Internship Report On " Thermal Power Station Ukai
Internship Report On " Thermal Power Station Ukai
Internship Report On " Thermal Power Station Ukai
[200280109065]
UNDER SUPERVISION OF
ASHISH B. CHAUDHARI
[DEPUTY ENGINEER]
GSECL,UKAI
Duration:(27/07/2023 to 10/08/2023)
1
AHMEDABAD
2
3
LALBHAI DALPATBHAI COLLEGE OF ENGINEERING
Opp. Gujarat University
Navarangpura, Ahmedabad-380015
CERTIFICATE
Date:10/08/2023
4
L.D.COLLEGE OF ENGINEERING
Electrical Engineering Department
L.D. College of Engineering ,Opp. Gujarat University
Navarangpura, Ahmedabad-380015
DECLARATION
We hereby declare that the Internship report submitted along with the Internship titled
THERMAL POWER STATION UKAI submitted in partial fulfillment for the degree of
Ahmedabad, is a bonofide record of original project work carried out by me at UKAI THERMAL
of this report has been directly copied from any students reports or taken from any other source,
TABLE OF CONTANTS
1 ACKNOWLEDGEMENT 7
2 ABSTRACT 8
3 INFORMATION ABOUT THE COMPANY 9
4 CHAPTER 1- INTRODUCTION OF UTPS 10
5 CHAPTER-2 COAL HANDALING PLANT 12
6 CHAPTER-3 STATION DETAILS 14
7 CHAPTER -4 ELECTRICAL SYSTEM 19
8 CHAPTER -5 EMERGENCY SUPPLY 35
9 CHEPTER – 6 TRAINING OUTCOMES AND SELF 37
EVALUATION
10 CONCLUTION 38
5
11 REFERANCE 38
TABLE OF FIGURES
ACKOWLEDGEMENT
6
It was a great experience formed to work on training at GSECL Thermal power plant ukai
through which I could learn how to work in a professional environment.
Now I would like to thank the people who guided me and have been constant source of
inspiration throughout the tenure of my internship. I am sincerely grateful to Mr. ASHISH
BHAI CHAUDHARI (DEPUTY ENGINEER) at UTPS who rendered us his valuable
assistance and constant encouragement which made this training actually possible.
Also for continuously guiding the appropriate schedule to undertake the training. My
sincere thanks to Mr. Sandeep Chaudhari , Mr. Sachin Kadam(EE), Mr. B D Joshi(DE), and
Mr. R B Patel(EE)for having support, guidance at ground level and sharing valuable technical
knowledge. And at last but not least, I am also thankful to all the staff members of the company for
their kind corporation and valuable guidance throughout the process ofwork.
.
ABSTRACT
7
❖ INTRODUCTION TO GSECL
and restructured the Gujarat Electricity Board with effect from 1st April, 2005.
➢ Distribution Companies:
8
❖ Chapter 1 – Introduction of UTPS
➢ Ukai thermal power station located on the bank of tapi river in Tapi district under
GSECL Gujarat state electricity corporation limited India UTPS is one of the major
coal fired power plant, with installed capacity of 1110 MW.
➢ Before selecting the site various surveys were concluded to determine Geological,
Hydrological, Ecological aspects, Fresh water availability, water utilization and
other important factors.
➢ At present the site has 2 units of 200MW each, 1 unit of 210MW, 1 unit of 500MW.
Unit 3&4&5 has 1 boiler each and common turbine building and unit 6 has separate
power house with single boiler. There is common service building and have
different maintenance departments.
➢ The steam is produced in boiler is transported by pipes to the turbine building and
then turbine by governing system. The structure includes turbo generators, feed
water heaters, boiler feed pump, condensers, and one unit has its own control room
and standby power supply facilities.
➢ The service building holds chemical laboratory ventilation system and access to the
turbine buildings , has mechanical workshop and electrical testing lab.
➢ The layout of the plant consisting all the major buildings and facilities is shown
below:
➢ Turbine building
➢ Main power house#6
➢ Service building
➢ Electrical maintenance department2
➢ Electrical maintenance department6
➢ Turbine maintenance department2
➢ Turbine maintenance department6
➢ Cannel water pump house
➢ Electrical and mechanical tool rooms
➢ De- mineralized plant
➢ 220KV and 400KV switchyard
➢ Cooling tower
➢ The coal extracted from the mines is brought to the UTPS through train. The coal is in
imported from Bihar, Jharkhand (corba) and Maharashtra by train. In one train there is 55 to
60 wagon are there. There is capacity of 60 to 70 ton coal I wagon. The coal from wagon is
unloaded by tippler. There is various types of coal
3. Bituminous coal(45-86%)
4. Anthracite(86-97%)
10
Figure 2.1 coal storage
❖ Tippler
➢ Tippler is motor driven assembly which unload the train wagon by rotating 180º
➢ The motor used in tippler is of 6.6 kvopreyedy operator when tipper hold the wagon
➢ After the coal is unloaded form wagon it falls on Apron feeder. Apron feeder is a
mechanism
moving on the shafts and return Roller. It ca manage flow of stones , powder like coal.
11
❖ Magnetic separator
➢ It is mechanism in which metal parts are remove from coal so that crusher inlet has
only coal / is metal parts are not remove from coal then crusher might get damaged
or mechanically locked.
➢ After metal parts have been removed from coal if, coal is I from of big stones then
its is given to the crusher unit.
➢ There is motor of 6.6kv used in crusher. it has hammer on there surface so that they
can break stones of coal In to small parts.
➢ In UTPS total coal consumption per day is 15 to 17000 Matric tons. Approx.
because it depend on load demand
There is around 33 metric ton coal used in one mill
❖ Chapter 3: STATION DETAILS
➢ The type of boiler used in this station is Hanging type water tube boiler and the Fuel used is
Coal. There is auxiliary equipments like Id fan, Pa fan, Fd fan, here every unit has its own
ID fan, FD fan, PA fan, Feeder, Crusher. From the coal storage the coal is transferred by
conveyer belt to the RC feeder or vertical gravity feeder then according to commands from
control room the feeder feeds coal to the clinker or crusher, after that the coal converted into
powder form and by FD fan it is blowed to furnace were using oil and other factors the coal
is burned and for flame there is normal oxygen is provided by PA fan.
➢ There is nearly 1200℃-1300℃ is in furnace. The steam is inlet in Hp turbine then tireturns
to boiler the reheated steam flows to the IP turbine and Lp turbine, after rotating turbine the
steam goes to the condenser and there the steam is condensed using normal water.
➢ The turbine shaft is coupled with generator so the generator rotates. There is no cooling
system for water so used water returns to cannel but in unit 6 the cooling tower is available
so water used for condenser or cooling is taken to the cooling tower, and after cooling it is
reused.
➢ The turbine building holds control room battery room is near to the boiler and other related
components. The water required for initial charge is drawn from the ukai reserve from the
cannel which is for agricultural purpose, by the water pumps through the intake structure
and pipe lines.
12
4 200 September 1979 Running
5 210 January 1985 Running
6 500 2013 Running
1. water tube
2. Fire tube
❖ BOILER SYSTEM
❖ CONDENSER
❖ ECONOMIZER
❖ AIRPRE-HEATER
❖ SUPERHEATER
13
❖ CONDENSER:
➢ the condenser is heat exchanger which removes the latent heat from exhaust steam so that it
condenses and can be pumped back into the boiler. The feed system completes the cycle
between boiler and turbine to enable the exhausted steam to return to the boiler as feed water.
❖ Economizer:
➢ economizer in power plant used to capture the waste heat from boiler flue gas and transfer
it into boiler feed water
❖ Air pre-heater:
➢ the purpose of the air pre-heater is to recover the heat from the boiler flue gas which
increases the thermal efficiency of the boiler by reducing the useful heat lost in flue gas.
❖ Super heater:
➢ a super heater is a device used to convert saturated steam or wet steam into superheated
steam or dry steam. superheated steam is used in steam turbines for electricity generation,
steam engines, and in processes such as steam reforming .there are three types of super
heaters radiant, convocation and separately fired.
14
❖ Turbine
❖ HIGH PRESSURE
➢ Steam inlet temperature is 540℃ and pressure is 130kg/cm^2.
❖ INTERMEDIATE PRESSURETURBINE
➢ Steam inlet temperature is 540degree Celsius and pressure is 30kg/cm^2
❖ LOW PRESSURETURBINE
➢ The steam in LP come from IP turbine with reduces pressure and temperature and goes to
condenser.
15
Figure 3.4 steam turbine
4
➢ Generating system
❖ GENERATING SYSTEM:
➢ A generator converts Mechanical energy into Electrical energy. There is 2 types of generator..
1. AC generator 2.
DC generator
16
Figure 4.1 generator
➢ Here in thermal power station ukai generator used is turbo generator which is Water and
hydrogen cooled.
➢ There is different ratings of generator like there is generator with capacity of 235300KVA,
here is the name plat photo.
➢ Capacity:235300KVA
➢ Voltage:15750
➢ RPM: 3000
➢ Frequency:50
➢ Stator winding connection: 3 phase start-star
➢ Hydrogen pressure:3.0kG/cm2
❖ Same as in unit 6 with more capacity this produce 500MW here the name plate below.
➢ K.W:500,000
➢ P.F: 0.85LAG
➢ K.V.A: 588,000
➢ VOLTS: 21000STATOR
➢ AMPS: 16200 STATOR
17
➢ VOLTS; 340ROTOR ➢ AMPS :4040ROTOR
➢ RPM: 3000
➢ FREQUENSY:50
➢ PHASE: 3
➢ CONNECTION: star-star
➢ COOLANT: Water and hydrogen
❖ BUS DUCTS
➢ Each generator is connected to its own generator transformer(GT) through isolated phase
bus ducts. This arrangement affords a maximum reliabilities and availability of the unit. this
reduces the chance of phase to phase and phase to ground faults in 21kv and 15.75kv.
➢ Tap off connection are provided in bus duct for the following :
➢ Unit transformer
➢ Unit station transformer
❖ There is auxiliary buses of 11kv, 6.6kV with Bus A & B for equal and parallel operation.
❖ STATIC EXCITATIONSYSTEM
➢ The generator is provided with terminal connected static excitation system.
Static excitation system has been accepted as it has following advantages over
the conventional excitation system employing shaft connected exciters, pilot
exciters separate regulators.
➢ Improved stability
➢ Field breaker
➢ Protection device
❖ GENERATOR AUXILARYSYSTEM
➢ Seal oil system, stator cooling water system, and hydrogen cooling system.
18
❖ SEAL OIL SYSTEM
➢ Seal oil system is design to prevent the escape of the hydrogen gas present along the
shaft to the atmosphere. It is done by supplying oil at slightly higher pressure about
0.8kg/cm2 over the maximum hydrogen pressure. Hydrogen pressure is 3.5kg/cm2,
there for the seal oil pressure is maintained in between 0.7 to 0.9 kg/cm2. this system
avoids major fire by not allowing the hydrogen to mix with the atmospheric air to
form the explosive mixture. Shaft seals are provided at the ends of the generator to
prevent the escape of hydrogen.
➢ ADVANTAGES
• Easily available
• Due to h2 cooling the size of generator is very small compare to air cool.
➢ DISADVANTAGE
• Large quantity has to be supplied
• It is highly flammable. It can catch fire when comes to contact with air.
❖ GENERATOR PROTECTION
➢ Generator differential
19
➢ Over voltage (time delay)
➢ Over fluxing
➢ Field failure
➢ Over speed
❖ MAIN OUTPUT SYSTEM
❖ TRANSFORMERS
➢ GSECL, UTPS has 6 GTs of different MVA capacity. unit produce 15.75kV the
generator transformer steps up from 15.75kv/220kV.there is respective GTs for
every unit.
➢ In unit no 6 there is 21kv is generated by generator and there per phase one
transformer is available as there is higher capacity power is generated. so GTs
in unit 6# step-up 21kv/400kv
Table 4.2 generator transformer name plate
20
MAKE BHARAT HEAVY
ELECTRICALS
(BHEL)
RATING 250MVA
VOLTAE RATIO 15.75KV/220KV
PERCENTAGE IMPEENCE
VECTOR GROUP YNd11
TAP CHANGER OFF LOAD
FREQUAENCY 50Hz
TYPE OF CONSTUCTION THREEPHASE,OUTDO
OR
T21YPE POF COOLING OFWF(oil Force,Water
Force)
❖ STATION TRANSFORMER
➢ Ukai TPS has 4 ST of different capacity. The function of station transformer is in
emergency case or when station has to start the unit station transformer feed power to the
auxiliarys from switchyard .
➢ Station transformer step down 220kV/7kV and makes two bus 6.6KvA and 6.6kvB.
➢ There station transformer of higher capacity in unit 6. There is station transformer which
takes 400kV from yard and steps-down it to 11kv/6.6kV.
➢ There is two buses of 11kV A & B, and two buses of 6.6kV A &B. here one station
transformer in spare too.
Table 4.3 station transformer name plate
21
FACTORY (NGEF)
RATING 25MVA
VOLTAGE RATIO 220KV/7KV
PERCENTAGE IMPEDENCE 11.87%
VECTOR GROUP
TAP CHANGER ON LOAD
FREQUANCY 50Hz
TYPE OF CONSTRUCTION THREE PHASE OUTDOOR
TYPE OF COOLING ONAN-OIL NATURAL AIR
NATURAL
ONAF-OIL NATURAL AIR
FORCE
POWER FREQUAENCY
SHORT DURATION WITH
STAND TEST VOLTAGE
HV
WINDING
LV
WINDING
➢ All the MCC panels and motors run on this supply aspect higher capacity motors. So
the auxiliaries and the switchgear system are supplied from this UT,
UST, and UAT Like 415V switchgear, 6.6kV switchgear, ID fan, PA fan,
22
Figure 4.4 switchyard
➢ Here in ukai thermal power station AIS .this type is in open atmosphere. The high
voltage lines are insulated by air, and it occupies more space than GIS.
❖ COMPONENTS OFSWITCHYARD
➢ Lightning arrester
➢ Circuit breaker
➢ Isolator
➢ Bus-bar
➢ Potential transformer
➢ Current transformer
➢ Wave trap
➢ Bus coupler
➢ Earth switch
➢ Transformer
❖ LIGHTNING ARRESTER
➢ IT IS PROVIDED AT THE TOP OF SUPPORT ATRUCTURE. For sole purpose of
safety from lightning incidents . Directly connected to earth to avoid electrical damage.
Current from the surge is diverted around the protected insulation in most cases to earth.
23
Figure 4.5 lightning arrester
❖ CURRENT TRANSFORMER
➢ CT is one type of transformer which is used for measurment as well as protection.
It produces current in its secondary which is proportional to the current in its
primary.
➢ In an SF6 circuit breaker, sulphour hexafluoride gas is sed as the arc quenching
medium.
➢ The sulphour hexafluoride gas(SF6) is an electronegative gas and has a strong
tendency to absorb free electrons. The contacts of the breaker are opened in a high
pressure flow of SF 6 gas and arc is struck between them.
➢ Its dielectric strength is 2.5 times than of air and 30% less than dielectric oil.
24
Table 1.4 SF 6 circuit breaker ratings
PARAMETER VALUE
25
Figure 4.8 Isolator
❖ BUS
➢ There is 2 bus system in the switchyard. In double bus-bar system two identical bus-
bar are used in such way that any outgoing or incoming feeder can be taken from
any of the bus.
1. Main bus
2. Auxiliary bus
➢ Bus bar protection is provided and there is separate Circuit breaker is allotted for
bus-bar protection.
26
Figure 4.9 bus
❖ POTENTIAL TRANSFORMER
➢ The transformer which is used for protection and measurement in the power
system. Potential transformers are step-down transformers, it contains more turns
in primary but less in secondary.
➢ It is connected in parallel and used for voltage measurement.
➢ It is also known as line trap. It is connected in series with the transmission line. It
is designed to carry the rated power frequency 50-60 Hz current, as well as to
withstand the substation fault currents
27
Figure 4.10 wave trap
4.3.4 SINGLE LINE DIAGRAME OF 220kV SWITCHYARD
28
FIGURE 4.10.1 SINGLE LINE DIAGRAM(220 KV)
29
FIGURE 4.10.2 220KV SWITCHYARD DIAGRAM
30
❖ 400 KV SWITCH YARD SLD
31
❖ Chapter 5: Emergency supply
❖ Battery set
➢ There two set of battery each set have 2 battery ban which are
connected in parallel and the batteries are connected series.
➢ NI-Cd battery are used each battery have 169 battery cell and
voltage12volt.
32
Figure 5.2 ups diagram
➢ Normally input to UPS is from 415V bus. In the event of failure of this supply, 415V
battery will supply the requirements of entire bus via inverter module. Under this
condition battery voltage will fall down to about 340V.
➢ When invertors is supplied from DC batteries only, this terminal voltage will expected
to gradually drop further to 300V at the end of about 30 minutes, when the battery will
be fully discharged as per designed capacity for 30 minutes discharge.
❖ Chapter 6: Training outcomes and self evaluation
➢ This 18 days of internship really help me to get practical knowledge of the field. I had trainmy
self to and talk with technical persons present their about asking my doughts. With
communication I got to know more about work life experience and learn how to work in
professional environment.
33
❖ CONCLUSION:
This is my first interaction with any industry during my college time. I have learned so many
things from this internship which will be surely helpful for me in my future career. I have
gained good knowledge of thermal and hydro power station. during these internship I learned
about power generation, transmission, protection and electricity conversion.
❖ REFERENCE
➢ https://en.wikipedia.org/wiki/Ukai_Thermal_Power_Station
➢ Trainingmanual
➢ https://www.gsecl.in/projects/ukai-thermal-power-station/
➢ https://www.electrical4u.com/ups-uninterruptible-power-supply/
➢ https://www.sciencedirect.com/topics/engineering/seal-oil-system
34