Report of Industrial

Training
at

Singareni Thermal Power Plant,

Pegadapalle
submitted by
Kowshik Kadari 160120734034
Natham Santhosh 160120734047
Merugu Sagarika 160120734017

Under the guidance of

Karnakanti Santhosh Kumar (DGM-STPP)

In partial fulfilment of the requirements for the award of the degree of

BACHELOR OF ENGINEERING
IN
ELECTRICAL AND ELECTRONICS ENGINEERING
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
CHAITANYA BHARATHI INSTITUTE OF TECHNOLOGY
HYDERABAD-500075, TELANGANA, INDIA, AUGUST 2022
 INDEX
Acknowledgement
Abstract

Chapter-1 Introduction of Indian Power Sector

1.1 Theory of Thermal Power Plant
1.2 Basic Power Plant Cycle
1.3 General Layout of Thermal Power Plant

Chapter- Training Highlights

2
2.1 Inputs
2.2 Coal Handling plant
2.2.1 Ignition System
2.3 Raw Water
2.3.1 Pre-treatment
2.3.2 De-Mineralization
2.4 Boiler
2.5 Turbine
2.6 Generator
2.6.1 Generator Cooling
2.7 Transformers
2.8 Ash Handling Plants
 2.9 Switchyard
2.9.1 Switchyard Operation activities and Equipment

Chapter- Conclusions & Summary

3
3.1 Conclusion

Chapter- About the Company- Basic organization overview of STPP and its components
4
4.1 Company Profile
4.2 Office Location
4.3 Product Profile
4.4 Prominent Customers
4.5 Organization of the Company (public, private, listed etc, brief structure)
 CHAPTER-1
Introduction to Indian Power Sector
The power sector in India has undergone significant progress after independence in 1947. The
country had a power generating capacity of 1326 MW. Hydropower plants and thermal plants were
the main sources of generating electricity. The generation and distribution of power were mainly
carried out by private utility companies. Power was available only in few urban centres; rural areas
and villages did not have electricity. After 1947, all new power generation, transmission, and
distribution were done in the rural sectors and urban centres which came under the state and
central government agencies. State Electricity boards were formed in all the states.

Present Energy Scenario of India:

India’s electricity consumption accounts for about 4% of world’s total electricity consumption and it
is growing at a rate of 8-10% per year.

 The electricity sector in India has an installed capacity of 205 MW as of June 2013, which is the
fifth-largest in the world.

 Thermal plant constitutes 70% of the installed capacity, hydroelectric constitute about 15% and
the rest is the combination of the wind, small hydro plants, and biomass, waste to electricity, and
nuclear plants.

 India generated 885TW electricity during the 2011-12 financial year.

 In terms of fuel, coal-fired plants constitute 56% of the total India’s installed capacity, compared to
South Africa’s 92%, China’s 77%, and Australia’s 76%.

 India is the world’s fourth-largest consumer after the United States, China, and Russia.

Theory of Thermal Power Plant:

The theory of thermal power station or working of thermal power station is very simple. A power
generation plant mainly consists of alternator runs with help of steam turbine. The steam is obtained
from high pressure boilers. Generally, in India, bituminous coal, brown coal and peat are used as fuel
of boiler. The bituminous coal is used as boiler fuel has volatile matter from 8 to 33% and ash content
5 to 16%. To increase the thermal efficiency, the coal is used in the boiler in powder form.
In coal thermal power plant, the steam is produced in high pressure in the steam boiler due to
burning of fuel (pulverized coal) in boiler furnaces. This steam is further supper heated in a super
heater. This supper heated steam then enters into the turbine and rotates the turbine blades. The
turbine is mechanically so coupled with alternator that its rotor will rotate with the rotation of
turbine blades. After entering in turbine, the steam pressure suddenly falls and corresponding volume
of the steam increases. After imparting energy to the turbine rotor, the steam passes out of the
turbine blades into the condenser. In the condenser the cold water is circulated with the help of
pump which condenses the low-pressure wet steam. This condensed water is further supplied to low
pressure water heater where the low-pressure steam increases the temperature of this feed water, it
is again heated in high pressure.

For better understanding we furnish every step of function of a thermal power station as follows,

 First the pulverized coal is burnt into the furnace of steam boiler.
 High pressure steam is produced in the boiler
 This steam is then passed through the super heater, where it further heated up.
 This supper heated steam is then entered into a turbine at high speed.
 In turbine this steam force rotates the turbine blades that means here in the turbine the
stored potential energy of the high-pressured steam is converted into mechanical energy.
 After rotating the turbine blades, the steam has lost its high pressure, passes out of turbine
blades and enters into a condenser.

 In the condenser the cold water is circulated with help of pump which condenses the low-
pressure wet steam.
  This condensed water is then further supplied to low pressure water heater where the low-
pressure steam increases the temperature of this feed water, it is then again heated in a
high-pressure heater where the high pressure of steam is used for heating.
 The turbine in thermal power station acts as a prime mover of the alternator.

Schematic diagram of thermal power plant

1.2 BASIC POWER PLANT CYCLE:

Thermal Power Station is sometimes also referred to as steam power station, as steam has the major
role in generation of electricity. After the steam is passed through the turbine, it is then processed
into a condenser where it is condensed to liquid state so that it can be fed back to the boiler for
conversion and the cycle repeats.
All the thermal power plants work on the principle of Rankine cycle. It is a thermodynamic cycle
ofheat engine, that converts heat energy into mechanical work while undergoing phase change.
Physical layout of Rankine cycle consists of:

1) Pump

2) Boiler

3) Turbine
4) Condenser
There are four main cycles in Rankine Cycle:

Rankine Cycle

Cycle 1-2: In this cycle, the fluid is pumped from low pressure to high pressure as shown. Very little
input energy is required since the fluid is in liquid stage.

Cycle 2-3: The liquid is now at higher pressure inside the boiler. The liquid is heated here at this
constant pressure by external heat source to develop into dry saturated vapour. In other words,
cycle 2-3 is a constant heat addition at constant pressure.
Cycle 3-4: The dry saturated vapour expands through a turbine generating power. The condensation
takes place in this process and temperature and pressure of the liquid is decreased. The input energy
required can be calculated using enthalpy-entropy graph.
Cycle 4-1: It is the final process of the cycle where wet vapour enters the condensers and is
condensed at constant pressure to again turn into liquid phase.

And the cycle repeats

1.3 General layout of Thermal Power Plant:

General layout of thermal powerplant

1.3.1 Description:

Coal is conveyed from an external stock and ground stock to a very fine powder by large
metal spheres in the pulverized fuel mill with preheated air driven by the forced draught fan. The hot
air-fuel mixture is forced at high pressure into boiler where it rapidly ignites. Water of a high purity
flows vertically up the tube-lined walls of the boiler where it turns into steam, and it passes tothe
boiler drum, where steam is separated from any remaining water. The steam passes through a
manifold in the roof of the drum into the pendant super heater where its temperature and pressure
increase rapidly to around 200 bars and 570ºC, sufficient to make the tube wall glow a dull red. The
steam is piped to the high-pressure turbine, the first of three stages turbine process. A steam
governor valve allows for both manual control of the turbine.
The steam is exhausted from the high-pressure turbine, and reduced in both pressure and
temperature, is returned to the boiler re-heater. The reheated steam is then passed to the
intermediate pressure turbine and from there passed directly to the low-pressure turbine set. The
exciting steam now a little above its boiling point, is brought into thermal contact with cold water
(pumped in from the cooling water) in the condenser, where it condenses rapidly back into water,
creating with cold water (pumped in from the cooling water) in the condenser, where it condenses
rapidly back into water, creating near vacuum-like conditions inside the condenser chest.
The condensed water is then passed by a feed pump through a deaerator, and pre-warmed, first in a
feed heater powered by steam drawn from the high-pressure set, and then in the economizer, before
being returned to the boiler drum. The cooling water from the condenser is sprayed inside a cooling
tower, before being pumped back to the condenser in cooling water cycle. The three turbinesets are
coupled to the same shaft as the three-phase electrical generator which generates an intermediate
level voltage (typically 20-25 KV). This is stepped up by the unit transformer to a voltage more
suitable for transmission (typically 250-500 KV) and is sent out onto the three-phase transmission
system.
Exhaust gas from the boiler is drawn by the induced draft fan through an electrostatic precipitator
and is then vented through the chimney stack.
 CHAPTER-2
Training Highlights
2.1 Inputs:

Water: The water that is extracted from the river Godavari and river Pranahitha is stored in the
balancing reservoir. The water level in the balancing reservoir is monitored day-to-day.
Coal: Being a thermal power plant, it utilises coal in large quantity. This coal is available at a large
scale from the Singareni Coal mining company nearby and is transported using the MGR (Merry-
go-round) system wherein, a train comes on one rail route, delivers coal and returns on another
route.Usually, fuel contains combustible elements like carbon and hydrogen with small amounts of
sulphur, which combine with oxygen to produce heat in the form of hot gases. Combustion means
burning and it’s a chemical reaction. Such a chemical reaction is exothermic.
Other petroleum products required:

 Turbine oil (SP-46) for turbine Lubrication

 HFO, Heavy fuel oil for boiler start-up

 LDO, Light Diesel oil

 Diesel for DG sets (Power backup)

 Other oils (SP-360) for various hydraulic controls and circuits

2.2 Coal Handling Plant:

The plant obtains the coal from the coal mines available within the range of 20kms of the plant, is
stored at an area. The coal which that is obtained are large in size and contains many impurities like
stones, iron particles and some other metals. There are coal pickers for picking up these stones.
After picking up these stones, the conveyor belt passes through magnetic separators where all the
iron particles are removed. Now the conveyor belt transports the coal to crusher house. Here the
coal is crushed down to a size of 20mm. from here it is transferred to coal bunkers. There are 8 coal
bunkers within the plant. Here the coal is stored and supplied to the mills through the feeders.
Feeders supply the required amount of coal to the mills. The crushed coal is made into fine powder
in the mills.

Coal Handling Plant

Ignition System: HFO is stored in the storage tanks having a capacity of 500 m3. From HFO
tanksthe oil is pumped through fuel oil pump house. The oil is heated to 90°C with the help of steam.
The thermostat is used here to cut down connection when the temperature exceeds the permit level.
From here the HFO is sent out the boilers and sprinkled into it through the guns either through
corners or from front. Oil is sent back if there is no necessity in the boiler.

HFO tank

2.3 Raw Water:

Raw water is one of the main raw materials used in the thermal power plant. Raw water is supplied
from the river Godavari and river Pranahitha. This water is stored in reservoir and pumped into the
raw water pump house whenever required. The water contains lot of impurities that causes
oxidation of the turbine blades which makes it unsuitable for use. Hence it is treated in the water
treatment plants. The estimated water requirement for 2x600 MW plant under operation is 88,800
KLD (3700 m3/hr).

Raw Water Reservoir

These impurities are separately removed in two stages. They are

1) Pre-treatment

2) De-Mineralization

2.3.1 Pre-treatment
Pre-treatment of water is used to remove the physical impurities present in the water. The raw
water is pumped into the flocculating chamber. Here alum dozing and chlorination process takes
place. Al2(SO4)3 is used as an alum. Chlorination is done to remove the organic matters present in
the water. Alum Solution is added to remove turbidity of the water. The residual chlorine should be
0.5 ppm which indicates that the organic matter present in the water is completely dead. This water
is sent into the clarifier. The clarifier can pump 3000m3/hr. But since the need is not up to that level
only 300 -400 m3/hr of water is used. The alum particles and other turbid particles are attracted and
form a bulk particle. Due its high density it settles downs in the clarifier. The water falls into the clear
water pit where the macro particles such as leaves etc. are blocked by the small V-shaped iron blades.
From the clarifier, by the gravity the water is taken into the gravity filter bed. The water gets filtered
in the gravity filter bed. The bed consists of Anthracite Coal which absorbs the residual chlorine
present in the water and remove minute impurities if any present. The water is then stored in the
gravity filter sump. From the gravity filter pump the water is pumped to DM plant for removal of
chemical impurities.

2.3.2 De-mineralization
Mineralization is the process of removing chemical impurities i.e., salts Present in the water. In DM
plant there are beds which has resins which are capable of removing the ions present in the water.

Demineralisation Plant
2.4 Boiler:

A steam generator or boiler is a closed vessel made of steel. Its function is to transfer the heat
produced by the combustion of fuel to water and ultimately to generate steam. The boilers furnace
walls are made of reflecting materials such as fire clay, silica, kaolin. These materials have the
property to resist change of shape, weight or resist change of shape, weight or any physical
properties at high temperatures. The boiler type used in the plant is Sub-critical pulverized fuel, coal
fired unit to produce subcritical steam parameters. The capacity of the boiler is 2050 TPH. The main
steam pressure of the boiler is 175 bars and temperature inside it is 540 degrees Celsius. It has an
overall efficiency of 87%.

Boiler

2.5 Turbine: The turbine is a device consisting of blades mounted on a cylindrical metal object
which is kept on a shaft itself is coupled to the generator. Turbine is divided into three categories.
They are:

High-Pressure Turbine: The steam from the boiler drum, first is sent on to the HPT, where it rotates
the turbine. Here, the steam is at a temperature of 539.63 Deg.cel and a pressure of 360 kg/sq.cm and
most of the temperature and pressure of the steam is used by the HPT itself.

Intermediate Pressure Turbine: The steam from the re heater is sent to the IPT, where it is used to
rotate the turbine. Which is having temperature of 328 Deg.Cel. And pressure of kg per Sq. cm.

Low-Pressure Turbine: The expanded steam from the IPT is sent to the LPT. But the pressure
decreases to a negative value of -0.86 kg/sq. cm.

Low-Pressure Turbine

2.6 Generator:

A three-phase synchronous machine, doubly excited ac machine, because its field winding is
energized from a dc source and its armature winding is connected to an ac source. When working as
a motor, the synchronous machine takes active power from an ac source. During its working as a
generator, synchronous machine always absorbs or takes in power from a dc source. Since a
synchronous generator delivers ac output, it is also known as an alternator. Under steady state
conditions, operating speed of a synchronous machine depends on frequency of armature currents
and number of field poles. The equation is given as under:
f = (P*Ns)/120
Two sets of generators are used in the plant and has a rating of 600 MW each. Rated terminal
voltage of the generator is 21 kV and rated stator current of 19407A and rated power factor
0.85(lag). The generator efficiency at the plant is as follows:
At 100% load --> 98.79%
At 75% load --> 98.84%
At 50% load --> 98.76%

Generator
2.6.1 Generator Cooling:
Cooling of electrical machines is essential for dissipating the heat generated by various losses and
thus to prolong the life of insulating materials. In small electrical machines, natural cooling is
adequate. Forced air cooling is used for large machines. Air is first passed through cleaning filter and
then forced into the machine for cooling purposes. For such generators closed air circuit ventilation
system is not sufficient to cool the system. So, hydrogen cooling is opted for cooling the system.
Types of cooling:

a) Stator winding: direct water cooled

b) Stator Core: direct H2 gas cooled

c) Rotor core: direct H2 gas cooled
d) bushing: Water cooled

2.7 Transformers: The transformer is a device that transfers electrical energy from one electrical
circuit to another electrical circuit through the medium of magnetic field and without a change in
frequency. The electric circuit which receives energy from the supply mains is called primary winding
and other circuit which delivers electrical energy to load is called secondary winding. There are three
types of transformers used in the plant.

i) GeneratorTransformer: Generating transformer is a transformer which is used to step up the

voltage from generator to switch yard. The rating of the transformer is 260MVA, 21/420kV. It is
connected in delta star connection.

Generator Transformer

Station Transformer: Station transformer is a transformer which is used for all the common
ii)
equipment of power plant. The rating of the transformer is 100MVA, 400/11500.

Station Transformer

Unit Transformer: Unit auxiliary transformer is a transformer which is connected to all the
iii)
auxiliaries of the unit such as PA Fan, FD Fan, Pumps etc. Each unit consists of a separate UAT.
Voltage ration is 21/11.5kV. The connection is made as star
connection in LV side and delta connection in HV side.
 Unit Transformer

2.8 Ash Handling Plants: Coal combustion gives out considerable amount of ash. The ash thus
produced is carried by means of some jet system and treated.

Ash Handling Plants

2.9 Switchyard: 400 KV Switchyard of Singareni Thermal Power Station is the most vital
switchingstation in the southern Grid 1200 MW of Bulk Power generated by two 600 MW STPP is
evacuated for supplying to the southern states. Switchyard consists of two 400 KV bus bar.
 Switchyard

2.9.1 Switchyard operation activities: As mentioned elsewhere, STPP switchyard is

handling bulk power and its operation and Maintenance has become critical. Any ambiguity in the
operation of the switchyard may lead to such disasters like grid failure, station outages crippling not
only the normal life of people but also the very economy of the country. Even in less serious situations
such as cascade tripping of Auto Transformers due to unplanned over 2loading has causedunder-
utilization of our generating capacity many times. The operation of switchyard calls for a very alert
staff that shall have to sense the abnormalities in time and prompt to concern timely to enable
normalcy of the system.

2.9.1 Switchyard Equipment:

a) Circuit Breaker: It is an automatic device capable of making and breaking an Electrical Circuit
under normal and abnormal conditions such as short circuits. The type of the circuit breaker used is
SF6 Gas outdoor type with rated voltage of 145kV. Under normal condition, its rated current is
1600A. KV lines are of Minimum oil type operating on spring charge mechanism. The other circuit
breakers used is of 400kV.

Circuit Breaker
b) Capacitive Voltage Transformers (CVTs): The CVTs step-down the system voltage to sufficiently
low value (110 V) for measuring, protection and synchronizing circuits. CVT has a H.F. terminal
pointfor receiving & transmitting the high frequency signals for carrier protection and
communication. The rated voltage is 132/3kV.

Capacitive Voltage Transformers

c) Lighting Arresters: Surge Arresters are provided to ground the over voltage surges caused by
switching and lighting surges. Surge Arresters provide leakage path to the ground whenever the
system voltage rises above the specified value. They are equipped with surge monitors, which
measures the leakage currents and a counter to record the number of surges taken place. The rated
voltage is 120kV.

Lighting Arrester

d) Current Transformer (CT): Current Transformers are provided to step down the current to low
values suitable for measuring protection and control instruments. Current Transformers also isolate
measuring and protective devices from high system voltage. CTs in the switchyard consist of five
secondary cores. Core 1&2 are used for busbar protection, 4 & 5 are for main 1&2 protection and
core 3 is for measuring instruments. The current transformer ratio is 400-800/1A.
 Current Transformer

e) Isolators: Isolator is an off-load device provided in conjunction with circuit breaker to disconnect
the equipment or the section, which is to be isolated from all other live parts. The isolators provided
in the switchyard are of central break type. The operation of Isolators can be done from control room
(remote) or local. Motorized operation for opening & closing of Isolator is provided, however
Isolators can also be opened & closed manually in the event of non-availability of motorized
operation. The rated voltage of the isolator is 132kV, rated current is 1250/1600A.

Isolator

f) Earth Switch: Earth switch is mounted on the isolator

base on the line side or breaker side depending upon
the position of the isolator. The earth switch usually
comprises of a vertical break switch arm with the contact,
which engages with the isolator contact on the line
side. Earth switch is required to discharge the trapped
charges on the line or equipment (under shut down)
to earth for maintaining safety. Earth switch can be operated only from local either by electrical
operation or manually.

Earth Switch

g) Busbar: Busbar is Aluminium tube of 4’’ IPS having wall thickness of 0.4’’, where all incoming and
outgoing feeders are connected in a schematic way to enable smooth operation and Maintenance of
equipment without any interruption to the system. At STPP one and half breaker scheme is provided
for 600 MW generator feeders and 400 KV outgoing lines.

Busbar
CHAPTER-3
 CHAPTER-4
About the Company
4.1 Company Profile:

Singareni Thermal Power Plant (STPP), is a coal fired power station, located in Pegadapalle
village of Telangana. It has an installed capacity of 2, 600MW units, and is operated by Singareni
Collieries company. The project was initiated in the year 2011 consisting of 2, 600MW plant. NTPC
was given contract to handle the commissioning of the project. Contract for Boiler Turbine
Generator and balance of plant was given to BHEL and McNally Bharat Engineering Company
Limited, Kolkata. Power Plant synchronization was completed on 13 March 2016 for unit 1 and on 1
September 2016 for unit 2.
The plant takes the raw material from 8 different coal mines, 2 open casts and other 6 being inclined
mines. The plant is distributed over the land area of 300.792 Ha with 700 active manpower working
all year around. The main source of water is from the river Godavari and the river Pranahitha. The
water requirement is around 1.05 thousand million cubic feet from the river Godavari and 2 thousand
million cubic feet from the river Pranahitha. STPP comes under the 5th largest thermal power plant
in the state of Telangana with a single unit of 800MW station still under construction and is
expected to get inaugurated in the year upcoming years (target in next 5 years).
The plant registered plant load factor of 91.74% during three-month period between April and July,
and stood at the fifth position out of 25 plants surveyed at the national level.
 Singareni Thermal Power Plant (STPP), Pegadapally(V), Jaipur(M), Mancherial(D), Telangana

4.2 Company location:

The plant is located at the coordinates of 18° 50’ 20.461’’N and 79°46’15.318’’E in a village viz.
Pegadapalli, Jaipur, Telangana.
4.3 Product Profile: The TG Hall or the Turbo-Generator Hall or the Turbine-Generator Hall is
the hall or space where the turbine-generator sets are present. Singareni Thermal Power Plant has a
common hall for both the turbo generator set. These TG halls are equipped with heavy overhead
cranes that assist in the transportation of material to, from and within the TG hall. These cranes find
their use greatly during overhauls. There are 2, 600MW units with output of each generator being
22kV, which is then converted to 400kV with step up transformer.

Turbo-Generator Hall

4.4 Prominent Customers: The switchyard is the place where the station last takes care of the
power it produces. The switchyard links the power generated to the southern Power grid.
The major transmission points are:

 Sundilla (2 lines)

 Ramadugu (2 Lines)

4.5 Organization of the Company:

The Singareni Thermal Power Plant is owned by the company The Singareni Collieries Company
Limited (SCCL) is a Government coal mining company jointly owned by Government of Telangana
and central Government in the ration of 51:49. The Singareni coal reserves is spread across 350 Km
of the Pranahita – Godavari Valley of Telangana with a geological reserve aggregating to whopping
8791 million tonnes. SCCL is currently operating 18 opencast and 27 underground mines in 4 districts
of Telangana with a manpower around 48,942.