VOCATIONAL TRAINING REPORT ON

BANDEL THERMAL POWER STATION (WBPDCL)

SUVADIP ROY

DEPARTMENT OF APPLIED PHYSICS (BTech ELECTRICAL ENGINEERING) UNIVERSITY COLLEGE OF SCIENCE AND TECHNOLOGY UNIVERSITY OF CALCUTTA

ACKNOWLEDGEMENT
As a student of The Department of Applied Physics (B.Tech. in Electrical Engineering), University College of Science and Technology, University of Calcutta,I am thankful to all the respected employees of various departments where we undergo this training session. It is not easy to know the full system of BTPS but they always try to answer our curiosity. The experience of this training as an electrical engineering student is excellent.

PREFACE
Practical knowledge means the visualization of the knowledge which we read in the books. For this we perform experiments and get observations. Practical knowledge is very important in every field. One must be familiar with the problems related to the field so that he may solve them and become a successful person. After achieving the proper goal of life, an engineer has to enter in professional life. According to this field he has to serve an industry, may be public or private sector or self-own. For efficient work in the field he must be aware of practical knowledge as well as theoretical knowledge. To be a good engineer, one must be aware of the industrial environment and must know about management working in industry, labour problems etc., so he can tackle them successfully. Due to all the above reasons and to bridge a gap between theory and practical, our engineering curriculum provides a practical training course of 20 days. During this period a student in industry gets all type of experience and knowledge about the working and maintenance of various types of machinery. I have undergone by 20 days of training at BANDEL THERMAL POWER STATION. This report have been prepared on the basis of the knowledge which I have acquired during my 20 days (17/06/2013 to 09/07/2013) training in the plant.

SUVADIP ROY

Department of Applied Physics (EE), University of Calcutta

CONTENTS

BTPS AT A GLANCE ................................................................................................................................................................4 SCHEMATIC REPRESENTATION OF A THERMAL POWER PLANT.................................................................5 COAL HANDLING PLANT .....................................................................................................................................................6 COMBUSTION AND FUEL EFFICIENCY ......................................................................................................................10 MECHANICAL OPERATIONS ...........................................................................................................................................11 INSTRUMENTATION & PROCESS CONTROL, CONTROL & INSTRUMENTATION ...............................20 OPH .............................................................................................................................................................................................23 RELAY AND INSTRUMENTS............................................................................................................................................28 IPH ...............................................................................................................................................................................................33 MAJOR CONSTRAINTS AT BTPS CONCLUSION.

Department of Applied Physics (EE), University of Calcutta

BTPS AT A GLANCE
Situated on the western bank of Bhagirathi River, Bandel Thermal Power Station is just 1 Km from the Assam Road and connected with a heavy duty metal lead road 3 km off the Grand trunk Road, NH2. Bandel Thermal Power Stations nearest rail head is Tribeni on the Bandel- Katwa- Azimgunj Line under Eastern Railways. Successfully meeting the power sector demand for the State for more than four decades, Ban del Thermal Power Station still remains a prominent player in the states power supply chain. Bandel Thermal Power Stations fifth unit with a capacity of 210 MW installed in 1982, was first of its kind in Eastern India & fifth in India. Today, with five operational units the total installed capacity of the station stands at 450 MW . Total area of land acquired by WBPDCL for BTPS is as under: BTPS Township: BTPS Plant: Ash Plant: 350 acres 800 acres 100 acres

The various units at BTPS and their commissioning dates are as under: Unit 1 2 3 4 5 6 Date of Commissioning 01.01.1974 16.07.1975 06.12.1978 03.03.1981 07.04.2009 30.06.2011 Capacity (MW) 120 120 120 120 250 250 Status Shut Down Shut Down Shut Down Shut Down Operational Operational

BTPS has achieved the meritorious award from electricity authority from 1992 1993 on the following: 1. Maximum Generation 2. Minimum Auxiliary Consumption 3. Minimum Specific Fuel Consumption
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A SCHEMATIC REPRESENTATION OF A THERMAL POWER PLANT

1. Cooling tower 2. Cooling water pump 3. Transmission line 4. Step-up transformer 5. Electrical generator 6. Low pressure turbine 7. Condensate pump 8. Surface condenser 9. IPT

10. Steam Control valve 11. High pressure turbine 12. Deaerator 13. Feedwater heater 14. Coal conveyor 15. Coal hopper 16. Coal pulverizer 17. Boiler steam drum 18. Bottom ash hopper

19. Superheater 20. Forced draught (draft) fan 21. Reheater 22. Combustion air intake 23. Economizer 24. Air preheater 25. Precipitator 26. Induced draught fan 27. Chimney

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Coal Handling Plant

Brief Descriptions:
Equipments of CHP
o o o o Two nos. chain driven wagon tipplers U1 and U2 , each of capacity 100 T &one no. rope driven wagon tippler U3 of 90 T capacity. Sixteen (16) nos. vibrating feeders (two nos. unbalanced motor type and six nos. originally EM type feeder for each wagon tippler) U1 & U2. Three(3) nos. unbalanced motor type vibrating feeders for wagon tippler U3. Reversible belt feeders U1 & U2, conveyors 1A & 1B ,conveyors 2A 2B,conveyor 3A & 3B, conveyor 6A/6B, conveyor 7A/7B, conveyor 8A/8B, conveyor 11A/11B, conveyor 12A/12B. o o Underground conveyor 9A /9B , conveyor 10A / 10B & conveyor 4A &4B. Six nos. reciprocating vibrating feeders below Reclaim hoppers for feeding to conveyors 9A /9B and six nos. EM vibrating feeders below Reclaim hoppers for feeding to conveyors 4A/4B . o o o o o o Two nos. Rotary(Two Rolls) Crushers house -1 for stacking route. Vibrating Screens 1 and 2. Ring Granulator type Crushers 1 and 2 in Crusherhouse-2 for direct bunker feeding. Stacker 1 & stacker2 (Boom stacker:both swing and hoisting mechanism are in running condition). Inline magnetic separators on conveyors 1A/1B , 6A/6B &9A/9B. Two nos. Cross belt Magnetic separators on conveyor 11A/11B .

Route Description
a) Wagon tippler to crusher
From Wagon tippler -1/2, coal is fed to respective reversible belt feeder U1/U2 through vibrating feeders. From either of the reversible belt feeder U1 & U2 coal

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7 flows to any of the conveyors 1A/1B or 6A/6B. conveyor 1A/1B feeds coal to two rotary crushers for stacking. From Wagon tippler U3 ,coal is fed to the conveyors 6A/6B only. Conveyor 6A/6B feeds coal to either of the two conveyor 7A/7B. Subsequently from conveyor 7A/7B, coal is fed to either of the two screen 1/2 .Smaller size coal i.e. below 24 mm flows to either of the two conveyors 8A/8B bypassing the crushers. Bigger size coal from screen -1 goes to Ring Granulator type crusher-1and coal from screen -2 fed to Ring Granulator type Crusher-2. At the head ends of conveyors 1A /1B & 6A /6B, In line magnetic separators (ILMS) have been provided.

b) Crusher to stack yard

Crushed coal from Rotary Crusher of size below 24 mm is fed to either of the conveyors 2A &2B. From conveyor 3A, coal is fed to yard conveyor 3A for stacking and from conveyor 3B , coal is fed to yard 3B for stacking purpose.Stacker-1 and stacker -2 run along with yard conveyor 3A & 3B respectively and are standing in fixed position in the existing coal stack yard. The crusher coal from Ring Granulator type crushers flows to either of the conveyors 8A &8B. For stacking, coal from conveyor 8A/8B is fed to either of the conveyor2A/2B. Coal from conveyor 2A is fed to 3A and subsequently stacked in stack yard through static stacker1 . Coal from conveyor 2B is fed to conveyor 3B and subsequently stacked in the stack yard through static stacker-2.

c) Crusher to Boiler bunker

For direct feeding to bunker of Unit #5, coal is fed to conveyor 11A/11B from 8A/8B and then from conv. 11A/11Bfed to conv. 12A/12B . For direct feeding to bunker to Unit#(1-4) coal bunker ,coal from conv. 12B is fed to conv. via conv. 13 &14. There are three stacking zones via stack yards 1,2 &3 in CHP of BTPS as indicated in layout Drawing ,dimension of each stock pile is 300m x 61m. 1. Stacker -1 can discharge coal to stack yard 1 and stack yard 2 2. Stacker -2can discharge coal to stack yard 3 and stack yard 2
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8 In each zone, there are four reclaim hoppers, two for feeding conveyor 9A/9B ,two for feeding coal to conveyor 4A/4B. The coal stacks are leveled with the help of bulldozers

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9 d) Stack yard to Unit #(1-4)

For bunker feeding of unit #(1-4) from stack yard,coal is fed to six nos. reclaim hoppers by bulldozing. Vibrating feeders under the reclaim hoppers are feeding coal to conveyors 4A/4B. From conveyor 4A/4B coal flows to bunker through mobile tippler on conveyor 5.

e) Stack yard to Unit #5

Coal is fed to six nos. reciprocating feeders under six nos. reclaim hoppers by bulldozer. These reciprocating feeders feed coal to conveyor 9A/9B which subsequently feed to conveyor 10A/10B.From either of the conveyor 10A/10B,coal is fed conveyor 11A/11B. From either of the conveyor 11A/11B,coal is fed conveyor 12A/12B. At the head ends of conveyors 9A &9B, Inline magnetic separators have been provided. In addition, on conveyor 9A/9B , metal detectors have been provided for acting ILMS if any metal is detected on flowing coal. Two nos. cross belt magnetic separators each on conveyor 11A &11B are in service.

Technical Details:
Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Conveyor No. U1/U2 U3 1A/1B 2A 2B 3A/3B 4A/4B 5 6A/6B 7A/7B 8A/8B 9A/9B 10A/10B 11A/11B 12A/12B 13 14 Capacity (TPH) 400 500 400 400 400 500 400 400 500 500 500 500 500 500 500 500 400 Belt width (mm) 1000 1000 900 900 900 900 900 900 1000 1000 1000 1000 1000 1000 1000 1000 1000 Speed (M/s) 1.67 2.0 1.67 1.67 1.67 1.67 1.67 1.67 2.0 2.0 2.0 2.0 2.0 2.0 2.0 1.67 1.67 15 15 50/50 20 30 40/40 100/100 30 75/75 60/60 50/50 50/50 50/50 125/125 45/45 30 30 9A/10A(380V) R25(415V) 9A/10A(380V) 9A(380V) 10A(380V) 9A/10A(380V) 11A(380V) 11A(380V) R24/R25(415V) R24/R25(415V) R24/R25(415V) R24(415V) R24/R25(415V) R31(415V) R31(415V) R31(415V) R31(415V) Motor HP Power supply MCC Length (M) 20 18 125 95 155 280 283 120 110 91 64 136 118 177 68 13 22

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Recent Development
New approach for breaking of coal lump & removal of stones at CHP
A most effective approach has been taken for breaking of coal lump and removal of stones from coal on net of Wagon tippler-3 by using Hydraulic Excavator at very faster rate which will facilitate us to reduce demurrage charge for detention of rakes beyond free time.

Hydraulic Excavator

New Shade Over Wagon Tippler-1&2 (Erection in 2012)

To facilitate O&M job
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11

4.3 Bottlenecks in CHP

BTPS does not have any Stacker cum Reclaimer. So coal from different grade cannot be blend which is bare necessity in present scenario to get optimum fuel efficiency. BTPS does not have Track Hopper facility so unloading of wagons through conventional wagon tippler system delays whole coal unloading activity & this leads to

huge demurrage inadequate coal feed rate to the system depleted stock.

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COMBUSTION & FUEL EFFICIENCY

Its a techno-commercial department which checks the quality of fuel & coal from BCCL, ECL & provides it to CHP. The department quantifies the coal by Weigh Bridge (Load cell) & fuel by fuel meter & randomly checks the quality of coal and fuel. Based on the ash content, gross calorific value and useful heat value; Indian coal is classified in six categories as given in Table below: CLASSIFICATION OF INDIAN COAL: Grade A B C D E F G (Ash + Moisture %) Approx. (UHV) (Kcal/kg) 19.5 or less 24.0 - 19.5 28.7 24.0 34.0 - 28.7 40.0 34.0 47.0 40.0 55.0 47.0 Useful heat value (UHV) Above 6200 5600-6200 4940-5600 4200-4940 3360-4200 2400-3360 1300-2400

GRADING OF INDIAN COAL: Serial No. 1 2 3 Grading of Coal Superior grade Intermediate grade Inferior grade Criteria Grade (A+B+C) (5800 Kcal/kg) Grade (D) (5800 Kcal/kg) Grade (E+F+G) (4000 Kcal/kg) High ash content in the coal supplied to the power plants not only possess environmental problems but also results in poor plant performance and high cost for Operation & Maintenance and ash disposal.
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MECHANICAL OPERATIONS

Overview: In a Thermal Power Station, Chemical Energy of fuel, which is either Coal or Oil, is converted to Electrical Energy. This energy conversion takes place in different stages. First, in the Boiler, the chemical energy in fuel (Coal /Oil) is converted into heat energy. During the process of combustion heat is absorbed by the water from water-walls of the furnace and generates steam (heat energy). Secondly, in the Turbine, this heat energy, in the form of steam, is converted into mechanical energy. And finally, in the Generator, directly coupled to the turbine, this mechanical energy is converted into electrical energy. In a modern boiler of a Thermal Power Station, combustion process is very fast due to high steaming rate with increased unit capacity. Moreover, to reduce cost, the present boilers are operated at maximum permissible temperature limit of its metal. Further, due to small capacity of the Drum and high steam output to water storage ratio, the modern boiler demands continuous water feeding and a constant drum water level. This is essential to prevent starvation of the boiler. To prevent boiler explosions and flame failure, the furnace draft (pressure) is to be maintained constant. All the above things indicate that the steam pressure & temperature, drum water level, furnace drafts etc are to be maintained constant. The entire mechanical functioning of any Thermal Power Plant can be classified into various cycles which have been briefly described in the following pages through block diagrams and descriptions on the equipments and machines required with specifications of the ones used at BTPS.

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14 THE BASIC THERMODYNAMIC CYCLE: The basic thermodynamic cycle employed in a thermal power plant is Rankine Cycle. The diagram shown below is a schematic representation of how Rankine Cycle is maintained in a thermal power plant. Work done

Weak steam Heat extracted Turbine Condenser

Heat provided

Boiler Drum

BFP

Heat is being given to the DM water at the boiler drum which produces steam to cause the turbine to rotate and do work. The weak steam coming out of the turbine is being condensed at the Condenser extracting heat from the steam. The temperature at the boiler drum and the condensate is given by T1 and T2 respectively. The efficiency of Rankine cycle (T1 T2). Thus to obtain an efficient Rankine cycle temperature of the boiler drum should be increased enormously as well as temperature T2 should be decreased. This however isnt practically suitable as enormous rise in temperature at the boiler drum results in development of stress inside the material, which may cause the drum to buckle up. To avoid the above mishaps regenerative heating and reheating is done. Regenerative heating involves tapping of the steam coming out of the boiler drum and directing it to different water paths causing heat to be added to the water before entering the boiler drum. Two turbines instead of one turbine is used. Steam extracted from the boiler drum is made to pass through the High Pressure Turbine (HPT) first and is made to pass through a reheater and then to a
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15 Low Pressure Turbine (LPT), thus enhancing the efficiency of the system. This also prevents the expanded steam from condensing, which would have caused erosion to the turbine blades. The above process is called Reheating. TURBINES: The turbine is a tandem compound machine with separate HP, IP and LP sections, the HP and IP sections being single-flow cylinders and LP sections double-flow cylinders. The turbine rotors and the generator rotor are connected by rigid couplings. The HP turbine is nozzle controlled. The initial steam is admitted before the blading by four combined main stop and control valves. The line leading from the HP exhaust going to the reheater is provided with swing check valve which prevent hot steam from the reheater flowing back into the HP turbine. The steam coming from the Reheater is passed to the IP turbine via two reheat stop and control valve combinations. Cross around pipes connect the IP and LP cylinders. Bleeds are arranged at several points of the turbine. HP TURBINE: The outer casing of the HP turbine is of the barrel type and has neither an axial nor a radial flange. This prevents mass concentration which would have caused high thermal stresses. The almost perfect asymmetric design of the casing permits moderate and nearly uniform wall thickness at all sections. The inner casing is axially split and supported so as to be free to move in response to thermal expansion. As only slight pressure differences are effective, the horizontal flange and joint bolts of the inner casing can be kept small. The barrel type casing permits flexibility of operation in the form of short start-up times and a high rate of change of load even at high initial steam conditions. IP TURBINE: The IP turbine section is of single flow construction with horizontally split casings. Allowance is made for thermal movement of the inner casing within the outer casing. The inner casing carries the stationary blading. The reheated steam enters the inner casing from top and bottom. The provision of an inner casing confines high steam inlet conditions to the admission section of this casing, while the joint flange of the outer casing is subjected only to the lower pressure and temperature effective at the exhaust from the inner casing.
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LP TURBINE: The casing of the double-flow LP cylinder is of three-shell design. The shells are horizontally split and are of rigid welded construction. The innermost shell, which carries the first rows of stationary blades, is supported so as to allow thermal expansion within the intermediate shell. The intermediate shell rests at four points on longitudinal girders, independent of the outer shell. Guide blade carriers, carrying the last stationary blade rows are also attached to the intermediate shell.

TURBINE GENERATOR SET AT BTPS

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17 AIR CYCLE: Cold PA Damper 80C PA Fan Regener ative Air Heater FD Fan Mill

Hot PA Damper

Furnace

PA Fan Primary Air Fan FD Fan Forced Draft or Secondary Air Fan The air pressure coming out of the PA Fan is much higher than the one coming out of the FD Fan due to their different modes of operation. The PA Fan mainly provides air which is used to blow the pulverized coal from the mill into the furnace. Hence requires a higher pressure. Whereas the FD Fan is used only to provide the excess air required for proper combustion of coal inside the furnace.

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18 FEED WATER CYCLE:

Boiler Drum

Condensate

HPH6
Economizer

HPH5

Deaerator

LPH2 LPH1

Steam

LPH3

BFP

CEP

Drain Valves

CEP Condensate Extraction Pump BFP Boiler Feed Pump HPH High Pressure Heater LPH Low Pressure Heater The regenerative cycle or the feed water cycle is actually the loop through which the feed water entering the boiler drum passes through the regenerative heating phase from the condenser so as to have its enthalpy raised. In the condenser the weak steam loses its energy and water (condensate) is obtained and is collected in the hot well. The condensate extraction pump (CEP) then extracts the condensate from the condenser and pumps it towards the deaerator. The Low Pressure Heater(LPH) heats up the condensate extracted by the CEP, which is done by steam extract from various parts of the steam cycle. There are 3 LPHs from LPH1 to LPH3. The
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19 condensate on emerging out of LPH3 has certain amount of heat in it which it has gained progressively while passing through different the different LPHs. The CEP output pressure raises the heated up water up into the deaerator. The condensate on reaching the deaerator is called the feed water. At the deaerator steam is applied to the feed water. The steam on emerging out of the feed water forms bubbles which on going up increases in size and thus increases in surface area, causing heat transfer to occur from the steam to the feed water. Here the feed water also gets free from the entrapped air. The Boiler Feed pump pumps the feed water into the boiler drum after passing through High Pressure Heaters (HPH) and finally the economizer. This is a pump that must be reliable and rugged to withstand not only continuous high-pressure pumping operation but also transient system upset conditions and possible frequent loading variations to match the plants load output requirements. The Economizer adds the final heat to the feed water before entering the drum.

FLUE GAS CYCLE: The combustion of coal inside the furnace forms Flue gas that leaves the plant through the chimney after passing through various heat exchanging ducts. This path is called the flue gas cycle.

FURNACE

REHEATER

PLATEN SUPER HEATER

FINAL SUPER HEATER

PRIMARY SUPER HEATER

STACK (CHIMNEY)

ID FAN

ESP

REGENERATIVE A/H

ECONOMISER

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20 FURNACE: The rectangular furnace is about 50 feet (15 m) on a side and 130 feet (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (58 mm) in diameter. Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the center. The thermal radiation of the fireball heats the water that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the boiler is three to four times the throughput and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700 F (371 C) and 3,200 psi. The pressure inside the furnace is maintained at a negative value, firstly so that the hot air inside doesnt escape out in case of any leakage. Secondly the pressure is negative so as to allow the flame to be observed through a peep hole (Judas Window) to check for proper combustion. REHEATER: The steam flows through the reheater of three horizontal banks, bottom intermediate, and top placed in parallel with the horizontal primary super heater, pendent intermediate bank, reheater horizontal two sides of unit before the safety valves on the reheater inlet piping. The function of reheaters is to re superheat the partly expanded steam from the turbine. This is done so that the steam remains dry as far as possible through the last stage of the turbine. SUPERHEATERS: Fossil fuel power plants can have a superheater section in the steam generating furnace. In a fossil fuel plant, after the steam is conditioned by the drying equipment inside the steam drum, it is piped from the upper drum area into tubes inside an area of the furnace known as the superheater, which has an elaborate set up of tubing where the steam vapor picks up more energy from hot flue gases outside the tubing and its temperature is now superheated above the saturation temperature. The superheated steam is then piped through the main steam lines to the valves before the high pressure turbine. Primary Superheater - This is a single steam pass arranged in counter flow with respect to the gas flow.

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21 Platen Superheater - Steam passes from the primary superheater outlet box to the platen superheater inlet box. This is a single steam pass in parallel flow with the gas. Secondary Superheater - This is also a single steam pass arrangement parallel flow with the gas.

ECONOMIZER: It is the device which heats the feed water on its way to bowl by driving heat from the fuel gas. The result is rising boiler efficiency, saving fuel & reduce stresses the boiler due to higher temperature of feed water. An Economizer consists of a large number of closely spaced parallel steel tubes connected by headers o f drum. The feed water flows through these tubes and the flue gas flows outside. A part of heat of flue gas is transferred to feed water, thus rising the temperature of the latter. ID FAN: The ID fan maintains a differential pressure between the furnace and the stack (or chimney), so as to force the flue gas to pass through the chimney via different heat exchanging ducts. Type: BAB 65 AEROFOIL BLADE Double Inlet No. per boiler: 2, Coupling: Hydraulic Type Bearing Type: High Speed spherical reheated ring lubricated water cooled. Motor HP: 900, Motor RPM: 740 CHIMNEY (STACK): The chimney is a structure for venting hot flue gases from the furnace to the outside atmosphere. Chimneys are typically vertical, or as near as possible to vertical, to ensure that the gases flow smoothly, drawing air into the combustion in what is known as the stack, or chimney, effect. The height of chimneys plays role in their ability to transfer flue gases using stack effect, the dispersion of pollutants at higher altitude helps to ease down its influence on surroundings. The dispersion of pollutants over greater area reduces their concentrations in compliance with regulatory limits. The two chimneys at BTPS are each 220 meters high.

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INSTRUMENTATION AND PROCESS CONTROL, CONTROL AND INSTRUMENTATION

TEMPERATURE MEASUREMENT: Temperature is a very fundamental parameter in Thermal Power Plant. The temperature of air, water, motor, boiler, furnace etc. are measured & controlled there. Various temperature measuring instruments are given below: 1. Thermocouple: Here two different metal (A & B) wires make closed path, having two junctions-one is kept at measuring (hot) temperature (T1) & the other is kept cold. Then a potential difference proportional to temperature difference between the two junctions is produced. Thermocouple produces voltage output which is calibrated in terms of temperature. 2. Resistance Temperature Detector (RTD): Its principle is based on the change of resistance with temperature. Two types of RTDs are: 2-Wire & 3-Wire RTD. RTD - materials: Cu(-150 to 250C), Ni(0 to 325C), Pt(-190 to 660C). Areas of application: Pt 100 is most frequently used in power plants for air, water, and motor windings/bearings etc. temperature measurement usually within 400C. This is called Pt 100 because it has 100 ohm resistance at 0C. Temperature resistance table: The resistance of Pt 100 increases linearly with temperature. The selected part of the temperature-resistance is given below: TEMPERATURE (C) RESISTANCE ()

0 50 100 150 200 250

100.00 119.09 138.50 157.30 175.8 194.08

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23 PRESSURE MEASUREMENT: In a Thermal Power Plant measurement of control of pressure of liquid and gases is very important e.g. in furnace the pressure must be maintained -3 to -4 mmHg. Otherwise malfunction may arise. For local indication Bourdon Gauge must be used. 1. Pressure gauge: Here mechanical deformation of an elastic material is done due to the measuring pressure. Measuring the deformation pressure is measured. 2. Pressure transmitter: It converts the mechanical output from sensors to mechanical equivalent. It consists of three elements pressure sensing element (e.g. diaphragm, bourdon tube), primary conversion element, secondary conversion element. FLOW MEASUREMENT: In a Thermal Power Plant measurement of flow rate of air, water, and steam is very important. Instruments for flow measurements are given below: Venturi Tube: It follows Bernoullis theorem. It is used where permanent pressure loss is of prime importance and maximum accuracy is desired for high viscous fluids. Orifice Plate: Its the simplest and cheapest flow measuring instrument. Here pressure loss is maximum. Rota meter: Here flow rate is proportional to area. Here linear scale is used. A float moves up and down the tube as indicator. LEVEL MEASUREMENT: In a Thermal Power Plant, measurement of level is essential for the purpose of safe and efficient operation of the plant. For the purpose of co-ordination and control, level measurement is also required. In a Thermal Power Station, measurement of level is carried out for liquid and solid. The coal level in the coal bunkers is measured, which is an example of measurement of the level of solids. Measurement of Boiler drum water level, De-aerator water level, Condenser Hot well level, etc are examples of measurement of level of a liquid. In some cases, level is measured for remote indication and for control. For this type of level measurement differential pressure transmitters (DP transmitter) are normally used. The DP

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24 transmitter may be of the LVDT, Reluctance, or Capacitance type. Areas of application: Drum level control (three element control), De-aerator level control, HP heaters level control, LP heaters level control, Hotwell level control.

ANALYTICAL INSTRUMENTS: Depending on the paramagnetic effect, chemical heating etc. some instruments are used to analyze various samples. Various application fields are: Oxygen in flue gas: Excess oxygen indicates inefficiency & less oxygen indicates incomplete combustion. So for efficient operation this measurement is important. Dissolved oxygen in feed water: Dissolved oxygen in feed water may react with metal parts of boiler & turbine & result in corrosion. So measurements are to be made to check removal of oxygen from the feed water. Conductivity of feed water: If water is acidic or alkaline, it may affect the boiler. So pH measurement is necessary. Hydrogen purity: Hydrogen is used for cooling of stator & rotor of alternator. Heating of generator causes reduction of load. So purity measurement of hydrogen is important. Opacity of flue gas: Opacity/dust particles in flue gas are monitored by opacity monitor. PNEUMATIC ACTUATOR: Actuator causes movement of valve stem according to applied signal. Actuator is opened, closed or positioned by air, hydraulics or manually. In spring-diaphragm actuator variable air pressure is applied to flexible diaphragm to oppose spring. This force is used to balance fluid force on valve. Both spring-diaphragm and piston type actuator produce linear motion to move the valve.

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OPH SWITCH YARD:

BUS BAR ARRANGEMENT: At the 132 KV switch yard in the Bandel thermal power station main bus with transfer bus scheme has been used. It ensures continuity of supply in case of bus fault with the disadvantage of additional cost. SWITCH YARD EQUIPMENTS: FEEDERS: 1. 132 KV Dharampur#1 2. 132 KV Dharampur#2 3. 132 KV Dharampur#3 4. 132 KV Bighati#1 5. 132 KV Bighati#2 6. 132 KV Adisaptagram#1 7. 132 KV Adisaptagram#2 8. 132 KV Khanyan 9. 132 KV Satgachiya 10. 132 KV Chanditala 11. 132 KV Liluah 12. 132 KV Kalyani CIRCUIT BREAKER: Circuit breakers are designed to operate in faulty conditions of a circuit and have rated breaking and making capacities in MVA. Making capacity is decided by consideration of asymmetrical making current during closing of circuit breaker in an already short circuited line. Hence calculation of Fault MVA by network analysis is essential for selection of circuit breakers to be of the adequate capacity. Some of the circuit breakers at BTPS are SF6 circuit breakers. As SF6 is a strong electro negative gas, it is de ionized and recovers breakdown voltage very rapidly and the arc extinguishes at natural current zero. Zero current interruption is an excellent feature which makes it free from any form of current chopping, high TRV and restriking. Therefore no damping resistance is required to
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26 control the TRV. Pre-Closing circuit breakers are used when such breakers are employed in long transmission lines of comparatively high voltage to control voltage surge during closing of breakers. On the contrary MOCB has inherent problems of current chopping and requires damping resistance.

BULK OIL CIRCUIT BREAKER: In this circuit breaker the current interruption take place inside the interrupter. The enclose of interrupter is made of insulating material link porcelain. Hence the clearance between the live parts and the enclosure can be reduced and lesser quantity of oil requires for internal operation.
SPACIFICATIONS:-

Name Voltage level Current level Fault level Medium used

SF6 138 KV 1600 A 10000MVA SF6

OCB 145 KV 1600 A 7000MVA Oil

ACB 145 KV 1600 A 7000MVA Air

132 KV BOCB at BANDEL THERMAL POWER STATION SWITCHYARD CONDUCTORS: The Conductors used at the BTPS switch yard is of the ACSR type. Aluminum conductor steel reinforced (or ACSR) cable is a specific type of high-capacity, high-strength stranded cable typically used in overhead power lines. The outer strands are aluminum, chosen for its excellent conductivity, low weight and low cost. The center strand is of steel for the strength required to support the weight without stretching the aluminum due to its ductility. This gives the cable an overall high tensile strength. Each conductor can carry currents up to 900 A. The strands are in the sequence of 12, 18 and 24.

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27 LIGHTNING ARRESTOR: Over voltages may occur in substation by incident on travelling wave from transmission line due to lightning impulse with steep waveform in the range of 1/50 micro sec. temporary over voltages (TOV) may be caused by a number of systems, events such as line to ground fault, circuit back feeding, load rejection, Ferro resonance, etc. there may be also be other internal surges known to be switching surges due to current chopping, successive restrike by interruption of capacitive current, etc. A lightning arrestor resembling a safety valve of the system diverts this over voltages to ground by lowering its resistance and also interrupts power frequency follow up current by developing its own resistance to high value as soon as the voltage comes to a normal value.

ISOLATORS: Isolators are used for no load opening and closing of circuits. They can be operated from remote by motorized, hydraulic, or pneumatic mechanisms. Three poles are either mechanically or electrically ganged and may be provided with earth switching having either electrical or mechanical interlock or both for safe operation only during de energized condition. The isolators are interlocked with circuit breakers for their operation while breaker status is OFF only. This electrical interlock is achieved by isolation of DC control power of isolator at ON position of breaker.

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28

CURRENT TRANSFORMER (CT): A basic element of relaying and metering, CT is a series connected transformer having single bar primary, several protection cores and one metering core of respective accuracy class and secondary. Transient saturation, DC offset is the ruling factor in the design and deciding accuracy of CT, and pose problem where the relaying scheme operates on current balance principle. The performance characteristics of distance relaying are also affected by these factors. The entire transformer element is kept in porcelain case with transformer oil in sealed condition and in pressurized by nitrogen for reducing corona. The salient particulars of a protection class current transformer are current ratings, VA burden, accuracy class (viz 5P, 10P, 15P). Accuracy limit factors (ALF viz 5, 10, 15, 20, 30), short time factor, knee point voltage. The cables from CT are taken to a nearby CTJB (Junction Box) where shorting links and earth connections are provided and then to control room panels. VOLTAGE TRANSFORMER (VT): Electromagnetic voltage transformer (EMVT) is common up to 220 KV and its insulation is economically designed by cascade connection of several VTs in which there primaries are in series. Coupling windings alongside the primary windings equalize the voltage. Secondary connections from VT are taken through fuses. WAVE TRAP: A wave trap traps the high frequency communication signals sent on the line from the remote substation and diverting them to the telecom/teleprotection panel in the substation control room (through coupling capacitor and LMU).
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29 This is relevant in Power Line Carrier Communication (PLCC) systems for communication among various substations without dependence on the telecom company network. The signals are primarily teleprotection signals and in addition, voice and data communication signals. The Line trap offers high impedance to the high frequency communication signals thus obstructs the flow of these signals in to the substation busbars. If there were not to be there, then signal loss is more and communication will be ineffective/probably impossible.

CAPACITOR VOLTAGE TRANSFORMER: A capacitor voltage transformer (CVT), or capacitance coupled voltage transformer (CCVT) is a transformer used in power systems to step down extra high voltage signals and provide a low voltage signal, for measurement or to operate a protective relay. In its most basic form the device consists of three parts: two capacitors across which the transmission line signal is split, an inductive element to tune the device to the line frequency, and a transformer to isolate and further step down the voltage for the instrumentation or protective relay. The CVT is also useful in communication systems. CVTs in combination with wave traps are used for filtering high frequency communication signals from power frequency. This forms a carrier communication network throughout the transmission network.

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30

SWITCHYARD AT BTPS

GENERATOR TRANSFORMER: The generator transformer is the one connected directly after the generator. Each operational unit at BTPS has one generator transformer each with H.V side: 132 KV and L.V side: 13.8 KV.

GENERATOR TRANSFORMER UNIT5, BTPS

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31 STATION TRANSFORMER: These transformers are used when there is no generation at a unit, and to supply auxiliary power to the units. AUXILIARY TRANSFORMER: When the units are in operation, unit transformers are used to provide auxiliary power to them. Each operational unit at BTPS (1,2,3&4) have one auxiliary transformers each. All are of 13.8/3 KV. The 5th unit has two auxiliary transformers of 15.75/6.6 KV.

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32

RELAY AND INSTRUMENTS

GENERATOR PROTECTION: 1. Low Forward Power Protection: The generator will not develop output power when turbine input is less than the no load losses and motoring action develops on the turbine. The generator is able to generate power, usually 55 to 10% of generator capacity, within predetermined time after closing of breaker. 2. Reverse Power Protection: The reverse-power relay senses real power flow into the generator, which will occur if the generator loses its prime-mover input. Since the generator is not faulted, CTs on either side of the generator would provide the same measured current. In a steam-turbine, the low pressure blades will overheat with the lack of steam flow. Therefore, anti-motoring protection is recommended whenever the unit may be connected to a source of motoring power. 3. Differential Protection: In this type of protection the relay picks up when the vector difference of two same electrical entities reaches above a particular set value. This is applicable to generators, motors, transformers, as well as bus bars. 4. Loss of Excitation Protection: When the synchronous machine with excitation, is connected to the grid, it generates reactive power along with active power to the grid and the rotor speed is same as that of grid frequency. Loss of field or loss of excitation results in loss of synchronism between rotor flux & stator flux. The synchronous machine operates as an induction machine at higher speed and draws reactive power from the grid. This will result in the flow of slip frequency currents in the rotor body as well as severe torque oscillations in the rotor shaft. As the rotor is not designed to sustain such currents or to withstand the high alternating torques which results in rotor overheating, coupling slippage and even rotor failure. A loss of excitation normally indicates a problem with the excitation system. Sometimes it may be due to inadvertent tripping of filed breaker, open or short circuit of field winding or loss of source to the exciter. 5. Over Excitation Protection: Over excitation can occur due to higher than rated voltage, or rated or lower voltage at less than rated frequency. For a given flux level, the voltage output of a machine will be proportional to frequency. Since maximum flux level is designed for normal frequency and voltage, when a machine is at reduced speed, maximum voltage is proportionately reduced. . IEEE C50.13 specifies that a generator should continuously
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33 withstand 105% of rated excitation at full load. With the unit off line, and with voltageregulator control at reduced frequency, the generator can be overexcited if the regulator does not include an over excitation limiter. 6. Under Voltage Protection: When two or more generators are working in parallel and one of them suddenly trips then the other generators may experience overload condition and in this time the load current will increase with the gradual decrease in terminal voltage. The under voltage protection restricts the fall of terminal voltage up to a specified value. 7. Over Voltage Protection: The protection used is an AC over voltage relay which has a pick up value of 110% of the normal value and operates instantaneously at about 130% to 150% of the rated voltage. The operation of the relay introduces resistance in the generator or exciter field circuit and if the over voltage still persists the main generator breaker and the generator or exciter field breaker trips. 8. Over Frequency Protection: Over frequency results from the excess generation and it can easily be corrected by reducing its power output with the help of the governor or manual control. 9. Under Frequency Protection: Under frequency occurs when the generator undergoes through over load condition. The power system survives only when we drop the excess load. The rate at which frequency drops depend on the time, amount of overload and also on the load and generator variations as the frequency changes. The scheme drops the load in steps as the frequency decreases. Generally load shedding drops 20 to 50 % of load in four to six frequency steps. Load shedding scheme works by tripping the substation feeders to decrease the system load. 10. Back Up Impedance Protection: As in name implies, it is used to protect the generator from supplying an over loaded or faulty system. It is the backup protection of the generator over current protection. It measures ratio of the voltage and current supplied by the generator and initiates trip signal when the measured impedance is less than the preset value. 11. Out of Step or Pole Slipping Protection: When a generator pulls out of synchronism with the system, current will rise relatively slowly compared to the instantaneous change in current associated with a fault. The out-of-step relay uses impedance techniques to sense this condition. The relay will see an apparent load impedance swing as impedance moves from Zone 1 to Zone 2. The time it takes for the load impedance to traverse from Zone 1 to Zone 2 is used to decide if an out of step condition is occurring. Moving impedance is identified as a swing rather than a fault, so appropriate fault detection relaying may be blocked.

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34 12. Turbine Over Speed Protection: The speed goes up whenever there is sudden loss of load, i.e. there is sudden loss in the o/p of the generator. This reduction in the o/p can be detected by using a watt metric relay at the generator terminals which operates instantaneously to close its contacts. 13. Negative Sequence Protection: In negative sequence protection, a current segregating network is used. The output of which is proportional to the generator negative sequence current and is fed to a relay with an inverse square law characteristic. i.e. I2t = k. The pickup and time delay adjustments are provided such that the relay characteristic can be chosen to match closely any machine characteristic. It is normally an IDMT relay. 14. Earth Fault Protection: It is similar to generator differential protection in working. It protects the high voltage winding of 11/220 KV power transformer against internal faults. One set current transformers of the power transformer on neutral and phase side, is exclusively used for this protection. The protection cannot detect turn-to-turn fault within one winding. Upon the detection of a phase-to-phase or phase-to-ground fault in the winding, the unit will be tripped without time delay. Once the restricted earth fault protection is operated, the unit cannot be taken into service unless the transformer winding is thoroughly examined by the maintenance staff for any internals faults. 15. Over Current Protection: Normally generators are designed to operate continuously at rated MVA, frequency and power factor over a range of 95 to 105% rated voltage. Operating the generator at rated MVA with 95% voltage, 105% stator current is permissible. Operating of the generator beyond rated MVA may result in harmful stator over current. A consequence of over current in winding is stator core overheating and leads to failure of insulation. TRANSFORMER PROTECTION: 1. Over Flux Protection: Transformer over fluxing can be a result of: Overvoltage Low system frequency A transformer is designed to operate at or below a maximum magnetic flux density in the transformer core. Above this design limit the eddy currents in the core and nearby conductive components cause overheating which within a very short time may cause severe damage. The magnetic flux in the core is proportional to the voltage applied to the winding divided by the impedance of the winding. The flux in the core increases with either increasing voltage or decreasing frequency. During startup or shutdown of generator-

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35 connected transformers, or following a load rejection, the transformer may experience an excessive ratio of volts to hertz, that is, become overexcited. When a transformer core is overexcited, the core is operating in a non-linear magnetic region, and creates harmonic components in the exciting current. A significant amount of current at the 5th harmonic is characteristic of over excitation. 2. Earth Fault Protection: The restricted ground fault function can be used to provide differential protection for such ground faults, down to faults at 5% of the transformer winding. Restricted ground fault protection can be a low impedance differential function or a high impedance differential function. The low impedance function has the advantage to being able to precisely set the sensitivity to meet the application requirement. This sensitive protection limits the damage to the transformer to allow quicker repair. The restricted ground fault element uses adaptive restraint based on symmetrical components to provide security during external phase faults with significant CT error. This permits the function to maximize sensitivity without any time delay. 3. Over Current Protection MOTOR PROTECTION: 1. Thermal Overload Protection: Stator over heating is caused due to the overloads and failure in cooling system. It is very difficult to detect the overheating due to the short circuiting of the lamination before any serious damage is caused. Temperature rise depend upon I2Rt and also on the cooling. Over current relays cannot detect the winding temperature because electrical protection cannot detect the failure of the cooling System. So to protect the stator against overheating, embed resistance temperature detector or thermocouples are used in the slots below the stator coils. These detectors are located on the different places in the windings so that to detect the temperature throughout the stator. 2. Earth Fault Protection (Derived and Sensitive) 3. Negative Sequence Protection 4. Short Circuit Protection

5. Stalling Protection: The stall protection is only inactive during the starting procedure of the
motor. When the motor is running and then all of a sudden a stall situation happens, then the motor will be tripped at once, when the parameterized stall current (e.g. 400%) is reached.

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36 FEEDER PROTECTION: 1. Over Current Protection: The over current protection is the simplest and cheapest form of protection. It is the most difficult to apply and needs readjustments whenever a change occurs in the circuit. The other advantages of o/c protection are that in case of non directional o/c relays no a.c voltage is required. O/C protection is also used for phase and ground faults where distance protection is costly. Over current protection is mainly used as back up protection where the primary protection is provided with distance schemes. 2. Distance Protection: Whenever over current relaying is found slow or is not selective, distance protection should be used. Since the fault currents depend upon the generating capacity and system configuration, the distance relays are preferred to o/c relays. 3. Power Line Carrier Communication Protection BUS BAR PROTECTION: 1. Breaker Protection 2. Local Breaker Back Up Protection: This protection is initiated only when the confirmation of the tripping of the main breaker is not received within a specified amount of time. This may have happened due to the mechanical failures in the main breaker. 3. Bus Differential Protection: This protection is provided between two main buses coupled with a bus coupler breaker; so that in case of a fault in one main bus, the excess fault current in that bus trips the particular relay which opens the bus coupler breaker contacts. This isolates the faulty bus from the system and hence isolates the fault.

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37

IPH

The IPH comprises of two 6.6 KV UNIT SWBD (5SA & 5SB) and two 6.6 KV STATION SWBD (OSA & OSB). From each unit Bus the power is supplied to: 1. ELECTRO STATIC PRECIPITATOR (ESP) PMCC (5DB & 5DC) to ESP cum AHP (ASH HANDLING PLANT) control bldg & Vent MCC 2. MLDB 3. Unit PCC (5DA) to (i) (ii) (iii) Turbine Auxiliary(5KA) MCC and Turbine V/V ACDB(5KB) Boiler Auxiliary MCC (5HA), SOOT Blower MCC (5HC) & Boiler V/V ACDB Emergency MCC(5EA) & 415 V EMER DG PCC

4. From Emergency MCC (5EA) to ACELDB 1 & 2 through 100 KVA Dy11 415/433 V Transformer For SWBD # 5SA the above is done by transformers 5DAT01, 5DBT01 and 5DCT01 each of 2 MVA capacity and rating 6.6 KV/415 V. And for SWBD # 5SB the transformers used are 5DCT02, 5DBT02 and 5DAT02 each of capacity 2 MVA and rating 6.6 KV/415 V. From each station SWBD (OSA & OSB) the power is supplied to: 1. Ash Handling Switch Gear (i) (ii) (iii) (iv) (v) Ash Handling PMCC to Ash Handling MCC and Silo Area MCC through 1.6 MVA ODFT01 & 02 transformer Fly Ash PMCC to Fly Ash Conveyer Blower BLDG MCC and Ash Water Recovery PMCC Raw Water PMCC to Clarified Water P/H MCC and Chemical House MCC and DM Plant MCC CW Area PMCC to Fire Water MCC and Chlorination PLANT MCC Station PCC to (a) Vent MCC TG Hall MCC to UPS
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38 (b) Power House AC MCC (c) Power House ACDB The Breakers used in the 6.6 KV system are Vacuum Circuit Breakers and the ones used in the 415 V system are Air Circuit Breakers. When the unit is not working or is about to start, the station transformer will supply the required power to the unit bus trough the Bus Coupler breaker. STATION BATTERY AND BATTERY CHARGER: One 240 V battery ad one battery charger of adequate capacity are provided. The system supplies DC power to the turbo generator for emergency lubrication purpose as well as to the seal oil pumps. It also supplies power to the emergency lighting systems and to the tripping circuit of the circuit breakers. BRUSHLESS GENERATOR EXCITER: With the advent of mechanically robust silicone diode capable of converting A.C. to D.C. at a high power levels, brushless excitation system has become popular and being employed. The basic arrangement of a typical brushless excitation system presently is used in BHEL machines. This system consists of main components as listed below: 1. Three phase pilot exciter 2. Three phase main exciter 3. Rotating rectifier wheels 4. Cooler 5. Metering and supervisory system.

THREE PHASE PILOT EXCITER: Three phase pilot exciter has a revolving field with permanent magnet poles. The controlled rectified d.c. is fed to the main exciter field. The induced Three Phase a.c voltage is rectified in the rotating rectifier bridge and is fed to the generator rotor winding through the d.c leads in the shaft. The pilot exciter has 16 poles. The output is 220 V (+ - 10%), 400 Hz. Ten magnets are housed together in a non magnetic enclosure and this make one pole. These magnets are braced between the hub and external pole shoe with bolts.
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39 THREE PHASE MAIN EXCITER: The three phase main exciter is a six pole rotating armature unit. The field poles with the damper windings are arranged in the stator frame. Laminated magnetic poles are arranged to form the field winding. To measure the exciter current a quadrature axis coil is fitted between two poles. The winding conductors are transposed within the core length, and the end turns of the rotor windings are secured with steel bands. The connections are made at rectifier wheel end. A ring bus formed at the winding end and leads to rotating rectifier wheel are also connected to the same. The complete rotor is shrunk fit on the shaft. The rotor is supported on a journal bearing positioned between the main and the pilot exciters. Lubrication of the bearing is formed from the turbine oil system. ROTATING RECTIFIER WHEELS: The silicon diodes are arranged on the rectifier wheels in three configurations. The diodes are so made that the contact pressure increases during rotation due to the centrifugal force. There are two diodes. COOLERS: Because of these properties, hydrogen will extract more heat per unit volume/min. Thus for a given rise of temperature, machine capacity can be increased. It has been estimated that by use of Hydrogen 20% reduction in active construction materials can be affected. At 0.035 kg/cm of hydrogen, machine rating is increased by 22-25% and at 2.109 kg/cm the rating increase is 35%.

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40 Major Constraints at BTPS Major Constraints a) Technology being vintage most of the drives of the system has to be run manually. This has to lead to higher MAN/ MW Ratio in comparison to Modern Power Station. b) All Boilers of BTPS having Front Fuel Firing System which cater toward good combustion, only with good quality of coal. But with the dwindling supply of good quality of coal and with the compulsion to use inferior quality of coal in power plants, all boiler technology has shifted to Corner Fuel Firing System leading to better combustion with inferior quality of coal. So in present worst coal scenario with low GCV & high ash content, Front Fired Boiler has become a major concern at BTPS. Constraints in Power evacuation BTPS Switch Yard faces constraints in power evacuation due to following reasons: Single 132 KV main bus system. Space constraints During peak hours excessive VARs are catered by BTPS generating units almost bordering on its capability limit. Constraints in CHP No provision of Stacker cum Reclaimer & Track Hopper Further to that BTPS is really handicapped with huge amount of stones that comes with coal which further increases demurrage and unwarranted damage of the equipment.

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41 Conclusion

In the present scenario of Indian Power Sector, Bandel Thermal Power Station which has very small capacity, 450 MW only, consisting very old technology like pneumatic control in instrumentation system, electro-magnetic relays in most of the electrical systems etc. plays a vital role in west Bengal due to its location and heritage of power stations. At the Plant level, there are so many attempts done to improve systems at BTPS. After imposing Electricity Act, 2003 it is better to generate power in efficient way by using the optimization of assets. So the Ministry of Power, West Bengal already gives encouragements to do the R&M works for all units in BTPS. The EER&M of Unit 5, BTPS will be started on 2013.The effect of power blackout on 31.07.12 has been depicted to search the root cause and to analysis the parameters at generating stations under WBPDCL, eastern grid etc. during the grid collapse.

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