STUDY OF

ELECTRICAL
SYSTEMS IN
VIZAG STEEL
PLANT




























Page | 2






A PROJECT REPORT ON
Electrical Systems in Vizag Steel Plant

UNDER THE GUIDANCE OF
SRI AJEET KUMAR SEN
ASSISTANT GENERAL MANAGER(ELECTRICAL)
THERMAL POWER PLANT
A Dissertation report submitted to the
TRAINING AND DEVELOPMENT CENTRE
RASHTRIYA ISPAT NIGAM LIMITED
In partial fulfillment of the degree of
PROJECT TRAINING IN ELECTRICAL ENGINEERING
SUBMITTED BY:-


Page | 3

CONTENTS

S.No TOPIC Page No.
1 CERTIFICATE 04
2 ACKNOWLEDGEMENT 05
3 DECLARATION 06
4 ABSTRACT 07
5 THERMAL POWER PLANT -AN INTRODUCTION 08
6 POWER REQUIREMENT 10
7 SOURCES OF POWER 13
8 MAIN EQUIPMENTS OF TPP. 20
9 BOILERS 21
10 TURBO-GENERATORS 25
11 TURBO-BLOWERS 36
12 AUXILIARIES OF TPP 37
13 POWER GENERATION AND DISTRIBUTION 45
14 ISLAND OPERATION SCHEME 48
15 BASIC KNOW-HOW OF ELECTRICAL ENGINEERING 49
16 CONCLUSION 52

Page | 4


RASHTRIYA ISPAT NIGAM LIMITED
VISAKHAPATNAM STEEL PLANT
TRAINING AND DEVELOPMENT CENTRE


CERTIFICATE


This is to certify that the project work entitled Study of Electrical Systems
in Vizag Steel Plant is a original record of study carried out by, a bona
fide students of National Institute of Technology, Silchar under the guidance
and supervision of Mr. Ajeet Kumar Sen, Assistant General Manager
(Electrical).

Mr. Ajeet Kumar Sen
Assistant General Manager
Electrical Department
Thermal Power Plant
Vizag Steel plant






Page | 5

ACKNOWLEDGEMENT

It is my privilege to have the working knowledge under the guidance of Mr.
Ajeet Kr. Sen who extended his support and spared his valuable time to guide
me through the course of the project. He provided an insight into the
functioning of the thermal power plant along with delivering practical
knowledge.
I also extend my sincere thanks to Sri Abhay Kr., Sri M. C. Mane of ERS,
Sri Hanumant Rao of ECR and Sri Shailendra Kumar, for sharing their
valuable knowledge.
I also show my gratitude to Mr. Krishnasish Chanda for availing me the
opportunity for training in Vizag steel plant
With sincere regards,
VIKASH NAGAR
MD. AFTAB ANSARI
AJAY KUMAR CHANYAL
NISHANT KUMAR
GAURAV KHANDELWAL
ANAND PRAKASH GAUTAM
AMIT KUMAR MISHRA
MEHUL MADHUKAR

Page | 6

DECLARATION


We, Anand Prakash Gautam, Mehul Madhukar, Gaurav
Khandelwal, Vikas Nagar, Ajay Kumar Chanyal, Nishant
kumar,Md. Aftab ansari & Amit Kr. Mishra, students of 4th year,
Electrical Engineering of National Institute of Technology, Silchar hereby
declare that the project entitled Study of Electrical Power in Captive
Thermal Power Plant at Vizag Steel Plant submitted in partial fulfillment of
the degree of Project Training in Electrical Engineering is our own.



B.Tech ,
Electrical Engineering
N.I.T. Silchar


Page | 7


ABSTRACT

This project entitled Study of Electrical Systems in Captive Thermal Power Plant
at Vizag steel Plant covers the complete operation of the Thermal Power Plant and
power distribution in Vizag Steel Plant.
The main objective of the project is to study the various equipments provided for
generation and distribution of power with their proper integration to meet the purpose.
Also some essential electrical ideas and facts which were learnt in due course are
incorporated at the end of this project report.

A generating station which converts heat energy obtained by the combustion of coal
into electrical energy is known as Thermal Power Station. A Thermal power plant
basically works on the principle as seen in Rankine cycle. Steam is produced in the boiler
by utilizing the heat obtained by combustion of coal. This steam is used to run the
prime movers where it gets expanded. This expanded steam is then condensed in a
condenser to be fed into the boiler again. The prime mover (here the steam turbine)
drives the alternator which converts the mechanical energy of the turbine into electrical
energy. Such types of power stations are generally commissioned where its main source
coal and water are available in abundance. As, this thermal power plant is annexure of
Vizag steel plant. Here we are also using Blast Furnace Gas, Coke Oven Gas, Fuel oil in
proper proportion for obtaining net heat for Rankine cycle.
Generated electrical power is distributed to various sections of steel plant and township
through different substations which are connected to generating unit. The total demand
is collectively meet by Captive TPP and Andhra Pradesh State Electricity Board.
Page | 8

THERMAL POWER PLANT-AN INTRODUCTION

The fact that thermal energy is the major source of power generation itself shows
importance of Thermal power plants in India. More than 60% of electrical power is
produced by Thermal powered steam plants in India. The steep rise in the demand for
power demands a larger unit setup which requires the use of more fuel. These plants
are trying to keep the overall cost of power generation low using modern techniques
and devices.
In steam power plants the heat obtained by the combustion of fossil fuels (coal, oil or
gas) is utilized by the boilers to raise the steam to a high pressure and temperature. The
steam so produced is used in driving the steam turbines and sometimes steam engines
coupled to generators and thus in the generation of electrical energy. The steam
turbines or steam engines thus used not only act as prime movers but also as drives for
auxiliary equipments such as pumps, fans, turbo blowers etc.
The steam power plants may be installed either only to generate electrical energy or
electrical energy generation along with steam generation for industrial purposes such as
paper mills, sugar mills, chemical works, plastic manufacture, food manufacture etc.

Page | 9

Generally Thermal power plants are categorized as
Utility Power Plant- Power is produced solely for the purpose of generation and
supplied to the various kinds of customers through grid.
Captive Power Plant- Power is produced for supplying quality power for the
effective functioning of the actual plant (say a case of a Thermal power plant
present in a steel plant). The import and export of power takes place in
accordance with the load.

The Thermal power plant seen in Vizag Steel Plant is a captive power plant. The power
requirement of VSP is met through captive generation as well as supply from APSEB
grid.
Captive capacity of TPP in VSP : 300.5 MW
3 units of 60 MW generation capacities.
1 unit of 67.5 MW generation capacity.
2 units of 7.5 MW capacities at Back Pressure Turbine Station (BPTS).
2 units of 12 MW capacities at Gas Expansion Turbine Station (GETS).
1 unit of 14 MW from new coke Oven battery.
The specialty of this power plant is that the energy from the flue gas is not wasted. It is
used in BPTS and GETS and some power is generated.


Page | 10


POWER REQUIREMENT
Integrated Steel Plants are major consumers of electricity, with specific consumption of
power at around 600-650 kWh/Ton of liquid steel. The estimated annual power
requirement of Visakhapatnam Steel Plant, at full level of production in each shop
(corresponding to 3.0 MT of liquid steel), is 1932 million kWh. This corresponds to an
average demand of 221 MW. The demand is found to be 227 MW on an average and
260 MW peak value. The estimated energy consumption and average demand of major
shops is given below:

SHOP


Annual Energy
(10
6
kW Hrs.)

Average
Demand (MW)

RMHP 35 4.0
CO & CCP 171 19.5
SINTER PLANT 254 29.0
BLAST FURNACE 210 24.0
SMS & CCS 126 14.5
LMMM 100 11.5
WRM 118 13.5

Page | 11


SHOP

Annual Energy
(10
6
kW Hrs.)

Average Demand
(MW)

MMSM 100 11.5
CRMP 35 4.0
TPP 310 35.0
ASP 258 29.5
COM. STATION & CWP 131 15.0
AUXILIARY SHOPS 20 2.5
WATER SUPPLY 15 2.0
TRAFFIC & OTHERS 7 1.0
TOWNSHIP 28 3.0
LOSSES

14 1.5




Page | 12

COAL CONVEYING SYSTEM OF TPP









Page | 13

SOURCES OF POWER

Power requirement of VSP is met through captive generation as well as supply from
APSEB grid. The captive capacity of 270 MW is sufficient to meet all the plant needs in
normal operation time. In case of partial outage of captive generation capacity due to
breakdown, shutdown or other reasons, the short fall of power is availed from APSEB
grid. Turbo Generators of VSP normally operate in parallel with state grid. Excess
generation over and above plant load is exported to APSEB.
The agreement with APSEB provides for a contract demand of 150 MVA and permit
export of power. Tariff for import, export; demand charges, penalties etc. are
stipulated. For purpose of billing, import and export energy is separately metered at
Main Receiving Station (MRS).

APSEB SUPPLY NETWORK
Power is supplied to VSP from APSEB switching station over two 220 kV lines on double
circuit towers. Power is received at the Main Receiving Station (MRS) located near Main
gate and further distributed to various units within the plant.



EXTRA HIGH VOLTAGE DISTRIBUTION (220 kV)
Page | 14

Power from APSEB is received at Main Receiving Station (MRS). The entire plant is
configured as five electrical Load Blocks and Step down sub-stations are provided in
each block (designated as LBSS 1 to 5) with 220 kV transformers to step down power to
33/11/6.6 kV and for further distribution as indicated below:

STATION DESIGNATION


AREAS COVERED

LBSS1 (220/11/6.6 kV) RMHP, CO & CCP, Sinter Plant, BF
LBSS2 (220/11/6.6 kV)
(220/33 kV)
BF, SMS, ASP, CRMP, Comp. House-1
Ladle furnace in SMS
LBSS3 (220/11/11 kV) MMSM
LBSS4 (220/11/11 kV) LMMM, WRM, Aux. Shops, Adm. Building
and Kanithi reservoir pump house.
LBSS5 (220/11&220/11/11 kV) TPP, Plant essential category loads, KBR &
Township pump houses & hospital.
MRS (220/33 kV) Plant, Township and construction network.

Power is distributed within VSP, between above major blocks and MRS over 220 kV
lines on double circuit towers. MRS and LBSS5 at TPP are interconnected by three tie
lines for bi-directional power flow. LBSS1 is connected to LBSS5 by two radial lines.
LBSS2, LBSS3 and LBSS4 are connected to MRS by two radial lines each.
Page | 15

To ensure continuity of supply and also facilitate maintenance, the stations are
connected by double circuit lines. MRS and LBSS5 are designed with double bus (Main
Bus-1, Main Bus-2) and transfer bus arrangement. At LBSS1, 2, 3 and 4 provisions are
made so that with only one 220 kV line and two transformers in service, all the loads can
be catered to. The equipment installed is suitable for 15000 MVA fault level. The
various equipment installed in these stations include 220 kV lighting arrestors, current
transformers, potential transformers, isolators, SF
6
/MOCB circuit breakers,
Transformers, Aluminum pipes, ACSR conductors, insulators structures, Relay and
control panels, batteries etc.
Carrier communication apparatus is provided at MRS to contact any of the APSEB
stations.




HIGH VOLTAGE DISTRIBUTION (33/11/6.6 kV)
Two 220/33 kV Transformers installed at MRS feed power to Township step down
station (called as CPRS) through 33 kV cables. Here the voltage is further stepped down
to 11 kV by two nos. of 33/11 kV transformers. Outgoing feeders from this station
supply power at 11 kV through cables to township network. 11 kV overhead
construction power lines are connected to this sub-station.
The 33 kV supply form the transformer at LBSS2 feeds SMS ladle furnace transformer
and capacitor banks through cables. This is a highly fluctuating load and the voltage dips
on 220 kV systems can be felt when the furnace is in operation.
Page | 16

Electric power at 11/6.6 kV stepped down at above LBSS station is distributed to smaller
Load Block Distribution Station (LBDS) located in each unit. Load Centre Sub-station
(LCSS) transformers which convert power form 11 kV to 415 V; converter, arc furnace,
11/6.6 kV High Voltage Load Centre (HVLC) transformers and 11 kV motors (above 200
kW rating generally) are connected to LBSS/LBDS, 11 kV switch boards through circuit
breakers. Power supply to essential category loads of various zones is extended form
TPP directly from Generator Switch Board (GSB) at 11 kV. Cross-linked Poly Ethylene
(ELPE) cables are used for 11 kV distributions.
6.6 KV supply is mostly used for motors (of rating >20KW and <200 kW generally). In
the zones fed by LBSS3, LBSS4 stations and also where 11 kV supply from TPP is
connected for motor drives, where ever required, step down 11/6.6 kV High Voltage
Load Centers (HVLC) are formed with suitable capacity transformers (20/10/6.3 MVA
capacity). High Voltage Motor Control Centers (HVMCC) are fed from 6.6 kV
LBSS/LBDS/HVLC stations. 6.6 kV motors are connected through breaker to
LBSS/LBDS/HVLC/HVMCC switch boards. Sometimes vacuum contactors are also used
for motor switching. Cross-linked poly ethylene cables are used for 6.6 kV distributions.
The 11 kV switch gear is of 1000/750/500 MVA rating. The 6.6 kV switch gear is of
450/350 MVA rating. All the equipment selected is suitable for use with ungrounded
system specifications. Zig-zag connected transformers are connected to Delta
connected secondary windings of 220/11/6.6 kV transformers to create neutral point.
The 11 and 6.6 kV system neutrals are grounded through resistance to limit the earth
fault current to 1000/600 Amps respectively. Appropriate protective relays provided to
quickly isolate faulty feeders/apparatus with suitable discrimination. All varieties of
breakers such as Bulk Oil/MOCB/VCB/SF
6
/Air Blast are used.

Page | 17

MEDIUM VOLTAGE DISTRIBUTION (BELOW 650 V)

In each shop, to cater to Medium and Low voltage load, 11 kV/415 V LCSS are formed.
Power is fed from LCSS to motors, MCC, Power Distribution Boards (PDB), Lighting
Distribution Boards (LDB), ESP transformers etc. and for further distribution. The 3
phase 415 V distribution is solidly earthed neutral system. The transformers are of
standard rating 1600/1000/750/630/250 kVA in plant and township areas. PVC cables
are used for medium voltage distribution generally.
The secondary windings of converter transformers feed DC converters and other special
equipment for variable speed AC/DC drives. The secondary voltage of these
transformers suits to the particular application for which they are provided

LOW VOLTAGE DISTRIBUTION (250 V & BELOW)

Low voltage distribution consists of power supply on single phase to lighting
equipment, ceiling fans, portable hand tools and domestic appliances etc. For safety
reasons, 24 V distributions are also provided to cater to hand lamps etc. in some areas.
PVC cables are used.


SCADA
Page | 18


The 220 kV, 11 kV and 6.6 kV distribution system is monitored by a centralized
Supervisory Control And Data Acquisition system. The plant generation,
import/export and consumption in each unit are monitored through SCADA.






Page | 19







MAIN EQUIPMENTS IN TPP
The process of power generation takes place with the help of the following equipments
in chronological order:-
Boilers
Turbo-generators
Transformers
Turbo-blowers
Chemical water treatment plant
Coke Dry Cooling Plant (CDCP) boilers
Back Pressure Turbine Station(BPTS) and Cooling Water Plant (CWP) -1
and 2
Gas Expansion Turbine Station (GETS)

Page | 20






BOILERS

No. of boilers : 5 (4 working+1 standby)
Steam capacity : 330Tons/Hr
Pressure : 101 ata
Page | 21

Temperature : 540
o
C
Fuel : Pulverized coal, BF Gas, CO Gas,

Furnace oil/LSHS
Type : single drum, natural circulation,
suspended type, radiant,
multiple fuel, corner fired.



Coal for the plant is obtained from Talcher, Orissa. Lignite coal is obtained. Lignite is
porous, has 30-50% moisture, light weight. It is stored in coal bunkers (Immediate stock
bins) and then ground in coal mills i.e. pulverized to increase the surface area of
combustion. Then Primary Air (PA) fan sweeps the pulverized coal for combustion to
occur. The heat resulting due to this combustion is used to raise the steam in boiler to
the required temperature and pressure.
The water input given to the boiler is demineralized before sending into the boiler, to
prevent the corrosion and damage of boiler tubes and turbine blades.
A boiler channel on the whole is divided into 2 passes:
Combustion pass
Non-combustion pass
The boiler drum consists of steam at different temperatures. The one with higher
temperature is at top. On an average, the temperature of the boiler is 318
o
C .The boiler
Page | 22

seen in VSP undergoes natural circulation i.e. due to density difference the circulation
occurs. The heat is transferred by means of radiation.
There are super-heaters which are used to increase the steam temperature to 540
o
C.
The heat from flue gas is used for the same. There are 3 types of super-heaters used,
namely,11100
Low temperature super-heater
Platen or Radiant super-heater
Final super-heater
A tubular air-heater is present which is used to preheat the primary air i.e. air from the
PA fan. This is done as low temperature air sticks dust and flue on to the pipes. Similarly
a Regenerative air-heater is used to preheat the combustion gas by using heat from flue
gas. Finally, an economizer is present to increase the feed water temperature, by using
heat from the flue gas.
A Forced Draft Fan is present to provide the required air for combustion. Also a negative
pressure is maintained in the furnace using the above.
As it is a multiple fuel and water tube- boiler, the temperature may change. A control on
the temperature of steam is highly essential. So a de-superheater is used.
It sprays a steam at lower temperature (300
o
C approx.) to cool down the temperature.
Also some tilting arrangements in the burner are provided in some places for the same.


FUEL COMPARISON:-
Page | 23

Fuel Calorific Value
Coal 3200 4500 KCal / KG
Coke-Oven gas 4425 KCal / NM
3

Blast Furnace Gas 800 KCal / NM
3

Fuel Oil 10000 KCal / KG


To maintain a constant level in the boiler drum, a Feed Regulation System (FRS) is used.
Steam or water from FRS is sent to the boiler drum via economizer and platen water
tubes.
Ignition is done with the help of spark plugs. There are some igniter fans for cooling the
igniter guns if necessary. Also there are Flame Scanners to know if flames have occurred
or not. And for cooling the above, Scanner air fans are present.
0.2
23
30
46.8
Typical fuel Mix in Boilers
Oil
BFG
COG
COAL
Page | 24

Below the boiler, a Bottom Ash Hopper is present. About 15% of the ash is collected by
gravitational force. This is removed every 8 hours. Rest gets passed as flue gas,
precipitated in ESP (Electro Static Precipitator).
An Induced Draft Fan is present at the far end of this system, to suck the gas thus
obtained and leave it out through the chimney high up in the atmosphere.

TURBO-GENERATORS

GENERATOR (60 MW)- TG#1,2,3
No. of units : 3
Make : BHEL
Type & description : TARI 930-36P
Rated power Active : 60000 kW
Rated power Apparent : 75000 kVA
Power factor : 0.8
Page | 25

Rated stator voltage : 11000 5% Volts
Rated stator current : 3936 Amp
Rated rotor voltage : 300 Volts DC
Rated rotor current : 596 Amp
Rotational speed : 3000 RPM
Frequency cycles : 50 HZ
Critical speed : 1765 n1, >4500 n2
Class of insulation of winding : F
Air gap between stator and rotor : 55 mm
Type of cooling : Air cooling indirectly
Maximum temp. rise of stator winding : 120
O
C
Maximum temp. rise of rotor winding : 130
O
C
Winding type : double layer-with 36 slots
Turbine type : impulse-reaction (1:40)

EXCITATION SYSTEM:-
Type of excitation : Static
Rated output : 255 KVA
Rated voltage : 359 Volts
Page | 26

Rated current : 711 Amp
Exciter ceiling voltage : 575 Volts
Nominal exciter response ratio : 2:4


GENERATOR COOLING SYSTEM
Make : BHEL
Type : Elements for tubes
Number (3 Operating & 1 standby) : 4 Elements
Material & construction details : Carbon steel
Quantity of cooing water required : 360 M
3
/hr
Max. temp of water inlet of cooler : 36
O
C
Max. temp cooling air at cooler : 40
O
C



GENERATOR AIR COOLER
Service unit : Air
Position : Horizontal
Page | 27

Heat duty : 1027 kW
Qty. circulation air : 108000 M
3
/hr
Cool air temp. : 40
O
C
No of cooler elements : 4
No. of water paths : 2
Air design pressure : 6 kg/cm
2

Test pressure : 9 Kg/cm
2

Design temperature : 100
O
C

GENERATOR (67.5 MW) - TG#4
No. of units : 1
Make : BHEL
Type & description : TARI 930-36P
Rated power Active : 67500 kW
Rated power apparent : 84375 kVA
Power factor : 0.8
Rated stator voltage : 11000 5% Volts
Rated stator current : 4429 Amp
Rated rotor voltage : 300 Volts DC
Page | 28

Rated rotor current : 625 Amp
Rotational speed : 3000 RPM
Frequency cycles : 50 HZ
Critical speed : 1765 n1, >4500 n2
Class of insulation of winding : F
Air gap between stator and rotor : 55 mm
Type of cooling : Air cooling indirectly
Maximum temperature rise of stator winding : 120
O
C
Maximum temperature rise of rotor winding : 130
O
C

EXCITATION SYSTEM
Type of excitation : Static
Type of excitation : Static
Rated output : 255 KVA
Rated voltage : 308 Volts
Rated current : 625 Amp
Exciter ceiling voltage : 461 Volts
Nominal exciter response ratio : 2:4
GENERATOR COOLING SYSTEM
Page | 29

Make : BHEL
Type : Elements for tubes
Number (4 Operating & 1 Standby) : 5 Elements
Material & construction details : Carbon steel
Quantity of cooing water required : 420 M
3
/hr
Max. temp of water inlet of cooler : 36
O
C
Max. temp cooling air at cooler : 38.38
O
C
GENERATOR AIR COOLER
Service unit : Air
Position : Horizontal
Heat duty : 1161 kW
Qty. circulation air : 108000 M
3
/hr
Cool air temp. : 42
O
C
Hot Air Temperature : 74.34C
No of cooler elements : 5
No. of water paths : 2
Air design pressure : 6 kg/cm
2

Test pressure : 9 Kg/cm
2

Design temperature : 100
O
C
Page | 30

There are 3 turbines which rotate and thus make the turbo generators to rotate.
STEAM TURBINE:

SPECIAL FEATURES
Electro Hydraulic Turbine Governing System.
Controlled extraction at 13 ata and 4 ata for process steam needs. (Only in TG
1,2 & 3)
Central admission of steam to reduce axial thrust.
Air cooled Generators.

Each Turbo-Generator has the following auxiliaries:
One condenser is designed to achieve the vacuum of 760 mm Hg.
Three condensate extraction pumps of 50% capacity each
2 steam ejectors- 1 standby
1 starting ejector to create vacuum within 30 minutes
Gland steam condenser
Page | 31

2 HP Heaters to condensate from 90
o
C to 140
o
C
2 LP Heaters to heat feed water from 140
o
C to 215
o
C.
Electro-Hydraulic control system
Turning gears, main oil pump, auxiliary oil pump, emergency oil pump, and
jacking oil pump.
4 oil coolers (2 standby)
7 boiler feed pumps ( with multistage centrifugal pump and barrel type casing)

OPERATIONAL LIMITS:
For analyzing the operational problems and taking necessary steps, operational limits of
the generator should be known to the operator. If the generator operates within the
limits, the system will work without any disturbance. These are the possible occurrences
of disturbance due to some fault seen in generator.

Problems are studied to occur at the following conditions:
a. Generator field failure trip
b. Generator negative phase sequence trip
c. Over voltage and over current trips
d. Fault in static extension equipment and pole slipping trips
e. Fault in Automatic Voltage Regulator
Page | 32

f. Stator or rotor temperature high
VARIATION OF TERMINAL VOLTAGE
Generator can develop rated power factor when the terminal voltage changes within +/-
5% of the rated value i.e. 10.45 to 11.55 kV. The stator current should accordingly be
changed within corresponding values of the MVA outputs and stator currents are also to
be carefully observed. During operation of generator at 110% of the rated value of
continuous operation, stator current should not exceed 4130 A corresponding to 105%
of the rated value.
VARIATION IN FREQUENCY
The generator can be operated continuously at rated output with a frequency variation
of +3 to -5% over the rated value i.e. 47.5 to 51.5 Hz. However the performance of the
generator with frequency variation is limited by the turbine capacity. The variation in
frequency depends on the load and generation. Frequency detector is connected to
sense the frequency variation which gives command to governing system which control
the steam flow to turbine by opening or closing the valves.
Generation>demand : High frequency
Demand>generation : Low frequency
OVERLOADING
Under abnormal condition, generator can be overloaded for a short duration.
Permissible value of short time-overloads in terms of stator and rotor currents and
corresponding duration at rated power factor and rated voltage and rated parameters
of cold air and stator and rotor temperatures can be applied.

Page | 33


OPERATION UNDER UNBALANCED LOAD
The turbo generator is capable of operating continuously.
When unbalanced system loading is provided, a continuous negative sequence current
during this period shall not exceed 5% of the rated stator current.
If unbalance exceeds permissible levels, measures are to be taken immediately to
eliminate or reduce the extent of unbalance within 3 to 5 minutes. If not, the machine
trips.

SYNCHRONISATION
A generator requires to be synchronised if it is to be run in parallel with others. Before
it is connected electrically to energised bus bar, the following conditions must be
satisfied.
(a) Equality of voltage
(b) Equality of frequency
(c) Synchronisation of phases
With these requirements fulfilled, there will be no voltage difference between any
corresponding pairs of terminals of machines and bus bars, so that points can be
electrically connected without disturbance.


Page | 34


ASYNCHRONOUS OPERATION
Asynchronous operation of the generation on field failure is allowed depending upon
the permissible degree of the voltage dip and acceptability of the system from the
stability point of view. During field failure there are important points to be noted.
Field failure with under-voltage
Field failure without under-voltage
Field failure with under voltage will be sensed and the machine will get tripped without
any delay.
During field failure without under voltage, active load on the generator shall be
decreased to 40% of rated load immediately. The generator can operate at 40% of the
rated load asynchronously for a total period of 15 minutes from the instant of failure of
excitation. Within this period, steps should be taken to establish the reasons of field
failure to restore normalcy. If it cannot be restored then the set has to be switched off.
Then the set should be switched over to the reserve excitation.

SOME OBSERVATIONS
When excitation is removed from the turbo generator, it acts as induction generator. It
takes reactive power from the grid and gives active power to the grid. Note that the
reactive power in a generator is nothing but the power derived from the magnetisation
due to excitation of the generator.
Page | 35

On stopping the mechanical input to the generator, the machine starts working as a
synchronous motor. It takes active power from the grid and supplies reactive power to
the grid.
If both excitation and input to the generator are stopped, it acts as an induction motor.
So these methods cannot be used to shut down a generator.
SHUTDOWN OF GENERATOR
Slowly bring down mechanical input to a minimum level. Then the machine is tripped
using breakers from the grid. Load is also reduced to avoid abnormality i.e. to prevent it
from affecting other systems.

TURBO BLOWERS
BLOWERS - 3 (2 Working + 1 Standby)
CAPACITY - 6067 m
3
/min

SPECIAL FEATURES
Constant Speed with EHTC (Electro Hydraulic Turbine Governing system)
Inlet Guide Vane Control
Axial type largest blowers in India.
Page | 36

VSP has 2 blast furnaces. To meet the blast air requirement, 3 turbo blowers, each of
6067 nm
3
/min capacity, are installed at TPP. These blowers are of axial type and are the
largest blowers installed in India.
These blowers are provided with suction filters, pre-coolers and inter-coolers.

AUXILIARIES OF TPP
These include coal conveyors, cooling towers and pump house#4 for cooling water
system, pump house for ash water, ash slurry, fire water and fuel oil and emergency
diesel generators, electric switch gear for power distribution, ventilation and air
conditioning equipment etc. The entire power generated at Back Pressure Turbine
Station (BPTS) and Gas Expansion Turbine Station (GETS) is transmitted over 11 kV
cables to power plant, stepped up through a 220 kV transformer at LBSS5 and
transferred to plant grid.

TRANSFORMERS
Page | 37


TRANSFORMERS CONNECTED TO 60 MW GENERATORS (EXCITATION SYSTEM)

Make : May & Christ W.G.
Type : Dry type air cooled
Connection symbol : DYN5
Class of insulation : F
Power rating : 650 KVA
Primary voltage : 11 kV volts
Secondary voltage : 480 Volts
TRANSFORMERS CONNECTED TO 67.5 MW GENERATORS (EXCITATION SYSTEM)

Make : BHEL, JHASI.
Type : Dry type air cooled
Connection symbol : DYN5
Class of insulation : F
Power rating : 500 KVA
Page | 38

Primary voltage : 11 kV volts
Secondary voltage : 380 Volts

There are 2 main types of transformers present in a Thermal Power Plant :-
Generator transformer
Auxiliary transformer
A Generator Transformer is one which steps up the voltage to the grid for the purpose
of distribution.
An Auxiliary transformer is one which steps down the voltage for the plant purposes.
The transformer consists of a conservator tank, breather, buckholz relay, transformer
oil mainly. It also has on-load tap changers.
Conservator tank is used for conserving the transformer oil when it expands or
contracts due to change in temperature in insulation.
For the contact of air from inside to outside and vice-versa, a breather is present. It
consists of silica gel to trap moisture. When it changes from blue to pink, it has to be
replaced.
The transformer is generally surrounded by gravel, to avoid the growth of grass, and to
prevent insects, snakes and to isolate, restrict the area.
There is a Buckholz Relay which is used to show if there is any internal fault. When the
above occurs, bubbles get generated and float up, thus tripping the relay. There are 2
balls in this relay. The top one is for alarm and the bottom ball completely trips the
transformer.
Page | 39

The reading in the transformer is seen to be 50/63 MVA, which means it can withstand a
maximum of 50 MVA during natural cooling and 63 MVA during forced cooling.

SOME OBSERVATIONS
Transformer can have troubles in the following ways as observed.
Bus bar protection
Over flux protection
Over current
Earth fault
Under frequency
There are breakers and isolators in the switch yard along with CTs and PTs. Breakers are
on-load devices, while isolators are off-load devices since breakers have an arc-
quenching medium. The breaker in VSP is mainly made of SF
6
.
The speciality of this breaker is that the SF
6
gets ionised and recombines as soon as the
arc is quenched.


CHEMICAL WATER TREATMENT PLANT
The Chemical Water Treatment Plant located in TPP produces high quality purified
Demineralised Water and soft water. There are 6 streams of de-mineralising units each
Page | 40

capable of producing 125 m
3
/hr. 2 softening units of 125 m
3
/hr each is present.
Demineralisation is done by the Cation and Anion Exchange process.
PROCESS
Water from the Kanithi reservoir is sent to a clariflocculator, where water is churned
and the suspended impurities settle down due to the centrifugal force and action of
gravity. Then this water is passed through anion exchanger beds where anions get
exchanged with Zeolite which combines with sulphuric acid and forms water. A similar
process takes place in cation exchanger beds also.
This DM water is supplied to TPP, Steel Melt Shop (SMS), CDCP Boilers at Coke Ovens
and Rolling mills. Soft water is supplied to Chilled Water Plant-I, II and SMS mould
cooling.


COKE DRY COOLING PLANT (CDCP) BOILERS
In VSP, hot coke produced in the coke oven batteries is cooled by circulating nitrogen in
CDCP. The hot circulating gas is passed through Waste Heat Boilers in which the steam is
produced at 40 kSCA pressure and 440
o
C temperature. There are 3 CDCPs and 4 Waste
Heat Boilers. These boilers are of 25T/Hr capacity.


EFFICIENT PRODUCTION
Page | 41

The heat of the flue gas is not wasted much in this plant. It is efficiently used for further
purposes in Back Pressure Turbine Station (BPTS) and Gas Expansion Turbine Station
(GETS). BACK PRESSURE TURBINE STATION (BPTS)
BPTS GENERATOR (7.5MW)
No. of units : 2
Make : BHEL
Type & description : TGN 218226/2
Rated power Active : 7500 kW
Rated power Apparent : 9375 kVA
Power factor : 0.8 lag
Rated stator voltage : 11000 5% Volts
Rated stator current : 492 Amp
Rated rotor voltage : 140 Volts DC
Rated rotor current : 596 Amp
Rotational speed : 3000 RPM
Frequency cycles : 50 HZ
Critical speed : 1900 n1

Class of insulation of winding : B(Stator &Rotor)
Type of cooling : Closed Circuit Air cooling
Page | 42

Short Circuit Ratio : 0.610
Generator field Resistance : 0.334 at 20C
Moment of Inertia of Rotor : GD = 101tm
Max. Short Circuit Torque(for Coupling) : 15368 kg-m
No. of Generator Terminals : 6
Generator Phase Connection : Star
Generator Brushes : 4 for Ring (2 Rings)
Size : 32 x 32 mm
Grade : HM6R
Minimum Permissible diameter of Slip Ring : 370mm
Max. output with one cooler out of service: 6562 kVA
Volume of cooling Air : 28800m/hr
Designed for : Tropical Climates

GETS GENERATOR (12MW)
TG-1 TG-2
Make : RUSSIA RUSSIA
Type & description : T-122-3 T-12-2T3
Rated power Active : 12000 KW 12000KW
Page | 43

Rated power : 15000 KVA 15000KVA
Power factor : 0.8 lag 0.8 lag
Rated stator voltage : 6300/10500 Volts 11000 Volts
Rated stator current : 1375/825 Amp 787Amps
Rated rotor voltage : 230/232 Volts DC 232 Volts DC
Rated rotor current : 268/270 Amps 270Amps
Rotational speed : 3000 RPM 3000 RPM
Frequency cycles : 50 Hz 50Hz
Critical speeds : 1720 n1, 4720 n2 1700n1, 4800n2
Efficiency : 97.6 97.6
Type of cooling : Closed Circuit Air cooling
Mass of Rotor : 6980kg 7500kg
Stator Mass : 14500/15300kg 15300kg
Rotor fly wheel Moment : 1.42 tm 1.42tm




Page | 44


POWER GENERATION AND DISTRIBUTION

Page | 45



Each generator of group 1, 2 and 3 is connected to one section of Generator Switch
Board (GSB). Each section of GSB-1 is in turn connected with each other by a bus coupler
with reactor and without reactor scheme.
The TG#4 which was added later on to augment power position of the plant and to
utilize full capacities of 4 running boilers, is connected through a power transformer to
220 kV side of the Load Block Sub-Station (LBSS)-5.
In addition, the plant has got total of 4 small generator sets (2 at coke ovens [CO] and 2
at blast furnaces) which utilize the waste heat and blast furnace top pressure
respectively to produce power.
Page | 46

Sets operating at CO area have a capacity of 7.5 MW each and at BF area have a capacity
of 12 MW each. One set each from CO and BF areas are connected to GSB-2 and GSB-3
respectively. New coke oven battery recently set up which treats upon the heat of waste
water has a capacity of 14MW.
GSB-1 is connected to the plants 220 kV circuit at LBSS-5 with 3- 11/220 kV, 50/63 MVA
transformers. GSB-2 and GSB-3 are connected to plants 220 kV circuit at LBSS-5 via a 3
winding 11/11/220 kV transformer. Power requirement of power plant is met by 2
switch boards namely 5LBDS7 and 05HVLC-1 connected to 3 section of GSB-1.
5LBDS-7is mainly a 11 kV switch-board with 3 sections and caters to the need of various
load centres throughout TPP. 05HVLC1 is a 6.6 kV load centre which meets the
requirement of HT drives.

ESSENTIAL CATEGORY LOADS
Some of the technological process/equipment requires all time availability of electricity.
Such loads are approx. 70 MW and spread over various plant units. These include
exhausters in CO & CCP, Cooling water pump houses in BF, SMS, Rolling mills, Intake
pump house, Kanithi Balancing Reservoir pump house, TPP auxiliaries, Township pump
house, Hospital etc. Disruption of supply to these loads may cause wide spread
dislocation to the process, involve dangerous situation to equipment etc. These are
classified as special/essential category-I loads. Power supply to them is envisaged from
two sources i.e. from Thermal Power Plant generator 11 kV switch board through cables
and also from 220 kV sub-station in that area. Depending upon level of captive
generation, the 220 kV system is so configured that in the event of isolation of captive
generators form APSEB grid, the load throw off at TPP and disturbance to plant units is
minimized.
Page | 47

POWER DISTRIBUTION OF THERMAL POWER PLANT
To meet power requirement of its auxiliaries any power plant relies on station auxiliary
transformer in case of outage of its generation. But in the case of TPP whenever such
situation occurs, power requirement of its auxiliaries are met by the same power
transformer (which are used for power evacuation in case of normal generation)
through Generator switch board.











ISLAND OPERATION SCHEME

Page | 48

A scheme has been envisaged at TPP to get isolated from the grid in case of system
disturbance or low frequency condition with ABB make relay type FCX 103b relay for
some conditions. Frequency is considered as the main parameter for this operation as it
is highly reliable compared to voltage and current.

The conditions are
When a frequency of 47.5 Hz or goes above 51.5 Hz is sustained for 0.5 seconds,
the mainline breaker will trip, isolating the plants 220 kV from grid. This is called
first stage of isolation.
When the frequency further drops down to 46.9 Hz and is sustained for 1 second,
the 11 kV section is cut off from the grid. This is called second stage of isolation.

If the rate of change of frequency is 2 Hz/second, sustained for 100 ms, isolation
occurs. Process is conventionally termed as Island operation Scheme.





BASIC KNOW-HOW OF ELECTRICAL ENGINEERING
Page | 49

The basic principle of electrical safety is how to avoid electric shocks and fire hazards. At
the outset we will discuss about electric shocks.
The seriousness of the electric shock depends upon the following factors:
i) CURRENT STRENGTH: It has been experienced that in alternating current of low
frequency the current between 1mA and 8mA are just bearable, but currents between
8mA and 15mA give painful shock.
Thus it is seen that it is the current which gives shock although it depends on voltage.
The leakage current is given by I=V/R, where V=supply voltage and R=body resistance.
The body resistance is different under different conditions. When the body is dry, its
resistance varies between 70,000 - 1,00,000 /cm
2
, but when the body is wet, its
resistance reduces to 700-1000 ohm/ cm
2
. The average effective resistance of the body
may be taken as 50 k- when dry and 1-2k when wet. The high voltage causes burns.
Hence it is concluded that when body is wet, 100V supply is as dangerous as 10,000V
when body is dry.
ii) FREQUENCY OF CURRENT: The lower the frequency, more dangerous is the shock
and direct current shock is the most severe.
iii) PATH OF CURRENT: If the path of leakage current is without involving the chest
or heart, survival is possible but there will be severe burns on the parts of the body,
involved in the shock depending upon the value of the current.
WHY A FUSE IS NOT USED IN NEUTRAL:
Suppose a fuse be inserted in neutral path and let the metallic body of the electric
appliance be earthed to avoid electric shock. If the insulation value of the appliance
deteriorates and there is leakage current and which makes the fuse in the neutral to
melt first. But as soon as the operator touches the appliance in order to know what has
Page | 50

happened, he will complete the circuit through his body to earth and he will get a
severe shock since it is still connected from live lines.
ELECTRICAL SHOCK:
Electricity is an ideal form of energy which is efficient, economical, clean and quick,
available at the touch of finger. However, it is quicker and more efficient in causing
damage if safety aspects are not properly followed. To those who are unskilled and
inexperienced in electrical work, electricity is a serious source of potential danger.
Electrical hazards are not usually obvious. For instance, a live conductor does not differ
in appearance from a dead conductor, or the lack of grounding of a metal casing may
pass unnoticed until it is too late when it is touched and found to be dangerously live.
An electrical shock causing 10mA of current to pass through the heart will stop many
human heart beats. Voltage as low as 25V DC/ AC RMS should be considered dangerous
and hazardous since it can produce a fatal current under certain conditions. Higher
voltages are even dangerous.
We experience an electric shock when the body's nervous system is suddenly and
accidentally stimulated by electric current that will flow due to difference in voltage.
Shocks occur when the body becomes part of an electric circuit. The current enters the
body at one point and leaves at other. It may occur in one of the following three ways:
With both wires of an electric circuit
With one wire of an energised circuit and the ground.
With a metallic part that is in contact with an energised wire.

SKIN EFFECT :- It is the tendency of a alternating electric current to distribute within the
cross Section of the conductor such that current density is largest near the surface of
the conductor and decreases with greater depths in the conductor. This causes increase
Page | 51

in resistances of the conductor at higher frequencies where the skin depth is smaller
thus reducing the effective cross section of the conductor.

Why area of cross section of neutral of 3-phase 4 wire system is half of that of
phase wire?
The current carrying by the neutral of 3 phase 4 wire system is the unbalanced current.
If the three phase system is completely balanced on all the three phases there could be
no need for a neutral eg. 3 phase motor. This neutral current will be less than the phase
current so, the reduction in neutral side is allowed.

Difference between a Switch and an isolator ?
A switch is a simple device to connect or disconnect power supply in one equipment or
service. An isolator can have multiple areas of power distribution and these are can be
isolated from power supply and taken for maintenance without functionally affecting
the other areas. Hence, isolators are largely used in industries in power distribution
panels. Isolator gives us a physical confirmation of whether the circuit has been closed
or not.







CONCLUSION
Page | 52


The detailed discussion over the generation and distribution of electrical power in
the captive thermal power plant has been made in this report. An overview of
the thermal power plant has been presented based on the study conducted in the
period of the project training. In the due course we also learnt some basics of
electrical engineering under the guidance of our project guide. An effort has been
made in this project to bring out the complete idea behind the functioning of the
thermal power plant and distribution scheme in Vizag steel Plant under Rashtriya
Nigam Limited.












Page | 53


A unit of absolute pressure in the metric.ATA(s): Abbreviation for "Atmospheres Absolute", defines
as the total pressure exerted on an object, by a gas or mixture of gases, at a specific depth or
elevation, including normal atmospheric pressure.