Chapter one:

Title: Industrial attachment at Katakhali 50 MW peaking power plant

Objectives:
1. To gather the practical knowledge about the power plant
2. To compare the practical and theoretical knowledge of the power generation ,distribution
and transmission
3. To know about the different types of power plant and of their advantages and
disadvantages.
4. To know about the efficiency of the diesel engine power plant
5.To know about the electrical and mechanical side of the power plant
6.To know about the safety of the power plant and the safety component of the power plant
7.To know about the digital implementation in the power plant such as control room, safety
control room with the PLC (programmable logic circuit)

Introduction to power plant:

A power station also referred to as a generating station or power plant is an industrial facility
to generate the electric power.
Most power stations contain one or more generators, a rotating machine that converts
mechanical power into electrical power. The relative motion between a magnetic field and a
conductor creates an electrical current. The energy source harnessed to turn the generator
varies widely.Most of the power plant burn the fossil such as coal,gas ,diesel etc. Now the
nuclear power plant is also popular to the power generation. The most demand able power
plant is the renewable energy power plant such as wind,solar,Hydroelectric and wave.

Introduction to Diesel Engine Power plant:

A diesel engine power plant is the combination of the diesel engine with an electric generator
to generate electrical energy . At the katakhali 50 MW peaking power plant is a diesel engine
power plant. Actually the diesel engine performs as the prime mover thats drives the
alternator.

Advantages of Engine base power plant:

1.This is simple in design point of view
2.Required very small space
3.It has quick starting facility
4.Cooling is very easy and the requirement of water is very small
5.Initial cost is less than other types of plant
6.Thermal efficiency is quite higher than coal ,( about 40-45%)
Disadvantages of Engine power plant:
1.The cost of fuel is higher than the coal
2.The power generation small quantity
3.Cost of lumbricants is very high
4.Maintenance is quite complex and cost is high

Peaking power plant:

When load of the national grid is maximum / the load value is in the peak load , the power
plant running at the peak load only, this types of power plant is called the peaking power plant.
Peaking power plant meets the daily peak load, which may only be for one or two hours each
day. While their incremental operating cost is always higher than base load plants, they are
required to ensure security of the system during load peaks. Peaking plants include simple cycle
gas turbines and sometimes reciprocating internal combustion engines, which can be started up
rapidly when system peaks are predicted.

Base load power plant:

These types of plant is running at the Base load value and this types of plant, generation cost
per units is very low. Base load power plants run nearly continually to provide that component
of system load that doesn't vary during a day or week. Base load plants can be highly optimized
for low fuel cost, but may not start or stop quickly during changes in system load. Examples of
base-load plants would include large modern coal-fired and nuclear generating stations, or
hydro plants with a predictable supply of water.

Fuel use at the Katakhali 50 MW power plant:

At this power plant , Furnace Oil is used as a fuel.But this fuel is very high density so the fuel
cant use as the direct burning. For direct burning ,Furnace oil is viscous as well as not suitable
for complete combustion. It is pre-heated to (55-60) degree celcius temperature . so the flow of
the fuel increases and it improves the combustion also.For the pre heating the furnace oil , this
power plant uses the steam Boilers. The steam is flowing through the pipe that heat the fuel
and the density of the fuel is decreasing.
The calorific value of the furnace oil is as 10000 cal/gm.

As the furnace oil is cheaper than the diesel,so we use the furnace oil.As the others fuel such as
Gas,Coal etc are not available at the Rajshahi , so we use the furnace oil as a fuel for this power
plant. It is about 42 taka per litter.
Chapter two:
Major parts of power plant:
Now we can divide the plant about two major parts:
1.Electrical sides
2.Mechanical sides

Electrical sides of the power plant:

Now the Electrical sides can be classified as the three main category:
1.Generation of power
2.Transmission of power to the power grid
3.Protection of the system
Now we briefly discuss this parts which we observe at the power plant:
1.Generation of power:
Generation of power is the basic principle of alternator. The diesel engine is the prime mover of
the alternator . The alternator works on the principle of Faradays law of Electromagnetic
induction
which says the current is induced in the conductor inside a magnetic field when there is a
relative motion between that conductor and the magnetic field.

An alternator is basically a type of a.c generator also known as synchronous generator, for the
simple reason that the field poles are made to rotate at synchronous speed Ns = 120 f/P for
effective power generation.
Here , f= represents the alternating current frequency
P=represents the number of pole

In this power plant , There are six generator units and the capacity of each generator unit is
the 8.7 MW .
Number of generator units = 6
Each generator capacity = 8.7 MW
So , the installed capacity =6*8.7 MW
=52.2 MW
So the reserve capacity =(52.2-50)MW=2.2 MW
The generated voltage of this power plant = 11 KV
The prime mover speed= 750 rpm
The generated frequency of this power plant is varied (48.5 Hz to 51.5Hz).
The generation of this plant in the Y-connected , but the transmission is in the Delta
connection. The neutral is directly connected to the ground.Then the generated power feed to
3 single phase transformer to transmit the grid system.

The generated voltage and current rating directly observe in the control room with the PLC
circuit and the sensor of the PLC circuit control the generation of the power by the digital
controlling system.

Power factor of this Plant: The power factor of this plant is the p.f=0.8 lagging

2.Transmission of Power to the grid:

Power transformer:
Power transformer is generally used in transmission network for steeping up or down the
voltage level.It operates mainly during peak or high loads and has maximum efficiency at or
near the full load.
Here the power plant use three single transformer with 25 KVA rating for the purpose of the
power transformer.

Auxiliary Transformer:
The Unit Auxiliary Transformer is the Power Transformer that provides power to the auxiliary
equipment of a power generating station during its normal operation. This transformer is
connected directly to the generator out-put by a tap-off of the isolated phase bus duct and thus
becomes cheapest source of power to the generating station. In this power plant the auxiliary
transformer rating: 20 KVA

Instrument transformer:
Instrument transformers include C.T and P.T which are used to reduce high voltages and
currents to lesser values which can be measured conventional instruments. The potential
transformer use in this power plnat : voltage rating- 145 KV
Current transformer (C.T) : current rating- 2000/1 A
The generated power of the alternator transmit to the alternator with the step up transformer.
As the generated voltage is the 11KV and the transmitted voltage of the grid is the 132 KV.
Transmitted voltage= 132 KV
Here , the plant use the 3-single phase transformer to make the three phase transformer.
Transformer rating are given below:
Each single phase transformer rating:= 25 MVA
So the three phase transformer rating = 25*3 MVA= 75 MVA
. Here, for the safety, PT( potential transformer ) is used.The rating of the potential transformer
is 145 KV and the VA rating is varied , 200 VA for single phase.
When the power transmit to the grid , 2000/1 A current transformer is used to protection
purpose.

Protection system of the power plant:

Introduction to protection system:
power system protection is a branch of electrical power engineering that deals with the
protection of electrical power systems from faults through the isolation of faulted parts from
the rest of the electrical network.
Protection system comprise the five components:
1 .Current and voltage transformers
2. Protective ralays to initiate the faults and initiate a trip
3 .Circuit Breakers ot open/close the system
4. Batteries to provide power in case of power supply disconnection
5. Communication channels to allow analysis of current and voltage at remote terminals of a
line and to allow remote tripping of equipment.

For the protection purpose different types of protective ralays are used and the different types
of circuit breaker(CB) are used .
Objectives of protection system:
The objectives of the protection system of the power plant is to isolate a faulty section of
electrical power system from rest of the live system so that the rest portion can function
satisfactorily without any severe damage due to fault current.
Generator protection:
An electrical generator can be subjected to either internal fault or external fault or both. The
generators are normally connected to an electrical power system ,hence any fault occurred in
the power system should also be cleared from the generator as soon as possible otherwise it
may create permanent damage in the generator.
Generator protection are classified into two types:
1.protective ralays to detect faults occurring outside the generator
2.protective ralays to detect faults occurring inside the generator
*Protection against insulation failure: The main protection provided in the stator winding
against phase to phase or phase to earth fault, is longitudinal differential protection of
generator.
*Stator Earth Fault protection: When the stator neutral is earthed through a resistor , a current
transformer is mounted in the neutral to earth connection . The rating of the C.T is used in this
power plant : 1000/1 A .
*Rotor Earth Fault protection: This types of fault may be major mechanical damage to the
bearing of the generator.
* Unbalance stator loading protection: Unbalancing in loading produces negative sequence
currents in the stator circuit. This negative sequence current produces a reaction field rotating
at twice of synchronous speed with respect to the rotor and hence induce double frequency
current in the rotor.
* Protection against stator overheating
*Protection against Lubrication Oil failure
*Protection against prime mover failure
*Over speed protection
*Protection against Vibration
*Back up Protection of Generator
*Under frequency protection: When the generator is on the overloading the generator speed is
slow down , so the stator winding is over heating. The following are some of the effects of
under frequency :
@. High flux density in electric machinery ,thereby causing higher magnetizing currents
@. High core loss and over heating of the machines and possible failure.
@. Lower efficiency
@. Reduction in speed
@. The level increases due to reduced reactance
*Over frequency protection: When the speed of the prime mover goes above the rated speed
the over frequency problem occurs.
* Over voltage Protection: The protection against transient high frequency or impulse over
voltage due to lighting and switching surges can be offered by lighting arrestors. But the over
voltage ralay is required to protect the stator conductors insulation of the generator against
power frequency over voltages. In this plant , 11 KV arrestor is used.
The earth of the power plant is first meshed and then the component of the power plant is
setting up to the earth . Here also use the stone for the high insulation purpose at the time of
fault.
2. Transformer Protection:
The power transformer is one of the most important components in a power system network.
The faults in the transformer can be divided into three main classes:
@. Faults in the auxiliary equipment of the transformer
@. Internal faults in the transformer windings
@. External faults.
Faults in auxiliary windings:
*.Oil leakage in the transformer Tank: For the safety ,The conservator tank is provided with an
oil indicator having an alarm facility.If the level of the oil drops below a predetermined value
,the alarm will ring.
*.Deterioration of Dielectric strength of oil: If the moister is entered into the transformer tank
, the dielectric strength of the transformer oil is deteriorated .
*.Failure of ventilation system: For the safety ,Oil flow indicator is used to monitor the oil flow.
*.Weakening of insulation between lamination core and core-bolt insulation:
*.Improper joints or connections:
*.Inter turn faults: If the few turns of the transformer winding is short circuited, the ralay can
not operate and the over heating is created.
Internal Faults:
There can be phase to phase faults, phase to ground faults, faults between h.v and l.v sides of
the transformer. So the protective ralays are used for the safety purpose.
External Faults:
This types faults can be occurred due to overloads or external short circuit faults. The over load
protection, thermal relays are used and the short circuit condition, time grade over current
relays are usually used.
Buchhloz Relays:
The Buchhloz Relay operates an alarm when a specified amount of gas has accumulated. This
type of relay can only be fitted to the transformer which are equipped with conservator tanks
as it is installed in between the and the conservator tank.
Over current Protection: For this purpose, the differential relays are used .we should consider
this aspects for implementing a over current protection:
@. Magnetizing current inrush
@. Primary full load current should be considered while setting the over current relays
@. The same set of current transformer cannot be used for both differential protection and
over current protection.
Earth fault protection: If the neutral of the star connected h.v winding is isolated or non
effectively earthed the phase to earth voltage is rising from the normal phase to neutral
voltage. So the back up earth protection is used for the protection purpose.
Introduction to circuit Breaker:
Electrical circuit breker is a switching device which can be operated manually as well as
automatically for controlling and protection of electrical power system respectfully. As the
modern power system operates at the high current, the designing of a circuit breaker should be
safe interruption of arc produced during the operation of circuit breaker.
This power plant for the protective purpose ,use the circuit breaker , namely
CB Model: SF6, rated current:1250 A
Fault current: 1400 A
SF6 circuit breaker: A circuit breaker in which the current carrying contacts operate in Sulphur
hexafluoride or SF6 gas is known as an SF6 circuit beaker. It has the excellent insulating
property.

Chapter three:
Mechanical sides of this power plant:
Fuel Supply System:
In fuel supply system there are one storage tank, where oil in stored. Strainer : This oil then
pump to dry tank, by means of transfer pump. During transferring from main tank to smaller
dry tank, the oil passes through strainer to remove solid impurities. From dry tank to main tank,
there is another pipe connection. This is over flow pipe. This pipe connection is used to return
the oil from dry tank to main tank in the event of over flowing. From dry tank the oil is injected
in the diesel engine by means of fuel injection pump.
In this power plant ,there are two types of storage tank:
1.Day Tank
2.Storage Tank
The from the storage tank transfer to the Day tank for the daily use of fuel. The sediment and
the heavy materials of the fuel is separated by the pump about the 9000 rpm speed and the
lightly portion of the fuel is transferred to the day tank.

Air Intake System:

This system supplies necessary air to the engine for fuel combustion. It consists of a pipe for
supplying of fresh air to the engine. Filters are provided to remove dust particles from air. The
air is compressed about 20 to 25 bar for the engine. Air is used for the supply of oxygen.So the
air compressor is used for this purpose. For six engine , we need six air compressor in this plant.

Exhaust System:
The exhaust gas is removed from engine, to the atmosphere by means of an exhaust system. A
silencer is normally used in this system to reduce noise level of the engine.
In this power plant , there are about six(6) chimney for the exhaust of the engine.
Cooling System:
The heat produced due to internal combustion, drives the engine. But some parts of this heat
raise the temperature of different parts of the engine. High temperature may cause permanent
damage to the machine. Hence, it is essential to maintain the overall temperature of the engine
to a tolerable level. Cooling system of diesel power station does exactly so. The cooling system
requires a water source, water source, water pump and cooling towers. The pump circulates
water through cylinder and head jacket. The water takes away heat from the engine and it
becomes hot. The hot water is cooled by cooling towers and is re-circulated for cooling.

Lubricating System:
This system minimizes the water of rubbing surface of the engine. Here lubricating oil is stored
in main lubricating oil tank. This lubricating oil is drawn from the tank by means of oil pump.
Then the oil is passed through the oil filter for removing impurities. From the filtering point, this
clean lubricating oil is delivered to the different points of the machine where lubrication is
required the oil cooler is provided in the system to keep the temperature of the lubricating oil
as low as possible.

Starting System:
For starting a diesel engine, initial rotation of the engine shaft is required. Until the firing start
and the unit runs with its own power. For small DG set, the initial rotation of the shaft is
provided by handles but for large diesel power station. Compressed air is made for starting.

Boiler:
Here, the boiler is used for the purpose of heating the HFO( heavy furnace oil) to reduce the
density of the furnace oil. The steam is produced and passes through the pipe to heat the
fuel/furnace oil.
Chapter four:
Digital control room of the power system:
The control room of the power plant, control power plant by digitally. The power plant also
control manually. The control room of the relays, circuit breaker and the generation condition
of the power plant is monitored by the control room all time. In this power plant, the control
room updates their generating voltage every 15 minutes.
PLC controller: By the programmable logic circuit, the power plant control their generation,
transmission and protection system digitally . All the relays and circuit breaker is controlled by
the micro controller programming. Here, different types of sensors are used for the control the
power system. Relays are operated by the micro controller program.
Discussion and conclusion:
From this attachment, we know about the engine base power plant and its operation. The
generation of three phase power and the transmission power to the grid. We know about the
different types of protection system. Actually, the practical knowledge is developed by this
attachment. We acquire knowledge of the practical operation of a power plant. Here ,we also
emphasizes to the safety first. We also know that, the difference between the practical and
theoretical knowledge. So we acquire the overall basic knowledge about the power plant.