Chapter 1

Introduction
1.1 History:
PAKISTAN is one of the developing countries, where always remaining the deficiency of the power like those of other developing countries, so for this purpose KOT A ! T"#$%A& PO'#$ STATION pro(ect was initiated in )*+, -y 'AP A with the purpose to fulfil the increasing demand of electricity in PAKISTAN. Installing the latest technology completed this power pro(ect. In )**/ following the policy of privatisation 0#NA1I$ 2O3#$N%#NT privatised this power station. NATIONA& PO'#$ 4a !K -ased company5 gave the highest -id, a-out $S 6+ -illion to purchase 7/8 shares of this powerhouse. Thus a company named KAP9O -ecame the owner of this thermal station -ecause according to the contract the management of this organisation was transferred to KAP9O. &ater on KAP9O purchased ):8 more shares from 'AP A. SO now KAP9O is having ;/8 shares of this powerhouse with total management control.

1.2 About The Project:

Kot Addu is situated in istrict %u<affar 2arh, )::=K% north west of %ultan on the left -ank of Indus $iver at a distance of )/=K% from TA!NSA 0A$$A2# in ivision era 2ha<i Khan. The area is covered with fertile agricultural land. There are some ad(acent areas covered with wind -lown land dunes, which were formed with the passage of time. These sand areas too are -eing gradually converted into agricultural land. 'ith the installation of Kot Addu power station, (o- opportunities have -een provided to a-out **7 personnel. 9urrently the strength of the officers and staff is **7. 0eside the regular staff a num-er of people have -een engaged on daily wages also. Kot Addu, which is now on the National map as a power plant site, has -een supplying power on the National 2rid since )*+, through );7 k3 and 77: k3 transmission, lines.

1.3 Site Selection:

'hile making the site selection following factors was kept in view. #>isting PA$9O facility for transportation of "S from Karachi to %ehmood Kot, which is

a-out ;6 km from Kot Addu. ?rom %ehmood Kot, a ): inches pipeline has -een laid to this power station and "S pumping was started in @une )*+*. Sweet under ground water. ?uture load centre of Northwest areas. Possi-le use of 2as from near-y hodak field. Kot Addu (unction railway station. To provide (o-s opportunities to the locals. 2eneral uplift and development of areas.

1.4

About The Plant:

The gas tur-ines, despite of their low installation cost, easy and speedy erection and high rate, perhaps could not win the deserving popularity over the steam tur-ines due to the poor efficiency. In the conventional gas tur-ine unit, su-stantial amount of heat energy was lost through the tur-ine e>haust gases, which leave the tur-ine at a-out 6+: degree centigrade. To make use of this wasteful energy, an innovative concept of the com-ined cycle plant, now has -een introduced -y the gas tur-ine manufacturers. !nder this design, the e>haust of the gas tur-ine is made to pass through a conduction type -oiler. The high=pressure steam so generated is then used to run the steam tur-ine, which thus produces power without any fuel. This raises the plant efficiency to nearly A78 against the 7+8 of the conventional gas tur-ine. 2enerally a com-ined cycle plant comprises of two gas tur-ines and one steam tur-ine. ?or relia-ility of machines, each gas tur-ine is provided with e>haust gases control dampers. These dampers lead the got gases into the -oiler or to the atmosphere as per operation mode of the machine. 'ith this provision, the gas tur-ine can -e run in single cycle mode if the associated steam tur-ine is under maintenance or unavaila-le due to some other reason.

1.

!"er"ie#:

There are many different types of power plants including thermal power plants and hydel power plants. Thermal power plants -urn fuel such as 2as, "S , ?urnace Oil or nuclear fuel to produce heat energy that is converted to electrical energy through a series of intermediate processes. "ydel power plants convert the potential energy of water to electrical power as it flows from higher to lower elevations.

The BtraditionalB thermal power plant is the $ankine cycle plant, named after the man who invented the cycle. A power plant cycle is a series of processes in which a fluid, generally waterCsteam, is used to convert heat energy to mechanical energy. The $ankine cycle in its simplest form consists of a -oiler, a tur-ine, a condenser, and a -oiler feed pump. #arly plants had thermal efficiencies of appro>imately 768 to ;:8. Only 768 to ;:8 of the heat energy in the fuel -urned in these plants was converted to electrical energy. The rest was lost in various ways. The $ankine cycle has -een refined considera-ly over the years and made more efficient -y the addition of components like #conomi<er, ?eedwater heaters, Superheaters and $eheaters. The efficiency of the $ankine cycle has also -een improved -y increasing the pressure and temperature of the cycle. The laws of thermodynamics and considerations such as material limitations have prevented any significant improvement since then. Power plants commonly use heat rate to measure efficiency. "eat rates in KAP9O power plant on different fuels are shown in ta-le ). Thus, heat rate shows the amount of heat in k@Ckwh that is reDuired to produce a kilowatt=hour of electrical energy. Thermal efficiency can -e converted to heat rate -y using the conversion factor given -elow.The heat rate of the KAP9O 2eneration 9omple> varies -etween A:8 to AA8. Thermal efficiency depending on fuel selection and am-ient conditions.

Chapter 2

An Introduction To All $loc%s:&

CC' 1 Block 1 CC' 2 Block 2 CC' 3 Block 3

2.1

Plant (esi)n (ata !* $loc% + ,1:

2.1.1 -as Turbines ,1 . ,2:

%anufacturer %odel Starting evice

Siemens 42ermany5 3 *A.7 2en runs as %otor A min A A7/ kgCsec Iskamatics *6 %'

Starting time upto ;::: rpm Tur-ine Stages ?lue gass mass flow 9ontrol 9apacity I 9

2.1.2 -as Turbines ,3 . ,4:

%anufacturer %odel Starting evice

?IAT %CS 2I# 4Italy5 T2 6: ))K3E)*)6K' 76 min A ;77 kgCsec 9onventional relay type +7 %'

Starting time upto ;::: rpm Tur-ine Stages ?lue gass mass flow 9ontrol 9apacity I 9

2.1.3 Stea/ Turbines ,0 . 1,:

%anufacturer %odel $ated Power 3accume "P Steam inlet pressCTemp &P Steam inlet pressCTemp 9apacity I 9 ST2 F :* 9apacity I 9 ST2 F ):

A00 42ermany5 K7:6/ ))7.7 %' :.:*) -ar A,.* -ar C A*6 9 ;.;* -ar C )*:./ 9 +7 %' *, %'

2.2

Plant (esi)n (ata !* $loc% + ,2

2.2.1 -as Turbines , To ,1:

%anufacturer %odel Starting evice

A&ST"O% 4?rance5 %S *::) # /./K3E):::K' ): min ; A:/ kgCsec %ark A Speedtronic ,* %' +7 %' ,,%' ,* %'

Starting time upto ;::: rpm Tur-ine Stages ?lue gass mass flow 9ontrol 9apacity I 9 2T F :6 9apacity I 9 2T F :/ 9apacity I 9 2T F :, 9apacity I 9 2T F :+

2.2.2 Stea/ Turbines 11 . 12:

%anufacturer %odel

$AT#A! 4?rance5 3#2A 7:*=)):0

$ated Power 3accume "P Steam inlet pressCTemp 9apacity I 9 ST2 F )) 9apacity I 9 ST2 F )7

):;.A %' :.:*) -ar A: -ar C 6): 9 ,/ %' +7 %'

2.3 Plant (esi)n (ata !* $loc% + ,3

2.3.1 -as Turbines 13 . 14:&
%anufacturer %odel Starting evice SI#%#NS 42ermany5 3=*A.7 2en runs as a %otor A min A A,) kgCsec T#&#P#$% ):/ %'

Starting time upto ;::: rpm Tur-ine Stages ?lue gass mass flow 9ontrol 9apacity I 9 2T F :6

2.3.2 Stea/ Turbine 1 :&

%anufacturer %odel $ated Power "P Steam inlet pressCTemp

SI#%#NS 42ermany5 :;:=)/ , N;: G 7H6 G + I* )A+./ %' 6, -ar C 67+ 9

&P Steam inlet pressCTemp 9apacity I 9 ST2 F )6

6.,+ -ar C 77) 9 )7: %'

Chapter 3

Turbine Side
As we are using com-ined cycle in our power station, we will discuss it first then will move forward a-out a little -it description of each part.

3.1

Introduction to Co/bined Cycle Po#er -eneration:

9om-ine cycle refers to a power plant in which a gas tur-ine is integrated with a steam tur-ine cycle unit.The rankine cycle makes use of the much of the heat in the gas tur-ine e>haust gases . Thermodynamically,the com-ined cycle can -e represented -y (oining the high temperature 0rayton cycle with the moderate pressure and temperature $ankine cycle.

Fig Process of GTPS

3.2

2hy co/bined cycle is pre*erable:&

One of the principal reasons for the popularity of the com-ined cycle power plants is their high thermal efficiency. 9om-ined cycle plants with thermal efficiencies as high as 678 have -een -uilt. 9om-ined cycle plants can achieve these high efficiencies -ecause much of the heat e>haust from the gas tur-ine4s5 is captured and used in the $ankine cycle portion of the plant. The heat from the e>haust gases would normally -e lost to the atmosphere in an open cycle gas tur-ine.

Another reason for the popularity of com-ined cycle plant is that it reDuires less time for their construction as compared to a conventional steam power plant of the same output. Although it takes longer time to -uild a com-ined cycle plant than a simple gas tur-ine plant

3.3

Co//on 3uels 4sed In Co/bine Cycle:&

Natural gas is the most common fuel used -y com-ined cycle gas tur-ine power plants. At KAP9O three fuels are used 2as "S 4"igh speed diesel5 ?urnace Oil

3.4

The -as Turbine 5$rayton6 Cycle:&

The ma(or component of the com-ine cycle power plant is the gas tur-ine.In installation where the gas tur-ine e>hausts directly to the atmosphere, it is said to -e operating in Jopen cycleK mode. 'hen a gas tur-ine e>hausts into a heat recovery steam generator 4"$S25 the resultant steam is used to operate a steam tur-ine generator, the plant is referred to as a com-ined cycle power plant. A common arrangement of a gas tur-ine driving an electric generator is shown in figure. The -asic gas tur-ine consists of a compressor, a com-ustion cham-er and a tur-ine. The air is drawn into the compressor, which raise the pressure. The temperature also increases with compression and may -e as high as ;6: 9 at the compressor discharge.

10

Fig Gas Turbine In the com-ustion cham-er , fuel is in(ected into the compressed air and is -urnt to convert the fuelLs chemical energy into heat energy. 0urning the fuel results in a high temperature and high pressure gases with considera-le thermal energy.These hot gases enter the tur-ine where they e>pand ,giving up their thermal energy to the -lades of the rotating tur-ine.In the process of e>panding and cooling through tur-ine ,the thermal energy of gas is converted into mechanial energy that is used to do work.A large of work from the tur-ine ,a-out /:8 is used to drive the compressor .The remaider of the tur-ine work is availale to produce power -y driving a generator.The e>haust temperature of unit )M7 is in the range of 6:,9 to 66:9.

Fig Gas Turbine Rotor

11

3.4.1 7ain Co/ponents !* -as Turbine:

). 9ompressor Assem-ly 7. ;. A. 6. /. ,. ?lame Tu-e 0urner %i>ing 9ham-er Tur-ine Tur-ine shaft #>haust iffuser

Fig

Gas turbine Parts

3.4.1.1

Co/pressor

The a>ial=flow compressor consists of the rotor and the enclosing casing. Included within the compressor casing are the inlet guide vanes, the ), stages of

12

rotor and stator -lades and the e>it guide vanes. In the compressor, air is confined to the space -etween the rotor and stator -lades where it is compressed in stages -y a series of alternate rotating and stationary airfoil= shaped -lades. The rotor -lades supply the force needed to compress the air in each stage and the stator -lades guide the air so that it enters in the following rotor stage at the proper angle. The compressed air e>its through the compressor discharge casing to the com-ustion cham-ers. Air is e>tracted from the compressor 6 th stage for -earing sealing and from ))th stage for pulsation control. Since minimum clearance -etween rotor and stator provides -est performance in a compressor, parts have to -e made and assem-led very accurately.

a6

Co/pressor 'otor:

The compressor rotor is an assem-ly of )6 individual wheels, two stu-=shafts, each with an integral wheel, a speed ring, tie -olts and the compressor rotor -lades. #ach wheel and the wheel portion of each stu-=shaft have slots -roached around its periphery. The rotor -lades and spacers are inserted into these slots. Selective positioning of the wheels is made during assem-ly to reduce -alance correction

b6

Co/pressor Stator:
The stator 4casing5 area of the compressor section is composed of four ma(or sectionsN inlet casing forward compressor casing aft compressor casing compressor discharge casing

These sections, in con(unction with the tur-ine shell and e>haust frame form the primary structure of the gas tur-ine. They support the rotor at the -earing points and constitute the outer wall of the gas=path annulus.

Inlet Casin)

The inlet casing is located at the forward end of the gas tur-ine. Its prime function is to uniformly direct air into the compressor. The inlet casing also

13

supports the no.) -earing housingO a separate casing that contains the P ) -earing.

Fig . 3or#ard Casin)

Inlet Casing

The forward compressor casing contains the first four compressor stator stages

c6

Co/pressor 'otor $lades

14

The compressor rotor -lades are airfoil shaped and designed to compress air efficiently at synchronous speed. The -lades of first eight stages are attached to their wheels -y dovetail arrangements. The compressor stator -lades are also airfoil shaped and are mounted -y similar dovetails into ring segments. The stator -lades of the last nine stages and two e>it guide vanes have a sDuare -ase dovetail that are inserted directly into circumferential grooves in the casing. &ocking keys also hold them in place.

Fig

Com ressor Rotor

3.4.1.2

Co/bustion Section

15

The com-ustion system is of the reverse=flow type with )A com-ustors arranged around the periphery of the compressor discharge casing. This system also includes fuel no<<les, spark plug ignition system, flame detectors and crossfire tu-es. "ot gases, generated from -urning fuel in the com-ustors, are used to drive the tur-ine. "igh pressure air from the compressor discharge is directed around the transition pieces and into the com-ustor liners. This air enters the com-ustion <one through metering holes for proper fuel com-ustion and through slots to cool the com-ustor liner. ?uel is supplied to each com-ustor through a no<<le designed to disperse and mi> the fuel with the proper amount of com-ustion air. 9om-ustors are num-ered counter=clockwise when viewed looking down= stream and starting from the top of the machine.

Fig Combustion !ra

er

16

a6

Co/bustion 2rapper:

The com-ustion wrapper forms a plenum in which the compressor discharge air flow is directed to the com-ustors. Its secondary purpose is to act as a support for the com-ustorLs assem-lies. In turn, the wrapper is supported -y the compressor discharge casing and the tur-ine shell.

To Co'er

Combustor Liner GT 5-8

Retaining 4ut 5ock Plate Insulator Gasket

b6 Co/bustors:
"isc#arge air from t#e a$ial%flo& com ressor flo&s into eac# combustion flo& slee'e from t#e combustion &ra er (see figure). T#e air flo&s u stream along t#e outsi*e of t#e combustion liner to&ar* t#e liner ca . T#is air enters t#e combustor+s reaction ,one t#roug# t#e fuel no,,le s&irl ti - t#roug# metering #oles in bot# t#e ca an* liner an* t#roug# combustion #oles in t#e for&ar* #alf of t#e liner. T#e #ot combustion gases from t#e reaction ,one ass t#roug# a t#ermal soaking ,one an* t#en into a *ilution ,one &#ere a**itional air is mi$e* &it# t#e combustion gases. .etering #oles in t#e *ilution ,one allo& t#e correct amount of air to enter an* cool t#e gases to *esire* tem erature. /long t#e lengt# of t#e combustion liner an* in t#e liner ca are o enings &#ose function is to

Tie Bolt

Terminal 0$tension S ring Cylin*er

1.23 (111 mm) Stroke

Piston 6 Ro* /ssembly

S ark Plug !as#ers

Core /ssembly 07ual Ga s &it#in 8.813 (8.22 mm) 8.8213 (1.39 mm) 8.8883 (8.88 mm)

17

Figure CI-40 Spark Plug Assembly

ro'i*e a film of air for cooling t#e &alls of t#e liner an* ca as s#o&n in figure. Transition ieces *irect t#e #ot gases from t#e liners to t#e turbine no,,les. /ll 11 combustion liners- flo& slee'es an* transition ieces are i*entical.

c6 Cross*ire Tubes:
All fourteen com-ustors are interconnected -y means of crossfire tu-es. Once a flame is esta-lished in one com-ustor, the difference of pressure e>isting -etween a fired com-ustor -asket and an unfired one, is enough to cause a temporary flame through the crossfire tu-e which fires the com-ustor -asket unfired.

d6 Spar% Plu)s:
9om-ustion is initiated -y means of the discharge from two high=voltage retracta-le electrode spark plugs installed in ad(acent com-ustors no. )7 and );. These spring=in(ected and pressure=retracted plugs receive their energy from ignition transformers at ); K3. At the time of firing, a spark at one or -oth of these plugs ignites the gases in a cham-erO the remaining cham-ers are ignited -y crossfire through the tu-es that interconnect the reaction <one of the remaining cham-ers. As rotor speed increases, cham-er pressure causes the spark plugs to retract and the electrodes are removed from the com-ustion <one.

e6 3la/e (etectors:
uring the starting seDuence, it is essential that an indication of the presence or a-sence of flame -e transmitted to the control system. ?or this reason, a flame monitoring system is used consisting of four sensors which are installed on four com-ustors no. ;, A, 6 and )), and an electronic amplifier which is mounted in the tur-ine control panel. The ultraviolet flame sensor consists of a flame sensor, containing a gas filled detector. The gas within this flame sensor detector is sensitive to the presence of ultraviolet radiation which is emitted -y a hydrocar-on flame. A dc voltage, supplied -y the amplifier, is impressed across the detector terminals. If flame is present, the ioni<ation of the gas in the detector allows conduction of current in the circuit which activates the electronics to give an output defining flame. 9onversely, the a-sence of flame will generate an opposite output defining Bno flameB. After the esta-lishment of flame, if voltage is re=esta-lished to the sensors defining the loss 4or lack5 of flame a signal is sent to a relay panel in the

18

tur-ine electronic control circuitry where au>iliary relays in the tur-ine firing trip circuit, starting means circuit, etc. shut down the tur-ine. The J?ailure to ?ireK or J&oss of ?lameK is also indicated on the annunciator. If a loss of flame is sensed -y two flame detector sensor, the control circuitry will cause an annunciation only of this condition.

*6 3uel 8o99les:
#ach com-ustor is eDuipped with a fuel no<<le that emits the metered amount of the reDuired fuel into the com-ustion liner. The fuel no<<le functions to distri-ute the liDuid fuel into the reaction <one of the com-ustion liner, in a manner which promotes uniform, rapid and complete com-ustion.
Purge /ir Fuel Gas

GC< Gas Control <al'e

Atomi<ing air is utili<ed with liDuid fuel to assist in the formation of a finely divided spray. The liDuid fuel and atomi<ing air enter the fuel no<<le assem-ly through separate connections. Then, they are introduced through separate -ut concentric passages in the no<<le -ody. ?uel enters the inner passage. Atomi<ing air enters around the fuel no<<le and split fuel into very fine particles. In this way fuel ignites easily and -urns completely. ?uel -urning process completes within com-ustor liner <one and flame finishes after the liner. Therefore, only flue gas enters into the transition piece.

SR< S ee* Ratio <al'e

Purge air <C=%2

Combustion /ir Gas outlet /tomi,ing /ir

5i7ui* Fuel Inlet

Fig System :f Fuel 4o,,le

5i7ui* Fuel "rain

;S" or Furnace :il Combustion /ir /tomi,ing air

<C=%1

To Sum Tank

19

Fig Fuel 4o,,le

3.

The Stea/ 2ater 5 'an%ine 6 Cycle

The -oiler 4often called a steam generator5, A tur-ine, A condenser A -oiler feed pump.

A simple $ankine 9ycle consists of only four componentsO

The efficiency of conventinal steam power plants is a-out ;:8 to ;68 . Actual steam power plants are considera-ly more comple than the simple cycle as shown in figure. 0ecause the components such as #conomiser,&PM"P ?eed water heaters,Air preheater are added to improve efficeincy.Typically only +68 to *:8 of the heat energy input is a-sor-ed in -oilers.This means tat the -oiler is only +68 to *:8 efficient. The $ankine 9ycle used in conventional steam power plants can -e represented on a T=S diagram. As with the 0rayton 9ycle, each line segment corresponds to a process in the cycle.

20

0oiler is shown with a superheater, thus the steam entering the tur-ine is a-ove saturation temperature.

Fig > Gra # :f Rankine Cycle

i.

Issentropic :;pention5Stea/ Turbine6

The working fluid is pumped from low to high pressure, as the fluid is a liDuid at this stage the pump reDuires little input energy.

ii.

Isobaric Heat 'ejection5Condenser6

The high pressure liDuid enters a -oiler where it is heated at constant pressure -y an e>ternal heat source to -ecome a dry saturated vapor.

iii.

Isentropic Co/pression5Pu/p6

The dry saturated vapour e>pands through a tur-ine, generating power. This decreases the temperature and pressure of the vapor, and some condensation may occur. The output in this process can -e easily calculated using the #nthalpy=entropy chart or the steam ta-les.

21

i"

Isobaric Heat Supply5$oiler6

The wet vapour then enters a condenser where it is condensed at a constant temperature to -ecome a saturated liDuid. In an ideal $ankine cycle the pump and tur-ine would -e isentropic, i.e., the pump and tur-ine would generate no entropy and hence ma>imi<e the net work output. Processes )=7 and ;=A would -e represented -y vertical lines on the T=S diagram and more closely resem-le that of the 9arnot cycle. The $ankine cycle shown here prevents the vapor ending up in the superheat region after the e>pansion in the tur-ine, which reduces the energy removed -y the condensers.

3. .1

Stea/ Turbine

The tur-ine converts the thermal and kinetic energy of the steam into rotational mechanical energy. ST=)6 has 7/ stages of "P and +Q+ stages of &P tur-ine and their sealing steam system. There are two types of tur-ine -lades, Impulse and $eaction types. Normally, tur-ine consists of com-ination of impulse and reaction types. The main steam flows to the steam tur-ine which drives the air cooled generator of ma>. ),6 %3A .The steam tur-ine is designed as a single = shaft machine with separate "P and &P sections. The "P section is a single flow cylinder and the &P section is a dou-le flow cylinder. Tur-ine -ypass system is to dump the e>tra steam in the condenserduring start up and steam unloading conditions.

22

Fig

Steam turbines

3. .1.1

I/pulse Turbine :

The -asic idea of an impulse tur-ine is that a (et of steam from a fi>ed no<<le pushes against the rotor -lades and impels them forward. The velocity of the steam is a-out twice as fast as the velocity of the -lades. Only tur-ines utili<ing fi>ed no<<les are classified as impulse tur-ines.

3. .1.2

'eaction Turbine:

A reaction tur-ine utili<es a (et of steam that flows from a no<<le on the rotor. Actually, the steam is directed into the moving -lades -y fi>ed -lades designed to e>pand the steam. The result is a small increase in velocity over that of the moving -lades. These -lades form a wall of moving no<<les that further e>pand the steam. The steam flow is partially reversed -y the moving -lades, producing reaction on the -lades. Since the pressure drop is small across each row of no<<les 4-lades5, the speed is comparatively low. So more rows of moving -lades are needed in a reaction tur-ine than in an impulse tur-ine.

23

3. .2

Heat 'eco"ery Stea/ -enerator

The "$S2 is -asically a heat e>changer composed of a series of economiser,evaporator and super heater sections.These sections are positioned from gas inlet to gas outlet to ma>imi<e heat recovery from the gas tur-ine e>haust gases.The heat recovered in the "$S2 is used to supply steam to the steam tur-ine at the proper temperature and pressure. In open cycle mode of operation,the temperature of e>haust gases of unit ) and 7 leaving KAP9O is 6:, 9 to 66: 9. "igh temperature gas represents a source of heat energy,some of which can -e recovered if the means to do are availa-le. 0y recovering some of this waste heat,the output and the efficiency of a power plant is increased. The function of heat recoThe function of heat recovery steam generator 4"$S25 is to recover the waste heat availa-le in these e>haust gases and transfer that waste heat to water and steam.The heat is used to generate steam at high pressure and high temperature.The steam is then used to generate additional power in a steam tur-ine driven generator.The "$S2 provides the critical link -etween the gas tur-ine and the rankine cycle in a com-ined cycle plant. The "$S2 is a key component in com-ined cycle efficiency.

3. .2.1

HP section:

24

The "P section consists of #conomiser, #vaporator, and 9irculation system for economiser and evaporator and Super heater.

3ro/ Condensate Pu/ps

"earator Fee* !ater Storage Tank

<P 3# Pu/p 5P "rum HP 3eed#ater Pu/p

<P :"aporator

HP :cono/i9er ;P "rum
.

HP :"aporator

Super heater 3lue -ases Inlet = 4, >C

To Stea/ Turbine "esu er#eater

Figure ! " #$SG-! Simpli%ie& 'iagram

3. .2.2

<P section:

The &P section consists of #vaporator and 9irculation system for evaporator. The re=circulating pumps cause the mechanically induced circulation in the -oiler.

3. .2.3

Pu/ps:

These pumps are installed for the circulation of water and they include "P ?eedwater pumps or "P #vaporator recirculation pumps deliver the feedwater into -oiler drums of the steam generators at the design pressure under all operating conditions. The function of the circulating water system is to provide a heat sink for the condenser and remove the heat to the environment via the cooling tower. ?urther the system is connected with the closed cooling water system via the service cooling water system. &P ?eedwater pumps or &P #vaporator recirculation pumps feed the water from the storage tank to the drums of the preheating system in the "$S2Ls in order to preheat the feed water in the feed water storage tank.

3. .2.4

HP Syste/:

The "P=system of the -oiler is producing the "P steam. ?or this purpose it has to -e supplied with the right amount of feedwater at any time during its operationN

25

e.g. during start up, load variations etc. Additional it has to produce steam of a specific Duality, which means of correct pressure and temperature which varies again with the different operation modes and load conditions. The "P=system generates steam at /: -ar I 6;: R9 from the thermal energy contained in the 2T e>haust gas.

3.2.2.2

<P Syste/:

The &P=system of the -oiler is producing the &P=steam. ?or this purpose it has to -e supplied with the right amount of feedwater at any time during its operationN e.g. during start up, load variations etc. The &P=steam in the range of ;=): -ar is used for condensate heating and for the feedwater deaeration in the deaerator.

3. .3

Condenser and ?accu/ Pu/p

It condenses steam when it finishes its work and e>it from the tur-ine. 3acuum pump regularly runs to evacuate any air accumulation in the condenser.

3. .3.1

Condensate Tan%:

One condensate storage tank for controlling the water level is provided. The condensate is further deaerated in the feedwater tank to the specified o>ygen content

3. .3.2

Condensate Pu/p:

0oth the e>haust steam and the -ypass steam are condensed -y means of a water cooled -o> type condenser. 9ondensate pumps take suction from the condenser hot well and discharge through the gland steam condenser and the &P=preheater to the feedwater storage tank

Chapter 4

The :lectrical Section

26

4.1 The -enerator :

Synchronous generator or alternator is used to convert mechanical energy into electrical energy. ItLs working principle is as followsN

4.1.1 2or%in) principle:

According to ?areadayLs law of electromagnetic inductionN JIf there is a relative motion -etween conductor and magnetic field, then an #%? will -e induced into the conductorK. To create this relative movement, it doesnLt matter weather the magnet is rotating and the conductor is stationary or weather the conductor is moving and magnet is stationary. The magnitude of the induced #%? is directly proportional to the No of conductors 4N5 and the rate of change of magnetic flu> crossing the conductors. # S N 4dTCdt5

4.2

(i**erence bet#een AC )enerator and (C )enerator:

27

There is one important difference -etween an A9 and 9 generator. In 9 2enerator the armature rotates -ut the field system remains stationary -ut in A9 generator the case is reverse -ecause here armature remains stationary -ut field winding rotates. The general thing to keep in mind in this reference is that armature is a thing which produces alternating magnetic field. So in 9 this magnetic field is -eing produced -y rotor which is called the armature and in A9 this remains stationary and here it is called the stator. The stator consists of a cast iron frame which supports the armature core having slots on its inner periphery for housing the armature conductors. In a slip ring induction machine the rotor winding terminals are coming out and then they are supplied with a 9 supply to produce the stationary magnetic field which is converted into the rotating magnetic field -y rotating the rotor -y an e>ternal source which is called the prime mover. 'hen the rotor rotates, the stator conductors are cut -y magnetic flu>, hence they have an induced #%? produced in them. As magnetic poles are alternately N and S, they induce an #%? and hence current starts flowing in armature conductors, which first flows in one direction and then in the other. "ence alternating #%? is produced in the stator conductors whose freDuency depends on the No of N and S poles moving past a conductor in one second and itLs direction is given -y ?lemingLs right hand ruleN ?irst fingerUUUUUUUU..%otion of the conductor Second fingerUUUUUUU. irection of current Thum-UUUUUUUUUU irection of #%? induced

4.3

2hy #e use stationary ar/ature@

The advantages of having stationary armature and a rotating field system areN ). The output current can -e led directly from fi>ed terminals from the stator to the load circuit without having to pass it from -rush contact. 7. It is easier to insulate stationary armature winding for a high A9 voltage which may have a high value as ;: kv or more. ;. The sliding contacts 4slip rings5 are transferred to the low voltage, low power 9 field circuit which can therefore -e easily insulated. A. The armature winding can -e more easily -raced to prevent any deformation -eing produced -y the mechanical stress set up as a result of short circuit current and the high centrifugal force.

(ata sheet:

28

Type of generator Type of winding esigned for freDuency $ating esigned for power factor 4cos W5 SeDuence of phases Type of e>citation #>citation voltage #>citation current Type of cooling %a> air cooling temp. Stator weight $otor weight

; G phase VV 6: "< );6::: K3A :.+6 !3' #>ternal ;;; 3 /A) A Air cooling A:R9 )/6 tons ;* tons

4.4 (etails o* construction:

29

The two pole generator uses directly air cooling for the rotor winding and indirect air cooling for the stator winding. All types of losses 4iron, friction, windage, stray and etc5 are also dissipated through air. 2enerally a generator consists of following partsN ). 7. ;. A. 6. /. ,. +. Stator $otor #>citation system 9ar-on -rushes and Slip rings $etaining rings 0earing $otor grounding system 9ooling system

516

Stator
It is a stationary part of the generator. The stator has two main componentsN Stator frame %agnetic core Stator winding Stator #nd shields

i.

Stator *ra/e:

The frame is for to support the laminated core and winding and also for to increase the mechanical strength of the machine. It is the heaviest part of the generator. Air ducts are provided for the rigidity of stator frame. #nd shields are also -olted to this frame. ?or the foundation purposes feet are provided.

30

ii.

7a)netic core:

The stator core is stacked from insulated electrical sheet=steel laminations with a low loss inde> and suspended in the stator frame from insulated guide -ars. The entire magnetic core is -uild up of thin laminations in order to minimi<e the hysteretic and eddy current losses of rotating magnetic field which interact with core. #ach lamination core is made up from a num-er of individual segments. The segments are punched in one operation from .;6 thick electrical sheet steel lamination having high silicon content. The core is stacked with lamination segments in individual layers while -eing supported on the pressure plate. The segments are staggered from layer to layer so that a core of high mechanical strength and uniform permea-ility to magnetic flu> is o-tained. The No of slots are created in the core to accommodate the stator winding. The complete stack is kept under pressure and located in the frame -y means of clamping -olts and pressure plates. If there is any damage to the core occur during operation, then Alcid test is performed to check the insulation -etween layers.

31

Fig ( stator core)

iii.

Stator #indin):

It is no-le part of the generator. It is composed of conductors wedged into the magnetic core. #ach stator slot accommodates two -ars. There are two distinct parts of stator windingN ). The straight part is within magnetic core. 7. The end winding which are outside the core and which serve to connect -ars of different slots together to complete the winding. This winding is fractional pitch two layer type consisting of individual -ars. In order to minimi<e the stray losses, the -ars are composed of insulated strands which are transposed -y ;/:R.

32

Fig(stator en* &in*ing) According to the %icalastic system, high voltage insulation is provided -y which several half=overlapped layers of mica are applied to the -ars. The mica tapped is sandwiched -etween two fa-ric layers with epo>y as an adhesive. The No of layers depends upon the machine voltage. This high voltage insulation o-tained is characteri<ed -y e>cellent electrical, mechanical and thermal properties in addition to -eing fully waterproof and oil resinant. To minimi<e the 9orona discharge -etween the insulation and the slot wall, a final coat of semiconducting varnish is applied to the surface of all -ars within the slot range.

i".

Stator :nd shields:

The stator end shields are attached to the end of the stator frame. It contains the generator -earings and also the generator coolers. The generator coolers are accommodated in the vertical wells of stator end shields. The -earing oil is supplied to the -earing saddle via a piece permanently installed in the end shield and is then passed on to the lu-ricating gap via ducts in the lower -earing sleeve. The oil drained from the -earing is collected in the -earing compartment, then it is discharged from the lower half of the end shield and then is returned to the tur-ine oil tank.
33

Fig (stator en* s#iel*)

:lectrical connection o* bars and Phase connectors:

#lectrical connection -etween the top and -ottom -ars is made -y -ra<ing. One top -ar strand -eing -ra<ed to one strand of associated -ottom -ar, so that the -eginning of each strand is connected without having any electrical contact with the remaining strands. This connection offers the advantage that circulating current losses in the stator -ars are kept small. The phase connectors consists of flat copper sections, the cross section of which results in a low specific current loading. The ends of each phase are attached to the circular phase connector, which leads from winding ends to the top of the frame. The phase connectors are mounted on the winding support, using clamping pieces and glass fa-ric tape.

34

Fig (stator en* &in*ing)

526

'otor:

It is the rotating part of the generator. It is driven -y the tur-ine and it creates rotating magnetic field. There are two types of rotorN 9ylindrical type Salient=pole type The cylindrical type rotor is used in tur-o alternators and a having a uniform air gap. Normally it is used in all types of thermal power stations where the rotating speed of rotor is high like ;::: rpm in PAKISTAN. ?or ;::: rpm, it has two poles. The field winding is accumulated in slots on the solid rotor. Salient pole rotors are used for low speed operation like a-out )/, rpm for 6: "<. ?or this arrangement, we use ;/ poles of the rotor. $otor has the following main componentsN

35

i6

'otor sha*t:

The rotor shaft is made of single gorging whose ingot is made in an electric furnace and then vacuum cast. The rotor consists of an electrically active portion and the two shaft ends. A forged coupling is used to couple the rotor to the tur-ine. The longitudinal slots hold the field winding. Slot pitch is selected so that two solid poles are displaced -y )+:R electrical. In these slots field coils are milled into shaft -ody and is arranged so as to generate magnetomotive force wave approaching a sine wave. $otor teeth are provided with a>ial and radial ducts ena-ling the cooling air to -e discharged into the air gap for intensive cooling of the end winding.

Fig (rotor s#aft)

ii6

'otor #indin):
$otor winding has also two distinct partsN ). The shaft contained in shaft -ody. 7. The part outside the shaft -ody.

The rotor winding consists of several coils which are inserted into the slots and series connected such that two coil groups form one pole. #ach coil consists of several series connected turns, each of which consists of two half turns which are connected -y -ra<ing in the end section. The insulated turns are insulated from each other -y strips of laminated glass fa-ric. The edges of slots is made up of high conductivity material and they are there to act as damper winding. At the ends the clots are short circuited -y retaining rings.

36

iii6

'otor *an:

The generator cooling air is circulated -y two a>ial flow fan located at the end of the shaft. To argument the cooling of the rotor winding, the pressure esta-lished -y the fan in con(unction with the air e>pelled from the discharge port along the rotor.

The moving of the fan have threaded roots for -eing screwed into the rotor shaft. Threaded roots fastening permits the -lade angle to the reDuired level.

536

:;citation syste/:

The e>citation system is to supply the direct current to rotor which allows the generator to maintain a controlled voltage -etween itLs terminals when connected to the network. The e>citation system is driven -y a voltage regulator. The e>citation power for the generator is supplied -y an e>citer with rotating diodes that are fitted at the end of main generator shaft. The e>citation voltage is developed -y rotating diode -ridge that supplies the rotor winding. These rectifying diodes are given supply -y an e>citation transformer of which the primary winding is supplied -y the main generator. Then the secondary winding is rectified -y a three phase thyrister -ridge. The e>citation eDuipment, Slip ring, and car-on -rushes are used to supply the e>citation current to the rotor. If there comes a need to change the -rushes of the machine during operation at full load or any load, -rush gear assem-ly is used to do this (o-. uring start up and in case of stator voltage drop, the e>citation power is supplied -y 77: 3 9 source. e= e>citation of the generator is performed -y the

37

opening of the e>citation contactor and a non linear resistor ensures the discharging of the e>citer.

i6

:;citation connection:

The current supplied -y e>citation unit to the rotor winding is sent through -ars 4central shaft connection5, radial connecting rod, and outer a>ial connection that feed directly into the winding. It is made up of two shaped solid -ars, separated -y a layer of insulation and housed in shaft -ore.9ar-on -rushes and two slip rings arranged at the end of the shaft. The electrical connection -etween slip rings and rotor winding is esta-lished -y means of radial -olts and insulated conductors arranged in hollow -ore of rotor at the e>citer end.

546

Carbon brushes and slip rin)s:

?ield connection provide electrical connection -etween rotor winding and slip ring. Steel slip rings are fitted to the shaft e>tension at the non drive end and insulated from the end. The slip ring contain a uniform current distri-ution.

Fig

(sli ring)

9ar-on -rushes are used to make live connection -etween the e>citation system and rotor winding, -ecause our rotor is moving continuously and this is the only option to make such a connection.

38

Fig Rings

Sli

The slip rings have a>ial and radial holes for ventilation of slip ring. This forced ventilation system ensure the removal of car-on dust sue to -rush wear.

5 6 'etainin) rin):
The end winding which are e>tend -eyond the shaft -ody are held against centrifugal forces -y retaining ring of non magnetic steel cylinders. One end of each ring is shrunk on the rotor -ody, while other end of the ring over hangs the end winding without contacting the shaft. The shrunk on the end ring at the free end of the retaining ring serves to reinforce the retaining ring and also secures the winding in the a>ial direction. A snap ring is provided for additional protection against a>ial displacement of the retaining ring.

39

Fig

(retaining ring)

To reduce the straw losses the ring is made up of non=magnetic material. 9omprehensive tests such as ultra sonic e>amination and liDuid penetration e>amination ensures the specified mechanical properties.

5A6 $earin)s:
0earing are used to lift the shaft, to make the vi-ration of rotor as small as possi-le and to make the friction during the movement of the shaft. As shaft is connected with -earing, this shaft is lifted -y oil flowing in the -earing. Ta main purpose of using oil in these -earings is cooling of -earings which are heated -ecause of running of the shaft. ?riction is also reduced when we use oil in the -earing.

To

eliminate the shaft currents, all -earings are insulated from the stator and -ase plate respectively. The temperature of the -earing is monitored -y thermocouples mounted tin the lower -earing part so that the measuring points are located directly -elow the -a--it.

5B6 'otor )roundin):

2rounding system is necessary thing to make the generator grounded -ecause when we are working at the generator then flu> or static charge which was stored in the rotor winding during operation is needed to -e grounded. That flu> can -e harmful if not grounded.

40

2rounding -rushes are fitted to the stator end shield.

516

The coolin) syste/

The heat losses arising in the generator interior are dissipated to the secondary coolant 4cooling water5 through air. irect cooling of rotor removes hot spots and differential temperature -etween the ad(acent components. Indirect cooling is used for stator winding. Air and hydrogen are two cooling media for the generator cooling. The field and armature copper losses are evacuated -y airC hydrogen gas flowing inside the generator. The a>ial fans circulate the air. In KAP9O all generators are air cooled.

i6

Ad"anta)es o* Air coolin)

). lower cost price 7. #asy maintenance ;. Short inspection

ii6

Air coolin) circuit

41

9ooling air is circulated in the generator -y two a>ial=flow fans on the rotor shaft. 9old air is drawn -y fans from cooler and then divided into three partsN 3lo# path 1:

Is directed into the rotor end winding and cools the rotor winding. Along this path heat of the rotor winding is directly transferred to the cooling air. 3lo# path 2:

Is directed over the stator end winding to the cold air ducts and in the stator frame space -etween the generator housing and the stator core. 3lo# path 3:

Is directed into the air gap via the rotor retaining rings. This path mainly cools the rotor retaining rings, the end of the rotor -ody and end portion of the stator frame. Then this flow of air is mi>ed up in air gap from where it goes for the cooling of the other remaining portion of the stator core and the stator winding. The hot air is returned to the cooler via hot air ducts recooling and draw again -y the fans.

42

Fig (air circulation system)

iii6

Air cooler:

43

Air cooler is shell and tu-e type heat e>changer which cools the air in the generator.

?our identical coolers are provided. The stator end shields contain the vertically mounted coolers. The cooler section is solidly -olted to the upper half of the stator end shield. All four coolers are parallel connected on their water side. The reDuired cooling water flow depends on the generator output and is ad(usted -y control valves on the hot water side.

i"6

Ad"anta)es o* hydro)en coolin) syste/:

). 'indage losses of the rotor turning are only )8 of those in air. 7. The higher thermal conductivity of "ydrogen allows generator to develop 768 more output than those of air. ;. "ydrogen increases the life of generator -ecause of the a-sence of O>ygen. A. The X of generator can -e taken as *+8 with air cooling and **8 with hydrogen cooling.

"6

(ra#bac%s o* Hydro)en coolin):

44

). 2enerator -ody must -e gas tight. 7. Special type of oil seal is used on the -earing to stop the leakage of "ydrogen. ;. Precaution should -e taken to prevent any air leakage into the machine. A. A mi>ture of air and hydrogen inside the machine casing is risky and may cause in e>plosion.

"i6

Stator coolin):

The magnetic core is cooled -y the air flowing through the radial vent ducts under the action of the fans. The vent ducts are formed -y splitting up the core, along itLs whole length into packets separated from each other -y radial spacer ri-s. 9ore cooling is thus of radial type. The current flowing through the stator winding creates heat losses which is escaped to the core due to close contact -etween the winding and core. This is called indirect cooling. The end winding area is cooled circulation of air.

"ii6

'otor coolin):

The main rotor heat losses occur in the field winding. It is dissipated -y direct contact with air flowing through the coil. The slot portion of the winding is cooled circulating air. All rotor winding is su-divided into four cooling <ones. One cooling <one includes the slots from center to the end of the rotor -ody, while another cover s half of the end winding. This generator is now connected to the unit transformer converting the out put voltage into );7 kv4-lock )5 or 77: kv 4-lock 7 M ;5 which then goes to the switch yard for the transmission purposes. The cooling air for the slot portion is admitted into the slot -ottom ducts -elow the rotor winding. The hot air is then discharged into the air gap -etween the rotor -ody and stator sore though radial opening in the conductors and in the rotor slot wedges. The cooling air is drawn from -elow the rotor end winding. It rises radially along the individual coils and is then discharged into the air gap via ssssa>ial and radial slots in the end portion of the rotor teeth.

45

Chapter

The Trans*or/er
.1 2or%in) Principle !* The Trans*or/er:

A transformer is a static piece of apparatus -y means of which electric power in one circuit is transformed into the electric power of the same freDuency in another circuit. It can raise or lower the voltage in a circuit -ut with a corresponding increase or decrease of the current. The overall power remains same to the -oth sides of the transformer.

The -asic working principle of the transformer is the mutual induction -etween two circuits linked -y a common magnetic flu>. Simply it consists of two inductive coils which are electrically separated -ut magnetically coupled with each other. If one coil is connected to an A9 source, an alternating flu> is setup most of which is linked with the other coil in which it produces mutually induced e.m.f. according to the ?aradayLs &aw of electromagnetic induction. This law states that,

46

J'hen one coil is placed in such a medium where it faces change in the flu> then an emf is induced in that coilK %athematically, we can say that eS % dICdt where e S Induced voltage % S mutual inductance dI S rete of change in the current dt S rate of change in time If the circuit of the second coil is closed, a current flows in it and so in this way electric energy is transferred from one coil to the coil. The first coil in which electric supply is connected is called the primary coil and other coil to which the power is supplied is called the secondary coil. In a -rief transformer is a device that Transfers electric power form one circuit to the other. It does so without change in freDuency. It accomplishes it -y the electromagnetic induction. 'here two circuits are electrically isolated -ut magnetically coupled.

.2

Trans*or/er construction:

Simple elements a transformer consist of two coils having mutual inductance and laminated steel core. The two coils are insulated from each other and from the steel core. Other necessary parts areN Some suita-le container for the assem-led core and winding. Suita-le insulating medium to provide insulation -etween the core and its winding from itLs container. Suita-le -ushing for insulation and -ringing out the terminals of the winding from the tank.

.3

Types o* the Trans*or/er:

47

In all types of transformer, the core is constructed of transformer sheets, steel laminations to provide a continuous magnetic path with minimum air gap. Transformers are classified -y several meansN 9onstruction wise. !se wise According to cooling media According to consumer 0ased upon rating

Or -y some other means.

.3.1 Construction #ise:

9onstructionally, transformers are of two general types. Shell type. 9ore type.

They are distinguished from each other -y such manner in which the primary and the secondary coils are placed around laminated steel core.

.3.2 4se #ise

Transformers can -e classified according to there use. e.g. Instrument transformer istri-ution transformer Power transformer !nit au>iliary transformer &ow voltage au>iliary transformer Start up transformer Instrument transformers are of very small rating and mostly they are used in appliances. istri-ution transformers are those which are directly connected with the consumer or which are looked -eside roads or in streets. Power transformers are those which are connected to the transmission lines. They convert power from very lowChigh voltage to very lowChigh current keeping the power same.

.3.3 $ased upon ratin)

48

'e can classify them according to there rating. e.g. 7:kva,)::kva, 6::kva,):::kva and n the same pattern the others.

.3.4 Accordin) to coolin) /edia

They are classified as,

ry 4Air cooled5

These are used according to the environment temperature and heat dissipation. They are less e>pensive and they reDuire less maintenance. Its main disadvantage is that itLs output rating decreases -y )amp with an increase of )Yc temp.

.3.

Accordin) to consu/er

Transformers are also classified -y means that how a consumers uses it. Step up trans*or/er

"ere turns of secondary are large then that of primary. i.e. output voltage is greater than input voltage -ut on the other hand, primary current is large than that of secondary. Step do#n trans*or/er

"ere reverse process takes place than that of the step up transformer. Generally following type of transformers are used in our power house: !nit transformer Start up transformer Au>iliary transformer &ow voltage au>iliary transformer

.4 4nit trans*or/er
(ata sheet
49

$ating Type of transformer Type of cooling ?reDuency 'inding $ated voltage Tape changer type 9onnection

,,C*6.6 %va unit step up transformer Three phase, core type, oil immersed power transformer ONANCONA? 6: "< Primary ))kv On load Star VNd)) elta Secondary );* Z ,[).A7+8

3ector group 4primary to secondary5 The neutral of the transformer is solidly grounded

.4.1 !ur 4nit Trans*or/er Consist !* 3ollo#in) Parts:

). Power fans 7. 9ondenser type -ushing ;. Oil conservator A. 0uchol< relay 6. Air drier /. Pressure relief valve ,. Thermostat and thermometer +. Iron and oil temp detector *. 9urrent transformers ):. Tap changer )). #arthing tower )7. ?ire protection cooling system );. Automatic voltage regulator

516

Po#er 3ans:

50

The natural cooling of the transformer can -e increased -y the addition of power fans placed at the -ase or along the side of radiators, whether they are fitted directly to the tank or groups in outside gangs. The fans are of helical type and are of capa-le of generating an air flow. The motor designed for an a-sor-ed power .76 \) "P is closed, self cooling, with cage rotor and mounted on -earing. Normally the fans are controlled automatically through a thermostate. In addition to make manual operation possi-le as well, a preselector is often -uilt into the system, allowing operation -y means of push -uttons on the protection and control cover. 'hen forced cooling is provided the power fans unit is split into two units each controlled through itLs own switch -y same thermal relay. 7aintenance

Once a month, it is advisa-le to check the operation of the fans and to remove all traces of drift dust from the fan wheel -lades. The motor -earing do not reDuire any lu-ricant, s this is put into the closed housing of the -earing at the time of assem-ly.

526

Condenser type $ushin):

The -ushing are packaged in cases, generally in the vertical position. Packing is provide to protect the -ushing from -lows and moisture during transients. %oreover, the part of each -ushing normally immersed in oil is protected from moisture -y a cup shaped metal or plastic covering directly fitted to the -ushing flange. On spare -ushing, not used for transformer testing, a water proof film may -e found for some construction type on the surface of resin paper. 0efore using the -ushing this film should -e removed with a -lunt tool, so as not to damage the surface underneath. The -ushing should -e stored in dry place, always in the vertical position, even for short period.

536 At/oseal Type air&cell oil conser"ator:

51

?or air cell conservator the contact -etween oil and ouside air is prevented. %oreover the pressure on the oil surface remains constant and eDual to the atmosphere pressure. 'hen transformer is running, it reDuires a very small maintenance limited to routine inspection. In conservator an oil resistant, fle>i-le, ru--er oil=cell is arranged in communication with the outside through a dreir that prevents condensation in the cell. The air cell gets -igger or smaller so as to compensate oil volume variations and to keep pressure an oil surface at the atmospheric valve.The working condition of the 0uchols relays installed on the tank to conservator pipe are not out all affected -y the air cell. Co/ponents:

). 9onservator designed to allow oil e>pansionfrom =7:9 to *:9. 7. Oil resistant ru--er air=cell ;. Silica gel drier on the pipe -etween air=cell and outside air 4in order to avoid that most air enters the cell and forms condensated5. A. On=Off valve on pipe. 6. 2ate valve for filter pressure for connection of vacuum pump during operations. /. 2ate valve for eventual vacuum gauge. ,. 0y pass -etween air cell inside the conservator. +. Overpressure valve. *. Oil level gauge in conservator. ):. $emova-le -ottom to allow air=cell assem-ly and conservator cleaning. )). 0uchols relays with On=Off valve )7. 9onservaotr drain cock. );. Oil level window.

546 $uchhol9 type )as accu/ulation relay:

This relay is provided for transformer protection when electrical -reakdown occurs -etween the live parts, or in the event of fault to ground, short circuits -etween turns, phase interruptions, -urning of core, oil leakage in the tank or in the oil cooling system. This relay will operate on the occurrence of gas formation or on sudden variations of oil level resulting from a-normal transformer conditions -y actuating an alarm signal and if the fault is serious or persistent, -y putting the transformer out of service.The 0uchhol< relay is installed directly on the oil pipe connecting the tank to the conservator and is normally flooded with oil, in which itLs inner armature is permanently immersed with the actuating device. The upper contact for signalling purpose is closed -y operation of pertaining float, when due to an inflow of gas to the relay or the other reason, the oil level contained in the upper part of the relay is lowered.

52

The lower contact which controls the tripping circuit, is operated -y the corresponding float when the oil level reaches the lower part of the relay. The vane is fitted with an ad(usta-le counterpoise, provided to select the desired oil speed at which the cooling should occur, thus closing he contact to trip the circuit -reaker of the transformer. In the event that an internal fault should occur in the transformer, thee gas developed and collected in the 0uchhol< relay actuates the alarm and tripping contacts. Thus the speed of gas accumulation and conseDuently the speed of action depends upon the e>tent of fault. The alarm and trip contacts are also closed in the event that the oil level should -ecome e>ceedingly low. 'hen the alarm and tripping contacts close, it is necessary to check through the relay windows the colour and Duantity of gas. 2enerally, colourless gas indicates decomposition of paper and card -oard, yellowish gas denotes faults in wooden parts, grey denotes -urning of core and -lack means oil decomposition. In order to facilitate gas inspection the relay is connected -y means of a pipe to a gas collector located at manLs height. Such device consists of -o> with wide windows, eDuipped with two cocks, -esides the one for the connection to the relay. One of them is for gas -reathing and the other is for oil drain. In order to see weather the gas is inflamma-le , open very slightly the gas drawing cock and put a flame close to it. If the gas proves not -e flamma-le , the transformer can -e put again in the service. If no gas comes out of the cock, or even air is sucked in, the oil is too low. It is always advisa-le to perform a chemical analysis of the gas -y means of the gas tester. 'henever the 0uchhol< relay operates the alarm and the tripping circuit, it is necessary to open the gas drawing cock and to make sure that gas is released. 7aintenance

The relay does not reDuire any special maintenance, however, it is recommended that the operation of float and of alarm and of tripping contacts -e checked at regular interval. ?or this purpose, the relay is fitted with a test device which may -e Duite different for each type of 0uchhol< relay.

53

Fig Buc##ol,+s relay

5 6 Air driers
The silica gel drier is fitted on the -reather opening of the oil conservator in each transformer, or in the opening of other accessories in which the insulating oil is in contact with the atmosphere. The drier is formed -y a glass vessel with silicagel grains, the whole -eing enclosed inside a metallic protection container having a metallic protection container having suita-le opening for visual inspection of silicagel conditions. The following types of driers are used generallyN Fig 1 with air intrack having a seal for transformer or accessories containing up to /6: liters of oil , with gas pipe threaded connections . Fig 2 with air intake having hydraulic seal for transformers containing up to *:,::: liters of oil with flange connection.

54

Fig 3 with threaded lower flange for Nitrogen admission pipe and with filter , with flange connection suita-le for transformers or accessories containing up to *:,::: liters of oil. !peration

The silica gel is used for the driers is chemically pure silicon o>ide having a very high power of a-sorption, so that a charge may -e renewed at ; to / months intervals according to the degree of humidity of am-ient where the transformer is installed, to season and to the loading cycles of transformer. The silica gel is treated with a special coloring su-stance sensitive to the humidity, so that itLs saturation condition can -e evaluated -y itLs color. 0lue colorUUUUUUUU..9harge is dry 3iolet colorUUUUUUUUA-sor-ed humidity is 7: to ;:Y. Pink colorUUUUUUUU.. The charge is saturated with moisture. In all types of driers the silica gel should have ;.6 to / mm grain si<e. 7aintenance:

The silica gel is reactivated -y heating it at )7: to 7::9. It is recommended to mi> it during heating in order to o-tain a homogeneous drying of whole charge. The charge will -e reactivated when all silica gel grains have acDuired the -lue color again.

55

5A6

Pressure relie* "al"e

This valve is normally located on the transformer cover or on the wall of the transformer tank and has the purpose of providing release of e>cess pressure that may -e produced in the transformer in the con(unction with serious damage such as an under oil arc produced through -reakage of short circuit.

5B6

Ther/ostat and ther/o/eter

This device is used for the temperature control and consist of a -ul- at the top part of the transformer tank and connected through the capillary tu-e to a dial indicator. 0esides indicating the temperature, this instrument closed a circuit connected to an alarm device and su-seDuently a second circuit directly connected to the main -reaker and capa-le to cause the detatchment of the transformer from the line. The measurement system can -e of liDuid thermometer type. The scale is not linear -ut appro>imately logrethmic e>panda-le with the temperature.

516

Iron and oil te/perature detector

According to the terms of the specifications, the following are installed in the transformerN One or more thermometric pro-es to measure the coil temperature. A num-er of thermometric pro-es to measure the temperature of magnetic core. The oil temperature detectors are directly installed on the cover in the position indicated in the overall drawingO connected to the head of the pro-e the leads to the terminal -oard of au>iliary service -o>. The terminals of the iron temperature detectors are -rought outside through appropriate terminal -oard located on the coverN from here they too go to the terminal -oard of the au>iliary service -o>. (etails o* the detectors are as *ollo#s: Nickle thermometric resistor $esistance valueN ):: ohms at :9 Temperature coefficientN /.),[ ): %a>imum temperatureN )7: 9 Platinium thermometric resistor $esistance valueN ):: ohms at :9 Temperature coefficientN ;.+6[ ): %a>imum temperatureN )7: 9

506

Current trans*or/ers :

56

9urrent transformers are used in power transformers as a source of energy for operation of relays, to measure the eDuipment of a thermal image plant, a line drop compensator and protection system etc. The current transformers normally incorporated in power transformers may -e of -ushing type with primary winding.The primary is formed -y connection which goes from the winding of each individual phase of the transformer to the corresponding insulator and which crosses the transformer centrally. If the transformer ratio is very low and the accuracy is high, it is advisa-le to use the type with the primary winding. As far as possi-le, these current transformers are arranged on the machine in an easily accessi-le position. 7aintenance

If the secondary of the transformer is left open, the core may -ecome permanently magneti<ed and dangerously high voltage will e>ist across the secondary terminals. The 9.TLs can -e demagneti<ed -y passing a-out )6: percent normal current through the primary, with the secondary connected to the resistance of 6: ohms and gradually reducing the resistance to <ero.

51,6 Tap chan)er:

This is such a type of component of our power transformer that changes the out put voltage manually. If -y some how, there comes a condition that out put voltage drops or increases, then tap changer changes the tapping of transformer to -ring the out put voltage at reDuired level e.g. If the e>citation current decreases then out put voltage of our generator decreases, this means that out put of unit transformer also decreases which is -eing controlled -y this tap changer. The operation of tap changer is controlled and e>amined -y &9$ and also -y 99$. 0oth centers are e>amining each and every time the out put voltage of the transformer, and also noting the reading of -efore and after regulating the voltage and if there come a condition to change out put voltage they do it -y changing the tapping. Normally tapping is kept at the place manufactureLs advice. There are two types of tap changerN ). On load tap changer 7. Off load tap changer !n load tap chan)er:

57

In this type of tap changer tapping is changed -y keeping the transformer loaded. i.e. the transformer is not -eing isolated for to change the tapping. This is done in running condition. !** load tap chan)er:

In this type of tap changer transformer is made off or disconnected from the system and then the tapping is changed. Tap changer is always installed to the high voltage side -ecause in this side current is very small and if the current is small then there will -e very rare chance of producing arcs and if they are produced, there intensity will -e very small.

5116 :arthin) to#ers:

They are installed on each out going phase of transformer. They are there to protect the transformer winding -ecause during lightning the voltage is increased to the very high level and it can damage the winding. So -y installing these towers, the lightning is -eing earthed. There is a counter on each tower which is counting that how many times lightning occurred. Such a type of counter is installed on each tower.

5126 3ire protection coolin) syste/:

These are special type of no<<les consisting of alcohol. This alcohol senses the temperature and if the temperature rises from a certain level then they are -urn out. As a result of which water comes out from the pipe. These no<<les are installed on water pipes surrounding the transformer from almost all sides and if any of the no<<les -urns all are opened, so water comes from all sides. ifferent alcohols of different colors sense the temperature of different level. e.g. 2reen alcohol S +: to +6 9 Vellow alcohol S *6 to ):: 9

136 Auto/atic "olta)e re)ulator:

This device senses out put voltage if, -y ?rauntyLs effect or -y increasing the capacitive -ehavior of the transmission line, out put voltage increases then it controls the voltage automatically. ItLs operation is also checked -y &9$ or 99$.

.4.2 !ther types o* trans*or/ers used in po#er house:

). !nit Au>iliary transformer

58

7. &ow voltage au>iliary transformer ;. Start up transformer A. #>citation transformer All are small transformers as compared to unit transformers. The working principle and other parts are almost same. The only difference is of there si<e and there use and depending on there use some e>ternal parts are not used in small transformers. "ere is a drawing which is showing the connection -Cw all transformers.

.4.3!"erall /aintenance o* trans*or/ers:

All kinds of maintenance tests are -eing performed at the time of there reDuirement. e.g. ). TT$4transformer turns ratio test5 7. Oil analysis ;. ?ire protection system test A. Silica (ell test Similarly some other important tests are also performed.

Chapter A

59

The $attery 'oo/s

A.1 Purpose?
The purpose of the -attery room is to provoid d.c. supply needed for the relay action 4mostly for protection purposes5.They are also source of e>citation in case of -lackout thud have vital use as d.c. -ackup supply.

A.2

The $attery 'oo/ In 4nit &1 :

They are two in num-er i.e. one is in 9.9.$ and the other is in the tur-ine hall near the generator.

A.3

The $atteries:

They are of the two types w.r.t. the out put voltage out put voltage of A+3 out put voltage of 77:3

They are of led acid type having sulfuric acid 4"7SOA5 as the electrolyte. The standard specific gravity of the acid is 1.23 gm/lit. when charged fully.

@.1

The Conductor:

They are made of copper and are stranded to provide fle>i-ility and heavy eligi-le of carrying ma>imum possi-le current at any condition , minimum resistance for high efficiency and insulated properly to fulfil reDuirements.

Chapter B

S#itch Card
60

A Switchyard or Su-station, consisting of large -reakers and towers, is usually located in an area close to the plant. The su-station is used as the distri-ution

center whereN electrical power is supplied to the plant from the outside, and electrical power is sent from the plant. Often there are at least 7 main 3ery high voltages 4typically 77:,::: or );7,::: volts5 are present. 2as and oil circuit -reakers are used. The gas 4e.g. sulfur he>aflouride5 or oil is used to e>tinguish the arc caused when a -reaker is opened, either -y a control switch or due to a fault %anually or motor operated disconnects are provided on either side of the -reaker to allow the -reaker to -e electrically isolated so that maintenance work can -e performed.

B.1

$rea%er Sche/es:

There are usually two schemesN Single 0reaker Scheme

61

 One and "alf 0reaker Scheme

B.1.1 Sin)le $rea%er Sche/e

In this scheme two circuits 4-us -ars5 share the two -reakers. The scheme is used for );7 k3 or lower switchyards. The main disadvantage of this scheme whenever we want to work on a -reaker the entire circuit -us -ar should -e disconnected from the generator and feeder sides.

B.1.2 !ne and Hal* $rea%er Sche/e

A method of interconnecting several circuits and -reakers in a switchyard so that three circuit -reakers can provide dual switching to each of two circuits 4-us -ars5 -y having the circuits share one of the -reakers, thus a -reaker and one=half per circuitO this scheme provides relia-ility and operating

62

fle>i-ility, and is generally used at 77: k3. The scheme is so called -ecause there are 7 circuits 4-us -ars5 and ; -reakers. The main advantage of this scheme, whenever we want to work on a -reaker the -us -ars are still alive from the generator and feeder sides.

B.2

Inside the S#itchyard

%ainly there are different -ut most important things for the protection, measurement, metering and for the other purposes. ). 9ircuit 0reaker 7. Isolator ;. Insulator strings A. 0us 0ar 6. 9urrent transformer 49.T.5 /. Potential transformer 4P.T.5 ,. Auto Transformer +. 9onductor *. 9ontrol Switch ):. $elays

516 Circuit $rea%er

This is the -asic and the most important part of the switchyard. Isolators are used for itLs protection -ecause the minimum cost of the circuit -reaker which has -een installed in KAP9O is of ): million rupees. So, we are reDuired to provide protection to it to avoid the -urning and the familiar of the -reaker. !bjecti"e

This is installed to protect or making some disconnection or connection part, So that there can -e a -ridge -etween the two parts. This is an automatic device which opens and closes -y sensing the characteristics defined -y the designer. Suppose if we want to work on the transmission line going to any other region, then we make open the connections of the circuit -reaker. On the other hand, if any fault occurs on any side of the -reaker, then current transformer which is certainly installed with a -reaker, senses the a-normal current and sends information to the central control room and also perform some action to protect the system from any accident. Any of the line is no longer in contact with the generator, all lines are coming out from the -us -ar and there is a circuit -reaker in -etween the line and the -us -ar. So, -y chance, if there occurs a fault in transmission line

63

then we can easily recover it -y opening the -reaker. Similarly the line from the step=up transformer to the -us -ar is also protected -y a circuit -reaker. So, this circuit -reaker is a kind of connection and disconnection -etween the generator, -us -ar and the transmission line. So, -y this way, the transmission line or su-station or -us -ar itself and also generator are protected from any kind of small or -ig accidents.

i6

Co/ponents o* the circuit brea%er

5a6 Au;iliary s#itch This is only for the purpose of the taking information a-out the working of the 9.0. e.g. it consists of P&9Ls which take information that whether the -reaker is open or close.The information a-out the opening and the closing of the -reaker is taken -y such a way that there are some Normally open and Normally closed contacts in au>iliary switch. So, if the -reaker is closed then information from the Normally closed contacts is sent to 9.9.$. 49entral 9ontrol $oom5 and a light is made ON there showing that 0reaker is in closed condition. Similarly is the -reaker is open, then Normally open contacts are closed and in the similar fashion descri-ed a-ove, light is made ON in 9.9.$. showing that -reaker is in open condition.

5b6 7echanical s#itchin) This process is done with help of the oil pressure. A certain oil pressure is o-tained and then according to the information supplied -y the manufacturer, opening and closing of the -reaker is done at some pressure defined. i.e. if pressure goes less than 7,; -ars than -reaker is opened and then does not close itself until it is done manually.

64

5c6

Inside protection

As -ecause of the opening and closing of contacts os -y some other reasons , archs are produced inside the -reaker which are dangerous for the life and the characteristics of the -reaker. So, these archs must -e Duenched. There are many methods for Duenching these archs. e.g. Air Duenching 2as Duenching 3acuum Duenching Now a days, most commonly used methods for Duenching these archs is the use of the S?/ gas which is very much efficient for doing this task.

ii6 Ter/inolo)y !* $rea%er:

'upture Current: The current at the time of opening operation of the -reaker is called rupture current. It may -e the ordinary regular current value or very large fault current value depending on the condition of operation .

65

'upture Current 'atin): This the ma>imum interrupti-le value of current at the instant of operation. This is the ma>imum value of current at which the -reaker can successfully provide protection against re striking of arc. 7a%in) Current: This is the value of load current at the point of making contacts close 'ated 7a%in) Current? This is the ma>imum -eara-le current at the time of making the contact . $rea% Ti/e : This is the time reDuired to do the -reak operation. 'ated 8or/al Current: This is the ma>imum amount of current that can -e applied to the -reaker on normal working conditions for long time without effecting the efficiency , without a-normal temperature and without any damage. 'ated 8or/al ?olta)e: The ma>imum amount of voltage applica-le for long passage of time. 'ated Short Ti/e Current? This is the ma>imum -eara-le short interval 4second or less5 current that can -e applied to the circuit -reaker.

iii6 Types o* Circuit $rea%er

They can -e classified w.r.t. two criteria w.r.t arc Duenching w.r.t. construction w.r.t. arc Duenching media , we have most used types listed -elow the oil circuit -reakers the air circuit -reakers the S?/ circuit -reakers the vacuum type
66

!il Type: In the oil type ckt -reaker, the arc is produced in the oil thus oil decomposes and replaced -y the surrounding oil thus provides -oth cooling and give proper dielectric strength. Such an arrangement can work for -reaking duty not e>ceeding )6:%3A. Addition can -e done to increase the rating -y providing pressure pot and e>ternally generated pressure to e>tinguish the arc -y pushing it and also -y dividing it into sections -y means of insulators .0y these means, a rating of ,6::%3A at );7 k3 is possi-le. Also low oil content -reaker can -e used to decrease the si<e and increase the life and performance of oil. Air Type? A>ial, radial or cross -last is used in these -reakers to e>tinguish arc and also insulators can -e added to increase the dielectric strength. ?acuu/ Type: In this type, the vacuum is created at the contact position. 'hen the contacts open, the resistance -ecome very high since no ioni<ation in the medium occurs only source of electrons is thermionic emission through the surfaces. So no chance of re=striking arc after it is once e>tinguished. The S3A $rea%ers: They are the -reakers using sf/ gas as the arc Duenching media. They are special with compact si<e, high relia-ility and heavy ratings . The sf/ gas has high affinity to electrons thus have great de=ioni<ation power. It is necessary to replenish the gas from time to time.

67

Fig SF@

i"6

$rea%ers In The S#itch yard !* 4nit&3:

They have hydraulic type mechanic and are advance. They can -e controlled from c.c.r. or from the local control ca-in in the switch yard .They use sf/ as arc Duenching medium .Since used in one and the half scheme, have isolators at the -oth ends .They get information from p.t. and c.t. for their operating system.. There are three -reakers in each -ay. #ach one is manufactured -y

S:I7:8S 5-er/any6
The model num-er is 3!" 1 .The specifications are as under 1. 2. 3. %. &. (. -. .. 0. #ated $oltage 2%&k$ power fre'. withstand $oltage 1 min 3() * %() k$ #ated normal current 31&) ! #ated short time current 1sec+ %) k! #ated peak current 1)) k! #ated ,reaking current %) k! #ated making current 1)) k! /reak time (& or &) msec inspection after 2) years

The working temperature conditions at Kot Addu are very tough ranging from as high as 6:Q in summer to as low as += degrees 9elsius .

68

Also the humidity conditions are also very hard ranging from very high humid conditions in summer 4 -ecause of the great river Indus and wet land conditions5 to very low humidity conditions in winter4foggy most of the time5. 0ut the -reaker has wonderful working performance since have -een tested and used even harder weather conditions.

526 Isolator:
69

These are used for the protection of the any unit. This is a mechanical device and information a-out the opening and closing of the isolator is send to the 9.9.$. in the same manner as descri-ed a-ove.

!bjecti"e
ItLs main purpose is to isolate one unit from the other unit. %ainly two isolators are used for the protection of -reaker.

. Fig Isolators

536 Insulation Strin)

ItLs main purpose is to provide the insulation -etween the transmission line, su-station, transformer etc. This is such an important device that without it there is not any concept of the transmission.

Fig Insulating string

546 22, %" D132 %" $us $ar

70

77: kv -us -ar is our main -us -ar. This is the line or -us -ar which is connected to the our national 77: kv -us -ar forming ring main system. This is the line to which all generator are connected and supplying there power. 'e can take out or in it the reDuired power. Power is delivered to any area only through this -us -ar, -ecause it is (ust like a see of electrical power in which all rivers 42enerators5 are supplying water 4Power5 and some rivers 4Power5 are taking water 4Power5 out of it. ?or e>ample the load side.

Fig 228 k' Bus Bar

5 6 Current Trans*or/er
There are five ciols of 9T and three -asic purposes of using 9T. ). %easurement of the current. 7. Protection of the relays and -reakers etc. ;. %etering And the forth one is A. for the 0reaker failure protection. As very high amount of current is flowing through the line so we canLt measure such a -ig amount of current -y simple ammeters. If we want to design an ammeter for this purpose, then the si<e and the cost of that meter will -e very -ig costly respectively. So, to overcome this pro-lem, we use 9T which gives output in ratio like 7A::C) or /::C) or 7AC) which means that if suppose 7A:: amperes current is flowing then it will give the output as ) ampere. Similarly we can say that if ) amp current is flowing in secondary of 9T then itLs mean that 7A:: or /:: amp are flowing in the primary of it. Similarly for the protection of relays, it counts current flowing through them to ensure that whether the current is flowing in the limited region or not, if not then

71

make the relay isolated from the system with the help of the of the Isolator. Similarly, if -y chance there occurs a fault in transmission line, then it counts current and sends information to distance protection relay to operate it earlier which is nearest to the fault and similarly to send information to the over current relay to make itLs operation. As KAP9O or any generating company is also supplying energy to the 'AP A, so it is to count that energy which is given to 'AP A and to take the charges from them. So we use 9T for this purpose of metering.

Circuit *iagram of PT

Fig PT

72

5A6 Potential trans*or/ers

It is used to measure the voltages and it has -een installed with the -us -ar to measure the voltage across the -us -ar. 'e are checking for high voltage and low voltage -ut carefully for the low voltage -ecause the au>iliaries which we are running from this voltage will draw very high current if the voltage is very low and this can damage our eDuipment. So, we keep on checking for the low voltage and the high voltage. 'e have to use P.T. -ecause we canLt design such a -ig voltmeter.

Circuit *iagram of PT

Fig PT

73

5B6Auto Trans*or/er
An autotransformer is an electrical transformer with only one winding. The auto prefi> refers to the coil acting on itself rather than any automatic mechanism. In an autotransformer portions of the same winding act as -oth the primary and secondary. The winding has at least three taps where electrical connections are made. An autotransformer can -e smaller, lighter and cheaper than a standard dual=winding. transformer however the autotransformer does not provide electrical isolation. Autotransformers are often used to step up or down -etween voltages in the )):= )),=)7: volt range and voltages in the 77:=7;:=7A: volt range, e.g., to output either )): or )7:3 4with taps5 from 7;:3 input.

Fig /uto Transformer

516 Conductors:
Normally we use two conductor scheme for our switch yard to distri-ute the load of the current in a conductor. This conductor scheme can -e of three or four conductors -ut such schemes are used for the transmission lines. 'e adopt such a scheme to make one conductor cool and to avoid from the -urning of the conductor -ecause one cone conductor may not carry such high amount current. These conductors are necessary things for to make connections -etween the unit transformer and the -reaker similarly -etween the -reaker to the -us -ar or even we can say that -etween the -us -ar and the transmission line..

506 Control s#itches:

These are some -ut important -o>es looked inside the switch yard. These are important -ecause they are controlling the switching action of the -reaker and making connection of the relays to make it operate at the reDuired time. These are also used for the opening and closing of the isolator to make the connection and the disconnection -etween the two things. 'e can say that

74

we are controlling every thing in switch yard -ecause all remaining things are going to operate on the -asis of the -reaker and the isolator -ecause these are the most important and the -asic things in switch yard.

51,6 'elays:
These are operated -y taking information from 9.T. and P.T. #ach and every thing of the system even in the switch yard is -eing protected -y relays -ecause they are made very much sensitive for the faults. They sense every fault for which it has -een designed and then some other important devices are operated from the signal of the relay. There are many types of the relaysN ifferential over current relay. Over current relay. Over and under voltage relay. irectional over current relay.

Similarly there are many other types of the relays which we will discuss later.

Chapter 1

3uels Section
1.1

Co//on 3uel 4sed In EAPC!

Natural 2as "i Speed iesel 4"S 5 ?urnace Oil 4?O5

75

Fig

Fuels Section

1.2

Tan% area introduction.

There are twenty seven tanks in the tank farm ,five of them 4A,6,/,)) M 7:5 are used for "S storage,eleven tanks 4)7=)* M 76=7,5 are used for the storage of untreated &S?O and remaining eleven tanks4)=;, ,=): M 7)=7A5 are used for the storage of treated &S?O.The capacity of all tanks is almost the same.The suction heaters of tanks 47)=7,5 are placed out side the tanks.

Pi) station
this is the station where fuel is received from the pipeline coming from the &al Pir depot.from Pig station &S?O 4&ow Sulphur ?uel Oil5 and "S are fed to the respective headers for filling the tanks.Initially when pumping of &S?O starts fom &al Pir depot the line is packed with "S .Pig is entered in the line from &al Pir in order to avoid the mi>ing of two fuels.In this period "S valves are kept
76

open.'hen ?O reaches at the comple> the "S valves are closed after checking the result of the fuel and valves for feeding the untreated tanks are opened.'hen ?O pumping is stopped pig is entered in the line and "S is pumped in the line for removing the ?O from the line.The pig takes seven and half hours to reach at the Pig Station.After at the Pig Station ,it is taken out of the line.

<S3! Pu/pin):
'hen &S?O is -eing pumped through pipeline then the valve of the "S is closed that of &S?O header going to the untreated tanks is opened. header

HS( Pu/pin):
'hen "S is pumped through the pipeline then "S and &S?O header valve is closed. headers valve is opned

(ecantin) station
0oth of the fuels are -rought to KAP9O through tankers ,which are decanted at the decanting station.There are four pumps at the decanting station,which pumps &S?O in the &S?O header and "S in the respective header.The capacity for the parking and decanting of 7: tankers at the time .0ut now only ?O is -rought at the comple> tankers.

PS! 'eceipt At the Site:

The Duantity of pumped oil is measured -y taking the dip of tank at the %ehmood Kot and the site tank in which fuel is -eing filled. The difference -etween two reading gives the Duantity of the fuel pumped from %ehmood Kot.

(i/ension and Construction (etail o* the Tan%s

"eight S);.6;/ m iameter S;: m ?illed "eight S)).6 m4working capacity5 Over ?low S)7=)7.6 m4changing from tank to tank5 9apacity S;::: m; esign capacity S*6:: m; ?illing $ate S ;:: m;C hr. #mptying $ate S;:: m;Chr.

$otto/ Heater
1t is a steam heater ,which is used for raising the temp.of the &S?O in the tank.It consists of tu-es and fins ?O$ the purpose of the heat e>changing ,which are placed at the -ottom the tank. It raised the temp. of the &S?O up to A: : 9 4can -e up to ,:: 95.

Suction Heater.

77

The suction heater is at ).6 m a-ove the -ottom of the tank to avoid the suction of sludge. It consists of !=shaped tu-es through which steam flow. There are -affle plates mounted on the heater, which force the oil to flow through the heater in <ig<ag style in order to increase the time for heat e>change -y which 7: : 9 temp. rise is achieved at the suction of -ooster pump .

'etainin) #all
All the tanks have retaining walls to retain the spillage of oil a-out );/:: m ; in case of leakage from the tanks.

8o. o* $ooster Pu/ps *or di**erent -roup Tan%s

?or tanks )A,)6 ,)/ M ), ,there are two 0ooster Pumps for the common header. ?or tanks )) M 7:,there are two 0ooster Pumps for the common header. ?or tanks )7,);,)+ M )*,there are two 0ooster Pumps for the common header. ?or tanks )A,)6,)/, M ),,there are two 0ooster Pumps for the common header. ?or tanks 7),77,7;,M 7A,there are two 0ooster Pumps for the common header. ?or tanks 76,7/, M 7,,there are two 0ooster Pumps for the common header.

(i**erence $et#een di**erent Tan%s

tanks from 7)=7, have their suction heater placed out side the tank in the retaining wall. These tanks have no recycle line.while other tanks have their suction heaters at a height of ).6 m from the -ottom of the tank. As "S needs no heating therefore "S tanks do not need -ottom and suction heaters. Therefore this facility is not provided to these tanks.

1.3

Pipin) in Tan% Area:

There are different headers in the tank area Othe details of the headers are under : 1. 3or untreated tan%s ?illing header from Pig Station and ecanting Station . "eader from untreated tanks to ?OTPs. $ecycling header from ?OTPs.

2. 3or treated tan%s:

?illing headers for treated fuel from ?OTPs to the treated tanks. $ecycling header from ?OTPs.
78

!nits feeding header from tanks. $etun header from unit.

3. 3or HS( Tan%s:

?illing header from Pig Station and ecanting Station. ?illing headers for treated fuel from ?OTPs to the treated tanks. $ecycling headers from ?OTPs. !nit feeding header from tanks. $eturn header from unit.

Color Codin) o* the ?al"es:

?or untreated tanks the color coding is as underN $ed Sfilling valve 0lue S?OTP feeding valve Vellow S$ecyling valve ?or treated tanks the color coding ia as underO 0lue S?OTOP feeding valve Vellow S$ecyling valve 0rown Streated ?O from ?OTP 0lack M white Scommon header valve of all units feeding 0lack Sunit 6=+ feeding valve 'hite Sunit ),7,); M )A feeding valve 2reen Sreturn valve from units ?or "S tanks color coding is same as for treated tanks -ut with yellow strip.

1.4

!perations !* Tan%s:

!peration o* untreated tan%s:

?or filling of untreated tanks the filling valve of that tank is opened .In this way fuel from the filling header is filled to the tank .?or sending the fuel for treatment to ?OTPs the suction valve of the 0ooster Pumps is opened. The procedure for shifting of fuel from one tank to another is as underN

79

The discharge valve of the desired tank and 0ooster pump are opened. The recycle valve of the desired tank is opened. The shifting valve near tank F +4-lue Cyellow5 is opened. uring this process all ?OTPs should not operate and also the suction valve of ?OTPs remain closed.

It should -e checked carefully that the recycle valve of any other tank should not -e opened. 2he procedure for feeding the F32P is as under: The suction valve to -ooster pump is opened. In this way the fuel is feed to the header going to feed ?OTP.The inlet valve to ?OTP is opened and so the fuel is supplied from untreated tanks. If the result of treatment are not satisfied then there is an option to recycle the fuel in any of the untreated tank. In this case the divertor valve is selected to recycle mode and the fuel is recycled to the desired tank.

!peration o* HS( Tan%s:

?or filling of "S tanks from the Pig Station the &S?O filling header valve is closed and the "S filling header valve is opened. Now the filling valve of the tank to -e filled is opened. ?or the treatment of "S the 0ooster Pump of the tank is operated and the valve for feeding ?OTP is opened. The inlet valve of the ?OTP is opened and after treating the fuel it is fed to the desired tank through treated from ?OTP via tank filling pipe. To shift untreated "S underN from one tank to the other ,the procedure is as

The discharge valve of the desired tank and 0ooster pump are opened. Open the ?OTP feeding valve. Open the shifting valve4-lueCyellow5 Open the recycle valve of the desired tank.

80

uring this process ?OTP F7 should not -e in service and the inlet valve should -e closed. At the same time the recycle valve of any other tank must -e closed.

The shift treated "S from one tank to another tank,the procedure is as underN The discharge valves of the desired tank and 0ooster pump are opened. Open the valve 4white5 for feeding 2T ),7,);,)A. Open the shift valve 4-rownCwhite5. Open the filling valve 4-rown5 of the desired tank.

uring this process 2T ),7,);,)A are unavaila-le on "S .

!peration o* Treated Tan%s:

After treatment of &S?O from the ?OTP it is filled in any of the treated tank through the treated header.In case if the Duality fuel of the treated tank is poor then it fed the ?OTP and from ?OTP it is again fed to the treated tank. This process is called recycling of the treated tank. ?or shifting of the treated &S?O from one tank to another ,the procedure is as under. The discharge valves of the desired tank and the 0ooster pump are opened. Open the valve of the header for feeding 2T 6=+. Open the shifting vave Open the shifting valve of desired tank.

uring this process ?OTP are not service. ?or shifting of treated &S?O -etween tank )=; ,the procedure is as under. The discharge valves of the desired tank and 0ooster pump are opened. Open the valve of the header for feeding units 6=+. 9lose the valve of the header for feeding units 6=+ near tank F). Open the valve connected to the filling line of the tank where ?O is to -e shifted.

81

This is the procedure for shifting the ?O from tank 7 M ; to any of the tanks ),7,M ;.0ut for shifting the ?O from tank F) to any one of 7 M ; ,the procedure is as underN The discharge valves of the desired tank and -ooster pump are opened. Open the valve of the header for feeding units ),7,); M )A. 9losed the valve of the header for feeding units )6=+ near tank F) to stop feeding to the units from this section of the header. 9lose the valve of the header for feeding units ),7,); M )A near tank F ) to stop feeding to the unit from this section of header. Open the valve of the header for feeding units 6=+. In this way header for units 6=+ is energi<ed.

1.

3uel !il Treat/ent Plant:

Introduction
There are five ?OTPs in this comple>.The ?OTPs ),7,;M A are of same type while ?OTP=6 is of different type than )st four i.e. centrifuge type. ?OTP =7 is used for the treatment of "S while others are used for the treatment of &S?O.The purpose for the treatment of fuel is to remove waterGsolu-le salts of potassium and sodium from the fuel -ecause the metling point of these salt is low.Therefore when fuel -urn at the high temp. these salt melt and deposit on the surface of the tur-ine -lades and cause un-alance of shaft.

A brie* introduction to the operation o* 3!TP51&46

The function and the operation of different parts of ?OTP are descri-ed as under in seDuence.

3uel oil circuit

?uel oil is fed to ?OTP -y opening the main feeding valve. The fuel is filtered and then pumped -y the OP pumps.

!P51&26:

82

These pumps are used to pump the oil in the economi<er for the heating of fuel.These are screw pumps.

:cono/i9er:
These are two economi<er ,where heat is e>changed from treated fuel to untreated fuel. In this way the hot treated oil is used to raise the temp. of untreated fuel.?rom economi<er the fuel goes to the thermal oil heat e>changer .There is also an option to -ypass the economi<ers.

Heat :;chan)ers
There are two heat e>changers in which fuel oil is further heated -y thermal oil.After heating the fuel ,It is fed to the stage ) -y means of OP ;=A.

83

Fig

Process *iagram of F:TP

!P 53&46
These pumps are used to pump the oil into the ?OTP.

3!TP Sta)es
There are three different stage in the ?OTP.The discharge of OP 4;=A5 is fed to stage =).'ater coming out of stage=)) and demulsifer are fed to the fuel feeding line of stage =) -efore mi>ing valve. ?rom stage=) fuel is fed to stage=)). 'ater coming out of stage =))) and demulsifier are fed to the fuel feeding line of stage= )) -efore mi>ing valve. ?rom stage=)) fuel is fed to stage=))) . ?resh water and demulsifier are fed to the fuel feeding line of stage=)) -efore mi>ing valve . Treated fuel from stage=)))is sent to the treated tanks. Thermal oil is supplied to each stage for heating the contens of the stage. There are two transformer on each stage . The rating of the transformer is A::C)*:::v. The high voltage is used to produce dipole moment in the water .

84

ue to the creation of dipole moment the dia of the water drop increase. ue to increase in dia the setting rate of the water drop increase and it settles at the -ottom of the stage .?O having low specific gravity than water comes up .?rom where it is collected and is discharged from the stage.

2P 51&26
These pumps are used to fresh water into stage=))). The discharge of 'P is heated in economi<er in order to raise the temp of the fresh water. The effluent water is then fed to the effluent storage tank.

2ater Heater.
The water after heating from the economi<er is further heated in a heater -y thermal oil.?rom this heater the heated fresh water is fed to the fuel feeding line of stge=))).

'P 51&46
There are four recycling pumps .$P4)=75 are used to pump the water from stage =))) to stage =)). 'here as $P4;=A5 is used to pump the water from stage=)) to stage=).

Che/ical 3or#ardin) and (osin) S%id

?or the treatment of fuel oil different chemical are dosed at the ?OTP.The details of dosing process are as under.

(e/ulsi*ier (osin)
The demulsifier is a chemical ,which is an emulsion -reaker .This chemical is stored in the demulsifier storage tank from where it is pumped -y 9P pumps to three stages. emulsifier is pumped in three different lines . Two of them are connected to the fuel oil feeding to stages 7M ; -efore mi>ing valve. The ; rd line is connected to the fuel oil line after the duple> filter. The dosing of demulsifier in any stage depends upon the Duantity of water in that stage . If Duantity of water is more then demulsifier dosing is increased and vice versa.

3locculant (osin).
This chemical is used to separate oil from water . This chemical is stored in ?locculant storage tank. %i>ing fresh water in the flocculant dilution tank makes the diluted solution .The fresh water is pumped in the flocculant dilution tank -y means of ? P.'hich works on the level of the flocculant dilution tank. ?rom the

85

dilution tank the diluted solution is pumped -y two pumps to AS? and oily water separator through three feeding lines.

3uel Additi"e Seprator:

?uel oil dosing chemical is stored in this storage tank. ?rom this tank the chemical is sent to the additive=dosing skid through pumps for -eing dosed in the fuel.

!il 2ater Seprator:

The effluent water is pumped -y water recycling pumps 4'$P ),75 into oily water separator .'here oil mi>ing in water is separated -y means of "oney com- package .The flocculent also dosed in the oily water separator feeding line. This assem-ly has small tu-es through which the effluent water passes ,the oil -eing lighter than water comes up through these tu-es and water deposits in the -ase of the oily water separator tank . The oil separated -y this separator is stored in the sludge tanks . The effluent helps oil drops present in the effluent water to separator from the water. The water from the separator goes into the Air ?lotation !nit.

Air 3lotation 4nit:

In this unit the oil still present in the effluent water is removed -y using air flotation techniDue .The flocculent is added in feeding line of water and in the ; rd stage of A?S. ?our -lenders driven -y motors -lend the effluent water . ue to this process the oil comes up like -utter and is collected in the oil cham-er of A?S. ?rom this cham-er oil is pumped and sent to sludge tank. The water is pumped into the pit of pit for the 9T of "$S2s.

86