided in Stage-IInd & IIIrd).

1.4.1.2 FILTRATION.
For potable and boiler feed water, passing clarified water through pressure
sand filters further reduces this turbidity.
1.4.1.3 CHLORINATION.
Chlorination is done to destroy fungis bacteria. This also suppresses
biological decomposition of sludge blanket of clarifier.

1.4.2. REMOVAL OF DISSOLVED SOLIDS.

This process is called the Demineralization Process and is performed in
DM Plant. This basically consists of 2 units in series, one is called the Cation
Exchanger Units and the other Anion Exchanger Unit. The former is filled with
Cation Resins which exchange Hydrogen ion in the resin for all the Cations in
water. Similarly, Anion Exchanger has Anion resin which exchanges Hydroxyl
ion
(OH) for all the Anions in the effluent of Cation exchanger. The result is
Dematerialized Water, e.g. let us take dissolved impurity of Calcium Sulphates.
1.

Reaction of Cation Exchanger Units

Ca SO4 + H2

(R)

Ca

(R)

+ H2 SO4

Calcium Sulphates + Cation Resin = Calcium salt + Sulphuric acid

2.

Reaction in Anion Exchanger Unit

H2 SO4

+ R ( OH ) 2

Sulphuric + Anion
Acid

Resin

RSO4

Sulphates

+ 2H
+ Water salt

Therefore, in reaction (1) Ca SO4 has been converted to H2 SO4 and in reaction
(2) the same H2 SO4 becomes water. After sometimes, resin become in-effective due
to saturation of exchange sides of resins with Ions and these are regenerated with acid
and Alkali to bring them back to original conditions.

1.5 D.M. WATER SPECIFICATION.

i.

pH

ii. Silica Contents

iii. Conductivity

6.8 to 7.00
0.02 ppm (parts per million)
0.2 Micro mho/cm.

1.6 INTERNAL WATER TREATMENT.

Regardless of purity of water obtained from external treatment, internal
chemical treatment is normally required for complete protection against scale
corrosion and foaming.
1.6.1 PHOSPHATE DOSING.
Calcium Carbonate in the drum will react with Tri-sodium phosphate, forming
Calcium triphosphate, which can be removed by blow down of drum water. Thus
scaling is avoided:
.
1.6.2. HYDRAZINE DOSING.
Oxygen in feed water is removed in Deaerator to a considerable
degree. The residual Dissolved Oxygen in Deaerator water is removed by
dosing Hydrazine (N2H4) at suction of Boiler Feed Pump to nullify effect of
dissolved Oxygen.
Hydrazine+ Oxygen=Water + Nitrogen
N2 H4+ O2=2H2O + 2N2

2N 2H4
2NH4 + N2
Hydrazine=Ammonia + Nitrogen.
Ammonia keeps water Alkaline and N2 being volatile pass through
steam cycle unchanged and condenses in condensate and (N2) is not harmful.
Blow-down reduces concentration of solids in Boiler water by removing
sludge and concentrated impurities and these are replaced by fresh water.
Continuous blow down prevents formation of corrosion, carry over by keeping
concentration of salts in Boiler at desired level.
The Water samples in laboratory are tested to achieve Feed\Boiler water
1.7 HARDNESS.
It indicates Calcium and Magnesium salts present in water. Bicarbonates
and Carbonates of these salts constitute temporary hardness and Sulphates,
Nitrates, Chlorides etc. constitute permanent hardness. These cause scale formation
in the Boiler and their removal from water is called softening.

2.PRE AND POST CHEMICAL CLEANING PROCEDURES

INTRODUCTION
The chemical cleaning process for the internal surfaces of the Steam
Generating section comprises of an initial Alkali boil out followed by an acid-cleaning
schedule. The acid pickled surfaces are later passivated to safeguard the exposed
metal surface from corrosion attack.
The whole exercise is intended to ensure through cleaning of the water side of
the Boiler prior to pressing the Steam Generator into regular operation.

In addition to the above, the Pre-boiler system is also cleaned with a hot
Alkaline solution.
2. 1SCOPE OF CLEANING
The scope of cleaning includes a portion of the feed line, entire evaporative
system of the Boiler and the Economizer. Super heaters and Reheaters are excluded
from the described schedule. During the process, the Super heaters are isolated by
providing plugs at the mouth off the take tubes from the Drum.
2.2 PROCESS
Main steps involved in the process are:i.

Alkali boil out

ii.

Acid cleaning

iii.

Passivation stage-Ist and Stage-IInd.

2.3 TECHNIQUE
Alkali boil out at a pressure of 40 Kg/cm2 is carried out using a combination of
Trisodium Phosphate (1000 ppm as Na3 PO4, 12 H2 O) and Sodium Carbonate
(500 ppm as Na2 CO3,) this process makes sure of the surface free from any oil/grease
contamination. Besides, a portion of the loose muck mainly of Iron Oxide gets flushed
out of the system.
Adopting circulation technique, using inhibited (0.1-0.15 Redine 213 spl)
Hydrochloric acid (4 to 5% w/v) at 65 oC mixed with 0.5 % Ammonium Biflouride,
pickling is carried out. This is followed by a rinse using dematerialized water and a
rinse at 55o C using Ammoniated Citric acid of 0.2% with a solution pH maintained at
3.5 - 4.0. Later the system is thoroughly washed with Demineralised Water ensuring
that the remnant iron is not more than 25 ppm.
The entire pickled surface is neutralized with 1% solution of Sodium
Carbonate at a temperature of 90oC to 95oC. Finally; the cleaned surface is passivated

with a solution of dematerialised water containing (a min. of 200 ppm) Hydrazine and
Ammonia (pH 10.0).
Prior to the steam blowing operation, the surface is again passivated at a
pressure of 40 Kg/cm2, with Hydrazine Ammoniated Dematerialized Water.
2.4 EQUIPMENTS FOR CLEANING
Essentially, it consists of a dissolving tank, circulation pumps, connecting
pipes and valves to facilities circulation. Nitrogen capping arrangement also forms a
part of the system.
The dissolving tank acts as a reservoir for the circulation of various solutions.
The pumps force the solution through the Economiser, Drum, and Water walls and
Down comers and through the Ring header back to the dissolving tank.

3.GENERAL ASPECT TO BOILER, AIR PREHEATER & SOOT BLOWERS

3.1 GENERAL DESCRIPTION.
The steam generator is of radiant, reheat, natural circulation, single drum,
dry bottom and semi-outdoor type unit, designed for firing coal as the principal
fuel and the HFO oil firing capacity is equivalent to 22.5% boiler MCR. 4 LDO
burners are capable for 7.5% boiler MCR heat input. Layout arrangement is of
conventional type i.e. with the mills in front of the Boiler. The complete
furnace section is of fusion welded wall type, arranged as a gas and pressure
tight envelope. The extended side wall section (where reheaters are located) is
covered with water cooled fin welded walls.

The super heater steam system has mainly three sections. The LTSH
(arranged in the back pass of the unit),the radiant platen super heater ( arranged at
the outlet section of the furnace) and the final super heater (arranged after the
reheater).
Two numbers super heater desuperheaters are provided in between the
LTSH section and the platen super heaters (in the connection links ) for
controlling superheated steam temperature over wide load range . The complete
back pass of the boiler (up to the economizer) has been covered with steam
cooled super heater wall sections.
The complete reheater has been arranged as one section and located in the
horizontal pass of boiler in between the radiant platen super heater and final super
heater. Two no. Reheater desuperheaters are provided in the cold reheat steam piping
at inlet of the reheater for emergency control of the final steam temperature.
The maximum flue gas velocity in the pressure part system is limited to 10-12
m/ sec. at 100% boiler MCR load.
All the headers in the pressure part system are provided with necessary hand
holes and hand hole plates arrangements. All headers are located outside the gas path,
except for the economizer inlet header, intermediate headers and LTSH inlet header
are located in the low gas temperature section.
The complete pressure parts is suspended from the boiler structural steel roof
sections and arranged for free expansion downward.
3.2. LOW TEMPERATURE SUPERHEATER.
The LTSH section is of the continuous loop, plain tubular, drainable,
horizontal, in line spaced type, with steam flow upwards and gas flow downwards
arrangements. This section is in two blocks and located above the economizer section,
in the back pass of the unit. This convective spaced bearing surface has 120

assemblies, 4 elements per assembly. The outlet section of LTSH alone is arranged
vertically.

3.3. RADIANT PLATEN SUPERHEATER.

The radiant platen super heater section is of the continuous loop, plain,
tubular, non-drainable, vertical, in line tangent tube type, arranged for parallel flow.
The platen super heater section assemblies are widely spaced, and located in the
radiant zone at the furnace outlet section. The radiant platen-heating surface has 29
assemblies- 7 elements per assembly.
3.4 FINAL (FINISH PENDENT) SUPERHEATER ( FSH ).
Finish pendent super heater (FSH) section, is of spaced type continuous loop,
plain tubular, non-drainable, vertical in line spaced type, arranged for parallel flow.
This FSH is located in the horizontal pass, after the reheater section. The convective
final super heater has 89 assemblies- 2 elements for assembly.

3.5 RE HEATER SYSTEM.

The reheater section is a single stage, spaced type, continuous loop, and plain tubular, on
drainable, vertical in line spaced type, arranged for parallel flow. The reheater- front pendant
& rear pendant section is located in horizontal pass, in between the Radiant Platen super
heater and final super heater section. This convective reheater section has 59 assemblies 6
elements per assembly. The approx. total convective heating surface is 3100 msq. The entire
reheater section is suspended from the roof structural steel section.
3.6 SUPER HEATER DE SUPERHEATER.
For controlling the final super heater steam temperature at rated value, two
numbers of spray type de-super heaters are located in the steam connecting links
between the LTSH outlet header and platen SH inlet header. This inter stage de-super
heaters are of welded type. Spray tubes and liners are provided.

For emergency control of the reheater outlet temperature, two numbers

spray type de-super heaters are provided. These are located in the cold reheat
piping and used during any abnormal emergency conditions for the steam
temperature control. The desuperheaters are of welded type , spray nozzles and
liners are provided.
3.7 ECONOMISER SYSTEM.
The economizer, a single block unit, is of the continuous 100p plain
tubular, drainable, horizontal, in line arrangement with water flow upwards and
gas flow downwards. The economizer tubes are suspended from economizer
intermediate header, using ladder type supports. The heating surface is
4550msq.An economizer recirculation system is provided, connecting the down
comer (near water wall lower ring header) and economizer inlet pipe to ensure
required flow through economizer tubes during starting conditions of the unit.

3.8 STEAM DRUM.

The steam drum is of the fusion welded construction, fabricated from carbon
steel plates. At each end of the drum, a man hole of 406mm dia is provided, arranged
to open inwards. The drum is located on the upper front of the unit , the ID of the
steam drum are welded type. The drum is equipped with primary turbo separators,
secondary corrugated scrubbers and screen dryers, to limit the solids carry over in the
steam leaving the drum. All drum internals are of carbon steel construction. The turbo
separators ( along with the scrubbers ) and the screen driers are of the removable type.
The drum is suspended from boiler roof structures.
3.9 DOWN COMER PIPES.

Six (6) Nos. Down Comers are provided, connecting the steam drum and
water wall lower ring heater.
3.10 WATER WALL SYSTEM.
The water wall system comprises of front wall, rear wall, side walls- all of
fusion welded construction. The extended side walls are of fin welded construction.
Furnace Width

13,868 mm

Furnace Depth

10,592 mm

Furnace Volume (Approx.)

5200 m3

Furnace affective Projected.

2100 m2

3.11 RISER PIPES.

From the outlet headers of the wall system, the steam water mixture are taken
to the steam drum through 118 numbers pipes rolled uprisers.

3.12 WATER WALL / FURNACE DESIGN PRESSURE.

The complete furnace walls, and the other steam-cooled walls (in second
pass), are strengthened by providing buck stays and tie bars system, to withstand
furnace/forces.

3.13 SUPPORTS / SUSPENSION.

The complete circulation system is suspended from boiler roof structures and
is arranged for free expansion downwards.

3.14 FURNACE.
The furnace hopper outlet section is provided with an opening of approx. 1100
mm depth, for the full width of the furnace. On each side wall, in the furnace hopper
area, one water cooled access door (oval in shape of size 406 x 457 mm) is provided .

These openings are provided for taking maintenance cradle parts/ scaffolding sections
etc. inside the furnace during maintenance of the furnace.

3.15 TILTING TANGENTIAL FIRING SYSTEM.

3.15.1 TANGENTIAL FIRING.
In the tangential firing system the furnace it self constitutes the burner. Fuel
and air are admitted into the furnace through four wind fox assemblies located in the
furnace corners. The fuel and air streams from the wind fox nozzles are directed to a
firing circle at the center of the furnace. The relative or cyclonic action that is
characteristic of this type of firing is most effective in turbulently mixings the burning
fuel in a constantly changing air and gas atmosphere.
3.15.2 AIR AND FUEL NOZZLE TILTS
The air and fuel streams are vertically adjustable by means of moveable air
deflectors and nozzle tips, which can be tilted upward or downward through a total
angle of 60 degrees. However, for the maximum angle of tilt of nozzle tips refer
contract assembly drawing. This movement is effected through connecting rods and
tilting mechanism in each wind box compartment, all of which are connected to a
drive Unit at Each corner operated by automatic control. Provision is given in UCB to
know the position of nozzle tips during operation. The tilt drive Units in all four
corners operates in unison so that all nozzles have identical tilt positions.
3.16 WIND BOX ASSEMBLY
The fuel firing equipment consists of four-wind box assemblies located in the
furnace corners.
Each wind box assembly is divided in its height into number of sections or
compartments. The coal compartments (Fuel air compatment0 contain a coal nozzle,
the top, bottom and intermediate compartments are used for admission of secondary

air (Intermediate air compartments). Combustion air (Secondary air) is admitted to the
intermediate air compartments and each fuel compartment (around the fuel nozzle)
through sets of louver dampers. Each set of dampers is operated by a damper drive
cylinder located at the side of wind box. The drive cylinders at each elevation are
operated either remote manually of automatically by the Secondary Air Damper
Supervisory system.
Some of the (auxiliary) intermediate air compartments between coal nozzles
contain a retractable oil gun.
Eddy plate igniters are installed igniter nozzles are directly adjacent to the oil
guns and are mounted at a fixed angle to the fuel nozzles so that the igniter flame
crosses the path of the main fuel and air stream.
Retractable High-energy Arc (HEA) igniters (if applicable) are located
adjacent to the retractable oil guns. These igniters directly light up the oil guns.
Optical flame scanners are installed in flame scanner guide pipe assemblies in
the auxiliary air compartments. The scanners pick-up visible light given off by the
flame and there by prove the flame.

4. BOILER AIR AND GAS SCHEMES

AIR IS REQUIRED IN BOILER MAINLY FOR THE FOLLOWING PURPOSE AT
GGSSTP ROPAR.
i.

For combustion of fuel in the furnace, called secondary Air.

ii.

For drying and transportation of pulverized coal to the furnace from the mill ,

called primary Air.

4.1. COMBUSTION SECONDARY AIR

The secondary air is supplied by two forced Draft Fans. The rating of FD
fans is given below:The secondary air for combustion is preheated upto 317oC by means of
regenerative air-heater (Rotary Air Heater). The air heater air out ducts are
interconnected to provide a balanced air flow to the furnace and to make it possible to
operate the unit at reduced load if one fan is out of service. Distribution of secondary
air to the Wind Box compartments is controlled by the secondary Air dampers. The
steam coil air reheaters (SCAPH) one each at the outlet of F.D. Fans &before RAH
has been provided to avoid the corrosion of RAH by increasing the temperature of
secondary air entering the RAH when the Boiler is initially Lighted-up .

SR

PARTICULARS.

SUPPLIERS DATA.

1.
2.
3.
4.
5.
6.
7.
8.
9.

Equipment
Type of operation
No. of fans
Medium handled
Fan Orientation
Location
Type of Fan
Capacity
Total head

Forced draft fan.

Continuous
Two Per Boiler
Atmospheric Air
Horizontal delivery and vertical suction
Ground Floor
Axial type
110.m3 /sec.
520 mm wc

10
11.
12.
13.
14.

developed
Temp. of medium
Fan speed
Motor Rating
Motor Type
Fan bearings

500C
1480 RPM.
750 KW, 6.6KV,1480RPM.
SQ,CAGE Induction
Forced oil lub.

15.
16.
17

lubrication
Motor bearing lub.
Fan Regulation
Fan Weight

Grease.
Variable pitch fan
8570 kg.

N
o
.

4.2 CONVEYING AND DRYING OF PULVERISED COAL

The air used to dry and transport the pulverised coal is referred to as primary
air. Two primary air fans supply the air to the pulverisers. The specifications of PA
fans are given below:SR

PARTICULARS.

SUPPLIERS DATA.

Equipment
Type of operation
No. of fans
Medium handled
Location.
Orientation

PA Fan
Continuous
Two per Boiler.
Atmospheric air.
Ground Floor.
Vertical Suction Bottom Horizontal

Fan capacity
Total head developed
Fan speed
Temp. of medium
Motor rating
Fan bearing lub.
Motor bearing lub.
Type of fan regulation

delivery
70m /sec.
1210mmwc
1435RPM
500C.
1250 KW, 6.6 KV, 1480RPM
Forced oil lub.
Grease
Inlet Damper control

N
o
.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
11.
12.
13.
14.

To ensure proper drying in the Pulverisers, both hot and cold air must be
available. Therefore, a Portion of the air from the primary air fans passes through the
air pre-heater . The primary air fan inlet vanes modulate to Maintain a predetermined
pressure in the hot air duct.
The air flow and mill outlet temp. can be controlled by simultaneous
operation of hot and Cold air dampers. If a primary air fan is not available for
service, it must be isolated from the system by its closing its control and outlet shut
off dampers. The Primary Air Path has been shown in Figure no. 13.

5.

HEAT IGNITOR

5.1 SYSTEM DESCRIPTION.

The high energy Ignitor is designed to ignite a variety of fuel ranging from
high speed diesel to Heavy Fuel Oil (HFO) or Heavy Petroleum Stock (HPS). The
equipment gives a high intensity electrical spark which immediately ignites the oil
particles surrounding the spark, thus creating a flame pocket in the oil spray. The
flame propagates into the oil spray from this pocket giving a successful ignition.
The Ignitor works in combination with the discriminating flame scanner which
is capable of sensing the associated flame only. The discriminating flame scanner
senses the flame immediately after the ignition and permits the firing to continue.
The major components of HEA Ignitor are:1.

Ignitor Exciter

2.

Flexible cable

3.

Spark rod

4.

Replaceable firing tip

5.

Spark tip

6.

Guide pipe

1.1

Specifications.
Input Voltage

-110V AC + 10%

- 15%
50 + 5 hertz
Out put voltage

2500 + 150 V.DC

5.2 THEORY OPERATION.

Application of 100-130 volts AC, 50/60 Hz to the primary side of the exciter
induces a high voltages on secondary of the power transformer. The high voltage
generated in the secondary of the power transformer is rectified in the double circuit

by the action of the two solid state rectifiers and double capacitors, so that with each
change, in the polarity a pulse of DC voltage reaches the storages capacitor. The
resister and inductor in the double circuit serve as limiters.
When this voltage reaches the predetermined level for which the spark gap in
the discharge tube has been calibrated, the gap will ionize. Current will flow from the
storage capacitor(s) through the discharge tube, the center conductor of output lead to
the firing tip, returning to storage capacitor through the output load. When the energy
is dissipated at the ignitor tip, the storage capacitors will be recharged.
Bleeder resisters are provided to dissipate any residual charge on the storage
capacitors between cycles. Resisters in the output circuit provide a discharge patch for
storage capacitor energy in the event that the ignitor fails to fire, or the unit is
subjected to open circuit operation.

6.COAL HANDLING PLANT

Coal handling Plant has the following basic functions to perform:

1. Unloading of coal wagons.
2. Reclaiming of crushed and uncrushed coal.
3. Coal crushing.
4. Removal of unwanted particular from the coal.
5. Coal feeding to the raw coalbunkers of running units.
6.1 WAGON TIPPLER:
Wagons tippler- theseare5 in no are used for unloading the coal wagon tippler consists of rail
table, tracks, pits holding beam. It has a pit. In pit there is suspension. At the top of wagon
tippler, there is holding beam for holding the wagon. The wagon is unloaded on grating. The
rail table is turned at an angle of 135. With the help of A.C. motor whose H.P. is 95. The
whole process is mechanical. Shunters are used for placing the wagons on rail table. The
whole wagon get unload in 4 minutes (app.). The weight of wagon is measured with the help
of electronics motion wave Bridge. Approximately weight of wagon is 82 ton including
weight of wagon. Each wagon contains 58 tons of coal. The types of wagon are n-type and ctype. Shunter or loco have the H.P. of 450 H.P. and 650 H.P. During measuring of wagon, the
speed of train should be 5Km/hr-10Km/hr and weight is measured with electronics motion
wave bridge.

Coal is stored in crushed and uncrushed form uncrushed form, raw coal pile

area where uncrushed coal is stocked. Crushed coal at stacker cum reclaimer. Stone pickers
are stationed at primary and secondary crushers to remove the stones the iron particles are
removed by magnets. Magnets used are of permanent magnet or cross belt suspended
magnets.

Permanent magnets are on the conveyer belts used to lift the particles and

particles are removed. Cross belt suspended magnets are surrounded the belt in circular
motion it has iron bars comes near the belt and become magnet and picks up the iron
particles. When it moves away, it demagnetizes and removes the particles.
MUTH- (manual unloading track hopper) when there is fault in wagon tippler, it is used.
Coal is unloaded manually on grating.

SCR- (stacker cum reclaimer) when coal size is reduced to 25mm. The coal is in large
quantity, then crushed coal is stacked and when necessary is reclaimed.
ERH- (emergency reclaimer hopper) when there is emergency, coal is reclaimed.

6.2 MANUAL UNLOADING:

Manual unloading is done by the labor itself by using the suitable equipments. The wagon
capacity is 58 tons and it itself weights 2 tons. The capacity of bunker hall is 660 tons, which
is sufficient for 22 hours. The raw coal has a size of the order of 500 mm approx. This coal is
sent to the primary crusher on conveyor belts and reduced to a size of 125 mm. This coal
from primary crusher is sent to secondary crusher. Secondary crusher further reduces the size
of the coal to 25mm. This coal from secondary crusher is sent to coal mills on the conveyor
belts. CHP also has stackers and reclaimers.

7 Coal pulverizing system

At G.G.S.S.T.P Bowl mills have been installed for pulverizing the raw coal. The coal is
reduced to the form of talcum powder. Coal of size 25mm is in raw bunkers from CHP.
Fineness of coal is measured as the percentage of coal that will pass through a lost sleeve then
it has the desired fineness. Designed mill capacity is 39.7-tons/hr. but it depends on the hard
groove grind ability index (HGI), the moisture content of coal and fineness requirement of
pulverized coal.
Coal with a bulk density 71.2T/m3 should be rejected.
Designed air flow/mill: - 53.89 tons/hr
Mill outlet temperature: - 75 to 80C
Mill differential pressure: - 200 to 225 mm of WC
Mill no load current: - 34 Amp
Mill full load current: - 46 Amp
7.1 BOWL MILL
Broadly the Bowl Mill can be divided into four parts:
7.1.1 MILL BASE
This is the lowest position of the mill and it contains mill drive system i.e.
worm shaft, worm gear, vertical shaft, oil cooler as main parts. The gear hosing is
always filled with lubrication oil before the pulverizer is put into operation . Level of
the oil can be checked from the oil level gauge provided on the mill base. Correct
level is indicated only while the mill is idle. For cooling the oil while mill is in
operation , tube type water coolers have been installed in the Gear Housing.
7.1.2 MILL SIDE

This portion is just above the mill base and it contains mill side liners, scrapper
assembly and Tramp iron spout discharge arrangement & vane assembly. Heated
primary air enters the mill side housing below the Bowl . Any tramp iron etc. drops in
this portion and is scrapped to the Tramp iron discharged spout.
7.1.3 SEPARATOR BODY ASSEMBLY.
This portion is just above the mill side housing and this is the portion where coal
is pulverized. Main parts of this assembly are Bowl , Journal assembly , Grinding Roll
Assembly , Bowl segment liners, Inner cone, Classifier Assembly , Separator Body
Liner Assembly and Center Feed Pipe . The Grinding Rolls do not touch the Bowl if
the mill is empty. When the raw coal from center feed pipe comes in between the
Grinding Rolls and revolerving bowl , it causes the roll to turn and thus , the coal gets
pulverized.
The roller journals is lubricated by means of a self contained circulating
system . Seal air is supplied to roller journal shaft to prevent coal dust from entering
the roller journal bearings.
7.1.4 MILL OUTLET ASSEMBLY
This portion contains classifier venturi and deflector regulator. Mill discharge
valve assembly is connected at the top of this portion from where the pulverized coal
is sent to each of four coal nozzles at one elevation .

7.2 OPERATION
The coal is fed through center feed pipe into the revolving Bowl where it travels
towards outer perimeter of Bowl due to centrifugal force. Thus, the coal comes below
the roll and gets pulverized. Hot air entering the mill side housing below the bowl
passes upward around the Bowl. It picks up the pulverized coal and passes through
deflector openings at the top of inner cone and goes out through the venturi to mill
outlet part assembly. The deflector blades impart a spinning action to coal air mixture
and thus, oversize coal is sent back to the Bowl through the inner cone for additional

grinding. Any tramp iron or other foreign material which is difficult to grind drops out
through the air stream to the lower part of the mill side housing where it is swept to
the tramp iron spout by the two scrappers attached to the bowl mill skirt.

7.3 OPERATING PARAMETERS

AIR FLOW AND MILL OUT LET TEMPERATURE.
Hot air is supplied to the mill by Primary Air Fan which is heated in the Air Pre
heaters. Of course, the temperature of the air can be controlled by mixing cold air
from cold primary air duct.
a.

The designed airflow per mill is 53.89 tones/hr.

b.

Recommended mill outlet temperature is 75oC to 80 oC

c.

Lower air flow and mill outlet temperature below 60oC may not dry the coal
sufficiently, and may cause chocking.

d.

Outlet temperature must not exceed 95oC in any case as the high temperature
may lead to mill fires.

e.

Higher airflow mill cause excess wear and upset the classifier etc.
The airflow and mill outlet temperature can be controlled by simultaneous
operation of hot and cold air dampers.

7.4 PULVERIZED FUEL FINENESS

Fineness of coal is measured as the % of the coal that will pass through a test
sieve, if 70% of coal passes through 200-mesh sieve then it has the desired fineness.
The fineness can be controlled by operating the classifier vanes. It must be
remembered that operating the mills at higher fineness increases the wear rate and
reduces the capacity of the mill.
7.5 MILL CAPACITY.

Designed mill capacity is 39.7 tonnes/hr. But it depends on the hard groove
grind ability index, the moisture content of coal and fineness requirement of
pulverized coal.

8. BOILER FEED PUMP

Boiler Feed Pump is very import auxiliary of the power house . It has to take
supply of water from the Deaerator, and supply it to Boiler drum against the positive
drum pressure. The supply of the water to the Boiler drum is regulated by the Feed
control station and scoop tube.
a. Feed control station has:
i.

Main Feed Line (100%)

ii.

By pass Line (100%)

iii.

Low load Line (30%)

b.

Scoop tube variation is from 30% to 100%30% is the minimum scoop tube
position.

8.1 IMPORTANT OBSERVATIONS IN CASE OF DEAERATOR.

i.
ii.

Minimum level

(+) 300 mm.

Deaerator pressure:The Deaerator pressure is to be maintained according to

Feed water temperature as per following table:-

FEED WATER TEMPERATURE

110o C
120 o C
130 o C
140 o C
150 o C
160oC

DEAERATOR PRESSURE.
0.5 kg/cm2
1.0 kg/cm2
2.0 kg/cm2
3.0 kg/cm2
4.0 kg/cm2
5.5kg/cm2

There is minimum recirculation line which is meant to keep the minimum flow
of water to be maintained. There is a recirculation valve (pneumatic valve) which
opens when the flow of water in the line falls to 100 Tons/hr
There is one manual valve also in the recirculation line. It is to be kept open
all the time & locked. The pneumatic valve closes when feed flow is high of the order
of 225 Tons/Hr.
There are three Boiler Feed Pumps available in a unit. But two no are
sufficient to run the Unit. When on full load , the third is to be kept on auto stand by .

8.2 TRIPPING OF BFP.

1. BFP running and discharge pressure low less than 40 kg/cm2 with time delay of
15secs.
2. BFP running & suction flow very low(below 80 T/hour ) time delay 15 secs.
3. Suction flow very high (480 T/hour and above with time delay of 10 secs.
4. Deaerator level very low (control from each of very low level switch L&R in
parallel with time delay of 1.5 2 secs.)
5. Motor DE/NDE Bearing temperature very high (setting 90oC).
6. Working oil temperature very high (130 oC).
7. Hydraulic coupling bearing No.-6 only (95oC) temperature very high.
8. Lub. oil pressure very low below 0.8 kg/cm2 + 10 secs. time delay.
8. Booster pump suction pressure very low (below 1.9 kg. /cm2 +time delay 6 secs.)

9 BOILER AND ITS AUXILIARYS GENERAL DESCRIPTION:

BOILER
The steam generator is of radiant, reheat, natural circulation, single drum, dry bottom and
semi-outdoor type unit designed for firing coal as the principle fuel and the HFO oil firing
capacity is equivalent to 22.5% boiler MCR. Four LDO burners are capable for 7.5% boiler
MCR heat input. A layout arrangement is of conventional type that is with the mills in front

of the boiler. The complete furnace section is of fusion welded wall type, arranged as a gas
and pressure tight envelop. The extended sidewall section (where re-heaters are located) is
covered with water-cooled fin welded walls.
The super-heater steam system has mainly three sections:
1) LTSH (arranged in the back pass of the unit).
2) Radiant Platen Super-heater (arranged in the outlet section of the furnace).
3) Final Super Heater (arranged after the re-heater).
Two nos. super heater de super-heater are provided in between the LTSH section and the
Platen Super-heater for controlling superheated steam temperature over wide load range. The
complete back pass of the boiler has been covered with steam cooled super-heater wall
sections.
The complete re-heater has been arranged as one section and located in the horizontal pass of
the boiler in between the radiant platen super-heater and final super heater. Two nos. re-heater
de super-heater are provided in the cold reheat steam piping at the inlet of the re-heater for
emergency control of final reheat of the steam temperature. The maximum flue gas velocity
in the pressure part system is limited to 10 -12 m/sec at 100% boiler MCR load. All the
headers in the pressure part system are provided with necessary hand holes and hand holes
plates arrangement. All headers are located outside the gas path, except for the economizer
inlet header; intermediate headers and LTSH inlet header are located in the low gas
temperature section.
The complete pressure parts are suspended from the boiler structural steel roof sections and
arranged for free expansion downwards.
9.1 LOW TEMPERATURE SUPER-HEATER:
The LTSH section is of the continues loops, plain tubular, drainable, horizontal, in line spaced
type, with steam flow upwards and gas flow downwards arrangements. This section is
divided in two blocks and located above the economizer section; in the back pass of the unit.
This convective spaced bearing surface has 120 assemblies, four elements per assembly. The
outlet section of LTSH alone is arranged vertically.
9.2 RADIANT PLATEN SUPER-HEATER:

The Radiant Platen Super-heater section is of the continuous loop, plain, tabular and nondrainable vertical in line tangent tube type arranged for parallel flow. The platen super-heater
section assemblies are widely spaced and located in the radiant zone as the furnace outlet
section. The radiant platen-heating surface has 29 assemblies, 7 elements per assembly.

9.3 FINAL SUPER-HEATER:

Finish pendant super-heater section is of spaced type, continuous loop, and plain, tabular,
non-drainable, vertical in line spaced type, and arranged for parallel flow. This FSH is located
in the horizontal pass, after the re-heater section. The convective final super-heater has 89
assemblies, two elements per assembly.
9.4 RE-HEATER SYSTEM:
The re-heater section is of single stage, spaced type, continuous loop, and plain tubular, nondrainable, vertically in line spaced type arrangement for a parallel flow. The re-heater front
pendant and rear pendant section is located in the horizontal pass, in between the radiant
platen super-heater and final super-heater section. This convective re-heater section has 59
assemblies, 6 elements per assembly. The approx. total convective heating surface is 1300 m2.
The entire re-heater section is suspended from the roof structure steel sections.
9.5 SUPER-HEATER DE-SUPER-HEATER:
For controlling the final super-heater temperature at the rated value, two no. of spray type desuper-heater are located in the steam connecting links between the LTSH outlet header and
platen super-heater inlet header. For emergency control of the re- heater outlet temperature,
two no. spray type de-super-heater are provided. These are located in the cold reheat piping
and are used during any abnormal conditions for the steam temperature control. The desuper-heater are of welded type, spray nozzles and liners are provided.
9.6 ECONOMIZER SYSTEM:
The economizer is a single block unit and is of continuous 100% plain tubular, drainable,
horizontal in line arrangement with water flow upwards and gas flow downwards. The
economizer tubes are suspended from economizer intermediate header, using ladder type
support. The heating surface is of 4550 m2 and economizer re-circulating system is provided,
connecting the down comer and economizer inlet pipe to ensure the required flow through
economizer tubes during starting conditions of the unit.
9.7 STEAM DRUM:

The steam drum is of fusion-welded construction fabricated from carbon steel plates. At each
end of the drum, a manhole of 406 mm diameter is provided, arranged to open inwards. The
drum is located on the upper front of the unit; the body of the steam drum is welded type. The
drum is equipped with primary turbo separators; secondary corrugated scrubbers and screen
dryers, to limit the solids carry over in the steam leaving the drum. All drum internals are of
carbon steel construction. The turbo separator along with the scrubbers and the screen dryers
of removable type. The drum is suspended from boiler roof structure.
9.8 DOWN COMER PIPES:
Six number down comers are provided, connecting the steam drum and water wall lower ring
header.
9.9 WATER WALL SYSTEM:
The water wall system comprises of front wall rear wall, sidewalls and is fusion-welded
construction. The extended sided walls are of fine welded construction.
Furnace Width 13868 mm.
Furnace Depth10592mm.
Furnace Volume

5200m3.

9.10 RISER PIPES:

From the outlet headers of the water wall system, the steam water mixture are taken to the
steam drum through 118 no of pipes rolled upstairs.
9.11 WATER WALL/FURNACE DESIGN PRESSURE:
The complete furnace walls and the other steam cooled walls are strengthened by providing
buck stay and tie bars system, to with stand furnace pressure/forces.
9.12 SUPPORTS/SUSPENSION:
The complete circulation system is suspended from boiler roof structures and is arranged for
free expansion downwards.
9.13 FURNACE:
The furnace hoppers outlet section is provided with an opening of approx 1100 mm depth, for
the full width of the furnace. On each sidewall, in the furnace hopper area, one water-cooled
access door is provided. These openings are provided for taking maintenance cradle
parts/scaffolding sections etc, inside the furnace during maintenance of the furnace.
9.14 SPECIAL FITTINGS AND VALVES:

Access doors, feed water valves, gauge glasses and safety valves etc are included.
9.15 MAJOR AUXILIARIES:
Following are the major auxiliaries of boiler at GGSSTP:
1. I.D.FAN

3 No. Including one stand by.

2. F.D.FAN

2 No.

3. P.A.FAN

2 No.

4. MILLING CIRCUIT

6 No.

5. ROTARY AIR HEATERS

2 No.

6. ELECTROSTATIC PRECIPATOR

28 No.

7. ASH HANDLING PLANT

8. FUEL OIL SYSTEM
9.16 BOILER PARAMETERS:
1. Super heated outlet steam flow
2. Steam Pressure at SH outlet

690 T/Hr.
155 Kg/cm2.

3. Steam temperature at SH outlet

540C.

4. Re-heat outlet steam flow

597.5 T/Hr.

5. Steam pressure at RH inlet

37.6 Kg/cm2.

6. Steam pressure at RH outlet

36.1 Kg/cm2.

7. Steam temperature at RH inlet

342C.

8. Steam temperature at RH outlet

540C.

9. Feed water temperature entering economizer 243C.

10. Ambient Air temperature

40C.

9.17 SOOT BLOWERS:

Soot blowers have been provided with cleaning and soot blowing the water walls, superheaters and re-heaters tubes for efficient heat transfer in both radiation and convection zones.
Soot blowers are operated as often as necessary to keep the external surface clean. A high
economizer exit gas temperature that is 346C normal or erratic steam temperature control
action may be an indication of need for blowing off soot i.e. 140C at chimney. Recording
and comparing the exit gas temperature at various loads and furnace condition can establish a

proper soot-blowing schedule. The requirement of main/HRH steam temperature control

system can be used as an indication of the fouling in the furnace SH and RH since DESH
spray quantity, fuel nozzle tilt movement and gas re-circulation quantity reflect the changes in
the tube surface cleanliness.
Abnormal low steam temperature may be due to a fouled SH/RH externally or internally and
abnormal high steam temperature may be due to a dirty furnace. If the steam temperature is
too low, the furnace walls should be cleaned only as necessary, in steps using one wall blower
operating for a period and using another wall blower at another wall, cleaning all the furnace
walls at once may give an extremely low steam temperature. If the steam temperature is
generally too high, the furnace should be cleaned thoroughly. As slag develops in the furnace,
the heat absorption rate of the furnace will be decreased considerably and steam temperature
and over all performance of the unit will be affected. There are two types of soot blowers in
the furnace of 210 MW units.

9.18 TANGENTIAL FIRING SYSTEM:

In the tangential firing system the furnace itself constitutes the burner. Fuel and air are
admitted into the furnace through four wind-box assemblies located in the furnace corners.
The fuel and air stream from the wind-box nozzles are directed to a firing circle at the center
of the furnace. The rotating action that is a characteristic of this type of firing is most
affective in turbulently mixing the burning fuel in a constantly changing air and gas
atmosphere.

9.19 AIR NOZZLES AND FUEL NOZZLE TILTS:

Air and fuel streams are vertically adjustable by means of moveable air deflectors and nozzle
tips, which can be tilted upward or downward through a total angle of 60. This movement is
affected through connecting roads and tilting mechanism in each wind-box compartment, all
of which are connected to a device unit at each corner operated by automatic control.
Provision is given in UCB to note the position of nozzle tips during operation. The tilt drive
units in all four corners operate in union so that all nozzles have identical tilt positions.

9.20 WIND-BOX ASSEMBLY:

The fuel firing equipment consists of four wind-box assemblies located in the furnace
corners. Each wind-box assembly is divided in its height into a number of sections. The coal
compartment contain a coal nozzle, the top, bottom and intermediate compartments are used
for admission of secondary air. Combustion air is admitted to the intermediate air
compartments and each fuel compartments through sets of louver dampers. A damper drive
cylinder located at the side of wind-box operates each set of dampers. The drive cylinders at
each elevation are operated either remote manually or automatically by the secondary air
dampers. Some of the intermediate air compartments between coal nozzles contain a
retraceable oil gun. Optical flame scanners are installed in flame scanner guide pipe
assemblies in the auxiliary air compartment. The scanners pick up visible light given off by
the flame and thereby prove the flame.
9.21 GENERAL COMBUSTION OF PULVERIZED COAL:
The system for direct firing of pulverized coal utilizes bowel mills to pulverize the coal and
tilting tangentially wind-box to admit the pulverized coal together with the air required for
combustion to the furnace. As crushed coal is fed to each pulverizer by its feeder primary air
is supplied from the primary air fan. The primary air-dries the coal, as it is being pulverized
and transports the pulverized coal through pulverized coal piping system to the coal nozzles
in the wind-box assemblies. A portion of the primary air is pre heated in the air heater. The
hot and cold primary air is mixed proportionally prior to admission to the pulverizer to
provide the required drying as indicated by the pulverizer outlet temperature. The total
primary airflow may constitute from approx. 20 30% of the total unit combustion air
requirement.
The pulverized coal and air discharged from the coal nozzles is directed towards the corner of
the furnace to form a firing circuit. Fully pre heated secondary air for combustion enters the
furnace around the coal nozzles and through the auxiliary air compartments directly adjacent
to the coal nozzle compartments. The pulverized coal and air streams entering the furnace are
initially ignited by a suitable source at the nozzle exit. A large portion of the ash is carried out
of the furnace with the flue gases the remainder is discharged through the furnace bottom into
the ash pit.
9.22 COMBUSTION OF PULVERIZED COAL:

The velocity of the primary air and coal mixture with the fuel nozzle tip exceeds the speed of
flame propagation. Upon leaving the nozzle tip the stream of coal and air rapidly spreads out
with a corresponding decrease in velocity especially at the outer fringes where eddies form as
mixture with the secondary air. Here flame propagation and fuel speeds equalize, resulting in
ignition. The speed on which the air and coal mixture ignites after leaving the wind-box
nozzles depends large, on the amount of volatile matter in the fuel.
9.23 HEAT IGNITER:
The high-energy igniter is designed to ignite a variety of fuel ranging from high-speed diesel
to heavy oil or heavy petroleum stock (HPS). The equipment gives a high intensity electrical
spark, which immediately ignites the oil particles surrounding the spark, thus creating a flame
pocket in the oil spray. The flame propagates into the oil spray from this pocket giving a
successful ignition. The igniter works in combination with the discriminating flame scanner,
which is capable of sensing the associated flame only. The discriminating flame scanner
senses the flame immediately after the ignition and permits the firing to continue.
The major components of HEA igniter are:
1. IGNITER EXCITER.
2. FLEXIBLE CABLE.
3. SPARK ROD.
4. REPLACEABLE FIRING TIP.
5. SPARK TIP.
6. GUIDE PIPE TIP.

10.ELECTROSTATIC PRECIPITATOR

In India coal is widely used to generate power. The exhaust gases from the furnace contains
large amount of smoke and dust. If these gases are emitted directly into the atmosphere, it
will cause great environmental problems. So it is necessary to extract this dust and smoke
before emitting the exhaust gases into the atmosphere.
There are various methods of extracting dust but electrostatic precipitator is the most widely
used. It is due to its high efficiency of about 99% and less maintenance.

Its various other advantages are as follows:

1.Ability to treat large volume of gases at high temperature.
2.Ability to cope with the corrosive atmosphere.
3.It offers low resistance to the flow of gases.
WORKING PRINCIPLE:
The electrostatic precipitator utilizes electrostatic forces to separate dust
particles from the gases to be cleaned. The gas is passed through a chamber, which contains
steel plates (vertical) curtains. These steel curtains divide the chamber into number of parallel
paths. The framework is held in place by four insulators, which insulate it electrically from all
parts, which are grounded.
A high voltage direct current is connected between the framework and the
ground, thereby creating strong electric field between the wires in the framework and the
curtains. Strong electric field creates corona discharge along the wire. The ionized gas
produces positive and negative ions.
In the chamber plates are positively charged whereas the wire is negatively
charged. Positive ions are attracted towards the wire whereas the negative ions are attracted
towards the plates. On their way towards the curtains negative ions strike the dust particles
and make them negatively charged. Thus ash is collected on the steel curtain.
The whole process is divided into the following parts:
1.CORONA GENERATION.
2.PARTICLE CHARGING.
3.PARTICLE COLLECTION
4.PARTICLE REMOVAL.

10.1 CORONA GENERATION:

It is basically a gas discharge phenomenon associated with the ionization of gas
molecules by electron collision in a region of high electric field strength. It requires nonuniform electric field, which is obtained by wire as one electrode and cylinder or plate as
other.
The corona process is initiated by the presence of electrons in the electric field near
the wire. These electrons are accelerated to high velocities and possess sufficient energy so
that on impact with the gas molecules in the region they emit orbital electrons from the gas
molecules. These electrons also accelerate and enter into ionization. In this region of corona
discharge, there are free electrons and positive ions. The behavior of charged particles depend
upon the polarity of the electrodes. Both positive and negative coronas are used in industrial
gas cleaning.
In case of negative corona, positive ions generated are attracted towards the
negative electrode wire and the electrons towards the collecting plates. Beyond the corona
glow region, the electric field diminishes rapidly and if electronegative gases are present,
electrons will be captured by the gas molecules. On impact the negative ions thus generated
moves towards the collecting electrodes and serves as the principle means of charging dust.
Temperature and pressure influence the generation of corona by changing the gas
density. In the avalanche process, the time available for accelerating the electrons during the
collision is a function of gas density. With the increased molecular spacing, higher velocities
can be achieved between the collisions. Thus energy can be achieved with low field and for
low gas densities. Increased molecular spacing results in penetration of free electrons further
into the inter electrode region before captured to form negative ions. This increases the
mobility in the inter electrode space and hence higher current.
Corona is affected by dust on emitter and collector electrodes. It alters the electric
field and the sparking condition.

10.2 PARTICLE CHARGING

There are two physical mechanisms by which gas ions charge the dust particles. The electric
field causes localization of field so that the electric field intersects the particles. The ion
which move along the path of maximum voltage gradient, intercepts the particle thus net
charge flow through the particle. The ion is held with the dust particle by induced image
charge force between the ion and the dust particle. As additional ions are held with the dust
particle, it becomes charged to a value sufficient to divert the electric field from the particle.
For small particles field dependent charge mechanism is less important and collision between
the gas ion and the particle is governed primarily by the thermal motion of the ions.
Rate of charging depends upon:
10.2.1FIELD STRENGTH:
Higher the field strength more is the charging.
1.

Concentration of uncharged dust in the section.

10.3 PARTICLE COLLECTION:

Forces acting on the charged particles are gravitational, inertial, electrical and aerodynamical.
Electrical and aerodynamical are more important.
If the particle is suspended in a laminar gas flow stream, charge will act on the
particle in the direction of the collecting electrode. This force is opposite to the viscous drag
force of the gases. In a short time particle would reach the terminal velocity at which
electrical and viscous drag forces are equal. This is called the migration velocity. The other
force is the aerodynamic force by the gas stream. The motion is along the line defined by the
vector sum of these two forces. Under laminar flow all particles are collected at given
precipitator length. But this is never achieved. The turbulent gas flow causes particles to flow
in random path through the precipitator.
10.4 REMOVAL:

Dust collected must be removed. This is done by causing the liquid to flow down the
collector electrode or by rapping mechanism. Rapping is done periodically. The success of
the rapping system depends upon accumulation of sufficient thickness of material on the
plate. The acceleration required to remove the collected dust vary with the property of the
dust and gas stream. Reentrainment of dust during rapping is evidenced by the increased dust
loading at the exit. To minimize this effect, only small section of the precipitator is rapped at
a time.
10.5 RAPPING MECHANISM:
It consists of a geared motor which moves a long shaft placed near the support of the
collector electrode. The shaft is provided with hammers. When shaft moves, hammers fall on
the supports and hence dust is removed from the plates. For the collecting electrodes this
system is provided at the bottom of the casing and for emitting system it is provided at the
centre.
At the exit of hoppers heaters are provided. When we start the precipitator. Hoppers
are at normal temperature but the ash collected is very hot. So there is a chance of ash deposit
at the exit of the hopper thus causing problem of removing the ash. To avoid this heaters are
provided which increase the temperature at the exit point of the hopper thus avoiding any
undue accumulation of ash at starting.
The whole precipitator is divided into two parts:
10.6 ELECTRICAL SYSTEM:
Transformer rectifier unit, auxiliary control panel, safety inter locks and field equipments.
10.7 MECHANICAL SYSTEM:
Casing, hopper, gas distribution system, collecting system and rapping mechanism.
In precipitator we require high voltage dc supply to generate sufficient electric field.
Two main equipments which are used to generate and control high voltage are:
1. High voltage transformer rectifier

2. Electronic controller
Electronic controller provides control ac voltage through thyristors and associated controls.
The high voltage transformer rectifier converts this controlled ac into high voltage dc, which
is supplied across the electrode.

SPECIFICATIONS:
INCOMING SUPPLY

415V, +-10%, 1 PHASE,

CURRENT DRAWN FROM SUPPLY

I/P VOLTAGE TO PRIMARY OF HVR

50HZ+-5%
167 AMP A.C FOR 800MA D.C
0 TO 373.5 VOLTS A.C

AFTER A.C REACTOR

OUTPUT VOLTAGE FROM THE

0-415V RMS

THYRISTOR
DC OUTPUT OF HVR
DC OUTPUT CURRENT
FORM FACTOR
OPERATING TEMPERATURE
MAX ARCING CURRENT

CONTINUOUSLY ADJUSTABLE
0-70 kV(PEAK)
800 MA(MAX AVG)
1.4 (MAX)
-5 TO 50 C
3 ANP(PEAK)

The transformer rectifier unit consists of an oil- immersed step up transformer, ac

reactor, high voltage rectifier, high frequency choke and other measuring and protection
components.
The transformer is a single phase, 60 KVA, 373/53570v, 50 Hz with ONAN cooling.
It is double wound core type.
Ac reactor is provided for limiting the primary current in an event of flash over or
short circuit on the dc side. It also improves the form factor. The reactor is specially designed
to provide linear inductance up to 300% of the rated current. Its inductance is about 2 mH.
High frequency dc choke is connected on the dc side. It provides high impedance to
high frequency currents that may be generated due to arcing. It also provides limiting effect
on di/dt for the rectifier diodes. Inductance is about 2 mH at 100 kHz.

High voltage rectifiers are made up of specially designed diodes. They are designed
to with stand voltage and current repetitive peaks. The high voltage rectifier consists of an
integrated series connection of avalanche diodes. The diodes are assembled on a printed
circuit board and are embedded in epoxy resin partially and body of the diode is kept above
the epoxy resin for oil cooling. Seven modules are connected in series to form an arm for
single phase. Such four arms are assembled along with bus bar termination for ac and dc
connections of full wave single-phase bridge rectifiers. Complete assembly is fitted inside the
oil filled transformer tank.

11.GENERATOR

MAXIMUM CONTINUOUS KVA

247000 KVA

RATING
MAXIMUM CONTINUOUS kW RATING
RATED TERMINAL VOLTAGE
RATED STATOR CURRENT

210000 kW
15750 V
9050 A

RATED POWER FACTOR

EXCITATION CURRENT AT MCR

0.85 LAG
2600 A

CONDITION
EXCITATION VOLTAGE AT MCR

310 V

CONDITION
RATED SPEED
RATED FREQUENCY
EFFICIENCY AT MCR CONDITION
SHORT CIRCUIT RATIO
NEGATIVE SEQUENCE CURRENT

3000 RPM
50 HZ
98.55%
0.49
I2T=8

CAP.
DIRECTION OF ROTATION VIEWED

CLOCKWISE

FROM SLIP RING SIDE

PHASE CONNECTION
NO. OF TERMINALS BROUGHT OUT

DOUBLE STAR
9( 6 NEUTRALS AND 3 PHASES)

Rotor shaft made up of chromium nickel molybdenum and vanadium steel.

Rotor winding made up of silver bearing copper.
Rotor slot wedges made up of duralumin.
11.1 STATOR FRAME:
It is a totally enclosed gas tight fabricated structure made up of high quality mild
steel and austenitic steel. It is suitably ribbed with annular rings called inner walls to ensure
high rigidity and strength. Size of inner walls is selected on the basis of vibration
considerations resulting partly in greater wall thickness than required from the point of view
of mechanical strength. The natural frequency of stator body is well away from any of the
exciting frequencies. Inner and sidewalls are suitably blanked to house four longitudinal
hydrogen gas coolers inside the stator body.
11.2 PIPE CONNECTIONS:
To attain a good aesthetic look the water connection to the gas coolers is done by
routing stainless steel pipes inside the stator body which emanate from the bottom and
emerge out of the side walls. These pipes serve as inlet and outlet for the gas coolers. From
sidewalls these are connected to gas coolers by means of 8 u tubes outside the stator body.
For filling the generator with hydrogen, a perforated manifold is provided at the top inside the

stator body. The feed and vent terminating flanges for hydrogen, carbon dioxide and air are
provided at the bottom of the stator body.
11.3 TERMINAL BOX:
The beginnings and the ends of the stator winding are brought out to the slip ring
side of the stator body and brought out through 9 terminal bushings in the terminal box.
11.4 STATOR CORE:
A rotating magnetic flux threads with the core. In order to minimize the
magnetizing and eddy current losses in this active portion of the stator. The entire core is built
up of thin laminations. For reasons of manufacture, each lamination layer is made up of a
number of individual segments.
The segments are stamped out with accurately finished die from sheets of cold
rolled high quality silicon steel. Before insulating with varnish each segment is carefully
deburred. The stator body is turned on end while the core is stacked with lamination segments
in individual layers as shown. The segments are assembled in an interleaved manner from
layer to layer so that a monolithic core of high mechanical strength and uniform permeability
to magnetic flux is obtained. The stampings are held in position by twenty core bars having
dovetail section. Insulating paper pressboards are also put between the layer of stampings to
provide additional insulation and to localize short circuit which may occur due to failure of
varnish insulation of sheet stamping. To ensure tight monolithic core the stampings are
hydraulically compressed during the stacking procedure at different stages when a certain
heights of stack are reached forming different pockets. Between two packets one layer of
ventilating segments is provided. The steel spacers are spot welded on stamping as shown.
These spacers form ventilating ducts from where the cold hydrogen from gas coolers
enter the core radially inwards there-by taking away the heat generated due to eddy current
losses.
The pressed core is held in pressed condition by means of two massive nonmagnetic steel castings of Press Ring. The press rings are bolted to the ends of core bars. The
pressure of pressing is transmitted to stator core stampings through press fingers of nonmagnetic steel and duralium placed adjacent to press rings. The non magnetic steel press
fingers extend up to the tip of stamping teeth so as to ensure the firm compression of the teeth

part of the core portions too. The stepped arrangement of the stampings towards the bore at
the two ends provides an efficient support of the tooth portion and contributes to a reduction
of eddy current losses and local heating in this range in addition to the provision of more area
of cross section for gas flow. To avoid heating of press rings due to end leakage flux two
rings made of copper sheet are used as flux shield. The rings screen off the flux by shortcircuiting. To monitor the formation of hot spots, resistance temperature detectors are placed
along the bottom of slots.

11.5 GENERAL:
The stator has a three-phase double layer and bar type of windings having two
parallel paths. Each slot accommodates two bars. The slot lower bars and slot upper bars are
displaced from each other by one winding pitch and connected at their ends so as to form coil
groups. The coil groups are connected together by bus bars inside the stator frame in
conformity with the connection diagram.
11.6 CONDUCTOR CONSTRUCTION:
Each bar consists of solid as well as hollow conductors with cooling water passing
through the latter. Alternate arrangements of hollow and solid conductors ensure an optimum
solution for increasing current and to reduce losses.
The conductor of small rectangular cross-section are provided with glass lapped
strand insulation. These are arranged side by side in two layers. The individual layers are
insulated from each other by a separator. In the straight slot portion the strands are transposed
by 360 degrees to reduce the eddy losses.
The transposition provides for a mutual neutralization of voltages induced in the
individual strands due to the slot cross-field and end winding field and ensures that no
circulating currents will arise.
The current flowing through the conductor is thus uniformly distributed over the
entire bar cross section so that the current dependent losses are reduced.
At the roebal crossover points the insulation is reinforced by putting insulating strips of
thermosetting tape.
To ensure that strands are firmly bonded together and to give dimensional

stability in
slot portion, a layer of glass tape is wrapped over the complete stack. After that the stack
is pressed and cured in steam heated hydraulic press.
Prior to applying the bar insulation, overhangs on both ends of the bar is
formed as an involute in hydraulic press. Coil plugs for electrical and water connections
are brazed at both the ends.
Bar insulation is done with epoxy mica thermosetting insulation. This insulation is
void free and possesses better mechanical properties.
Thermosetting epoxy insulation is more reliable winding insulation, especially
for high voltages. The insulation is applied continuously to the slot and end turn
connections right up to the end connection. It thus provides effective protection against
over voltages arising in normal operation and against the high stresses that may occur
at the slot ends when high-test voltages are applied.
This insulation shows only a small increase in the dielectric dissipation factor with
increasing test voltage.
The bar insulation is cured in an electrically heated press and thus epoxy resin fills all
the voids and eliminates air inclusion. The insulation is highly resistant to high temperature
and temperature changes. The composition of insulation and synthetic resin permits the
machine to be operated continuously under conditions corresponding to those of class B
insulation.
11.7 ROTOR:
It is a long forging measuring about 9 metres in length and 1 metre in diameter. High quality
heat-treated steel is used whose main constituents are chromium, molybdenum, nickel and
vanadium. The shaft and body are forged integral to each other by drop forging process. On
two thirds of its circumference the rotor body is provided with longitudinal slots to
accommodate field winding. Slot pitch is selected in such a way that the displacement
between two solid poles is 180 degrees. Additional slots of short length are provided on
poles. One acts as an outlet for the hydrogen, which cools the over hang, and the other is used
to accommodate damper segments acting as damper windings. Longitudinal slots are milled
on sophisticated milling machines. These slots house the field winding. One north and one
South Pole are obtained on the shaft. The conductors are made up of hard drawn silver
bearing copper. It has low electrical resistance and high creep resistance so that the coil

deformation due to thermal cycling at the start operation is minimized. Layer of glass
laminates insulates the individual turns from each other. This laminate is built by glass prepeq
strips on the turn of copper and baked under temperature and pressure. Coils are insulated
from the rotor body by u-shaped glass laminate moulded slots troughs made of glass cloth
impregnated with epoxy varnish. The rotor winding is cooled by means of direct cooling
method or gap pick up method. Hydrogen in gap is sucked through elliptical holes on the
rotor wedges and is directed to flow along lateral vent ducts on rotor. Winding is secured in
slots by slot wedges made from duralumin alloy of copper, magnesium and aluminium. Slot
wedges behave as damper winding bars during unbalanced operation. Slip rings consist of
hexially grooved alloy steel rings shrunk on the rotor body shaft. Both rings are mounted on
single bush. Slip rings are connected to the field winding through a semi flexible copper leads
and current carrying bolts. Two semi circular copper bars insulated from each other and shaft
are placed in a central bore of rotor joining two sets of current carrying bolts. The rotor shaft
is supported on pedestal type of bearing. Rotor winding is solidly connected to the slip rings.
Field current to the rotor winding is provided by a brush gear. Brush gear is rigidly fixed on
the exciter side. Two brush gear stands each made of two symmetrical silicon brass casting
half rings. The brushes are spring-loaded type to maintain required contact pressure of 0.2
kg/cm2. Brushes have low coefficient of friction and are self-lubricating provided with
double flexible copper leads. Before filling brushes are rubbed with medium and fine
sandpaper in the direction of rotation to obtain equal current distribution. Excessive pressure
causes chattering and bouncing of brushes. Insufficient pressure tends to cause sparking. Hot
hydrogen gas is cooled by four gas coolers mounted longitudinally inside the stator body. It
consists of cooling tubes of brass with coiled copper wires wound on them to increase the
cooling surface.
11.8 STARTING OF GENERATOR:
Before starting following work should be completed:
1. All constructional work.
2. Erection of auxiliary and main equipment.
3. Checking of oil, water and gas systems.
4. Checking and setting of all protection and signaling schemes.
5. Safety precautions including fire fighting.

Before starting following is to be ensured:

1. Proper supply of oil in the bearings.
2. Fill the generator with hydrogen upto the desired purity and rate pressure.
3. Charge the stator with distillate.
4. Generator circuit breaker should be open.
5. Field breaker should be open.
When the generator comes to the rated speed check the:
1. Temperature of bearing babbit seal and bearing drain oil.
2. Performance of brush gear.
3. Phase sequence of generator.
4. Bearing vibration in all directions.
After ensuring that the mechanical running of the set is normal, field breaker is switched on.

11.9 SYNCHRONIZATION:
CONDITIONS:
1. Phase sequence should be same.
2. Generator and system voltage should be in phase. Angle difference not to be more than
10 degrees.
3. Effective value of voltage should be same.
4. Frequency should be same.
Generator can be synchronized in auto as well as manual mode.

11.10 UNLOADING AND SHUT DOWN:

1. Reduce the load on unit by operating the turbine side controls.

2. Simultaneously, reduce the reactive load by de exciting the machine.
3. Open the generator line circuit breaker.
4. Cut out the auxiliary to manual mode
5. Seal oil supply should be kept ON as long as gas is under pressure.
6. Bearing oil supply should also be kept in operation.
7. Cooling water to gas cooler may be stopped. For prolonged shut down dry
compressed

air is blown into the winding at 850 m3/hr to drain out the distillate.

8. To achieve uniform cooling during shut down, the machine is put on barring speed for
some time. Even after shut down the rotor is to be turned through 180 degrees periodically to
avoid thermal deflection of rotor.
9. During shut down all excitation should be removed at the time speed reaches 2000 rpm.
If not done temperature of the rotor will increase as ventilation decreases due to decrease in
speed.

11.11 STATOR WATER COOLING SYSTEM:

One of the efficient ways of taking away the losses due to heat from the winding of any
machine is by direct cooling using water. High quality demineralized water is circulated
through the hollow conductor of the stator winding. The cooling water must have
conductivity less than 2.5 micro mho/cm.
Cooling circuit make use of either of the following water supplies:
1. Distilled water.
2. Fully demineralized water from boiler feed water plant.
3. Condensate.
Water from the feed water plant or condensate may only be used if no chemicals
such as ammonia, hydrazine or phosphates are present in water. A part of water is
bypassed and is treated in mixed bed ion exchanger, connected in parallel with the stator
winding, magnetic filter and expansion tank and returned to the section side of water
pump.

The heat absorbed by the Demineralized water is dissipated to the secondary coolant in the
primary water cooler.
Water treatment plant provided across stator winding, essentially comprises of an
exchange tank filled with anions and cations resins. The base substance of the exchanger
resins is generally a polymer containing group of diverse character featuring exchange
activity. Cation exchanger contains highly acidic group whereas anion exchanger contains
highly basic group.
Any accidental leakage of hydrogen into the main distilled water stream is
detected by a gas trap device. Water from the outlet is collected in an over head expansion
tank which provides constant level of water during normal running conditions. A water jet
ejector is connected to the expansion tank for creating vacuum for the purpose of
removing any traces of gas in the water.
The stator water cooler is shell and tube type heat exchanger. It is vertically
mounted. Demineralized water flow through the non-magnetic shell. Cooling water flows
through the stainless steel tubes provided inside the cooler.

The magnetic filter is permanent magnet type designed to trap ferro magnetic
particles

present in the water. Filter mainly consists of upper and lower body housing the

permanent magnet system comprising of magnets, pole shoes and pole rings. It is vertically
mounted.

12DIFFERENT TRANSFORMERS INSTALLED IN TRANSFORMER YARD:

Transformer is a static device which is used to change the voltage level keeping the power
and frequency same. In the plant transformer is one of the most important equipment. In the
whole plant there are about 136 transformers installed at various places to operate the
auxiliaries.
Main transformers which are necessary:
1. To step up the generated voltage.
2. To supply power to the auxiliaries from the generator.
3. To start the plant by taking the supply from the grid.
Are installed in a transformer yard. It is located in between the main plant and the switchyard.
The main transformers installed in the transformer yard are:

12.1 GENERATOR TRANSFORMER (GT):

It steps up the voltage from 15.75 kV to 220 kV. It connects the plant with the grid.

12.2 STATION TRANSFORMER (ST):

It is a step down transformer with 50 MVA capacity. It is used to step down 220 kV from
the grid to 6.6 kV.
12.3 UNIT AUXILIARY TRANSFORMER (UAT):
It is a step down transformer with 15 MVA capacity. It steps down the voltage from 15.75
kV to 6.6KV.
12.4 STATION SERVICE TRANSFORMER (SST):
It is a step down transformer with 2MVA capacity. It is used to step down from 6.6KV to
415 V.
12.5 UNIT SERVICE TRANSFORMER (UST):
It is a step down transformer with 2 MVA capacity. It is used to step down from 6.6 kV to
415 V.
12.1 GENERATOR TRANSFORMER:
Type of cooling
Rating HV(in MVA)

ONAN
125

ONAF
180

OFAF
250

Rating LV(in MVA)

Line current HV

125
314.15

180
452.37

250
628.30

Line current LV
Temperature rise in oil
Temperature rise in wdg

4587.58
45
50

6606.11
45
50

9175.15
45
50

There are 6 generator transformers in the plant. One for each unit. The output from the
generator is fed to the generator transformer which steps up the voltage from 15.75 kV to 220
kV and supplies power to grid. Generator transformer is a star delta transformer with the high
voltage winding connected in star with a phase displacement of -30 degrees. Three-phase
supply from the generator is connected to the low voltage side bushings and the output is
taken from the opposite side. Neutral point on the H.V side is provided at the side of the tank.
In case of three or four G.Ts neutral is connected to earth through the earthing transformer.
In other cases the neutral is solidly grounded. In case neutral is solidly connected to the earth
a very small current flowing through the neutral causes the tripping of the transformer. So in
this case more care is to be taken. In case neutral is connected to the earth through an earthing
transformer, small amount of fault current will flow. So solid earthing is generally avoided.
The main parts of a transformer are:
12.1.1 Steel tank:
Whole of the transformer winding is immersed in the oil in this tank. The tank is
airtight. The tank should be strong enough to bear the pressure generated inside the tank
without bursting. To avoid bursting of the tank two pressure relief valves are provided on
both sides of the tank. In case pressure inside the tank exceeds 0.39 kg/cm2 these valves
operate. The diaphragm inside bursts and oil spills out thus tripping the generator.
12.1.2 Bushings:
Porcelain bushings are provided on both sides of the tank from which L.V and H.V winding
is connected to the external circuit. These bushings insulate the winding terminals from the
body. Bushings are also filed with transformer oil, which helps in cooling as well as
insulation.
12.1.3 Cooling system:
During the operation of the transformer, which raises the temperature of both the oil and the
winding. For proper operation the temperature should be kept within limits. To cool the oil
separate cooling system is provided. It consists of radiator, cooling fans and motor pump. Hot

oil enters the radiating fins from the top. There are a large number of radiating fins provided.
When oil flows through these radiator fins it cools down and again enters the main tank from
the bottom. The large number of fins increase the surface area thus increasing rate of heat
dissipation.
12.1.4 IN TRANSFORMER THERE ARE THREE TYPES OF COOLING:12.1.4.1 Oil Natural Air Natural (ONAN):
In this type cooling of oil is done by the natural flow of the oil. It is done when the load on
the transformer is below 125 MVA.
12.1.4.2 Oil Natural Air Forced (ONAF):
When the load on the transformer is between 125 MVA to 180 MVA, natural air striking the
fins is not able to cool down the oil properly due to increase in the heat generation. So air is
forced on the radiating fins. This is done by using the fans installed below the radiator fins.
12.1.4.3 Oil Forced Air Forced (OFAF):
With further increase in load, more heat is generated which necessitates forced cooling of oil
also. This is done by energizing the pumps placed in the bottom pump near the main tank.
These force the oil to flow which results in the cooling of the oil.
G.T is provided with all these three methods of cooling. But in SST, UAT, USST cooling is
achieved by ONAN system only. ST is provided with ONAN and ONAF.
12.1.5 Conservator Tank And Breather:
With constant heating of oil there is a loss of oil due to evaporation and there is
expansion of oil. If some space is provided above the oil level in tank. As the tank is
completely sealed, so stresses will develop on the tank due to the expansion of oil. So a
ventilating system is provided which avoids stresses in the tank and helps in the proper
expansion of the oil. A conservator tank with a breather is provided on the top of the tank.

Conservator contains oil to some level and air cell. During expansion of the oil level inside
the conservator tank increases. Due to this air cell contracts and air inside is pushed out.
When the oil cools down, oil level decreases. Air cell expands and sucks air inside. The
atmospheric air contains moisture and if oil comes in contact with this moist air its properties
degrade. This is avoided by placing a drying agent in the breather. Calcium chloride or silica
gel in the breather absorbs the moisture from air. Thus moisture less air enters the tank. In
normal conditions the color of silica gel is blue. When its color changes to pale pink, it
should be replaced immediately.
12.1.6 Buccholzs relay:
It is the most important protective device for internal faults. It is a gas-activated relay.
During any fault inside the winding light gases like hydrogen are generated. The Buccholzs
relay is connected on the pipe between the conservator and the main tank. These gases rise up
and try to go into the conservator. These gases get struck in the Buccholzs relay and cause
the level of oil in the relay to go down. Due to this a mercury switch is operated which makes
the contact and gives a signal. In the beginning only an alarm is there. But if the fault persists
and becomes serious there is a second mercury switch, which gets operated and trips the
transformer. The various readings for the alarm and trip signal are:
Alarm signal- 220 mm Hg
Trip signal- 500 mm Hg.
12.1.6. Tap changer:
Tap changers are provided in the transformer to get the desired output voltage by changing
the number of turns.
The tap changers are of two types:
1.

On load tap changer

2.

Off load tap changer

12.1.6.1 .On load tap changer:

In this we can change the tapping of the transformer On load. The tap changer is
generally provided on the H.V side as current on this side is very less. These are
installed on S.T.
12.1.6.2 .Off load tap changer:
These are installed on G.T. The tap is changed mechanically after disconnecting the
transformer from the circuit.
To monitor the temperature of oil as well as winding two temperature gauges are
provided. In the gauge two capillary tubes are provided. One is dipped in oil to measure
its temperature and the second one is dipped near the winding.

Oil temperature gauge

85 c- alarm
95 c- trip

Winding temperature gauge

95 c- alarm
105 c- trip

12.2 STATION TRANSFORMER:

When the unit is to be started, power supplied to the auxiliaries is taken from the
station transformer. The rating of the station transformer is 50 MVA. It takes power from the
grid at 220 kV and steps it down to 6.6 kV. At the time of starting all the auxiliaries are
supplied from the station transformer. When the generator is synchronized and starts
producing power, about 80 % of the load is shifted on to the unit auxiliary transformer. The
load that requires uninterrupted supply is left connected on the station transformer.
For example LOP, coal handling plant.
There are 4 S.Ts in the plant. One for each stage (for two units) and the remaining one
(S.T 3) is stand by.

Type of cooling
MVA rating

ONAN

ONAF

H.V

40

50

L.V

26

31.05

Tertiary
Current (line)

13.33

16.67

H.V

105.09

131.37

L.V

2178.01

2638.85

Tertiary

1751.97

2189.96

Voltage (line)
H.V
220 kV

L.V
6.9 kV

Tertiary
4.4 kV

Oil-30.9 KL
Symmetrical short circuit current- 54 kA
Time- 3 sec
Each station transformer is core type, two-tier transformer. This means that it has one primary
winding and two secondary windings of 6.6 kV each. Tertiary winding is connected in delta.
There are two station buses for each station transformer. One bus is supplied by one tier
winding of station transformer. Two unit auxiliary transformer buses (one for each unit) are
inter connected with one station bus. When generator starts generation unit auxiliary
transformer buses are automatically cut off from the station bus and gets supply from their
respective unit auxiliary transformers.

12.3 UNIT AUXILIARY TRANSFORMER:

Each unit has two unit auxiliary transformers. When the unit starts generating electricity
these transformers are energized and then supplies power to the auxiliaries. Before starting of
the unit, UAT bus is connected to the station bus. Auxiliaries of one unit takes about 15 MW
of power. UAT is connected between the generator and the GT. A tapping is taken from the
power coming from the generator to the GT. UAT relieves GT form extra load of about 15
MW which is to be supplied to the auxiliaries via GT and ST thus increasing the efficiency. It
is a step down transformer, which steps down the voltage from 15.75 kV to 6.6 kV. The rating
of UAT is 15 MVA. UAT bus supplies only those auxiliaries, which are not necessary to be
energized in case of sudden tripping of generator.

12.4 STATION SERVICE TRANSFORMER:

It is a step down transformer, which is connected to the station bus. It steps down the voltage
from 6.6 kV to 415 V. it is used to supply the low voltage auxiliaries.

12.5 UNIT SERVICE TRANSFORMER:

It is also a 66 kV/ 415 V transformer which is used to supply the auxiliaries connected to the unit
secondary switchgear bus.

13. 220 kV SWITCHYARD AND DIFFERENT EQUIPMENTS INSTALLED AND BUS

SCHEMES:
13.1 BUS SCHEME:

Main function of the sub stations is to receive the energy and transmit it at the required
voltage level with the facility of switching.
At RTP following are the bays:
1. Bus coupler-1
2. Sahnewal-1
3. Sahnewal-2
4. Generator transformer-1
5. Station transformer-1
6. Bus section-1
7. Jallandhar-1
8. Gorayan
9. Generator transformer-2
10. Station transformer-2
11. Generator transformer-3
12. 100 MVA transformer
13. Gobindgarh-1
14. Bus section-2
15. Station transformer-3
16. Generator transformer-4
17. Gobindgarh-2
18. Bus coupler-2
19. Gobindgarh-3
20. Generator transformer-5
21. Station transformer-4
22. Gobindgarh-4
23. Mohali-1
24. Generator transformer-6
25. Mohali-2
13.2 BUS SYSTEM:
There are mainly two buses.

1. Main bus with three sections and a bus coupler.

2. Reserve bus.
Materials of bus bar- Tarantull Al conductor with a capacity of 1800 amperes.
Bus coupler-1 can be used as GT breaker for unit 1, 2 and 3.
Bus coupler-2 can be used as GT breaker for unit 4, 5 and 6.
Only one bus coupler can be used as a GT breaker at a time.
13.3 BREAKER:
There are two types of breakers here.
1. Air Blast Circuit Breaker
2. SF6 Circuit Breaker.

13.4 Air Blast Circuit Breaker:

In this type of circuit breaker air is used as a quenching medium for arc.
Also air is used for closing and tripping the circuit breaker.

Working pressure: 29 kg/cm2

Air pressure low annunciation: 28.5 kg/ cm2
Trip coil unhealthy: 27.5 kg/cm2

At 10 kg/cm2 the breaker closes automatically. Air supply to the air blast circuit breaker has
been supplied by air compressor installed at compressor control room.
There are three numbers of air compressors, which supply air to storage tank at 65 kg/cm2.
From the storage tank the pressure is reduced to 29 kg/cm2 by the reducer.
13.4.1SPECIFICATIONS OF AIR BLAST CIRCUIT BREAKER:
Operating pressure
Impulse voltage
Rated voltage
Rated current
Rated coil closing voltage
Rated coil opening voltage
Breaking current (symmetrical)
Breaking current (asymmetrical)

27.31 kg/cm2
1050kVp
245 kV
4000 A
220 V D.C.
220 V D.C
31.5 kA
38.4 kA

13.5 SF6 GAS CIRCUIT BREAKERS:

In this type of breaker quenching of arc is done by SF6 gas. The opening of the circuit
breaker is done by air. The closing of the circuit breaker is done by the tension of the spring.

13.5.1 WORKING PARAMETERS:

Air pressure
Gas pressure
Annunciation:

15 kg/cm2
6 kg/cm2

Air pressure low

Annunciation:

13 kg/cm2

Air pressure very low

SF6 gas pressure low

12 kg/cm2
5.5 kg/cm2

SF6 gas pressure very low

5 kg/cm2

There are two compressors in each breaker (one stand by) which maintains the pressure
at 15 kg/cm2
If all the poles of the circuit breaker do not close simultaneously then the pole
discrepancy relay will operate and trip the breaker. Also at the time of tripping, if all the
breakers do not trip simultaneously, then again the tripping command through the pole
discrepancy relay will initiate to trip the breaker and annunciation will appear in the sub
station control room and the UCB.
13.6 ISOLATORS:
Isolators are used to make or break the circuit on no load. They should never be operated on
load. The isolators installed in the sub station have a capacity of 1200 amperes. They are
double break type, motor operated and can be operated from local as well as remote.
13.7 CURRENT AND POTENTIAL TRANSFORMERS:
These are used for metering and protection. It should always be kept in mind that a CT should
never be open circuited and a PT should never be short-circuited.
13.8 LIGHTINING ARRESTOR AND ARC HORNS:
Protection against lightning.
13.9 CHANGE OVER SCHEMES:
When main breaker is in service (on load change over):
1. Ensure reserve bus is free ( check any temporary earthing)
2. Charge the reserve bus by closing bus coupler isolator and circuit breaker.

3. Put the switches provided on bus coupler on generator control cum desk panel.
4. Close isolator 29A and ensure indication on CT connected to the reserve bus.
5. Open 29B isolator.
6. Put Normal Inter or Transfer selection switch at UCB at inter position.
7. Close the 29D isolator.
8. Trip the main breaker and open the main breaker isolator.
9. Put the NIT switch to transfer position.
13.10 BUS COUPLER TO MAIN BREAKER:
1. Close 29C and 29F isolator of main breaker.
2. Put NIT switch on inter position.
3. Close the main breaker.
4. Open 29D isolator.
5. Close 29B isolator. Ensure that CT is connected to the main bus.
6. Open 29A isolator.
7. Put NIT switch to normal position.
8. Trip bus coupler breaker.

13.11 SYNCHRONISATION OF THE GENERATOR TO THE GRID:

13.11.1 NORMAL SCHEME: ( generator breaker is used)
13.11.1.1 With the main bus:
1.

Close the isolator with the bus section.

2.

Close the isolator on both sides of the generator breaker.

3.

On GCDP:

A) Put the switch NIT in normal position.

B) Put the synchroscope ON.
C) Master the voltage and speed matching. Conditions will be indicated by checking the
synchronizing lamp on GCDP and close the generator breaker.
13.11.1.2 With the reserve bus:
1.

Reserve bus should be in charge position by the closing isolator on both sides of the
bus coupler.

2.

Close the bus coupler breaker.

3.

Close the reserve bus isolator of generator transformer circuit.

4.

Close the isolator on both sides of generator breaker. Take action as per 3 in case of
main bus.
13.12 TRANSFER SCHEME:

(Using coupler breaker as generator breaker)

1.

Make reserve bus free.

2.

Put the NIT switch on the GCDP in transfer position with turbine at 3000 rpm and field
breaker closed.

3.

Close the isolator on both sides of the bus coupler.

4.

Close the isolator with the reserve bus.

5.

Switch ON the synchroscope.

13.13 IMPORTANCE OF THE RESERVE BUS:

Reserve bus is normally free and is used if

1.

There is use of bus coupler breaker as generator breaker or any other out going breaker.

2.

Shifting of load from any of the bus section or all the bus section to the reserve bus.

13.14 SPECIFICATIONS OF GAS CIRCUIT BREAKERS:

Rated lightning impulse with stand voltage
Rated short circuit breaking current
Rated operating pressure of air
First pole to clear factor
Rated duration of short circuit current
Rated voltage
Rated current
Rated closing circuit voltage
Rated opening circuit voltage
Rated voltage, frequency of auxiliary

1050 kVp
40 kA
15 kg/cm2
1.5
3 seconds
245 kV
3150 A
220 V DC
220 v DC
415 V ac 50 Hz

circuit
13.15 EARTH SHIELDING:
It is a mesh of wire upon the tower. Its main purpose is to protect the sub station
equipment from direct lightning strokes. Metallic body of each equipment is properly earthed.
The earthing resistance of any switchyard is about 0.2 ohm. Before the building up of the sub
station earthing material of G.I wire is buried in the ground whose depth depends upon the
moisture content of ground. Earthing electrodes are provided at various points. This increases
the number of parallel paths and hence resistance of earth decreases.
14 TURBINE AND ITS AUXILIARIES
STEAM TURBINE:
The steam turbine is a prime mover that converts the stored energy in steam to rotational
mechanical energy.
MAIN DATA:
RATED OUTPUT
TYPE

210 MW
3 CYLINDER MIXED FLOW TANDEM

RATED SPEED
INLET STEAM PRESSURE
INLET STEAM TEMPERATURE

COUPLED.
3000 RPM
150 KG/CM2
535 DEGREE C

MAKE
WEIGHT OF TURBINE
OVERALL LENGTH
OVERALL WIDTH
HEIGHT OF TURBINE
L.P EXHAUST DIMENSIONS
NO OF STAGES

BHEL
475 T (APPROX)
16.975 M
10.5 M
15.75 M
6.3 * 4.75 M2
3
HIGH PRESSURE
INTERMEDIATE PRESSURE
LOW PRESSURE

14.1 GENERAL DESIGN FEATURES:

The turbine is of tandem compound design with separate High Pressure (HP), Intermediate
Pressure (IP) and Low-Pressure (LP) cylinders. The HP turbine is of single flow type while IP
and LP turbines are of double flow type. The turbine is condensing type with single reheat. It
is basically engineered on reaction principle with throttle governing. The stages are arranged
in HP, IP and LP turbines driving alternating current full capacity turbo generator.
The readily designed HP, IP and LP turbines are combined and sized to required power
output, steam parameters and cycle configuration to give most economical turbine set. The
design and construction features have proved their reliability in service and ensure trouble
free operation over long operating periods and at the same time ensuring high thermal
efficiencies.

14.1.1 BARREL TYPE HP TURBINE:

The outer casing of the HP turbine is of barrel type construction without any massive
horizontal flange. This unique construction permits rapid startup from any thermal state and
high rates of load changes of the turbo set. The steam and metal temperature matching
requirements are also less stringent as there is no asymmetry of mass distribution in traverse or
longitudinal planes. The barrel type outer casing does not cause any problems during over
hauls and capital maintenance as the assembly and disassembly of the turbine can be done in a
relatively short time as compared to the conventional design.

14.1.2 I.P TURBINE:

The IP turbine is double flow type with a horizontal split, inner split being supported within
the outer casing. IP inner and outer casings as well as LP inner casing are suspended from top
halves so as to totally eliminate the effect on TG centre line with the heating of the flanges.
Although the casing are of horizontal split design yet these do not impose any constraints in
startup timings and rapid load fluctuations.

14.1.3 L.P TURBINE:

LP turbine is also double flow type with exhaust area optimally selected for the expected
vacuum conditions. Special design measures have been adopted to remove the moisture from
the last stages by reducing the thickness of water film on the guide blades. The axial
clearances between the guide blades and the moving blades have been so chosen so as to
reduce the droplet sizes and attendant erosion of leading edges. Low-pressure extraction has
been optimized not only from thermodynamic considerations but to effectively drain out
moisture also.
Free standing blades have been envisaged. The blades are designed to operate in the
speed range corresponding to 47.5 Hz to 51.5 Hz grid frequency.

LP TURBINE

14.2 VALVES:
HP turbine is fed from 2 combined emergency stop and control valves. Each combined valve
consists of an emergency stop valve and a control valve fitted in a common body. The valves
are placed on the floor in front of the turbine.
IP turbine is also fed from 2-combined reheat stop and control valves. These are also mounted
in the same way as the HP valves.
14.3 ROTORS, COUPLINGS AND BEARINGS:

The rotating elements consisting of three mono block rotors of HP, IP and LP turbines
coupled together solidly by means of internally forged flanges thus in effect forming a single
shaft system. The critical speeds of the HP and IP rotors are designed to be above the normal
rated speeds. Each rotor is subjected to 20% over speed test.
All the bearings are independently supported on separate bearing pedestals. This arrangement
ensures maintenance of rotor alignment under all operating conditions. The coupled rotors are
located relative to the stationary components by the thrust bearing.
14.4 TURNING GEAR:
High speed hydraulic turning gear is envisaged to ensure uniform and rapid heating and
cooling of the casings during startup and trip out respectively. As there is no mechanical
contact between the hydraulic turning gear and the shaft the likelihood of a break down is far
less than the mechanical types employing disengaging gears, interlocks and checking devices.

14.5 GOVERNING SYSTEMS:

The turbine is equipped with Electro Hydraulic governing system backed up with the hydro
mechanical system ensuring stable operation under any grid fluctuations and load throw off
conditions.
The Electro Hydraulic system has a number of advantages not the least of which are its high
accuracy, high operating speed and sensitivity. It permits governed run up to the rated speed
and allows only a small value of temporary speed deviation during a sudden loss of load. The
linear power output/frequency characteristic can be adjusted between closer limits even while
the machine is in operation.

14.6 ELECTRO HYDRAULIC GOVERNING SYSTEM:

It is there to facilitate the operation of the turbo set in an inter connected grid system. The
electrical measuring and processing of signals offer the advantages such as flexibility,
dynamic stability and simple representation of complicated functional relationship. The

processed electrical signal is introduced at a suitable point in the hydraulic circuit through an
Electro hydraulic converter. The hydraulic control provides the advantage of continuous
control of large positioning forces for control valves.
14.7 ELECTRICAL EQUIPMENT:
The electrical equipment of the Electro Hydraulic Governing System comprises of measuring
devices, the electronic controllers, Electro hydraulic converter etc. To facilitate easy and
efficient operation of the Electro hydraulic governing system it is provided with indicators,
push buttons and annunciators.
14.8 TURBINE STRESS EVALUATOR:
The turbine stress evaluator continuously scans the critical sections of the stop valves, HP and
IP turbines and provides instantaneous information regarding the safe limits of load
fluctuations based on the fatigue life of the material and state of thermal stresses at that
particular instant. This ensures a stress consistent startup and operation.
14.9 BLADING:
In steam turbine the blades transform the thermal energy into mechanical energy. It is obvious
that blading has got a direct impact on the efficiency and reliability of the turbine.
Appropriate blade profile with high aero thermodynamic efficiency and sufficient mechanical
strength to withstand the steam forces are determined after extensive research. Particular care
is taken to avoid resonance and to ensure that the natural frequencies of unshrouded free
standing rotor blades are compatible with the rotational frequency of the machine. A final
accurate check is made when the blades have been fitted into the rotor and also to check the
root fastening of the blades.
14.9.1 BLADE TIP SEALING:
In reaction turbine stages there is a drop in pressure across both the fixed and moving blades.
This pressure differential between the inlet and outlet sides of the blades also causes steam to
flow over the tips of the blades between them and fixed or moving components. This amount

to a loss and in order to keep it as small as possible it is essential to provide proper sealing at
this joint.
For this both the fixed and moving blades are fixed with a continuous shrouding in which
steps have been turned to produce a labyrinth seal. Various arrangements of tip sealing
employing 3 rows of sealing strips are used. The number of rows of sealing strips chosen
depends upon the stage pressure and the differential axial expansion between the rotor and
casing at the particular section of the blading involved. The sealing strips are easy to replace
and can be replaced any time.
14.10 AUTOMATIC TURBINE TESTING SYSTEM:
A fully automatic sequence for testing all the safety devices has been foreseen which ensures
that the testing does not cause any unintentional shutdown and also full protection to the
turbine is provided during testing.
An automatic turbine tester for the safety devices of steam turbine which fulfills all the above
mentioned requirements has been provided. Testing system covers the following safety
devices.
1) Two electrical remote turbine trips.
2) Two over speed trips.
3) Hydraulic vacuum safety trip.
4) Thrust bearing trip.

14.11 PROTECTIVE DEVICES:

14.11.1 MAIN TRIP VALVES:
The operation of the trip system closes all the turbine stop and control valves. The main trip
valves draw oil from the pressure oil circuit. Due to the decrease in the oil pressure the trip
operates.

14.11.2 MANUAL TRIP:

Turbine can be tripped manually also. It can be used in case of emergency.
14.11.3 OVER SPEED TRIP:
The turbine is fitted with two over speed trips which trip the turbine when its speed exceeds
the rated speed by a certain value which can be adjusted between 10-12%. Trip initiation
takes place with the assistance of mechanical over speed governors.

14.11.4 THRUST BEARING TRIP:

In the event of axial displacement of the shaft beyond the permissible limit it causes
operation of the thrust bearing trip hydraulically.
14.11.5 LOW VACUUM TRIP:
Deterioration of vacuum inside the condenser causes the trip to be initiated in order to protect
the condenser from over pressure. In this way the steam supply through the turbine to the
condenser is interrupted.
14.11.6 LUBRICATING OIL PRESSURE TOO LOW:
The supply of oil to the bearings is endangered when the lubricating oil pressure sinks. The
emergency stop valves and control valves are closed when the oil pressure sinks. The control
oil circuit is connected to the lubrication oil circuit. Therefor the turbine trip is ensured when
the lubrication oil pressure sinks.
14.11.7 FIRE PROTECTION:
Turbine trip is initiated within the framework of the fire protection `measures to stop the
delivery of the main oil pump as quickly as possible. The fire protection measures can be
initiated manually or automatically by means of Low Oil Tank device.

14.11.7.1 OIL TANK LEVEL TOO LOW:

A leakage must be assumed in the event of an inadmissible drop in the level in the oil tank.
There is then a risk that the oil will ignite. As the oil supply system is fed by the main oil
pump that is driven by the turbine, turbine trip is initiated via the fire protection logic section.
`
14.11.8 BOILER PROTECTION:
When the boiler protection signal is annunciated turbine trip is initiated to protect the steam
generator by preventing an inadmissible drop in the steam pressure. Without trip initiation the
steam conditions which alter quickly otherwise would represent an unnecessary risk to the
steam generator and the turbine.
14.11.9 ELECTRICAL GENERATOR PROTECTION SYSTEM:
Turbine trip is initiated together with the response of the electrical generator protection
system and parallel to generator shutdown in order to preclude damage by removing the
turbine torque.
14.11.10 TURBINE OIL SYSTEM:
Mineral oil with additives( for increasing the resistance to corrosion and ageing) is used as a
fluid for actuating the governing system, lubrication of bearings and seal oil to the generator
seals. It also supplies oil for the Jacking system and the hydraulic turning gear during startup
and shutdown of the set.
14.11.11 OIL SUPPLY DURING OPERATION:
During the normal operation the main oil pump supplies oil to the lubrication, seal oil system
and governing system.
14.11.12 OIL SUPPLY DURING STARTUP AND SHUTDOWN:

During the startup and shutdown the oil requirement of the TG set is met by 2 auxiliary oil
pumps. They draw oil directly from the oil tank and discharge it into the pressure oil line and
continue in operation till the main oil pump takes over the oil supply. A pressure switch in the
pressure oil line gives an indication for switching off the auxiliary oil pump. During the
shutdown another pressure switch automatically switches on the auxiliary oil pump.

14.11.13 OIL SUPPLY DURING DISTURBANCES:

When the pressure in the pressure oil line falls below a set point the auxiliary oil pumps are
automatically started by pressure switches. The setting of pressure switches is arranged in
stages so that on fall in oil pressure first one auxiliary oil pump is started and the second
pump is started only when the first pump fails to establish necessary oil pressure in the
pressure oil line. In case main and auxiliary oil pumps cease to operate simultaneously a
pressure switch in the lubrication oil line starts D.C emergency oil pump.

14.12 MAIN OIL PUMP:

The main oil pump is driven by the turbine and develops the rated discharge pressure at 9095% rated speed. The main oil pump is sized to meet the normal requirements of lubrication,
seal oil and governing systems. However it is absolutely essential to establish flow in
lubrication seal oil and governing system even before the turbine is rolled. For this purpose it
is necessary to establish an independent source for meeting these requirements.

14.13 AUXILIARY OIL PUMP:

Two A.C auxiliary oil pumps supply the oil requirements of the turbo set during startups and
shutdowns. The pumps can either be switched on manually or automatically through pressure
switches, which operate when the oil pressure drops to approximately 60% of the normal
value. The settings of the pressure switches is such that one pump comes into operation
before the other one with the second one remaining in reserve. The pumps continue to remain

available for immediate service through the auxiliary oil pump automatic control system. It is
stopped after the TG set has come to full speed and main oil pump has taken over.

14.14 D.C EMERGENCY OIL PUMP:

It is a standby pump, which can be started manually or automatically through a pressure
switch when the oil pressure drops down to 50% of the normal value. this occurs only when
the main and the auxiliary pumps fail to operate or there is a breakdown in the electricity
supply system to the pumps. D.C emergency pump should be fed from the station batteries.
14.15 JACKING OIL PUMP:
When the set is stationary the shaft comes into metallic contact with the bottom bearing
lining. The normal bearing oil supply at low speeds is unable to penetrate to these surfaces
and considerable force is required to initiate rotation of the shaft from rest. This is overcome
by forcing high-pressure oil through bottom bearing sheels thereby lifting the shaft in the
bearings and allowing an oil film to form. Now shaft can be set in motion by the application
of considerably lower force. Jacking oil pump is a high pressure and low discharge pump.

14.16 AUTOMATIC TURBINE RUN UP SYSTEM:

A successful startup of the turbine normally requires acquisition, analysis and collection of
wide variety of information pertaining to various parameters like speed, steam temperature,
vacuum oil pressure, warm up condition of turbine and pipelines. Apart from this it is
important to know whether vital auxiliary equipment are on automatic control loop or not. It
is an arduous task for the operator to handle and collate so many bits of information swiftly
and correctly. Automatic run up system relieves the operator of arduous task of operating
large number of equipment surveying and analyzing parameters and thus enables him to
effectively attend to the performance of main equipment. It is based on functional group
control philosophy, which divides the main plant into clearly defined technical sections called
functional groups. These groups in conjuction with the wall stress evaluator and Electro
hydraulic governing system accomplish the various functions.

14.17 CONDENSERS:
The steam after working in the turbine is condensed in condenser in each unit installed below
the LP exhaust.
The condenser is of surface type made of fabricated construction in single shell. The tube nest
is of divided type double pass arrangement, having two independent cooling water inlet outlet
and reserve and water boxes. This arrangement facilitates the operation of one half of
condenser when the other half is under maintenance. The condenser is provided with integral
air cooling zone at the centre from where air and non-condensable gases are continuously
drawn out with the help of mechanical vacuum pump.
The condensate is collected at the bottom portion of the condenser called the hot well from
where it is pumped up to the deaerator by the condensate pumps through the different heating
stages. The function of the condenser is to condensate the outcoming steam from LP turbine.
In the condenser cooling water flows through the tubes and exhaust steam from the turbine
outside the pipes.
Area of condenser

: 9655 m2

Cooling Water flow rate: 24000 cubic metre per hour.

14.18 DRAIN COOLER:

It is provided to sub cool the drains coming from the L.P heater to improve the cycle
efficiency by heating up the condensate flowing through the tube system.
The main parts are:
1) Inlet water box
2) Outlet water box
3) Shell
4) Tube system
It is a horizontally mounted shell and tube type heat exchanger. The condensate flows in
single path through the tube system. Segmental partitions are provided for effective heat
transfer in the tube system.

14.19 LOW PRESSURE HEATERS 1,2 & 3:

The L.P heaters are of surface type. They are designed for vertical mounting.
The main assemblies of the heater are:
1) Water box
2) Tube nest
3) Shell
Water flows inside the tubes in four paths and the heating steam washes the tube system from
outside. The tubes are designed for the full pressure developed by the main condensate pump.
The tubes are supported by partitions, which shall prevent vibration and also ensure even
distribution of steam. The level of condensate in heaters is maintained at preset range with the
help of automatic controllers.
14.20 HIGH PRESSURE HEATERS:

There are two numbers of high-pressure heaters in the feed heating system with individual
bypass arrangement. The H.P heaters are of surface type, vertical arrangement and consists
mainly of the following parts:
1) Shell
2) Tube nest
3) Water chamber
4) Tube sheet
5) Baffles
The H.P heaters are vertical surface type located on the discharge side of the boiler feed
pump, extracting steam from suitable stages of the turbine.
The heaters consists of three zones:
1) Desuperheating zone

2) Condensing zone
3) Drain cooling zone
The feed water flows through the tubes from the coldest zone to the hottest zone before
leaving the heaters. The steam flows from hot most zone to the coldest zone and the drain
(condensed steam) is subsequently cascaded to lower pressure heaters to further utilize its
differential enthalpy and hence saving bled steam quantity in corresponding lower pressure
heaters.
14.21 CONDENSATE EXTRACTION PUMPS:
Each of the 210 MW set will be provided with two condensate pumps. The condensate pump
unit shall consists of a vertical centrifugal pump submerged in a tight outer barrel based plate
flange above which shall be a discharge head, a motor mounting stand and an electric driving
motor coupled to the pump. The pump shall be designed for high condensate vacuum
pumping. In normal operation one condensate pump is required. But if required the two
condensate pumps are run in parallel.
The pump will pump the condensate from the condenser hot well through low-pressure
heaters to the deaerator.

TYPE

DISCHARGE
SPEED
MOTOR
MAKE

UNIT 1
VERTICAL

UNIT 2&3
VERTICAL

CENTRIFUGAL

CENTRIFUGAL

5 STAGE CANNISTER
19.8 KG/CM2
1480 RPM
500 kW
WIER MAKE

5 STAGE CANNISTER
21.5 KG/CM2
1685 RPM
600 kW
WIER MAKE

15. LT SWITCHGEAR AND DIFFERENT SCHEMES:

415V SUPPLIES:
415V LT supply is mostly used to run various LT motors/equipment at GGSSTP, Ropar.
These supplies are available at number of Low-Tension switchgears situated at different
locations depending upon the service required for various equipment.
The various LT switchgears are:

1.

Unit Service Switchgear

2.

Station Service Switchgear

3.

Normal Cum Emergency Switchgear

Beside above there are three major 415V supplies. There are other 415V LT buses situated at
different locations to run auxiliaries for each unit.
15.1 COMMON FOR TWO UNITS OF EACH STAGE:
1.

CWPH Switchgear

2.

FOPH Switchgear

3.

DM Plant Switchgear

4.

Ash Handling Plant Switchgear

5.

Coal Handling Plant Switchgear

6.

415V A.C Supply For 220 kV Substation

7.

220V D.C Unit Board

8.

220V D.C Station Board

9.

220V D.C MCC At 220 kV Substation

15.2 FOR INDIVIDUAL UNITS:

1.

Boiler MCC

2.

Boiler Valve MCC

3.

TG Valve MCC

4.

Soot Blower MCC

5.

ESP Switchgear

6.

DG Switchgear

15.3 415 VOLTS UNIT SERVICE SWITCHGEAR:

In every unit there are two unit service buses i.e. USS-A and USS-B. These 415V unit buses
are energized independently from two unit service transformers, each having 1600 KVA

capacity and 6.6 kV/433 V voltage ratio. There is a bus coupler breaker between the two
sections.
Under normal conditions both USS-A AND USS-B should be independently charged through
UST-A and UST-B respectively and bus coupler breaker should be kept open. In case any one
of the UST incomer breaker trips, bus coupler automatically closes down.
PROCEDURE:
DEAD BUS CLOSING:
A) Say USS-A.
1.

Close 6.6 kV breaker UST-A.

2.

Put relevant key in synchronizing switch and keep it in pass position.

3.

Close breaker 14F1. UST-a will charge. Bus coupler 15F1 will also close in case trip

command is not given to 17F1.

B)

To normalize supply say USS-B(when USS-B is charged through bus coupler and

UST-B breaker is off)

1.

Close 6.6 kV breaker of UST-B.

2.

Put key in the synchronizing switch of 17F1 and check the lamp.

3.

Close 17F1. 15F1 will trip at auto.

C)

To isolate one of the USTs(say UST-A)

1.

415v USSG trip selection switch to be put on breaker A.

2.

Synchronizing switch of 15F1 bus coupler to be put in synchronizing position. Check

the relay lamp. It should glow.

3.

Close bus coupler breaker 15f1. 14F1 will automatically get off.

15.4 415V STATION SERVICE SWITCHGEAR:

There are two 415v station service switchgear buses, which are energized, from two station
service transformers each having a capacity of 2000 KVA and voltage ratio of 6.6kV/433v.
Each of the station service switchgear buses are situated at 4.5 metre elevation. These two
buses are connected through two breakers named TieBreaker and Isolator Breaker.

Under normal conditions bus coupler (19F1) is kept open and isolator breaker is kept closed.
In case any one of the
station service switchgear trips due to under voltage bus coupler breaker will close on auto.
15.5 415V EMERGENCY SUPPLY:
415v normal cum emergency buses of each unit are normally charged from USS-A
bus. In case USS-A is not available due to some fault in UST it can be charged from USS-B
bus through the bus coupler. Thus normal cum emergency bus remains charged through USSB.
If due to some reason USS-B is also not charged normal cum emergency bus can also be
charged from EMT-1 and EMT-2 for unit 1 and unit 2, provided that DG sets (Diesel
Generator set) A, B and C are not running.
Normal cum emergency bus can also be charged through the starting of DG set A,
B and C. when the above two sources of supply i.e. from the USS-buses or EMT are not
available under grid failure conditions.
15.6 BOILER MCC:
Boiler MCC of all units are situated at 15.5 metre elevation on both sides of UCB.
There are two sections of boiler MCC, v12 A and B. These two sections are fed from 415v
unit service switchgear section A and B respectively through LT breaker of 800 amp capacity
of siemmens make. The two bus sections are connected through a bus coupler. In case of any

fault in one-section main breaker trips and the faulty section gets supply from other section
through the bus coupler.
15.7 BOILER VALVE MCC:
This MCC is also situated at 15.5 metre elevation in the same building where the
boiler MCC is situated.
Boiler valve MCC is charged from boiler MCC through an isolating switch (200/250
amp). 5F1 and 12F1 are there on each bus section A and B and are normally kept ON. When
boiler MCC A is not charged the boiler valve MCC can be charged through section B by
closing the isolating switch 11F1 provided that the isolating switch 10F1 should be open and
vice versa.
15.8 SOOT BLOWER MCC:
Soot blower MCC is also situated where boiler MCC is situated. It is charged from section B
of boiler MCC through an isolating switch 13F1, which normally remains closed.
Isolating switch 10F2 on soot blower MCC can be closed to charge the bus.
15.9 TG VALVE MCC:
It is also situated at 15.5 metre elevation along with the boiler MCC. It is fed from the USSG
buses through isolating switches. TG valve MCC supply can be controlled through isolating
switches provided on TG valve MCC. The bus is charged from one USSG bus at a time. In
case one bus trips the TG valve MCC can be charged from healthy USSG bus.
15.10 WATER TREATMENT PLANT MCC AND FUEL OIL PUMPHOUSE MCC:
Water treatment plant MCC is situated at 0-metre level opposite to the main gate of service
building FOPH MCC is situated at 0 metre near the oil tank area.
415v water treatment plant MCC is charged from 6.6kV/415v 1600 KVA transformer from
unit auxiliary transformer bus A and fuel oil pump house MCC is also charged through
another transformer of same rating from UAT bus B. In case of fault in the water treatment

plant transformer the WTP MCC can be charged from FOPH MCC through tie breaker
transformer installed on FOPH MCC and vice versa. Isolating breaker on WTP MCC remains
normally closed.

16.HIGH TENSION (HT) SWITCH GEARS (6.6 KV)

The 6.6KV switch gear for stage 1 of GGSSTP Ropar comprise of station board CI A and CI
B and Unit Boards 1A, 1B and 2A, 2B apart from CWPH, coal handling and coal handling/
ash handling switch boards. In addition, there are station boards CII A and CII B.Station
boards CIA & CIB are being fed from 50 MVA, 220/6.6 KV station transformer no.1 and
station boards CIIA & CIIB are fed up from 50 MVA, 220/6.6KV station transformer no.2.
There is provision for feeding CIA and CIB buses from CIIA and CIIB buses respectively
through tie breakers.

For stage 2, station buses CIIA & CIIB are fed from station transformer no.3, unit buses 3A
and 3B are from unit 3, 4A and 4B are from unit 4. When unit is not running, unit buses 3A &
4A are fed from CIIA and 3B & 4B from UAT transformer no. 3A & 3B respectively and 4A
and 4B from UAT transformer no.4A & 4B respectively.
Stage 3 buses CIVA, CIVB are fed from station Transformer no.4. The buses CIVA and
CIVB can be fed from station transformer no.2 also. Making an extension bus at CIIIA &
CIIIB bus has madethis arrangement.
The 6.6 KV system has following buses and feeding transformer:
1. Station Bus (2 no. For each stage)
2. Unit Bus: (2 no. For each unit)
STAGE 1:
The station bus is fed from station transformer (50 MVA, 220/6.6 KV)
The another arrangements of buses stage wise is as follows:
a) The CIA & CIB buses are fed from station transformer no.1.
b) There is a link from station buses to:
1) CWPH switchgears.
2) Coal handling switchgears.
3) Coal cum ash handling switchgears.
The CWPH 6.6KV has 2 sections A & B with a bus coupler breaker in between. But there
is no scheme for no load change over or offload change over an auto.
But if the bus coupler breaker is to be y used for charging, the incomer breaker of that
particular bus has to be off and the DC of that particular breaker should be kept on.
Similar arrangement is there in the core handling and handling cum ash handling buses.
For tie to unit buses there is isolator in between the station and unit buses on the unit buses
( which on all the time) and there is breaker on the station bus which has the selective shange
over and fast change over and flow change over facility.
There is a set of two breakers for the purposes of tie link between the station buses 1 and
station bus II.
For this purpose, there are two no. Of isolators on station bus II are provided.
In stage 1, the station transformer no. 2 is installed. This is a stand by transformer. In
addition to the duty as a stand by transformer, it has following stand by transformers fed from
the buses of these transformers.
1) Electrostatic Precipitator Transformer.
2) Ash handling Transformer.

3) CWP Transformer.
Unit buses are fed from 15 MVA, 15.75/6.6 KV unit auxiliary Transformer. The unit buses are
supplying the following load:
1) Primary Air Fan
2) Induced draft fan
3) Forced draft fan
4) Coal mills
5) Boiler feed pumps.
6) Condensate extraction pump.
7) Electrostatic precipitator transformer.
8) Unit service transformer.

17.D.C. BATTERIES

17.1 How the grid failure occurs?

Grid failure - A grid is a interconnection of substations. In India there are five grid
station, North zone, East zone, West zone central and South zone.
Grid failure occurs due to two main reasons 1) increase in voltage 2) change or less
in frequency. It leads to cascade effect A trip in transmission time leads to cascade
effect, it will effect other transmission time and hence grid failure. In this way, effect
goes on.

Due to grid failure, turbine will come to stand still position, it will not rotate Turbine
is very heavy, its weight is in tones. Therefore jacking pump oil, which are both A.C.
and D.C. auxiliary oil pumps are used. Jacking pump oil will pick up the shaft with
pressure and auxiliary oil pumps will help in lubricating and control the bearing
temperature and turbine rotate at slow speed (250 rpm-300rpm) otherwise shaft will
bend to few mm due to high temperature and weight and is of no use.
Hydrogen pressure and stator water-cooling is used for cooling of generator so
as to maintain the temp. to 45C Hydrogen pressure is of 3.5kg/ cm 2. Sealing oil
pressure is used two block the Hydrogen pressure. If hydrogen leaks out of
generator leads to bombardment. Seal oil pressure is of 5kg\ cm*cm. The differential
is 1.5kg\cm2. Auxiliary oil pump will continue if the temperature of turbine is above
170C and if it is below 170C then it may be stopped.
D.C Batteries are used in case of failure. D.C. batteries will operate for 10 minutes
because diesel engine takes 10 minutes to start. There are 110 batteries which are
connected in series to produce net 220V, 1400Ah. Each cell cost Rs. 30000. Tiles
are placed on the floor because tiles are acid-proof. The cells should be placed in an
airy room so that proper air can pass through but it placed in vacuum, quantity of
oxygen is less because there is ash & other dust particles. The cells are at a height
of I feet from ground so that heat can eject from bottom. There are three types of
batteries head acid storage, stationary batteries high discharge performance. In plant
there are HDP batteries. There are two batteries one is used when there is failure
and other is stand by.
There are three Stages: Stage 1,
Stage 2 and
Stage 3
Stage 1 includes 2 units
In stage1

220V for system

24V for control system

Stage 2: - includes 2 units

220V for system
24V
48V

for control panels

Stage 3: - involves next two units ------- are computerized

220V

system

24V
26V for control panels
48V 360V U.P.S
Life of batteries is checked by specific gravity. Specific gravity should be 1200 +- 5v at 27C
specific gravity is checked by hydrometer. The level of acid should be in between two red
tables. For control panels battery charger ratings 24V\600 Ah & 24V\1200Ah for system is
220V\1400 Ah