1.

INTRODUCTION TO IPGCL & PPCL

Life depends on energy; energy is a source that can neither be created nor
destroyed. It merely changes its shape and form, when captured energy generates
power. To supply power to the citizens of Delhi, earlier it was Delhi Electric Supply
Undertaking(DESU) which was formed in 1958 which was subsequently converted
into Delhi Vidyut Board (DVB) w.e.f. 24.02.97.DVB was split into 6 companies, viz.,
BSES Rajdhani Power Limited, BSES Yamuna Power Limited, North Delhi Power
Limited, Delhi Transco Limited, Indraprastha Power Generation Company Limited,
and Delhi power Company Limited .

1.1 PPCL
To bridge the gap between demand and supply and to have reliable supply to
capital city a 330 MW combined cycle gas turbine power project was set up on fast
track basis. This plant consists of 2 *104 MW frame 9-E gas turbine units
commissioned in 2002-03 and 1 *122 MW steam gas units commissioned in 2003-
04. Gas supply has been tied up with GAIL through HBJ pipeline.

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1.2 BRIEF HISTORY OF THE POWER PLANT
A contract was signed with BHEL for installation of 330 MW gas-based power
plant in the vicinity of 220V, I.P extension. The station is comprised of 2*104MW gas
turbine of GT- frame 9E and 1*122MW steam turbine. The waste heat emanating
from gas turbine is being utilized to generate 122MW power through steam turbine.
The hot gases of 560 degree C with a mass flow of approx. 14000 metric ton per
hour is passed through 0.2 no’s waste heat recovery boiler to generate steam.
The environmentally friendly quality power generation through this station is pumped
to 220KV substation of DELHI Transco limited and entire power is being utilized by
citizen of DELHI.

1.3 PLANT OVERVIEW

PPCL combine cycle power plant uses both steam and gas to generate
power. These combine cycle plants produced higher energy conversion efficiency
than gas or steam alone plants. In PPCL a gas turbine generator generates
electricity and waste heat is used to make the steam to make additional electricity via
steam turbine, the last step enhances the efficiency of electricity generator. Typically,
combine cycle power plants utilizes heat from the gas turbine to generate steam. In
combine cycle power plant, the heat of the gas turbine exhaust is used to generate
steam by passing it through heat recovery steam generator (HRSG) with live
temperature between 420 degree C and 580-degree C. In case of gas turbine
Brayton cycle is used and Rankine cycle is used in case of steam turbine. Electronic
mark-5 processor is used in case of both GT-1 and GT-2.

CAPACITY OF GT 1 = 104MW
CAPACITY OF GT 2 = 104MW
CAPACITY OF STG = 122MW
TOTAL CAPACITY= 330MW

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1.4 FUEL
The primary fuel for gas turbine is natural gas supplied by GAIL through HBJ
pipeline. The gas is received at GAIL terminal installed in the vicinity of power
station. The GAIL is committed to supply 1.75 MCMD gas on daily basis. The
calorific value of natural gas received for power generation is in the band of 8200-
8500 kilocalories.
The secondary fuel of gas turbine is HSD/NAPTHA which is to be used only in the
case when no supply of gas is available. De-mineralized water is injected to control
NOx while machine is operated in liquid fuel.

1.5 RAW WATER

Raw water requirement is met through sewage treated water being drawn
mainly from DELHI gate sewage treated plant. the DM water requirement for steam
generation is met up through sewage treated water by treating this through reverse
osmosis (RO) de mineralized process.

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 2. INTRODUCTION TO GAS TURBINE

2.1 Introduction
The gas turbine is a common form of heat engine working with a series of
processes consisting of compression of air taken from atmosphere, increase of
working medium temperature by constant pressure ignition of fuel in combustion
chamber, expansion of SI and IC engines in working medium and combustion, but it
is like steam turbine in its aspect of the steady flow of the working medium. It was in
1939, Brown Beaver developed the first industrial duty gas turbine. The output being
4000 KW with open cycle efficiency of 18%. The development in the science of
aerodynamics and metallurgy significantly contributed to increased compression and
expansion efficiency in the recent years.

At PPCL, the GE-Alstom make Gas Turbine (Model 9E) has an operating efficiency
of 31% and 49% in open cycle and combined cycle mode respectively when natural
gas is used as fuel. Today gas turbine unit sizes with output above 250 MW at ISO
conditions have been designed and developed. Thus, the advances in metallurgical
technology have brought with a good competitive edge over conventional steam
cycle power plant.

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2.2 PPCL Gas Turbine Plant
The modern gas turbine plants are commonly available in package form with
few functional sub-assemblies. The 9E model GEC-Alstom package consists of

 Control compartment
 Accessory compartment
 Turbine compartment
 Inlet exhaust system
 Load package
 Generator excitation compartment
 CO2 fire protection unit

Each station component is a factory assembled pre-tested assembly & is housed in

all weather & acoustic proof enclosure

2.3 COMBINED CYCLE

Combine cycle power plant integrates two power conversion cycle-Brayton
cycle (Gas turbine) and Rankine cycle (Steam turbine) with the principal objective of
increasing overall plant efficiency.

2.4 BRAYTON CYCLE

Gas turbine plants operate on this cycle in which air is compressed. This
compressed air is heated in the combustor by burning fuel, where plant of
compressed air is used for combustion and the flue gases produced are allowed to
expand in the turbine, which is coupled with the generator. In modern gas turbines
the temp. of the exhaust gases is in the range of 500 °C to 550 ° C

2.5 COMBINING TWO CYCLES TO IMPROVE EFFICIENCY

We have seen in the above two cycles that exhaust is at temperature of 500-
550 °C and in Rankine cycle heat is required to generate steam at the temperature
of 500-550 °C. Therefore, gas turbine exhaust heat can be recovered using a waste
heat recovery boiler to run a steam turbine on Rankine cycle. If efficiency of gas
turbine cycle (when natural gas is used as fuel) is 31% and the efficiency of Rankine
cycle is 35%, then overall efficiency comes to 49%. Conventional fossil fuel fired
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boiler of the steam power plant is replaced with a heat recovery steam generator
(HRSG). Exhaust gas from the gas turbine is led to the HRSG where heat in exhaust
gas is utilized to produce steam at desired parameters as required by the steam
turbine.

2.6 ADVANTAGES OF GAS TURBINE PLANT

Some of the advantages are quite obvious, such as fast operation, minimum
site investment. Low installation cost owing to standardization, factory assembly and
test. This makes the installation of the station easy and keeps the cost per installed
kilowatt low because the package power station is quickly ready to be put in
operation. Site implementation includes one simple and robust structure to get unit
alignment.

Transport: Package concept makes easier shipping, handling, because of its

robustness. Low standby cost: fast start up and shut down reduce conventional
stand by cost. The power requirements to keep the plant in standby condition are
significantly lower than those for other types of prime movers.

Maximum application flexibility: The package plant may be operated either in

parallel with existing plants or as a completely isolated station. These units have
been used, widely for base, peaking and even emergency service. The station can
be equipped with remote control for starting, synchronizing & loading.

Control reliability: the microcomputer-based control, with an integrated temperature

system (ITS) provides accurate control, quick protection and complete sequential
startup & shut down & operation. Maintenance Cost is comparatively low.

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 3. PPCL POWER PLANT: CONTROL SYSTEM

3.1 BRIEF DESCRIPTION OF THE POWER PLANT SYTEM

The basic functional sub-assemblies of GT Power Plant Control system are:

 Control compartment
The control compartment contains the equipment needed to provide control
indication and protection functions. Arrangement can be made for manual operation
or for remote unattended operation. The control compartment is located at central
control room with control interface of turbine control panel, generator control panel,
batteries and battery charger.

 Accessory compartment
The accessory compartment, contains the mechanical and control elements
necessary to allow the gas turbine to be a self, contained operational station. The
major components located in the accessory compartment are the lubricating oil
system and reservoir, lube oil cooler, starting means, accessory gear fuel system,
turbine gauge panel, hydraulic system and atomizing air system, water system,
cranking motor exhaust frame blowers (88TK- 1, 88 TK-2.)

 Turbine compartment
The gas turbine has a 17-stage axial compressor. The compressor rotor consists of
individual discs for each stage, and is connected by through bolts to the forward and
aft stub shafts. The turbine rotor consists of three stages, with one wheel for each
bucket stage. The turbine rotor wheels are assembled by through bolts similar to the
compressor, and with two spacers, one between the first and second stage wheels,
and the other between the second and the third stage wheels.

The entire stator stages utilize precision cast, segmented nozzles, with the 2nd and
3rd stage segments supported from the stationary shrouds. This arrangement
removes the hot gas path from direct contact with the turbine shell.
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The turbine rotor stages also have precision cast, long shank buckets (air foils on the
compressor wheels are called blades, those on turbine wheels are called buckets)
and this feature effectively shields the wheel rims and bucket dovetails from the high
temperature of the main gas steam. The gas turbine unit and shells are split and
flanged horizontally for convenience of disassembly. Compressor discharge air is
contained by the discharge casing, combustion wrapper, and turbine shell. The 14
combustion liners are mounted completely inside the combustion wrapper, which
eliminates the need for combustion cans.

 Inlet and exhaust system

The inlet arrangement includes inlet air filters, silencing, ducting and trash screens to
protect the compressor from debris. The inlet arrangements generally come out from
the back of the inlet air house, over the control and accessory compartments, and
down to the inlet plenum, which is mounted on the turbine base. The exhaust
arrangement includes the ducting, silencing, and necessary expansion joints. The
exhaust gases exit from the side to exhaust plenum, which is mounted separately on
its own base, and are directed straight out to the exhaust arrangement.

 Load package
The load package consists of an air-cooled, synchronous generator and associated
equipment. The generator also has roof-mounted terminals for outgoing leads. An
air-cooled open ventilation of generator and associated equipment’s can be used in
the load compartment

 Fire protection unit

The fire protection system consisting of on base piping, detectors etc. capable of
distributing a fire extinguishing agent (CO2, or Halon) in all the compartments of the
gas turbine and local control room. The bulk of fire extinguishing agent stage unit is
located near gas turbine with one main CO2 skid.

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  OPERATION

The package plant has been designed to provide maximum operational flexibility and
simplicity. The actual operating sequence can be best understood by considering the
four basic operating modes: Stand By, Start, Run and Shutdown.

 Stand by

During stand by, each component must be maintained in a state, which allows for
immediate startup operation if needed.
All the station components that are affected by low temperature or moisture are fully
protected during stand by. The lubricating oil and the control compartment are
maintained at a minimum temperature. The batteries are kept fully charged and
heated. Turbine compartment is also maintained hot.

 Starting the unit

Start-up can be ordered either remote or from the control compartment. (LCR) The
starting sequence is given below: The starting system consists of an induction motor
and torque converter coupled to the accessory gear. The staring system is energized
and connected to the turbine up to the value from which Turbine becomes self-
sustaining. At about 12% normal speed, fuel is injected and ignited. To avoid thermal
shocks in hot parts of turbine, the unit is accelerated under acceleration mode after a
short Warm-up period. When the turbine becomes self-sustaining, the gas turbine
speeding up continues, but the starting system (Cranking motor) is automatically
made off at 60% speed.

 Running

The operator at either the local or remote station has the option of holding the station
at spinning reserve, or loading to a point, or running under maximum load exhaust
temperature control. The load can be varied manually over the entire load range.

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  Shut down

Upon initiation of a normal shut down signal, either locally or remotely, the following
events occur:
1. The generator load is gradually reduced to zero.
2. The generator breaker is opened.
3. The fuel supply is reduced & then is shut off.
4. The gas turbine coasting down to rest.

The starting system components also provide slow speed rotation of the turbine for
cool down purposes after shut down. A crank and restart can be initiated at any time
below 10% speed & can also be started above 95% speed.

3.2 GAS TURBINE EQUIPMENT DATA SUMMARY

COMPRESSOR SECTION

Number of compressor stages Seventeen

Compressor type Axial flow, heavy duty

Inlet guide vanes Modulated

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TURBINE SECTION

Three
Number of turbine stages

Casing splits
Horizontal

Nozzles Fixed area

COMBUSTION SECTION

Type 14 multiple combustors, reverse flow design

Fourteen
Fuel nozzles One per combustion chamber i.e. (one for gas & one for
liquid)
Spark plugs Two electrode type, spring-injected self-retracting.
Flame Four, ultra-violet type
detectors

3.3 STARTING SYSTEM

Starting device Electrical starting motor 1 MW drive Torque converter Hydraulic with
adjustor drive Fuel pump Accessory gear-driven, Continuous output screw type
pump Gas stop ratio & control valve Electro hydraulic servo-control

3.4 CONTROL SYSTEM

SPEEDTRONIC MARK IV control system

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 4. Mechanical Equipment’s

4.1 Heat recovery steam generator

A heat recovery steam generator or HRSG is an energy recovery heat
exchanger that recovers heat from a hot gas stream. It produces steam that can be
used in a process or used to drive a steam turbine. This combination produces
electricity more efficiently than either the gas turbine or steam turbine alone. The
HRSG is also an important component in cogeneration plants. Cogeneration plants
typically have a higher overall efficiency in comparison to a combined cycle plant.
This is due to the loss of energy associated with the steam turbine.

The HRSG at PPCL

4.2 Evaporator Section

The most important component would, of course, be the Evaporator Section.
So, an evaporator section may consist of one or more coils. In these coils, the
effluent (water), passing through the tubes is heated to the saturation
point for the pressure it is flowing.

4.3 Superheater Section

The Superheater Section of the HRSG is used to dry the saturated vapor
being separated in the steam drum. In some units it may only be heated too little
above the saturation point where in other units it may be superheated to a significant
temperature for additional energy storage. The Superheater Section is normally
located in the hotter gas stream, in front of the evaporator.

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4.4 Economizer Section
The Economizer Section, sometimes called a preheater or preheat coil, is
used to preheat the feedwater being introduced to the system to
replace the steam (vapor) being removed from the system via the superheater or
steam outlet and the water loss through blowdown. It is normally located in the
colder gas downstream of the evaporator. Since the evaporator inlet and outlet
temperatures are both close to the saturation temperature for the system pressure,
the amount of heat that may be removed from the flue gas is limited due to the
approach to the evaporator, whereas the economizer inlet temperature is low,
allowing the flue gas temperature to be taken lower.

The steam turbine-driven generators have auxiliary systems enabling them to work
satisfactorily and safely. The steam turbine generator being rotating equipment
generally has a heavy, large diameter shaft. The shaft therefore requires not only
supports but also has to be kept in position while running. To minimize the frictional
resistance to the rotation, the shaft has a number of bearings. The bearing shells, in
which the shaft rotates, are lined with a low friction material like Babbitt metal. Oil
lubrication is provided to further reduce the friction between shaft and bearing
surface and to limit the heat generated.

4.5 Condenser
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. Such condensers use steam ejectors or rotary motor-driven
exhausters for continuous removal of air and gases from the steam side to maintain
vacuum.

A typical water-cooled condenser

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.
Since the condenser temperature can almost always be kept significantly below 100
C where the vapor pressure of water is much less than atmospheric pressure, the

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condenser generally works under vacuum. Thus, leaks of non-condensable air into
the closed loop must be prevented.

4.6 Deaerator

A steam generating boiler requires that the boiler feed water should be devoid
of air and other dissolved gases, particularly corrosive ones, in order to avoid corrosion
of the metal. Generally, power stations use a deaerator to provide for the removal of
air and other dissolved gases from the boiler feedwater. A deaerator typically includes
a vertical, domed deaeration section mounted on top of a horizontal cylindrical vessel
which serves as the reaerated boiler feedwater storage tank.

A typical water-cooled condenser

4.7 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 rely
solely on air to cool the working fluid to near the dry-bulb air temperature. The towers
vary in size from small roof-top units to very large hyperboloid structures that can be
up to 200 meters tall and 100 meters in diameter, or rectangular structures that can
be over 40 meters tall and 80 meters long. Smaller towers are normally factory-built,
while larger ones are constructed on site.

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 5. Electrical Equipment’s

5.1 Generator
At PPCL 3000 rpm, 50 Hz generators are used of capacities 122 MW. As the system
load demands more active power from the generator, more steam (or fuel in a
combustion turbine) needs to be admitted to the turbine to increase power output.
Hence more energy is transmitted to the generator from the turbine, in the form of a
torque. This torque is mechanical in nature, but electromagnetically coupled to the
power system through the generator. The higher the power output, the higher the
torque between turbine and generator. The power output of the generator generally
follows the load demand from the system. Therefore, the voltages and currents in the
generator are continually changing based on the load demand. The generator design
must be able to cope with large and fast load changes, which show up inside the
machine as changes in mechanical forces and temperatures. The design must
therefore incorporate electrical current-carrying materials (i.e., copper), magnetic
flux-carrying materials (i.e., highly permeable steels), insulating materials (i.e.,
organic), structural members (i.e., steel and organic), and cooling media (i.e., gases
and liquids), all working together under the operating conditions of a turbo generator.

OPEN TYPE GENERATOR

Since the turbo generator is a synchronous machine, it operates at one very

specific speed to produce a constant system frequency of 50 Hz, depending on the
frequency of the grid to which it is connected. As a synchronous machine, a turbine
generator employs a steady magnetic flux passing radially across an air gap that exists
between the rotor and the stator. (The term “air gap” is commonly used for air- and
gas-cooled machines). For the machines in this discussion, this means a magnetic
flux distribution of two or four poles on the rotor. This flux pattern rotates with the rotor,
as it spins at its synchronous speed. The rotating magnetic field moves past a three-
phase symmetrically distributed winding installed in the stator core, generating an
alternating voltage in the stator winding. The voltage waveform created in each of the
three phases of the stator winding is very nearly sinusoidal. The output of the stator
winding is the three-phase power, delivered to the power system at the voltage

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generated in the stator winding.
In addition to the normal flux distribution in the main body of the generator, there
are stray fluxes at the extreme ends of the generator that create fringing flux patterns
and induce stray losses in the generator. The stray fluxes must be accounted for in
the overall design. Generators are made up of two basic members, the stator and the
rotor, but the stator and rotor are each constructed from numerous parts themselves.
Rotors are the high-speed rotating member of the two, and they undergo severe
dynamic mechanical loading as well as the electromagnetic and thermal loads. The
most critical component in the generator is the retaining rings, mounted on the rotor.
These components are very carefully designed for high-stress operation. The
stator is stationary, as the term suggests, but it also sees significant dynamic forces in
terms of vibration and torsional loads, as well as the electromagnetic, thermal, and
high-voltage loading. The most critical component of the stator is arguably the stator
winding because it is a very high cost item and it must be designed to handle all of the
harsh effects described above. Most stator problems occur with the winding.

5.2 STATOR
The stator winding is made up of insulated copper conductor bars that are
distributed around the inside diameter of the stator core, commonly called the stator
bore, in equally spaced slots in the core to ensure symmetrical flux linkage with the
field produced by the rotor. Each slot contains two conductor bars, one on top of the
other. These are generally referred to as top and bottom bars. Top bars are the ones
nearest the slot opening (just under the wedge) and the bottom bars are the ones at
the slot bottom. The core area between slots is generally called a core tooth.

5.3 ROTOR
The rotor winding is installed in the slots machined in the forging main body
and is distributed symmetrically around the rotor between the poles. The winding
itself is made up of many turns of copper to form the entire series connected
winding. All of the turns associated with a single slot are generally called a coil. The
coils are wound into the winding slots in the forging, concentrically in corresponding
positions on opposite sides of a pole. The series connection essentially creates a
single multi-turn coil overall, that develops the total ampere-turns of the rotor (which
is the total current flowing in the rotor winding times the total number of turns). There
are numerous copper-winding designs employed in generator rotors, but all rotor
windings function basically in the same way. They are configured differently for
different methods of heat removal during operation.

5.4 BEARINGS
All turbo generators require bearings to rotate freely with minimal friction and
vibration. The main rotor body must be supported by a bearing at each end of the
generator for this purpose. In some cases where the rotor shaft is very long at the
excitation end of the machine to accommodate the slip/collector rings, a “steady”
bearing is installed outboard of the slip-collector rings.

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 BEARINGS

This ensures that the excitation end of the rotor shaft does not create a wobble that
transmits through the shaft and stimulates excessive vibration in the overall
generator rotor or the turbo generator line. There are generally two common types of
bearings employed in large generators, journal” and “tilting pad” bearings. Journal
bearings are the most common. Both require lubricating and jacking oil systems.
Jacking oil pumps and Lube oil pumps are used for this purpose.

5.5 AUXILIARY SYSTEMS

All large generators require auxiliary systems to handle such things as
lubricating oil for the rotor bearings, hydrogen cooling apparatus, hydrogen sealing
oil, de-mineralized water for stator winding cooling, and excitation systems for field-
current application. Not all generators require all these systems and the requirement
depends on the size and nature of the machine. For instance, air cooled turbo
generators do not require hydrogen for cooling and therefore no sealing oil as well.
On the other hand, large generators with high outputs, generally above 400 MVA,
have water-cooled stator windings, hydrogen for cooling the stator core and rotor,
seal oil to contain the hydrogen cooling gas under high pressure, lubricating oil for
the bearings, and of course, an excitation system for field current. There are five
major auxiliary systems that may be used in a generator. They are given as follows:

1. Lubricating Oil System

2. Hydrogen Cooling System
3. Seal Oil System
4. Stator Cooling Water System
5. Excitation System

5.6 PROTECTION

The protection system of any modern electric power grid is the most crucial
function in the system. Protection is a system because it comprises discrete devices
(relays, communication means, etc.) and an algorithm that establishes a coordinated
method of operation among the protective devices. This is termed coordination. The
key function of any protective system is to minimize the possibility of physical
damage to equipment due to a fault anywhere in the system or from abnormal

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operation of the equipment (over speed, under voltage, etc.). Protective systems are
inherently different from other systems in a power plant. Electric power generators
are most often the most critical electrical apparatus in any power plant.

Protection systems can be divided into systems monitoring current, voltage (at the
machine’s main terminals and excitation system), windings, and/or cooling media
temperature and pressure, and systems monitoring internal activity, such as partial
discharge, decomposition of organic insulation materials, water content, hydrogen
impurities, and flux probes. Protective functions acting on the current, voltage,
temperature, and pressure parameters are commonly referred to as primary
protection. The others are referred to as secondary protection or monitoring devices.
Secondary functions tend to be monitored real time, or on demand. For instance,
hydrogen purity is monitored on-line real time, while water content (for water leaks) is
not. Temperature detectors (RTDs or thermocouples) on bearings (and sometimes in
on windings) may be monitored on-line real time, or they may not. Furthermore,
these functions may more often than not result in an alarm, rather than directly trip
the unit (e.g., core monitors).

To the primary protective functions monitoring currents, voltages, temperatures and

pressures, there can be added the mechanical protective function of vibration.
Typically, it will alarm, but it can also be set to trip the unit. Protections function can
also be divided into short circuit protection functions. The short-circuit protection
comprises impedance, distance, and current differential protection.

5.7 GENERATOR PROTECTIVE FUNCTION

Protection devices are designed to monitor certain conditions, and subsequently, to
alarm or trip if a specified condition is detected. The condition is represented by a
function or protective function code. Thus, there is a relay for every protective
function. A multi-functional relay containing all the protective functions required for
the protection of a generator can be combined with a few discrete relays providing
backup protection for critical functions.
Relays or protection devices are divided into two categories according to how they
process data. The first category is that of analog relays; the second is that of
numerical (also called digital) relays. Bear in mind that a relay can be electronic but
still process the data in an analog manner.

5.8 TRANSFORMER
ANSI/IEEE defines a transformer as a static electrical device, involving no
continuously moving parts, used in electric power systems to transfer power between
circuits through the use of electromagnetic induction. The transformer is one of the
most reliable pieces of electrical distribution equipment.

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 A 220 kV Transformer at a Power Plant

It has no moving parts, requires minimal maintenance, and is capable of withstanding

overloads, surges, faults, and physical abuse that may damage or destroy other items
in the circuit. Transformers are exclusively used in electric power systems to transfer
power by electromagnetic induction between circuits at the same frequency, usually
with changed values of voltage and current. There are numerous types of transformers
used in various applications including audio, radio, instrument, and power.

There are various types of transformers placed in PPCL.

• Generating transformers:10.59KV to 220KV to feed into the line.
• UAT: Unit Auxiliary Transformers: 10.59KV to 6.6KV for plant aux equipment
(only HT equipment)
• Smaller Transformers: 6.6KV to 440V for LT equipment in the plant

All power transformers have three basic parts, a primary winding, secondary winding,
and a core. Even though little more than an air space is necessary to insulate an “ideal”
transformer, when higher voltages and larger amounts of power are involved, the
insulating material becomes an integral part of the transformer’s operation.

5.10 Core
The core, which provides the magnetic path to channel the flux, consists of
thin strips of high-grade steel, called laminations, which are electrically separated by
a thin coating of insulating material. The strips can be stacked or wound, with the
windings either built integrally around the core or built separately and assembled
around the core sections.

Just like another components in. In larger units, cooling ducts are used inside the
core for additional convective surface area, and sections of laminations may be split
to reduce localized losses. The grounding point should be removable for testing
purposes, such as checking for unintentional core grounds. Multiple core grounds,
such as a case whereby the core is inadvertently making contact with otherwise
grounded internal metallic mechanical structures, can provide a path for circulating
currents induced by the main flux as well as a leakage flux, thus creating
concentrations of losses that can result in localized heating.

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5.11 ELECTRIC MOTORS

An electric motor uses electrical energy to produce mechanical energy. The

reverse process that of using mechanical energy to produce electrical energy is
accomplished by a generator or dynamo. Traction motors used on locomotives and
some electric and hybrid automobiles often performs both tasks if the vehicle is
equipped with dynamic brakes.

High Power Electric Motor

Comparison of Motor Types

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5.12 Induction Motor
An induction motor (IM) is a type of asynchronous AC motor where power is
supplied to the rotating device by means of electromagnetic induction.

Three Phase Induction Motors

The basic difference between an induction motor and a synchronous AC

motor is that in the latter a current is supplied onto the rotor. This then creates a
magnetic field which, through magnetic interaction, links to the rotating magnetic field
in the stator which in turn causes the rotor to turn. It is called synchronous because
at steady state the speed of the rotor is the same as the speed of the rotating
magnetic field in the stator. By way of contrast, the induction motor does not have
any direct supply onto the rotor; instead, a secondary current is induced in the rotor.
To achieve this, stator windings are arranged around the rotor so that when
energized with a polyphase supply they create a rotating magnetic field pattern
which sweeps past the rotor. This changing magnetic field pattern can induce
currents in the rotor conductors. These currents interact with the rotating magnetic
field created by the stator and the rotor will turn. However, for these currents to be
induced, the speed of the physical rotor and the speed of the rotating magnetic field
in the stator must be different, or else the magnetic field will not be moving relative to
the rotor conductors and no currents will be induced. If by some chance this
happens, the rotor typically slows slightly until a current is re-induced and then the
rotor continues as before. This difference between the speed of the rotor and speed
of the rotating magnetic field in the stator is called slip. It has no unit and the ratio
between the relative speeds of the magnetic field as seen by the rotor to the speed
of the rotating field. Due to this an induction motor is sometimes referred to as an
asynchronous machine.

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 6. Safety Equipment’s

6.1 DIRECT ON LINE STARTER

A direct on line starter, often abbreviated DOL starter, is a widely-used
starting method of electric motors. The term is used in electrical engineering and
associated with electric motors. There are many types of motor starters, the simplest
of which is the DOL starter. A motor starter is an electrical/electronic circuit
composed of electro-mechanical and electronic devices which are employed to start
and stop an electric motor. Regardless of the motor type (AC or DC), the types of
starters differ depending on the method of starting the motor. A DOL starter connects
the motor terminals directly to the power supply. Hence, the motor is subjected to the
full voltage of the power supply. Consequently, high starting current flows through
the motor. This type of starting is suitable for small motors below 5 hp (3.75 kW).
Reduced-voltage starters are employed with motors above 5 hp. Although DOL
motor starters are available for motors less than 150 kW on 400 V and for motors
less than 1 MW on 6.6 kV. Supply reliability and reserve power generation dictates
the use of reduced voltage or not.

Direct On Line Starter

Major Components
There are four major components of a Direct On Line Starter. They are given as
follows:
1. Switchgear
2. Fuse
3. Conductor (Electromagnetic)
4. Thermal Overload Relay (Heat & Temperature)

6.2 SWITCHGEAR
The term switchgear, used in association with the electric power system, or
grid, refers to the combination of electrical disconnects, fuses and/or circuit breakers
used to isolate electrical equipment. Switchgear is used both to de-energize

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equipment to allow work to be done and to clear faults downstream.

Oil-filled equipment allowed arc energy to be contained and safely controlled.

By the early 20th century, a switchgear line-up would be a metal-enclosed structure
with electrically-operated switching elements, using oil circuit breakers. Today, oil-
filled equipment has largely been replaced by air-blast, vacuum, or SF6 equipment,
allowing large currents and power levels to be safely controlled by automatic
equipment incorporating digital controls, protection, metering and communications.

A View of Switchgear at a Power Plant

Types

• Oil circuit breakers rely upon vaporization of some of the oil to blast a jet of oil
through the arc.
• Gas (SF6) circuit breakers sometimes stretch the arc using a magnetic field,
and then rely upon the dielectric strength of the SF6 to quench the stretched
arc.
• Vacuum circuit breakers have minimal arcing (as there is nothing to ionize
other than the contact material), so the arc quenches when it is stretched a
very small amount (<2-3 mm). Vacuum circuit breakers are frequently used in
modern medium-voltage switchgear to 35,000 volts.
• Air circuit breakers may use compressed air to blow out the arc, or
alternatively, the contacts are rapidly swung into a small sealed chamber, the
escaping of the displaced air thus blowing out the arc.
• Circuit breakers are usually able to terminate all current flow very quickly:
typically, between 30 MS and 150 MS depending upon the age and
construction of the device.

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Classification

Several different classifications of switchgear can be made:

By the current rating:

 By interrupting rating (maximum short circuit current that the device can
safely interrupt)
 Circuit breakers can open and close on fault currents
 Load-break/Load-make switches can switch normal system load currents
 Isolators may only be operated while the circuit is dead, or the load current is
very small.

By voltage class:

 Low Tension (less than 440 volts AC)

 High Tension (more than 6.6 kV AC)

By insulating medium:

 Air
 Gas (SF6 or mixtures)
 Oil
 Vacuum

By construction type:

 Indoor
 Outdoor
 Industrial
 Utility
 Marine
 Draw-out elements (removable without many tools)
 Fixed elements (bolted fasteners)
 Live-front
 Dead-front
 Metal-enclosed
 Metal-clad
 Metal enclose & Metal clad
 Arc-resistant

By IEC degree of internal separation:

 No Separation
 Bus bars separated from functional units
 Terminals for external conductors separated from bus bars
 Terminals for external conductors separated from functional units but not
from each other

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  Functional units separated from each other
 Terminals for external conductors separated from each other
 Terminals for external conductors separate from their associated functional
unit

By operating method:

 Manually-operated
 Motor-operated
 Solenoid/stored energy operated

By type of current:

 Alternating current
 Direct current

By application:

 Distribution.
 Transmission system

One of the basic functions of switchgear is protection, which is interruption of

short-circuit and overload fault currents while maintaining service to unaffected
circuits. Switchgear also provides isolation of circuits from power supplies.
Switchgear also is used to enhance system availability by allowing more than one
source to feed a load.

HIGH TENSION SWITCHGEAR

High voltage switchgear is any switchgear and switchgear assembly of rated

voltage higher than 1000 volts. High voltage switchgear is any switchgear used to
connect or to disconnect a part of a high voltage power system. These switchgears
are essential elements for the protection and for a safety operating mode without
interruption of a high voltage power system. This type of equipment is really
important because it is directly linked to the quality of the electricity supply. The high
voltage is a voltage above 1000 V for alternating current and above 1500 V for direct
current.

High Tension Switchgear at a Power Plant

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6.3 Disconnectors/Isolators and Earthing Switches
They are above all safety devices used to open or to close a circuit when
there is no current through them. They are used to isolate a part of a circuit, a
machine, a part of an overhead-line or an underground line for the operating staff to
access it without any danger. The opening of the line isolator or busbar section
isolator is necessary for the safety but it is not enough. Grounding must be done at
the upstream sector and the downstream sector on the device which they want to
intervene thanks to the earthing switches. In principle, disconnecting switches do not
have to interrupt currents, but some of them can interrupt currents (up to 1600 A
under 10 to 300V) and some earthing switches must interrupt induced currents which
are generated in a non-current-carrying line by inductive and capacitive coupling with
nearby lines (up to 160 A under 20 kV).

A Vacuum Circuit Breaker (High Tension Switchgear)

6.4 Contactor
Their functions are similar to the high-current switching mechanism, but they
can be used at higher rates. They have a high electrical endurance and a high
mechanical endurance. Contactors are used to frequently operate device like electric
furnaces, high voltage motors. They cannot be used as a disconnecting switch. They
are used only in the band 30 kV to 100 kV.

6.5 Circuit Breaker

A high voltage circuit breaker is capable of making, carrying and breaking

currents under the rated voltage (the maximal voltage of the power system which it is
protecting): Under normal circuit conditions, for example to connect or disconnect a
line in a power system. Underspecified abnormal circuit conditions specially to
eliminate a short circuit. From its characteristics, a circuit breaker is the protection
device essential for a high voltage power system, because it is the only one able to
interrupt a short circuit current and so to avoid the others devices to be damaged by
this short circuit. The international standard IEC 62271-100 defines the demands
linked to the characteristics of a high voltage circuit breaker. The circuit breaker can

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be equipped with electronic devices in order to know at any moment their states
(wear, gas pressure etc.) and possibly to detect faults from characteristics
derivatives and it can permit to plan maintenance operations and to avoid failures.
To operate on long lines, the circuit breakers are equipped with a closing resistor to
limit the overvoltage. They can be equipped with devices to synchronize the closing
and/or the opening to limit the overvoltage and the inrush currents from the lines, the
unloaded transformers, the shunt reactance and the capacitor banks.

6.6 Switchyard

Electrical power transmission networks are protected and controlled by high-

voltage breakers. The definition of high voltage varies but in power transmission
work is usually thought to be 72.5 kV or higher, according to a recent definition by
the International Electro technical Commission (IEC). High-voltage breakers are
nearly always solenoid-operated, with current sensing protective relays operated
through current transformers. In substations the protection scheme can be complex,
protecting equipment and busses from various types of overload or ground/earth
fault. High-voltage breakers are broadly classified by the medium used to extinguish
the arc.

6.7 Bus Coupler

Bus couplers are used in distribution system to provide better isolation and
protection from electrical arcs. They are used on Transformers to connect it to the
distribution system. It has it advantage over direct coupling w.r.t arc suppression as
they provide greater impedance to the path of the load. So, they provide better arc
protection especially, during the transient or switching period. Even if only one non-
terminated coupler acts as the bus because all devices (bus controller, remote
terminals, etc.) are connected to the coupler’s stubs, the external bus connections of
the coupler must be terminated. A dual-terminated coupler (with or without non-
functional bus connectors) can be employed where the coupler acts as the bus
without other couplers.

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6.8 Lightning arrester
A lightning arrester is a device used on electrical power systems to protect the
insulation on the system from the damaging effect of lightning. Metal oxide varistors
(MOVs) have been used for power system protection since the mid-1970s. The
typical lightning arrester also known as surge arrester has a high voltage terminal
and a ground terminal. When a lightning surge or switching surge travels down the
power system to the arrester, the current from the surge is diverted around the
protected insulation in most cases to earth.

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 7. Water Treatment

7.1 DEMINERALIZED WATER

Purified water is water from any source that is physically processed to remove
impurities. Distilled water and deionized water have been the most common forms of
purified water, but water can also be purified by other processes including reverse
osmosis, carbon filtration, microporous filtration, ultrafiltration, ultraviolet oxidation, or
electrodialysis. In recent decades, a combination of the above processes has come
into use to produce water of such high purity that its trace contaminants are
measured in parts per billion (ppb) or parts per trillion (ppt). Purified water has many
uses, largely in science and engineering laboratories and industries, and is produced
in a range of purities.

7.2 METHODS OF PURIFYING WATER

 Distillation
Distilled water is often defined as bottled water that has been produced by a process
of distillation and has an electrical conductivity of not more than 10 µS/cm and total
dissolved solids of less than 10 mg/L. Distillation involves boiling the water and then
condensing the steam into a clean container, leaving most solid contaminants
behind. Distillation produces very pure water but also leaves behind a leftover white
or yellowish mineral scale on the distillation apparatus, which requires that the
apparatus be frequently cleaned. Distillation does not guarantee the absence of
bacteria in drinking water; unless the reservoir and/or bottle are sterilized before
being filled, and once the bottle has been opened, there is a risk of presence of
bacteria.
For many applications, cheaper alternatives such as deionized water are used in
place of distilled water.

 Double-distillation
Double-distilled water is prepared by double distillation of water. Historically, it was
the de facto standard for highly purified laboratory water for biochemistry and trace
analysis until combination methods of purification became widespread.

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  Deionization
Deionized water which is also known as demineralized water (DI water or de-ionized
water; can also be spelled deionized water, see spelling differences) is water that
has had its mineral ions removed, such as cations from sodium, calcium, iron,
copper and anions such as chloride and bromide. Deionization is a physical process
which uses specially-manufactured ion exchange resins which bind to and filter out
the mineral salts from water. Because the majority of water impurities are dissolved
salts, deionization produces a high purity water that is generally similar to distilled
water, and this process is quick and without scale buildup. However, deionization
does not significantly remove uncharged organic molecules, viruses or bacteria,
except by incidental trapping in the resin. Specially made strong base anion resins
can remove Gram-negative bacteria. Deionization can be done continuously and
inexpensively using electrode ionization.

It should be noted that deionization does not remove the hydroxide or hydronium
ions from water; as water self-ionizes to equilibrium, this would lead to the removal of
the water itself.

 Other processes
Other processes are also used to purify water, including reverse osmosis, carbon
filtration, microporous filtration, ultrafiltration, ultraviolet oxidation, or electrodialysis.
These are used in place of, or in addition to the processes listed above.

What is the use of demineralized water in power plants?

It is most probably use in a closed-loop steam generation cycle to drive the turbines
that produce electricity. After passing through the turbine, the steam will eventually
be condensed into water to be fed back to the boiler to repeat the cycle.
Demineralization will protect the boiler from the formation of salt deposits on its inner
surfaces

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