INDUSTRIAL TRAINING REPORT-2012

Jai Narain College of Technology, Bhopal

Name of Student

University ID Number

Name of Training Place (Industry Institution, Govt. Department, etc) :

Address of Training Place with Telephone No. and Email :

Name and Designation of Training Incharge (Under whom training was completed) :

Training Period

June 01 June 30, 2012

Training Subject

TRAINING REPORT OF ADANI POWER PLANT

Prepared By:-

Chandan kumar

CERTIFICATE

Certified that Mr. Rama Kant Singh, a student of B.E. (Computer Science and Engineering) from Jai Narain College of Technology & Science, Bhopal was placed under the supervision of undersigned for his Industrial Training at our Organization started from June 01, 2012 and ended on June 30, 2012. He was engaged in Computer Aided Design (CAD) at our well equipped Laboratory. During his training period he was busy in learning and operating the CAD system, computing program with Pro Engineer and other software currently in operation. Mr. Singh is hardworking person and punctual in attendance. His behavior and nature was liked by all the staff of our organization. To the best of my knowledge, Mr. Singh bears a good moral character. I wish him a better future.

Place. the officer Date. designation

Signature of Name and

ACKNOWLEDGEMENT

The time we spent here at Adani power Ltd. has been a tremendous learning experience. Not only we have learnt a lot by way of practical application of our theoretical knowledge, we have also gained valuable insights into an exciting industry, its dynamics, and the way a mega project erects.

For this I am grateful to my guide Mr. Himmat Rathod (HOD, CHP, APL) and Mr. Vasant Patel (HOD, Switchyard, APL) for his valuable time, able guidance, encouragement, feedback, support at every step and his timely inputs.

We would also like to thank all those who helped me in my vocational training.

Submitted By: Chandan Kumar

Submitted To: Mr. Kamlesh Jogi (HR Dept., APL)

CONTENTS 1. 2. 3. 4. 5. 6. OBJECTIVES INTRODUCTION OVERVIEW OF POWER PROJECT AT MUNDRA COAL HANDLING PLANT D.M AND R.O PLANT BOILER 6.1.. DEFINITION OF BOILER 6.2.. BOILER CLASSIFICATION 7. COOLING TOWER 8. ELECTRICAL SYSTEM OVERVIEW 9. ELECTRICAL PROCESS IN PLANT 10.ELEMENTS OF ELECTRICAL SYSTEM 11.SWITCHYARD INTRODUCTION 12.INTRODUCTION OF 330 MW UNITS 13.SWITCHYARD OF PHASE-I AND II 14.INTRODUCTION OF 660 MW UNITS 15.SWITCHYRAD OF PHASE-III AND IV 16.INTRODUCTION OF HVDC

OBJECTIVES

Adani Power Ltd. is one of the upcoming projects of Adani Power, using Super Critical Technology (660 MW Capacity Boiler), which is the second time in India. Proposed Plant Capacity is 4620 MW (5 X 660 MW +4 X 330 MW), which needs an investment of Rs195.00bn. So my basic objectives were:-

To get familiar with the working of a thermal power plant. To understand the current technology that is being used in the erection of a thermal power plant. To get an overview of the major components of a thermal power plant.

INTRODUCTION

Electricity is the only form of energy which is easy to produce, easy to transport, easy to use and easy to control. So, it is mostly the terminal of energy for transmission and distribution. Electricity consumption per capita is the index of the living standard of people of place or country.

Electricity Demand and Supply in India: India is facing energy shortages of 11% of demand and even higher peak shortages of 14%Demand-supply gap is more acute in Western region (where 70% of the Projects power will be supplied) with energy deficit at 16% and peak deficit at 21% Capacity additions of 160,000 MW required in the next 10 years satisfying Indias power needs new capacity will need to come from a combination of coal, hydro, gas, nuclear and wind projects

Types of Power Plants: Electricity in bulk quantities is produced in power plants, which can be of the following types: Thermal Nuclear Hydro Gas turbine Geothermal

Thermal Power Plant: - Here the main fuel is used as a coal and then its steam is used to rotate the turbine and it generates the electricity.

Nuclear Power Plant: - Here the main fuel is used as a nuclear fuel and its process is repeated.

Hydro Power Plant: - In this power plant the turbine is rotated with the help of water which is then used to produce electricity.

Gas Turbine Power Plant: - In this power plant the gas is used to rotate the turbine. This gas can be produced from anywhere and is used to generate the electricity.

Geothermal Power Plant: - The temperature difference between core of the planet and its surface drives a continuous conduction of thermal energy in the form of heat from the core to the surface. And this heat generated due to above temperature difference is used to produce the electricity.
3% 6% 55%
Coal & Lignite Gas

26%

Hydro Nuclear

10%

Other Renewables

Indias Installed Capacity (132329 MW)

Mundra Thermal Power Project

Power Generation Capacity

3rd Largest Power Plant In PLANT CAPACITY 4620 MW Largest Thermal Power Plant In

INDIA ON SINGLE PLACE

PHASE I PHASE II PHASE III

World
PHASE IV

2 x 330MW

2 x 330MW

2 x 660MW

3 x 660MW

Adani Groups foray into power sector The Groups foray into power sector is natural extension for Adani Group, which has emerged as Indias largest coal importer and second largest powe r entity in the country.

Adani Power Ltd (APL) is setting up a 4620 MW power project at Mundra based on imported coal. The execution will be done in the following ways as under: 2*330 Phase I 2*330 Phase II 2*660 Phase III 3*660 Phase IV (sub critical) (sub critical) (super critical) (super critical)

COAL HANDLING PLANT AND COAL MILL:

What is C.H.P ??? The Coal Handling Plant is envisaged for unloading of coal received in wagons and conveying the unloaded coal to bunkers through crushers , alternatively staking the crushed or uncrushed coal, reclaiming and supplying coal to the coal bunkers. The reclaiming process included the systems of stacker-cum-reclaimers or through reclaiming hoppers from uncrushed coal yard or crushed coal yard. There is a three types of switches are placed for the protection of the conveyor belt. One is the Pull Quote Switch which is used for emergency stop of the belt. This type of switch is placed at every 50 m distance on the belt conveyor. Second one is the Belt Sway Switch which is used for balancing of the belt if the belt is shifted from the centre of the pulley to the left or right side then this type of switch will be close by the pressure of the belt. This type of switch is placed at the Header, Centre and Ending of the belt conveyor. Third switch is the Zero Sway Switch which is used for the giving the feedback to the PLC system which is controlling the whole system.

COAL ANALYSIS In thermal power plants PROXIMATE analysis is used to evaluate the quality of coal. Proximate analysis: It consists of analyzing the coal for 1. Moisture. 2. Ash 3. Volatile matter 4. Fixed carbon 5. Gross calorific value(GCV ) or Useful heat value (UHV )

Types of Coal Peat Lignite Sub-bituminous Bituminous Carbonaceous Anthracite

% Carbon 51-59 59-75 75-80 80-91 91-93 93-95

COAL MILL PROCESS: Main parts of coal mill are: Gear Plate Motor Gear Box Bottom Housing Grinding track carrier and Scraper Grinding track and nozzle ring Grinding Roller Loading Frame Housing Case Hydraulic Cylinder Rotary Unit Rotary Classifier Oil Lubrication Unit

D.M.PLANT AND R.O.SYSTEM The main requirement of Boiler is water and coal for the production of steam. Sea Intake draws water from the sea which is then passed to 20MLD and 7MLD where MLD stands for Million litres per day.20MLD is used for 660 MW units and 7MLD is used for 330 MW units. This water is then passed to the RO plant (where Reverse Osmosis takes place) for reducing its conductivity and heavy water is removed as waste which is expelled back to sea. The conductivity of water is as high as 75000 W/m^2K which if passed will damage the turbine vanes and will also corrode the blades. Hence it is necessary to reduce the conductivity from 75000 W/m^2K to 1500 W/m^2K which is performed in RO plant. The RO purified water is stored in RO tank which then goes to DM plant for the removal of the many impurities present in water like Na,Cl,Mg,Ca etc. In DM plant there are many purification systems like anion exchanger, strong acid cat ion exchanger,degazer etc.There are many Resin plates for removing the positive and negative ions from water. In anion exchanger there are R-H+ resin plates and in cat ion exchanger there are R-OH- resin plates so that if NaCl is present in water then Na+ and Cl- can be removed by these R-H+ and R-OHplates. The reaction can be explained as follows: The Na+ ion bonds with R replacing H+ which then bonds with Cl- forming R-Na+ and HCl. R-H+ NaCl R-Na+ HCl This HCl goes to the strong acid cat ion exchanger where R-OH- plates are present which results in the formation of H2O and R-Cl.The reaction is expressed as: R-OH + HCl R-Cl + HO The water thus produced is then stored in DM storage Tank which is then passed to the boiler for the production of the steam. To obtain the original R-H+ and R-OH-, HCl & NaOH are passed through the anion exchanger & cation exchanger respectively .The by-product of the above process is NaCl which is drained out by other process.

BOILER: Definition of boiler ;

Boiler a Pressure vessels used for generating (a) steam for power generation, process use or heating purposes and (b) hot water for heating purposes. However, according to the Indian Boiler Act, 1923, a boiler is a closed pressure vessel with capacity exceeding 22.75 litres used for generating steam under pressure. It includes all the mountings fitted to such vessels, which remain wholly or partly under pressure when steam is shut off.

Various Types of Boilers: Fire Tube Boiler Water Tube Boiler

Fire Tube Boiler:

Cornish Boiler Simple vertical boiler Cochrane boiler Locomotive Boiler Scotch Marine Boiler Water Tube Boiler: Benson Boiler Waste Hear Boiler

Fire Tube Boilers:

A fire tube boilers, is the boiler wherein the products of combustion pass through inside of the tubes (either one or several) and water which is to be converted in to steam is made to surround outside these tubes. Fire Tube Boilers are used where the steam pressure is normally low and the steam is not generally required to be the superheated. Fire tube boilers are compact and can be easily manufactured in a factory and assembled as a packaged boiler. Fire tube boilers cannot be manufactured in large sizes beyond certain limit due to large size of shell involved. Fire tube boilers have the advantage of low manufacturing and operating cost.

Water Tube Boilers:

In this type of construction of Boilers the fuel is fired in a confined chamber and the water is circulated through divided flow path inside a number of small-bore tubes, which are exposed to the heat generated inside the combustion chamber. In Adani power plant water tube boiler is used.

Water tube are classified as

Sub critical boiler Super critical boiler

Difference between Sub-Critical and Super-Critical Boilers

SUB-CRITICAL BOILERS

SUPER-CRITICAL BOILERS

Operating pressure is below 225.5 Operating pressure is above 225.5 bar. bar. Normal circulation: circulation by Lower load start-up pump assisted or natural circulation. below 35% NR load. circulation:

Power plant efficiency is around Power plant efficiency is around 35%. 39%. Pressure : 169 bar SH Temp : 538C RH Temp : 538C Base Vertical water walls. Pressure : 254 bar SH Temp : 571C RH Temp : 569C Additional cost to manufacturing and erection of furnace wall. Spirally wounded tilted water walls. Spirally ensures: wounded water walls

Uniform heat distribution. Avoid higher thermal stresses in water-walls by reducing the fluid temp. difference in adjacent tubes. Drum is used Drum is not used

COOLING TOWER

Cooling tower is used for the purpose of cooling the heated sea water. In electricity generation process steam passes through the H.P, I.P, L.P Turbines but there is some heat which is present reduces the efficiency for next cycle. So this heat is transferred to the sea water via use of condenser.

Here the sea water is feed into the condenser which transfers the heat of steam to the sea water. This sea water is transferred to the cooling tower through the pipes. In cooling tower according to the design it will flow to the upper head of the cooling tower. At the top portion L.T motors are present which fetches the cool air from the atmosphere. The flow of air is from top to ground which cools the water.

Here water free falls on the fins. There is some space for the circulation of natural atmospheric air throughout the cooling tower. By this way water looses its heat and water is now feed to the circulating water pump through underground water canal system.

ELECTRICAL SYSTEM OVERVIEW

In Adani Power Plant it consist of 9 units in which unit 1,2,3,4 are subcritical and unit-5, 6, 7, 8, 9 are supercritical plants. The power generated by these units is then transferred to the necessary parts of Gujarat.

For the transmission of this power in Adani Power Plant four switchyard units are placed. In which the first switchyard unit gets the power from Unit-1 & Unity-2 and its capacity is of 220 KV. The second Switchyard unit gets the power from Unit-3 & Unit-4 and its capacity is of 400 KV. The Third Switchyard Unit gets the power from Unit-5 & Unit-6 and its capacity is of 400 KV. The Fourth Switchyard Unit gets the power from Unit-7, Unit-8 & Unit-9 and its capacity is of 400 KV. Here STATION TRANSFORMER units are also used for the input power of Plant in case of failure or breakdown of entire plant power. This power is supplied by the Government of Gujarat i.e. GEB to the station transformer and it is then distributed in the plant. The power generated by the plant via turbines is the supplied to the Generating transformer and it is then distributed to the switchyard units respectively. Another small transformers of lower capacity i.e. Unit Auxiliary Transformer UATs are then supplied power from the turbo generators and then they are distributed. It consists of two UATs which is of 6.6 KV output and is used for running the auxiliaries fitted in the plant. For the Backup plan the another two systems are made they are 1) Battery Backup Plan 2) D.G.SET Backup Plan

ELECTRICAL PROCESS IN PLANT

ADANI POWER PLANT comprises of 9 units. It is mainly divided into 4 phase. Phase 1 consists of unit-1 & 2. Phase 2 consists of unit-3 & 4. Phase 3 consists of unit-5 & 6 and phase 4 consists of Unit- 7, 8, & 9. Capacity of plant is 4620 MW. Unit 1 to 4 has a capacity of 330 MW and Unit 5 to 9 has capacity of 660 MW. Generated power is then distributed to the different commercial area as well as industrial and SEZs area through the different switchyard and some amount of power is used for the plant to run the plant auxiliaries like motors, control circuits, etc.

In Unit 1 to 4 the mechanical energy generated by the high pressure, intermediate pressure and low pressure turbine is then transferred to the electrical energy by turbo alternator. Here the turbine is used as a prime mover for the turbo alternator. So by use of prime mover the armature winding rotates in the magnetic field which is produced by the field pole and the magnetic field is constant and when the armature winding cuts the magnetic field and induced EMF is generated and we can obtain this EMF via brush. This generated EMF is also called terminal voltage.

TURBO GENERATOR TYPE RATED OUTPUT RATED VOLTAGE RATED CURRENT 1255-460 330000 KW 24000 V 9339 A RATED EXCITING VOLTAGE RATED EXCITING CURRENT ROTOR WINDING COOLANT STATOR WINDING COOLANT 542 V 2495 A H2 H20

POWER FACTOR FREQUENCY SPEED ABSOLUTE HYDROGEN PRESSURE CONNECTION

0.85 50 3000 0.4

ROTOR WINDING INSULATION TYPE STATOR WINDING INSULATION TYPE STATOR CORE & ROTOR COOLANT STANDARD

F CLASS F CLASS H2 IEC

STAR

PROTECTION TYPE

IP54

Now the generated voltage is then distributed to the different areas and also some part of power is used for the internal auxiliaries of the plant and for that it passes through different networks and different equipments. The power which is used for distribution is first send to the generating transformer and it is then distributed to the different areas by different networks and different switchyard.

POWER THAT IS USED FOR PLANT AUXILIARIES

In ADANI POWER PLANT there is mainly two type s of auxiliaries which is operated by 6.6. KV and 415V. The auxiliaries operated by 6.6 KV are known as H.T. auxiliaries. The auxiliary which is operated by 415 V is known as L.T. auxiliaries. So to operate these types of auxiliaries we need 6.6 KV and 415 Volt supply. Without these auxiliaries we cannot start up the plant. So first of all we have to take this electric power from the outsource from GEB or other power plant and it is in form of 220 KV. In ADANI POWER PLANT for each unit there is one station transformer which is used to step down the voltage at 6.6 KV.

ELEMENTS OF ELECTRICAL SYSTEM: -

1) Lightning arrestor: -

A lightning arrester is a device used on electrical power systems and telecommunications systems to protect the insulation and conductors of the system from the damaging effects of lightning. The typical lightning arrester has a high-voltage terminal and a ground terminal. When a lightning surge (or switching surge, which is very similar) travels along the power line to the arrester, the current from the surge is diverted through the arrestor, in most cases to earth.

In telegraphy and telephony, a lightning arrestor is placed where wires enter a structure, preventing damage to electronic instruments within and ensuring the safety of individuals near them. Smaller versions of lightning arresters, also called surge protectors, are devices that are connected between each electrical conductor in power and communications systems and the Earth.

2) Current 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 tuning of the divider to the line frequency makes the overall division ratio less sensitive to changes in the burden of the connected metering or protection devices. The device has at least four terminals: a terminal for connection to the high voltage signal, a ground terminal, and two secondary terminals which connect to the instrumentation or protective relay.

CVTs are typically single-phase devices used for measuring voltages in excess of one hundred kilovolts where the use of wound primary voltage transformers would be uneconomical. In practice, capacitor C1 is often constructed as a stack of smaller capacitors connected in series.

3) ISOLATORS: -

A disconnected or isolator switch is used to make sure that an electrical circuit can be completely de-energised for service or maintenance. Such switches are often found in electrical distribution and industrial applications where machinery must have its source of driving power removed for adjustment or repair.

High-voltage isolation switches are used in electrical substations to allow isolation of apparatus such as circuit breakers and transformers, and transmission lines, for maintenance. Often the isolation switch is not intended for normal control of the circuit and is used only for isolation; in such a case, it functions as a second, usually physically distant master switch (wired in series with the primary one) that can independently disable the circuit even if the master switch used in everyday operation is turned on.

There are two types of isolators: 1) Single break type isolator 2) Double Side Double Break type isolator

4) CIRCUIT BREAKER: -

A circuit breaker is an automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and, by interrupting continuity, to immediately discontinue electrical flow. Unlike a fuse, which operates once and then must be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation. Circuit breakers are made in varying sizes, from small devices that protect an individual household appliance up to large switchgear designed to protect high voltage circuits feeding an entire city.

5) CURRENT TRANSFORMER: -

A current transformer (CT) is used for measurement of electric currents. Current transformers, together with voltage transformers (VT) (potential transformers (PT)), are known as instrument transformers.

When current in a circuit is too high to directly apply to measuring instruments, a current transformer produces a reduced current accurately proportional to the current in the circuit, which can be conveniently connected to measuring and recording instruments.

A current transformer also isolates the measuring instruments from what may be very high voltage in the monitored circuit. Current transformers are commonly used in metering and protective relays in the electrical power industry.

6) WAVE TRAP:-

Line trap also is known as Wave trap. 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 teleportation signals and in addition, voice and data communication signals.Line trap also is known as Wave trap. What it does is trapping the high frequency communication signals sent on the line from the remote substation and diverting them to the telecom/ teleportation panel in the substation control room (through coupling capacitor and LMU). 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 teleportation 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 bus bars. If there were not to be there, then signal loss is more and communication will be ineffective/probably impossible.

7) TRANSFORMER: A transformer is a device that transfers electrical energy from one circuit to another through inductively coupled conductorsthe transformer's coils. A varying current in the first or primary winding creates a varying magnetic flux in the transformer's core and thus a varying magnetic field through the secondary winding. This varying magnetic field induces a varying electromotive force (EMF), or "voltage", in the secondary winding. This effect is called inductive coupling. If a load is connected to the secondary, current will flow in the secondary winding, and electrical energy will be transferred from the primary circuit through the transformer to the load. In an ideal transformer, the induced voltage in the secondary winding (Vs) is in proportion to the primary voltage (Vp) and is given by the ratio of the number of turns in the secondary (Ns) to the number of turns in the primary (Np) as follows:

By appropriate selection of the ratio of turns, a transformer thus enables an alternating current (AC) voltage to be "stepped up" by making Ns greater than Np, or "stepped down" by making Ns less than Np. The windings are coils wound around a ferromagnetic core, air-core transformers being a notable exception.

8) REACTORS: Essentially a reactor is an inductor. Physically it is a coil of wire that allows a magnetic field to form around the coil when current flows through it. When energized, it is an electric magnet with the strength of the field being proportional to the amperage flowing and the number of turns. A simple loop of wire is an air core inductor. More loops give a higher inductance rating. Quite often some ferrous material such as iron is added as a core to the winding. This has the effect of concentrating the lines of magnetic flux there by making a more effective inductor. 9) INSULATOR: A true insulator is a material that does not respond to an electric field and completely resists the flow of electric charge. In practice, however, perfect insulators do not exist. Therefore, dielectric materials with high dielectric constants are considered insulators. In insulating materials valence electrons are tightly bonded to their atoms. These materials are used in electrical equipment as insulators or insulation. Their function is to support or separate electrical conductors without allowing current through themselves. The term also refers to insulating supports that attach electric power distribution or transmission conductors to utility poles or transmission towers.

SWITCHYARD INTRODUCTION: A Switchyard or Substation, consisting of large breakers and towers, is usually located in an area close to the plant. The substation is used as the distribution center where:

electrical power is supplied to the plant from the outside, and electrical power is sent from the plant

Often there are at least 2 main Buses. Very high voltages (typically 220,000 or 345,000 volts) are present. Gas and oil circuit breakers are used. The gas (e.g. sulphur hexafluoride) or oil is used to extinguish the arc caused when a breaker is opened, either by a control switch or due to a fault. Manually or motor operated disconnects are provided on either side of the breaker to allow the breaker to be electrically isolated so that maintenance work can be performed. Switchyard forms an integral part of any power plant i.e. Industrial CPP, Thermal Power Utilities, Gas Turbines based power plants or Hydel power plants. These power plants have their main plant equipment integral controls (Boiler / Turbine / Gas Turbine / Hydro Turbine) as well as plant DCS System (BoP / Station C & I). While the entire power plant is integrated at the DCS level, true unification is achieved by incorporating / integrating switchyard controls (SCADA) also in the plant DCS. The Supervisory control and data acquisition system (SCADA) of switchyard consists of Operator Stations, Engineer's Stations, Historical Storage, Computers and associated peripherals and the switchyard bay control systems interconnected through a high speed network . The system constitutes several operator work stations and engineer's work station with high resolution Colour display monitors, touch screen, function key board, mouse, track ball and printers. The system collects digital and analog information available throughout the plant and presents information in various graphic displays, alarms, logs.

INTRODUCTION OF 330MW UNITS:

There are four units of 330 MW which consists of four 24KV generator coupled to their respective turbines. Generators are having two types of cooling systems. Stator winding is having Water Cooled system and Stator core, Rotor winding and Rotor core having Hydrogen cooled system. There are two UATs (Unit auxiliary transformers),one station transformer, one generating transformer per unit. Generator generates 24 KV which is stepped up by generating transformer to 220KV, which then is transmitted to Nanikhakhar and Tapper via the switchyard .There are two tapings that emerge from 24 KV line which is fed to the two UATs which steps down 24 KV to 6.6 KV .The secondary of UAT is connected to 6.6 KV bus which is used to feed the H.T motors. Further there is another transformer that steps down 6.6 KV from UAT to 415V which is used to feed the L.T motors. H.T motors are used in RO plant and sea intake.L.T motors are used in LDO, HFO,DM Plant,Cooling Tower,etc. In case of black out the S.T draws power from GEB (Gujarat Electricity Board) from the same 220KV bus and steps down to 6.6 KV which is used to drive the auxiliary equipments /Components so as to enable the plant to generate power. The generator used in 330 MW units is provided with Brushless DC excitation. The 330 MW unit also consists of control panel which works on 220 V DC supply. The control panel indicates the amount of current flowing as well as the voltage of the auxiliary components and the protective devices used for protection purpose. A control panel consists of Relays,Earth switch,CTs,Circuit Breakers,Fuses,MCB,etc. Rating of the STEAM TURBINE GENERATOR is as follows: Output Power: 330 MW Voltage Current Frequency : 24000 V : 9339 A : 50 Hz Power Factor: 0.85 Phase Speed :3 : 3000 r/min

Switchyard Phase-I & II:

It is define as an assembly of apparatus which transforms the characteristics of electrical energy from one form to another i.e. AC to DC or from one voltage to another. And The LAYOUT of switchyard is the most convenient location where systematic electrical apparatus arrangement done. The switchyard is the interconnecting link between the Power Station and the consumer. Generator generates 24 KV voltages and then the generating transformer which is Delta/Star connected generates 220 KV voltages and by the means of conductors the power is supplied to the MRSS lines. In between there are many important apparatus are connected like Lightning Arrester, CVT, Isolator, Circuit Breaker, Current Transformer. There are two current transformer are used one is for the Protection purpose and second one is for the measuring purpose.CT for measuring purpose is having Two core on the secondary side and which is for Protection purpose having 5 core on secondary side. Phase I is having transfer bus for supplying power to the MRSS in case of any one of the main bus is having the problem of maintenance or if the fault occurs in main bus then we can switchover to the transfer bus and supply the power to the load. Phase I is having BUS SECTIONALISER which is having CT, Isolator and SF6 Circuit Breaker. For connecting the Phase I and II there is a Inter Connected Transformers are placed which has a rating of 220/400 KV, 315 MVA. There are two ICT placed in the Phase I and II. Phase I is having Line Conductor for the bus system and Phase II is having Pipe Bus System and having 1.5 Circuit Breaker Scheme which means between the two main bus there is a Three Circuit Breakers are placed. Phase I is having 220 KV switchyard and Phase II is having 400 KV switchyard. Phase I is having all control panels in the control room i.e. relay,fiber optic system etc. And 400 KV switchyard is having all the controlling devices in the field and only fibre optic system is in the control room.

220 KV SWITHYARD (Phase I)

Manufacturer and Main Supplier: ABB LTD.

220KV bus configuration system

2 Main Bus and 1 Transfer Bus scheme is used. Main Bus 1 : 220 kV, 2500 A, 40 kA for 3 sec. Main Bus 2 : 220 kV, 2500 A, 40 kA for 3 sec. Transfer Bus : 220 kV, 1600 A, 40 kA for 3 sec.

Main System Parameters

Nominal Voltage Rated System Voltage Frequency No. of Phase : 220 kV : 245 kV : 50 Hz :3

 Basic Insulation Level BIL

: 1050 kVp

1 Minute Power Frequency Withstand Voltage : 460 kV Cree page Short Circuit Rating (Other than CT) Short Circuit Rating for CT : 31 mm/kV : 40 kA for 3 sec. : 40 kA for 1 sec.

INTRODUCTION OF 660 MW UNITS: There are five 660 MW units consisting of five generators that are coupled to five turbines (each turbine consisting of two LP turbines so that vary low pressure steam can be produced). These five generators generates 22KV which is stepped up to 400 KV by G.T .There are two tappings that are taken from 22KV line that emerges from generator which are fed to the UATs. In 660 MW units the UATs consists of two tappings producing 6.6KV as well as 11KV.11KV is produced so as to feed the 11MW boiler feeder pump motor which is used to feed the demineralized water from the DM plant to the boiler for production of the steam.The generators of 660 MW unit are given DC excitation using carbon brushes i.e. it is given brush excitation. The brush excitation is given by the excitation transformer which is step down voltages from 6.6KV to 415 V and then Automatic Voltage Regulation room converting AC voltages into DC voltages. DC voltages then supplied to the carbon brushes i.e. positive and negative supply is given to the generator excitation scheme. The 400KV that is stepped up by the generating transformer is then passed through the RLC filter circuit to remove the ripples and to obtain a pure sine wave and then is stepped down to 212 KV and is fed to the rectifier circuit. There are two buses in the rectifier house. The rectifier circuit consists of connection of many thyristors in series. Some of the thyristors are connected in STAR and are connected to a bus where as some of them are connected in DELTA and are connected to another bus. Its a Twelve pulse rectifier circuit with a firing angle of 60. The output of the rectifier circuit DC of 500KV magnitude which is then transmitted to Haryana spanning 1050 km.

Rating of the MDBFP Motor: Rated Power : 11000 KW Rated Voltage: 11000 KV Rated current: 654 A Frequency: 50 Hz Connection: STAR Speed: 1487 r/min

Switchyard Phase III & IV:

In APL there are 5 units of 660 MW. Phase III consisting of units 5 and 6. And Phase IV is having units 7,8 and 9. Layout and design of the switchyard is same for the Phase III and Phase IV. Generator generating 22 KV and this voltages directly connected to the Generating Transformer which is stepped up the voltages from 22 KV to 400 KV. In 660 MW units there are Three Single Phase transformers are connected for the generating purpose. Due to higher cost of the insulation providing in the transformer there are three single phase transformer are connected instead of connecting one three phase transformer. After the generation of the 400 KV voltages this voltages are supplied to the HVDC system of the 500 KV. In Phase III and Phase IV switchyard there is a Reactor is placed for the reducing the reactance of the line. Due to the Ferranti Effect the at the receiving end of the line the capacitance and reactance of the voltages will be higher and it will cause damage of the equipment which is connected at the receiving end. So for that reactor are connected in this phase. Reactor is connected to the main bus and the output of the reactor is grounded. This switchyard is also having One And Half Breaker scheme. Which is very costly as compared to the other scheme. In this scheme there are three breakers are placed one is at the Bus-1 , second one is the Tie Circuit Breaker which is used for the connecting the two Bus and the third one circuit breaker is placed at the Bus-2.There are many protection devices are connected in Bay like Current Transformer for the measuring the value of current, Isolator, Earth switch. Earth switch is provided for the earthing purpose and isolator is placed for the protection of circuit breaker. Isolator is always run on OFF Load. When anything is happened in the circuit breaker the isolator will be opened and maintenance of the circuit breaker will be done. Isolator is placed both the sides of the circuit breaker.

INTRODUCTION TO THE HVDC:

Units 7,8 & 9 are generating 660 MW each. Steam Turbine generators are generating 22 KV then these voltages are step up to the 400 KV. These voltages are step up by the generating transformer. Next the power will be supplied to the HVDC department for generating 500 KV DC voltages. In Gujarat only ADANI POWER having this type of HVDC Sub-Station. In this sub-station the voltages will be taken from the generating transformer and by means of line conductor voltages are applied to the capacitor filters are placed for the reduction in the harmonic component and for generating reactive power. This reactive power is applied to the Three converting transformer each has a capacity of 500 MVA. These converting transformers are used for the step down voltages from 400 KV to 211 KV.

Transformer having two types of bushing big and small. Big bushing is used for the Star type connection because in the star connection the current is higher and

the voltages are less as compared to the current. Small bushing is used for the Delta type connection because in this winding voltages is higher than the current. After that the voltages are applied to the Thyristor which converting AC voltages in DC voltages. For the transformer protection one control room is there for operating the valves. This transformers are having the oil tank capacity of 1,35,000 Ltr. Thyristor which is used for conversion process having 12 Pulse with the firing angle of 60 degree. When the DC voltages are generated then the Smoothing Reactor is placed between the generation station and transmission lines. Smoothing Reactor is used for the smoothing the DC voltages. It is also used for the protection against the faulty current. If the fault occurs in the system it will ground the fault current. Then the 500 KV voltages are transmitted to the HARYANA which is 1050 Km. far from the Mundra. HVDC project is the Turn-Key project of SIEMENS. The overall cost of this project is approx.1400 Corers. Special room is there for the thyristor and for other equipments to generate 500 KV DC.