CHAPTER 1

INTRODUCTION TO KSTPS

1.1 HISTORY OF KSTPS

Rajasthan is well on its way for a 'brighter' future, a future that promises electricity to every
city, town and village of the state, a promise of making the state completely self- dependent
in power production. Kota Thermal Power Station is Rajasthan's First major coal power
station. Presently it is in operation with installed capacity of 1240 MW

A large portion of the country’s repository of power and energy belongs to the state of
Rajasthan. In order to bring about changes that would escalate the prospects of growth and
development in the power sector and to enforce the power sector Reforms. The
Government of Rajasthan set up the Rajasthan Vidyut Utpadan Nigam LTD. (RVUNL) in
accordance with the promulgations of the companies Act 1956. Keeping in view the higher
demands of power it was decided to house Kota Super Thermal Power Station at kota on
techno-economic reasons as follows:-

1. Availability of clean water required for station.

2. Location of station on board Gauge main railway line.
3. Proximity to Madhya Pradesh Coal fields.
4. Concentration of load in Kota region due to large number of industries located.

The source of water and cooling is the reservoir formed by “Kota Barrage” on the river.
The comparative use of water from barrage by the Power Station is 2.75 cusec for each 110
MW units. Chambal river acts as the heart of water supply for kota super power station and
provides continuous supply of water through out the year. Pump houses is constructed just
near the shore of the Chambal river which further reduces the efforts to bring the water to
the power plant.

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For the power generation with 2x110 MW, 3x210 MW and 2X195 MW of K.S.T.P.S.
authorities are required to be operative to active full operation. The auxiliaries are basically
operation either on L.T. System i.e. 415 V 3-Ø power supply is made available to the
system after providing the station transformer of 3x50 MVA capacity with voltage 220 KV/
7.2 /7.2 KV and different service transformers of capacity 1.0 MVA, 1.5 MVA,
2.0 MVA, which are located near the load center as the transformer having the voltage of
6.6 KV/ 415 V.

The 6.6 KV power is distributed through 6.6 KV interconnected Bus System for all the five
units with a control through DC of 220 V. The 415 V power supply is done through a
L.T. switchgear which are located nearby the distribution transformer as well as the load
centers. The all incomers, which are breaker controlled, are having the control the L.T.
switchgear are having the control system on 110/ 220 V AC.

The 6.6 KV power supply to various draining g equipment’s i.e. more is made through
breakers which are either MOCB of Jyoti make air circuit breaker which are either of
voltage makers as well as SF 6 of NGEF make. The LT supply is also controlled through
air break circuit breaker which are either L&T make or English Electric Company of India.
The various H.T. motors are switched on started through on direct ON line in order to
inverse the availability of equipment at full efficiency without time gap.

There are total 11 feeders from KSTPS each having 220V over it. Each line is going as:-

Table.1.1: Feeders of KSTPS

1 LINE SANGANER
1 LINE HERAPURA
1 LINE MODAK GSS
2 LINE POWER GRID NAWTA

2 LINE BYAWAR

4 LINE SAKATPURA GSS

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K.S.T.P.S. is designed in following stages:-
Table.1.2: Stages of KSTPS

INSTALLED DATEOF
STAGES UNIT NUMBER CAPCITY COMMISSIONING
STAGE 1 UNIT-1 110 MW JANUARY,1983
STAGE 1 UNIT-2 110 MW JULY,1983
STAGE 2 UNIT-3 210 MW SEPTEMBER,1988
STAGE 2 UNIT-4 210 MW MAY,1989
STAGE 3 UNIT-5 210 MW MARCH,1994
STAGE 4 UNIT-6 195 MW JULY,2003
STAGE 5 UNIT-7 195 MW MAY,2009

Stage 1 : Two Units of 110 MW capacity were installed. The first unit was synchronized
at 17.1.1983 and second unit was synchronized at 13.7.1983. It cost 143 Crores.

Stage 2 : Two units of 210MW capacity were installed. Third unit was synchronized at
25.9.1988 and the fourth unit at 01.5.1989. It cost 480 Crores.

Stage 3 : One unit 210MW capacity was installed. The fifth unit was synchronized at
26.3.1994. It cost 480 Crores.

Stage 4 : One unit 195MW capacity was installed, the sixth unit was synchronized at
31.7.2003. It cost 635 Crores.

Stage 5 : One unit 195MW capacity was installed, seventh unit was synchronized at
30.5.2009. It cost 880 Crores.

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1.2 SITE SELECTION CRITERIA

1.2.1 Location

The Kota Thermal Power Station is ideally on the left bank of Chambal River at upstream
of Kota Barrage. The large expanse of water reached by the barrage provides an efficient
direct circulation of cooling system for the power station. The 220 KV GSS is within half
kilometer from the power station.

Fig.1.1: Site view of KSTPS

1.2.2 Land

Land measuring approx 250 hectares was required for the project, for disposal of ash tank
very near to power station is acquired which the ash in slurry form is disposed-off through
ash and slurry disposal plants.

1.2.3 Coal

The Coal India Limited owns and operates all the major coal fields in India through its coal
producing subsidiary companies viz. Eastern Coal Fields Limited, Western Coal Fields
Limited, Coal India limited supply coal from its coal mines of coal producing subsidiaries
BCCL, SECL & ECL to Kota thermal power station.

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1.2.4 Water

The source of water for power station is reservoir formed by kota barrage on the chambal
river. In case of large capacity plants huge quantities of coal and water is required. The cost
of transporting coal and water is particularly high. Total water requirement of KSTPS is
around 3155750m3/day.

1.3 RECORDS OF EXCELLENCE

KSTPS has established a record of excellence and has earned meritorious productivity
awards from the Ministry of Power, by government of India during 1984, 1987, 1989, 1991
and every year since 1992-93 onwards. KSTPS has earned golden shield award from Union
Ministry of Power for Consistent outstanding performance during 2000-01 to 2003-04. The
Golden Shield was presented by Hon’ble President of India Dr. A.P.J. Abdul Kalam on
24.8.04. KSTPS has achieved the distinction of about 100% fly ash utilization during the
year 2010-11. The fact that thermal energy is the major source of power generation itself
shows the importance of thermal power generation in India – more than 60 percent of
electric power is produced by steam plant in India.

1.4 ENVIRONMENTAL PROFILE

1. Adequate measures have been taken at KSTPS to control pollution and comply to
the norms laid by environment protection act. 1986.
2. Height of 180 meter stacks have been provided to release flue gases into the
atmosphere at an approx. velocity of 25 m/sec. so as to disperse the emitted
particulate matter over a wide spread area.
3. The on-line stack s.p.m monitoring system has been installed for requirement of
central pollution control board. Microprocessor based intelligent controllers to
optimize the ESP of 99.82% efficiency have been provided.
4. Development of green belt, about 3 lakhs plants of various species have already
been planted in KSTPS the survival rate of plants is watched periodically.

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1.5 BASIC IDEA OF THERMAL POWER PLANT
A control system of station basically works on Rankine Cycle. Steam is produced in Boiler
is exported in prime mover and is condensed in condenser to be fed into the boiler again.
In practice of good number of modifications are affected so as to have heat economy and
to increase the thermal efficiency of plant.

Fig.1.2: Basic layout of a thermal power plant

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1.6 GENERAL LAYOUT OF KOTA SUPER THERMAL POWER
PLANT

Fig.1.3: General layout of KSTPS

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Kota Thermal Power Station is divided into four main circuits:
 Fuel and Ash Circuit.
 Air and Gas Circuit.
 Feed water and Steam Circuit.
 Cooling Water Circuit.

1.7 FUEL & ASH CIRCUIT

Fuel from the storage is fed to the boiler through fuel handling device. The fuel used in
KSTPS is coal, which on combustion in the boiler produced the ash and is approximately
35-40% of coal used. This ash is collected at the back of the boiler and removed to ash
storage tank through ash disposal equipment

1.8 AIR AND GAS CIRCUIT

Air from the atmosphere is supplied to the combustion chamber of Boiler through the action
of FD fan and ID fan. The flue gases are first pass around the boiler tubes and super-heated
tubes in the furnace, through dust collector and then economizer. Finally, they are
exhausted to the atmosphere through fans.

1.9 FEED WATER AND STEAM CIRCUIT

The purpose of a power boiler is to create steam by applying heat energy to water. The
water supplied to the boiler, which is converted to steam, is called feed water. This feed
water system removes any impurities in the condensate, which is steam converted back to
water, preheats and pressurizes it then returns it to the power boiler steam drum. The power
boiler control system maintains the proper flow of feed water to the boiler.

1.10 COOLING WATER CIRCUIT

A large quantity of cooling water is required to condense the steam in condenser and
marinating low pressure in it. The water is drawn from reservoir and after use it is drained
into the river.

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 CHAPTER 2

SWITCHYARD
A switchyard is the interconnection of generation and transmission sections of our power
system. The electrical power generated by the generators is initially fed to the buses of the
switchyard where the voltage level of the generated power is stepped up to higher levels so
that the transmission losses get reduced by the significant amount. The equipment used in
switchyard are:

1. Electrical Power transformers

2. Instrument transformers
3. Conductors & Insulators
4. Isolators
5. Bus bars
6. Lightning arresters
7. Circuit breakers
8. Relays
9. Capacitor banks

Fig.2.1: Switchyard

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2.1 ELECTRICAL POWER TRANSFORMER
A static electrical machine used for transforming power from one circuit to another circuit
without changing frequency is termed as Power transformer. These are generally used to
step down or step up the voltage levels of a system for transmission and generation purpose.
Transformers are classified into different types based on their design, utilization purpose,
installation methods, etc.

Fig.2.2: Power transformer

2.2 CURRENT TRANSFORMER

Current transformer is used for the measurement of the alternating current by taking
samples of the higher currents of the system. These reduced samples are in accurate
proportions with the actual high currents of the system. These are used for installation and
maintenance of the current relays in substations for protection purpose which are normally
have low-current ratings for their operation.

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 Fig.2.3: Current transformer

2.3 POTENTIAL TRANSFORMER

Potential transformer is quite similar to the current transformer, but it is used for taking
samples of high voltages of a system for providing low-voltage to the relays of protection
system and also to the low-rating meters for voltage measurement. From this low-voltage
measurement, the actual system’s high voltage can be calculated without measuring high
voltages directly to avoid the cost of the measurement system. The current and voltage
transformers are together called as the Instrument transformers.

Fig.2.4: Potential transformer

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2.4 CAPACITOR PANEL

The material or object that obeys the electrical property conductance and that allows the
flow of electric charge is called conductor. Conductors permit free movement of the flow
of electrons through them. These are used for the transmission of power or electrical energy
from generating station to consumer point where power is consumed by the loads through
substations. Conductors are of different types and mostly aluminum conductors are
preferred in practical power systems.

Fig.2.5: Capacitor bank

2.5 INSULATORS
The metal which does not allow free movement of electrons or electric charge is called as
an insulator. Hence, insulators resist electricity with their high resisting property. There are
different types of insulators such as suspension type, strain type, stray type, shackle, pin
type and so on. Insulators are used for insulation purpose while erecting electric poles with
conductors to avoid short circuit and for other insulation requirements.

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2.6 ISOLATORS

Isolator is a manually operated mechanical switch that isolates the faulty section or the
section of a conductor or a part of a circuit of substation meant for repair from a healthy
section in order to avoid occurrence of more severe faults. Hence, it is also called as a
disconnector or disconnecting switch.

Fig.2.6: Isolators

2.7 BUS BARS

The conductor carrying current and having multiple numbers of incoming and outgoing
line connections can be called as bus bar, which is commonly used in substations. These
are classified into different types like single bus, double bus and ring bus.

Fig.2.7: Bus bars

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2.8 LIGHTENING ARRESTERS
The substation equipment’s such as conductors, transformers, etc., are always erected
outdoor. Whenever light surges occur then; a high-voltage pass through these electrical
components causing damage to them. Therefore, to avoid this difficulty, lightening
arresters are placed to pass the entire lightening surges to earth.

Fig.2.8: Lightening arrester

2.9 CIRCUIT BREAKERS

For the protection of substation and its components from the over currents or over load due
to short circuit or any other fault the faulty section is disconnected from the healthy section
either manually or automatically. In general mostly used circuit breakers are Oil circuit
breaker, Air circuit breaker, SF6 circuit breaker, Vacuum Circuit Breaker, etc.

Fig.2.9: Sf6 circuit breaker

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2.10 RELAYS

Relays are used for disconnecting the circuits by manual or automatic operation. Relay
consists of the coil which is excited or energized and such that making the contacts of
relay closed activates the relay to break or make the circuit connection. There are
different types of relays such as over current relays, definite time over current relays,
voltage relays, auxiliary relays, reclosing relays, solid state relays, directional relays,
inverse time over current relays, microcontroller relays, etc.

Fig.2.10: Circuit representation of relay

Fig.2.11: Physical overview of relay

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 CHAPTER 3
WATER TREATMENT PLANT

Raw water is taken from the upstream of Chambal River, then it goes to cooling water
pump house units 1-5, then to condenser this is for units 1-5 and to pre-treatment plant. The
filtered water from pre-treatment plant then goes to de-mineralized plant and to cooling
water pump house units 6-7. Water from DM plant goes to boiler and baring cooling water
pump. Water from C.W.P.H. units 6-7 goes to condenser units 6-7 and then to cooling
tower. DM water is sent to the boiler and then is used further.

3.1 D.M. PLANT

In this plant process water is fed from all these dissolved salts. Equipment for
demineralization cum softening plant is supplied and erected by M/s. Wanson (India) Ld.,
Pune. This plant consists of two streams each stream with activated carbon filter, weak
acid, cation exchanger and mixed bed exchanger. The filter water to DM plant through 250
dia. header from where a heater top off has been taken to softening plant.

Two filtered water booster pumps are provided on filtered water line for meeting the
pressure requirement in DM Plant. Sodium Sulphate solution of required strength is dosed
into different filtered water by mean of dosing pump to neutralize chlorine prior to activated
carbon filter. When water passed an activated carbon filter will remove residual chlorine
from water. Provision is made for back washing the activated carbon filter.

The deception water the weak base anion exchanger unit water then enters de-gasified unit
where free CO2 is scrubbed out of water by upward counter flow of low pr. air flow through
degasified lower and degassed water is pumped to strong base exchanger (anion
exchanger). Arrangement for dosing ammonia solution into de-mineralized water after
mixed bed unit has been provided p+1 correction before water is taken in de-condensate
transfer pump the DM water to unit condensor as make up.

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3.2 C.W. PLANT

Circulating water pump house has pumps for condensing the steam for condensor. Five
pumps are used for condensing Unit No.1 & 2 and after condensing this water is discharged
back into the river. Each pump has capacity of 8275 M 3 /Hr, and develop pressure about
1.94 Kg./Cm2. Three seal water pump are used for sealing circulating water pump shaft at
pr. 4.5 kg./cm2. Two pump for unit 1 & 2 with one stand by is used for supplying raw water
to chlorified chemical dosing is tone between and chlorified water is taken through main
line.

From main line water passes through filter bed to filter the water. Chlorified water is
pumped to 42 m elevation by two pumps of capacity 270 M3/Inch at discharge pressure of
6.9 Kg./Cm2. At 42 M elevation the water is stored in tank and used for cooling the oil
coolers and returned back to river. Oil coolers are situated on ground and there are no. of
tress for each unit.

3.3 B.C.W. PUMP HOUSE

Filter water after demineralization is used for bearing cooling from BCW pump house after
passing through strainer and heat exchanger it enters at 30-32oC and leave exchanger at
38oC. The raw water used in ash handling plant and remaining quantity is stored in sumps
of BCW Pump House. From here the water is pumped to CW Pump by TWS (Traveling
water screens) pumps are run by motors of 90 KW and has a capacity of 240 Cum/hr/pump
at pressure of 5 kg/cm2.

BCW here stand for water used for cooling oil used for cooling the bearing. In CW pump
house water is discharged from nozzle and impinged for traveling water screens for
cleaning it.

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