CONTENTS

Acknowledgement Abstract Certificate Importance of energy About PSPCL Introduction to GHTP Thermal Power station Salient Features of GHTP Substation Transformer yard Coal Handling Plant GHTP Main control room Analysis of GHTP Future proposal Conclusion References

ACKNOWLEDGEMENT
I am extremely thankful & indebted to the numerous PSPCL Engineers who provided vital information about the functioning of their department thus helping me to gain an overall idea about the working of organization. I am highly indebted to my project guides, Er. Krishan kumar, Er. Luder kumar for giving me their valuable time and helping me to grasp the various concepts of switchyard equipment, coal handling plant and the overview about the working of thermal power station. I would also like to thank Dr. Smarajit Ghosh(Head of E.I.E.D), Mr. Shakti Singh(Training Coordinator), Dr. Sanjay Kumar Jain and other members of the council. Last but not least, I would like to thank my teachers, parents and my fellow trainees who have been a constant source of encouragement and inspiration during my studies and have always provided me their support in every walk of my life.

SHIVI KUMAR GARG

ABSTRACT
The industrial training is meant for the students of the engineering colleges to get exposed to the professional life and the related problems, so that they get mentally as well physically prepared to the odds of the engineering life. Our Thapar University has also devised such training for us, keeping in view the all aspects of professional life. So I undertook my training at: Guru Hargobind Thermal Plant, Lehra Mohabbat (Bathinda) I faced certain problems in the beginning, but coped with circumstances later on. I learned about many things like substation maintenance, Transformer yard, coal handling plant and other concepts related to my field. I am highly thankful to all those who guided me in getting my training at GHTP (Lehra mohabbat). I also express my gratitude to all the people in industry, who helped me in making my training a success.

IMPORTANCE OF ENERGY
Energy provides the power to progress. Availability of sufficient energy and its proper use in any country can result in its people rising from subsistence level to the highest standard of living. It is interesting to note that more than the half of worlds population lives in Asia but the energy consumption is barely 8-10 per cent of worlds total.

Different types of energy sources and efficiency in their use

Primary fuels in meeting worlds energy requirements are: Solid fuels Liquid fuels Natural gas Hydro Nuclear

Energy sources

Percentage Efficiency in Percentage Efficiency in use factor in Industry use factor by Private consumer
25 35 30 85 40 67 62 80

Coal Gas Petroleum ELECTRICITY

Electric power is the backbone of industrial world of today. Large population of the world depends upon the electric power.

DEMAND FOR ELECTRICITY

COUNTRY INDIA JAPAN U.S.A. Approximate % of energy requirement met by electricity 1955 1970 1985 2000 8 25 18 16 40 27 28 55 48 40 70 85

ABOUT PSPCL
Punjab State Power Corporation Limited (PSPCL) is the electricity generating company of the Government of Punjab state in India. PSPCL was incorporated as company on 16-04-2010 and was given the responsibility of operating and maintenance of states own generating projects. The business of Generation of power of erstwhile PSEB was transferred to PSPCL. The existing Thermal Power Plants under PSPCL are GURU NANAK DEV THERMAL PLANT BATHINDA, GURU GOBIND SINGH SUPER THERMAL PLANT ROPAR and GORU HARGOBIND THERMAL POWER PLANT LEHRA MOHABBAT (BATHINDA). The existing hydro power plants are RANJIT SAGAR DAM, SHANAN POWER HOUSE, ANANDPUR SAHIB HYDEL PROJECT, MUKHERIAN HYDEL PROJECT STAGE-I and U.B.D.C. HYDRO ELECTRIC POWER HOUSE STAGE I & II.

MEGAWATT STORY Total power from states current sources Peak demand in 2011-2012 Demand increase per year Present shortfall 6950 MW 10010 MW 8% 3100 MW

Thermal generation (ropar, lehra mohabbat, 2620 MW bathinda) Hydel generation 1000 MW BBMB projects Central pool and banking Solar ( 9 plants) Biomass (3 plants) Micro hydel (2 plants) 1250 MW 3200 MW 14.5 MW 6 MW 0.85 MW

Introduction to GHTP LEHRA MOHABBAT

1.) Location of plant
Located at Lehra Mohabbat in between Bathinda and Rampura on Bathinda-Barnala highway no.7. Situated Between 29km and 32km milestone on the same highway.

2.) Area occupied

1000 Acres

3.) Cost of project

65000 lacs

4.) Coal consumption per year

13,86,000 tonnes

5.) Ash production per year

4,85,000 tonnes

6.) Main features Highest generation during 2000-2001. Highest P.L.F during march,2001. Lowest oil consumption during Feb,2001. Lowest D.M. water make up during August,2000. 7.) Brief History of Plant
Ever widening gap between the power demand and its availability in the state of Punjab was one of the basic reasons for envisaging a thermal plant at Lehra Mohabbat Distt Bathinda. The other favourable factors were low initial cost and generation period as compared to hydroelectric generating stations, its good railway service and proximity to load centre. Initially it was going to set up at Bathinda under GNDTP but the air force personnel restricted its set up at Bathinda hence plant shifted to Lehra Mohabbat about 22 km from Bathinda city. Later this plant was approved as a separate autonomous body with its name as GURU HARGOBIND THERMAL PLANT. The construction of plant commenced in 1992.

Commissioning of its 4 units consists of 2 stages: STAGE-1 First unit commissioned on 27/12/1997 Second unit commissioned on 16/10/1998 STAGE-II Third unit commissioned on 16/10/2008 Fourth unit commissioned on 31/01/2009

8.) Power Generation

The capacity of both units of stage-I is 210MW each and that of stage-II is 250MW each. It meets 20-25%of total power requirement of Punjab. The main companies whose technology paved the way for the plant are Tata Honeywell and BHEL in turbine and boiler control. Power is generated from two units of stage-1(each 210MW) at 15.75KV and two units of stage-2 (each 250MW) at 16.75KV which is stepped up through 250MVA (15.75/220KV) and 315MVA generators respectively. Power is transmitted through 8 220KV bi-directional feeders. The whole system is connected to northern grid. Supply to auxiliary of thermal plant is given through UAT (unit auxiliary T/F) of output 6.6 KV and UST (unit station T/F) of output 6.6 KV.

9.) Rail and Water Facilities

Rail line is taken from Lehra Mohabbat railway station from Dhuri Bathinda Broad Gauge railway line. Water requirement of all type of need is met from Bathinda branch of Sirhind canal.

10.) Geological and Climatic conditions

The subsoil of the area generally consists of alternating layers of poorly graded silt sand and clay sand. Bathinda has hot dry but very healthy climate. Relative humidityMax: 83% Min: 22% Rainfall depends on SW monsoon. Average annual rainfall is around 600mm.

11.) Fuel used

Primary fuel is coal from PANEM (PSEB captive mine established as joint venture with EMTA group), CCL & ECL and the subsidiary companies of Coal India Limited. Secondary fuel is Furnace Oil and Light Oil.

12.) Total energy contribution

Total contribution is 233.03 lac units daily (as on 27 october 2011) Contribution is 6902 lac units in the month of May 2012 which is best amongst previous records. Annual contribution is 7621.252 MUs(in year 2011-2012).

13.) Cost of generation

240.78 paisa per unit

WHAT IS THERMAL POWER PLANT?

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A thermal power station is an electricity generating plant which uses coal as fuel and there it is burnt to boil water for steam generation. That steam is used to run turbines and thereafter running generators.

Schematic layout of a typical coal-fired thermal power station

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SALIENT FEATURES OF THERMAL POWER STATION

1.) SITE
Generally located near the load centre but other factors such as transportation of fuel, enough water for cooling the condensate, cost of land are also kept in view. Present thinking is to install thermal stations near coal mines.

2.) COST
(i) Initial cost (approximate) Lowest among all other types of power stations, i.e., hydro-electric, nuclear, diesel. (ii) Running cost High because of great demand and high cost of coal. Maintenance cost High because of energy consuming auxiliaries like coal handling plant, ash disposal plant, ESPs etc.

(iii)

3.) TIME REQD. FOR COMPLETION

3-4 years

4.) SIMPLICITY & CLEANLINESS

Causes air pollution Disposal of ash is another problem

5.) FIELD OF APPLICATION

Generally used to supply base load

6.) RELIABILITY
Less reliable

7.) SPACE
Needs a lot of space but much less than hydro stations Huge space for storage of fuel is reqd.

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Four main circuits of a thermal plant:

Fuel and Ash circuit
Fuel (coal) from storage is fed to the boiler through fuel feeding device commonly known as coal handling plant(CHP). Ash produced as a result of combustion of coal collects at the back of the boiler and is removed to ash storage through ash handling plant.

Air and Gas circuit

Air from the atmosphere is supplied to the combustion chamber of the boiler through the action of a forced drought (F.D) fan and/or induced drought (I.D) fan. The air before being supplied to the boiler passes through air preheater where it is heated by the heat of the flue gases which are then made to pass the chimney. The flue gases first pass around the boiler tubes and superheater tubes in the furnace, next through dust collector and then through the economiser. Finally they are exhausted to the atmosphere through the air preheater and through the electrostatic precipitator (ESP).

Feed water and Steam circuit

The condensate leaving the condenser is first heated in a closed feed water heater through extracted steam from the lowest pressure extraction point of the turbine. This water then passes through deaerator and a few more water heaters before it goes into the boilers through the economiser. A small part of steam and water is lost in passing through different components of system. Therefore, water is added in the feed water system as make up water.

Cooling Water circuit

A large quantity of cooling water is required to condensate the steam in the condenser and in maintaining a low pressure in it. For this purpose cooling towers are made.

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IMPORTANT PARTS OF A THERMAL POWER STATION

1.) Boiler
A boiler is a closed vessel in which water or other fluid is heated. The heated or vaporized fluid exits the boiler for use in production of steam under pressure. Steam boilers are broadly classified into fire tube and water tube types. Generally water tube boilers are used. If the hot combustion gases are restricted to inside the tubes and the tubes are surrounded with water the boiler is a fire tube boiler while if the arrangement is opposite, i.e., water is inside the tubes the boiler is water tube boiler. Fire tube boilers have low initial cost, are more compact but are more likely to explode. Water tube boilers have less weight of metal for a given size, are less liable to explosion, produce higher pressure, are easily accessible and can respond quickly to change in steam demand.

Fire tube boiler

Water tube boiler

2.) Economizer
Its purpose is to heat feed water so as to recover a part of heat which would otherwise be lost through flue gases.

3.) Air Preheater

Since the entire heat of the flue gases cannot be extracted through the economizers air preheaters are used to recover some of the heat in the gases. On an average an increase of 20 C in the air temperature results in an increase in the boiler efficiency by 1%.
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4.) Condensers
The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be pumped. If the condenser can be made cooler, the pressure of the exhaust steam is reduced and efficiency of the cycle increases. The surface condenser is a shell and tube heat exchanger in which cooling water is circulated through the tubes. The exhaust steam from the low pressure turbine enters the shell where it is cooled and converted to condensate (water) by flowing over the tubes as shown in the adjacent diagram. The limiting factor is the temperature of the cooling water and that, in turn, is limited by the prevailing average climatic conditions at the power plant's location (it may be possible to lower the temperature beyond the turbine limits during winter, causing excessive condensation in the turbine). Plants operating in hot climates may have to reduce output if their source of condenser cooling water becomes warmer; unfortunately this usually coincides with periods of high electrical demand for air conditioning. The condenser generally uses either circulating cooling water from a cooling tower to reject waste heat to the atmosphere, or once-through water from a river, lake or ocean. For best efficiency, the temperature in the condenser must be kept as low as practical in order to achieve the lowest possible pressure in the condensing steam.

5.) Cooling Towers

Cooling towers are heat removal devices used to transfer process waste heat to the atmosphere. Cooling towers may either use the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature or, in the case of closed circuit dry cooling towers, rely solely on air to cool the working fluid to near the dry-bulb air temperature.

6.) Reheater
Power plant furnaces may have a reheater section containing tubes heated by hot flue gases outside the tubes. Exhaust steam from the high pressure turbine is passed through these heated tubes to collect more energy before driving the intermediate and then low pressure turbines.

7.) Turbine
Turbines act as a prime mover for the alternator. Turbines used in thermal power plant are steam type turbines. A steam turbine is a device that extracts thermal energy from pressurized steam and uses it to do mechanical work on a rotating output shaft. Because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generator about 90% of all electricity generation is by use of steam
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turbines. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible process. They are further classified into 2 types: Impulse turbine and reaction turbine An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These jets contain significant kinetic energy, which is converted into shaft rotation by the bucketlike shaped rotor blades, as the steam jet changes direction. A pressure drop occurs across only the stationary blades, with a net increase in steam velocity across the stage. As the steam flows through the nozzle its pressure falls from inlet pressure to the exit pressure (atmospheric pressure, or more usually, the condenser vacuum). Due to this high ratio of expansion of steam, the steam leaves the nozzle with a very high velocity. The steam leaving the moving blades has a large portion of the maximum velocity of the steam when leaving the nozzle. The loss of energy due to this higher exit velocity is commonly called the carry over velocity or leaving loss. In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles. This type of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the stator as a jet that fills the entire circumference of the rotor. The steam then changes direction and increases its speed relative to the speed of the blades. A pressure drop occurs across both the stator and the rotor, with steam accelerating through the stator and decelerating through the rotor, with no net change in steam velocity across the stage but with a decrease in both pressure and temperature, reflecting the work performed in the driving of the rotor.

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8.) Alternator
An alternator is an electromechanical device that converts mechanical energy to electrical energy in the form of alternating current. Most alternators use a rotating magnetic field with a stationary armature but occasionally, a rotating armature is used with a stationary magnetic field; or a linear alternator is used. In principle, any AC electrical generator can be called an alternator, but usually the term refers to small rotating machines driven by automotive and other internal combustion engines. Alternators in power stations driven by steam turbines are called turboalternators. Alternators generate electricity using the same principle as DC generators, namely, when the magnetic field around a conductor changes, a current is induced in the conductor. Typically, a rotating magnet, called the rotor turns within a stationary set of conductors wound in coils on an iron core, called the stator. The field cuts across the conductors, generating an induced EMF (electromotive force), as the mechanical input causes the rotor to turn. The rotating magnetic field induces an AC voltage in the stator windings. Often there are three sets of stator windings, physically offset so that the rotating magnetic field produces a three phase current, displaced by one-third of a period with respect to each other. The rotor's magnetic field may be produced by induction (as in a "brushless" alternator), by permanent magnets (as in very small machines), or by a rotor winding energized with direct current through slip rings and brushes. The rotor's magnetic field may even be provided by stationary field winding, with moving poles in the rotor. Permanent magnet machines avoid the loss due to magnetizing current in the rotor, but are restricted in size, due to the cost of the magnet material. Since the permanent magnet field is constant, the terminal voltage varies directly with the speed of the generator. Brushless AC generators are usually larger machines than those used in automotive applications. An automatic voltage control device controls the field current to keep output voltage constant. If the output voltage from the stationary armature coils drops due to an increase in demand, more current is fed into the rotating field coils through the voltage regulator (VR). This increases the magnetic field around the field coils which induces a greater voltage in the armature coils. Thus, the output voltage is brought back up to its original value. Alternators used in central power stations may also control the field current to regulate reactive power and to help stabilize the power system against the effects of momentary faults.

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WORKING OF THERMAL PLANT

Coal received from collieries in the rail wagon is mechanically unloaded by wagon tippler and carried by belt conveyor system boiler raw coal bunkers after crushing in the coal crusher. The crushed coal when not required for raw coal bunker is carried to the coal storage area through belt conveyor. The raw coal feeder regulates the quantity of coal from coal bunker to the coal mill, where the coal is pulverized to a fine powder. The pulverized coal is then sucked by vapour fan and finally stored in the pulverized coal bunkers. The pulverized coal is then pushed to the boiler furnace with the help of hot air steam supplied by primary air fan. The coal being in pulverized state gets burned immediately in the boiler furnace. The water gets converted in the steam by heat released by the combustion of fuel in the furnace. The air required for the combustion of coal is supplied by draught fan. This air is however heated by the outgoing flue gases in the air heaters before entering the furnace. The products of combustion in the furnace are the flue gases and the ash. About 20% of the ash falls in the bottom ash hopper of the boiler and is periodically removed mechanically. The remaining ash carried by the flue gases, is separated in the electrostatic precipitator and further disposed of in the ash damping area. The cleaner flue gases are let of to the atmosphere through the chimney by induced draught fan. The chemically treated water running through the water walls of the boiler furnace gets evaporated at high temp into steam by absorption of furnace heat. The steam is further heated in the superheater. The dry steam at high temp is then led to the turbine comprising 3 cylinders. The thermal energy of this steam is utilised in turbine for rotating its shaft at high speed. The steam discharged from high pressure turbine is returned to the boiler reheater for heating it once again before passing it into the medium pressure turbine. The steam is then let to the coupled to turbine shaft is the rotor of generator, which produces electricity. The power from generator is pumped into power grid system through the generator transformer by stepping up the voltage. The steam after doing the useful work in the turbine is condensed to water in the condenser for recycling in the boiler. The water is pumped to deaerator from the condenser by the condensate extraction pump after being heated in the LP heater from the deaerator, a hot water storage tank. The boiler feed pump discharge feed water to boiler at the economiser by the hot flue gases leaving the boiler, before entering the boiler drum to which water walls and superheater of boiler are connected. The condenser is having a large no. of brass tubes through which cold water is circulated continuously for condensing the steam passing out on sides of the surface of brass tubes, which has discharged down by circulating it through the cooling tower shell. The natural draught of cold air is created in the cooling tower, cools the water fall in the sump and is then recirculated by circulating water pumps to the condenser.

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SALIENT FEATURES OF G.H.T.P.

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BOILERS
Manufacturers Steam Pressure Steam Temperature Feed Water Temperature Efficiency STAGE I Maximum Continuous Rating 690 T/hour B.H.E.L. 155 kg/cm^2 540(Celsius) 240(Celsius) 86% STAGE II 810 T/hour

BOILER FEED PUMPS

STAGE I Number Capacity Discharge Head 3 475 m^3/hr 2105 MWC STAGE II 3 520 m^3/hr 2235 MWC

CONDENSER
STAGE I Area Cooling Water Flow 11500m^2 26000 m^3/hr STAGE II 15468m^2 32000 m^3/hr

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STEAM TURBINE
Manufacturer Rated Speed Inlet Steam Pressure Inlet Steam temperature No. Of Cylinders STAGE I Rated Output 210MW B.H.E.L. 3000 rpm 150 kg/cm^2 535(celcius) 3 STAGEII 250MW

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GENERATOR
Manufacturer STAGE I Capacity 210 MW 247 MVA Voltage Current 15750 Volts 9050 Amp B.H.E.L. STAGE II 250 MW 294 MVA 16500 Volts 10290 Amp

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COOLING TOWERS
Number Water cooling capacity Cooling range Height Dia at top Dia at bottom 4 1800 T/hr 10 to 20 degree C 120m 58m 95m

CONDENSATE PUMP
STAGE I Quantity Capacity 2 No. 680 m3/hr STAGE II 2 No. 795 m3/hr

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CIRCULATING WATER PUMP

No. of pumps Type Rated discharge Discharge head 3 Mixed Flow 8600 T/hr 24 MWC

CHIMNEY
Type Height Dia at top Dia at bottom Multiflue 220m 13m 26m

Different Type of Insulation

Class of Insulation A Class E Class B Class F Class H Class Temperature 105 Degree c 120 Degree c 130 Degree c 155 Degree c 180 Degree c Application Used for transformer Used for coils Used for motors Used for motors Used for motors

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SUBSTATION

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Introduction
Electrical energy management system ensures supply of energy to every consumer at all times at rated voltage, frequency and specified waveform, at low cost and minimum environmental degradation. The switchgear, protection and network automation are integral parts of the modern energy management system and national economy. Modern 3 phase 50 Hz AC interconnected system has several conventional and nonconventional power plants, EHV-AC and HVDC transmission system, back to back HVDC coupling stations, HV transmission network, substations, MV and LV distribution systems and connected electrical loads. To fulfil these requirements, state of art, scientifically and technological advanced substation is required. The substation at GHTP has one 220KV switchyard. There are 4 input units, 2 having a capacity of 210 MW each and the other 2 have capacity of 250 MW each. The generated voltage is limited to 15.75 KV and 16.5 KV which is stepped up to 220 KV via generating transformer manufactured by BHEL. A part of 15.75/16.5 KV supply is fed to unit auxiliary transformer, which is used to run the auxiliaries of the plant. After step up, the 220 KV output from the generator transformer is fed to either of the two bus bars through relays and circuit breakers and these are connected to various feeders through various equipment.

What is an Electrical Substation?

Electric power is generated in power stations and transmitted to various cities and towns. An electrical substation is a subsidiary station of an electricity generation, transmission and distribution system where voltage is transformed from high to low or the reverse using transformers. Electric power may flow through several substations between generating plant and consumer and may be changed in voltage in several steps.

Elements of a substation
Substations generally have switching, protection and control equipment and one or more transformers. In a large substation, circuit breakers are used to interrupt any short circuit or overload currents that may occur on the network. Smaller distributions stations may use reclose circuit breakers or fuses for protection of distribution circuits. Substations do not usually have generators, although a power plant may have a substation nearby. Other devices such as power factor correction capacitors and voltage regulators may also be located at a substation.

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 Transmission substation
A transmission substation connects two or more transmission lines. The simplest case is where all transmission lines have the same voltage. In such cases, the substation contains high-voltage switches that allow lines to be connected or isolated for fault clearance or maintenance. A transmission station may have transformers to convert between two transmission voltages, voltage control/power factor correction devices such as capacitors, reactors or static VAR compensators and equipment such as phase shifting transformers to control power flow between two adjacent power systems. Transmission substations can range from simple to complex. A small "switching station" may be little more than a bus plus some circuit breakers. The largest transmission substations can cover a large area (several acres/hectares) with multiple voltage levels, many circuit breakers and a large amount of protection and control equipment (voltage and current transformers, relays and SCADA systems). Modern substations may be implemented using international standards such as IEC Standard 61850.

Distribution substation
A distribution substation transfers power from the transmission system to the distribution system of an area. It is uneconomical to directly connect electricity consumers to the main transmission network, unless they use large amounts of power, so the distribution station reduces voltage to a value suitable for local distribution. The input for a distribution substation is typically at least two transmission or sub transmission lines. Input voltage may be, for example, 115 kV, or whatever is common in the area. The output is a number of feeders. Distribution voltages are typically medium voltage, between 2.4 kV and 33 kV depending on the size of the area served and the practices of the local utility. The feeders run along streets overhead (or underground, in some cases) and power the distribution transformers at or near the customer premises. In addition to transforming voltage, distribution substations also isolate faults in either the transmission or distribution systems. Distribution substations are typically the points of voltage regulation, although on long distribution circuits (of several miles/kilometres), voltage regulation equipment may also be installed along the line. The downtown areas of large cities feature complicated distribution substations, with highvoltage switching, and switching and backup systems on the low-voltage side. More typical distribution substations have a switch, one transformer, and minimal facilities on the lowvoltage side.

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Outgoing lines of substation at GHTP

1.) 220 KV line Barnala Himmatpura Bathinda Mansa Bajakhana

2.) 66 KV line Vikram cement factory Phul Lehra mohabbat Bhucho mandi Bhairupa Rampura Ballianwali Nathana

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Brief description of all outdoor equipments

1.) Bus bars

Bus bar is a term used for main bar of conductor carrying an electric current to which many connections are made. These are mainly convenient means of connecting switches and other equipment into various arrangements. At GHTP there are two 220KV bus bars and two 66KV bus bars which are made of aluminium. All incoming and outgoing supplies are connected through the bus bars.

Specifications
Minimum short circuit current in bus bars 40KV Minimum phase to phase clearance 2.5m Number of horizontal levels of tubular bus bar/flexible bus bars 2 Height of tubular bus bar of first level above ground 6m Height of tubular bus bar of second level above ground 4m Tubular aluminium bus bar AL ASTMB241 4IPS(international pipe standard)

2.) Power transformer

These are used to step up/down the voltage from one ac voltage to another ac voltage level at the same frequency. In GHTP there are 2 power transformers located in substation which converts 220KV to 66KV of power 100 MVA each.

3.) Indicating and Metering Instruments

Ammeters, voltmeters, wattmeters, KWhr meters and KVar meters are installed in substation to work over the currents flowing in the circuits and the voltages and the power loads.

4.) Circuit breaker

These are mechanical devices designed to close and open contact or electrical circuit under normal or abnormal conditions. CB is equipped with a strip coil directly attached to relay or other means to operate in abnormal conditions such as overpower.
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 In GHTP 3 types of CB are used: SF6 CB is used to control 220KV in switchyard. Vaccum CB is used to control 6.6KV in switchgear . Air blast CB are used to control 415V in switchgear. A CB is an automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and by interrupting continuity to immediately discontinue electrical flow. Unlike a fuse, which operates once and then has to be replaced, a circuit breaker can be reset either manually or automatically to resume normal operation. Circuit breakers are made in varying sizes, from small devices that protect household appliances to large switchgear designed to protect the high voltage circuits feeding an entire city. Once a fault is detected, contacts within the circuit breaker must open to interrupt the circuit. When the fault is cleared, the contacts must again be closed to restore power to the interrupted circuit. Small CB may be manually operated; larger units have solenoids to trip the mechanism. The CB contacts must carry the load current without excessive heating and mus talso withstand the heat of the arc produced when interrupting the circuit. Contacts are made of copper or copper alloys, silver alloys and other materials.

5.) Capacitor bank

A capacitor bank is a grouping of several identical capacitors interconnected in parallel or in series with one another. These groups of capacitors are typically used to correct or counteract undesirable characteristics, such as power factor lag or phase shift inherent in
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alternating current (AC) electrical power supplies. Capacitor banks may also be used in direct current (DC) power supplies to increase stored energy and improve the ripple current capacity of the power supply.

Transformer yard
1.) Generator transformer
The generator transformer is the first essential component for energy transmission, allowing energy supplied by the generator to be transferred to the network at the required voltage. To transmit power to various stations, we have to step down current because there are I2r losses in transmission line. To do this, generator transformer is used. Power from each generator is stepped up to 220KV by 250/315MVA 50 Hz 3phase 15.75/220 or 16.5/220 KV generator transformer with off load tap changer. There is one Generator transformer for each unit.

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SPECIFICATIONS:3-phase, 50-Hz Design Ambient temp. 50(Celsius) Insulation level HV: 950 KV LV: 125 KV Cooling type Rating HV (MVA) Rating LV (MVA) No Load Voltage HV (KV) Line Current HV (Amp) Line Current LV (Amp) Temp. rise oil (Celsius) Temp.rise winding(Celsius) Oil Quantiy 314.15 4587.5 ONAN 125 125 ONAF 180 180 230 452.37 6606 45 50 54000 litres 628.3 9175.15 OFAF 250 250

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2.) Station transformers

In general station transformer is used for supplying power to auxiliary equipment in the power plant when the plant is not generating any power. Station Transformer takes power grid at 220KV and steps it down to 6.6 KV. Rated KVA corresponds to the load of common auxiliaries of the station. This corresponds to the 10% to 15% of the rating of the generating power. These transformers are outdoor type.

Particulars Make Ratings(KVA) Volts on no load(KV) HV LV Ter. Amperes HV LV Ter. Phase Frequency(Hz) Type of cooling Total mass(kg) Temp. Rise in oil/wdg. Year of manufacture

Specifications Bharat Bijlee ltd. Bombay 20000/31500 220000 6900 6900 52.5/82.7 1674/2636 558/879 3 50 ONAN/ONAF 46000 45degC/50degC 1996

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3.) Unit Auxiliary Transformer

The purpose of unit auxiliary transformer is to feed power to generator auxiliaries of that unit. These transformers are connected to generators and are used as stepping down transformers. The HV side transformer voltage corresponds to the voltage of the generating unit and the LV side voltage is stepped down to 6.6KV. Rated KVA of unit auxiliary transformers is approximately 15% of the generating rating. Usually these transformers are outdoor transformers. One unit auxiliary transformer is present for every generating unit.

Particulars Make Type of cooling Rating No load voltage HV LV Full load current HV LV Temp. rise of oil Temp. rise of wdg. Phase Frequency(Hz) Weight of oil filling Total weight Oil quantity Year of manufacture

Specifications APEX Ltd. ONAN 15000 KVA 15.75 KVA 6.9 KVA 549.9 A 1255.1 A 45 degC 50 degC 3 50 7120 kg 32420 kg 8000 ltr. 1996

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Desirable properties of coal for generation purposes:

High calorific value Small sulphur content(less than 1%) Good burning characteristics for complete combustion High grind ability index High weather ability

Grading of coal is done on the following basis:

Heating value Size Ash content Sulphur content Ash softening temperature

The coal used at GHTP is of bituminous and sub-bituminous type and this is received from some collieries of M.P. and Bihar.

The designated composition of coal is as below: Type Net calorific value Moisture content in coal Ash content Volatile matter Grind ability index Bituminous coal 4300 Kcal/kg 10% 30% 24% 50 hard groove

Coal storage is required for 30 days.

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Various stages are followed before combustion of coal in the boiler. These are:

Delivery of coal
Raw coal is supplied by rail wagons. Each wagon has 51 tonnes of coal.

Unloading of coal
Unloading of coal at thermal power station is done by using wagon tippler arrangement. It is most efficient and economical method till date. The wagon containing coal is fastened onto the platform of the wagon tippler and tilted at an angle of 118 degrees and the coal is emptied into the hopper.

Preparation of coal
Coal undergoes various stages or processes before feeding to combustion chamber to convert it to proper size so that it maximum energy can be obtained from it and proper sizing also helps in storage. Various processes are: Crushing Sizing Drying Separation of impurities

Transfer of coal
Means carrying coal from unloading point to the storage site where it is discharged to the firing equipment. It can be done by using following arrangements: Belt conveyors Screw conveyors Bucket conveyors Skip hoists Flight conveyors

All above mentioned processes are carried out in a thermal power station at Coal Handling Plant

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COAL HANDLING PLANT

All the processes done on the coal before feeding it to the combustion chamber are carried out at the coal handling plant. Major auxiliaries of CHP are:

1.) Wagon tippler

These are the giant machines having gear boxes and motor assembly and are used to unload the coal wagons into coal hoppers in very less time (e.g. 20 wagons/hr. or more). At wagon tippler each wagon is taken to the platform and then is automatically clamped during operation and tilted at an angle of 118 degrees. Thus in this way wagons are unloaded in the hoppers.

2.) Storage area

Storage is divided into 2 categories: Dead storage Live storage

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3.) Conveyor belts

These are the synthetic rubber belts which move on metallic rollers called idlers and are used for shifting of coal from one place to other places. Belt capacity Belt width Belt speed Troughing angle 1000 tonnes/hr 1200 mm 2.8m/s 20 degs.

4.) Trippers These are the motorised or manually operated machines and are used for feeding the coal to different coal bunkers as per their requirement. 5.) Electromagnetic Separators Electro magnets are used for removal of iron and magnetic impurities from coal. 6.) Dust Extraction System This system is provided in CHP for suppression of coal dust in coal handling plant. 7.) Gas Extractors Gas extractor are provided at the bunker level to remove all types of poisonous and non-poisonous gases from the working area.

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8.) Coal Crusher

We receive the coal in the form of odd shaped lumps. These lumps are to be crushed to required size. These lumps are crushed by coal crushers.

Capacity of crushers at G.H.T.P. Primary crusher 1000T/hr Secondary crusher 1000T/hr

Operational Cycles
1. Normal Bunkering Cycle Shifting of coal received from coal wagons directly to coal bunkers is normal bunkering cycle. 2. Stacking Cycle When there is no coal requirement at coal bunkers even then CHP has to unload the received coal which is stacked at open ground called yard. This is stacking cycle. 3. Reclaiming Cycle As and when coal wagons are not available the requirement of coal bunkers is fulfilled from the stacked coal this is reclaiming cycle.

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Coal Stacking and Reclaiming

Stackers/reclaimer Stacking Reclaiming Stack height Stacker travelling length 2 Nos. 1000 Tonnes/hr 1000 tonnes/hr 10 m 410 m

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G.H.T.P MAIN CONTROL ROOM

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ANALYSIS OF G.H.T.P.

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YEAR WISE GENERATION(In MUs)

Year
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11
8000 7000 6000 5000 4000 3000 2000 1000 0

Generation
3309.244 3145.915 3443.172 3642.629 5610.091 7515.158 6833.087
7515.158 6833.087 5610.091

3309.244

3145.915

3443.172

3642.629

2004-2005

2005-2006

2006-2007

2007-2008

2008-2009

2009-2010

2010-2011

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PLANT LOAD FACTOR

120 100 81.35 80 60 40 20 0 91.63 89.94 83.56 78.98 93.58 85.51 95.1 95.99 96.44 84.79

87.71

THERMAL EFFICIENCY(%)
38.5 38 37.5 37 36.5 36 35.5 35 34.5 2003-2004 2004-2005 2005-2006 2006-2007 2007-2008 2008-2009 2009-2010 2010-2011 35.82 36.99 37.76 37.13 37.16 37.94

36.13 35.73

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NO. OF TRIPPING
60 52 50 40 30 20 10 0 17 20 21 17 36 36 52

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15

AUXILIARY CONSUMPTION(%) NET

9.5 9.11 9 8.5 8 7.5 7 6.5 8.95 8.9 8.95 8.91

8.32 7.83 7.81 7.83

7.74

7.73

7.67

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HIGHLIGHTS OF PERFORMANCE OF G.H.T.P. DURING 2010-2011

GHTP, Lehra Mohabbat has been awarded First National Energy Conservation Award 2010 (First prize at National level) by Honble Power Minister of India on 14th December 2010. Lowest ever annual Auxiliary Consumption: 7.67% (as in year 2010-2011). Stage-II units have achieved 96 days of its longest ever continuous run from 26.12.2010 to 01.04.2011 without any tripping surpassing the previous record of 74.87 days from 04.02.2010 to 20.04.2010. Stage-I units have achieved their longest ever continuous run of 96.2 days from 03.01.2010 to 09.04.2010 without any tripping surpassing the previous record of 93.49 days from 28.08.2008 to 29.11.2008. Unit 3 has achieved 108 days of its longest ever continuous run after capital over haul from 14.12.2010 to 01.04.2011 without any interruption.

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ACHIEVEMENTS OF GHTP DURING 2011-2012

Achievements of Yearly Generation Previous best
Highest ever annual generation at GHTP Highest ever annual generation on Stage-I Highest ever annual PLF on Stage-I Highest ever annual deemed generation at GHTP Highest ever annual deemed PLF at GHTP 7621.26 MU 3562.12 MU 96.55% 8006.40 MU 7515.16 MU (2009-10) 3531.71 MU (2008-09) 95.99% (2008-09) 7583.32 MU (2009-10)

99.07%

97.53% (2009-10)

Achievements of monthly Generation Previous best

Highest ever monthly generation on Unit-1 Highest ever monthly PLF on Unit-1 Highest ever monthly generation on Unit-3 Highest ever monthly PLF on Unit-3 Highest ever monthly generation on Unit-4 Highest ever monthly PLF on Unit-4 Highest ever monthly generation on Stage-II Highest ever monthly PLF on Stage-II 162.47 MU (Oct-11) 161.93 MU (Mar-10)

103.99% (Oct-11) 194.86 MU (Oct-11)

103.64% (Mar-10) 192.01 MU (Mar-10)

104.76% (Oct-11) 193.73 MU (Oct-11)

103.23% (Mar-10) 190.23 MU (Mar-10)

104.15% (Oct-11) 388.59 MU (Oct-11)

102.27% (Mar-10) 382.24 MU (Mar-10)

104.46% (Oct-11)

102.75% (Mar-10)

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Achievements in maintenance of units

Lowest ever annual planned Maintenance at GHTP 1.90% Previous best 2.32% (2009-10)

The annual maintenance & 1st inspection of Generator of Unit 4 has been completed in 25.66 days against approved shut down of 30 days thereby bringing the unit 4.34 days ahead of schedule which has resulted into an extra generation of 260 LU.

Achievements in performance
Lowest ever annual Heat Rate (Kcal/KWH): 2402 Lowest ever annual auxiliary consumption 7.87% Lowest ever annual DM Water make up of four units Lowest ever monthly auxiliary Consumption Lowest ever monthly DM water Make up of four units Highest ever monthly plant Utilisation factor 0.69% Previous best 2417 (2010-11) 8.08% (2010-11) 0.79% (2010-11)

7.35% (Feb-12)

7.37% (Jan-12)

0.58% (Mar-12)

0.61% (Feb-12)

104.30%(Oct-11)

103.21%(Mar-10)

Average monthly PLF remained more than 100% during second half of the year 2011-12.

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Achievements in continuous run of units

Unit 1 has run continuously for 129.64 days without any tripping w.e.f. 20.07.2011 to 27.11.2011. It was the 6th time that unit-1 crossed 100 days of its continuous run. GHTP Unit-3 has achieved its longest ever continuous run of 158.09 days from 14.12.2010 to 21.05.2011 without any tripping surpassing its previous record of 121.08 days from 04.02.2010 to20.04.2010. Unit -4 has achieved its longest ever continuous run of 114.01 days from 26.12.2010 to 19.04.2011 without any tripping surpassing its previous record of 74.87 days from 04.02.2010 to 20.04.2010. Stage-II units have achieved their longest ever continuous run of 114.01 days from 26.12.2010 to 19.04.2011 without any tripping surpassing its previous record of 74.87 days from 04.02.2010 to 20.04.2010.

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AWARDS AND INCENTIVES WON BY GHTP

GHTP, Lehra Mohabbat has been awarded First National Energy Conservation Award 2010 (First prize at National level) by Honble Power Minister of India on 14th December 2010. Gold Shield for the Year 2003-04. Presented by Honble President of India for Outstanding Performance. Silver Shield for the Years 2000-01, 2001-02 for good Performance. Presented by Honble Power Minister, Government of India. Bronze Shield for the Year 2004-05. Presented by Honble Prime Minister of India for Outstanding Performance. Certificate of Merit for years 2001, 2002 & 2003 for reduction in Specific Secondary Fuel Oil consumption. Certificate for Meritorious performance for the year 2002-03 for Meritorious Performance Awarded by Honble Power Minister, Government of India. Silver Medal for the Year 1999-2000. Meritorious Productivity Award for the year 1999-2000. Incentive Award for the calendar year 2000, for reduction in the secondary oil consumption. Incentive Award for the calendar year 2000, for reduction in the Auxiliary consumption.

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POLLUTION CONTROL DEVICES

Following Pollution Control devices have been provided at GHTP, Lehra Mohabbat: 1. ESP of 99.864 % efficiency has been provided with each unit to keep the atmosphere pollution within permissible limits. Punjab State Electricity Board is very particular about providing effective pollution control measures so that environment remains healthy. 2. 220 Mts. high RCC Multi Flue Chimneys. 3. Dust suppression system consisting sprinkling of water to check the fugitive emissions. 4. Dust Extraction System consisting of Cyclone Separators & Bag Fillers to arrest coal dust.

AIR POLLUTION MONITORING STATIONS

ON LINE MONITORS have been provided on the Chimneys to monitor the suspended particulate matter, Oxides of Nitrogen and Sulphur and the results are monitored regularly. Four Ambient Air Stations have been fixed at the following locations: 1. GHTP Field Hostel

2. Village Lehra Mohabbat 3. Patti Karam Chand, (Village Mehraj) 4. Village Lehra DhurKot

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DRY ASH UTILISATION

Huge quantity of Ash generated is a major cause of concern for GHTP management. Therefore, a target has been fixed to use 100% ash generated by the Thermal Plant. To encourage utilization of fly ash, Ash is being supplied to M/s Gujrat Ambuja and M/s Vikram cement units and other various medium and small cement grinding units in Punjab, HP and J&K free of cost.

Ash silo-Dry: Dry fly ash collection

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FUTURE PROPOSAL

The power station is operated by Punjab Electricity Board. The project comprises of 2 phases and a third phase is proposed.

Project details of phase III

Sponsor: Punjab State Power Corporation Name Plate Capacity: 500 MW

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CONCLUSION
The phase of summer training has proved to be quiet fruitful. It provided an opportunity for encounter with such huge machines like wagon tippler, turbines, generators etc. The architecture of the plant, the way various units are linked and the way working of whole plant is controlled make the student realize that engineering is not just learning the structured description and working of various machines, but the greater part is of planning proper management. It also provides an opportunity to learn how technology used at proper place and time can save a lot of labour e.g wagon tippler (CHP). In short summer training has proved to be quite beneficial. It has allowed an opportunity to get an exposure of the practical implementation to theoretical fundamentals.

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REFERENCES
Generation of electrical energy by B.R. GUPTA A Textbook on Power System Engineering by A. Chakrobarti & M.L.Soni A course in Power Systems by J.B. Gupta www.pseb.gov.in/docs/lehra mohabbat Wikipedia www.google.co.in Tribune newspaper

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